Pumping

modERn todAY
PRoviding SolUtionS FoR thE WoRldWidE PUmP indUStRY FEBRUARY 2013

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PUMPS AND ENERGY
PERFORMANCE
DEWATERING IN AN EMERGENCY HARNESS THE POWER OF HYDRAULICS INSIST ON BETTER PUMPS
ContEntS
4 8
FEBRUARY 2013
10 Unraveling a Super-Synchronous Pump vibration issue 18 Solving a very dirty Problem

Perforated plate dewatering boxes help the pumping and filtration industry clean our water
industry news trade Show Profile Case Studies
10
22 A new hope for a Common Water treatment Plant Problem
Water & Wastewater Solutions

Combining bearing carrier and shaft grounding ring mitigates electrical bearing damage in vertical pump motors
26 insist on Better Pumps

Part 2: Breaking the Cycle of Pump Repairs
maintenance Solutions
18
32 history Repeats itself
Pump Solutions
Laying the groundwork for the next generation of centrifuge technology Hydraulically driven submersible pumps offer advantages over electric alternatives
36 harness the Power of hydraulics
40 dewatering in an Emergency
A flooding concern
dewatering Solutions
44 Pumps and Energy Performance
motor Solutions
54
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266

@ModPumpMag
48 Cool, Calm, and Collected

An analysis of a circulating water pump system
Power generation Solutions Processing Solutions

Circumferential piston pump increases productivity and consistency demands for bakery
TIM GARMON Publisher tim@modernpumpingtoday.com JEFF FLETCHER Associate Publisher jeff@modernpumpingtoday.com RANDY ARMISTEAD Associate Publisher randy@modernpumpingtoday.com J. CAMPBELL Editor jay@modernpumpingtoday.com DONNA CAMPBELL Editorial Director donna@modernpumpingtoday.com SCOTT GORDON Art Director scott@modernpumpingtoday.com LISA AVERY Assistant Art Director lisa@modernpumpingtoday.com RUSSELL HADDOCk Sr. V.P. of Sales/Marketing russell@modernpumpingtoday.com CHRIS GARMON General Manager chris@modernpumpingtoday.com JAMIE WILLETT Circulation Director jamie@modernpumpingtoday.com INGRID BERkY Administrative Assistant RANDY MOON Account Executive NANCY MALONE Account Executive DAVID MARLOW Account Executive DON MORGAN Account Executive
54 the BlockBuster Rises to the Challenge
56 monitor Your Pump for Process Efficiency 60 no Seals? no Problem! 62
valves & Controls Solutions Sealing Solutions

Non-metallic drum pump is a sealless solution evacuating hazardous and corrosive fluids
64 What Comes next?
modern Pumping Products Pumping trends

Nidecs Tim Albers on government regulation, industrial standards, and the global customer base of the future
www.highlandspublications.com
312 Lorna Square | Birmingham, Alabama 35216 T: 866.251.1777 | F: 205.824.9796

LARRY DAUGHETY President TIM GARMON Vice President DENNIS DAUGHETY Vice President
56
60
No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without permission in writing from the publisher. The views expressed by those not on the staff of Modern Pumping Today, or who are not specifically employed by Highlands Publications, Inc., are purely their own. All Industry News material has either been submitted by the subject company or pulled directly from their corporate website, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to jay@modernpumpingtoday.com. For address changes, please contact Jamie Willett: jamie@modernpumpingtoday.com
INDUSTRy news
Pump buyers requesting price quotes on PumpScout.com now have access to a range of pumps manufactured by Patterson Pump Company, a Gorman-Rupp Company. This partnership is not only great news for PumpScout.com, its also fantastic for the thousands of pump buyers who use PumpScout.com to find suppliers and pumps, says Justin Johnson, CEO of PumpScout. com. Patterson is known around the globe for the quality of their water and waste water products and services. Patterson specializes in heavy duty flow control equipment for a range of applications that involve moving water and other liquids such as fire suppression, flood control, HVAC, and industrial. The company offers numerous pump types including vertical turbine, vertical in-line, horizontal split case, and mixed and axial flow models. The pump manufacturer has sales and service offices, as well as manufacturing plants, in locations around the world. Pattersons global presence means their customers can easily
PATTERSON PUMP COMPANY PARTNERS WITH PUMPSCOUT.COM
tap into to the companys expertise and service whenever they need. We are excited about being a featured supplier on PumpScout.com and connecting with the increasing number of buyers who use the website, says Brian Henry, in Pattersons marketing/technical services. Weve already received several high-quality leads and were looking forward to getting even more. PumpScout.com aims to streamline the pump buying process by providing buyers with an easy way to find suppliers and get multiple product quotes. PumpScout users fill-out the simple quote request form, and then PumpScout immediately connects them with pump suppliers who can provide the appropriate product. Were proud of the highvalue leads that were sending our partners every day, Johnson says. Weve created an innovative way to ensure that the thousands of people searching the Web for pumps connect with the right suppliers. And the end result is a faster process for buyers and more sales for suppliers.
4 | FEBRUARY 2013
INDUSTRy news
NEW CLOUD-BASED CMMS LAUNCHES THIS MONTH
Cloudruge, Ltd. released the alpha version of its free online Computerized Maintenance Management Software (CMMS), known as cloudruge, on the February 13, 2013. The use of the software is by invitation only but users can visit cloudruge.com and request to be added to the invite list. The system is a cloud-based CMMS, so the application runs on cloudruge servers and users need only a browser to access it. This results in important cost savings as there is no need to employ specialized IT staff. Up-time on remote servers is also generally much higher than if the servers are kept in-house. The main features of the alpha version are a secure, efficient, and advanced web application framework; asset organization tree; manual work request / work order assigned to asset; multi-user; upload of documents assigned to assets or assigned to work ordersplus, the features go anywhere with its native mobile version. Other functionality to be available soon on the alpha version includes work-order scheduling, asset list import using an Excel file, and user level implementation. We are continuing our momentum in the commercial plumbing sector by offering several options for professionals to learn more about Uponor PEX-a piping systems, says Wes Sisco, training manager at Uponor. This includes webinars, field training, and now factory training with our newly constructed Commercial Uponor Commercial Plumbing Applications Lab Plumbing Applications Lab. The new Commercial Plumbing Applications Lab features all of Uponors products and systems for suspended piping, risers, in-suite and out-of-the-wall plumbing systems to showcase the benefits of the flexible, durable pipe in real-world applications. The two-day Commercial Plumbing Applications course is available six times throughout the year beginning in March. Attendees who complete the course are eligible for CEUs to meet continuing education requirements. The 2013 Uponor Academy factory training schedule also includes Radiant Hydronics and Design with Controls and Advanced Radiant Hydronics with Advanced Design Suite (ADS), which are also eligible for CEUs. To learn more about Uponor Academy factory training courses and to register, visit www.uponorpro.com/training.
UPONOR ADDS NEW COMMERCIAL PLUMBING COURSE TO 2013 FACTORY TRAINING SCHEDULE
Uponor recently announced its factory training schedule for 2013, which includes a new course on commercial plumbing applications. The course, which is eligible for continuing education units (CEUs), focuses on codes and standards, pipe sizing, unit piping, riser piping, distribution piping, public and service piping, and design and installation practices.
6 | FEBRUARY 2013
TRADE SHOW profile
Expect the Unexpected at MEOS 2013

