AUGUST 2016

PUMPSANDSYSTEMS.COM

PUMPS~SYSTEMS
The Leading Magazine for Pump Users Worldwide

>
It Doesn’t Need Repair.
It needs engineering solutions
for better performance and longer life.
Hydro’s aftermarket pump service organization provides engineering
expertise and essential support to pump users around the world.
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Engineering Solutions for Pump Reliability

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2 FROM THE EDITOR

A s August rolls around each year,

the Pumps & Systems team excitedly
prepares for the trek to Houston for the
EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
[email protected] • 205-278-2843
SENIOR TECHNICAL EDITOR: Mike Pemberton
Turbomachinery & Pump Symposia—
[email protected]
dubbed TPS. Last year, the event 205-314-8279
drew 5,500 people and 350 exhibiting MANAGING EDITOR: Amelia Messamore
companies from 48 nations across the [email protected]
205-314-8264
globe. While thousands gather for TPS
MANAGING EDITOR: Martin Reed
each year, the event feels more like a
[email protected] • 205-278-2826
reunion than anything—we love catching
MANAGING EDITOR: Savanna Gray
up with industry friends, both old and [email protected] • 205-278-2839
new. If we haven’t met you yet, we would CONTRIBUTING EDITORS: Lev Nelik,
love to! Please feel free to drop by our Managing Editor Amelia Messamore (middle) Ray Hardee, Jim Elsey
and Account Executive Garrick Stone (right) EDITORIAL INTERN: Caroline Hammond
booth (#1322) and say hello. meet with Flowserve at TPS 2015. [email protected] • 205-314-8269
Part of our preparation for TPS involves
CREATIVE SERVICES
publishing this special edition of Pumps & Systems. Every fall, we dedicate one issue of
DIGITAL PROJECT MANAGER &
the magazine to pump systems optimization, a topic that is more critical than ever. The SENIOR ART DIRECTOR: Greg Ragsdale
Hydraulic Institute (HI) in particular is making education and instruction on this topic ART DIRECTORS: Elizabeth Chick
a top priority. Why? Because they understand that optimization is critical for reaching WEB DEVELOPER: Greg Caudle
modern energy efficiency and reliability goals. DIGITAL COMMUNITY MANAGER: Amy Cash
We hope the contents of this issue’s cover series will give you the tools and insight you PRINT ADVERTISING TRAFFIC: Lisa Freeman
need to start or enhance your own pump systems optimization initiatives. [email protected] • 205-212-9402
To open the section, we provide a basic schematic of a closed-loop heat exchanger
CIRCULATION
pump system, as well as an outline of the components and how each affects overall
AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
operation (pages 50-54). The section continues with five steps to successful systems [email protected] • 205-278-2840
optimization, provided by HI (page 56). You’ll also find several real-world examples of
optimization at work. One article on page 62 tells the story of a desalination plant in ADVERTISING
Cyprus that optimized its operations to save €2.3 million per year in energy costs (that’s NATIONAL SALES MANAGER: Derrell Moody
[email protected] • 205-345-0784
about $2.5 million). We hope that these and the many other case studies and technical
ACCOUNT EXECUTIVES:
articles in this section give you what you need to hit your efficiency targets. Mary-Kathryn Baker
You also don’t want to miss our special section on couplings, seals and bearings, which [email protected] • 205-345-6036
contains case studies and tips that will help you make the most of this critical pump Mark Goins
system equipment. [email protected] • 205-345-6414
One final note: In last month’s issue, you may have noticed a headline that John Harris
[email protected] • 205-561-2607
read “Are You a Pump Ninja?” Columnist Jim Elsey provided this quiz to test your
Garrick Stone
pump knowledge, which has sparked a lot of conversation—and competition! If [email protected] • 205-212-9406
you haven’t taken the quiz yet, check out the July issue of Pumps & Systems or visit
MARKETING ASSOCIATE:
pumpsandsystems.com/pump-quiz. Once you get your score, email us at pumpeditors@ Sonya Crocker
cahabamedia.com to share your results—we look forward to hearing from you! [email protected] • 205-314-8276
As always, thanks for reading. SALES INTERN:
Alex Rodriguez
[email protected] • 205-314-8279

Managing Editor, Amelia Messamore

[email protected] PUBLISHER: Walter B. Evans Jr.
VP OF SALES: Greg Meineke
CREATIVE DIRECTOR: Terri J. Gray
CONTROLLER: Brandon Whittemore
Pumps & Systems
is a member of the following organizations:
P.O. Box 530067
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the Birmingham, AL 35253
right to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and
possessions $5, all other countries $15 US funds (via air mail). Call 205-278-2840 inside or outside the U.S. POSTMASTER: Send changes of address and EDITORIAL & PRODUCTION
form 3579 to Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253. ©2016 Cahaba Media Group, Inc. No part of this publication may be reproduced
without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements,
1900 28th Avenue South, Suite 200
articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The Birmingham, AL 35209
opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes 205-212-9402
no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS:
We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media Group, Inc.,
permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free ADVERTISING SALES
to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 24, Issue 8. 2126 McFarland Blvd. East, Suite A
Tuscaloosa, AL 35404
205-345-0784
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4
This issue AUGUST
Volume 24 • Number 8
COLUMNS
COVER
SERIES PUMP SYSTEMS OPTIMIZATION PUMPING PRESCRIPTIONS
14 By Lev Nelik, Ph.D., P.E.
Pumping Machinery LLC
Optimizing Pump Hydraulics:
When Is it Important?
PUMP SYSTEM IMPROVEMENT
18 By Ray Hardee
Engineered Software Inc.
Optimizing Large Cooling
Water Systems

COMMON PUMPING MISTAKES

24 By Jim Elsey
Summit Pump Inc.
Use this Checklist to Stop Oil Leakage
from Your Bearing Isolators

INDUSTRY INSIGHTS
28 By Mike Pemberton
Pumps & Systems

72 Overcoming Barriers to Pump

System Optimization

2 FROM THE EDITOR

50 OPTIMIZE FROM THE ONSET
By Bill Livoti, WEG 8 NEWS
Overview of a Closed-Loop Heat Exchanger Pump System 13 TRADE SHOW PREVIEW

56 5 STEPS TO SUCCESSFUL PUMP SYSTEMS OPTIMIZATION 104 PRODUCTS

By Mark J. Sullivan, Hydraulic Institute/Pump Systems Matter 108 ADVERTISERS INDEX
Evaluating the entire system for possible improvement will help facilities lower 108 PUMP USERS MARKETPLACE
energy use and improve reliability.
112 PUMP MARKET ANALYSIS
62 CYPRUS DESAL PLANT OPTIMIZES TO SAVE €2.3 MILLION PER YEAR
By Beat Schneider, Flowserve SPECIAL REPORTS
A facility in this island nation installed new technologies to meet continuous high 30 7 QUESTIONS TO ASK WHEN
water demand without changing the building’s footprint. UPGRADING A PUMP MOTOR
By Terry W. Bell,
66 SHORTCUTS CAN LEAD TO DISASTROUS OUTCOMES Baldor Electric Company—
By Chandra Verma, Hydro, Inc. A Member of the ABB Group
Design flaws cause catastrophic failure in a geothermal power station hotwell in When following the new DOE
New Zealand. guidelines, don’t forget these
considerations.
72 MAINTAIN PERFORMANCE ON OLDER PUMPS 32 RENTAL SECTOR GROWS TO
By Jerry Ruc, Sulzer MEET INCREASING DEMAND
To optimize system operation, designers must match the conditions that By Mike Delzingaro, Xylem
encompass the system curve. Pump manufacturers respond with
strategies to better meet needs from
construction, industry, municipal
and mining segments.

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6
This issue AUGUST
DEPARTMENTS
COUPLINGS, SEALS & BEARINGS
SPECIAL
SECTION 76 EFFICIENCY MATTERS
Advantages of AODD Pumps
in Sludge Drying & Thickening
36 EVALUATING CARBON Applications
RING ALTERNATIVES By Peter Schüten
By Peter Zanini, Inpro/Seal
Almatec
Operators should investigate the pros and
cons of each option to determine the best fit 81 MAINTENANCE MINDERS
for their applications. Troubleshooting Vibration Issues
38 HIDDEN DANGERS WITHIN ENERGY-
42
Without an Expensive Analyzer
EFFICIENT SYSTEMS By Mark Jennings
By Ed Kaineg, Schaeffler Group USA Engineering Consultant
End users must understand the conditions
that lead to early bearing failure to choose the best technology for their needs. 84 MOTORS & DRIVES
Understand Specifications for
42 GET IMPROVED PUMP PERFORMANCE WITH BEARING UPGRADES Large-Horsepower Motors
By Brian P. Dahmer, SKF USA Inc.
By James Nanney
Alternative bearing options can enhance reliability and increase energy efficiency. Power Electronics USA
46 API 610 DISC PACK COUPLINGS PROMOTE MAXIMUM RELIABILITY
By Brian Conner, R+W Coupling Technology 88 SEALING SENSE
Birth of the General-Purpose,
One unique design transmits torque across the disc pack assemblies purely by
friction, helping to prevent issues associated with stress concentration, backlash High-Performance ePTFE/
and chatter. Graphite Packing Fiber
By Carl Jones
FSA Member,
PRACTICE & OPERATIONS W.L. Gore & Associates
95 ADVANCES IN METERING PUMPS MEET 91 HI PUMP FAQS
SPECIFIC APPLICATION CHALLENGES
Key Considerations for
By Aaron Hinchliffe, IWAKI America
AU G U S T 2 0 16
PUMPSAN S S MS.COM
PUMPSANDSYSTEMS.COM

ON THE COVER Upstream Piping with Control-

The Leading Magazine for Pump Users Worldwide

Pump system concept Changing needs and requirements have caused Volume Metering Pumps &
provided by Ray pump technology to evolve. Requirements for Suction
OPTIMIZE
Hardee, Engineered Piping Design
98 CLOSED POWDER-HANDLING SOLUTIONS
YOUR SYSTEM

Software Inc. By Hydraulic Institute

CREATE EFFICIENCIES & INCREASE
SAFETY IN PROCESS INDUSTRIES
By Steven Coupal, ARO
These systems prevent a variety of possible
expenses and health dangers.

EDITORIAL ADVISORY BOARD

THOMAS L. ANGLE, P.E., MSC, Vice BOB DOMKOWSKI, Business TODD LOUDIN, President/CEO North SCOTT SORENSEN, Oil & Gas
President Engineering, Hidrostal AG Development Manager – Transport American Operations, Flowrox Inc. Automation Consultant & Market
BRYAN S. BARRINGTON, Machinery Pumping and Amusement Markets/ MICHAEL MICHAUD, Executive Developer, Siemens Industry Sector
Engineer, Lyondell Chemical Co. Engineering Consultant, Xylem, Inc., Director, Hydraulic Institute ADAM STOLBERG, Executive Director,
Water Solutions USA – Flygt Submersible Wastewater Pump
KERRY BASKINS, VP/GM, Milton Roy JOHN MALINOWSKI, Sr. Product
Americas WALT ERNDT, VP/GM, CRANE Pumps Manager, AC Motors, Baldor Electric Association (SWPA)
& Systems Company, A Member of the JERRY TURNER, Founder/Senior
R. THOMAS BROWN III, President,
Advanced Sealing International JOE EVANS, Ph.D., Customer & ABB Group Advisor, Pioneer Pump
(ASI) Employee Education, PumpTech, Inc. WILLIAM E. NEIS, P.E., President, DOUG VOLDEN, Global Engineering
CHRIS CALDWELL, Director of LARRY LEWIS, President, Vanton Northeast Industrial Sales Director, John Crane
Advanced Collection Technology, Pump and Equipment Corp. LEV NELIK, Ph.D., P.E., APICS, KIRK WILSON, President, Services &
Business Area Wastewater Solutions, WILLIAM LIVOTI, Business President, PumpingMachinery, LLC Solutions, Flowserve Corporation
Sulzer Pumps, ABS USA Development Manager/Energy HENRY PECK, President, Geiger Pump JAMES WONG, Associate Product
JACK CREAMER, Market Segment Efficiency Specialist, WEG Electric & Equipment Company Manager – Bearing Isolator, Garlock
Manager – Pumping Equipment, Corporation Sealing Technologies
MARIANNE SZCZECH, Director,
Square D by Schneider Electric Global Marketing and Product
Management, Pump Solutions Group

Augus t 2 0 1 6 | Pum ps & S y st e m s

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8 NEWS

NEW HIRES,
PROMOTIONS & RECOGNITIONS
JOSEPH LEVY, JOHAN WRAMSBY KYLE LEDNICKY, APPLETON GROUP
& ARASH HASSANIAN, HOOVER ROSEMONT, Ill. – Appleton Group, a business
CONTAINER SOLUTIONS unit of Emerson, announced the promotion of
HOUSTON – Hoover Container Kyle Lednicky to director of strategic engineering
Solutions has appointed Joseph procurement companies (EPC) accounts. He will
Levy as senior vice president report directly to Craig Morris, vice president of
and chief financial officer; Johan global accounts. In his new role, Lednicky will lead
Wramsby as senior vice president Joseph Johan the development of Appleton Group’s global project
Levy Wramsby Kyle Lednicky
and chief operating officer; and sales through engagement at EPC accounts. He
Arash Hassanian as senior vice president, global will also play a leadership role in the organization’s
sales and marketing. Levy will manage Hoover’s collaboration efforts with Emerson Automation Solutions’
banking relationships, worldwide IT efforts, merger Global Project Pursuit Program. emersonindustrial.com
and acquisition activity, integration initiatives, and
consolidation of international financial reporting. FRANK HEMMEN &
Wramsby will be responsible for North American DAVID SILVA, CURFLO
operations and the continued integration of the HOUSTON – Frank Hemmen and
TechOil and Hoover Offshore businesses. Hassanian Arash David Silva joined CURFLO’s team
will manage and oversee worldwide efforts to drive Hassanian
of sales engineers. Hemmen has
sales, marketing and business development, while 35 years of experience, including
managing operations in Malaysia, Brazil, the UAE and Australia. promotion, selection, installation
hooversolutions.com and commissioning, as well as Frank David
Hemmen Silva
assisting in the proper selection of
PHILLIP NELSON, SULZER the right equipment. Silva has 36
MERIDEN, Conn. – Phillip Nelson has joined Sulzer years of experience in process equipment
as the head of sales for the North American Mining sales and reliability upgrades with an emphasis
& Construction segment. Nelson has more than on pumps, both sealed and sealless. curflo.com
30 years of experience in the rotating equipment
industry with extensive focus on sales and HEATHER GRAHAM, PSG
distribution management. sulzer.com OAKBROOK TERRACE, Ill. – PSG, a Dover company,
Phillip Nelson
announced that Heather Graham has been
ROCKY JENSEN, BLACOH INDUSTRIES appointed vice president of human resources. In this
RIVERSIDE, Calif. – Blacoh Industries announced position, Graham will be responsible for PSG’s global
the appointment of Rocky Jensen to production Human Resource function. She will report directly
manager and lean facilitator. Jensen brings with to Karl Buscher, president of PSG. Graham has a
him 30 years of experience. With a degree in Bachelor of Political Science degree and a master’s
Heather Graham
manufacturing technology and certification in lean degree in labor relations and human resources from
mastery, Jensen will be responsible for maintaining Michigan State University.
superior standards for manufacturing safety, psgdover.com
quality and efficiency, including ISO-compliant Rocky Jensen
workflows, supplier scorecards and other lean
DIETER SAUER, GRUNDFOS
production methodologies. blacoh.com
DOWNERS GROVE, Ill. – Grundfos Pumps
Corporation appointed Dieter Sauer as regional
ANTHONY HERNANDEZ, ASAHI/AMERICA managing director of the Americas Region. In this
MALDEN, Mass. – Asahi/America Inc. has role, Sauer will oversee all aspects of the global
announced the addition of Anthony Hernandez to pump manufacturer’s North and South American
its sales team. He brings a wealth of knowledge and business, including driving regional growth and
experience to the Asahi/America team. Hernandez, maintaining a top-motivated employee workforce.
who will represent Asahi/America in eastern Dieter Sauer
Sauer, who has more than 20 years of pump
Pennsylvania, Long Island and New York City, New industry experience, will report directly to Grundfos
Jersey, Maryland, Delaware, northern Virginia, and Anthony
Hernandez Group Executive Vice President Poul Due Jensen.
Washington, D.C., has nearly a decade of experience Sauer replaces Duncan Cooper in his new role.
in the thermoplastics industry. asahi-america.com grundfos.com

Augus t 2 0 1 6 | Pum ps & S y st e m s

 9

AROUND THE INDUSTRY

US Municipal Water Infrastructure
Forecast Reaches $532 Billion
BOSTON, Mass. – Capital expenditures for U.S.
municipal water and wastewater utilities—including
spending on pipes, plants and pumps—are expected
to exceed $532 billion between 2016 and 2025,
according to new forecasts from Bluefield Research.
This new outlook, which draws heavily from planned
utility budgets, represents a 28 percent increase over
capital expenditures (CAPEX) during the last 10 years.
While CAPEX is forecasted to rebound, a significant
decrease in federal funding for water utilities—which
has fallen to $4.3 billion in 2014 from $16 billion in
1976—passes the burden onto states, municipalities
and ratepayers. Residential and sewer bills have
increased 5 percent and 20 percent annually,
respectively, since 2000, but their impact is expected
to continue to fall short of infrastructure needs,
according to Bluefield Research.
The enormity of the municipal sector’s capital
requirements is compelling utility decision makers
to adopt new, more advanced and cost-effective
approaches to infrastructure management and
build-out, according to Bluefield’s report. Going
forward, markets for trenchless technologies, real-time
data and analytics (or smart water), and advanced
treatment solutions are expected to show significant
growth. Opportunities for private capital in the
municipal water sector are also expected to proliferate.
bluefieldresearch.com

ValvTechnologies Announces
Membership in Valve Repair Council
HOUSTON, Texas – ValvTechnologies Inc. announced
its membership acceptance in the Valve Repair
Council (VRC). The VRC is an affiliate of the Valve
Manufacturers Association (VMA). Member companies
service, repair and rebuild valves and actuators and
adhere to the written quality-control procedures
appropriate to the markets served and acceptable to
VRC, which focuses specifically on high standards of
quality, safety and service.
The VRC was formed in 1989 as the VMA saw a need
to promote safety and quality in valve and actuator
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repair. valv.com

MERGERS & ACQUISITIONS

Wärtsilä acquires Weir American Hydro to strengthen hydro &
industrial services.
June 23, 2016

p u m p s a n d s y s te ms . co m | Aug us t 2016
10 NEWS

AROUND THE INDUSTRY

APATEQ Awarded as White House Promotes “Experimental Studies in Developing
Technology Pioneer by New Smart Manufacturing Safe Sanitation Solutions,” tested
World Economic Forum Innovation Institute potential low-cost additives to improve
TIANJIN, China – Luxembourg- WASHINGTON – At the third annual two-pit composting toilets that use
based clean-tech company APATEQ SelectUSA Summit in Washington, a natural anaerobic process to treat
was awarded as one of the World D.C., before an audience of business solid waste. The project also evaluated
Economic Forum’s Technology leaders, economic development the associated design constraints of
Pioneers, a selection of the world’s officials and investors from around the the current process.
most innovative companies. APATEQ world, President Obama announced Sinha received $10,000 and an
engineers and manufactures high- that the Smart Manufacturing all-expense paid trip to Stockholm,
efficiency water and wastewater Leadership Coalition (SMLC) will Sweden, where she will represent the
treatment systems based on unique lead the new Smart Manufacturing U.S. at the international competition
process technologies. APATEQ has Innovation Institute, in partnership during World Water Week, Aug. 28-
been chosen by a professional jury with the Department of Energy. Sept. 2. The international winner will
from hundreds of candidates as one of The winning coalition, receive $15,000 presented during a
the 30 selected companies. headquartered in Los Angeles, royal ceremony by the prize’s Patron
The Technology Pioneers were chosen brings together a consortium of HRH Crown Princess Victoria of
from among hundreds of applicants nearly 200 partners from across Sweden. wef.org
by a selection committee of 68 academia, industry and nonprofits
academics, entrepreneurs, venture from more than 30 states to spur MCAA Publishes 2016
capitalists and corporate executives. advances in smart sensors and Instrumentation &
The committee based its decisions on digital process controls that can Automation Market Forecast
criteria including innovation, potential radically improve the efficiency of U.S. POQUOSON, Va. – The Measurement,
impact, working prototype, viability advanced manufacturing. Control & Automation Association
and leadership. Past recipients include The Smart Manufacturing (MCAA) has published its Annual
Google (2001), Wikimedia (2007), Innovation Institute is the ninth Market Forecast for 2016. The
Mozilla (2007), Kickstarter (2011) and manufacturing hub awarded by the report focuses on the process
Airbnb (2013). apateq.com Obama administration. instrumentation and automation
The president also announced the (PI&A) markets in both the U.S.
Grundfos CEO Speaks at launch of five new manufacturing and Canada.
UN Summit in New York hub competitions, which will invest The PI&A market in the U.S.
NEW YORK – Grundfos CEO Mads nearly $800 million in combined experienced growth in 2015, but that
Nipper was among the speakers at the federal and non-federal resources growth was minimal. At $11.6 billion,
United Nations (UN) Global Compact to support transformative it was an increase from the 2014 level
Leaders’ Summit in New York, June manufacturing technologies. of $11.1 billion. Lack of growth was
24. He used his speech, among other After a decade of decline from 2000 attributed to a decline in oil prices
things, to remind the approximately to 2010, the U.S. manufacturing sector as well as a downturn in mining
800 listeners that the corporate sector has added more than 800,000 jobs and mineral spending due to falling
wants political action and will use since February 2010 and remains more commodity prices. Another factor
the UN’s 17 sustainability goals as a competitive for jobs and investment is surplus capacity in the metals,
lever for development, innovation today compared with recent decades. cement, and pulp and paper sectors
and business. smartmanufacturingcoalition.org that is suppressing demand for
“Sustainability and responsibility those products.
are not a department or a report. New Jersey High School Five industries within the U.S. are
They are the very essence of every Student Wins 2016 US expected to experience above-average
company who wants to think ahead Stockholm Junior Water Prize growth for the period 2015-2020:
and accomplish something greater ALEXANDRIA, Va. – Nishita electric utilities, pharmaceuticals,
than just creating short-term profit,” Sinha from Chatham, New Jersey, chemicals, refining, and food and
Nipper said. won the 2016 U.S. Stockholm Junior beverage.
Grundfos has already established Water Prize (SJWP), the most These industries will account for
a collaboration with a number of prestigious youth competition for $7.8 billion in 2015, expanding to $9.4
NGOs and UN organizations to speed water-related research. billion in 2020.
up the engagement. This offensive Sinha and 53 other students, In Canada, process industries will
approach, according to Nipper, is to representing a total of 47 states and grow slightly slower than in the U.S.
raise awareness among other global Puerto Rico, competed in the national The drop in oil and gas and mining
companies, NGOs, governments finals in June at the University of and minerals spending resulted in a
around the world, and especially the North Carolina at Charlotte. 4 percentage point drop in the PI&A
UN system. grundfos.com Sinha’s two-phase project, growth rate for 2015. measure.org

Augus t 2 0 1 6 | Pum ps & S y st e m s

 11

EVENTS
Pump School On-Site Special Session
August 10 – 11, 2016

We provide
Mount Pleasant Waterworks Municipality
Mount Pleasant, South Carolina
770-310-0866 / pumpingmachinery.com/pump_school/

more than just

pump_school.htm

Pump School On-Site Special Session

August 23 – 24, 2016

bearings
Evansville, Wisconsin
770-310-0866 / pumpingmachinery.com/pump_school/
pump_school.htm

The Water Expo 2016 – 5th Edition

August 31 – September 1, 2016
Miami Airport Convention Center
Miami, Florida
305-412-3976 / thewaterexpo.com

TPS 2016
September 12 – 15, 2016
George R. Brown Convention Center
Houston, Texas
979-845-7417 / pumpturbo.tamu.edu

We provide
3rd International Rotating Equipment Conference
September 14 – 15, 2016
Congress Center Dusseldorf

Soluuons
Dusseldorf, Germany
49 (0) 69 / 66 03-1296 / introequipcon.com/en_GB/

WEFTEC 2016
September 24 – 28, 2016
New Orleans Morial Convention Center
New Orleans, Louisiana
240-439-2954 / weftec.org

MINExpo International 2016

September 26 – 28, 2016

800-523-3382
Las Vegas Convention Center
Las Vegas, Nevada
800-752-6312 / minexpo.com
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PACK EXPO International & Pharma EXPO 2016

November 6 – 9, 2016
McCormick Place
Chicago, Illinois
866-833-3569 / packexpointernational.com

Groundwater Week 2016

December 6 – 8, 2016
Las Vegas Convention Center www.bartlettbearing.com
Las Vegas, Nevada
800-551-7379 / groundwaterweek.com Follow us on Twitter
@bartlettbearing
p u m p s a n d s y s te ms . co m | Aug us t 2016
12 NEWS

AROUND THE INDUSTRY

CORTEC Relocates CMS is currently the dedicated dealer in the AWWA Launches Water Loss
Manufacturing Facility to aggregate market for Weir’s Trio line Technical Assistance for
Port Allen, Louisiana of crushing, screening and washing California Systems
PORT ALLEN, La. – CORTEC has equipment, and aftermarket. Kimball RANCHO CUCAMONGA, Calif. – The
expanded its CORTEC Manifold Systems Equipment Company will now be a full- American Water Works Association’s
Lafayette manufacturing facility and line distributor. weirminerals.com California-Nevada Section (CA-NV
relocated to new premises in Port Allen, AWWA) announced the launch of
Louisiana. The facility now supports Baldor Electric Facility its Water Loss Technical Assistance
a full range of CORTEC’s service Reaches 18 Years Without Program (TAP), a $3.2 million program
operations, including sales, engineering, Lost-Time Accident that will train and assist California’s
quality, machining, product assembly FORT SMITH, Ark. – Baldor Electric urban water agencies in producing
and testing, inventory, and coating. Company’s gearbox manufacturing validated system water audits.
The 55,000-square-foot facility is plant located in Belton, South Carolina, The Water Loss TAP is part of CA-NV
equipped with specialized machinery recently completed 18 years without a AWWA’s broader initiative of combating
capable of manufacturing high-pressure lost-time accident, and the employees water loss through the Water Loss
metal-seated ball valves and testing have worked one year without any Control Collaborative. CA-NV AWWA
equipment designed for severe service recordable accidents. Recently the has selected the Water Systems
applications. The location has capacity South Carolina Department of Labor, Optimization / Cavanaugh team to serve
for 35 employees, but additional Licensing and Regulation recognized as program manager for the initiative.
acreage and building plans are in place the facility as a 2016 Palmetto Shining The Water Loss TAP will specifically
to expand and accommodate four times Star recipient for achieving 1 million or aid systems in complying with the
that number. uscortec.com more safe work hours without a lost- provisions of California Senate Bill 555,
time injury. which established the requirement
SignalFire Wireless In addition, the Baldor employees of that each urban retail water supplier,
Telemetry Adds New the Fort Smith motor plant completed on or before Oct. 1, 2017 (and annually
Distribution Channels 15 million hours without a lost-time thereafter), submit a validated water
HUDSON, Mass. – SignalFire Wireless accident May 10. They have been loss audit report to the California
Telemetry has contracted four new working toward this achievement since Department of Water Resources.
manufacturer representatives to Aug. 26, 2010. baldor.com waterlosscontrolcollaborative.org
expand the brand of its wireless remote
monitoring and control systems beyond Team KSB-USA Earns Gold in Texas Water Board Approves
the oil and gas industry to an array Germany at IFAT 2016 $14.8 Million for Wastewater
of new markets including chemical MUNICH, Germany – Team KSB-USA Plant, Reclaimed Water System
processing, refineries, downstream was awarded the gold medal in Munich, AUSTIN, Texas – The Texas Water
oil and gas, power generation, and Germany, as the overall winner of the Development Board (TWDB) approved
food and beverage. The representative third Open German Championship in financial assistance totaling $14.8
organizations were chosen based on Wastewater Technology as part of IFAT million for a new wastewater treatment
their product expertise and client 2016. The all-star Operations Challenge plant and a reclaimed water system. Of
relationships in key territories that team competed against 36 teams from this funding, $2 million was designated
will play a major factor in supporting six countries as part of a trade fair for for a rural water project.
SignalFire’s growth throughout the water, sewage, waste and raw materials The board also approved $525,689 in
country. Additions to SignalFire’s management, which ran from May 30 grants through the TWDB’s Agricultural
representative team include TechStar, to June 3. Water Conservation Grants Program.
Protech, Enpro Inc., and E W Process. Organized by the Water Environment The program offers grant funding to
signal-fire.com Federation (WEF) and sponsored by state agencies and political subdivisions
KSB Inc., the U.S. team included Coach for activities that promote water
Weir Minerals Announces Dave Vogel and members Dale Burrow, conservation in the state. www.twdb.
New Dealer for Utah, Donnie Cagle and Steve Motley. texas.gov/conservation/Agriculture/
During the two-day competition, index.asp
Nevada & Arizona
MADISON, Wis. – Weir Minerals the teams were judged in five core
announced the appointment of Kimball competencies of wastewater operations. Read more online at
Equipment Company as its dealer in the Team KSB-USA accumulated the most pumpsandsystems.com/
aggregates market for Utah, Nevada and points from each discipline to take first news.
Arizona. Kimball Equipment Company place, followed by two German teams:
has offices in Salt Lake City, Utah; Las second-place winner Nuremberg–Die
To have a news item considered, please
Vegas and Sparks, Nevada; and Phoenix, Drei Wreckla and third-place winner
send the information to Amelia Messamore,
Arizona. Kimball Equipment Company Stadt Stuttgart Pumpis. ksb.com
[email protected].

