Water Well Journal Q&A

STEVE ANDERSON
Merrill Manufacturing Co. president talks failure prevention and best practices learned in the field.

By Thad Plumley

Long before Steve Anderson stepped into leadership, Merrill Manufacturing Co. was built around one simple idea: listen to contractors and solve real problems in the field.

Steve’s father Noel was working closely with water well contractors in 1949 when he recognized a recurring issue—yard hydrants that simply didn’t last. By focusing on durability, real-world conditions, and what installers actually needed, he helped develop a more reliable solution. That contractor-driven mindset became the foundation of Merrill Manufacturing and remains central to the company today.

After nearly five decades in the groundwater industry, Steve Anderson has seen just about every way a water well system can succeed or fail. As president of Merrill Manufacturing, he oversees a company best known for producing durable, field-tested water well components used by contractors and distributors across the world. Merrill’s products are found in residential, agricultural, and commercial water well systems where reliability isn’t optional, it’s expected.

Before leading Merrill, Steve built his career immersed in engineering, product design, and real-world application. He worked closely with contractors, distributors, and engineers to understand not only what components fail in the field, but why those failures happen in the first place.

“I’ve always believed the best products and the best advice come from understanding how things actually get installed, serviced, and repaired,” Anderson says. “Most failures aren’t mysterious. They’re preventable.”

Water Well Journal caught up with Anderson to talk failure prevention and best practices, covering common issues that lead to callbacks, downtime, and unnecessary costs for contractors.

Water Well Journal: When you think about system failures in the field, what do you see most often and what’s usually the root cause?
Steve Anderson: Most failures come down to small details being overlooked. It’s rarely a catastrophic product defect. More often, it’s installation shortcuts, skipped checks, or assumptions that “it’ll be fine.”

A lot of components fail not because they’re bad, but because they’re misapplied, undersized, or never properly checked after installation. Over time, those small oversights turn into callbacks, burned-out equipment, or frustrated customers.

In many cases, the system technically works at startup, so the problem goes unnoticed. But six months or a year later, that same system is cycling too often, losing pressure, or suffering electrical damage. The good news is that many of these failures are easy to prevent if contractors follow a few consistent best practices and take the time to verify the fundamentals.

WWJ: Let’s start with multi-size wire connectors. Why are these an important failure prevention item?
Anderson: Wire connections are one of those things that seem minor until they’re not.

Multi-size wire connectors are designed to handle variations in wire gauge properly. When installers try to force a connector that isn’t sized correctly, you end up with poor contact, overheating, or corrosion issues over time.

What makes this tricky is that the failure often isn’t immediate. The connection may pass initial testing, but vibration, temperature changes, and moisture slowly degrade it. Eventually, that weak connection becomes a service call, or worse, causes damage to the motor or control components.

Using properly designed multi-size connectors ensures a solid electrical connection, reduces resistance, and minimizes heat buildup. It’s a small cost upfront that protects the entire electrical side of the system and saves a lot of headaches later.

WWJ: Check valves are another area you’ve emphasized, specifically VFC [variable flow control] check valves. What should contractors be paying attention to here?
Anderson: Check valves are critical, but they’re also frequently misunderstood.

With VFC check valves, placement and spacing matter just as much as the valve itself. Improper spacing can cause water hammer, pressure fluctuations, and unnecessary stress on the pump and piping.

True VFC valves are needed for the system to be as trouble-free as it should be. One of the most common mistakes we see is either installing too few check valves too far apart or not installing them where they’re actually needed. Both scenarios create problems.

Contractors should pay close attention to system depth, pump type, and manufacturer recommendations. Proper VFC valve placement helps maintain consistent pressure, reduces mechanical stress, and extends the life of both the pump and the overall system.

WWJ: Why does improper check valve spacing cause so many issues?
Anderson: When check valves aren’t spaced correctly, pressure waves or water hammer don’t dissipate the way they should. Instead, they bounce back and forth through the system.