rganized by the Society of Petroleum Engineers (SPE), the Middle East Oil and Gas Show and Conference, or MEOS, is the biggest conference of its kind in the Middle East. Furthermore, as the most widely attended petroleum technology show in the oil-rich region, MEOS plays a crucial role in spreading vital operations information, providing professional networking connections, and allowing a spotlight for the industrys latest trends. At MEOS 2013, those who believe oil and gas technology has become endlessly grandfathered by set procedures will be surprised by the wideranging seminars on new techniques and views of the industrys future. Featured speakers address topics ranging from shale gas and shale liquid acquisition to unconventional drilling methods to revolutionary facilities management. The exhibit floor will showcase the global reach of the oil and gas industry. From regional companies to national oil trusts to multinational conglomerates, every aspect of the petroleum field shows their face at MEOS. Since 1979, the conference has maintained a tradition of open and cooperative exchanges within the industry. MEOS is also rightly heralded for its innovative training courses. This years conference will offer three training courses, each addressing unique needs of oil and gas professionals: How to Charge Your Body Cell Phone, presented by Dr. Abdullah Al-Mulhim, MD, of the Vital Work Center, offers participants a chance to learn the psychological factors that employees need to unlock their potential. Geomechanics for Effective Shale Gas Exploitation, instructed by Dr. Safdar Khan of Schlumberger Canada, presents the theoretical underpinning and representative cases for successfully optimizing shale gas exploitation using geomechanics. Enhanced and Improved Oil Recovery Methods, led by Professor Hemanta
8 | FEBRUARY 2013
K. Sarma of the Petroleum Institute, Abu Dhabi, offers participants an interactive environment to discuss the right time for EOR implementation, an overview of options and tools, and broader issues from field experience. For attendees, exhibitors, and presenters, the 18th Middle East Oil and Gas Show and Conference is truly an oasis of advancement, information, and partnership.
CASE Studies
U nraveling a S Uper -S ynchronoUS ib n i SSUe at on ti p Ump V Vibration ra io br Vi

By maki onari and Eric olson, mechanical Solutions, inc.
pump OEM (original pumps that were being used Radial Optical equipment manufacturer) in vacuum bottoms service at Proximity Tachometer Probes needed help to solve a a sizable petroleum refinery. Torsional Strain Gage and RF puzzling, super-synchronous Vacuum residuum (a mix of Transmitter machinery vibration issue. water, oil, and coke) typically Excessive vibration had was pumped at a 700 degrees emerged in a set of centrifugal, Fahrenheit (371 degrees double suction pumps that the Celsius) in this application. OEM recently had designed The rated capacity of the new and built for one of their pumps was 1160 gallons per larger customers in service minute (4391 liters per minute), subject to coke formation. 750 feet (228.6 meters) TDH, During the OEMs routine and 245 horsepower. The pump Triaxial performance testing of the featured a six-vane double Accelerometer newly manufactured pump, suction impeller and a wrapan elevated overall vibration around coke-crusher wear ring Figure 1: For the vibration testing, the problematic double suction pump was outfitted with an array of special instrumentation, such as the several key probes level was detected on the that was supported with three shown here. bearing housings. The 0.4 inch unevenly spaced struts. per second RMS vibration Radial Torsional level occurred at a superTHE INITIAL EVALUATIONS & Axial Strain Gage Proximity and RF synchronous frequency, YIELDED LIMITED INSIGHT Probes Transmitter approximately 100 Hertz. In To determine whether this was distinct contrast with this test a pump or system vibration data, the eleventh edition of issue, the OEM tested the the API 610 specification, pump with different drivers Centrifugal Pumps for General and piping arrangements at Dynamic Pressure Triaxial Refinery Service, requires less several facilities. Unfortunately Transducers Accelerometer than 0.12 inch per second RMS the OEM still measured at BEP (best efficiency point), consistently high vibration and 0.154 inch per second levels at the pumps bearing RMS below 70 percent BEP. housings, primarily superInterestingly, the hydraulic synchronous. This outcome efficiency of the pump as suggested that the vibration determined by the performance problems origin was internal to Figure 2: The accelerometers were roved to over one hundred locations, with a tests still exceeded the OEMs the pump, and that it was not single axis accelerometer always kept at the same location and direction for phase reference. related to the natural frequency expectations, in spite of the of the support structure, motor, high vibration level. electromagnetics, or the acoustic natural frequencies from the In this case, the OEM had customized an existing single piping system. stage, double suction, API pump design to replace the legacy
About the Authors

Maki Onari is the manager of turbomachinery testing and Eric Olson is the principal engineer at Mechanical Solutions, Inc. (MSI) of Whippany, New Jersey. For more information, visit www.mechsol.com .
10 | FEBRUARY 2013
THIS SecTIon SponSored by
www.yaskawa.com
Autospectrum (Signal 2) - Mark 1 (Real) \ FFT Analyzer