Augus t 2 0 1 6 | Pum ps & S y st e m s

 TRADE SHOW PREVIEW 13

Preview: TPS 2016

Sept. 12-15, 2016
George R. Brown Convention Center
Houston, Texas

Exhibition Hours
Tuesday, Sept. 13 noon – 2 p.m., 2:30 – 7 p.m.
Wednesday, Sept. 14 noon – 2 p.m., 2:30 – 6:30 p.m.
Thursday, Sept. 15 9:30 a.m. – noon

T he 45th Turbomachinery & 32nd International Pump

Users Symposia—dubbed TPS 2016—is returning to
Houston’s George R. Brown Convention Center, Sept. 12-15.
The annual event is organized by the Texas A&M University
System and the Turbomachinery Laboratory, which is part of
Texas A&M’s Engineering Experiment Station.
Organizers call the gathering the premier conference
for turbomachinery and pump professionals. They say the
event’s goal is to promote professional development, peer
networking, technology transfer and information exchange
among industry professionals.
The event officially kicks off Sept. 13 following short
courses on Sept. 12 in conjunction with the Symposia. This
year’s event is colocated with the Roseland Oil and Gas Expo.
Industries expected to attend TPS 2016 include oil
and gas, chemical and petrochemical, power generation,
manufacturing, mining and metals, and water. As of mid-
June, companies exhibiting at this year’s event totaled 345.
Last year’s event had more than 5,500 registrants along
with 350 exhibiting companies, 84 technical sessions and 48
countries represented. The 2015 event also had 19 lectures,
20 tutorials, 28 discussion groups and 18 case studies.
Registration information, along with other event details, 100 YEARS OF INNOVATION.
including a list of exhibitors and courses, is available online For 100 years NSK has been proudly
at pumpturbo.tamu.edu. designing motion and control products
The Turbomachinery Symposium started in 1972 and the that not only help increase productivity
International Pump Users Symposium launched in 1984. The but also help make the world a more
events were combined in 2011. safe, reliable and comfortable
Circle 131 on card or visit psfreeinfo.com.

place. Here’s to celebrating

the past, innovating in the
present and setting the
future in motion.
www.nskamericas.com

p u m p s a n d s y s te ms . co m | Aug us t 2016
14 PUMPING PRESCRIPTIONS
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board

Optimizing Pump Hydraulics:

When Is it Important?

T Looking at the Curve

he days of designing a pump for how efficient a final size
from scratch are long gone. selection will be. To illustrate this, To evaluate this question, we
After decades of evolving the 23 sizes shown in Figure 1 need to look at a more detailed
a particular pump product line, (composite curves) show individual performance characteristic of this
a typical original equipment performances at maximum and particular pump size (see Figure 2,
manufacturer (OEM), having minimum impeller diameters. The page 16).
initially started with a single pump approximate best efficiency points The curve (which was selected
size (whatever the first order flow (BEP) are marked with a circle. randomly from a manufacturer but
and head called for), now adds more For example, 1.5x3-6 size peaks is generic enough that it will give
sizes with hydraulic performances at 100 gpm (35 feet of head at roughly the same result as similar
covering the flow range. For 1,750 revolutions per minute). But pumps of other manufacturers)
example, Figure 1 shows 23 pump suppose the application needs only shows that a 6.06-inch maximum
sizes within the typical OEM’s 15 feet of head at the same flow; impeller diameter would need to
American National Standards this still falls within the 1.5x3-6 be trimmed to about 4.75 inches to
Institute (ANSI) product line. Why size, but how efficiently? accomplish that efficiency.
are there so many?
Could we not simply have three
Figure 1. Providing many pump sizes within a product line is a marketing advantage for an
sizes—small, medium and large— original equipment manufacturer. (Graphics courtesy of the author)
with small running at 100 gallons
per minute (gpm), medium at
1,000 gpm and large at 4,000 gpm,
then simply pick a pump size that
closely matches the required flow
the end user may need and finally
throttle the valve, adjusting the
pump to whatever flow and head
may be required?
It is possible, but the balance
between energy consumption and
initial hardware investment may
indicate that such an approach
would not be very wise. In fact,
having more sizes available within
a product line better positions
OEMs in the market, giving them
the ability to fine-tune their
offerings to make their pumps
less expensive (smaller) and more
efficient (less energy consumed
in operation).
Even with many pump sizes
available within a given product
line, there are still limitations

Augus t 2 0 1 6 | Pum ps & S y st e m s

Circle 104 on card or visit psfreeinfo.com.
16 PUMPING PRESCRIPTIONS

Unfortunately, with an impeller

cut, efficiency also gets cut: 62 percent
decreases to less than 50 percent—a 12
percent efficiency loss.

The Costs of Inefficiency But for a larger pump, this efficiency loss can
For a small pump, this would hardly be be much more significant. For a 1,000-hp pump,
noticed: The three-quarter-horsepower
(hp) consumer, running nonstop at
this 12 percent efficiency difference would
$0.10 per kilowatt-hour (kWh), would translate to $78,000 per year.
consume $490 a year, so a 12 percent
efficiency loss would only cost $50.
But for a larger pump, this efficiency
loss can be much more significant.
For a 1,000-hp pump, this 12 percent
efficiency difference would translate to Figure 2. 1.5x3-6 individual performance curve
$78,000 per year.

Customized Designs
FEET

This is where a customized design

approach comes in. This process is much 40 NPSHr
50 2’
more involved than simply picking 45
a pump from a catalog and applying 57 3’
6-1/16”0/ 60 4’
an impeller trim. A special impeller, 40
62
a casing volute insert or/and other
modifications would be required. Such 35
5-1/2” 62
extra work certainly translates to an 63
30
TOTAL HEAD

added cost, which should be compared 5” 57

to the energy saved as a result of the
25
customization by the specialized 4-1/2”
hydraulics. This is a question of 20
balancing technical know-how and 1.5 HP
cost benefits. 50

The Effects of VFDs 10 1 HP

As a parting question, how would 3/4 HP
a variable frequency drive (VFD) 5
application affect this process? Would
a VFD be an alternative to a hydraulics 0
optimization, a supplement to it or 0 20 40 60 80 100 120 140 GPM
neither? How would economics be
affected? The best answer will have the
chance to be published in the Pumps &
Systems Readers Respond section.

Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machinery, LLC, an Atlanta-
Find the link to the
Energy Estimator program based firm specializing in pump consulting, training, equipment troubleshooting
to enter your own example at and pump repairs. Dr. Nelik has 30 years of experience in pumps and pumping
pumpsandsystems.com/ equipment. He may be reached at pump-magazine.com. For more information, visit
pump-hydraulics. pumpingmachinery.com/pump_school/pump_school.htm.

Augus t 2 0 1 6 | Pum ps & S y st e m s

Coming in September

WEFTEC Issue
Don’t miss this exciting edition of Pumps & Systems –
one of the most popular issues of the year!

• Articles about a variety of pumps and how they are

used in wastewater applications
• Information about the latest in instrumentation,
controls and monitoring technology
• A full preview of the upcoming WEFTEC trade show

2 0 15
SEPTEMBER
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18 PUMP SYSTEM IMPROVEMENT
A better understanding of complete system operation
By Ray Hardee
Engineered Software Inc.

Optimizing Large Cooling Water Systems

I
recently received a comment works and what can be done to their motors were operating well
from a reader who pointed improve the system. into their service factor. After
out that all examples in my This real-world example shows a short discussion, operations
Pumps & Systems columns are small how a system energy balance personnel started the third pump
process systems with only one or was used in a large cooling water and modified the plant’s operating
two circuits. She asked if the same system in an industrial plant using procedure to operate all three
process could be applied to a larger such software. cooling water pumps. With all
system with multiple cooling loads three operating, the motor loads
in parallel. Looking back, most of The System & Challenge returned to satisfactory conditions.
the examples in my columns were During a software training course, The plant’s operating guidelines
selected to limit their complexity an attendee presented a project state that for critical systems, the
so I could concentrate on one involving his plant’s cooling water failure of one piece of equipment
aspect of the system at a time. This system. The system normally cannot cause the system to fail. The
month, I will demonstrate how the operated with two cooling water cooling water system was critical
same approach can be applied to a pumps providing sufficient cooling for continued plant operation,
system of any size. water to meet all plant loads. On a and with all three installed
Regardless of the size, hot summer afternoon, one of the pumps operating, personnel took
arrangement or design objective, two operating cooling water pumps immediate action to purchase and
all piping systems are made of tripped. Staff immediately started install a fourth pump to provide
three primary elements. The pump the standby pump to return the the necessary standby protection.
elements add all the energy to system to normal operation before The plant engineer wanted to see
move the fluid through the system, notifying the maintenance group. if piping simulation software could
the process elements use that fluid When electricians inspected determine if the changes would
energy to make the product or the motor on the tripped pump, correct the problem. The engineer
provide the service, and the control everything appeared normal. They took steps to determine the cause
system improves the quality of the notified operations after checking and what could be done to return
product. As we have seen, the head the motor loads on the two the system to normal operation as
developed by all the pumps is equal operating pumps and discovering quickly as possible.
to the head loss in the process
elements and control elements in Figure 1. An example of the cooling water system described in this column (Courtesy of the author)
every circuit of the system.
Most industrial plants have
extremely large cooling water Cooling Tower

systems that provide water CWP-1 CWP-2 CWP-3

to hundreds of cooling loads.

Balancing the energy in larger
systems is tedious to calculate by Additional
loads in
hand, but computers can quickly Cooling Water
System
handle these calculations. Software
can be used to build piping system
models and calculate the balanced
flow rates and pressures, providing Area 123 Area 255 Area 51
a clear picture of how a system

Augus t 2 0 1 6 | Pum ps & S y st e m s

Circle 111 on card or visit psfreeinfo.com.
20 PUMP SYSTEM IMPROVEMENT

The first step determined how circuits. Using this information, As the summer progressed and
the system would operate with the outlet temperature increased,
one can determine the differential
three pumps. The plant cooling the operators continued to
pressure across each control circuit.
water system was needed to Figure 1 shows an example of the open the throttle valve, further
operate the plant, so operation cooling water system. increasing the cooling water flow
of the physical system could not rate. The flow rate through the
be modified. The plant engineer Testing the Model system was greater than the two
decided to use piping system After completing the cooling water pumps could handle, causing one to
simulation software to discover system hydraulic model, the plant trip out on high motor overload.
why the system required three engineer ran the calculations to The plant engineer now had a
pumps to operate instead of the show how the system was designed good understanding of how the
initial two-pump operation. to operate with only two cooling throttle became open, but he
water pumps. still did not know if his model
The System Model The physical piping system accurately represented the physical
An accurate model of the required three cooling water pumps system. The plant engineer changed
piping system was created to avoid overloading the pump the piping system model to reflect
using all available design data, motors, so the physical system how the physical system was
manufacturer’s test and operating was not operating according to the working. After these calculations
data. The flow diagrams and computer simulation. were performed, the pump suction
the piping and instrumentation Now the engineer needed the and discharge pressure values
diagram identified all major differences between the physical accurately matched the pressure
equipment and interconnected piping system and the simulation. readings found in the plant.
piping. The flow rate, head, A quick look at the throttle Comparing the motor current on
efficiency and NPSHR as shown on values in the physical piping the three running pumps, the plant
the manufacturer’s supplied pump system pointed out the problem. engineer determined that the flow
curve were entered for each pump Reviewing the manual throttle rate through each pump accurately
in the circulating water system. valves’ position in the physical matched the model’s calculated
The data for the system’s process system revealed that the majority values. The engineer now had an
elements were entered. Using the were fully open instead of set to an accurate model of the total system.
manufacturer’s test data for the intermediate position to limit the
installed heat exchangers, the flow rate through each circuit. Using the Accurate Model
team entered the head loss versus The plant engineer discovered a After validating the piping system
flow rate in the system model. year earlier that many new loads model, the engineer set the design
Next, piping details such as pipe were added to the cooling water flow rate through each circuit in
material, schedule, diameter, along system. After those system changes the model to the design value.
with the valves and fittings, were were made, however, the system Using the valve manufacturer’s
entered. The density, viscosity was not rebalanced as had been supplied flow coefficient (Cv) data
and vapor pressure of the system done when the system was first versus the valve position for each
process fluid were specified. This placed in operation. throttle valve, the simulation
was a closed-loop recirculating The cooling water system was calculated the valve position
system, so elevation and pressure placed in operation, and the plant needed to meet the design flow rate
at the surge tank were entered. operators manually adjusted the through each circuit.
Next, the control elements in valve positions to each throttle The result was a calculated valve
each circuit were entered. Each load to maintain the required outlet position for each throttle valve
was sized for a specific rate of heat temperature. As each operator to balance the entire system. The
transfer. The rate heat needed to independently adjusted a throttle physical plant had three cooling
be removed from the process being valve, the flow rate through each water pumps in operation and
serviced. The system differential circuit was affected. Before long, all throttle valves open, so the
temperature between the hot the flow rate through each load in plant engineer wanted to balance
and cold fluid determined the the cooling water system was much the system without affecting the
cooling water flow rate through the higher than required by the design. plant’s operation.

Augus t 2 0 1 6 | Pum ps & S y st e m s

Circle 109 on card or visit psfreeinfo.com.
22 PUMP SYSTEM IMPROVEMENT

The engineer presented the When the plant was brought back The final problem was that the
results of the actual system and the to service, personnel performed only option the plant considered
model to plant management along further checks to ensure that the was adding a third operating pump
with a process to return the system cooling water system was operating and a backup pump. Rebalancing
to its normal operating conditions properly by checking the outlet the system solved the problem at
without adversely affecting plant temperature of each circuit load. hand, without the need to purchase
operations. The installation of The plant engineer determined that and install a fourth pump that
the fourth cooling water pump all but two of the heat exchangers would take four months to install,
was scheduled to take about four were operating properly. leaving the plant without a backup
months, so management decided to The cooling water flow rates cooling water pump.
attempt to balance the system. through these two circuits on the By developing a model of the
The plan involved cooling water system’s
setting the position of operation, the engineer
the throttle valves to the Rebalancing the system solved could understand how
value calculated by the the system was designed
plant simulation with the problem at hand, without to operate. He was able
two pumps operating in a the need to purchase and install to determine the source
planned shutdown. of the problem—all
a fourth pump that would take throttle valves open—by
Balancing the System four months to install. comparing the calculated
During the plant results to the physical
shutdown, the operators piping system.
set the physical throttle valves physical system were increased Validating the piping system
in each circuit to the calculated so the heat exchanger outlet model with the operation of the
position for the two-pump temperatures were within normal physical system allowed him to
operation. Then the cooling water operation. Once the outlet try alternative solutions to the
system was started with two temperatures were returned to problem. By simulating the system
pumps in operation. The operators normal, the positions of the two with the balanced flow rate set in
recorded the suction and discharge control valves were measured. the loads and two pumps operating,
pressures for the two pumps. The new positions of the throttle he was able to calculate the throttle
The observed differential valves were entered into the piping valve position needed to balance
pressure across the two operating system model. The calculated the system.
pumps matched the calculated results indicated that the increased In next month’s column, with the
results of the system model, flow rates through each load in aid of the piping system model, we
confirming the flow rate. Another the system were still within the will see how the plant was able to
test confirmed the flow rate acceptable range of operation. reduce system operation costs while
through each pump by comparing increasing system capacity.
the motor’s required electrical Summary To follow the process
power to the manufacturer’s This example shows how adding described in this example, visit
pump curve. To confirm flow rates cooling loads to an existing cooling pumpsandsystems.com/large-
through each circuit, an ultrasonic water system results in unintended system-optimization.
flow meter was used to show consequences for a critical system
whether the flow rates matched the in an operation plant.
Ray Hardee is a principal founder
flow rate entered in the piping Not rebalancing the flow rates
of Engineered Software, creators
system model. after changes to the cooling water
of PIPE-FLO and PUMP-FLO
As a result of these tests, the system was the first problem. The
software. At Engineered Software,
plant engineer determined that the second was that operators increased
he helped develop two training
system was balanced for the two- the flow rate through the plant
courses and teaches these courses
pump operation and was ready to loads without understanding how
internationally. He may be reached
return the cooling water system to changing one flow rate affects the
at [email protected].
its normal two-pump operation. flow rate in the other circuits.

Augus t 2 0 1 6 | Pum ps & S y st e m s

Circle 103 on card or visit psfreeinfo.com.
24 COMMON PUMPING MISTAKES
Simple solutions for end users
By Jim Elsey
Summit Pump Inc.

Use this Checklist to Stop Oil Leakage

from Your Bearing Isolators

T
he first bearing isolator contamination out and away from ❑ The bearing housing is
of the current design was the oil and the bearings; they are overfi lled (oil overfi ll). This is the
patented in 1977 and also designed to keep the oil in the most common problem I witness.
initially used on pumps and bearing housing of the pump. If The oil level should be maintained
mixers in the food processing and the isolators (and the pumps) are at the middle of the sight glass and
chemical industries. Since the properly installed, they will often no higher. This sighted level should
1980s, they have been installed on operate more than 10 years with correspond with the middle of the
most anything that rotates. no bearing isolator issues. At some lowest ball in the ball bearings,
During the last 10 to 15 point, the elastomers reach the end either radial or thrust (see Figure
years, most general-service, of their useful life, which is mostly 1). Note that in the case of an oil
frame-mounted and horizontal driven by environmental factors. overfi ll, it takes some time for
American National Standards Given the potential for a bearing the oil to be dissipated from the
Institute (ANSI) pumps include a isolator with a long lifespan, not isolator, so it is important to be
set of bearing isolators to protect all millwrights, operators and patient and continue cleanup of the
the bearing housing from the mechanics fully understand the oil for several days of running after
introduction of liquids and debris limitations and boundaries of the the overfi ll incident.
(contamination ingress). Keeping bearing-protection device. Over
the lube oil clean greatly improves the last 30 years, I have witnessed ❑ The pump is not level. To solve
the life of the bearing and, frequent errors and a general this problem, I recommend using
ultimately, the pump. misunderstanding of the rules and a Starrett or equal machinist-
Bearing isolators/protectors are principles for the devices. One of level model 98-6. The pump must
a marvelous improvement over the the most common field complaints be level in both directions (stem
previously used devices—lip seals. I hear is that the lube oil is leaking to stern and, in nautical terms,
To a lesser degree, interim devices out of the bearing housing. athwartships).
on higher-energy pumps involved The following general
stationary and occasionally checklist will help users find and ❑ The expulsion port (also known
rotating labyrinths of both axial troubleshoot potential reasons for as the drain port or, on some
and radial designs. Modern oil leakage (oil egress) from the models, the weep slot) on the
bearing isolators consist of a bearing isolator in the field. isolator is in the wrong location
non-contacting unitized rotor and This checklist does not cover all (installed incorrectly). The isolator
stator combination. Consequently, designs and is based on a typical must be installed so the expulsion
there should be no wear on the horizontal ANSI (B73.1) pump port is at the 6 o’clock position,
shaft and/or on the isolator itself. design because it is the most which is at the very bottom and
The earlier generation of bearing common type of pump used in lowest point. An exception is
protection (lip seal designs) had general industry. when the isolator is designed with
a relatively short operational This discussion is limited to numerous expulsion ports, as in
lifespan that was usually measured pumps, but isolators/protectors the case of units designed for the
in months. The edge of the lip are also commonly used on motors, outboard end of an ANSI pump
seal contacted the rotating shaft, mixers and other types of rotating design that uses a reverse-vane-
creating permanent damage. equipment. If you have something style impeller. These pumps adjust
Bearing isolators are not to add to this checklist, I would the axial clearance of the impeller
just designed to keep the appreciate your input. to the seal chamber (stuffing

Augus t 2 0 1 6 | Pum ps & S y st e m s

 25

Figure 1. Proper oil level is between one-quarter and one-half of the lowest ball in the
❑ The bearing isolator is
bearing housing. There are no advantages to a higher oil level. (Courtesy of the author) installed satisfactorily but is
improperly moved (axially). This
can occur when adjusting the
impeller clearance, measuring total
axial clearance, or when the shaft
is removed or installed.

❑ The isolator is reinstalled

without an O-ring on the OD of
the stator (certain types only).
Some bearing isolator styles have
stator OD O-rings that can be
used only once because they are
designed to purposefully shear
during the installation process.

❑ The constant level oiler

(commonly a Trico oiler) is set
incorrectly because the cross-nut
adjustment is set to the wrong
height (in this case, too high),
or it is installed in the wrong
bearing housing penetration
or on the wrong side of the
pump. Constant-level oilers are
rotationally sensitive for proper
operation. There is a correct and
box) by rotating the threaded ❑ The isolator is installed or incorrect side of the pump on
bearing carrier on the outboard reinstalled improperly. See which to install them that depends
end. The bearing carrier contains the manufacturer’s installation on the direction of rotation.
the isolator, and it could be in any and operations manual (IOM).
radial position in the process of Sometimes during maintenance
setting the impeller clearance. ❑ The bearing housing is over-
the unitized rotor and stator will pressurized. Potential reasons
become separated. If this happens, outside of large temperature
❑ The wrong isolator is installed. contact the manufacturer for
For example, a Type A outboard swings are too varied and detailed
advice before attempting to discuss here.
isolator used on a semi-open- to reassemble.
impeller-type ANSI pump is placed
on a reverse-vane impeller pump ❑ There is excessive pipe strain.
on the outboard end. These types ❑ The internal diameter (ID) The resultant forces and moments
have a singular expulsion port. of the bore on the pump of pipe-induced stress will cause
bearing housing is incorrect, the bearing bore and, consequently,
❑ Th e wrong isolator is installed or the outside diameter (OD) the isolator device bore to be out
(for reasons other than those of the stator is incorrect. of round or concentricity. This
previously stated). The isolators Perhaps a bearing failed and will also create a non-congruent
are the wrong size or of an turned (spun) in the bore, which or offset centerline with the sister
incorrect material (the temperature will score and destroy the critical bearing. Check for pipe strain
of the application and/or chemical clearances. Refer to the IOM by placing dial indicators in two
environment will dictate different and/or factory for proper planes on the coupling hub. Release
material requirements). dimensions and tolerances. the bolts on one of the pump

p u m p s a n d s y s te ms . co m | Aug us t 2016
26 COMMON PUMPING MISTAKES

Figure 2. A cross-section of the bearing protector: The green portion is the stator
and the orange portion is the rotor (Courtesy of Orion Engineered Seals)
side of the pump. The operators
wanted a direct line of sight to the
indicator and removed the sight
gauge from the starboard side of
the pump and relocated it on the
other side (port) of the bearing
housing. On almost all ANSI
pumps, there is a normally plugged
penetration where the finned oil
cooler would be located, if used.
Both the oil cooler and the sight
glass penetrations are sized at
1-inch national pipe thread (NPT).
However, the centerline of the
cooler penetration is at a slightly
lower level than the sight
glass penetration.
The result is that the new
flanges: If the dial indicator moves I saw this issue once on two corresponding oil level will be
more than 0.002 inches, there is large end-suction pumps in flue- incorrect and too low. Bearing
excessive pipe strain. Repeat for gas desulfurization service at a life will be severely compromised
the other flange. Correct the cause power plant. because of inadequate
of the stress before proceeding. lubrication. Note that some pump
❑ The bearing isolator may fail or manufacturers have penetrations
❑ A drivetrain component is work incorrectly in cases of high on both sides of the pump bearing
too close to the external isolator vibration on the pump. Excessive housing for the sight glass
face. In rare cases and mostly vibration could be caused by installation on both sides.
on larger pumps, if a drivetrain cavitation, air binding, imbalance,
component such as a rotating surging, improper operational area
coupling (spinning in the semi- and/or misalignment of the driver.
enclosed space of an OSHA guard) Note that vibration is not a likely
is too close to the external face cause of oil leakage because the
Jim Elsey is a mechanical
of the isolator, a low-pressure bearings and seals will normally
engineer who has focused on
area can form (caused by the air fail first.
rotating equipment design and
velocity, also known in this case
applications for the military
as windage). The low-pressure ❑ Occasionally the oil leaks out, and several large original
area creates a differential pressure but not because of the bearing
equipment manufacturers for
outside the bearing housing near isolator. During the repair and
43 years in most industrial
the face of the bearing isolator. maintenance cycles, sometimes
markets around the world. Elsey
Consequently, the oil can be picked the bearing housing gaskets are
is an active member of the
up and moved with the air flow omitted or of an incorrect material
American Society of Mechanical
windage. To correct this situation, or dimension, and/or the bolts are
Engineers, the National
you can distance the coupling not properly torqued. In rare cases,
Association of Corrosion
and OSHA guard from each other I have seen porous casting issues
Engineers and the American
and/or from the isolator face. An contribute to the problem.
Society for Metals. He is the
alternate solution in some cases is
general manager for Summit
to use a larger OSHA guard. ❑ The oil gauge is inaccessible. Pump, Inc., and the principal of
While not necessarily a leak issue,
MaDDog Pump Consultants LLC.
❑ The oil sight glass is at the I have seen end users install ANSI
Elsey may be reached at jim@
incorrect height (manufacturing pumps next to a wall with the oil
summitpump.com.
or repair facility defect). sight gauge (indicator) on the wall

Augus t 2 0 1 6 | Pum ps & S y st e m s

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28 INDUSTRY INSIGHTS
Trends & analysis for pumping professionals
By Mike Pemberton
Pumps & Systems Senior Technical Editor

Overcoming Barriers to
Pump System Optimization

W
hile pump system Another barrier is high capital optimization, and courses are
optimization has become costs required for mechanical and being developed through industry
much better understood control modifications to improve trade organizations, such as the
and has grown in popularity over system efficiency and reliability, Hydraulic Institute and the British
the last decade, it is still not used as well as process control Pump Manufacturers Association.
as much as one would expect improvements. While proper Pump and seal manufacturers also
based on the potential economic screening of pump systems, before are starting to develop or add staff
benefits. A number of issues selecting the highest value targets that are specialists in the emerging
constrain the adoption of pump for study and implementation, field of pump system optimization.
system optimization practices, but will yield good opportunities with The growth of a pump system
understanding them can help end payback in six to 18 months, the optimization BOK and associated
users overcome these barriers. capital costs for implementation practitioners is vital to move from
Pump system optimization are 0.5 to three times the pump awareness of the opportunity to
is more difficult to implement system’s life-cycle cost. implementation of system changes
than one might expect. From For example, an optimization that provide major benefits to
a historical perspective, pump study of 20 pump systems could pump system end users.
system designs routinely included identify $400,000 to $800,000 In the future, pump system
a safety margin, or more capacity in energy savings, not including optimization should be viewed
to ensure that the system could maintenance savings, with the same way as industrial
deliver more head (pressure) and total capital cost in the range of plant owner/operators view lean
flow than required. Th is was a $600,000 to $2.4 million. manufacturing or International
common-sense approach used in Pump system optimization is Organization for Standardization
case the original design data did seldom a single system change. It and American Society of
not cover the maximum case and often requires multiple changes Mechanical Engineers (ISO/ASME)
to ensure enough capacity if the at once that involve the piping, quality improvements.
production rate increased. pump, valves and controls. There Studies have shown that
In addition to rising energy is rarely a silver bullet that will 10 to 30 percent of installed
and maintenance costs, the cost return the pump system to a pump systems are operating
of process downtime resulting higher-efficiency operation. well below 40 percent efficiency.
from pump system failures Historically, pump system These systems represent a
has steadily increased as profit components have been seen as significant opportunity.
margins have decreased because items to be replaced when they fail The future of pump system
of global competition. Many and not as part of a system that optimization is bright. It is time
plants must operate around 80 needs to be tweaked or optimized. to make this strategy part of plant
percent of the year just to cover For this reason, most plants energy efficiency and reliability
fi xed and variable costs in order are not familiar with how to improvement programs.
to make a profit. With scheduled identify and implement the
downtime requiring 3 to 6 percent required changes to optimize a
of the remaining 20 percent of pumping system. Mike Pemberton is the senior
time for profitable operation, Today, there is a growing technical editor for Pumps &
every increment of unscheduled body of knowledge (BOK) Systems. He may be reached at
downtime incurs significant cost. that covers pump system [email protected].

