Inserts for

Sewer Odor and

Corrosion Control

M U N I C I P A L

S Y S T E M S

Sewer Drop Structures

Pumping Stations
Forcemain Discharge

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We build tough products for tough environments

VORTEX FLOW
A SIMPLE SOLUTION FOR ODOR
AND CORROSION CONTROL
ydrogen sulfide (H2s) gas and other odorous gases are
a fact of life with sanitary sewer drop structures. When
these gases become airborne, they not only generate
complaints from the neighborhood, but also impact air quality
and cause corrosion within the sewer system. Municipalities
spend millions on various forms of odor and corrosion control,
yet many of these methods are only partially successful and
require a considerable amount of maintenance and chemicals.

A new solution for municipalities is the IPEX Vortex Flow Insert

(VFI), a revolutionary technology for eliminating odorous
emissions and minimizing corrosion in vertical sewer drops.
With no moving parts and requiring no maintenance, VFIs have
delivered significant cost savings in installations across North
America.

Flow is accelerated
to supercritical
velocity

Influent Line

The VFIs patented spiral flow design eliminates odorous and

corrosive gases in a unique way. It uses the wastewaters own
flow energy to suppress the turbulence which releases noxious
gases. The spiral flow creates a downdraft which traps
airborne gases and forces air into the sewage flow to oxidize
odorous gases. By installing a Vortex drop structure,
municipalities can save thousands of dollars in monthly
chemical feed, air-phase treatment and maintenance costs.
In addition, land developers can save hundreds of thousands
of dollars in excavation costs in areas where conventional drop
structures are not allowed.

BUILT-TO-SPEC FOR ANY SIZE

Manholes, chambers and pumping stations are built in a variety of sizes. For that
reason, IPEX custom designs and custom builds every Vortex Flow Insert. The
Vortex drop height can be as little as 5 feet or more than 100 feet tall. Shop
drawings are prepared and submitted to the customer, and each phase of the
project is tightly-controlled to ensure the project's success.
IPEX VFIs are sized based on the peak flow that the unit is required to handle
flows as little as 0.3MGD to 120MGD. The insert can be installed in a standard
manhole without restricting access for maintenance.

HOW IT WORKS

1
Drop Structure

VORTEX TOP FORM

The wastewater flows into the Vortex Top
Form which directs the flow around a channel
of decreasing radius. At the same time, the
Vortex channel slopes downward to accelerate
the wastewater to a supercritical velocity.

Vortex Top Form

2
Vortex Channel

3
Vortex Drop Shaft

Flow Exit
Energy
Dissipation Pool

Effluent Line

VORTEX DROP SHAFT

Once the flow is channeled into the smaller
Drop Shaft, the velocity and centrifugal forces
generated within the VFI cause the flow to hug
the inside walls of the Vortex Drop Shaft. This
spiraling flow creates a negative air core, which
draws airborne gases down the Drop Shaft to
the Energy Dissipation Pool. Frictional forces
created within the Vortex Drop Shaft assist in
dissipating the fluid energy.

ENERGY DISSIPATION POOL

The flow exit is submerged in the Energy
Dissipation Pool at the bottom of the Vortex. Air
and gases drawn down the air core are forced
back through the wastewater and are reentrained into the flow. This significantly
increases the dissolved oxygen concentration in
the wastewater, and the re-entrained odorous
compounds are then quickly oxidized.

WINNER OF THE APWA TECHNICAL

ACHIEVEMENT AWARD
The American Public Works Association presents
Technical Innovation Awards to designers of devices,
processes or systems that benefit public works by
serving the public and protecting the environment. Dr.
Eugene Natarius, creator of the Vortex Drop Structure,
received an award for his revolutionary design. Since
then, units have been installed in cities across North
America including municipalities in Ontario, California
and Ohio.

REDUCED EXCAVATION COSTS AND LONG TERM SAVINGS

hile Vortex Flow Inserts leave manholes and pumping stations smelling better, they can
also make a land developers job easier and less costly.
Due to the odor and corrosion problems of conventional drop structures, many
municipalities have banned them altogether. Until now, the only alternative available to land
developers was to install sewers with a gradual grade to
trunk sewers deep underground, a practice which can
cause the cost of excavation to skyrocket.

But by installing Vortex Drop Structures (drop structures

with Vortex Flow Inserts), land developers can now
comply with municipality concerns and save thousands, if
not millions, in excavation costs. No wonder developers
across North America are taking advantage of this
revolutionary technology.

HOW VORTEX FLOW CAN SAVE

MUNICIPALITIES MONEY
REDUCED CORROSION EXTENDS SEWER LIFE
Hydrogen sulfide (H2s) emissions from forcemain discharges can literally eat
through a concrete drop manhole. By oxidizing dissolved H2s, a Vortex Flow
Insert in a municipal sewer drop can significantly reduce concrete and metal
corrosion, extending sewer life and saving the municipality money.