1 0.5 0.2 0.1 50m 20m 10m 5m 2m [in/s] 1m 500u 200u 100u 50u 20u 10u 5u 2u 1u
Autospectrum (Signal 17) - Mark 1 (Real) \ FFT Analyzer Cursor values X: 94.875 Hz Y: 0.229 in/s
2 1 0.5 0.2 0.1 50m
1x rpm 1.59x rpm
1x rpm
1.59x rpm
Cursor values X: 94.875 Hz Y: 0.229 in/s
[mil] 10m
5m 2m 1m 500u 200u 100u 50u 0 40 80 120 160 200 240 280 320 360 400 0
20m
OBB Vertical Overall: 0.38 in/s RMS
IBB Proximity Probe Y: 9.1 mils pk-pk @95 Hz
40
80
120
160
200
240 280
320
360
400
[Hz]
[Hz]
Figure 3: A representative trace of the velocity response in the vertical direction at the outboard bearing of the pump.
Figure 4: The vertical displacement response at the inboard bearings proximity probe, which occurred at full speed as load was increased.
The OEM then Radial Proximity Probes brought the pump to ~9.0 mils pk-pk ~9.5 mils pk-pk their research and development center, Orbit (Signal 14, Signal 14) (Nyquist) Orbit (Signal 16, Signal 17) (Nyquist) where the pump was Working : 1159 GPM Linear Rec 15 OK : Input : FFT Analyzer Working : 1159 GPM Linear Rec 15 OK : Input : FFT Analyzer coupled directly to an induction motor which was controlled through a variable frequency drive (VFD). This enabled the pump to be run at two different speeds: 2970 [mil] [mil] rpm (49.5 Hertz) and 3555 rpm (59.3 Hertz), which was the pumps rated speed. The pump was evaluated at different flow capacities. In all instances, the high supersynchronous vibration level remained, and was [mil] [mil] observed to increase with both flow and speed. OBB IBB As stated earlier, the Figure 5: The radial displacement responses at the inboard and the outboard bearings of the pump, as recorded by the pump was equipped with perpendicularly mounted radial proximity probes during the rotordynamic instability event. a wrap-around cokecrusher wear ring that featured three unevenly spaced struts. By circumferentially monitoring was performed to observe parameters which staggering the coke-breaker struts and also by removing them included the shaft and bearing vibration amplitudes and entirely, the OEM explored internal modifications to the pump orbits, the structural natural frequencies, the pressure to attempt to mitigate the excessive vibration. However, these pulsations, and the shaft lateral and torsional natural internal modifications proved to be ineffective. frequencies. Representative data are presented. Figure 3 illustrates the high RMS velocity response due SPECIALIZED TESTING HELD THE KEY to the vibration that was recorded, in this instance on the Ultimately, the root cause of the pumps unexpected outboard bearing housing, nearly 0.4 inches per second RMS rotordynamic issues was identified. A series of operating overall in the vertical direction. Two major peaks stand out deflection shape (ODS) and modal (bump) vibration tests of in the plot, one at 1X rpm and the other at 1.59X rpm. The the pump were completed, which required the installation of excessive peak-to-peak displacement responses at the bearing a number of transducers on the pump system (figures 1 and 2) housings, about 9 mils, are displayed in figure 4 in terms to collect the considerable amount of test data. of the vertical displacement at the inboard bearing, and in During the startup and the coast down of the pump, figure 5 in terms of the radial displacements at both bearing and also during the steady state of operation of the pump, housings.
FEBRUARY 2013
11
CASE Studies
Pump OBB X 1x rpm 1x rpm Pump OBB Y
Time(s)
Time(s)
Amplitude (mils pk-pk)
Frequency [Hz]
Frequency [Hz]
Pump IBB X 1x rpm 1x rpm
Pump IBB Y
Frequency [Hz]
Figure 6: Horizontal (X) and the vertical (Y) peak-to-peak displacement responses at the inboard and the outboard bearing housings of the pump.
Time(s)
Time(s)
Frequency [Hz]
OBB
2.3 2 1.8 1.6 1.4 1.2 1 0.8 0.6
Shaft position in time (seconds)
IBB
2.3 2 1.8 1.6 1.4 1.2 1 0.8 0.6
Shaft position in time (seconds)
Vertical [mils]
0.2 0 -0.2 -0.4 -0.6 -0.8 -1 -1.2 -1.4 -1.6 -1.8 -2 -2.3 -2.3 -2 -1.5 -1 -0.5 0 0.5 1 1.5 2 2.3
Vertical [mils]
0.4
0.4 0.2 0 -0.2 -0.4 -0.6 -0.8 -1 -1.2 -1.4 -1.6 -1.8 -2 -2.3 -2.3 -2 -1.5 -1 -0.5 0 0.5 1 1.5 2 2.3
Horizontal [mils]
Horizontal [mils]
Figure 7: Shaft center-line trajectory plots for the outboard and the inboard bearing housings of the pump, as viewed from the non-driven end (NDE) of the pump.
12 | FEBRUARY 2013
www.yaskawa.com
3D View
3D View
Z Y X Y
Z X
Figure 8: The operating deflection shape (ODS) computer model of the single stage, double suction pump system.
Figure 6 indicates the presence of the super-synchronous vibration in the peak-to-peak displacement responses that were recorded at both bearing housings. The supersynchronous vibration that had plagued the pump clearly is visible in each of the four plots, and it is shown to suddenly disappear below 1380 rpm. In figure 7, the shaft position is shown during the
coast-down of the pump from 3570 rpm, indicating that the shaft moved towards the upper left or nine oclock position after the pump was started. The green circles represent the shaft centerline locations at various points in time. When the shaft speed was above 1380 rpm, the destabilizing static cross-coupled stiffness force, FKyx, was larger than the stabilizing damping force, FCxx.
Operating Deflection Shape (ODS)

Operating deflection shape (ODS) testing also was executed during the steady state operation of the pump. The ODS graphical animations that were created from the test data demonstrated the relative motion of each portion of the pumps structure at a given frequency of vibration (figures 8 through 10). No cracks, delaminations, or loose bolts were
FEBRUARY 2013
13
CASE Studies
Z View BLK: ODS 01 REC 0 Freq: 59.4 Hertz [Complex] 3D View BLK: ODS 01 REC 0 Freq: 59.4 Hertz [Complex]
3D View BLK: ODS 01 REC 0 Freq: 94.8 Hertz [Complex]
X View BLK: ODS 01 REC 0 Freq: 59.4 Hertz [Complex]
Y View BLK: ODS 01 REC 0 Freq: 59.4 Hertz [Complex]
Dwell:1, Amp:5
Figure 9: Four stills from the ODS animation.
Figure 10: The operating deflection shape (ODS) of the pump system at 95 Hertz, including its rotor system centerline, and the red arrows in the figure indicate the directions of motion of the pump system at this frequency of vibration.
evident in the ODS animations, and except for the supersynchronous orbiting of the rotor, the motions due to the vibration of the operating pump generally were considered to be typical for this type of machine.
Experimental Modal Analysis (EMA)
Experimental modal analysis (EMA) testing was performed
during operation, using a cumulative time-analyzing procedure, to determine the mode shapes of the pump structure and of the rotor system at the pump assemblys natural frequencies of vibration. The data from this testing was mapped on the pump assembly. The data consisted of hundreds of sampling locations, which included the pump casing, the pump motor, the pedestals, and the baseplate
14 | FEBRUARY 2013