Augus t 2 0 1 6 | Pum ps & S y st e m s

Circle 105 on card or visit psfreeinfo.com.
30
SPECIAL REPORT

7 Questions to Ask When

Upgrading a Pump Motor
When following the new DOE guidelines, don t
forget these considerations.

BY TERRY W. BELL
BALDOR ELECTRIC COMPANY̶A MEMBER OF THE ABB GROUP

F 2
or motors used in the U.S., the selection Will the motor weigh more?
of an energy-efficient instead of premium- Yes. The required additional active materials (copper
efficient motor is no longer an option. The U.S. and electrical steel) could increase the motor weight by
Department of Energy (DOE) recently made as much as 20 percent, so the effect on mounting and
changes to the efficiency requirements for the majority of handling must be taken into consideration.
definite-purpose motors, including pump motors. These
new requirements went into effect June 1, 2016.
The new rule, known as the Integral Horsepower Motor
Rule, covers 1- to 500-horsepower (hp) (0.75 to 370
3 Will it operate at the same speed?
No. A premium-efficient motor has less slip than a
standard-efficient motor, so it will run at higher speeds.
kilowatts [kW]), three-phase, alternating-current (AC) For example, a two-pole standard-efficient motor would
induction electric motors and requires the motors to meet have a full-load speed of 3,419 revolutions per minute
premium-efficiency levels as defined similar to National (rpm). The two-pole premium-efficient motor will have
Electrical Manufacturers Association (NEMA) Standard a full-load speed of 3,452 rpm. The premium-efficient
Document MG 1-2014, Table 12-12. Only fire pump motor would run 33 rpm faster, and this increase in shaft
motors are allowed to remain at the energy-efficient level. speed will affect affinity law calculations. This results in
When replacing a standard motor with a premium- an increase in the pump’s flow, pressure and power and
efficient motor, several questions can arise pertaining to causes increased load to the motor.
form, fit and function. You may need to contact the pump manufacturer’s
representatives to see what they recommend on trimming

1 Will the premium-efficient motor be

dimensionally larger?
the impeller to reduce motor load from the higher speed.

It depends. Going from a standard-efficient to a

premium-efficient design requires additional active
materials such as copper and high-grade electrical
4 Will it draw less current?
No. The premium-efficient motor is running at a
higher speed, so you will see the same or possibly even
steel. In some cases, the motor size will not change, higher current draw because the motor is producing
because it depends on the horsepower, speed and room more work. Another item that affects current draw is
inside the motor frame. In other cases, the motor could the NEMA design code. NEMA design code B is the most
become longer, the frame diameter could be larger prevalent design and is found in the majority of installed
or a combination of both. However, the motor size is pump applications.
still bound by NEMA definition to have the standard In some cases, a motor must be designed to NEMA
mounting dimensions. design code A rather than B to achieve the required

Augus t 2 0 1 6 | Pum ps & S y st e m s

 31

Figure 1 (left). The active material stack length for a standard-efficient motor
Figure 2 (right). The active material stack length for a premium-efficient motor
(Courtesy of Baldor Electric Company)

Energy Efficient EPAct (1992) IE2 Premium Efficient EISA (2010) and
IHP (2016) IE3

premium efficiency. Design A motors have higher be mindful of the overall efficiency of the system. The
inrush current, which is the instantaneous input combined efficiencies of each component in the system
current required when the motor is first turned on. must be taken into consideration. Optimizing each
When energized for a few cycles of the input waveform, individual component may improve overall efficiency or
electric motors may draw several times their normal full- contribute to a reduction of the overall efficiency because
load current. of the cause and effect of each component, perhaps
The selection of overcurrent-protection devices such causing a particular component to operate in a less
as fuses and circuit breakers are more complicated when efficient manner.
high inrush currents are taken into consideration. The Users must consider how each effort to reduce energy
overcurrent protection must react quickly to overload consumption and cost affects the entire pump system.
or short-circuit faults but must not interrupt the circuit System optimization must include looking at how each
when the inrush current flows. component functions along with the other parts and
pieces of the system, ensuring that optimum efficiency is

5 Will it cost more?

Yes. The increase in active materials (copper
and high-grade electrical steel) required to meet the
achieved as a whole.
The benefits of an optimized pump system include
reduction in energy waste, maintenance cost and
premium-efficiency level adds cost, but the higher downtime. At minimum, a premium-efficient motor is a
efficiency translates into more energy savings and must to achieve these benefits.
reduced total cost of ownership. The purchase price of an Form, fit and function for your replacement premium-
electric motor is only about 2 percent of its life cost. More efficient motor may not be a direct drop-in replacement.
than 97 percent is electricity. Consult with your selected motor manufacturer. The
manufacturer can answer these questions and ensure that

6 What are the benefits of a premium-

efficient motor?
Premium-efficient motors have lower temperature
the replacement motor will work for your pump system.

rise, which extends motor life. There is also the added Terry W. Bell is the product manager for Baldor Electric
benefit of total cost of ownership, which is made up of a Company’s general-purpose and pump motors. Bell
combination of purchase price, cost of running the motor has worked for Baldor, a member of the ABB Group,
in terms of energy consumption over its lifetime and the for 19 years with a background in applications and
cost to a business if that motor fails to run when needed. support. He works closely with all industries
to create NEMA motors for pump, fan and

7 Will a premium-efficient motor optimize my other critical industrial applications. He

pump system? has developed and provided training on
Incorporating a premium-efficient motor in the pump efficiency requirements, motor selection
system is a step in the right direction, but one must and proper product application.

p u m p s a n d s y s te ms . co m | Aug us t 2016
32
SPECIAL REPORT

Rental Sector Grows to

Meet Increasing Demand
Pump manufacturers respond with strategies to better
meet needs from construction, industry, municipal and
mining segments.

BY MIKE DELZINGARO
XYLEM

T
he equipment rental market is growing as However, extreme and unpredictable
companies in sectors from municipal to mining weather events that threaten human
turn to rental as a means of accessing the tools lives, livelihoods and the environment
they need to get the job done. are quickly becoming the new normal.
According to a recent forecast by the American Rental According to the 2015 Annual Global
Association (ARA), the U.S. equipment rental industry Climate and Catastrophe Report,
is poised for stable growth over the next few years, with flooding was the costliest global catastrophe in 2015 at
projected total rental revenue increases of 6.6 percent in $27 billion. By 2050, flood damage in the world’s coastal
2016 and 5.6 percent in 2017. cities is expected to reach more than 900 billion euros
The trajectory is clear, but what is driving this trend? (more than $1 trillion) a year as sea levels rise and global
A combination of factors including climate change, warming triggers new extremes of heat, windstorms
an upturn in the global construction industry and and rain.
contractors’ increased focus on decreasing operating Rental dewatering and analytical solutions assist
costs means that equipment rental is gaining recognition communities in preparing for and responding to
as a viable and cost-effective alternative to purchase. extreme weather events. Equipment rental enables
Pump manufacturers are responding to this trend with cities to contract for emergencies, ensuring that they
a strategy to better meet the market demand from are adequately prepared for flood events with 24/7
construction, industry, municipal and mining customers. dewatering services in times of crisis. The rental model
means communities have access to the latest dewatering
Weather Response technologies and services while avoiding capital
Across the globe, efforts are underway to tackle rapid expenditure on dewatering equipment and associated
urbanization through the development of smart maintenance and storage costs.
cities. According to the UK Department for Business, In May 2015, rental dewatering solutions played a
Innovation & Skills, a smart city “brings together hard crucial role in the battle against record-setting floods in
infrastructure, social capital including local skills and Texas, which saw more than 35 trillion gallons of rainfall
community institutions, and (digital) technologies to in the state that month, according to calculations by the
fuel sustainable economic development and provide an National Weather Service. Preparations began a week
attractive environment for all.” prior to the flood event, with analytical equipment in
Smart technologies are driving ambitious place to predict the pattern and severity of the floods
advancements in transport and traffic management, and rental dewatering pumps deployed across the
energy, health care, and water and waste management. state, supplementing the fleets of contractors and local

Augus t 2 0 1 6 | Pum ps & S y st e m s

 Image 1. A temporary pumping system assists the Dannemora iron ore mine in Sweden to return to operating conditions.
(Courtesy of Xylem)

READ MORE ONLINE

For a detailed look at the pump technologies used in several of the extreme weather events mentioned in this article, check out
the following stories on the Pumps & Systems website:
• “Responding to Devastating Texas Floods” by Pumps & Systems Senior Editor Alecia Archibald, July 2015
pumpsandsystems.com/texas-floods
• “Pumps in Action: Hurricane Recovery” by Pumps & Systems Staff, December 2012
pumpsandsystems.com/hurricane-recovery
• “Rental Pumps in Panama Canal Project Move 1.7 Billion Gallons of Water in 22 Days”
by Dwight Evans, application engineer with Xylem’s dewatering business, March 2016
pumpsandsystems.com/panama-canal

municipalities. The dewatering effort continued during were able to safely track the hurricane’s impact in real
and after the event, helping communities and businesses time using field monitoring stations equipped with
to recover. sensor instruments—in place before, during and after
Early-warning capabilities can increase resilience by the storm. More than 500 dewatering pumps were also
providing valuable preparation time, which city managers deployed to remove floodwater and get communities in
and leaders can use to implement disaster plans to the storm-damaged region back to normal as quickly
reduce vulnerability and loss. Real-time information on as possible.
precipitation and water quality, water levels, and flow As extreme weather becomes more commonplace,
rates can save lives. numerous water technology companies are investing in
When Hurricane Sandy hit the East Coast of the U.S. in their rental offerings to ensure they are positioned
October 2012, a wall of water engulfed low-lying areas of to help communities manage and overcome
New York and New Jersey. Disaster management experts water-related challenges.

p u m p s a n d s y s te ms . co m | Aug us t 2016
34

Construction Growth Dewatering experts can advise on small dewatering

Growth in the global construction industry is proving tasks to comprehensive integrated dewatering strategies
to be a significant driver of the global rental market. The necessary to sustain operations.
Global Construction 2030 report, produced by Global Pump rental offers a quick, cost-effective means of
Construction Perspectives and Oxford Economics, tackling dewatering problems while eliminating the
forecasts that the volume of construction output will challenges associated with pump selection. Operators
grow by 85 percent to $15.5 trillion worldwide by 2030. can avoid significant capital expenditure by choosing
The report identifies emerging markets and the U.S. as the pump rental model while still having access to the
key growth markets accounting for 57 percent of global latest, cutting-edge technologies from leading brands.
growth in the period. Renting pumping solutions allows contractors to focus
The Smart Cities agenda, intended to mitigate the on their core businesses, scale up their existing fleets in
negative environmental impact of rapid urbanization, an affordable manner, pay only for the equipment and
will no doubt fuel this growth as cities move to enhance services they need, and eliminate costs associated with
the sustainable growth of public infrastructure and maintaining and storing equipment.
provide a better quality of life for their citizens. Rental For example, the Dannemora iron ore mine in Sweden
provides contractors with a cost-effective way to access recently opted for a customized temporary water-removal
the smart technologies required to deliver these major system to get the mine back in operation following a
urbanization projects. period of inactivity.
Ambitious construction projects such as the expansion The mine subsequently purchased a permanent system
of the iconic Panama Canal demand a vast amount of from the rental provider to keep the mine water-free. A
specialized construction and dewatering equipment, total of 4.5 million cubic meters of water was drained
and rental is increasingly becoming the preferred option from the mine with bespoke dewatering systems
for contractors. incorporating pumps and a supervisory control and data
In 2015, 15 rental dewatering pumps and 2.5 miles acquisition pump station control system that allows the
of high-density polyethylene pipe were deployed from operation to be monitored from ground level.
the U.S. to Panama to solve a complex water transfer For the Dannemora operation, the solution provided
challenge as part of the Panama Canal expansion project. ease of operation, flexibility and reliability, ensuring
The Authority of the Panama Canal required the third greater energy savings and lower operating and
set of basin locks on the canal’s Pacific side to be filled maintenance costs.
with 1.7 billion gallons of water as part of the system’s
performance trials prior to its commissioning. Over The Future of Rental
a period of 22 days, the pumps transported up to 122 “Rental companies are adept at identifying customers and
million gallons of water per day. relocating equipment to different areas to take advantage
The Panama Canal expansion project resulted in of increased demand,” says Christine Wehrman, CEO
the addition of a new traffic lane and two new lock and executive vice president of ARA. “This is a dynamic
complexes, one on the Atlantic Ocean and the other on industry that continues to have a bright future for
the Pacific side. revenue growth.”
As end users increasingly embrace rental as a
Lowering Operating Costs smart move in addressing water management, both
Many construction and mining operations are focusing economically and environmentally, water technology
on achieving higher production at lower operating costs. companies will continue to play an important role in
This involves maximizing the efficiency and productivity driving the efficiency and sustainability of construction,
of equipment to maintain or improve the bottom line. mining and municipal operations.
Specialized equipment rental aligns well with this
strategy by providing operators with access to reliable
technologies where and when they are needed. Through
rental contracts, operators can access the latest cutting- Mike Delzingaro is vice president
edge technology without having to invest funds in of sales with Xylem’s dewatering
purchasing this equipment. business. He is a degreed mechanical
Another advantage is the opportunity to gain valuable engineer with more than 20 years of
application expertise, which often leads to the most experience in industrial pump sales
efficient and effective means of overcoming a challenge. and pump rental.

Aug us t 2 0 1 6 | Pumps & S y st e m s

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Circle 108 on card or visit psfreeinfo.com.
36
SPECIAL SECTION

COUPLINGS, SEALS & BEARINGS

Evaluating Carbon
Ring Alternatives
Operators should investigate the pros and cons of each
option to determine the best fit for their applications.

BY PETER ZANINI
INPRO/SEAL

O
perators of general-purpose steam turbines
have long stated the shortcomings of
conventional carbon ring seals. One drawback
is wear at the ring’s inner bore, which
gradually increases shaft clearance and steam leakage and
leads to regular replacement—as often as four times per
year. Despite their disadvantages, carbon rings remain
the standard in general-purpose steam turbine sealing.
Because carbon rings are simple to install and have a Image 1. Machined gland boxes with a mechanical seal assembly (Images
replacement cost of less than $1,000 for a complete set, and graphics courtesy of Inpro/Seal)
the cost of maintaining sealing with carbon rings may
seem modest. With a design distinctly dissimilar to conventional
However, there are further costs associated with carbon rings, the mechanical seal requires major
the wear and potential breakage of carbon rings, modifications to a turbine’s existing gland box
including higher water costs resulting from steam configuration. On steam turbines where the steam
losses and degraded bearing performance because of oil chest and gland boxes are individual components, the
contamination and higher operating temperatures. mechanical seal assembly can be bolted to either end of
For operators looking to reduce steam leakage and the steam chest in place of the carbon ring gland boxes.
increase equipment reliability, two primary alternatives On turbines where the steam chest and gland boxes
to carbon rings are available on the market: mechanical are one piece, major machining is required to fit the
seals and the floating brush seal. mechanical seals.
In addition to gland box modifications, the turbine
Mechanical Seals shaft may require modification to secure the seal’s
Mechanical seals used in general-purpose steam turbines rotating assembly. Final setting of the mechanical seal
are a derivative of dry gas seals. A unique profi le—spiral requires careful alignment with the rotor and casing
grooves—on one of the seal faces draws in steam, which to ensure proper sealing between the rotating and
creates a pressure dam that pushes the rotating and stationary seal faces.
stationary seal faces slightly apart for a non-contacting, The hardware cost for a set of mechanical seals to
fi lm-riding sealing interface. Resulting leakage is replace the inlet and exhaust gland boxes can range from
extremely low and measured in parts per million. $20,000 to $30,000. In terms of hardware, installation

Augus t 2 0 1 6 | Pum ps & S y st e m s

 37

Image 3. Gland box with two floating brush seals and four
carbon rings

and downtime
costs, a mechanical
seal upgrade easily
can cost more than
half the price of a
new turbine.
The life of a
mechanical seal is
directly affected Image 2. Floating brush seal
by steam quality.
Mechanical seals work best
in dry steam conditions under
a continuous duty cycle to
alleviate condensate formation.
Even in such an environment,
steam impurities will crystallize
at the pressure dam over
carbon rings. The carbon ring of the FBS provides
time, which will increase face
a face seal against the downstream gland wall or
separation and leakage.
separator plate.
Intermittent duty cycles
Designed to fit the same space as a carbon ring,
can promote the formation of
an FBS can be a drop-in replacement. The seal has
condensate within the steam
a split design, with two segments held together
lines, steam chest and gland
by a garter spring. Its self-centering assembly
boxes while the turbine is
may eliminate the need for an involved alignment
at rest.
procedure in some applications.
Although operators may blow
Operators trained in the replacement of
condensate from the system
carbon rings can replace a carbon ring with an
prior to startup, residual
FBS, which has only two segments versus the
condensate can be problematic
carbon ring’s three.
for the mechanical seal. The
With a complete steam turbine upgrade to
flashing of the condensate into
FBS technology costing no more than half—
a gas, which can best be
Image 4. A carbon ring’s three and maybe even one-quarter—of the cost of
described as a small explosion,
segments and garter spring mechanical seal hardware and installation, an
can catastrophically damage
FBS may be a more cost-effective option for
the seal faces.
many operators.
A plant must evaluate which candidate for carbon ring
Floating Brush Seals
replacement fits all the required criteria: suitability for
The second candidate for replacing carbon rings is a
operating conditions, including steam quality and duty
floating brush seal (FBS). An FBS combines a carbon
cycle; sufficient reduction of steam losses; improved
seal with brush seal technology encased in a lightweight
reliability; and low investment and maintenance costs.
stainless steel band. This technology is designed to
withstand condensate fl ashing while providing a lower,
more stable leakage rate.
As a floating seal, the FBS tends to be more tolerant Peter Zanini is the business development and product
of vibration, bearing failures and radial movement than line director for brush seals at Inpro/Seal and its parent
other options. The brush seal acts as the primary company, Waukesha Bearings Corporation. He has a
shaft seal and faces the high-pressure steam. It Bachelor of Science degree in mechanical engineering
provides immediate pressure reduction while its bristles from Worcester Polytechnic Institute. Zanini may be
fi lter out steam contaminants, protecting downstream reached at 860-673-4096 or [email protected].

p u m p s a n d s y s te ms . co m | Aug us t 2016
38 SPECIAL SECTION COUPLINGS, SEALS & BEARINGS

Hidden Dangers within

Energy-Efficient Systems
End users must understand the conditions that lead to early
bearing failure to choose the best technology for their needs.

BY ED KAINEG
SCHAEFFLER GROUP USA

A
ll pump system operators and maintenance devices. Most VFD inverter circuits use an insulated
personnel must be aware of any side effects that gate bipolar transistor (IGBT) to perform the high-speed
can result from ongoing efforts to improve the switching required to control speed.
energy performance of pump systems. Negative The high-frequency switching of the IGBT will create
effects can be associated with modern variable frequency parasitic capacitances in the pump motor’s major
drive (VFD) systems, particularly with regard to the components, including the rotor and stator. Because the
motor’s bearing supports. To be clear, this is not about bearing acts as the bridge between these components, it
discouraging the continued proliferation of these highly can be exposed to these differences in electrical potential.
effective methods; rather, it is important to understand In many cases, the bearing mitigates this situation
the conditions that lead to early bearing failure. because of design features that offer inherent resistance
to current.
VFD Systems & Bearing Voltages In some cases, however, the electrical potential across
Many pump operators have achieved significant energy the bearing arcs through the contacting points, resulting
savings by varying the pump speed to match the demands in a phenomenon typically known as electrical erosion.
of the attendant system. Although there are many ways This effect can cause the bearing surfaces to deteriorate.
to achieve this objective, the most common is the use of
electrical control or VFD systems. Bearing Deterioration
A typical VFD system consists of an alternating-current First, a quick primer on basic bearing design, which
(AC) motor, a controller and an operator interface. VFD will focus on ball bearings because they represent
controllers are solid-state, electronic power-conversion the most common type of bearing used in motor
applications: Under load, the points of contact between
the balls and races will create a pressure ellipse because
of the elastic nature of the materials selected. The exact
shape of the ellipse depends on several factors, including
the following:
• the direction and magnitude of the bearing load
• the number and distribution of the load on the
bearing’s rolling elements
Image 1. Repeated electrical arcing can lead to a condition on • the geometric relationship between the race and the
the races known as fluting. (Image and graphics courtesy of rolling element
Schaeffler Group USA)
• the modulus of elasticity of the bearing materials

Augus t 2 0 1 6 | Pum ps & S y st e m s

Circle 110 on card or visit psfreeinfo.com.
40 SPECIAL SECTION COUPLINGS, SEALS & BEARINGS

Repeated EA can lead to a condition on the races

Figure 1. A typical loading situation on a ball
bearing used in an electric motor application known as fluting, which looks similar to the washboard
appearance found on rural roads (see Image 1, page
38). Because of the more random motion of the rolling
elements, the balls taken from a bearing exhibiting EA
will be frosty in appearance.

Avoiding Bearing Damage

According to some estimates, 10 to 20 percent of VFD
installations will develop premature bearing failure.
Evidence suggests that the probability of failure increases
over time. As contamination levels rise or the lubricant’s
basic lubricating characteristics degenerate, the odds
grow in favor of damage.
With a relatively large amount of variability related to
possible bearing damage, many end users may choose to
take relatively inexpensive steps to reduce their exposure
and improve machine uptime. Choosing between
Figure 1 shows a typical loading situation on a ball the most economical and the most effective bearing
bearing used in an electric motor application. The red protection usually depends on the timing of this decision.
areas represent the balls that are loaded during operation. An existing pump installation may call for a different
During normal operation, a properly lubricated bearing solution than what a new or reworked motor installation
will generate an elastohydrodynamic lubrication (EHL) may require. To understand the best solution, consider
fi lm between the rolling elements and the races. This fi lm the following options.
prevents surface-to-surface contact and surface damage
(see Figure 2). In electric motor applications, the fi lm Insulated Bearings
can also act as an insulating barrier against mild voltage Many bearing manufacturers provide bearings with
potential across the bearing. In addition to the normal insulating capabilities that, broadly speaking, can take
factors influencing the level of protection afforded by two basic forms: an insulating coating applied to bearing
the EHL fi lm, there are other considerations including components or non-conducting rolling elements that
lubrication degradation and contamination. replace the metal rolling elements.
When a VFD system is introduced, the bearing voltage Insulating coatings—usually aluminum-oxide-
potential typically increases and can exceed the EHL based—can be applied to either the bearing’s bore, its
fi lm’s insulating value. The resulting damage can vary outside diameter (OD) or both of these surfaces. The most
widely. If the voltage is low enough, the bearing can common coating surface is the outer race’s OD because
survive and the condition can go unnoticed. the outer ring tends to have a loose fit in the housing,
Under certain conditions, serious damage caused by which minimizes the potential for damage during
instantaneous electrical arcing (EA) between the rolling installation.
element and the race can occur. A single
EA event can create small craters as Figure 2. A properly lubricated bearing will generate an elastohydrodynamic
the charge rapidly passes through the lubrication film between the rolling elements and the races.
lubrication fi lm and actually melts the
material at the point of contact.
Once a crater has developed, it can
disrupt the EHL fi lm for subsequent
rolling elements as they pass over the
damaged area. This has the potential to
create even more craters. Other resulting
debris will cause the lubricant to degrade
and produce a stress riser, which is
formed by the debris that has found its
way between the roller and the race.

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 41

Coating thickness and insulating value will vary by a rotating connection makes contact with the rotating
bearing manufacturer, so when specifying bearings with rotor, conducting any electrical charge into a properly
insulated coatings, it is important to investigate these grounded motor base. This rotating connection can take
differences. Coating thickness, which typically ranges various forms, including shaft grounding rings, spring-
from 100 to 200 micrometers (µm), is a good indicator loaded brushes, annular brushes or rotating couplings.
of the protection level. Perhaps a better indicator of
insulating value is the disrupted voltage that the coating Conductive Bearing Methods
is capable of providing. Because a coating’s effectiveness A particularly promising method of protection under
depends on time and moisture, higher disruptive voltage development involves establishing an electrical path
values should be considered. through the bearing itself. This is accomplished by using
Bearings using non-conducting rolling elements are a conductive material in the same general region as the
typically known as hybrid bearings. This method of seal. Unlike the non-conductive seal, this solution would
preventing damage provides a more effective barrier than allow current to pass without damaging the bearing’s
coatings and practically eliminates any possibility of rolling surfaces. A cutaway of this concept is shown in
EA. The non-conductive rolling elements used in hybrid Figure 3.
bearings are normally silicon-nitride balls, although other While VFD systems are an effective tool for improving
ceramic materials are also employed. pump system efficiencies, they create conditions in the
controlled motor that can cause electrical arcing inside
the bearing. This can lead to premature equipment failure.
Figure 3. Conductive bearing concept
There are several methods to protect the bearing from
damage, and the best solution depends on the individual
installation. As a general rule, considering the inherent
energy savings offered by hybrid materials, a hybrid
bearing can provide the lowest-cost solution for new or
rebuilt applications.
For existing installations, on the other hand,
grounding devices offer a compelling cost-effective
method of protection. Considering the high cost of
unscheduled motor bearing failure, providing some form
of protection is always a sound investment.

References
1. D. Busse, J Erdman, R. Kerkman, D. Schlegel, and G. Skibinski,
“Characteristics of Shaft Voltage and Bearing Currents,” IEEE
Industry Applications Magazine, Vol. 3, No. 6, pp.21-32 Nov.-Dec.
1997
2. A. Willwerth, Electro Static Technology-ITW 31 Winterbrook Road,
Mechanic Falls, ME 04256
Initially limited by the high cost of ceramics to only a 3. R. Toney, EIS, Motion Industries, 7111 North Loop E. Houston, TX
4. C. Rechlin, Mercotec Inc. USA, 6195 Corte del Cedro #100 Carlsbad,
few highly engineered applications, hybrid bearings are
CA 92011
now more readily available because of more economical 5. Wayne C. Turner & Steve Doty, Energy Management Handbook, 6th
ceramic balls. The higher modulus and lower density of Edition
the ceramic materials used in hybrid bearings give them
additional advantages: The material’s stiff ness reduces
rolling friction while its light weight reduces the balls’
angular momentum losses. This configuration reduces Ed Kaineg is the pumps and motors industry manager
energy consumption in the bearing by up to 20 percent. for Schaeffler in the Americas. With more than 33 years
of experience in the bearing industry, his
Rotor Grounding Methods career includes positions in engineering,
Another common method of protection is to provide product management and manufacturing
a low-resistance grounding path for the rotor. This technology. He holds a bachelor’s degree
eliminates any electrical potential and, consequently, in mechanical engineering from Southern
any potential for arcing. The basic requirement is that Illinois University.

p u m p s a n d s y s te ms . co m | Aug us t 2016
42 SPECIAL SECTION COUPLINGS, SEALS & BEARINGS

Get Improved Pump

Performance with
Bearing Upgrades
Alternative bearing options can enhance reliability and
increase energy efficiency.

