Why Choose Forsta?
PRECISION ENGINEERING & ROBUST COMPONENT DESIGN
Based on years of hands-on experience and mechanical training, Forsta engineers design components for smooth integration and robust operating lifespans. Care has been taken to simplify installation and service with many models boasting unique access points that minimize the need for dismantling large amounts of equipment. Forsta self-cleaning filters have components that are optimized in material for their environment and range from carbon steel to titanium – depending on the requirement.
RIGOROUS EQUIPMENT TESTING
Forsta engineers are always trying to find ways to improve the robustness of typical wear parts. Research is conducted on filters in test conditions that simulate the most adverse real-world operating environments. The in-house testing has the goal of ongoing R & D to contribute to design upgrades. By subjecting equipment to the harshest environments possible, engineers are able to design for long-lasting component life. Test units are operated in a high pressure, high solids system using water that contains abrasive particles such as sand and silica. The continuous backwash test guarantees high-performance and durability of filter components even during upset conditions. The rigorous testing is used to ensure that Forsta equipment will not suffer during seasonal/periodic spikes in particle loading that may force the filter into high frequency cleaning.
The ongoing cycle testing shown below has yielded improvements in wear parts design.
AUTOMATIC SELF-CLEANING FILTER SPECS: BASIS OF DESIGN WORK
Many facilities require automated solids filtration solutions. Engineering specifications for Water Treatment Plants, Wastewater Treatment Plants, Irrigation Systems, HVAC Systems for Universities, Hospitals & Data Centers, Desalination Plants, Industrial Cooling Towers, and more, include equipment to reliably remove solids from process and effluent streams.
Forsta works extenstively with engineering firms across the United States and throughout the world to streamline design work and submittal processes. Major engineering firms that deal in the Water Industry often have a Master Specification that is populated with design criteria. The criteria can become onerous for contractors and engineers alike in verifying equipment suitability.
At Forsta Filters, we scour specifications for pertinent details and propose equipment that addresses the needs of the application. We propose simple, robust, easy-to-service and economical filtration options.
The graphic below shows some of the common specification sections that Forsta complies with. See also the fully customtizable features of Forsta’s filtration equipment. Engineers – let Forsta do some of the legwork for you to modify an existing spec and/or modernize your master spec. Contractors – get an ‘or equal’ submittal that will match the criteria of your project.
WATER – Efforts to use water more sustainably have led to a focus on conservation and efficiency. Infrastructure upgrades are continually improving water efficiency across the industrial, municipal and agricultural sectors. These advancements include the optimization of cooling towers and cooling tower filtration, recycling of sample water at cooling towers and implementation of closed loop water systems involving water reclamation and reuse systems. Forsta industrial water filters play an integral role in the performance of closed-loop systems by protecting equipment and ensuring uninterrupted flow.
Waste water treatment plants and pumping stations can connect (often through thousands of feet of reclaimed water pipes) to storage tanks, chillers, steam boilers and irrigation sites. Reclamation and reuse systems make highly treated or “reclaimed” wastewater available to meet a variety of non-drinking water needs thereby reducing strain on drinking water reservoirs and water treatment plants. Forsta self-cleaning water filters using the point of suction backwash technology provide the industry’s most efficient water filter.
Improving water efficiency can be as simple as replacing a wasteful sand media filter with a self-cleaning screen filter (where feed water quality allows.) Click on the chart below to see a quick and easy-to-read comparison based on a 300gpm flow with 50micron filtration.
POWER – Protecting pipes from scale buildup with Forsta self-cleaning filters prevents an increase in the energy required to pump system water. As pipe orifices become smaller, more energy is required to pump the same volume of water. Effects of flowing dirty water include excessive scale buildup, contaminants settlement, and clogged spray nozzles which all contribute to poor pump performance. Implementing Forsta self-cleaning filters prevents these consequences and saves energy.
MATERIAL – Forsta industrial water filters are at the forefront of sustainability. Forsta specializes in the construction of stainless steel industrial water filtration systems and irrigation filters. As people become more aware of their impact on the natural environment, the use of stainless steel as a production material, is gaining greater value than previously recognized.
In mill production 70-85% of the unprocessed material comes from recycled sources. Recycled stainless steel or other alloy scrap comprises the fundamental components that will create raw material after melting in an electric furnace.
Given that stainless steel is 100% recyclable, after exceptionally long life-spans, stainless steel products can be returned to a mill and forged into new raw material. Likewise, all stainless steel scrap left on hand in the production of new stainless steel forms is collected for recycling from within the plant itself.