Frequency Response (Signal 17, Signal 7) - Mark 1 (Magnitude) Working: Rotal Modal IBB Hor Rec 9 : Input : Enhanced
10m 3m 1m 100m 30m 10m
www.yaskawa.com
Frequency Response (Signal 14, Signal 7) - Input (Magnitude) Working: Input : Input : Enhanced
[mil/lbf]
300u 100u 30u 10u 3u 1u 0 40 80 120 160 200 240 280 320 360 400
[mil/lbf]
3m 1m 300u 100u 30u 10u 0 40 80 120 160 200 240 280 320 360 400
[Hz]
[Hz]
Figure 11: An experimental modal analysis test pump rotor frequency response function (FRF) plot recorded at the pumps inboard bearing radial proximity probe in the vertical (Y) direction, while the pump was not operating.
Figure 12: Additional experimental modal analysis frequency response test results.
(figures 11 and 12). The first bending mode of the pumps rotor was detected at 98 Hertz when the pump was not operating (figure 11) and shifted to about 111 Hertz while the pump was in operation (figure 12) due to the effect of speed and the stiffness from the wear rings. A visual inspection of the interior of the pump also was performed (figure 13). The large displacement response of the pump shaft that was detected, about 9 mils peak-to-peak, was enough to have caused contact with the internal wrap-around coke-crusher wear rings to occur, as is evident in the figure.
The intensive testing pointed to the source of the unusual pump vibration. The excessive vibration of the pump was due to rotordynamic instability which excited the first bending mode of the pump shaft. Fluid whirl rotated at a speed greater than running speed, due to conservation of angular momentum as the more slowly whirling fluid leaked through the double wear ring gaps. Resulting rotating, non-axisymmetric pressure within the pumps wrap-around coke crusher wear rings provided the excitation and feedback mechanisms for the unstable rotor whirl. Once the cross-coupling force from the
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FEBRUARY 2013
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15
CASE Studies
wear ring seals exceeded IB side impeller wear ring with the opposing net damping evidence of force that the seals and the rubbing bearings generated together, the rotordynamic instability ensued. The first bending mode of the pumps rotor, which occurred at 98 Hertz, shifted to approximately 111 Hertz while the pump was in operation. The significant excitation which occurred at 95 Hertz, from supersynchronous fluid whirl, led to the entrainment of the nearby rotors lateral natural frequency that enabled unstable response of the shaft vibration at the super-synchronous frequency.
Ru bb in g
Case wear ring rub only between 9 and 12 O'clock as viewed from the NDE or OBB Figure 13: Images of the pumps rotor recorded during the visual inspection.
Autospectrum (Signal 8) - Mark 1 (Magnitude) \ FFT Analyzer

1 0.5 0.2 0.1 50m 20m 10m 5m 2m [in/s] 1m 500u 200u 100u 50u 20u 10u 5u 2u 1u
A POTENTIAL SOLUTION WAS AT HAND
1x rpm
Cursor values X: 59.250 Hz Y: 8.510m in/s
A successful solution to the rotor instability problem was devised, based on collaborative discussions with the pump OEM. The solution consisted of the addition of swirl breaks to the wrap-around" coke-crusher case wear ring. The swirl breaks took the form of radial vanelets, which were generated through the machining of slots in the case wear ring of the pump. The removal of the material from the case wear ring to create the 18 equally spaced slots formed vanelets that had a width-to-depth ratio of 1:2. Four equally distributed slots were machined circumferentially at the bottom of the turn-around pocket, and the ID side of the case wear ring also was modified to have between two and three degrees of draft angle, so the exhausting flow rotation was slowed down by the opening gap, dropping its rotational speed away from the shafts bending natural frequency.
OBB Vertical Overall: 0.05 in/s RMS
40
80
120
160
200
240 280
320
360
400
[Hz]
Figure 14: Similar to figure 3, a trace of the velocity response in the vertical direction at the outboard bearing of the modified pump. Unlike in the earlier figure, the super-synchronous vibration has disappeared and the overall vibration level has been reduced dramatically.
THE SOLUTION WAS VERIFIED AS EFFECTIVE
Autospectrum (Signal 3) - Mark 1 (Magnitude) \ FFT Analyzer

0.2 0.1 50m 1x rpm 20m 10m
Immediately after the pump was reassembled, a limited range of vibration testing was performed by the pump OEM to verify how effective the wear ring modifications were at mitigating the supersynchronous pump vibration. Quickly it became apparent from the results of the testing that the wear ring modifications were successful (figures 14 through 16). Not only had the super-synchronous vibration disappeared, but the overall vibration from the bearing housing and the shaft were less than one quarter of their previous excessive levels. This confirmed that a rotordynamic instability had excited the first bending mode of the double suction pumps rotor and was the root cause of the pumps excessive vibration. This type of unstable operation could not have been predicted analytically through typical rotordynamic analysis. A detailed CFD analysis of the wear ring would need to have been performed to uncover this form of excitation, which is an expensive
16 | FEBRUARY 2013
Cursor values X: 59.250 Hz Y: 0.404 mil
[mil]
5m 2m 1m 500u 200u 100u 50u 0 40 80 120 160 200 240 280 320 360 400
~110 Hz IBB Proximity Probe Y: 1.1 mils pk-pk @59.3 Hz
[Hz]
Figure 15: Similar to figure 4, a trace of the vertical displacement response of the modified pump at the inboard bearings proximity probe verifies the effectiveness of the swirl breaks that had been added to the wear ring. www.modernpumpingtoday.com
www.yaskawa.com
Radial Proximity Probes

~9.0 mils pk-pk
Orbit (Signal 14, Signal 14) (Nyquist) Working : 1159 GPM Linear Rec 15 OK : Input : FFT Analyzer
~9.5 mils pk-pk

Orbit (Signal 16, Signal 17) (Nyquist) Working : 1159 GPM Linear Rec 15 OK : Input : FFT Analyzer
[mil]
[mil]
[mil]
[mil]
OBB
IBB
Radial Proximity Probes

~2 mils pk-pk Mostly Run-Out
Orbit (Signal 1, Signal 2) (Nyquist) Working : 1164 GPM Rec 11 : Input : FFT Analyzer
~2.1 mils pk-pk Mostly Run-Out