BY BRIAN P. DAHMER
SKF USA INC.

T
he performance and service life of a centrifugal
pump is affected by factors ranging from the
system’s design and critical components to
the many operating conditions encountered in
an application. But regardless of how closely a pump
may appear to conform to application requirements
at the outset, unanticipated problems can eventually
develop and equipment downtime may follow. In these
cases, operators should consider whether upgrades to
components—rather than a simple fi x—make sense.
Appropriate upgrades to existing pumps can enhance
reliability and improve productivity.
Rolling bearings represent one example of how
next-generation design, engineering and materials can
optimize pumps in service.
In general, bearings for rotating machinery support Image 1. Upgrading all-steel bearings with hybrid types integrating
shaft loads, reduce friction with rolling elements, and ceramic rolling elements can substantially improve bearing reliability
provide shaft location and system rigidity. For centrifugal and robustness in service. (Courtesy of SKF USA Inc.)
pumps, bearings support hydraulic loads imposed on the
• the use of ceramic material for rolling elements and
impeller and shaft, as well as loads created by couplings
super-tough steel for bearing rings
and drive systems. Bearings also keep shaft axial and
• specialized wear-resistant coatings
radial deflections within acceptable limits for a pump’s
• dissimilar opposing contact angles for rolling
impeller and shaft seal.
elements to withstand potential damage resulting
Pump operators can choose from many potential
from minimal axial loads
bearing upgrades. The following list outlines several
• optimized energy-efficient bearing designs
options, each offering distinct application advantages:

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ALL YOU NEED
TO KNOW
ABOUT
READING A
PUMP CURVE

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44 SPECIAL SECTION COUPLINGS, SEALS & BEARINGS

Making Material Changes The coated bearing surfaces retain the toughness of the
Bearings in especially tough pump applications, such underlying material—the coating is actually harder than
as oil and gas and hydrocarbon process industries, steel—while adopting the hardness, improved friction
typically must accommodate contaminated and corrosive properties and wear resistance of the coating.
environments, inadequate lubrication conditions, high Unique coating properties also promote high-speed
and low loads, and high or cryogenic temperatures. At the capabilities and will tolerate contamination more
same time, they must provide a high degree of service, effectively than other bearing types.
availability and safety. Coated bearings as upgrades can withstand many
These demands can test the limits of conventional severe operating conditions, including risks of smearing,
all-steel bearings. As an upgrade, hybrid bearings insufficient lubrication fi lm, sudden load variations, light
that integrate rolling elements made of bearing-grade loads, rapid speed changes, vibration and oscillations, and
silicon nitride can substantially improve reliability high operating temperatures. The anticipated outcomes of
and robustness. Such bearings are dimensionally these capabilities include increased reliability, extended
interchangeable with similarly sized all-steel bearings, service life, and reduced chances of premature bearing
eliminating the need to reconfigure or otherwise alter failure resulting from friction, wear and related factors.
pump equipment.
An engineered ceramic material, bearing-grade silicon Turning to Contact Angles
nitride offers a uniform and clean microstructure that is Typically, 40-degree matching contact angles for pump
extremely hard and 40 percent less dense than bearing bearing rolling elements have become the norm for
steel. As a result, rolling elements weigh less and exhibit paired single-row angular contact bearings in American
lower inertia, which reduces stress on a bearing’s cage Petroleum Institute (API) pumps. For conventional
during rapid starts and stops and significantly lowers double-row bearings used in American National
friction at high speeds. Lower friction translates to cooler Standards Institute (ANSI) pumps, matching 30-degree
running and longer lubricant service life. contact angles are typical.
In addition, silicon nitride demonstrates a higher Particularly for the 40-degree paired single-row
modulus of elasticity than steel, which promotes bearings, a change in the opposing contact angle can
increased bearing stiff ness and longer bearing service benefit many centrifugal pump applications by promoting
life in contaminated environments. The lower thermal smoother operation and longer service life in the way they
expansion for silicon nitride rolling elements allows support loads.
for more accurate preload control and less likelihood of Pump bearing arrangements engineered with
excessive preloading when temperature gradients exist dissimilar opposing contact angles—a combination
within the bearings. of 40-degree and 15-degree—can carry higher thrust
As an alternative to compensate for extreme loads with the 40-degree bearing without unloading
conditions, hybrid bearings are available with high- the opposed 15-degree bearing. Greater axial loads can
performance stainless steel rings instead of rings made be applied, and the bearing’s operating temperature
from conventional steel to promote superior corrosion will decrease.
resistance and to compensate for high temperatures. These 40/15-degree angular contact ball bearing
Hybrid bearings also can improve bearing reliability arrangements are ideal for applications where the
and service life in other ways. For example, smearing axial load is high in one direction and does not change
may result in bearings that face insufficient or improper direction during operation. The bearing sets can accept
lubrication conditions, high speeds and light loads, and/ momentary reversals in axial load, including those that
or sudden starts and stops. Smearing is surface damage occur during pump startups and stops.
to a bearing that results from sliding between the In centrifugal pumps with light thrust loads and
all-steel rolling elements and rings. Smearing will not predominantly radial loads—such as double-suction
occur between silicon nitride and steel, enabling hybrid impeller pumps or pumps with closed impellers—bearing
bearings to last longer in applications that have severe arrangements featuring only 15-degree contact angles
dynamic or improper lubrication conditions. offer yet another upgrade alternative.
Compared with conventional 40-degree matched
Resisting Friction & Wear bearing arrangements, the design of these 15-degree
To overcome several common causes of bearing failures, a bearings promotes cooler running, substantially reduced
low-friction, wear-resistant carbon coating can be applied vibration and extended service life in applications with
to the bearing’s rolling elements and inner ring raceways. high radial loads.

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 45

Generating Energy Efficiencies

Reducing energy consumption in a Process Pumps & Steam Turbines
system remains a top priority in today’s
marketplace, and certain bearings have
been introduced to help users reach this
goal. One of these bearing families includes
two types commonly used in centrifugal
pumps: deep-groove ball bearings and
double-row angular contact ball bearings.
Both types have been internally modified
to decrease energy consumption by
at least 30 percent compared with
standard International Organization for
Standardization (ISO) products while
maintaining the service life and load-
carrying capacity of conventional versions.
Relevant energy-saving technical
improvements to deep-groove ball bearings
for pumps include optimized internal
geometry, newly designed polymer cages,
and the use of lower-friction grease
for sealed or shielded variants. For the
double-row angular contact ball bearings,
Generating Power for Human Life, SNM
proprietary technical improvements that
deliver energy savings include optimized TOTAL SOLUTIONS APPROACH
internal geometry, steel shields on both SNM is the only manufacturer in the world that produces
sides and unique low-friction grease. API610 process pumps and API611/612 steam turbines in
Both types of bearings, which are the same factory. This total solutions approach uniquely
dimensionally interchangeable with addresses the needs of the oil and gas industry.
conventional bearings, have been highly
engineered to reduce friction and, in turn,
decrease energy use. ENERGY-SAVING SOLUTIONS
As these innovations demonstrate, Mounting data confirms that
pump bearing design and engineering energy savings are realized when
will continue to evolve as operators seek old pumps in aging plants are
to improve the performance of existing replaced with high efficiency,
pumps and take advantage of advanced
latest model pumps. At SNM our
technologies for minimizing problems and
maximizing output. pump products and solutions
address energy-savings concerns
facing clients across the globe.
Circle 116 on card or visit psfreeinfo.com.

Brian P. Dahmer is manager of

application engineering at SKF USA Inc.,
based in Lansdale, Pennsylvania. www.snm.co.jp Come visit us at
He may be reached
booth #1419
at 267-436-6517 or
brian.p.dahmer@
skf.com. For more
information, visit SALES OFFICES FACTORY

skfusa.com. TOKYO, JAPAN HOUSTON, TEXAS GLENDALE, CALIFORNIA BANGKOK, THAILAND HIROSHIMA, JAPAN
+81-3-6737-2631 +1-281-990-8594 +1-818-500-8165 +66-2-262-0740 +81-823-71-1111

p u m p s a n d s y s te ms . co m | Aug us t 2016
46 SPECIAL SECTION COUPLINGS, SEALS & BEARINGS

API 610 Disc Pack

Couplings Promote
Maximum Reliability
One unique design transmits torque across the disc pack
assemblies purely by friction, helping to prevent issues
associated with stress concentration, backlash and chatter.

BY BRIAN CONNER
R+W COUPLING TECHNOLOGY

A
PI 610, 11th Edition, is
one of many standards
written and regulated by
the American Petroleum
Institute (API) to ensure maximum
reliability in critical applications.
This regulation focuses on the
minimum safety, reliability and
maintainability requirements
for centrifugal pumps used in
petroleum, petrochemical and
natural gas applications. API 610
pumps can be found in various
locations including offshore
oil rigs, onshore oil production
facilities, oil refineries, petrochemical and natural gas Image 1. Example of an API 610 disc pack coupling
processing plants, and power stations. In addition to (Images courtesy of R+W Coupling Technology)
regulating pumps, bearings, guards and mechanical seals,
the standard includes key requirements for the flexible occur. API 610 pump packages should be designed for a
shaft coupling mounted between the pump and motor. minimum service life of 20 years and at least three years
of uninterrupted service.
Coupling Requirements Downtime could potentially cost operators millions
Because safety and reliability of a pump system in the of dollars per day, so component selection is extremely
oil and gas industry are critical, detailed requirements of important. From a maintenance standpoint, many
all components are needed. If end users do not carefully requirements are in place that allow for a quick and
select and design these pumps, catastrophic failures may simple overhaul of an entire system.

Augus t 2 0 1 6 | Pum ps & S y st e m s

48 SPECIAL SECTION COUPLINGS, SEALS & BEARINGS

Beyond these key characteristics, there are additional

requirements that ensure the installation of a highly
reliable and easy-to-use coupling, making the sizing and
selection of the flexible coupling in an API pump package
an important task.

Updated Technology
While coupling specifications have not changed much
over the years, end users have a few options to improve
the reliability of the couplings they use in these critical
applications. One company has included various updated
features in its disc pack couplings, for example, that are
unique from other designs. They transmit torque across
the disc pack assemblies purely by friction, helping to
prevent issues associated with stress concentration,
backlash and chatter, all of which can result from
transmitting torque across the shanks of shoulder bolts
and can lead to premature failure.
The friction drive design of this company’s disc pack
couplings serves to eliminate the bending load that can be
placed on the shoulder bolts in some traditional designs.
The bolts in this particular design are tightened through
the hubs, spacers, guard rings and bushings to a torque
Image 2. Frictional drive design with high-grade, class 9 bolts level sufficient enough to generate the necessary clamping
and nuts eliminates shear load that can be placed on shoulder pressure across the faces of the disc packs to transmit all
bolts in traditional designs.
of the power by friction. The frictional connection of the
disc packs further increases service life, while making the
complete coupling assembly more torsionally stiff.
API Specifications
The safety catch to retain the spacer in the unlikely
An API 610 coupling is an all-metal, flexible element
event of a disc pack rupture on this design consists of a
spacer coupling designed in accordance with American
guard ring assembly that captures the center member
Gear Manufacturers Association (AGMA) 9000 Class
by piloting the coupling hub to the guard ring itself. In
9 standards for balance quality to reduce vibration. If
the event of a disc pack rupture, the guard rings serve to
operating in excess of 3,800 revolutions per minute
contain the tube and prevent it from being thrown from
(rpm), this equipment must be balanced in accordance
the assembly.
with International Organization for Standardization
This design also helps to ensure that the center spacer
(ISO) 40441.
assembly with captured disc packs can be easily removed
In addition, the coupling must include corrosion-
for maintenance of items such as seals and rotors without
resistant flexible elements with steel hubs. A safety
disturbing the adjacent components. The scalloped hub
catch must be in place to retain the spacer if one of
and guard ring aims to eliminate unnecessary material
the flexible elements ruptures in the event of a
from the coupling, resulting in a lower inertia design.
catastrophic failure.
The nominal length of the center spacer (DBSE)
should be greater than the seal cartridge length for all
pumps other than overhung (OH) type and must allow
for removal of the coupling seal, bearing(s) and rotor
without disturbing the motor, coupling hubs or adjacent Brian Conner is the oil and gas industry product manager
pump components. at R+W Coupling Technology. He may be reached at
In pump design, it is recommended to leave a [email protected]. For more information on R+W’s
minimum of 1 inch of shaft between the bearing redesigned line of disc pack couplings, including the API-
housing and the coupling hub for alignment tools 610-compliant LPA and LPAI couplings, visit the website at
to be installed during the assembly process without rw-america.com or call 888-479-8728.
dismantling the coupling.

Augus t 2 0 1 6 | Pum ps & S y st e m s

Circle 195 on card or visit psfreeinfo.com.
50

PUMP SYSTEMS OPTIMIZATION

Optimize from the

Overview of a Closed-Loop Heat Exchanger Pump System
BY BILL LIVOTI, WEG

11

11

11

15

14 13

10

12

3
9

4
1

2 3 7 8 16 17

Augus t 2 0 1 6 | Pum ps & S y st e m s

 51

Onset P
umping systems are composed of various
components including motors, pumps,
drives, control valves, piping and ancillary
equipment. At each of these components,
there are inefficiencies. Because every system
component impacts total system efficiency in
different ways, focusing exclusively on individual
components can overlook potential cost savings.
To maximize the overall cost-effectiveness of their
operations, end users must turn to optimization of
the entire system.
Heat Exchanger 20 The graphic on the left depicts a simple
closed-loop heat exchanger system. Turn the page
for explanations of how each of the system’s parts
work together and for optimization tips.

1 Suction Source
2 Suction Piping
3 Block Valve
4 Suction Gauge
5 Sub-base
6 Primary Base Plate
7 Pump
8 Mechanical Seal
19 9 Discharge Gauge
MCC 10 Flow Meter
VFD 11 Discharge Piping
12 Check Valve
18
13 Bypass Valve
14 Bypass Line
15 Control Valve
16 Coupling
17 Motor
18 Input Power/Power Cable
19 VFD
20 Process (heat exchanger)

p u m p s a n d s y s te ms . co m | Aug us t 2016
52 COVER SERIES PUMP SYSTEMS OPTIMIZATION

4
Suction Gauge size, speed, power requirements, type
1
Suction Source
Suction fluid level must provide The suction gauge should be liquid- of drive, mechanical seal, and
adequate net positive suction head filled and sized according to the suction any ancillary components for the
(NPSH) to ensure the pump can meet pressure seen by the pump. If the pump application. Proper pump selection
design conditions without cavitating. experiences a vacuum condition, a is a multistep, multidiscipline process
The NPSH available (NPSHA) is a function gauge that reads vacuum as well as that requires a clear picture of the
of the following attributes of the pump pressure should be used. process system and piping, a thorough
and piping system: understanding of system operation
• elevation difference between the and energy requirements, and
knowledge of the economics over the
5
liquid level and the eye of the Sub-base
impeller The success of a reliable pumping life of the system.
• pressure on the liquid surface system begins with the sub-base. The
• head loss in the pump’s suction sub-base is the foundation on which the
pipelines primary base plate is installed. The sub-
8
Mechanical Seal
• pump suction nozzle flow velocity base must be of appropriate size and
Both the mechanical and support
• vapor pressure and density (as mass to support the primary base plate
system must be selected to meet the
function of temperature) of the as well as the components installed on
system requirements.
liquid being pumped the base plate. • Metal parts must be corrosion-
• barometric pressure at the
resistant.
pump site
• Mating faces must also
resist corrosion and wear
Sometimes pump performance (stationary and rotating).
• The proper type of seal is
is limited by NPSHA. It may be
2
Suction Piping
based on the pressure on
The majority of hydraulic
problems encountered in possible to reduce the piping the seal and on the seal
size.
pumping systems originate
in the suction piping. It is head losses by increasing the • Temperature can determine
the use of the sealing
important to provide the
best possible suction piping
suction piping diameter. members as materials
must be selected to handle
layout. Piping must be large
liquid temperature.
enough to carry the volume.
Piping configuration must

6
be such that the liquid is properly led Primary Base Plate
to the pump. Ideal piping configuration Torsional stiffness, rigidity and

9
should provide a minimum of 10 flatness (0.002 inches TIR at machined Discharge Gauge
surfaces) are the most important As with the suction gauge, the
diameters of straight pipe between the
considerations with respect to the discharge gauge should be liquid-filled
suction source and the pump suction.
primary base plate. By design, the and sized appropriately to meet the
The head loss component of NPSHA is
base plate (when grouted) should be maximum discharge pressure of the
based on the losses in the pump suction
piping. These losses can be significant approximately five times the mass of system with a slight margin.
and increase with the square of the the components it supports.
increased ratio of flow rate. Sometimes
pump performance is limited by NPSHA.

10
Flow Meter
7
It may be possible to reduce the piping Pump
head losses by increasing the suction Selecting a pump for an Various types of flow meters
piping diameter. application is based on the system are available for pumping systems,
head versus flow requirements, the including intrusive and non-intrusive
pump performance characteristics, design. Intrusive designs consist of
the pumping application, the orifices, venturies, nozzles, rotameters,
pitot tubes, turbine, vortex and
3
Block Valve footprint required for the pump and
Block valves are used to isolate driver, application specifications, calorimetric. Non-intrusive designs
the pump for repair and service codes, regulations, reliability and include ultrasonic doppler; this design
without having to evacuate the system. maintainability considerations, is installed externally on the piping and
Block valves should be installed at the and energy cost considerations. reads flow through motion of sound.
suction and discharge side of the pump, The specifying engineer may need Flow meters should be selected based
and they should never be used for to work closely with the pump on type of pumpage, temperature and
process control. manufacturer to select the best pump, accuracy of flow readings.

Augus t 2 0 1 6 | Pum ps & S y st e m s

 53

11 15
Discharge Piping Control Valve or the mechanical nature of
A piping system is composed of Control valves are used to control the machine. The motor torque
individual pipelines connecting the conditions such as flow, pressure, supplied to the driven machine
other system components. Because a temperature and liquid level by fully must be more than that required
pipeline is the basic building block of or partially opening or closing in from start to full speed. The greater
a pump system and pipelines are one response to signals received from the excess torque, the more rapid
of the major friction losses in a pump controllers. As with other pump the acceleration.
system, it is important to examine system components, the control valve • Acceleration: The necessary
the losses associated with piping to should be selected based on type of acceleration time should be
understand the total frictional head loss pumpage, temperature, pressure and considered. Acceleration time is
in the system. volumetric flow rate. Control valves directly proportional to the total
increase the friction head loss in the inertia and inversely proportional
system, resulting in wasted energy to the torque (motor vendor).
and potentially off-design operating • Duty Cycle (RMS Calculation):
12
Check Valve
conditions. Selecting the proper motor
An essential element in the design
depends on whether the load is
of a pumping system is the proper
steady, varies, follows a repetitive
selection of the check valve, whose
cycle of variation or has pulsating

16
purpose is to automatically open to Coupling torques. The duty cycle, defined as
allow forward flow and return to the The basic function of the coupling a fixed repetitive load pattern over
closed position to prevent reverse flow is to transmit power, accommodate a given period of time, is expressed
when the pump is shut down. Several misalignment and compensate for as the ratio of on-time to the cycle
types of check valves are available, axial movement (end movement of period. When the operating cycle is
including lift check valves, swing check shafts). Factors in coupling selection such that the motor operates at idle
valves and pump control valves. include torque, chemical compatibility, or a reduced load for more than 25
temperature, speed, starts and stops, percent of the time, the duty cycle
physical dimension, starting method, becomes a factor in selecting the
and system alignment.
13
Bypass Valve proper motor.
When evaluating what types of • Heating: The temperature of an AC
valves are suitable for installation in motor is a function of ventilation
bypass piping, end users must consider
17
Motor and losses in the motor. Losses such
the role of the bypass line. What was When selecting an alternating- as operating self-ventilated motors
the purpose of the installation of the current (AC) motor and associated at reduced speeds may cause
bypass line? Bypass piping can roughly equipment for an application, the above-normal temperature rises.
be divided into two categories: following points should be considered: De-rating or forced ventilation may
• Bypass piping that acts as a • Environment: Conditions such as be necessary to achieve the rated
backup line to allow operation ambient temperature, air supply, torque output at reduced speeds.
to continue while damaged and the presence of gas, moisture
equipment such as pressure- or dust should all be considered
reducing valves and steam traps
18
when choosing a motor. Input Power/Power Cable
are isolated and shut down during • Speed Range: The minimum Input power cable selection is
replacement or repair and maximum speeds for the dependent on whether or not a variable
• Bypass piping designed to application will determine the frequency drive (VFD) is used. Using the
supplement the performance of motor base speed. proper (shielded) cable when connecting
pressure-reducing valves and traps • Speed Variation: The allowable the VFD to the motor can impact system
These distinct objectives require amount of speed variation should reliability. Refer to the motor and drive
valves with different features, so the be considered. Does it require manuals to make sure you are using
optimal valve models will be different. constant speed at all torque values, the correct cable and implementing
or will variations be tolerated? the grounding according to the VFD
• Torque Requirements: The and motor manufacturers’ instructions.

14
Bypass Line starting torque and running Every VFD has a maximum motor cable
The bypass line should be sized torque should be considered when length. Before installation, you should
to accommodate no less than 50 selecting a motor. Starting torque know the maximum distance from
percent of the design flow of the pump. requirements vary from a small the motor to the drive. The reason for
Proper sizing will minimize the risk percentage of the full load to a maximum cable distance is the firing/
of premature pump failure should the value several times full-load torque. gating of the insulated gate bipolar
system requirements force the pump to The starting torque varies because transistors (IGBTs) can be adversely
operate back on the curve. of a change in load conditions affected by the capacitance of the

p u m p s a n d s y s te ms . co m | Aug us t 2016
54 COVER SERIES PUMP SYSTEMS OPTIMIZATION

20
cable. Conductors have a very small –Environmental considerations Process (heat exchanger)
capacitance, but the longer the wire, • Temperature: Is enclosure cooling The graph depicted on pages
the more capacitance is introduced to or heating needed? 50-51 is a closed-loop system with one
the system. • Ingress protection: Dust, moisture, pump feeding a heat exchanger. In
corrosive gas? order to size the pump to the system,
• Elevation: More than 3,300 feet we must establish a system curve.
above sea level? The system curve represents the head
19
VFD
Selection criteria for applying a • Hazardous site: Explosion-proof? required to move fluid through the
VFD to a centrifugal pump system: –Motor cable length system at various flow rates. It has two
–Voltage considerations • VFD output filters to protect motors components: friction head and static
• What is the voltage available on- or to avoid nuisance tripping issues head. The system will operate where
site? • Output sine wave filters the pump and system curve intersect.
• Does the VFD rated output voltage • dV/dt filters The process (heat exchanger) creates
equal motor voltage? • Common mode filters resistance to flow (friction) and is a
• Is it single-phase input? • Look at the big picture of the critical factor when determining the
–Amperage considerations motor, pump and drive as a required head and flow during the pump
• Motor full-load amps: Is the VFD complete system. selection process.
output rating sufficient? –Harmonic level: IEEE 519
• Motor service factor (SF) amps: Will • Line reactor
the motor run into the SF? • Direct-current (DC) choke
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The use and function of each device - with emphasis on

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To troubleshoot air problems at an introductory level

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56 COVER SERIES PUMP SYSTEMS OPTIMIZATION

5 Steps to Successful Pump

Systems Optimization
Evaluating the entire system for possible improvement will help facilities
lower energy use and improve reliability.

BY MARK J. SULLIVAN
HYDRAULIC INSTITUTE/PUMP SYSTEMS MATTER Figure 1 (top). Life-cycle cost of a standard 75-hp pumping system over 20
years of operation
Figure 2 (bottom). The impact on pump reliability when operating outside

W
of its acceptable range. Note that most of the issues occur when the pump
astewater treatment facilities, chemical is operating to the left of design, which is where pumps typically operate
and power-generation plants, electric due to oversizing. (Graphics courtesy of Hydraulic Institute)
and gas companies, municipalities, and
commercial buildings all have a common
prime mover—centrifugal pumps. Collectively, these
pumping systems represent an enormous amount of
electrical energy usage. Pump systems, on average,
represent the highest energy usage of any type of rotating
equipment employed in industrial and commercial
facilities. For example, pumping systems account for
20 to 30 percent of electrical energy consumption in
wastewater plants and up to 46 percent in municipal
water systems. By comparison, chemical and allied
product plants typically use enough electrical power in
pump systems to run a small city.
Pump system designs are normally in the range of 65
to 85 percent at their best efficiency point (BEP). Because
Total 20 Year Life-Cycle Cost=$757,145
of oversizing and sometimes undersizing, pump systems
typically operate well below their BEP. The excess energy
usage is transmuted into vibration, heat and noise, all of
which increase maintenance and energy costs.
When not optimized for best efficiency, pump systems
drain maintenance budgets by decreasing the mean time
between repairs. Pump systems represent one of the best
ways to reduce overall plant operating costs.

The Underlying Cause of Pump Inefficiency

One reason so many pumping systems run significantly
below their BEP is that organizations focus on purchase
price rather than the total life-cycle cost (LCC) of
the system. Figure 1 depicts the LCC of a standard
75-horsepower (hp) pumping system over 20 years
of operation. While the initial purchase price and
installation cost represent 17 percent of the LCC,

Augus t 2 0 1 6 | Pum ps & S y st e m s

 SHAFT
LOAD – BRG SHAFT
CAUSES
MOVEMENT

57
STUFFING BOX

Save Face.
55 percent of costs are related to
operations, and the 28 percent balance
LET US BEAR THE LOAD.
is maintenance costs. In severely
BEARING LOCKING MECHANICAL
oversized systems, the first cost of the (Prevents Movement) COLLAR

pump can drop to 10 percent or less.

(optional)
SEAL
Rather than base a purchasing decision
ATMOSPHERE
on price alone, plant designers should
evaluate a system’s total LCC and make
decisions that will minimize energy and
maintenance costs. – ORM (O-Ring Mount Bearing )
Another important factor affecting
pump efficiency is the lack of system
SHAFT
standards that guide the design LOAD
CAUSES
of efficient pumping systems. As a MOVEMENT
result, engineering, procurement and STUFFING BOX
construction (EPC) firms continue to
use the same design approaches—“if-it-
ain’t-broke-don’t-fi x-it syndrome.” These Mechanical seals are ultra-precision devices with seal
SILVER = C0.M0.Y0.K30
routine confi
Letterhead, Bills, gurations
envelopes... Simpletypically
and on consist faces carefully lapped to less than 1.8 microns. ThisFor use in layouts where the logo will be
white background - darker blue with PMS 877 DARK BLUE = C90.M50.Y5.K40
placed on a dark color field such as technical
of a for
fi xed-speed
contrast on white control valve system.
type of precision is expensive and downtime, due to
LIGHT BLUE = PMS285 or C91.M53.Y0.K0 services gray.
SILVER = C0.M0.Y0.K30
This design approach has been mostly Orange = C0.M56.Y92.K0
seal face parting and failure, is even more costly. LIGHT BLUE = PMS285 or C91.M53.Y0.K0
unchallenged. The design engineer often
cites time and budget as the reasons
other designs, such as not using a
PROTECT SEAL FACES FROM FAILURE
BLUE = C90.M50.Y5.K40 PMS 7462
variable-speed drive or parallel multi- ROTATING SHAFT SEALING EXPERTS
SILVER = PMS877 or C47.M38.Y38.K2
pump system in lieu of an oversized SealRyt’s patented bearing technology
control valve system, are not considered. augments Mechanical Seal performance by:
BLACK ONLY LOGO - FAX, ETC.
If the design process uses more due
diligence, engineering firms can easily
• Minimizing radial shaft movement from run out or misalignment
overcome perceived barriers to achieve • Acting as the replaceable wear surface
PATENTED TECHNOLOGY
the lowest practical LCC. Furthermore,
without a design standard, end users • Transferring load and wear from the seal faces to the bearing
GRAYSCALE LOGO

will lack the needed information to • Allowing the mechanical seal faces to remain in close contact
effectively challenge designers and prove and do their job
that a system is poorly or incorrectly PATENTED TECHNOLOGY

conceived. Even today, industry •

PREMIUM Aiding
MECHANIC inALvibration
PACKING dampening
continues to design and install oversized
pumping systems because of the lack of SEALRYT® – INSURANCE FOR YOUR CRITICAL MECHANICAL SEALS
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Westfield, EMAIL [email protected]
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to use pump and pipe design tools and 64 Servistar Industrial Way | Westfield, MA 01085 | Phone: 413-564-5202 | Fax: 413-564-5203
TECHNICAL SERVICES GRAY
C78.M64.Y50.K39
techniques that optimize the selection 64 Servistar Industrial Way | Westfield, MA 01085 | Phone: 413-564-5202 | Fax: 413-564-5203
of best pump, pipe and control valve
combinations PACKING AND toPACKRYT
achieve BLUE the lowest LCC.