The longevity of stainless steel products contributes to resource minimization since new resources are not required as frequently to replace corroded or worn products. Stainless steel that is recycled in electric furnaces is of equal quality as the original.
FORSTA SELF-CLEANING FILTERS – SCREEN ADVANTAGES:
It is important to select the correct type and size of water filter. A properly designed system will be able to handle unforeseen overload and adverse conditions.
Plan for a greater water flow than the system is expected to require. It is always better to have more capacity than not enough. A properly sized self-cleaning water filter will save time and money in the long run.
It is recommended to choose a screen element that is appropriate for the application. For example, if a water filter is needed to protect spray nozzles, a filtration degree of 100-200 micron is sufficient. Finer filtration would require an increase in screen area to handle the same flow rate (which is unnecessary and cost-prohibitive).
Each screen size has an upper limit to the particle loading it can handle. This will vary somewhat depending on the size of the particles in the water and the concentration of those particles at various sizes.
Customers often ask how much a Forsta self-cleaning water filter will reduce the solids concentration in a water system. Review of the water’s particle size analysis (PSA) and TSS (in ppm or mg/l) are required to answer this question. Particle size, concentration and total volume will dictate the solids reduction that can be achieved with any given screen size. Click on the chart below to review a sample particle size analysis and particle reduction efficiency with a 50 micron screen.
This section includes an in-depth treatment of self-cleaning filter model selection and operating principles based on system pressure.
35PSI AND UP: UTILIZE SYSTEM PRESSURE TO DRIVE CLEANING
When adequate system pressure is available (min. 35psi) – Forsta recommends keeping filtration equipment as simple as possible. Reduce energy consumption by taking advantage of existing pressure and and eliminate the need for an electric motor. The hydraulic motor refers to the sprinkler style component shown below.
When the flush valve opens to initiate the filter’s cleaning cycle, the result is a localized pressure loss in the hydraulic motor chamber. This creates rapid flow through the entire internal cleaning apparatus. Suction nozzles vacuum debris from the screen and expel it through the hydraulic motor nozzles.
OPENING FLUSH VALVE TO ATMOSPHERIC : PRESSURE POWERS SUCTION & ROTATION, ALLOWS LINEAR MOVEMENT
The magnitude of Forsta’s suction nozzle cleaning power comes from the pressure drop in the hydraulic motor chamber when the flush valve is opened. In hydraulic models this pressure drop also dictates the rotation of the particle remover (rpm).
In both hydraulic and electric motor-driven filters, linear movement of the particle remover is a result of pressure drop in the motor chamber. In both models, the speed of linear movement is regulated by the piston (shown below).
LOW PRESSURE 15-35PSI: DRIVE PARTICLE REMOVER ROTATION WITH AN ELECTRIC MOTOR
Some systems have maximum pressures below 35 psi. In these cases, Forsta offers self-cleaning filter models with an electric motor which uses a minimal amount of power consumption to drive the cleaning cycle. Electric motors are mounted on the cover of the filter (shown below), and aid rotation of the particle remover. Forsta’s low-pressure (motor-driven) filters operate in environments as low as 15psi.
Review full operating concepts of hydraulic and low-pressure filters by watching Forsta’s How It Works videos on each of the following product pages:
SELF-CLEANING FILTER SELECTION – COST
Waste disposal, labor, maintenance and downtime costs are frequently overlooked when implementing quick solutions. Installation or upfront cost must be weighed against ongoing operating cost in time, money and water.
Sand or media filters can take up to 10 minutes per backwash and upwards of 1000 gal during one cleaning cycle (depending on the flow rate). They can cost in excess of 70k for flows as low as 10gpm. Forsta self-cleaning water filters can handle the same flow at a fraction of the cost. Additionally, Forsta self-cleaning filters require minimal volume (as little as 1 gallon) per cleaning.
Cartridge and bag filter replacements can be most costly in terms of system downtime and labor.