Orbit (Signal 3, Signal 4) (Nyquist) Working : 1164 GPM Rec 11 : Input : FFT Analyzer
[mil]
[mil]
[mil]
[mil]
OBB
IBB
Figure 16: Comparison of the radial displacement responses (mils) at the inboard and the outboard bearings, which were recorded by the radial proximity probes during the before and after vibration monitoring of the pump.
and uncommon practice. Once the problem occurred, comprehensive vibration testing, including modal testing while the pump operated (as performed by the authors company) was able to diagnose the problem in sufficient detail that a solution could be prescribed. Swirl breaks were introduced to disrupt the fluid whirl and the non-axisymmetric pressure distribution that had previously been established in the wear rings during the pumps operation.
After the prescribed modifications to the wrap-around wear ring were implemented, the super-synchronous vibration completely disappeared. The overall vibration levels which had been recorded at the pump bearing housing and at the pump shaft were less than one quarter of their previous magnitudes, and fell considerably below the recommended 0.12 inches per second RMS vibration limit of the API 610 specification.
FEBRUARY 2013
17
CASE Studies
Figure 1: Dewatering boxes are a mobile solution for remote locations in need of filtration.
Perforated Plate dewatering boxes helP the PumPing and filtration industry clean our water
By Jeff Kaminsky, Accurate Perforating
very day in various industries throughout the United States, billions of gallons of our most precious resource are used and often wasted in order to produce something or support the manufacturing process. That precious resource is water. Contaminated water needs to be cleaned and, in many cases, the water needs to be cleaned on or near the job site. Often the job site is in the middle of nowhere and far away from large filtration plants or other infrastructure.
FRACKING AND WATER CONTAMINATION
Fracking is one of many industries that uses a large amount of water. Fracking is a technique that uses pressurized fluid to release petroleum, natural gas, or other substances for extraction. Water is pumped from rivers, lakes, and streams and used in the oil and gas industry for fracking or other energy related ventures. Water can also experience various levels of contamination as run-off from rain water
About the Author

Jeff Kaminsky is the national sales manager for Accurate Perforating, who offers a breadth of materials, patterns and finishes, customization, and specific capabilities to meet the needs of architects, OEMs, and service centers. He can be reached at 773.823.5050 or 800.621.0273 x310 or via email at jkaminsky@accurateperforating.com .
18 | FEBRUARY 2013

to agricultural contamination to raw sewage from floodingsuch as that from the recent floods from Hurricane Sandy. Either way, local municipalities, states, and even the federal government are requiring industry to clean and recycle the water that they use. And many industries are doing their part. In recent years, the fracking industry has received increased attention for this issue. According to drilling industry website GoMarcellusShale. com, a two drilling pad fracking site will use an estimated 12 million gallons of water. Even though that water is replaced naturally by rainfall in a two- to three-week period, the water that has been used still needs to be sufficiently cleaned before it can be returned to its natural environment. When we consider the droughts throughout much of the country this past summer, that amount of clean water becomes even more important to everyone. Another problem that needed to be addressed was how to handle the large volume of contaminated water that needs to be cleaned. That water needs to be pumped, is usually under pressure, and often contains large, heavy rock-like contaminants that can severely damage equipment. Accurate Perforating has been working with its customers in the pumping and filtration industries to help clean and recycle water long before it was popular to do so.
www.yaskawa.com
and contaminants efficiently and cost effectively. In the application in figures 2 and 3, Accurate Perforatings team of engineers developed unique tooling and perforated pattern that can perforate heavy steel plate from 3/16-inch (4.76 millimeters) thick to 1/4-inch (6.35 millimeters) thick. Accurate Perforating offers a tooling library with thousands
solid contaminants are pumped into a container. The perforated plate can be used to line the entire inside of the dewatering box as is the case in figures 2 and 3, or the perforated metal plate can be used to strengthen and support other filter media. In all cases, perforated metal plate allows the dewatering boxes to process large volumes of liquids
PERFORATED PLATE: PART OF THE SOLUTION
Accurate Perforating has a team of engineers and designers who work directly with their customers engineers to design the best perforated metal solution. The custom made perforated plate is a major part of the solution. Perforated plate, or perforated metal, is durable, long lasting, and allows engineers to control the flow of pumped materials. The perforated plate offers what is referred to as load support, as it can withstand the heavy sediments and solids that are pumped into large containers called filter shells, or dewatering boxes, which are mobile and able to be trucked to industrial sites in urban and rural areas alike. Other metals, such as expanded metal, are not able to offer control of the open area or structural integrity as they cannot retain their form when heavy sand, rock, and other
FEBRUARY 2013
19
CASE Studies
Figure 2: Perforated plate lining offers greater control than expanded metal.
Figure 3: A view inside a dewatering box using perforated plate.
of patterns suitable to work with a wide range of metals and gauges. Although perforated metal is typically made from carbon steel or stainless steel for heavy screening and filtering applications such as the dewatering boxes, it can also be made out of aluminum, galvanized,
and other metals for other screening and filtering applications. Once the perforated metal is made, it can be cut to size and welding to the dewatering box where it is then painted or coated. The consistency of the round holes in the perforated metal offers an added value by
allowing for easy cleaning of the dewatering boxes and helps to prevent debris from getting caught.
Accurate Perforating manufactures perforated and fabricated metal in
A VARIETY OF FILTERING APPLICATIONS
20 | FEBRUARY 2013
www.yaskawa.com
Figure 4: Exterior of a high volume dewatering container.
Figure 5: Interior of a high volume dewatering container.
the United States exclusively and can ship anywhere in the world. Perforated metal is used for thousands of OEM applications from dewatering boxes to filter baskets to aeration screens to guards and generator enclosures just to name a few. With air, water, and oil filtration, perforated metal is commonly used to support the filtration media while under intense pressure. Accurate Perforating works with engineers and designers to control the open area and flow by controlling the hole pattern. Some of the more common applications for filter shells or dewatering boxes using perforated metal plate include Potable water filtration for cleaning water from water wells for potable water in the desert areas. Dewatering the water and sand from active oil wells or reclaiming fracturing fluids from fracking units and recycling the flowback water for re-use. Removing the silt and clarifying the water from very large water dredging projects allowing waterways and shipping lanes to remain active. Raw sewage treatment facilities use perforated metal to screen intake flow from deep channels and pumping stations so that the
sewage water can be processed into secondary and tertiary filtration systems. In each application, the operators and engineering team needs to quickly and efficiently remove or separate solids and other heavy contaminants from the water. The water then needs to be pumped through high volume dewatering or filtration containers (such as the ones in figures 4 and 5) in order to clean and drain off fluids from contaminates. The water can then go on to be further processed and treated for recycling, while the non-liquid contaminants become sludge and other solids as the liquids continue to be removed. Landfills require solid materials and often times they wont accept liquids in order to meet federal and state regulations. The costs to transport and treat liquid waste become very costly to our infrastructure, our environment, and to the bottom line of many projects. Accurate Perforating has over seventy years of experience manufacturing perforated metal. That experience provides us with hundreds of tools that can be configured to offer thousands of different patterns in material as light as 24 gauge and as heavy as inches (12.7 millimeters) in widths up to 60 inches (1.52 meters). Not only can we produce perforated metal into custom coils, sheets, and blanks, we can fabricate and finish perforated metal into
a component thats ready to be installed.
Perforated metal is used in air diffusers for the HVAC market, acoustical panels for noise control, support for water filtration media, generator enclosures, and architectural elements in building construction. These are just a few of the applications for perforated metal. This highly sustainable material can be produced from recycled materials and lasts for generations. When its useful life is over, perforated metal can be completely recycled. Some metals such as stainless steel provide excellent corrosion resistance when left unfinished, or perforated metal can be finished with a variety of coatings to customize its appearance and further increase its longevity. The needs of manufacturers and metal fabricators are always changing, but the goal remains to bring the best possible product to market, on-time, and within budget. Accurates team of experts meets these needs through their close collaboration of engineering and logistics, an array of services, and responsive support from initial quote through final delivery. Although the process of filtration and dewatering can be very dirty, the results are spotless.
FEBRUARY 2013
OTHER INDUSTRY APPLICATIONS
21
WATER & WASTEWATER solutions
for a Common Water Treatment Plant Problem