C90.M50.Y5.K40

Effects of Pump Inefficiency

ROTATING SHAFT SEALING EXPERTS
For maximum efficiency, pumps should
operate at orFUTURE
nearBLUEtheir mechanical BEP. Call us to find out why reliability and maintenance managers are moving to our patented solutions!
C91.M53.Y0.K0
Optimally, pumps should not run at
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p u m p s a n d s y s te ms . co m | Aug us t 2016
58 COVER SERIES PUMP SYSTEMS OPTIMIZATION

surge and vibrate, creating potential When pumps operate at reduced thrust on the rotor will increase,
bearing and shaft seal problems while capacity, or lower than BEP, fi xed- causing higher shaft stresses, increased
requiring excessive power. Cavitation vane angles may cause eddy currents shaft deflection, and potential bearing
may also occur, causing damage to within the impeller, inside the casing and mechanical seal problems. Radial
pump components. and between the wear rings. The radial vibration and axial shaft movement
will also increase. Figure 2 shows the
effects of operating away from the BEP
on the pump.

The Need for Pump

Systems Optimization
Systems optimization is the process
of evaluating pumping systems
to identify opportunities for
improvements that will reduce energy
consumption and improve reliability.
Improving a single component—
installing a more efficient motor, for
example—will do little to improve
overall system efficiency. Engineers
who wish to implement systems
optimization must evaluate how all
pump components work together and
determine how to make certain system
changes to improve net efficiency.
Greater pump system efficiency
achieved through systems
optimization will improve reliability
and lower operating costs by reducing
wear and tear. This will decrease
downtime and costs associated with
lost production, maintenance and
repairs, while extending equipment
life. Costs associated with downtime
routinely exceed energy and reliability
costs combined.

Approaches to
Systems Optimization
As with any engineering project, the
pump systems optimization process
begins with organizing an assessment
team. The individuals chosen should be
knowledgeable in one or more critical
areas. The team will also work cross-
functionally with the team leader and
other members to meet the study’s
overarching goals. The following steps
are vital to a successful pump systems
optimization program.

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Augus t 2 0 1 6 | Pum ps & S y st e m s

 59

1 3
Prescreening • Level 3 is a quantitative review Data Collection
Initially, pumps are prescreened measuring system demands by The next step in the systems
to identify those with the greatest tracking and monitoring the system optimization process involves
savings potential. Pumping systems over longer time periods to obtain data collection. Data are collected on
should be screened for any of the various operating conditions. energy costs and the pump systems
following symptoms:
• highly throttled flow-control valves
• existence of bypass line
(recirculation) flow regulation
• batch-type processes involving
one or more pumps running
continuously
• frequent on/off pump cycling
• cavitation noise either at the pump
or in the system
• parallel pump system with the same
number of pumps always working
• a pump system that has undergone
a change in function without
modification
• a pump system with no means of
measuring flow, pressure or power

Pumping systems with one or

more symptoms are typically ideal
for further assessment. Large, high-
maintenance systems that are mission-
critical to the process or facility
operation are often a top priority.
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Assessment
Next, pump systems selected for
assessment must be thoroughly
evaluated. Depending on the
requirements of the plant or facility,
the selection of the correct pump
system assessment level is important
to meet the project’s goals.
• Level 1 pump system assessment
is a qualitative review that
determines potential energy
savings and reliability
improvements to identify pumps
worthy of further attention.
• Level 2 is a quantitative review
that determines energy
consumption and reliability
improvements based on
measurement made during steady-
state operating conditions using a
single set of measurements.
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p u m p s a n d s y s te ms . co m | Aug us t 2016
60 COVER SERIES PUMP SYSTEMS OPTIMIZATION

using appropriate data-acquisition systems. For example,

collected data can be used to compare the measured rates
TRAINING OPPORTUNITIES
of flow and head to the required rates.
An analysis may reveal an imbalance between
The Hydraulic Institute recently introduced a measured and required conditions, which is evidence
Pump Systems Assessment (PSA) Certificate of an inefficient system. Comparing existing operating
Program that provides instruction on how conditions to design conditions can also show an
to gauge the knowledge and capabilities of improperly sized pump.
individuals required to conduct pump systems
An original pump performance curve can be useful
assessments and implement process changes
for constructing a curve for the operating points of the
at facilities.
existing system.
As the pool of nationally certified PSA Comparing a single test point to the original curve can
professionals grows, industry will become help determine if the first step to systems optimization
increasingly confident in the implementation
will be the overhaul of a worn pump or if the system
of pump systems optimization initiatives.
must be further investigated. The curve will also help
Over time, this educational effort will help
increase the average pump system efficiency determine if the rotodynamic pump is operating at
above today’s average of 40 percent. Also, its BEP. Those operating outside the BEP range will be
energy consumption in pump systems inefficient and consume more energy.
will begin to decrease as recommended Other components of the existing system also must
mechanical and control modifications be assessed, including valves, bypass lines, piping
are implemented. configurations and suction piping that may provide
optimization opportunities.

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These pumps feature the revolutionary new single
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v i r t u a l l y e l i m i n a t e s c l o g g i n g , p l u gg i n g , a n d
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Augus t 2 0 1 6 | Pum ps & S y st e m s

 61

4 5
Life-Cycle Costing Benefits Documentation
Because the odds of receiving approval for Advantages of pump systems optimization not
optimization projects are significantly higher when readily quantified through an LCC analysis include:
the potential projects can be proven to improve plant • increased productivity
profitability and reduce operating costs, an LCC analysis • reduced production costs
can justify system optimization by indicating a lower • improved product quality
total cost of ownership. In an LCC analysis, the following • improved capacity utilization
elements are reviewed: • improved reliability
• initial purchase • improved worker safety
• installation and commissioning
• electrical or other energy costs These benefits should be presented to management
• operation costs as a focus on the bottom line. Relating pump system
• maintenance and repair costs improvements to cost efficiency will help sell the project
• downtime costs to management.
• environmental costs
• decommissioning/disposal costs
Mark Sullivan,, director of marketing and education
at the Hydraulic Institute/Pump Systems
LCC analysis requires an evaluation of alternative
Matter Educational Foundation, leads
systems. Because lifetime energy and maintenance
all strategic planning and development,
costs dominate life-cycle costs, end users must know
initiatives
marketing and technical training initiative
the current cost of energy to estimate the annual price
at the institution.
escalation for energy and maintenance costs.

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p u m p s a n d s y s t e m s . c o m | Au g u s t 2 0 1 6
62 COVER SERIES PUMP SYSTEMS OPTIMIZATION

Cyprus Desal Plant

Optimizes to Save
€2.3 Million Per Year
A facility in this island nation installed new
technologies to meet continuous high
water demand without changing the
building s footprint.

BY BEAT SCHNEIDER
FLOWSERVE

F
aced with continuous high water demand Building on Success
and increasing energy costs, the Cyprus Water The Larnaca desalination plant was constructed in 2000
Development Department decided to upgrade its and commissioned in 2001. The facility was originally
desalination plant in Larnaca, Cyprus, an island equipped with turbine/motor/pump units, including energy-
nation off the coasts of Syria and Turkey. recovery turbines (ERT), the most efficient ERD available at
While the plant’s production capacity met the department’s the time.
requirements, its owners were challenged to optimize the To further increase capacity and performance, the
efficiency of the plant without changing the footprint of the plant was upgraded to a maximum capacity of 64,000 cubic
existing building. meters per hour (m3/h), or 16 million gallons per day (mgd).
To meet this goal, the Larnaca plant was updated “The system ran successfully and very reliably for 10
with improved high-pressure (HP) pumps and advanced work years, with an availability exceeding 99 percent,” said
exchanger-type energy-recovery devices (ERDs), as well as Richard Long, director of product management, engineered
other state-of-the-art technologies. The new design exceeded product operations, for the pump supplier. “A decade
the project’s efficiency targets and reduced maintenance. later, though, water demand and energy costs were both
Specifically, the improved ERD technology installed in rising fast.”
the project is considered one of the most efficient ERDs When the original 10-year contract expired, the
available today, installed in many of the world’s largest Cyprus Water Development Department issued a tender
reverse osmosis plants. for a new desalination plant to be built within the existing
The ERDs are able to recover up to 98 percent of the facility layout.
energy in the brine stream, making them a substantial M.N. Larnaca Desalination, a consortium of Mekorot
improvement over alternative power recovery devices Development & Enterprise Ltd. and Netcom Co., won
and technologies. the bid.

Augus t 2 0 1 6 | Pum ps & S y st e m s

 63

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Circle 147 on card or visit psfreeinfo.com.
Figure 1. The Larnaca plant’s new installation
uses a high-pressure membrane feed pump.
The redesign reduces crossover losses by
40 percent. (Graphic and image courtesy of
Flowserve)

Economical Design
To achieve the most economical
design, plant personnel decided to
use fewer but larger seawater reverse
osmosis trains. Instead of the original
six trains, the new design was reduced
to two significantly larger trains with
higher-efficiency pumps and isobaric work
Simple, Reliable
exchangers, rather than the previously
used ERTs. Efficient
This equipment is more efficient, and Vapor Recovery? LPG Transfer? Natural Gas Boosting?
the capital cost of fewer large, high- The answer is the FLSmidth® Ful-Vane™ rotary vane compressor!
pressure membrane feed pumps is lower Built robustly for long service life, it has only three moving parts. Combined with low operating speeds
which minimizes wear and vibration, it is designed to not only outlast other compressors, but save you
than that of more smaller units. money on power and maintenance costs.
In addition, each of the new trains was
• Suitable for natural gas, flare gas, bio gases, LPG vapor, and ammonia refrigeration
outfitted with energy-efficient variable • Carbon fiber vanes last longer than traditional blades
frequency drives (VFDs). • Variable flows with VFD and/or bypass
• Single stage to 3000 SCFM, two-stage to 1800 SCFM
“We installed variable frequency
• Discharge pressures to 250 PSIG
drives on the intake, HP feed and energy • Made in the USA for over 80 years
recovery system (ERS) circulation pumps
Find out more at www.flsmidth.com/compressors
to ensure maximum efficiency under
changing conditions,” Long said.
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p u m p s a n d s y s te ms . co m | Au gu s t 2016
64 COVER SERIES PUMP SYSTEMS OPTIMIZATION

HP Pump Efficiency
To meet the new HP pump capacity and head requirements,
the end user selected an axially split, three-stage centrifugal
pump. With a redesigned continuous crossover that extends
more than 180 degrees, the selected pump is designed to
reduce crossover losses by 40 percent.
“The pump achieved a best efficiency point of 87.5 percent
when installed,” Long said.
Ringless impellers, Stellite-overlaid stationary rings and
impeller hub, and channel rings with 360-degree guide
vanes also contribute to greater pump efficiency, improved
reliability and less maintenance.

ERS Efficiency
While improvements to the ERS were critical from the start,
they soon became an even bigger concern. After the contract
was signed, energy costs in Cyprus surged from €0.15 per
kilowatt-hour (kWh) to more than €0.20/kWh.
To optimize capital versus operational costs, the existing
brine evacuation of the previously installed ERTs was reused.
Image 1. High-pressure membrane feed pumps with energy-recovery As a result, both the head and power consumption of the low-
turbines were used in the original installation. pressure feed pumps could be reduced.

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Augus t 2 0 1 6 | Pum ps & S y st e m s

 65

The user conducted an analysis to determine the The Result

optimal number of work exchanger ERDs that should The new Larnaca plant was commissioned in the second
be used. The goal was to optimize the differential head quarter of 2015 and met the owners’ ambitious efficiency
and simultaneously build in additional spare capacity. The targets while reducing maintenance requirements.
analysis showed six ERDs per train to be ideal for This success was possible because the project requirements
this installation. were analyzed to optimize the sizing of the pump system and
To fit the larger trains within the constraints of the ERS and to find the most efficient and cost-effective solution.
existing space, the user determined that the optimal design In the case of Larnaca, combining all of these aspects enabled
involved installing the electrical-driven linear actuators and the new design to reduce the power consumption of the HP
patented linear valves in the vertical position. The new train section by approximately 25 percent.
design also included: The Larnaca project illustrates how the optimization of
capital and operating costs can be achieved by clever, site-
• super duplex hydro-formed vessels, delivering specific process designs. Assuming an average energy cost of
extremely high accuracy with 100 percent €0.15/kWh, the energy savings for the plant will amount to
radiographic inspection to ensure the highest more than €2.3 million per year.
possible integrity
• double-seal pistons, reducing leakage to 0 percent Beat Schneider is director of global desalination at Flowserve
• a low-maintenance check valve designed for lowest Corporation. He joined Calder in 1993 as a project engineer
differential head and later became the engineering manager for desalination
• an electrical actuator to ensure maximum control and products as well as managing director. Calder was acquired
simplicity with minimal maintenance by Flowserve in April 2009, after which Schneider assumed
his current role.

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p u m p s a n d s y s te ms . co m | Aug us t 2016
66 COVER SERIES PUMP SYSTEMS OPTIMIZATION

Shortcuts Can Lead to

Disastrous Outcomes
Design flaws cause catastrophic
failure in a geothermal power
station hotwell in New Zealand.

BY CHANDRA VERMA
HYDRO, INC.

D
espite well-documented pump system
standards and basic requirements, omission
of certain crucial design steps remains
a problem in the industry, often causing
disastrous outcomes for the end user. When suppliers,
manufacturers and/or contractors take shortcuts, Image 1. An investigation revealed severe impeller-vane cavitation
technical and commercial risk can present serious damage. (Images and graphics courtesy of Hydro Inc.)
ramifications for a large project.
Communication failures between the end user’s
staff, suppliers and contractors can intensify problems,
especially when pumps that may not be appropriate for a
given job are commissioned and put into service. Without
the end user’s knowledge, a facility may install pumps
that have not been properly tested for the application,
were fabricated to inferior standards or subject to other
shortcuts that adversely affect performance.
Sometimes the end user becomes aware of shortcut-
derived flaws during the commissioning stage. Other
times, problems in equipment or system design might not
be evident immediately—they surface during subsequent
plant and equipment maintenance that reveals
potentially dangerous, hidden conditions. The ensuing
problems can lead to tense project politics and expensive
rectification, including hiring independent consultants.
Suppliers, manufacturers and contractors take
shortcuts for various reasons. These shortcuts can be Image 2. The investigation also showed a broken impeller vane.

Augus t 2 0 1 6 | Pum ps & S y st e m s

 67

Figure 1. The velocity distribution of the original (left) and modified geometries (right)
attributed to a lack of experience with
how a pump might be deployed in the
field. There may be miscommunication
of technical details from both the
user and supplier or between the user
and contractor.
Budget constraints and concerns
can also result in omissions;
commercial reality can cause a
manufacturer or supplier to make
a project’s bottom line cheaper by
reducing the cost of equipment and
cutting corners.

Severe Damage
One unfortunate case that occurred
at a geothermal power station in New
Zealand highlights the damage that
can happen quickly when a plant takes
shortcuts. Four relatively large, single-
stage vertical pumps—characterized by
a capacity of 45,000 gallons per minute

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p u m p s a n d s y s te ms . co m | Aug us t 2016
68 COVER SERIES PUMP SYSTEMS OPTIMIZATION

(gpm) at 75 feet, 590 revolutions per During commissioning, the pumps Inspection of this pump and its
minute (rpm) and 1,200-horsepower experienced unusual noise and partner revealed several failures
(hp) motors—were installed in vibration. The step change in the including severe impeller-vane
canisters in a hotwell application (two vibration level of one of the pumps cavitation (see Image 1, page 66), a
per turbine). prompted removal after seven weeks. broken impeller vane (see Image 2,
page 66), impeller/liner rub and line-
bearings wear.
A rough check on net positive
suction head available (NPSH A)
indicated marginal readings. However,
this condition would not have caused
the severe cavitation damage over such
a brief period. The cavitation damage
on both the suction and pressure
faces of the blades, with no fi xed
pattern, indicated a recirculation issue;
however, the pump flow was not low
enough to suspect the classical problem
of low-flow suction recirculation.
The root-cause investigation turned
to the intake design with particular
focus on suction-flow velocity
disturbance at the pump bell mouth
causing asymmetrical flow.
Pipe sizing and intake design were
both in line with the general flow-
velocity guidelines provided by the
Hydraulic Institute standard ANSI/
HI 9.8-1998. However, it became
clear that one of the basic model test
recommendations for pumps with
flows higher than 40,000 gpm per
pump had not been carried out.

Finding Answers
Further investigation showed that the
pump supplier had not previously used
this pump in a canister application.
Proper due diligence would have shown
the need for a computational fluid
dynamics (CFD) analysis of the sump-
intake design. When this analysis
was completed after the pumps were
pulled, it revealed that the flow was
biased toward the suction inlet pipe at
the bell mouth entry.
Other shortcuts had been taken
during pump manufacturing. A
machining concentricity error was
found between the suction bearing and
liner during the course of a mechanical
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Augus t 2 0 1 6 | Pum ps & S y st e m s
 69

setup check. This caused damage to the the broken vane and severe cavitation Since the incorporation of redesigned
impeller and liner that included heavy were remedied by sourcing new impeller parts, the pumps have been in operation
eccentric wear in the suction bearing. castings, produced under conditions with for two years. Vibration and noise are
A concentricity check of the complete better quality control. The machining now normal for this class of pump.
column assembly was performed on-site. errors were also corrected. Regular review by a maintenance team
Poor casting quality led to other
problems. The extent of such severe
cavitation damage within seven
weeks—a depth of 10 millimeters (mm)
at places (see Image 1, page 66)—and
the blade vane break (see Image 2, page
66) indicated an inferior product. The
casting problems were reconfirmed by
the surface-fracture analysis of the
blade root. Numerous surface blow holes
indicated gas porosity during casting.
With respect to poor-quality castings,
a defect at the blade/hub root in open-
vane impellers is common because of
sudden changes in thickness coupled
with insufficient metal feed during
casting. Although not an excuse, some of
the reasons for poor casting quality can
be attributed to a lack of experience by
new foundries. For example, sometimes
an old pattern made for one material
(usually cast iron) is reused for more
difficult castings (e.g. stainless steel)
without adequate modification to the
thickness, radius and method.

Success Through Modifications

After two engineering companies
conducted parallel sets of CFD analysis
to the intake and canister, a solution to
the suction-flow velocity disturbance
emerged. Trials of different geometry
changes were analyzed using CFD
analysis and confirmed by model tests.
The concept of the installation of a
hydraulic cone in each pump emerged to
rectify the situation. The velocities and
pressure distribution of the original and
modified geometries were compared (see
Figure 1, page 67, and Figure 2, page 70).
The flow straighteners were removed
and hydraulic cones were introduced to
the bottom of each pump canister. These
created a more uniform flow through the
bell mouth throat with minimum loss.
Concerning the manufacturing defects,
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p u m p s a n d s y s te ms . co m | Aug us t 2016
70 COVER SERIES PUMP SYSTEMS OPTIMIZATION

was recommended during the

Figure 2. The pressure distribution of the original (left) and modified (right) geometries
vulnerable reinstallation stage
to mitigate any long-term
maintenance issues.

Lessons Learned
The pump failures during
commissioning can be attributed
mainly to a lack of proper
technical specification and
communication during the
tendering stage about what
pump should have been procured
for this application. This resulted
in missed design steps required
for the intake design.
The situation was aggravated
by the poor manufacturing
and casting quality of the
pump itself. If there had been
due diligence with respect to
model tests and analysis prior

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Augus t 2 0 1 6 | Pum ps & S y st e m s
 71

to commissioning the pumps, required process during equipment

appropriate modifications could specification and selection in the
have been implemented. The casting tendering stage. This process should
should have been subjected to cast- focus on the long-term maintenance
flow modeling software as insurance effects of any pump purchase before Read other articles about
against poor-quality pump parts. order finalization. This step will CFD analysis online at
pumpsandsystems.com.
Although these tests and safeguards result in significant savings in the
might have increased the project plant’s overall life-cycle cost by
cost initially, they would have allowing more appropriate choices
reduced the life-cycle cost of the in pump selection or offering the
project and prevented a lot of stress. opportunity for pump modifications
On the manufacturing side, at before commissioning.
minimum, quality-assurance and This case represents just one
quality-control procedures should example of why proper design Chandra Verma is the engineering
always be followed. Taking shortcuts steps should always be followed manager at Hydro Australia. He
in vital production elements can based on sound engineering has nearly 40 years of experience
lead to costly maintenance and practice. Recommendations from in the pump aftermarket. In
replacement expenditures, as well as the Hydraulic Institute standard addition to Hydro Australia, he
reliability issues. should be satisfied especially for provides engineering support for
With respect to project new projects and equipment. Any Hydro Australia’s Southeast Asian
communication, a review by the end shortcuts to this approach may lead activities. He may be reached at
user’s maintenance team should be a to costly remedial action. [email protected].

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p u m p s a n d s y s te ms . co m | Aug us t 2016
72 COVER SERIES PUMP SYSTEMS OPTIMIZATION

Maintain Performance
on Older Pumps
To optimize system operation, designers must match the
conditions that encompass the system curve.

BY JERRY RUC
SULZER

M
any pumps in operation today were built in the consequences of dialing back pump flows,
the 1960s and ’70s, which is a testament which means measuring the operating conditions
to the original design and the skill of and calculating the point at which the pump will
matching the pump to the operating operate on the system curve.
demands of the application. A properly specified pump
will operate reliably for decades, requiring few repairs. Failure at Shutoff Flow
Still, pumping applications account for more than 20 This concept can be illustrated by a recent repair project.
percent of global electric motor energy consumption, A multistage boiler feed pump was brought to a service
so conscientious plant owners strive to maximize the center for repair, and it was immediately clear that the
efficiency of this equipment. The older the equipment, the pump had suffered severe damage. An initial inspection
more difficult the task becomes. showed that the suction-side seal, several impellers,
To optimize system operation—even those consisting sleeves and stationary components had been destroyed.
of older pumps—designers must match the conditions The evidence indicated that the pump had operated at or
that encompass the entire system, typically referred to near shutoff flow.
as the system curve. The system curve represents the loss When a pump operates in a boiler feed system, iron
of energy in the system with a variation in flow rate. It is oxide deposits are often found in the casing. In this
affected by a number of factors including frictional losses example, the deposits were absent in the first three
due to pipe diameters, surface roughness of the pipes and stages of the pump but intact on the latter stages. This
static losses, such as changes in pressure or elevation. The indicated that the pump had experienced a condition
pump duty point (design point) is at the intersection of where the input energy from the impellers had turned the
the pump characteristic curve and the system curve. water to steam before it had a chance to exit the pump.
As operating conditions evolve over time, pumping The presence of steam in a pump is a violent condition
application demands also change. These changes can be that induces vibrations and can lead to surface erosion.
seen in flow, media characteristics or duty. However, Normally, the frictional losses in a pump are converted
just because a pump is capable of operating on the outer to a few degrees of heat and discharged in the water
edges of the system curve does not mean performance or flow. With very low or no flow, this energy builds in the
reliability will not be negatively affected. pump. Eventually, the heat input to the liquid builds to an
For this reason, manufacturers establish the minimum amount that surpasses its vapor pressure and it becomes
operating flow as well as all of the limiting design two phases—liquid and gas. As the input of energy
conditions, including net positive suction head required increases, the liquid heats to the point of transformation
(NPSHR) and maximum flow. Operators must understand and turns completely into the gas phase.

Augus t 2 0 1 6 | Pum ps & S y st e m s

 Image 1. Process and maintenance engineers should review the
pumping system design in the event of a process change. (Image
and graphic courtesy of Sulzer)

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p u m p s a n d s y s te ms . co m | Aug us t 2016
 PUMP SYSTEMS
74 COVER SERIES
OPTIMIZATION

Operating a pump under these circumstances

is inefficient, and operators should take steps to
properly assess the minimum flow requirements of an
installation and perform remedial work to indicate
when this condition is not being met.

Causes of Failure
The possible causes of the pump failure were reviewed
with the plant owner who was keen to avoid similar
cases. A number of issues were highlighted, including
a misunderstanding of the required flow rate of the
pump. The plant bases calculations mainly on steam
rates, so these were converted to water flows and
plotted on the pump operating curve. This established
that the pump was operating close to the minimum

Figure 1. It is important to understand the consequences of dialing

back pump flows and the effects on reliability.

flow point and that its pump operating curve was fairly
fl at at the lower flow region.
To make matters worse, the failed pump discharges
into a header, along with other similar pumps. This
setup creates a parallel pumping system that is
designed to increase system flow. The balancing act of a
parallel operating system is to ensure that each pump
is operating equally in terms of flow. The main control
valve will provide the necessary backpressure to locate
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the pumps on their curves, but this is based on the

assumption of equal conditions at the suction point.
A centrifugal pump is a differential pressure device,
meaning lower suction will deliver lower discharge
pressure, which will position the pump on a slightly
different point on its curve.
The pumps automatically adjust their flow output to
match the backpressure within the system. Pressure
differences in the piping and the suction delivery
to each pump will affect pump performance, such
that the total resistance at the junction of the two
at the discharge point is equal. Typically, the small

Augus t 2 0 1 6 | Pum ps & S y st e m s

 75

differences are easily tolerated by the pump. The

Solutions for
problem arises when the required operating point
changes and is pushed back on the curve, closer to the
curve’s fl at portion.
At this point, the weaker pump can be pushed
back into the unstable operating region. This pump
Compressors
is perceived as weaker for a number of reasons, such
as lower suction pressure and flow, greater discharge
and Pumps
piping restriction, and the wear of the internal
clearances, which affects efficiency. For this reason,
many reliability engineers trend their equipment by
position, serial number, operating hours and number
of starts, as well as other factors. Their focus is to
ensure that the pumps are equal in the system and that
one will not have an advantage over any other.

The Key to Success

The key to a successful parallel pumping system is to
use pumps with the same characteristic curve shape
and to ensure identical operating environments for
each pump. This is best achieved using the same
model pump with identical impeller trims and setting
both mechanically to the same original equipment
manufacturer (OEM) standards, including the internal
wear parts and design clearances.
Using the same suction source for each pump will
result in the same suction pressure at the entry point
to each pump. The suction pipe should have the same
line size and length to each pump, and the valves also
should be the same size and type. In this way, the
friction losses are then equal for each pump.
Having addressed the suction side, the discharge
pipe needs to increase to full-line size as soon as
possible after the pump. If possible, the discharge
pipes should be symmetrical from the pumps to
the point at which the lines rejoin. One essential
aspect that is often overlooked is the minimum flow RATO DS SERIES
line, which should be required for each pump. This
ensures that the minimum flow condition is always
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satisfied, protecting the pump from overheating and

subsequent damage.