REDUCES ODOR TREATMENT COSTS

By increasing dissolved oxygen levels in wastewater and oxidizing sulfides
and other odorous compounds, the use of a Vortex Flow Insert in a drop
structure reduces the need for costly chemical injection, high-maintenance
biofilters and air scrubbers.

IMPROVES WASTE WATER QUALITY

Because a Vortex drop structure reduces the odorous and corrosive
elements in the flow, a Vortex Flow Insert, installed upstream of a treatment
plant, can actually improve wastewater quality prior to treatment, reducing
treatment costs at sewage plants.

REDUCED MAINTENANCE COSTS

The use of a Vortex drop structure eliminates the corrosion of
concrete and metal sewer components, dramatically reducing
municipal maintenance costs of manholes and sewers.

Finally, we have a long-term solution to our sanitary

system odor and corrosion problems. It is a onetime cost that requires no ongoing maintenance.I
would definitely recommend this product.

Frank A. Badinski, C.E.T.,

Asset Management Coordinator,
Regional Municipality of York;
NAAPI Chair;
NASTT Great Lakes St. Lawrence and Atlantic Canada Vice-Chair.

APPLICATIONS
Manholes, Chambers and Forcemains
- Wherever you have a drop from one pipe
to another, Vortex drop
structures can
transform drop
manholes from
potential maintenance
problems into effective
aeration devices that
control odor and
corrosion.

Pumping Station Wet

Wells - A Vortex drop
structure can minimize
gas emissions from
pumping station wet
wells.

Steep Grade Sewers

- Vortex Flow can
dissipate the flow
energy of water
running down a steep
grade, reducing the
flows discharge
speed.

Barometric Loop
- A barometric loop is
an area where a
forcemain is brought
up out of the ground to
improve the hydraulic
profile of the system.
Sometimes referred to
as a gooseneck due
to its appearance as it rises up out of the ground,
barometric loops can be used to slow the flow down and
improve flow characteristics at a force main discharge.

PRODUCTION AND INSTALLATIONS

PRODUCTION

Fabrication of a 60 MGD Vortex unit

Austin, Texas.

Hydrostatic testing of a large

Vortex unit.

Shipping from fabrication plant,

direct to site.

Offloading a Vortex Top Form.

A uniquely flanged Vortex,

Vancouver, British Columbia.

Vortex with a flanged entrance, Manassas,

Virginia.

Second effluent line at bottom, benching

from the EDP to direct flow, Sarnia, Ontario.

Strapping detail on Vortex unit, Buckeye,

Arizona.

Securing Vortex Flow unit, Burlington,

Kentucky.

Stainless steel straps and epoxy painted

walls for additional layer of corrosion
protection, Charlotte, NC.

Vortex Flow operating in a pumping station

wet well, Jacksonville, Florida.

Vortex Flow Insert reducing H2S

concentration levels,
Camden County, New Jersey.

INSTALLATION

UNIQUE INSTALLATIONS

Barometric loop for reduction of velocity and energy

dissipation at the WWTP Newburgh, IN

Dual influent lines with twin clockwise and counter-clockwise

flow Vortex units Davidson, NC

Structure with multiple Vortex

units at different influent
elevations and flow rates
Austin, TX

Vortex installed in 5 million

gallon CSO storage tank
adjacent to WWTP Port
Angeles, WA

VORTEX FLOW CASE STUDY

COST SAVINGS OVER CHEMICALS ST. ROBERT

The City of St. Robert, Missouri made the decision to
install a new state-of-the-art sewer system. The goal
was to use fewer lift stations and more gravity-based
linear feet in order to move 50% of the citys sewage.
The new system has 13,000 linear feet of 16" sewer
main and 25% of it is gravity-based, stated Jeff

The upside of this is the greater portion

of your line you have gravity-based, the
less maintenance youll have.

Jeff Medows, Project Engineer

Medows of C.M. Archer Group. We have reduced the

citys lift stations to just two and thats better for the
people of St. Robert. The upside of this is the greater
portion of your line you have gravity-based, the less
maintenance youll have, Medows said.

PROFILE
PROJECT
No. 6 Lift Station
City of St. Robert, Missouri

CONTACT
Steve Long
Public Works Foreman, City of St. Robert

ENGINEER
Jeff Medows, P.E.
C.M. Archer Group, P.C.

CONTRACTOR
Installed by municipality

INSTALLATION
One Vortex Flow Insert
Type:
Force Main
Flow Range: 0.48 3.65 MGD
Peak Flow: 3.17 MGD
VFI Design: 32" Top Form, 6' Drop

However, the challenge of a gravity-based system is

how to oxygenate the sewage and control odor and
corrosion. The cost of adding chemicals $140,000 in
the first year and $35,000 annually, would negate any
cost savings achieved by eliminating the pumps. Public
Works Foreman Steve Long had recalled seeing an
alternative device, the Vortex Flow Insert.
I saw this system in a magazine that I picked up at a
conference, Long said. Its gravity-driven. A Vortex
Flow Insert uses the wastewaters own flow energy to
suppress the turbulence which releases the noxious
gases. By installing one Vortex Flow unit, the
municipality was able to save the money it would have
spent on adding chemicals to manage the H2S
emissions.
The system features a 32" top form with a 6' drop and
is designed for a peak flow of 3.17 MGD. The total cost
was $25,750 for construction and installation. Its a
new green technology, Medows said. Its the first one
in the state of Missouri.
None other like it.