Combining bearing carrier and shaft grounding ring mitigates electrical bearing damage in vertical pump motors
By Adam Willwerth, Electro Static technology
A New Hope
(VFDs), also known as inverters or simply as drives. VFDs can save 30 percent or more in energy costs, but, whether used to control a motors speed or torque, they often induce shaft voltages that discharge through the bearings, leaving fusion craterspits in the bearing balls and race walls. Concentrated pitting at regular intervals along a race wall can form washboard-like ridges called fluting, which causes excessive noise and vibration. By this time, bearing failure is often imminent. The cumulative degradation of bearings in VFD-controlled motors is well-documented and believed to be caused by repetitive and extremely rapid pulses applied to THE VERTICAL MOTOR the motor from a modern VFDs SOLUTION non-sinusoidal power-switching For six years, Scott Wilkins, circuitry. The many names used vertical hollow Shaft motor manager of motor shop operations to describe this phenomenon The proprietary Vertical Motor Solution developed at Independent Electric Machinery include parasitic capacitance, by Independent Electric Machinery Company uses a well-tooled, ceramic-coated carrier and an AEGIS Company (IEMCO) in Kansas City, capacitive coupling, and common Bearing Protection Ring to block and divert currents has overseen the reconditioning mode voltage. The costly repair that would otherwise damage motor bearings. of hundreds of these vertical or replacement of failed motor motors (most of which run pumps) bearings can wipe out any savings through the process. None of that a VFD yields and severely them has had repeat bearing failure. After replacing the ruined, diminish the reliability of an entire system. pitted bearings, his team installs a shaft grounding ring next The energy-saving potential of drives has led to to the motors guide (lower) bearing, and, using proprietary a dramatic increase in their use, especially in new techniques, applies ceramic insulation to the carrier that holds construction, Wilkins explains. We often see the problem the thrust (upper) bearing in place at the motors drive end. in the motors at new water or wastewater treatment plants, Although destructive currents can occur in any motor, for example. As a result, general contractors and consultingWilkins reports that most of the bearing damage he sees is in specifying engineers (CSEs) frequently end up with unhappy motors controlled by energy-saving variable frequency drives customers, who discovered only after bearings failed
hrough trial-and-error and much hard work, a Kansas motor repair shop has developed a virtually foolproof process for protecting vertical hollow-shaft motors from electrical bearing damage caused by stray shaft currents. Vertical pump motors are commonly used in the water/wastewater industry, so this problem is a recurring concern at treatment plants around the world. However, a new technique, known as the Vertical Motor Solution, offers optimism in the face of this persistent risk that some water and wastewater engineers had accepted as inevitable.
About the Author

Adam Willwerth is the sales and marketing manager for Electro Static Technology. He can be reached at 207.998.5140 or by fax at 207.998.5143. For more information, visit www.est-aegis.com .
22 | FEBRUARY 2013
that most warranties do not cover electrical bearing damage. This leads to a lot of finger pointing, and typically the CSE and the end user get stuck with the repair costs.
IEMCO frequently retrofits brand new motors before they are put into service. Wilkins has even performed the Vertical Motor Solution for some SPREADING THE WORD motor manufacturers, who have sent In December 2011, while continuing to him complete new motors or motor service motors from its own customers, components prior to shipping them to IEMCO for the first time offered its end users. Vertical Motor Solution to a distributor, A carrier from a vertical pump motor, coated with ceramic We have seen an increase in specs the Philadelphia-based Bartlett Bearing insulation by Independent Electric Machinery Company, that include shaft current mitigation Company, Inc. The relationship appears using proprietary techniques. for VFD-driven motors, says Wilkins. to be mutually beneficial. Sometimes, the OEM or the general We often have our customer send contractor might not catch it in the bid, and it has to be fixed the carriers from motors that have experienced bearing later, to equip the motors with what was specifiedbetter damage to Scott Wilkins, says Bill Potts, Bartletts vice president of operations. In addition to applying the ceramic late than never. coating, he checks each carrier for mechanical integrity The elephant in the room is the growing awareness throughout the industry that these motorsall motors, in (axial and radial runouts) and maintains the correct finished factcould be built to withstand shaft currents in the first bearing tolerance. We benefit from his knowledge, his place. A few forward-looking motor manufacturers have experience, his expertise, and his workmanship. He does recently added the AEGIS SGR Bearing Protection Ring a fantastic job, like nothing else Ive seen in the industry, including the motor manufacturers. the same brand IEMCO usesas a standard feature on certain models, but retrofitting is still the most common way As for the motors guide bearing, Bartlett offers the AEGIS to prevent electrical bearing damage. shaft grounding ring in addition to options such as insulated
GROWING AWARENESS
Sadly, some of the failed motors IEMCO has reconditioned were originally marketed as inverter-rated, inverter-duty, or inverter-ready models. The perturbed users who purchased them did not understand that most of these motors have extra insulation to protect the windings but nothing to protect the bearings.
FEBRUARY 2013
23
WATER & WASTEWATER solutions