Jerry Ruc is a field engineer at Sulzer Southeast

RATO R SERIES RATO S SERIES DISCFLEX SERIES
Service Center in Piedmont, South Carolina, with
38 years of experience with a variety of rotating
equipment. He may be reached at jerry.ruc@sulzer.
American VULKAN Corporation
com or 864-846-9460. 2525 Dundee Road | Winter Haven | FL – 33884
Phone +1 863 324 2424 | Mail [email protected] www.vulkan.com

p u m p s a n d s y s te ms . co m | Aug us t 2016
76 EFFICIENCY MATTERS

Advantages of AODD Pumps in Sludge Drying &

Thickening Applications
For filter press operations, this technology offers a solid solution that incorporates a number of
characteristic benefits.

By Peter Schüten
Almatec

M
any industrial processes
use substances that are
in an aqueous or “muddy”
form, and the liquid portion must
be removed. This may take place
during production processes—for
example, in the fi ltration of edible
oils or yeast solutions—but more
frequently it happens at the end
of a process with waste sludge
from various industries, including
wastewater treatment.
Because the disposal cost of
such sludge is calculated using
weight and volume, thickening
and drying are particularly
lucrative for the producer. During
the process, sludge is treated
using chemicals and/or physical
processes so the substances in it
form flake-like solids.
After pH adjustment to
neutral or alkaline using milk
of lime, the dewatering process
separates out water for disposal
Image 1. Chamber filter press with an air-operated double-diaphragm pump
and significantly reduces the (Images and graphic courtesy of Almatec)
remaining sludge volume.
A chamber fi lter press includes cloths into drainage channels.
Chamber Filter Presses plastic frames that are pressed When all the chambers are
The simplest technology for this together under high pressure. completely fi lled, the sludge feed
process involves sludge collection Inside the frames are hollow stops. The press can be opened and
and thickening via gravity. It is chambers that are surrounded by the solid fi lter cake removed. After
more effective to use technical fi lter cloth. closing, the press is ready for a new
drying methods with processes When pressure feeds the sludge pressing process.
like centrifuges and evaporators, into the chambers, a “fi lter cake” To fi ll these presses, fi lter
or more commonly, chamber fi lter forms inside the chambers, and material and pressure are required.
presses (see Image 1). the fi ltrate flows through the fi lter The pressure—usually between 8

Augus t 2 0 1 6 | Pum ps & S y st e m s

 77

systems (where an air-pressure vessel AODD Pumps

is “charged” by the pump). This valve- By comparison, an air-operated double-
free procedure is advantageous when diaphragm (AODD) pump can be easier
processing large sludge quantities and to use in these applications. These pumps
when long fibers prevent the use of are low-maintenance, self-priming, self-
valves. There are constraints in small- regulating, highly compact, and resistant
and medium-sized plants because of to dry-running. Without the control or
their sensitivity to abrasion and dry- intervention of an operator or electronic
running. The space required to use this system, the counterpressure of the
system is also considerable. chamber fi lter press regulates the feed
Other utilized pumps include rate automatically.
hose-diaphragm piston pumps, The feed rate decreases continuously
which function in a similar way to as counterpressure increases
piston diaphragm pumps but with simultaneously to the degree of fi lling.
crimped hoses rather than diaphragms. This effect can be used to detect when the
Another is the piston pump, which chamber fi lter press is full. When this is
typically generates strong pulsation reached, the pump virtually stops—zero
and requires constant lubrication. feed rate—or only occasionally makes a
Both of these pumps are characterized delivery stroke.
by their simple electrical operation In addition, the use of compressed air
and fairly high installation and as drive power to move the diaphragms
Image 2. Wear factors based on the sand- maintenance costs. results in a highly efficient, regular
slurry process: PE UHMW = 1 (top); PP = 7
(middle); steel = 1.6 (bottom)

and 15 bar at its peak—should be even to s

w

Solid Under
avoid destroying the flocculated particles Flo
on
at i
during feeding. The flocs should also ov

Pressure
I nn
have enough free space in the feed area. re
W he
In addition to the constantly increasing
counterpressure that occurs until the
end of the pressing, another constraint is
that an empty-running sludge tank can
lead to dry-running of the pump used to
generate pressure.
To build pressure, variations of
displacement pumps are frequently
used. They include piston diaphragm
pumps, which are frequently applied for
large presses. New Almatec® AHD & AHS Series AODD pumps
are designed for safe operation in high-pressure
In these large units, one or two applications such as filter press feeding.
diaphragms are hydraulically actuated
• AHD with internal pressure booster provides 2:1
and feed the sludge into the press with ratio with max drive pressure of 100 psig (7 bar) and PSG Euro-Center™
discharge pressure of 220 psig (15 bar)
valves. These pumps incur large overhead 22069 Van Buren Street
Grand Terrace, CA 92313 USA
• AHS without internal pressure booster provides 1:1
costs, such as an air-pressure vessel to ratio with max drive pressure of 220 psig (15 bar) O: +1 (909) 512-1224
[email protected]
equalize the feed rate and a maximum supplied by the compressor itself or an external
booster and discharge pressure of 220 psig (15 bar) World Headquarters
pressure monitor or bypass. • Maximum capacities to 87 gpm for AHD and 35 gpm
Carl-Friedrich-Gauß-Str. 5
47475 Kamp-Lintfort, Germany
Eccentric screw pumps are also used, for AHS pumps O: +49/2842/961-0
either as self-regulating pumps (with • Automatic pressure/volume adjustment for filter [email protected]
press feeding almatec.de
motors that are electronically controlled
via a frequency converter) or as cyclical
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16-ALMA-0336 Almatec - Pumps & Systems - August 2016.indd 1 p u m p s a n d s y s te ms . co m | Aug us t 2016

7/5/16 9:44 AM
78 EFFICIENCY MATTERS

Figure 1. Functional principle of

and gentle cyclic drive that allows the press. It is often necessary to increase the an air-operated double diaphragm
pump with a feed pressure of 15 bar
medium to be fed smoothly. pressure, for which there are three very
A standard AODD pump is typically different technical solutions.
limited to the pressure of the supplied The first variant uses one of the
air, which is often insufficient to fi ll the diaphragms on a standard pump to

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We help configure systems for generate additional pressure. The force

applications requiring power ranges up
of this diaphragm, which is surrounded
to 3,000 HP.
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We are committed to providing quality to the feed diaphragm via the internal
products, prompt support services, diaphragm connection, enabling the
maintenance and, if necessary, repair. feed diaphragm to work with double
the pressure.
Call us at 814-868-8500 or visit our website This method is rarely used because
www.skinnerpowersystems.net to learn more about our capabilities. it leads to high pulsation, low feed
rates and high air requirements. It also
commands high service costs because
the diaphragm on the air side is very
sensitive and breaks quickly.
Another variant is to operate a
“A half-century of outstanding standard pump with an air pressure
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equipped with external reinforcements,
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Augus t 2 0 1 6 | Pum ps & S y st e m s

 79

from a technical perspective, the of the pressure-converting pump with pressures to high-pressure applications
standard pumps in question are an air section where no conversion of up to 15 bar (218 pounds per square
designed and built for significantly lower takes place. This version is suitable inch gauge). If users operate a pump
pressures and have limited resistance to for all applications under heavy load at such high air pressure—whether it
the increased strain. conditions, ranging from low-feed is from an external booster or directly
Additionally, the increased pressure
resulting from these air pressure
amplifiers, or “boosters,” pulsates
strongly and can influence the product’s
flow. Boosters also seem to reach their
limits in maintaining pressure (for
example, during repressing) because the
devices are almost always too small. They
yield the required end pressure but may
require a longer fi lling time.
The third variant is a pump with
internal pressure conversion. Figure
1 shows how this technical solution
applies compressed air to a differential
piston along with the diaphragms. The
increased surface area—typically twice
as large or more—causes the compressed
air to generate a corresponding amount
of increased force. This converted
force acts on the feed diaphragms with
increased (double) pressure.
The entire construction is designed for
the high strain caused by the maximum
amount of pressure, as well as the strain
caused by the typically abrasive sludge.
For this reason, the pump housing is
built from materials such as stainless
steel or polyethylene (PE UHMW). This
tough material is a decisive factor in the
durability of the pump (see the abrasion
test shown in Image 2, page 79).
Using compressed air to power a pump
is effective because of constructive
measures. The pump operates with
minimal dead space—the space inside
the pump that must be fi lled without
serving the actual feed process. As a
result, the pump always has sufficient
power reserves to handle large volumes
of wastewater.

A New Generation of Pumps

With the introduction of a new
generation of high-pressure AODD
pumps, there is an additional variant
that combines the highly robust housing
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p u m p s a n d s y s te ms . co m | Aug us t 2016
80 EFFICIENCY MATTERS

from the compressor—they can be On these new pumps, the diaphragms handle heavy loads. The diaphragm’s
assured that the pump is structurally are equipped with specially developed vulcanized core supports extremely
designed for such pressure ranges and heavy-duty diaphragms with an thick layers of elastomer. To transfer the
need not be held together by external integrated metal core that provides a suction forces, the core is reinforced with
reinforcements. long service life and the ability to a special textile that is barely flexible in
any direction.
In addition, these pumps can be
combined with a sensor that responds to
the diaphragm’s movement and allows
the cycle to easily be monitored. The
slow stroke frequency that accompanies
a full press rarely triggers a signal. If a
programmable logic controller is used to
program a time window within which a
stroke should take place, a full chamber
fi lter press is indicated by the fact that
these rare signals no longer occur within
this time window. The compressed air
can be switched off and a signal can be
set for the operator to empty the press.
This method functions purely by physical
means and is independent of sensitive
pressure gauges and contaminating
sensors in the wastewater current.
When selecting pumps for fi lter press
operations, AODD pumps are a solid
solution that incorporates a number of
characteristic advantages. Conventional
displacement pumps with electric drive
and control elements do not have these
properties that are specific to the design
of these pumps, which include run-dry
capability, good controllability and a
gasketless mechanical design.

Peter Schüten is a product manager for

Almatec Maschinenbau GmbH, located
in Kamp-Lintfort, Germany. He may be
reached at [email protected]
or +49 2842 961-0. Almatec manufactures
air operated double-diaphragm (AODD)
pumps. The company owns numerous
patents and has one of the largest
product ranges in the field of pneumatic
diaphragm pumps.
Almatec is part of PSG, a
Dover company. For more
information on Almatec
or PSG, visit almatec.de or
psgdover.com.
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Augus t 2 0 1 6 | Pum ps & S y st e m s

 MAINTENANCE MINDERS 81

Troubleshooting Vibration Issues Without

an Expensive Analyzer
Crunching numbers and evaluating costs are critical steps in determining the best way
to maintain equipment.

By Mark Jennings
Engineering Consultant

Editor’s Note: This article is part of an ongoing series by the author covering topics related to predictive maintenance.

I
n my last article, frequencies) is a valuable tool collect simple analog low-frequency
“Understanding Available for any facility. If you have a vibration data (fi lter out root mean
Technology Is Necessary for technician who can actually use the square [RMS] value), I typically
Successful Vibration Monitoring” device to its full capability, then find 15 to 20 percent of similar
(Pumps & Systems, July 2016), I you have a winning combination. equipment types on the high side
might have left you hanging. Yes, Without an analyzer or of an established normal vibration
there is a cost benefit to starting a competent technician, level. Of that 15 to 20 percent, up
with an analog-based vibration troubleshooting vibration to 5 percent of that equipment
monitoring program, but what do problems can be difficult. The has serious issues. If I were to
you lose when a digital device has sales team often insists that you supplement the low-frequency data
the potential to do more? need the best, most advanced collected with a round of high-
A digital vibration analyzer spectrum analyzer to monitor and frequency data, I would typically
that provides visual indication of troubleshoot—but is that true? find less than 5 percent of similar
both time domain (alternating- Based on experience, I know equipment types with indications
current [AC] signal) and frequency that if I go into a facility with no of potential bearing issues.
domain (spectrum of contributing knowledge of previous work and The more serious vibration
issues—those that result in
Table 1. Common vibration sources (Graphics courtesy of the author) shutdown—are usually caused
by design misapplication or
Source Probability of
occurrence installation errors. These issues
are hard to troubleshoot and even
Misalignment (soft foot, coupling, belts and sheaves, thermal) 50%
harder to repair. Once identified,
Balance 25% however, they generally require a
Resonance (at run speed; if a VFD is involved, will replace 15% one-time fi x.
balance as No. 2 cause)
Loose parts or components (loose nuts and bolts) 5% Real-World Troubleshooting
Electrical (voltage/current unbalance, air gap, overload, 3% To apply the above statistics,
eccentricity; if VFD is involved, will replace loose parts as consider the following example. If
No. 4 cause) I had 60 small-frame (American
Bent shaft, shaft dimensional defects 1% National Standards Institute
[ANSI] frame) pumps, all between
Blade pass, vane pass, gear mesh or bearing defect amplified 1%
by resonance 60 and 100 horsepower (hp), and
20 percent exhibit higher than
Rotor rub Less than 1%
normal values (alarm status), then
Leprechauns and gremlins Less than 1% I have 12 pumps on my watch list.

p u m p s a n d s y s te ms . co m | Aug us t 2016
82 MAINTENANCE MINDERS

Five percent of those pumps, or one Table 2. Alignment tolerances for small-frame pumps that are electrical-motor-
pump, would exhibit vibration driven
readings that would warrant a Shaft speed (rpm) Offset (mils) Angular (mils/in.)
shutdown status. Plus, I would 600 5 2.5
have two additional pumps that
indicate a potential bearing issue. 900 4 2
Of the two pumps with potential 1,200 3 1.5
bearing issues, one or both pumps 1,800 2 1
likely would be in the group of 3,600 1 0.5
12 watch-list pumps. For this
> 4,000 0.5 0.25
discussion, we will assume that
there are two additional pumps
that need attention. That means that the vibration issue on my one and the bearings replaced on my
I have one pump out of 60 that shutdown pump is probably a one- two pumps with potential bearing
requires immediate attention and time fi x. issues, what about the 11 others
13 that should be placed on a watch I could call a consultant to look that are in an alarm condition
list. Of the 13, two have a bearing at my pump(s). That would be and that I have placed on a watch
issue and 11 have another issue. more cost-effective than a digital list? How do I troubleshoot those
Do I need to spend money on a analyzer and the required technical without a spectrum analyzer?
spectrum analyzer to troubleshoot training. Plus, if the vendor does Statistical probability is key.
my one shutdown pump? Probably not provide a satisfactory outcome,
not. Between the cost of the I do not have to pay him. I must Common Causes of Vibration
analyzer and the training to use it, pay my technicians whether they If you have been in this business
I could buy and install a new pump, correctly identify the issue or not. long enough, especially over
maybe even two. Keep in mind With a defined and documented the last 20 years, you have
program that includes specific probably read everything there
vibration performance criteria is to read regarding vibration
ALIGNMENT METHODS
(discussed in my previous two troubleshooting. The internet is
Many users do not know articles, Pumps & Systems, June rich with comments, videos and
or understand the reverse 2016, July 2016), I can now include technical articles that focus on
dial indicator method of that performance criteria in a vibration monitoring.
alignment. The following service contract. One item that will pop up
resources discuss different For the two pumps with every now and then is a chart
alignment methods, show potential bearing problems, that shows the most common
when they are applicable replacing the bearings is the only causes of equipment vibration. I
and provide instructions
cost-effective option. Knowing have developed my own variation
on how to complete each
whether the problem is an inner based on my experience in power
one. Note: Web addresses
are case-sensitive. or outer race defect—something production, U.S. Department of
a spectrum analyzer would Energy (DOE) nuclear remediation
ludeca.com/brochures/ identify—is irrelevant. The main projects and manufacturing
Ludeca_A-Practical-
concern is the bearing issue. segments. Unlike many sources, my
Guide-to-Shaft-
Through a defined and top cause is alignment, not balance
Alignment.pdf
documented program, with (see Table 1, page 81).
lifetime-reliability.com/ established low- and high- For the remaining 11 watch-list
tutorials/maintenance-
frequency vibration performance pumps, I will schedule things I have
management/18_
criteria, I can also use the criteria immediate control over or can self-
ShaftAlignment.pdf
to ensure that my in-house rebuilds perform—things that are in the
reliabilityweb.com/index. are effective through post- top 10 vibration causes. I will check
php/articles/rim_face_ maintenance acceptance testing. mounting bolt tightness, electrical
alignment_method/
With a vendor contracted to sort components (balanced current/
out my one shutdown status pump voltage between phases) and the

Augus t 2 0 1 6 | Pum ps & S y st e m s

 83

Precision alignment is establishing and documenting

a measurable tolerance (acceptance criteria) for
flexibly coupled equipment based on equipment speed.

structure (resilient mounts, cracks current/voltage), verifying Added Value

and breaks). I will also schedule structural integrity and verifying The last step in this process is
precision-alignment checks. alignment will bring 75 percent to document the improvement
Precision alignment is of your watch-list pumps into an and show the value added by the
establishing and documenting a acceptable dynamic (vibration) improved performance of my 14
measurable tolerance (acceptance performance range. small-frame pumps. Do not expect
criteria) for flexibly coupled Now we have just two remaining to see a complete payback for your
equipment based on equipment watch-list pumps. For these, the monitoring equipment, training
speed. The most important part cause of vibration may be a bit and program investment. However,
is meeting that criteria when more difficult to identify and showing small gains from this
completing the alignment. correct. Based on our probability one specific equipment type can
Now I not only have performance chart, there is a good chance of a improve your credibility with CBM
criteria for my dynamic equipment mechanical balancing issue. If a program investment.
(vibration monitoring), but I also variable frequency drive (VFD) The easiest way to show added
have acceptance criteria that allows is involved, there may be a value for common equipment
me to meet that performance resonance issue. types, such as pumps and fans,
criteria (see Table 2). Now it is time to call an expert is to show deferred overhaul
These tolerances are based on consultant to provide support (rebuild) schedule—from a three-
the reverse dial indicator method for your maintenance staff. Just year overhaul cycle to a four-year
of alignment. All commercial laser remember to establish criteria in overhaul cycle, showing the cost
alignment sets on the market the contract for the consultant to deferment over a 10-year period.
today are based on this method work against. Make it clear that he So instead of three overhauls in 10
of alignment. or she only gets paid if there is an years, you now have two. And, if
What if your facility does not improvement. luck is on your side, one of your 14
have the skills or equipment to Using reason, logic, common deficient pumps will be a business-
perform this type of alignment? sense and world-class business critical pump. Here you could
You can use your established and practices, leveraging access to model the cost savings through an
documented precision alignment global media as a tool to determine avoided unscheduled outage—a
acceptance criteria to establish the most probable causes of $5,000 investment just saved you
vendor contract requirements. dynamic equipment degraded $1 million in production losses.
To double check the vendor’s performance, establishing
work, I now have established specific performance criteria and
low- and high-frequency vibration determining specific acceptance Mark Jennings is an engineering
performance criteria and can criteria will help me improve consultant. He previously worked
use that criteria to ensure the the dynamic condition of my for ARES Corporation, where he
vendor’s alignments are effective 60 small-frame pumps without provided PdM program training,
based on post-maintenance investing in a spectrum analyzer PdM technology application,
acceptance testing. and the required training. I am left commissioning-related PdM and
Based on my 30-plus years with the advantage of a validated consensus standard interpretation
of experience in the industry, and ongoing condition-based related to PdM. He may be reached
checking nuts and bolts, correcting maintenance (CBM) program at the at [email protected] or
any electrical issues (balanced best price. (509) 531-5614.

p u m p s a n d s y s te ms . co m | Aug us t 2016
84 MOTORS & DRIVES

Understand Specifications for

Large-Horsepower Motors
Evaluating system requirements and all available options can improve
reliability, efficiency and cost.

By James Nanney
Power Electronics USA

F
or a large pump package, specification created to cover every frame size adds 25 to 35 percent to
a medium-voltage motor contingency. The “inheritance” the cost of medium-voltage motors.
(above 1,000 volts) incurs of a specification leads to little Some parts of a specification may
significant cost. For this reason, understanding of cost or value for increase the frame size beyond the
many users ask a common the requirements laid out in the initial power requirements.
question: How can motor cost document. How does an engineer
be reduced? who is specifying get an idea of a Motor Enclosures
When looking at the specification’s cost drivers or know The first driver of the frame size
specifications, the question when a specific requirement is other than power is the enclosure
becomes: What are the cost drivers needed in the application? type. Users must evaluate and
for a larger motor? Are the options The cost of a motor, much understand the pros and cons
and accessories driving the cost, like that of a pump, is based on of each to determine the best
or is it the testing—or maybe frame size. When an end user solutions for their applications.
some part of the specification that communicates the power required The least expensive enclosure
has been passed down—that is to drive the pump to the motor is the totally enclosed fan-cooled
harming the reliability in the vendor, the base frame size is (TEFC) type, which is also called
new application? determined. The motor supplier a cast-frame or finned-frame
Many motor specifications tries to provide a motor with the motor. TEFC enclosures are the
are passed down from previous smallest frame for that power oversized “big brother” of typical
projects or are a general rating because each increase in low-voltage (below 1,000 volts)
industrial motors.
Table 1. Pros and cons of different enclosures (Graphics courtesy of the author)
The motor is enclosed, so it is
Enclosure Advantages Considerations suitable for outdoor applications.
TEFC Least expensive; Limited ability to customize for Because these motor types have
good for outdoors the application; common 1,000 hp little air inside to circulate for
but limited in larger sizes cooling, a fan at one end cools
the drive end bearing. The lack of
WPII More expensive than the An open motor but provides cooling limits the horsepower (hp)
TEFC; the least expensive some protection and can be used
of the fabricated frames outside; lowest reliability of the in this type of enclosure. Because
fabricated frames; can be noisy the frame is cast, this enclosure
type can limit options and
TEAAC Enclosed motor similar Larger frame than the WPII; accessories, and is generally more
to TEFC; suitable for 25 to 35 percent more expensive
outdoors; better reliability than WPII; can be noisy
of a “stock” product.
than the TEFC and WPII Fabricated frames, on the other
hand, are used for motors in the
TEWAC The most reliable 15 percent more expensive than megawatt range and can be fully
statistically and lowest a WPII and 10 to 15 percent less adapted to the specification.
noise expensive than a TEAAC

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 85

TEFC Cast Frames vs. TEAAC exchanger. This motor is typically

Fabricated Frames When the motor is outdoors and one frame larger than a WPII,
Fabricated frames are more too big for a TEFC and when a which increases cost by 25 to
expensive than cast versions and WPII type is not acceptable for 35 percent.
come in several basic types. environmental reasons, a totally
enclosed air-to-air cooled (TEAAC) TEWAC
Weather Protected II (IC01) enclosure is usually the next In many applications, the most
Weather Protected II (WPII) is an choice. The motor has a large air-to- reliable choice statistically is a
open enclosure seen primarily in air cooler on top so hot air created totally enclosed water air-cooled
North America and is suitable for in the motor is circulated up and (TEWAC) type, but it requires a
outdoor operation. It is open, but over the heat exchanger. Ambient cooling water system. The efficiency
the cooling air must make multiple air is forced by a shaft-driven of the air-to-water exchanger
turns before passing through the fan through the heat exchanger. reduces the frame to the
motor to keep airborne debris out The motors are statistically more size of the WPII. The cost is
of the motor’s internal parts. This reliable than a WPII. Air-to-air heat generally halfway between the
effective cooling method means exchangers are not efficient using WPII and TEAAC.
the frame can be a minimum size. ambient air of 40 C, so the frame
This type can be less reliable than will be larger compared with an Service Factor
other fabricated frames because it open or a WPII motor. When discussing service factor,
is open, and noise control can be TEAAC types are also noisy the safety margins for the system
difficult. A fabricated frame is more because the air is forced through must be considered. Service
expensive by 25 to 50 percent. the small tubes of the heat factor for a motor is defined by

Circle 134 on card or visit psfreeinfo.com.

p u m p s a n d s y s te ms . co m | Aug us t 2016
86 MOTORS & DRIVES

National Electrical Manufacturers (three cold or two hot starts) and specified are space heaters,
Association (NEMA) MG1 for the pump cannot be fully unloaded, winding resistance temperature
medium-voltage motors differently the only way to accommodate this detectors (RTDs) and Class F
than for low-voltage motors. requirement is to increase frame insulation, which are considered
Medium-voltage motors must size. If multiple restarts are not standard for most large motor
meet the service factor rating required, then this requirement suppliers so there is no additional
continuously. In other words, should be reviewed. charge. Other common options are
a 1,000-hp motor at 1.15 is listed in Table 2.
actually designed as a 1,150-hp Operating Voltage The cost of most options does
motor, which will probably cause The higher the voltage, the not increase with frame size so,
the frame size to increase. The higher the cost of the motor. This as a percentage, the cost of the
pump specification may require phenomenon typically occurs at options goes down compared with
10 percent additional operating 10,000 volts and higher. This is the the motor base cost. Vibration
margin or safety factor. point where most motor insulation probes and differential current
If the motor is also increased 15 systems add corona protection and transformers (DCTs) require
percent above the pump margin, the insulation for the coils has the additional controls, normally
the service factor becomes 26 maximum layers that the vacuum supplied by the pump original
percent, creating an oversized pressure impregnation (VPI) equipment manufacturer (OEM).
motor. There needs to be some resin can fully penetrate. As the RTDs typically are monitored by
margins above the calculated load, insulation gets thicker, there is less the motor protection relay.
but only one safety margin should room for the copper “magnetics,” Testing costs vary significantly
be required either at the pump or so the frame for higher-voltage depending on the manufacturer.
on the motor. motors will be larger for the same The test stand incurs high capital
power rating. costs and low usage rates, and
Starting Requirements Also note that switchgear costs requires experienced staff. Note
Starting requirements are a go up at a higher voltage, which that many tests are actually
common specification that is may be offset by lower cabling costs damaging and may reduce the
inherited with little understanding due to reduced amperage. motor’s life. For this reason, users
of what it is or the cost. A standard For pump stations with a high must ensure the value of each test
large motor will typically include voltage of 10,000 volts or more requirement is worth the effort.
a 2C/1H on the nameplate, which available from the utility, adding a Many test requirements are
means two cold starts or one hot stepdown transformer to operate carried over from one project to
start and indicates that the motor at 6,000 volts or less can reduce another with no real understanding
can start twice when the motor costs substantially. The reduced of the value. Two terms are
temperature is below ambient cost of the motor and switchgear “routine” test, which is the OEM’s
and once when it is above ambient can be significant if the motor sizes standard test, and a “complete”
without damage. The 600 percent are 5,000-hp or less. test, which is more thorough.
inrush or starting current decreases The complete test is common
until the motor speed approaches Options for larger motors and confirms
its nominal operating speed. What impact do options, the electrical and mechanical
The extra inrush current that is accessories and testing have on performance as well as compliance
not converted to torque becomes cost? The most common options with efficiency requirements.
heat, so the motor’s interior heats
rapidly because the cooling fans
Table 2. Average cost of common accessories
do not move much air until the
Winding RTDs & space heaters Less than $500
speed is well above 50 percent.
If the pump is starting in a Bearing RTDs Less than $500
lightly loaded condition, this Vibration probes only $5,000-$10,000 per set
specification has no impact on
Surge arrestors and surge capacitors $10,000-$15,000
motor sizing or pricing. If the
specification calls out 3C/2H Differential current transformers (DCTs) $2,500-$4,000

Augus t 2 0 1 6 | Pum ps & S y st e m s

 87

To understand a motor test’s purpose, a

good resource is the American Petroleum
Institute (API) standards for motors.
Changing the specification requires an
Introducing the ONIXline
understanding of motor specifications. Rotary Lobe Pump.
Because many engineering schools no longer
teach electric machinery, it is difficult to
learn except through working with an The proven BLUEline
experienced engineer. A resource that can
Rotary Lobe Pump.
fi ll the gap is a local motor repair shop that
services large motors. A service shop that
possesses local knowledge about issues such
as airborne dust, snow loading or utility
problems can help the engineer adopt a The new ONIXline
motor specification. An advanced generation of industrial pumps
Another good resource is API motor • Extremely pressure-resistant
standards such as API 541 for induction • Best Performance
motors. These standards are meant for • Highest energy efficiency
critical service applications where reliability
is required and cost is secondary. These
standards are some of the best resources
on terminology, testing and acceptance
criteria. Even if the application is not in the
petroleum industry, the standards represent
a great addition to a resource library.