VORTEX FLOW INSERT

TYPICAL PROJECT FLOW FOR A VORTEX FLOW INSERT

S T E P 1 : D E S I G N I N F O R M AT I O N F O R M
Customer provides a completed Design Information Form to
IPEX which assists IPEX engineers in developing a conceptual
design.
STEP 2: CONCEPTUAL DESIGN
IPEX designs the unit based on the Design Information Form.
IPEX provides conceptual drawings for the project and CFD
analysis (where necessary).
IPEX provides an engineering estimate.
STEP 3: DIMENSION SIGN-OFFS
Once the project has been bid and IPEX has received the
purchase order, IPEX will send Dimension Sign-Offs to the
Project Engineer and Contractor to verify that all the data is
correct.
S T E P 4 : D E TA I L E D D E S I G N
Upon receiving the completed Dimension Sign-Offs, IPEX
design engineers will begin the Detailed Design process.
S T E P 5 : FA B R I C AT I O N
Once the Detailed Design has been completed, the fabrication
of the Vortex unit will commence.
S T E P 6 : S H I P M E N T & I N S TA L L AT I O N
Once the fabrication process has been completed, the Vortex
will be shipped to the jobsite along with a full set of detailed
installation instructions.

R E C O G N I Z E D A S A N E W A N D I N N O VAT I V E P R O D U C T B Y T H E U . S . E PA
The U.S. Environmental Protection Agency (U.S. EPA) is charged by Congress with protecting the
nations land, air, and water resources. In the July 2006 publication, Emerging Technology for
Conveyance Systems New Installations and Rehabilitation Methods (EPA Report: 832-R-06-004)
the Vortex Flow Insert was recognized as a new and innovative product.

DESIGN INFORMATION FORM

Complete this form and fax it back to us at (905) 403-1124.

Dept.

Name

Title

Company

Address

City

Province

Postal Code

Phone

Fax

E-mail

Project Name

Project Location (City, Province )

Owner Name

Engineer

Bid Date

Construction Launch Date

Drop Structure Information

See depiction of a typical drop structure layout and to answer questions 2 6.
NEW EXISTING

WET WELL

1)

New or Existing Drop Structure

2)

Manhole Diameter

_________________ ft | m

3)

Ground Elevation

_________________ ft | m

4)

Manhole Floor Elevation

_________________ ft | m

5)

Influent Line Elevation

_________________ ft | m

6)

Effluent Line Elevation

_________________ ft | m

7) Comments on any unique details

_____________________________________________________________________
______________________________________________________________________
Flow Information
(Please provide us with the flow rate the Vortex will initially experience and also
the estimated build out flow rate.)
GRAVITY

FORCEMAIN

1)

Flow Type

2)

Todays Peak flow Dry Weather

_________________ MGD | m3/h

3)

Todays Average flow Dry Weather

_________________ MGD | m3/h

4)

Todays Peak flow Wet Weather

_________________ MGD | m3/h

5)

Build Out Peak flow Dry Weather

_________________ MGD | m3/h

6)

Build Out Avg. flow Dry Weather

_________________ MGD | m3/h

7)

Build Out Peak flow Wet Weather

_________________ MGD | m3/h

8)

Expected Sewage Velocity

_________________ FPS | m/s

9)

Pump rate capacity of all pumps (if applicable)

10) Expected Build Out Time Frame

___________ MGD | m3/h

_________________ YEARS

Influent Line Information

Notes:_______________________________________
_____________________________________________
_____________________________________________
_____________________________________________

1)

Influent line material

_________________

2)

Influent line nominal diameter

_________________ in | mm

3)

Influent line outer diameter

_________________ in | mm

4)

Influent line inner diameter

_________________ in | mm

5)

Slope of influent line

_________________ %

_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________

CONCEPTUAL DRAWING

SALES AND CUSTOMER SERVICE

Call IPEX Inc.
Toll free: (866) 473-9462

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About IPEX
As leading suppliers of thermoplastic piping systems, the IPEX Group of
Companies provides our customers with some of the worlds largest and
most comprehensive product lines. All IPEX products are backed by
more than 50 years of experience. With state-of-the-art manufacturing
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and performance.
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Plumbing and mechanical piping systems
PE Electrofusion systems for gas and water
Industrial, plumbing and electrical cements
Irrigation systems

Vortex FlowTM is manufactured by IPEX Inc

Vortex FlowTM is a trademark of IPEX Branding Inc.

This literature is published in good faith and is believed to be reliable.

However, it does not represent and/or warrant in any manner the information
and suggestions contained in this brochure. Data presented is the result of
laboratory tests and field experience.
A policy of ongoing product improvement is maintained. This may result in
modifications of features and/or specifications without notice.

BRMNVFIP140301C 2014 IPEX MN0021C