bearings (most commonly coated with ceramic, but sometimes with another nonconductive compound) and hybrid bearings with ceramic rolling elements. When using insulated bearings, shaft grounding rings are recommended to divert the bearing currents to ground, thus protecting attached equipment. Whether installed by IEMCO, a contractor, or the end user, the AEGIS ring should be mounted internally, to the lower bearing retainer or cap, Potts explains. Depending on the size and shape of the retainer/cap, Bartlett Bearing recommends one of three mounting methods: press fit, bolt through, or top hat. In the top hat method, a special fixture is created for the bearing retainer/cap, and the ring goes in the fixture. Whenever we have used an AEGIS ring in this formula, weve had 100 percent satisfaction, says Potts. We sell to HVAC contractors and to end users, but we deal primarily with over 1000 electric motor repair shops that are trying to solve end-user problems created by VFDs. So we get IEMCOs services and the AEGIS ring in front of the faces of a lot of potential customers. Not all of the shops that get bearings from Bartlett use IEMCO, however. Willier Electric, in Gibbsboro, New Jersey, coats the carriers themselves. Jim Willier tells of a municipal water supply plant with six 150 horsepower vertical solid-shaft pump motors that were plagued with recurring fluting of the bearings. Insulating bearings on the top and bottom, and other methods, never worked, he says. Willier then tried something new, installing the AEGIS ring at the lower end of a motor, with a brass insert to make sure the ring was centered and protected from bearing grease. Williers crew also applied an extrathick ceramic coating to the carrier at the upper end of the motor. Two of the six motors were upgraded this way and reinstalled early in 2012. So far everythings been workingno complaints, says Willier. The end user plans to upgrade the rest of the motors as they come out of service. Now, when we sell a new vertical pump motor and a drive together, we sell them with the insulated carrier and the AEGIS grounding ring, Willier adds. Based outside of South Bend, Indiana, Precision Electric, Inc., sells and services electric motors and industrial electronics. The company also designs and carries out automation projects. Most of their customers are in northern Indiana and southern Michigan. For two ailing vertical hollow-shaft pump motors (60 and 150 horsepower) at a municipal water plant, Precision Electric sent the carriers for the top (thrust) bearings to Bartlett Bearing, which shipped them to Kansas City for IEMCO to coat and machine. It doesnt mean we wont do it ourselves in the future, says Kerry Dodd, Precisions vice president and coowner. Were just not geared up to do it right now.
24 | FEBRUARY 2013 www.modernpumpingtoday.com
MORE SUCCESS STORIES
Taken from a failed motor, the fluted bearing race wall on the left resulted from inverter-induced bearing currents. Protected by an AEGIS SGR Bearing Protection Ring, the bearing race on the right is undamaged.
An AEGIS Bearing Protection Ring, mounted in the lower bearing retainer of a vertical pump motor.
Dodds shop did replace the motors upper and lower bearings. In addition, the lower bearing caps were machined with a press fit and AEGIS rings installed. It solved the problem, says Dodd. This customer was going through bearings like crazy, and we had actually measured significant shaft currents. Once we made those modifications, the currents were gone. Both motors have been running fine since. According to Dodd, the water plant intends to rotate out four more motors for the same fix.
Field emissions of electrons: Field emission is a form of quantum tunneling whereby electrons move through a barrier in the presence of a high electric field. It provides grounding across gaps of 2 nm to 5 m. Townsend avalanche of gaseous ions: This process results from the cascading effect of secondary electrons released by collisions and the impact ionization of gas ions accelerating across gaps greater than 5 m. These noncontact nanogap processes provide highly effective electron transfereven in the presence of grease, oil, dust, and other contaminantsand are unaffected by motor speed. Because no other grounding product works with both contact and noncontact electron transfer, no other product offers the long-term, maintenance-free performance of the AEGIS ring. Virtually all VFD-driven motors are vulnerable to bearing damage, and their widespread use means that virtually all water and wastewater facilities are vulnerable to breakdowns and exorbitant repair costs. To make the savings generated by VFDs sustainable, an effective long-term method of shaft grounding is essential. Although an AEGIS ring safely bleeds damaging currents to ground, vertical pump motors need something more. Some carriers conduct electricity, but Wilkins is convinced that a carrier should be electrically isolated, disconnecting the motor from the pump shaft electrically though not mechanically. In addition to protecting the motors thrust bearing from
Key to the AEGIS Bearing Protection Rings effectiveness is its patented Nanogap Technology, which ensures superior contact/noncontact grounding protection for the normal service life of the motors bearings. The AEGIS rings unique design includes proprietary conductive microfibers arranged in a continuous circle around the motor shaft, providing hundreds of thousands or even millions of contact and noncontact voltage discharge points. When the AEGIS ring is installed, its conductive microfibers overlap the motor shaft and, over time, slowly wear to fit the shaft surface perfectly, continuing to maintain excellent electrical contact throughout the life of the bearing. Electron transfer technology includes three distinct current-transfer processes that work simultaneously: Tunneling of electrons: This mechanism is based on the ability of electrons to tunnel across an insulating barrier, and works for gaps smaller than 2 nm.
AEGIS NANOGAP TECHNOLOGY
A LONG-TERM SOLUTION
electrical damage, this keeps shaft currents from jumping to the bearings of the pump itself, or to the bearings of a gearbox, tachometer, encoder, etc. Its the combination that does it, says Wilkins. The grounding ring does a great job, but the ring in a vertical motor is competing for the current that exists in the possible path of the thrust bearing. Weve found that in vertical applications the thrust bearing can be a lower-impedance path to ground, because of the Hertzian point contact of the thrust bearing and the load that it is placed under. So we have to eliminate that current path via insulation on the carrier. Many motor manufacturers and repair shops use carriers fabricated from inferior metals, inappropriate coatings, or application protocols that fail to provide long-lasting protection. To apply the coating of ceramic, IEMCO uses a tightly controlled flame-spray welding procedure. To minimize subsequent wear on the coated surface, proper bearing fit is of the utmost importance, so Wilkins team grinds each newly coated carrier to very tight tolerances. The finished carrier has a hardness of Rockwell 50C and provides a resistance of more than 1 gigohm at 1000 volts. The National Electrical Manufacturers Association (NEMA) standard for carrier isolation is only 1 megohm at 500 volts. IEMCO is by no means the first motor repair shop to realize that coating the bearing carrier with an insulating material is a good idea. But it may be the first shop to do it right. Frankly, its a technique that we feel we have perfected, says Wilkins. With a vertical hollow-shaft motor, after weve added the grounding ring and upgraded the carrier, the motor is truly inverter-ready.
FEBRUARY 2013
25
MAINTENANCE solutions
Part 2
i n a p a r t 4 - P s e r i e s
breaking the cycle part of pump repairs two

By heinz P. Bloch, Process machinery Consulting
ecall that this 4-part series of articles deals with avoiding the cycle of pump repairs. if your facility encounters repeat failures, the plant and its staff have perhaps not found the true root causes of the problem (see references 1 and 2). alternatively, someone knows the true root causes and has decided not to do anything about the situation. since there are only these two possibilities, you may move on and seek redress. here are some more items to pursue or investigate.
About the Author

Heinz P. Bloch, P.E., is one of the world's most recognized experts in machine reliability and has served as a founding member of the board of the Texas A&M University's International Pump Users' Symposium. He is a Life Fellow of the ASME, in addition to having maintained his registration as a Professional Engineer in both New Jersey and Texas for several straight decades. As a consultant, Mr. Bloch is world-renowned and value-adding. He can be contacted at heinzpbloch@gmail.com .
26 | FEBRUARY 2013