Conclusion
When reviewing a motor specification for
cost, look for items that increase frame
size such as the enclosure and starting
requirements. Understand where safety
margins or service factor are applied in the
The proven BLUEline
pump system specifications. 21 pump models in six series
If some specification requirements o n
• Pulsation-free operation
are not familiar, a good reference is the • Self-priming and low shearr
API 541 or 547 motor standards. This • Dry-run capabil
capabilitiess
includes testing to determine what is best
for the application in terms of cost and
motor life. Learn from the past by looking to
Circle 121 on card or visit psfreeinfo.com.

those who have experience and by visiting

a local motor repair center to understand
others’ mistakes.

James Nanney is director, Industrial

Division, of Power Electronics. He is a 45 th Turbomachinery &
member of the API motor committee and 32nd Pump Symposia
author of numerous papers and articles. For Houston, TX, Sept 12–15
more information, visit power-electronics.
Booth #1333
com. Nanney may be reached at jnanney@
power-electronics.com

p u m p s a n d s y s te ms . co m | Aug us t 2016
88 SEALING SENSE

Birth of the General-Purpose, High-Performance

ePTFE/Graphite Packing Fiber
By Carl Jones
FSA Member, W.L. Gore & Associates

A
great innovation in It was also a heat insulator with • Aramid fibers: They are divided
compression packing a low thermal conductivity of only into two categories: para-
was the development of 0.25 watts per meter per degree aramid and meta-aramid.
a new material class by Ritchie Kelvin (W/m K) and shaft speed They are differentiated by
Snyder of W.L. Gore & Associates and temperature limits of 2,000 the type of monomer that
in 1981. He envisioned a single feet per minute (ft/min) and 260 C determines molecular structure
material that would allow for broad (500 F), respectively. This material of the polymer chain. Para-
standardization across a wide required strict adherence to the aramids are bright yellow,
range of applications. It would installation procedure and operator while meta-aramids are white.
deliver the chemical compatibility knowledge. Any overtightening Para-aramids have high tensile
of polytetrafluoroethylene (PTFE) could lead to a negative feedback strength and cut resistance,
and graphite, with the mechanical loop of increased heat, leading and can be up to five times
strength of the then newly to more expansion, friction and the strength of steel wire of
expanded PTFE material (ePTFE). heat. These effects would damage the same weight. However,
Over the next 35 years, many the shaft or sleeve as a result of chemical resistance is limited to
pulp and paper, chemical, mining crystallization of the PTFE, leading a 4-11 pH range, temperatures
and power companies have to premature failure. up to 120 C (248 F) and
standardized their plants with Graphite was a great material speeds up to 1,500 ft/min.
this new material class of ePTFE/ for conducting heat. While Meta-aramids are chemically
graphite packing fiber. dimensionally stable and capable of resistant with a 1-13 pH range
Prior to this breakthrough, operating at higher temperatures, and temperature resistance up
end users working in chemical graphite lacks mechanical strength to 270 C (518 F), above which
applications had one option for and makes maintaining a lower glass transition limits its use.
standardization: a natural mineral leakage rate difficult. • PTFE: Although PTFE is a
fiber known as asbestos, which Because of inherent limitations, chemically inert material with
was effective because of its other material class options fell a 0-14 pH capability, very low
chemical inertness and high short of meeting the need for friction and self-lubricating
temperature rating. a general-service packing for properties, it is limited by
By the late 1970s and early standardization, including: mechanical strength, coefficient
1980s, however, it was actively • Natural fibers: The chief of thermal expansion and creep.
being eliminated from the market advantage of flax, ramie, jute It is good for shaft speeds up to
because of health concerns. As and cotton is low price, but 2,000 ft/min and a maximum
an alternative, pure PTFE was performance is negatively temperature of 260 C (500 F).
substituted, but it was a poor impacted by limitations, • ePTFE: This material has the
replacement because of its including poor chemical same chemical and thermal
inherent creep, mechanical resistance (5-9 pH), low heat expansion properties as PTFE
weakness and high coefficient of resistance (98 C/208 F) and but with higher mechanical
thermal expansion. speed (1,000 ft/min). strength and lower creep. It can

Augus t 2 0 1 6 | Pum ps & S y st e m s

 89

Figure 1. Graphic from the patent for the ePTFE/graphite invention

operate at shaft speeds up to 3,600
(Graphics courtesy of the author)
ft/min. In some cases, the material
can exceed the max temperature of
PTFE by up to 20 percent.
• Carbon/graphite: This material has
a range of properties depending on
the graphite/carbon makeup and the
mixture selected. The most common
offerings can handle shaft speeds up
to 4,000 ft/min and temperatures
up to 260 C (500 F) in centrifugal
pumps. They can also come in higher- Carbon also had better dimensional the high-strength ePTFE structure
purity forms, operating in valves up stability, with a coefficient of thermal in place of the conventional PTFE
to 675 C (1,247 F). expansion of 3.9 x 10 -6 inch per inch and adding a proprietary mixture of
per degree Fahrenheit (in/in/F) versus high-grade pure graphite and silicone
Some end users opted for carbon/ PTFE’s 7 x 10 -5 in/in/F, or 18 times less oil, he created a homogenous ePTFE/
graphite composite packings, which had thermal expansion than PTFE. graphite (G-Graphite, F-Fluorine,
a much better thermal conductivity of Snyder envisioned capturing the O-Oil) material. He fi led for patent in
10.83 to 13.97 W/m K, or up to 55 times best attributes of two materials— 1979, and the resulting product was
more than PTFE. Speed and temperature pure graphite and the new ePTFE— commercialized in 1981 (see Figure 1).
limitations were also higher at 4,000 ft/ eliminating many of the weaknesses This was a major breakthrough in
min and 675 C (1,247 F). of each. By combining them using compression packing technology because

Circle 142 on card or visit psfreeinfo.com.

p u m p s a n d s y s te ms . co m | Aug us t 2016
90 SEALING SENSE

Figure 2. Packing recommendations for valves and

centrifugal pumps

Over 500 deg F (260 deg C)

different expanded Next Month: Back to Basics:
Centrifugal Pumps Valves
PTFEs, lubricants Mechanical Seals
Die formed Graphite foil ring sets and graphite
Carbon and Wire reinforce Graphite foil braids combinations, and We invite your suggestions for article topics as well as
Graphite fiber
braids Wire reinforced plastallic cored
this material class questions on sealing issues so we can better respond
packings
Fiber reinforced to the needs of the industry. Please direct your
Graphite foil braids is still the standard suggestions and questions to sealingsensequestions@
Vegetable fibers: Flax, Raime, Jute by which all general- fluidsealing.com.
Synthetic fibers: PTFE coated,
Lubricated PTFE
Lubricated ePTFE with Graphite
Synthetic fiber braids service packings are
Acrylic, para-Aramid, meta-Aramid,
Novoloid, Polyimide, PBI, Rayon Dry PTFE braids measured. Those
who work with
compression packing
today owe a debt of
Under 500 deg F (260 deg C)
Be sure to confirm a manufacturer’s specific product ratings gratitude to one of
Carl H. Jones is the global product
the great industry
specialist for packing fibers sealant
of its low coefficient of friction, wide pioneers, whose creativity introduced
technologies at W.L. Gore & Associates.
chemical compatibility, low leak rate, this breakthrough technology.
He has a B.S. in chemical
long life and suitability for a broad range In light of an increased emphasis
engineering and an MBA
of applications as a general-purpose on sustainability, the ePTFE/graphite
in finance, with more than
packing (see Figure 2). material is once again—35 years after its
30 years of experience
More than 35 years later, various introduction—emerging as an important
in the fluid sealing
manufacturers provide a range of solution for optimizing resources used in
industry.
ePTFE/graphite compositions using the operation of centrifugal pumps.

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Augus t 2 0 1 6 | Pum ps & S y st e m s

 HI PUMP FAQS 91

Key Considerations for Upstream Piping

with Control-Volume Metering Pumps &
Requirements for Suction Piping Design
By Hydraulic Institute

What are the key Figure 7.8.7.1. Example of pulsing flow (Graphics courtesy of Hydraulic Institute)
considerations for upstream
(suction) piping for single
and multiple control-volume
metering pumps?

Because of the characteristic

pulsating flow of metering pumps
(see Figure 7.8.7.1), where peak
flow rates can reach three times the
average flow, operators must carefully
consider suction piping to ensure that
it can deliver adequate fluid to the
pump inlet.
• The piping must accommodate
the peak demands of the pump
throughout its full range of
operation, as well as prevent
offgassing of liquids with high could subtract 10 pounds per When connecting more than
vapor pressure or dissolved square inch from the pump supply one pump head to a single suction
gases. This can be accomplished pressure. For shorter runs of pipe manifold, operators must consider a
by appropriately increasing the with minimum restrictions, a number of issues. Suction manifold
diameter of the suction piping rule of thumb is to increase one piping must accommodate peak
and connections or by adding pipe size above the discharge demand of the pumps throughout
accessories to increase the flow of piping, or two pipe sizes above its full range of operation, as well as
liquid to the pump inlet. the pump’s suction connection. prevent offgassing of liquids with
• Long lengths of pipe, elbows, Long piping runs with multiple high vapor pressure or dissolved
tees, strainers, valves and other bends, elbows, restrictions and/ gases. This is accomplished by
accessories installed in the suction or higher-viscosity liquids require appropriately increasing the diameter
piping can decrease the net larger-size piping. of the suction manifold and pump
positive inlet pressure available • The most frequent reason head connections or by adding
(NPIPA) to an unacceptable level. for technical support calls to accessories to increase flow of fluid to
• The pulsating flow in the system pump manufacturers regarding the pump inlet. The most important
suction piping creates a pulse problems with pump performance consideration is whether the multiple
pressure that typically subtracts is suction piping that cannot heads are part of a multiplex pump
from system suction pressure. For supply the demands of the pump. (multiple heads connected to a single
example, a pump operating at 150 To ensure adequate flow to the motor or driver) or if the heads all
strokes per minute and 71 gallons inlet of the pump, refer to NPIPA have independent motors or drivers.
per hour drawing water from 10 calculations outlined in ANSI/HI In most cases, multiplex pumps are
feet of half-inch schedule 40 pipe 7.8-2016. connected to a common manifold

p u m p s a n d s y s te ms . co m | Aug us t 2016
92 HI PUMP FAQS

piping arrangement, driving these In a multiplex where a single driver is drive mechanism for each individual
recommendations. The other option used, if the pumps all operate from the pump head should be run out of phase
is to connect each pump head to its same gear set or with multiple gear sets (i.e. duplex pumps, 180 degrees; triplex
own suction line connected to the operating at the same stroking speed, pumps, 120 degrees; and so on). This
supply source. industry best practices suggest that the staggers the peak suction requirements
of the individual pumps.
Running several pumps from the same
driver (motor) with proper phasing of
the drive elements ensures this timing
during all running conditions and the
Training best suction flow characteristics as they
Resource relate to piping design.
Center When independent pumps, each
with its own driver, are connected
to a common suction line, or if the
application requires multiplex pump
heads operating in phase, operators must
make allowance in the piping design in
case all pumps simultaneously demand
peak suction flow.
For more information on piping
guidelines for control-volume metering
pumps, refer to the new standard ANSI/
SWPA, the #1 training resource for submersible HI 7.8 Control-Volume Metering Pump
Piping Guideline.
wastewater pumps, now offers on-demand training
opportunities and resources in one convenient place.
What are the requirements for
good suction piping design for
✔  On-Demand Webinars rotodynamic pumps?

✔  CEU Credits Good suction piping design must

eliminate air entrainment in the liquid,
minimize friction loss, provide straight
✔  Training Manuals and uniform flow at the pump inlet, and
avert excessive forces resulting from pipe
✔  Learning Resources strains at the pump.
Inlet flow disturbances such as swirl,
✔  Industry Events unbalance in the distribution of velocities
and pressures, and sudden variations
✔  Articles & White Papers in velocity can be harmful to a pump’s
hydraulic performance, mechanical
behavior and reliability.
Usually, the higher the energy level
and specific speed of a pump and the
Join SWPA and access on-demand training for FREE! Go to: lower the net positive suction head

pumpsandsystems.com/swpa
(NPSH) margin, the more sensitive
the pump’s performance is to suction
hydraulic conditions.

Augus t 2 0 1 6 | Pum ps & S y st e m s

 93

during a restart, causing a partial or affect pump performance. Check with

Figure 9.6.6.3. Suction pipe design
complete loss of pump prime, especially the pump manufacturer to determine
where the inlet line is kept full by a allowable levels of entrained gas.
foot valve at its intake. Any amount of The ideal flow entering the pump
entrained gas in the fluid may adversely inlet has a uniform velocity distribution

All inlet (suction) fitting joints should

be tight—especially when the pressure
in the piping is below atmospheric—to
preclude air leaking into the fluid. Any
valves in the inlet line should be installed
with stems oriented to minimize the
possibility of air accumulation. For
pumps operating with a suction lift, the
inlet line should slope constantly upward
toward the pump, with a minimum slope
of 1 percent (see Figure 9.6.6.3). For most
pumping systems, a shutoff valve should
be installed in the suction piping for
system isolation.
As liquid travels through a piping
network, entrained air tends to rise to
the highest point. If the pipeline slopes
upward, then the liquid’s velocity will
move the air bubbles toward this high
point. In contrast, if the pipeline is
fairly flat and the inside surface of the
pipe is rough, or if the pipeline slopes
downward, then the fluid velocity may
not be sufficient to keep the air bubbles
moving. As a consequence, a pocket of air
could collect at high points and gradually
reduce the effective liquid flow area. This
reduction in area can create a throttling
effect similar to a partially closed valve. A
slug of air could be swept into the pump
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p u m p s a n d s y s te ms . co m | Aug us t 2016
94 HI PUMP FAQS

without rotation and is stable nozzle, with the exception of low enough to avoid fl ashing of
over time. This ideal flow is continuous-bore, 100-percent- the liquid in the piping, especially
often referred to as undisturbed open valves (such as full-ported when fittings are present. A
flow, and it can be achieved by ball valves). reduction in pressure and/or
controlling pipe lengths and the The maximum velocity at any fl ashing can liberate dissolved air
type and location of fittings in the point in the inlet piping is 8 feet and vapor, which can be carried
suction piping system. The suction per second (ft/s), unless the liquid into the suction of the pump.
piping should be designed to be is a slurry. This velocity limit does For more information on piping
simple with gradual transitions if not apply to the straight run of requirements for rotodynamic
changing pipe sizes. pipe immediately upstream of the pumps, refer to the recently revised
The velocity in the suction piping pump suction flange provided this ANSI/HI 9.6.6 Rotodynamic Pumps
should be constant or should pipe is the same diameter as the for Pump Piping.
increase as the flow approaches the pump suction flange and directly
pump. Transitions resulting in flow connected to the pump.
deceleration at the pump should Individual values above 8 ft/s HI Pump FAQs® is produced by the
be avoided. should be evaluated with respect Hydraulic Institute as a service to pump
The suction pipe should be at to flow distribution, erosion, users, contractors, distributors, reps
least as large as the pump suction NPSH, noise, water hammer and OEMs. For more information, visit
pumps.org.
nozzle. Valves and other flow- and the manufacturer’s
disturbing fittings in pump inlet recommendations.
piping should be at least one pipe For fluids close to the vapor
size larger than the pump inlet pressure, the velocity must be kept

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Augus t 2 0 1 6 | Pum ps & S y st e m s

 PRACTICE & OPERATIONS 95

Advances in Metering Pumps Meet

Specific Application Challenges
Changing needs and requirements have caused pump technology to evolve.

By Aaron Hinchliffe
IWAKI America

I
n the American National Metering pumps were designed in use and can be seen in high-
Standards Institute standard to dispense a repeatable amount of pressure piston/plunger pumps,
7.0, the Hydraulic Institute fluid during a period of time. This mechanical and hydraulically
defines controlled-volume metering fluid—typically a chemical—could driven diaphragm pumps, and
pumps as “reciprocating positive then be delivered at a known, larger-capacity low-pressure
displacement pumps typically controllable and adjustable rate. pumps. While these larger, robust,
used for the injection of chemical Today, several types of metering mechanically coupled diaphragm
additives, proportional blending pumps are available with many and gearbox-driven pumps are still
of multiple components, or options, although much of their important in many applications,
metered transfer of a single liquid. design still traces back to their several factors have changed over
These types of pumps are used origin. Historically, the diaphragm the past 40-plus years that required
in applications requiring highly metering pump has been the the evolution of pump design and
accurate, repeatable and adjustable most common type and has an increase in capabilities to satisfy
rate of flow.” helped advance metering pump new demands.
technology to Over time, chemical companies
Figure 1. A cross-sectional view of a hydraulically backed metering pump. An where it is today. have reduced water content,
eccentric cam is used in the gear reduction assembly to change the stroke Diaphragm shipping less water and less weight,
length of the piston’s linear motion. The piston pressurizes hydraulic fluid,
pressing the diaphragm forward with even pressure and changing the volume metering pumps which makes operations more cost-
in the head cavity. Check valves turn this volumetric change into a repeatable have progressed effective. The resulting increase in
pumping motion. (Courtesy of IWAKI America) a long way since chemical concentrations has driven
the days of the demand for pump outputs
early positive to become both lower and more
displacement accurate. These new requirements
pumps. Modern contributed to the evolution of the
electric diaphragm electronic solenoid metering pump,
pumps started developed to accurately pump
out using large lower flow rates at lower costs and
alternating- with less routine maintenance.
current (AC) With the advent of electronic
motors coupled solenoid metering pumps,
to a gearbox to and as electronics technology
slow the motor concurrently evolved, a level of
speed and transfer control was introduced that was
rotational not previously affordable to many
direction into motor-driven pump applications.
reciprocating The addition of electronic control
linear motion. to the pump to power a solenoid
This design is still enabled easier pump control.

p u m p s a n d s y s te ms . co m | Aug us t 2016
96 PRACTICE & OPERATIONS

Whether by a stop/start inhibit signal, a

digital signal proportional to a measured
flow rate or the use of an analog control
signal, control of electronic metering
pumps became a standard and a more
economical offering. Proportional control
in the metering pump facilitated direct
connection to the driving equipment, such
as a water meter. This allows for automatic
Visit us at the adjustment without incorporating any
Pumps Symposia extra or custom hardware to control the
in Houston
Booth #2522 pump motor or changing the setting of a
stroke length adjustment knob.
Advancements in microprocessor and
display technology enabled the internal
pump electronics to move from analog to
digital, providing more information in a
display, improving resolution in control
and integrating many of the features.
As the electronics evolved, they began
to include outputs, such as alarm or
proportional output, for pump monitoring
Circle 150 on card or visit psfreeinfo.com. and diagnostic purposes.
At the same time solenoid metering
pumps saw increases in control capability,
other types of metering pumps evolved
in a similar manner and for the same
reasons. Smaller output requirements
and advancements in tube materials
transformed large hose pumps into the
digitally driven smaller peristaltic pumps
available on the market today. Like big
motor-driven diaphragm pumps, large
hose pumps still have applications in
various markets, but new tube materials
significantly increased chemical
compatibility and dramatically improved
life and reliability.
Higher concentrations and the need to
pump fewer chemicals also helped smaller
peristaltic pumps grow in popularity.
The new materials, in combination with
smaller tubes, were capable of higher
pressures—historically a weakness with
peristaltic pumps. Similar to diaphragm
metering pumps, the peristaltic
metering pump benefited from the same
improvements in electronic technology:
converting AC motors to direct current
(DC) to increase controllability, adding
control input and output features, and
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Augus t 2 0 1 6 | Pum ps & S y st e m s

 97

integrating digital displays. This shift

made these pumps strong competitors
in what was traditionally a diaphragm-
dominated marketplace.

2196
More recently—because of further

SN
advancements in motor technology at
lower costs—metering pumps have come
full circle, back to the motor-driven
variety. Instead of large, bulky and
expensive AC-voltage induction motors,
brushless DC-voltage motors are used to
drive the diaphragm or plunger. These
brushless DC and step-driven motors
have tremendously increased motor
speed and position control, improving Model SN Model 2196
pump accuracy and flow rates, while
making it easier to fully control the
pumps with inputs and outputs that
have become standard throughout the
industries in which they are used.
More pumps are incorporating Green Bay, WI | www.SUMMITPUMP.com | Celebrating Over 30 Years
machine languages (MODBUS,
PROFIBUS, etc.). With the lack of a Circle 154 on card or visit psfreeinfo.com.
global standard, establishing a common
protocol has been difficult. A more recent
integration of new technology has been
the addition of Ethernet connectivity to
the pump. This connection may facilitate
easy programming, feedback and even
control as part of a network.
Connecting to a smartphone, enabling
control and programming of pump
parameters are the newest trends. It
is only a matter of time before more
pump manufacturers integrate similar
communication connections and expand
their capabilities. Technology will
continue to advance for metering
pumps as they evolve to meet new
application challenges.

Aaron Hinchliffe has been the metering

pump product manager at WALCHEM/
IWAKI America Inc. for 14 years. He has
a B.S. in mechanical engineering from
Worcester Polytechnic Institute. Prior to
product management, he was in technical
sales and customer support with IWAKI
America focusing on specialized pumps in
the semiconductor industry.

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p u m p s a n d s y s te ms . co m | Aug us t 2016
98 PRACTICE & OPERATIONS

Closed Powder-Handling
Solutions Create Efficiencies
& Increase Safety in
Process Industries
These systems prevent a variety of possible expenses and
health dangers.
By Steven Coupal
ARO

T
oday’s process industries Central design objectives
use powders in a myriad for today’s powder transfer
of applications. While systems include keeping virgin
many processes employ similar ingredients safe from the
operations to convert raw processing environment and
materials into finished products, ensuring that individuals working
the complexities of handling in that environment are safe from
and transferring powders have the products. Depending on
earned this material category a material characteristics and
unique reputation among process toxicity, one or both of these
engineers and others involved in objectives must be met to ensure
designing and operating material- high standards of product quality
transfer systems. and operator safety.
From challenging dry There are several powder
bulk materials used in plastics transfer methods, each with its
manufacturing processes to own benefits and drawbacks. The
fragile tablet granulations and most basic of these methods is the
active pharmaceutical ingredients manual charging of powders into
(APIs), each application presents downstream processing equipment.
its own distinct set of requirements Manual handling is slow and can
that make powder handling delay production as well as present Mechanical transfer is a second
a critical aspect of process countless opportunities for spills method, introducing automation
manufacturing. and cross-contamination resulting through the use of energy-efficient
Efficiently containing fine in extensive routine cleanup. motors. This method, however,
powders, particles, tablets and While this may seem like a dated often involves complex, costly
granules is critical. approach, it remains a common routing that can make installation
Mistakes risk the expense practice in many facilities where complicated while leaving issues of
of product waste as well as the processes involving solids-handling containment and operator safety
accumulation of dust that occurs are performed. Although this unaddressed. The third and final
when product escapes during method does not require the use option is pneumatic conveying,
transfer, which can lead to of equipment or sophisticated which is the best method to
potentially deadly explosions and controls, it lacks the advantages of ensure the efficient and contained
other worker health issues. automated transfer solutions. handling of powders.

Augus t 2 0 1 6 | Pum ps & S y st e m s

 99

Visit us at Pump Symposia

Booth #1316

Complete BB3 Pump Package

for API-610

Standard Alloys Inc. is proud to announce

its engineered replacement bare shaft

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upgrade the equipment to the latest

Image 1. Powder handling and transfer can be a challenging aspect of
process manufacturing whether using dry bulk materials in plastics
manufacturing or fragile tablet granulations in active pharmaceutical version of API-610.
ingredients. (Images courtesy of ARO)
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www.standardalloys.com

Proactive Approach to Safety

In today’s competitive and highly regulated market, operator
ergonomics and worker safety are a priority. Processes involving
the handling and transfer of potentially hazardous materials
inherently introduce increased safety risks. Transferring powder
from one container to another, whether by pouring or scooping,
can release plumes of airborne dust that pose significant hazards
when transporting some materials, such as starch or activated
carbon. Even inert powders, when inhaled over time, can cause

p u m p s a n d s y s te ms . co m | Aug us t 2016
100 PRACTICE & OPERATIONS

systems in order to mitigate

BENEFITS OF AIR-OPERATED these risks and help make their
POWDER TRANSFER SYSTEMS operations more successful.”
Powder transfer systems are
• Self-priming from any start • Safely transfers carcinogens, designed to effectively move bulk
oxygen, or skin-sensitive and powders throughout a process
• Runs dry without damage
explosive powders without compromising worker
• Oil-free design
• Suitable for transfer of safety. Specialized air-operated
• No electrical hazards raw, intermediate or diaphragm pumps offer a
• Safe for use in hazardous finished products closed solution designed for the
and explosive environments • Considerable reduction consistent transfer of dry powders
(ATEX certified) or elimination of in a dust-free operation. With few
• Quiet, steady discharge operator exposure moving mechanics, noise levels
• Pumps at high temperatures • Considerable reduction in are also lower than comparable
transfer times and manpower electrical pumps. Opting for a
• Easy to operate closed powder-transfer solution
• Compact and portable for
• Quick assembly/disassembly maximum flexibility is not only an investment in
• Low maintenance – easier worker health and safety, but
• Optimized aeration and
to clean than mechanical also one with equal benefits in
reduced batch time through
systems terms of product quality and
integrated fluidization
• Pumps a wide variety of
process efficiency.
• No additional handling
powders and other materials equipment
(1,000-plus materials tested)

lung damage. Active ingredients vegetable and organic materials

can cause lung, skin and eye as well as with metal and other
irritation or damage, or trigger oxidizable dusts.
allergic reactions. “Hygroscopic materials that
Whether regulated or not, absorb moisture from the air
companies that transfer bulk and materials that explode
powders from drums or containers due to airborne exposure
should ensure that their processes pose serious health and safety
meet basic environmental and risks for workers and require
worker safety requirements. specialized handling and the
Pharmaceutical companies and use of highly reliable transfer
other regulated manufacturers equipment,” according to
are obliged to meet additional one industry expert. “With
protocol requirements as part increasingly stringent health
of Current Good Manufacturing and safety regulations, closed
Practice (CGMP). powder-handling solutions
Environmental safety hazards have become an issue even for
should not be overlooked. Any industries that have not been
airborne flammable dust in concerned until recently. Our
sufficient concentrations can material-handling experts
Image 2. One powder-transfer system is an air-
explode. Combustible dust on work with companies to make operated diaphragm pump that facilitates a closed
the ground can become airborne the necessary process changes powder transfer solution for dry powder applications
and introduce closed, ATEX- including carbon black, expanded mica, silicones,
and propagate an explosion.
acrylic resins and pharmaceuticals.
Such an event can occur with certified powder-transfer

Augus t 2 0 1 6 | Pum ps & S y st e m s

 101

Make Any
Transfer Performance
Variables such as fluidization, transfer
Pump GREEN
capacity and pump reliability can either
positively or negatively affect batch and with SIMSITE®
overall production times. To address
these issues, one powder-transfer system Impellers & Rings
features regulated aeration ports for
optimum powder aeration and diff usion,
as well as an integrated delay timer to
increase system efficiency, making this
pump a good choice for dusty or sticky
powders. The system is also outfitted with
a stall-free major air valve and a patented
four-way air induction system that
controls the amount of air or other inert
gases required for operating, resulting in
substantial cost and energy savings while
eliminating powder pack-out at startup.
Additionally, air-operated transfer
systems require less manpower compared
with manual transfer processes, allowing
workers to focus on higher-value activities.
Today’s powder-handling facilities
must be able to quickly adapt to market

High Efficie y
Efficiency
demands, with lean production units that
can accommodate fast process changes
based on mobile or modular technologies. with Low Operating Costs!
This particular system offers flexible
• Eliminate Corrosion
installation options and can be trolley-
mounted or installed on existing process • Eliminate Balance Issues
equipment while being easy to service. • Increase Efficiency
• Increase Longevity & Reliability
Pump Design & Equipment Life
The ability to keep a vessel closed while
introducing powder into the process is
considered a best practice for almost all
applications. Pneumatic powder-transfer
systems virtually eliminate the need to
constantly open storage or processing
Circle 126 on card or visit psfreeinfo.com.

tank manways, greatly reducing the risk

of damage and deterioration. Air-operated
diaphragm pumps are also optimized for
serviceability because they are easier to
clean and maintain.
This system offers a closed system design
that eliminates exterior contaminants
and substantially reduces equipment and
facility cleanup, which keeps operations
moving. Available in stainless steel and
aluminum construction, these pumps are
self-priming and can run dry or against a www.simsite.com | 1-201-792-0600

p u m p s a n d s y s te ms . co m | Aug us t 2016
102 PRACTICE & OPERATIONS

An engineering design firm helping pump manufacturers

accelerate organic growth closed discharge without the risk

through product and process of damage or heat buildup.
With few moving parts and the ability
innovation to run without electrical power, the
system’s pump can be ideal for various
We serve as a dynamic extension of your R & D: powder-transfer applications including
• Create differentiated product lines carbon black, expanded mica, silicones,
• Supplement your R & D resources acrylic resins and pharmaceuticals.
• Speed time to market
• Cut production cost up to 50%
• Utilize our Pump Innovation Lab
Other Factors
For many manufacturers, staying
Products in the pipeline for sale or license: competitive in today’s global market is
• ANSI sealless centrifugal: Breakthroughs in efficiency, NPSH, not possible without the safe, efficient
run-dry and cost plus aftermarket interchangeability. and hygienic transportation of bulk
• New sealless hygienic lobe: Simple design that is affordable
powder ingredients. Numerous quality
and fully interchangeable with leading manufacturers.
• New generation electric double diaphragm: Game-changing advantages across multiple phases of
efficiency, weight, size and affordability. production can be realized with contained
powder-transfer technologies and
processes—a topic that becomes even
Contact Bill Taylor: [email protected], 714-856-7222 more important in applications where
www.peopleflo.com product integrity is critical.
Closed transfer systems minimize the
Circle 151 on card or visit psfreeinfo.com. potential for environmental and material
contamination that could otherwise
jeopardize the purity of an entire
batch, resulting in lost production time,
product losses, wasted raw materials and
significant cost.
Additional benefits include increased
process repeatability by minimizing
opportunities for human error and
associated rework.
Flow characteristics and pump
construction factor into product quality.
Features such as a smooth flow path
and integrated fluidization capabilities
minimize the shear rate and any potential
for product damage during pumping.
This examined system is constructed
using non-reactive, additive or absorptive
components to ensure safety, integrity
or quality of the end user’s product while
maintaining the pump’s reliability. These
systems are also designed with removable
fluid caps to offer easy access to the
fluid chamber for servicing, cleaning or
diaphragm replacement without the need
for tools.
As manufacturers continue to
implement new methods and processes to
meet production goals while spending less,
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Augus t 2 0 1 6 | Pum ps & S y st e m s

 103

TFSEALSUSA.COM

Serving Manufacturers and Distributors for over 30 Years!

process engineers must make intelligent
decisions concerning powder handling.
A lower initial investment does not
always mean improved operating costs.
Poorly constructed or unreliable pumps
can increase downtime and power
consumption, impact revenue and
significantly add to maintenance costs,
while overinvesting in large complex
systems may be unnecessary for
We Deliver!
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many applications. cartridge metal bellows
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Certain powder pumps offer additional

benefits including material recovery.
Transfer efficiency metrics involving the Circle 155 on card or visit psfreeinfo.com.
use of mechanical systems can run as low
as 40 percent. For example, some systems
handling a load of 200 pounds of bulk
powder may transfer 80 to 90 pounds TM SPPC
before encountering dust-over incidents
that result in frequent shutdowns and Your in Progressive Cavity Pumps
time-consuming cleanup. Summit Pump Progressive Cavity (SPPC) Model Sealed Gear Joint Pump
Closed powder transfer systems
offer safe, effective and clean transfer
with virtually no scrap, resulting in
less cleanup and less manpower for
system maintenance.
In some cases, moving to a closed
powder-handling system can also lower
the costs associated with the use of
personal protective equipment required
with open systems.