Review the chart below to compare efficiency, cost etc. of various filtration technologies.
|Forsta Self- Cleaning Filters||High|
Flush water volume is very low and flush time is fast – 2 to 30 seconds
|Med-High||Easy Automatic operation does not interrupt system flow during the rinse cycle||Small||5 micron||Low|
|Gravity Coanda Effect Screen||Low Cannot be used in pressurized systems||Low||Easy||Large||200 micron and up||Requires periodic cleaning|
|Bag and Cartridge||High||Med-High||Easy||Small||Sub-micron||Labor intensive. Requires bag or cartridge change outs|
However, flush water volume is large and flush time can be very high- as much as 10 minutes or more
|Med-High||Twin systems are required for uninterrupted automatic operation||Large||1 micron||Requires periodic media changes|
Batch or continuous low flush water
|Low||Suitable for full-time automatic operation:||Small-Med||Captures down to 75-micron level but cannot filter particulates below ~ 1.1 specific gravity. Cannot filter algae and is flow sensitive||Low|
Require high flow cleaning cycle
|Low||Can be adapted to automatic operation||Small||Labor intensive. Requires periodic screen removal and pressure wash cleaning.|
The self-cleaning mechanism in a Forsta self-cleaning filters eliminate the need for routine maintenance by automating the cleaning cycle. Differential pressure is monitored by the controller which initiates the backwash cycle automatically. As a result, Forsta self-cleaning technology saves maintenance time and operating cost. Manual washes, spray downs, filter, cartridge and bag replacements become unnecessary. Basic bi-annual or annual inspection (depending on particle load) replaces the need for daily, weekly or monthly shutdowns.
Well-tested and time proven design make Forsta industrial water filters a dependable choice. A wide range of clientele whose applications require rigid filtration parameters and uninterrupted function report great success operating self-cleaning water filter technology. High standard material grade of Forsta industrial water filters prevents corrosion and guarantees a long life for each filter.
Debris collects inside the filter’s stainless steel screen. When differential pressure initiates the automatic cleaning cycle, flow reversal occurs at the point of suction rather than throughout the entire filter. This provides an important advantage in that it allows for continuous flow throughout the filter for the duration of each backwash cycle.
To preserve system continuity during bi-annual or annual maintenance, multiple self-cleaning water filters may be installed in parallel. This configuration provides a larger cumulative screen area and allows one or more water filters to be removed from service for periodic maintenance without interrupting the filtration process.
SHORT CLEANING CYCLE
Forsta self-cleaning water filters require only 2-30 seconds to perform a backwash cycle. Other filter technologies, such as sand, or bag and cartridge filters may necessitate several hours to complete their cleaning process.
Forsta offers self-cleaning filters in a wide range of sizes, orientations, and to varying degrees of filtration in order to answer any demand. Custom design solutions for unique applications are available as well. Forsta provides its self-cleaning water filters ready to install.
All Forsta self-cleaning water filters accommodate simple installation. The 180 series of filters have a parallel flange configuration, and will integrate with any straight pipeline.
The 90 series filters exhibit a right angle flange configuration that provides a compact filter unit.
Zero Series and Coarse Strainer automatic water filters have a straight flange configuration and like the 180 series, will also integrate with any straight pipeline.
Skid Mounted units are ready-to-go custom industrial water filters mounted on a single platform. Skid Mounted filtration systems combine any self-cleaning filter model with required pumps, manifolds, and controllers.
The control system of a self-cleaning water filter is an important part of the package. It is designed to be reliable, easy to operate and capable of initiating a flush cycle either by high differential pressure or on a timed basis. Why choose Forsta? Forsta’s control systems provide an alarm function to warn operators of filter malfunction. LCD displays also indicate the number of times the Forsta self-cleaning filter has backwashed.
Controllers are sized to fit the application ranging from large industrial controllers to small battery powered controllers. An industrial controller is capable of flushing up to four self-cleaning water filters in parallel. The small, battery powered controller features a one-year battery life and is ideal for controlling filters located where a power source is not available.
Forsta offers a free water testing service for customers looking to determine the most cost-effective water filtration system. Send a one gallon water sample and Forsta will determine the right solution for your application. With a representative water sample our engineers can estimate how often a self-cleaning filter will backwash and how much screen area will be needed to achieve the desired filtration degree.
Forsta is distinguished by our attention to prompt and thorough customer service. We are proud to offer same-day quotes for most projects, and are responsive to the unique documentation that each project calling for self-cleaning water filters requires. Engineers are available to assist you from the preliminary design and quoting stages through installation and startup and on into normal operations.
COMPETITIVE PRICING – OEM/RESELLER PROGRAMS
Forsta strives to be at the cutting edge of the competition and works to make our self-cleaning water filters accessible on all projects. OEM/Reseller pricing is available upon request as well as quantity purchase agreements.