Over time, that stress shows up as cracked fittings, damaged pumps, or noisy operation that customers complain about. It’s one of those issues that doesn’t always fail immediately, but it’s quietly shortening the system’s lifespan.

Proper spacing creates smoother operation and protects the entire water column. It’s not just about preventing failure; it’s about improving performance and reducing wear over the long term.

WWJ: Pressure tanks are another common source of failure. What’s the biggest issue you see there?
Anderson: Air precharge, hands down.

If the pressure tank isn’t set to the correct air precharge, the system will short cycle. Short cycling is one of the fastest ways to burn up a pressure switch or damage a pump motor.

What surprises me is how often this step gets skipped. Checking the air precharge takes only a few minutes, but it makes a massive difference in system performance and longevity. No product is always perfect, and slight air leaks happen. If the tank precharge is way low brand new, check it out.

Contractors should always verify the precharge before startup and recheck it if there are pressure-related complaints later. That simple habit eliminates a large percentage of avoidable failures.

WWJ: How does a loose spring on the differential factor into pressure switch problems?
Anderson: A loose spring on the differential is actually normal, but it still needs to be checked and understood.

The differential spring only comes into play when the switch is pressurized. The minimum differential on a typical mechanical switch is 12 PSI. Anything below will fail; 20 PSI is best.

If the pressure switch isn’t adjusted correctly, the system cycles more frequently than it should. That extra cycling creates heat and wear, which eventually leads to switch failure or motor damage.

Contractors who take the time to verify proper pressure settings and understand how the differential operates dramatically reduce callbacks related to pressure problems. It’s another example of how knowing the equipment pays off in fewer service issues later.

WWJ: Surge protectors or lightning arrestors don’t always get much attention. Why do you call them “cheap insurance”?
Anderson: Because that’s exactly what they are.

Surge protectors or lightning arrestors cost very little compared to the damage a surge can cause. A single lightning strike—or even a nearby one—can destroy electrical components instantly.

We’ve seen cases where everything in the system was installed correctly, but a surge wiped out controls, motors, and switches in seconds. Installing a surge protector-lightning arrestor protects those components and gives the system a fighting chance.

When you compare the cost of the arrestor to the cost of replacing damaged equipment and the downtime for the customer, it’s an easy decision.

WWJ: From your perspective, why do best practices sometimes get ignored in the field?
Anderson: Time pressure, familiarity, and habit.

When someone’s installed hundreds of systems, it’s easy to assume everything will go the same way as last time. But conditions change, components change, and even small differences can matter.

The contractors who consistently succeed are the ones who slow down just enough to verify the basics: wire connections, tank precharge, pressure settings, valve placement. That discipline separates good installations from great ones.

WWJ: What role do manufacturers play in helping contractors prevent failures?
Anderson: Manufacturers have a responsibility to design products that work in real-world conditions and to educate the industry on proper use.

At Merrill, we spend a lot of time listening to contractors. Their feedback drives design improvements and helps us provide clearer guidance on installation and application. We have also posted about 130 YouTube videos [and growing] on many topics such as repair, install tips, and product knowledge.

Failure prevention is a shared responsibility. When manufacturers and contractors work together, systems last longer, customers are happier, and the entire industry benefits.

WWJ: If you could leave contractors with one takeaway, what would it be?
Anderson: Most failures are preventable. Pay attention to the details—pump and tank sizing, wire sizing, check valve spacing, pressure settings, and surge protection. These aren’t extras; they’re fundamentals.

Doing it right the first time protects your reputation, saves money, and keeps customers satisfied. In this industry, that’s how you build long-term success.

WWJ: Thank you so much. Any closing thoughts?
Anderson: In an industry where reliability matters and mistakes are expensive, failure prevention isn’t about overengineering, it’s about respecting the fundamentals.

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Thad Plumley is the editor of WWJ and the director of publications for the National Ground Water Association. He can be reached at tplumley@ngwa.org, or (800) 551-7379, ext. 1594.