Steven Coupal is the global engineering

leader of diaphragm pumps for ARO.
As a fluid intelligence expert, Coupal
manages engineers globally to design Summit Pum
Pump Prog ssive Ca
Progressive ty (SPPC) Model Pin Join
Cavity Joint Pump
new technologies. The ARO
diaphragm pumps in his
Call or Em
Email:l
portfolio serve many 920-869-4800
industries. For more sales@summitpum
[email protected]
TM
information, visit Celebrating ove
over 32 years PUMP, Inc
arozone.com B d in Greeen Bay, WI
Based www.SUMMITPUMP.com

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p u m p s a n d s y s te ms . co m | Aug us t 2016
104 PRODUCTS

New & Notable Technology

Products selected by the Pumps & Systems editors:

1 METERING PUMP
WATSON-MARLOW FLUID TECHNOLOGY
GROUP has released the new Qdos 120, 3
which offers flows up to 31.7 gallons per 1
hour at a maximum pressure of 58 pounds
per square inch, double the flow of existing
models in the Qdos range of peristaltic
metering pumps. The addition to the product
range builds upon the company’s Qdos
suite of high-accuracy chemical metering
technology. Qdos 120 delivers a step-change
in performance and usability compared
with conventional solenoid or stepper-driven
diaphragm metering pumps.
Circle 201 on card or visit psfreeinfo.com.

2 HORIZONTAL CENTRIFUGAL PUMP

VERTIFLO PUMP COMPANY’S Model 5
1400LF “Low Flow” base-mounted horizontal
centrifugal pump is used for a wide range
of applications including boiler feed,
condensate, chemical process, washdown
and spray washers. It handles capacities
to 50 gallons per minute, heads to 345 feet
total dynamic head and temperatures to 250
F. Back pullout construction allows for easy
inspection or service/ maintenance without 4
disturbing the piping to the pump, which 6
can be an important cost-saving feature.
The radial vane impeller has external
impeller adjustment.
Circle 202 on card or visit psfreeinfo.com.

3 STAINLESS STEEL PUMP slow pipe fill, water well draw-down control, low water
BBA PUMPS is offering its most popular inlet pressure detection, under-load detection and
pumps from the dry self-priming BA series in motor temperature monitoring reduce pump system
corrosion-resistant stainless steel 316. These mechanical stress and help protect the motor and
pumps can be ideal for a variety of industrial pump from damage. The pump panel is part of the
applications, particularly with corrosive Accu-Series line of variable speed products developed
environments such as offshore or mining by Nidec.
that demand high-performance materials. Circle 204 on card or visit psfreeinfo.com.
The stainless steel 316 range consists of the
BA80H clear liquid pump and the BA100K, 6 SUBMERSIBLE LEVEL TRANSMITTER
BA150E and BA180E solids-handling pumps. 5 CAST IRON MOTOR VIATRAN has introduced its Model 59Y submersible
Circle 203 on card or visit psfreeinfo.com. CONNEX’S Xtrem-E Premium Efficient Cast Iron level transmitter series designed to provide accurate,
Motors meet or exceed National Electrical continuous liquid level measurements of water
Manufacturers Association premium standards. and wastewater within industrial and municipal
4 PUMP PANEL Xtrem-E is manufactured with an epoxy coat exterior environments. The Model 59Y Series features a
NIDEC MOTOR CORPORATION has for superior corrosion protection and epoxy-coated monolithic (one-piece) design, which measures
launched its U.S. Motors brand pump panel, rotor and stator for internal corrosion protection. The hydrostatic pressure of compatible media. Typical
which is a drive panel designed to operate Xtrem-E motor has oversized ball bearings on the applications include liquid level and depth, in-ground
seamlessly with inverter-duty vertical drive end and opposite drive end, heavy-duty cast iron and above-ground water tanks, water and wastewater,
Holloshaft motors to deliver high wire-to- frame, 100 percent copper windings and a heavy gauge lift stations, irrigation systems, holding ponds,
water efficiency. It is designed with pump cast iron junction box. It is also inverter rated with a chemical plants, wells, reservoirs and dams, and
system installers and agricultural producers Class F insulation. inventory tank gauging.
in mind. Pump-specific features such as Circle 205 on card or visit psfreeinfo.com. Circle 206 on card or visit psfreeinfo.com.

To have a product considered for this section, please send the information to Martin Reed, [email protected].

Augus t 2 0 1 6 | Pum ps & S y st e m s

 105

8
7
8 COUPLING
TB WOOD’S has released its new Sure-Flex coupling
design. The Sure-Flex Plus EPDM and Neoprene
sleeves have a 30 percent higher torque rating,
allowing many common applications to use a one-
size-smaller coupling at an average of 2 percent
cost savings, which can lower the cost of the initial
coupling purchase and future sleeve replacements.
The Sure-Flex Plus sleeve design is 100 percent
compatible with all existing TB Wood’s and
competitive coupling flanges.
Circle 208 on card or visit psfreeinfo.com.
7 FLOW METER
KROHNE Inc. is promoting its Optisonic 7300
9 ultrasonic flow meter as an economic solution 9 DIAPHRAGM METERING PUMP
for low-pressure gas measurement, whether NEPTUNE, part of PSG, a Dover company, is
the gas is wet or dry. It can handle natural showcasing its new Series MP7100 mechanically
gas, shale and biogas applications, as well as actuated diaphragm metering pump. The MP7100
hydrocarbon and process gas vents. Optisonic pump incorporates the ruggedness of a hydraulic
7300 operates independently of gas density diaphragm metering pump, eliminates the need for
and composition and features an integrated intermediate fluid or hydraulic oil to actuate the
flow computer for pressure and temperature diaphragm, and reduces the potential for gearbox
compensation. Available in sizes ranging from oil to contaminate the process. The result is a pump
2 to 24 inches, the Optisonic 7300 features an design that provides reliable and accurate dosing
overall sturdy and robust construction, with of a wide range of mild to aggressive chemicals,
no cables or sensitive parts exposed and no including those used in municipal water and
moving parts in the flow sensor. wastewater treatment.
Circle 207 on card or visit psfreeinfo.com. Circle 209 on card or visit psfreeinfo.com.

Comprehensive
Industry Coverage
• Positive Displacement Pumps
• Centrifugal Pumps
• Specialty & Other Pumps
• Industrial Valves
• Pneumatic & Hydraulic Valves
• Industrial Automation & Process Control
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• Compressors
• Custom Research
• White Papers

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effective growth strategies. We employ 50
years of experience in partnering with Global
1000 companies, emerging businesses and
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40 offices on six continents.
Visit us at www.frost.com
For more information, contact Liz Clark
at 210.477.8483 or liz.clark@ frost.com

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p u m p s a n d s y s te ms . co m | Aug us t 2016
106 PRODUCTS

10

10 DELUGE VALVE
SINGER VALVE has added three new Deluge
Valves to its line of fire valves. The three new
valves include the Electronic Operated Deluge
Valve, the Pneumatic Operated Remote Control
Deluge Valve and the Electric Pneumatic
Operated Deluge Valve. These UL-approved valves
are used in high hazard areas where high velocity
suppression is necessary to prevent the spread 11
of fire such as power plants, aircraft hangers and
chemical storage or processing facilities.
Circle 210 on card or visit psfreeinfo.com. 12 FLOW METER
SPIRAX SARCO has announced the
rebranding of the VLM10 Inline Vortex
11 CONDITION MONITORING KIT Flowmeter to VLM20. The VLM20 utilizes a
SKF is offering the basic condition monitoring kit common electronics platform that is now
CMAK 400-ML that equips manufacturing plants available in all the new 20 Series meters to
with a collection of measurement tools designed improve reliability and ease of use across
to assess the health of rotating machinery the product line. The VLM20 is precise and
across industries. The tools in the compact kit reliable with a steam or gas mass flow 12
enable multi-parameter machine assessment accuracy of +/- 1.5 percent of rate over a wide
by monitoring overall machine condition 30:1 flow range. Digital communications
and specifically testing bearings, pumps, deliver real-time calculations of density,
electric motors and compressors to advance temperature, pressure, mass and thermal
an operation’s maintenance and reliability energy flow using Modbus RTU, BACnet MS/
objectives. All tools in the kit are packaged in a TP and HARTcommunications in addition to
light, durable aluminum carrying case. the standard analog, pulse and relay outputs.
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Your Premier Manufacturer of

ANSI Pumps &
Centrifugal Mud U N M AT C H A B L E E X P E R I E N C E
I N F L OW C O N T RO L

Pumps TRANSACTIONS

• In stock, ready to ship

Jordan, Knauff & Company is a knowledgeable and
• Numerous makes and experienced provider of a comprehensive line of
models investment banking services to the pump, valve and
• Service and repair on ½PXVEXMSRMRHYWXVMIW±*PS['SRXVSP² 
existing pumps
Our lines of business include: selling companies,
raising debt and equity capital, and assistance
SREGUYMWMXMSRW

To learn more about Jordan, Knauff & Company,

contact any member of our Flow Control
XIEQ %GGIWW SYV *PS[ 'SRXVSP VIWIEVGL EX
[[[NSVHEROREYJJGSQ¾S[GSRXVSP

+'SSO.SVHER.V (EZMH%/EOEVIOE
Managing Principal Senior Associate
GN$NSVHEROREYJJGSQ HOEOEVIOE$NSVHEROREYJJGSQ
 

1113 Howard Avenue | Houston, TX 77536 | 281-479-5000

curflo.com MEMBER FINRA, SIPC

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Augus t 2 0 1 6 | Pum ps & S y st e m s

 107

14

14 CORROSION-RESISTANT COOLING
TECHNICAL SYSTEMS INC. announced that
many of its products, including air-cooled
15 condensing units, chillers, fluid coolers, remote
condensers, pumping packages and pumping
skids, are available in corrosion-resistant
designs. With the corrosion-resistant design,
these products are suitable for use in coastal
manufacturing, comfort and process cooling
environments. They are also ideal for inland
applications using corrosive chemicals, such as
poultry processing, animal byproduct production
13 HIGH-CAPACITY 13 and water treatment plants.
SUBMERSIBLE PUMP Circle 214 on card or visit psfreeinfo.com.
GOULDS WATER TECHNOLOGY, a Xylem
brand, has redesigned its high-capacity
4-inch submersible pump series with the 15 VARIABLE SPEED DRIVE
e-GS, replacing its GS high-capacity line. The CONTROL TECHNIQUES, an Emerson business,
borehole pump is specifically designed for has extended its range of high-power modular
use in 4-inch and larger wells and is ideal for drives. Both its Unidrive M and Powerdrive F300
irrigation systems, domestic and industrial variable speed drive ranges are now available
water supply, geothermal, and fountain in the larger frame size 11, providing a flexible
applications. The series has an innovative method of building compact, reliable high-power
floating stack advanced hydraulic design solutions. The new frame 11 is a 250-kW (400-hp)
that allows sand and abrasives to pass easily, module that allows system builders to create
reducing life-cycle costs and improving high-power solutions with the smallest number
efficiency by as much as 13 percent compared of components, keeping both footprint and costs
with previous models. to a minimum.
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NEW: Hydraulic Institute’s Wastewater

Treatment Plant Pumps Guidebook

This new guide provides the

guidance necessary to select
pump types, pump materials,
and auxiliary components so the
wastewater pumping system
performs effectively, efficiently,
and reliably in various plant
operations. Find out what’s
inside by visiting the link below.

leak-tightness with long-term benefits!

Attention Pumps & Systems Readers:
Take 15% off your purchase of this guide HN 8-WD: Leak-tightness is critical for hydraulic applications.
by applying coupon code WWPS15GB That is why our HN 8-WD plugs are most frequently used by
during checkout in the HI eStore at mobile hydraulics and drive engineering worldwide. The plugs
eStore.Pumps.org/Wastewater with integrated elastic sealing form-ring are easy to assemble
and tight. Available with FKM or NBR, from M 6 to G 2½", in yel-
low zinc and Cr-6-free plating. A precise and efficient solution!

Heinrichs USA LLC | [email protected]

www.heinrichs-usa.com It’s our turn!

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p u m p s a n d s y s te ms . co m | Aug us t 2016
108 PUMP USERS MARKETPLACE

Adverti se rs
Advertiser Name RS# Page Advertiser Name RS# Page Advertiser Name RS# Page

AE Pumps . . . . . . . . . . . . . . . . . . . . . . . . .163 111 Hoosier Pattern, Inc.. . . . . . . . . . . . . . . 127 73 ShinMaywa (America), Ltd. . . . . . . . . .140 60
AIGI Environmental Inc. . . . . . . . . . . . .117 67 Hydraulic Institute . . . . . . . . . . . . . . . . .160 107 Sims Pump Co. . . . . . . . . . . . . . . . . . . . . 126 101
Albin Pump USA . . . . . . . . . . . . . . . . . . 164 108 Hydro, Inc.. . . . . . . . . . . . . . . . . . . . . . . . .101 FC Sims Pump Co. . . . . . . . . . . . . . . . . . . . . .174 110
American Vulkan Corporation. . . . . . .119 75 Inpro/Seal . . . . . . . . . . . . . . . . . . . . . . . . 128 79 Sims Pump Co. . . . . . . . . . . . . . . . . . . . . .175 110
AutomationDirect.com . . . . . . . . . . . . .102 BC Jordan, Knauff & Company . . . . . . . . .161 106 Sims Pump Co. . . . . . . . . . . . . . . . . . . . . .176 109
Badger Meter Inc. . . . . . . . . . . . . . . . . . .103 23 KTR Corporation . . . . . . . . . . . . . . . . . . 150 96 Skinner Power Systems . . . . . . . . . . . . .141 78
Baldor Electric Company . . . . . . . . . . . 104 15 Load Controls, Inc. . . . . . . . . . . . . . . . . 129 90 SPM Instrument . . . . . . . . . . . . . . . . . . .177 111
Bartlett Bearing Company . . . . . . . . . 120 11 Load Controls, Inc. . . . . . . . . . . . . . . . . .169 110 SPXFLOW . . . . . . . . . . . . . . . . . . . . . . . . .142 89
Basetek, LLC . . . . . . . . . . . . . . . . . . . . . . .165 109 LobePro . . . . . . . . . . . . . . . . . . . . . . . . . . .170 109 St. Marys Foundry. . . . . . . . . . . . . . . . . .178 111
BASF The Chemical Company. . . . . . . .105 29 Magnatex Pumps, Inc. . . . . . . . . . . . . . .171 109 Standard Alloys . . . . . . . . . . . . . . . . . . . .118 99
BBA Pumps Inc. . . . . . . . . . . . . . . . . . . . .166 109 MasterBond Inc. . . . . . . . . . . . . . . . . . . .172 110 Sulzer Management Ltd Rotating
BJM Pumps, LLC . . . . . . . . . . . . . . . . . . .146 97 Meltric Corporation . . . . . . . . . . . . . . . .173 110 Equipment Services . . . . . . . . . . . . . 112 5
Blue-White Industries . . . . . . . . . . . . . .147 63 National Pump Company . . . . . . . . . . 130 58 Summit Industrial Products -
Boerger. . . . . . . . . . . . . . . . . . . . . . . . . . . 121 87 NSK Americas. . . . . . . . . . . . . . . . . . . . . 131 13 Dorsey Advertising . . . . . . . . . . . . . .143 80
CURFLO. . . . . . . . . . . . . . . . . . . . . . . . . . .157 106 PeopleFlo Manufacturing . . . . . . . . . . .151 102 Summit Pump, Inc. . . . . . . . . . . . . . . . . 153 103
Dan Bolen & Associates, LLC . . . . . . . .167 111 Proco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 70 Summit Pump, Inc. . . . . . . . . . . . . . . . . 154 97
Dickow Pump Company. . . . . . . . . . . . 122 68 PSG, A Dover Company . . . . . . . . . . . . .152 77 TF Seals . . . . . . . . . . . . . . . . . . . . . . . . . . 155 103
DP Pumps . . . . . . . . . . . . . . . . . . . . . . . . 123 61 PumpWorks Industrial. . . . . . . . . . . . . .109 21 Thordon Bearings Inc. . . . . . . . . . . . . . .144 9
Electro Static Technology . . . . . . . . . . .124 69 Quadrant . . . . . . . . . . . . . . . . . . . . . . . . . 134 85 Titan Flow Control.. . . . . . . . . . . . . . . . 156 96
EnviroGear . . . . . . . . . . . . . . . . . . . . . . . 125 65 R+W America . . . . . . . . . . . . . . . . . . . . . 133 74 Titan Manufacturing Inc. . . . . . . . . . . .179 109
FLSmidth Inc.. . . . . . . . . . . . . . . . . . . . . .148 63 Ruthman Companies . . . . . . . . . . . . . . .110 39 Tuf-Lok International . . . . . . . . . . . . . 180 108
Frost & Sullivan . . . . . . . . . . . . . . . . . . . 158 105 Salem-Republic . . . . . . . . . . . . . . . . . . . 135 64 Vaughan. . . . . . . . . . . . . . . . . . . . . . . . . . 113 IBC
FW Murphy. . . . . . . . . . . . . . . . . . . . . . . .149 102 Schaeffler Group USA Inc. . . . . . . . . . . 111 19 Vertiflo Pump Company . . . . . . . . . . . 181 111
GE Power Conversion . . . . . . . . . . . . . . .107 27 Schenck Trebel Corporation . . . . . . . . 136 93 Vesco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182 111
General Rubber Corp. . . . . . . . . . . . . . . .168 111 SealRyt . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 57 WEFTEC . . . . . . . . . . . . . . . . . . . . . . . . . 195 49
Graphite Metallizing Corp. . . . . . . . . . .162 105 SEEPEX . . . . . . . . . . . . . . . . . . . . . . . . . . 137 71 Xylem Water Solutions . . . . . . . . . . . . . .114 7
Grundfos . . . . . . . . . . . . . . . . . . . . . . . . . 106 3 Sensaphone. . . . . . . . . . . . . . . . . . . . . . . 138 54 Zoeller Company.. . . . . . . . . . . . . . . . . . .145 94
Heinrichs USA LLC . . . . . . . . . . . . . . . . 159 107 SEPCO . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 59 The Index of Advertisers is furnished as a courtesy, and
Hidracar S.A. . . . . . . . . . . . . . . . . . . . . . .108 35 Shin Nippon Machinery. . . . . . . . . . . . .116 45 no responsibility is assumed for incorrect information.

FREE PRODUCT INFORMATION

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Augus t 2 0 1 6 | Pum ps & S y st e m s

 109

REPS WANTED POLYMER BASEPLATES

Sims Pump, a fast growing structural
composite pump, pump parts, and COMPARED TO STEEL, THEY’R
RE FLAT O
OUT THE BEST!
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corrosive environments, such as 877-712-BASE (2273)
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industrial markets. A background in
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Please fax your resume to
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Since 1985 your process reliability and

profitability have been our number one priority!

IN STOCK, READY TO QUICK SHIP.

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Phone: 713.972.8666 | Toll Free: 866.624.7867

FAX: 713.972.8665
3575 West 12th Street, Houston, TX 77008

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p u m p s a n d s y s te ms . co m | Aug us t 2016
110 PUMP USERS MARKETPLACE

Helping engineers
find the right
adhesive system
EPOXIES

SILICONES

UV/LED CURING SYSTEMS

FAR
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Low Outgassing
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Augus t 2 0 1 6 | Pum ps & S y st e m s

 111

HIGH defInItIon
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PAS_Online_2,25x4.indd 1 2016-02-12 08:49

Solve
dry start
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Tollfree 1-866-635-7596 Circle 163 on card or visit psfreeinfo.com.
[email protected]
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p u m p s a n d s y s te ms . co m | Aug us t 2016
112 PUMP MARKET ANALYSIS

Wall Street Pump & Valve Industry Watch

By Jordan, Knauff & Company
Figure 1. Stock indices from July 1, 2015, to June 30, 2016

T he Jordan, Knauff &

Company (JKC) Valve Stock
Index was down 10.5 percent
over the last 12 months, while the
broader S&P 500 Index was up
including construction,
manufacturing, wholesale
trade, transportation
and warehousing, and
government, showed little or
1.0 percent. The JKC Pump Stock no change. Employment in
Index decreased 16.9 percent for mining continued to trend
the same time period.1 down. From April through
The Institute for Supply June, the U.S. added an
Source: Capital IQ and JKC research. Local currency converted to USD using
Management’s Purchasing average of 147,000 jobs per historical spot rates. The JKC Pump and Valve Stock Indices include a select list of
Managers’ Index (PMI) increased month, down from an average publicly traded companies involved in the pump and valve industries weighted by
to 53.2 percent in June from of 282,000 in the fourth market capitalization.
51.3 percent in May, its strongest quarter of 2015.
reading since February 2015. Last year, fossil fuels made commercial production, Algeria, Reference
Manufacturing registered growth up 81.5 percent of total U.S. Australia, Colombia, Mexico, 1. The S&P Return
for the fourth consecutive month, energy consumption, the lowest Poland and Russia began exploring figures are provided
and producing either natural gas by Capital IQ.
as 12 of the 18 industries reported level in more than 100 years. At
an increase in new orders and 10 percent, renewables’ share of or crude oil from shale and other
production in June. Export energy consumption was at its tight resources in 2015.
orders increased 1.0 point to highest level since the 1930s. Solar On Wall Street, the Dow Jones
Jordan, Knauff & Co.
53.5 percent, its highest level in and wind generation accounted Industrial Average gained 0.8
is an investment bank
more than a year and a half. The for the greatest growth in percent, the S&P 500 Index was based in Chicago, Ill.,
Employment Index managed to renewables over the past 10 years. up 0.1 percent, and the NASDAQ that provides merger
move back into expansion territory Coal consumption fell 13 percent Composite declined 2.1 percent and acquisition
for the month of June. For the advisory services to
at 50.4 percent after six months in 2015, the highest annual the pump, valve and
of below 50 percent readings. percentage decrease of any fossil full second quarter, both the Dow filtration industries.
U.S. manufacturing jobs fell by fuel in the last 50 years. Jones and S&P 500 showed gains Please visit www.
an average of 13,000 per month In the first half of 2015, China for the third consecutive quarter, jordanknauff.com for
rising 1.4 percent and 1.9 percent, further information
between February and May. and Argentina led shale resource
The U.S. economy added development outside North respectively. The NASDAQ declined on the firm. Jordan,
Knauff & Co. is a
287,000 jobs in June, and the America and have the potential 0.6 percent for the second quarter. member of FINRA.
unemployment rate rose to 4.9 to increase their production The unanticipated vote of Britain
percent. Job growth occurred in significantly. China drilled more to leave the European Union, May’s
leisure and hospitality, health than 200 shale gas and tight oil discouraging jobs report and the
care and social assistance, and wells, and Argentina drilled more Federal Reserve Bank’s reluctance
These materials were
financial activities. Employment than 275 since the beginning of to raise interest rates all had a prepared for informational
2014. While still short of reaching dampening effect on the markets.
purposes from sources that
in other major industries, are believed to be reliable
but which could change
without notice. Jordan,
Figure 2. U.S. energy consumption and rig counts Figure 3. U.S. PMI and manufacturing shipments Knauff & Company and
Pumps & Systems shall
not in any way be liable
for claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or com-
pleteness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
any investment offering or
Source: U.S. Energy Information Administration and Source: Institute for Supply Management Manufacturing deployment of capital.
Baker Hughes Inc. Report on Business and U.S. Census Bureau

Augus t 2 0 1 6 | Pum ps & S y st e m s

Increased efficiencies and UNMATCHED RELIABILITY allow the Vaughan Chopper Pump
to handle tough stringy solids often with the same motor size as a non-clog pump. Also
included is a back-pullout casing design, allowing external adjustments of clearances and
ease of maintenance.

- Advanced engineering, efficiency, maintainability and performance

- Handles tough stringy solids with the same motor size as a non-clog pump
- New larger sizes, configurations, and cutting-edge flushless seal design

See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP

Circle 113 on card or visit psfreeinfo.com.

Circle 102 on card or visit psfreeinfo.com.