The vulnerability of operating certain pumps in parallel is not always emphasized by pump vendors. There are problems with short elbows near the suction nozzle of certain pumps and flow stratification and friction losses are sometimes overlooked. Some sources advocate a minimum of 5, others advocate a 10-diameters equivalent of straight pipe run at the pump suction. Collective piping issues make up our Point 2. The tie-in between the lack of conservatism in piping and issues of less-thanadequate pump reliability is tenuous; still, the multipoint trouble illustration (our earlier figure 1 in Part 1) is of interest here. Suffice it to say that tight-radius elbows and their incorrect orientation can quickly wreck doubleflow pumps. Neglecting piping issues can be a costly mistake, but this is not a piping tutorial.
www.motionindustries.com
Therefore, its not just hydraulics, metallurgy, and driver selection. Start with a proper specification and put vendors on notice that you have good reasons to ask for and pay for better pumps. Dont overlook the merits of testing, foundation, mechanicals (reasonable L^3/D^4 ratios), reliable bearings and lube application methods, low-risk couplings, and then soundly selected pump drivers. An over-emphasis on (initial) cost-cutting
called the drive end. Using different words, the drive end of a process pump is also called the mechanical assembly (see reference 3). It comprises shaft seal, shaft, bearings, bearing housing or frame, and drive coupling or sheave. The same reference, SKF, distinguishes the hydraulic assembly from the mechanical assembly. SKF includes in the hydraulic assembly the impeller or propeller, the suction inlet, the volute, and the seal rings (see reference 3).
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Avoid flow close elbows and wrong elbow orientation in double-flow pumps. Install pipe reducers the right way.
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Moreover, by listing Point 2 we simply wish to make you aware of hydraulic and flow separation issues. The flow velocity at the small-radius wall of an elbow will differ from that at the large-radius wall. And again, because these facts are generally well known and many symposia have been devoted to them, we will direct our discussion to pump mechanical or drive end (power end) issues. Our topic is failure avoidance. Every so often, we must remind ourselves of the basic question: Why do we have repeat pump failures and how can we avoid them?
WHY INSIST ON BETTER PUMPS?
The term better pumps describes fluid movers that are designed beyond just soundly engineered hydraulic efficiency and modern metallurgy. Better pumps are ones that avoid risk areas in the mechanical portion commonly
FEBRUARY 2013
27
Breathers
It will also discredit, or cast aspersions at, an entire profession. All involved parties should pay very close attention to lube application matters related to process pumps, which is our Point 3.
LUBRICATION ISSUES
As we examine figure 3, we can be certain of five facts: In figure 3, oil rings are used to lift oil from the sump into the bearings. These oil rings tend to skip and jump at progressively higher shaft surface speeds, or if not perfectly round, or if not operating in perfectly horizontal shaft systems. The back-to-back oriented thrust bearings of figure 3 are not located in a cartridge, which limits flinger disc dimensions (if they were to be retrofitted) to no more than the housing bore diameter. Bearing housing protector seals are missing from this picture (figure 3). Although the bottom of the housing bore (at the radial bearing) shows the needed oil return passage, the same type of oil return or pressure equalizing passage is not shown near the 6 oclock position of the thrust bearing. There is uncertainty as to the type or style of constant level lubricator that will be provided. Unless specified, the best one is rarely supplied on new pumps. As discussed, our considerations are confined to lubrication issues on process pumps with liquid oillubricated rolling element bearings. Bearing housings with liquid oil reaching to the center of rolling elements at the lowermost part of the bearing will be involved, as will housings with oil levels purposely maintained at much lower levels. Each has its purpose and limits. For now we will exclude sliding bearings although some principles do, in fact, apply to pumps with sleeve bearings. It should be noted that the angular contact thrust bearings in figure 3 will usually incorporate cages (ball separators) that are angularly inclined, which means they are arranged at a slant. These cages often act as small impellers, and impellers promote flow
Oil Rings
Figure 3: A bearing housing with several potentially costly vulnerabilities.
by pump manufacturers and purchasers has negatively affected the drive ends of many thousands of process pumps. Each party blames things on the other and its a fruitless argument to say any more. Still, flawed drive end (power end) components contribute to elusive repeat failures that often plague these simple machines. Pump drive end failures represent an issue that has not been addressed with the urgency it deserves. Please remember that repeat failures can only happen if the true root cause of failure has remained hidden or, if the true root cause is known, someone decided not to do anything about it. Either of these two possibilities runs counter to the avowed goals of asset preservation and operational excellence. As to our nomenclature, please refer back to SKFs definition. They label as drive end the mechanical assembly; a bearing housing with its bearings and bearing protector seals is a major component of the mechanical assembly. SKF includes mechanical seals in the mechanical assembly, but excludes what it calls seal rings. We believe SKFs seal rings are really the throat bushing(s)a component closest to the impeller. For the sake of our tutorial, the driver is either an electric motor or a steam turbine. While located near the drive end, drivers are not included in our tutorial definition of drive end or mechanical assembly. The tutorial deals with process pumpsnotably API pumps.
28 | FEBRUARY 2013
User plants will usually get away with one or two small deviations from best available technology. But when three or more deviations occur, we usually increase failure risk exponentially. That said there are a number of reasons why a few well-versed reliability engineers are reluctant to accept pumps that incorporate the drive end shown in figure 3. The short overview of reasons is that reliability-focused pros take seriously their obligation to consider the actual, lifetime-related and not just short-term, cost of ownership. They have learned long ago that price is what one pays, and value is what one gets. Anyway, while at first glance the viewer might see nothing wrong, figure 3 contains a few clues as to why many pumps tend to fail relatively frequently and often randomly. The illustration shows areas of vulnerability, and not eliminating these vulnerabilities is a costly mistake. Allowing these risk increasers to exist will sooner or later hurt the profitability of users and vendors alike.
DEVIATIONS FROM BEST AVAILABLE TECHNOLOGY
POINT 3
Oversights can affect lube application.
from the smaller towards the larger of the two diameters. This is more readily evident from figure 4, and particular attention should be given to windage created by the impeller-like air flow action of an inclined bearing cage. In many cases, the pump manufacturer places an oil ring to the left of this bearing. Note that the design intent is for oil to flow from left to right.
As it tries to flow from left to right the lubricant is often opposed by windage Windage in AC bearings can effects that act from right to left. oppose oil flow. So, whatever oil application method is chosen, it will be necessary for the lubricant to overcome this windage. Windage is thus our Point 4, and we must ask: How does one alleviate windage and its effects? The fact that windage may be generated by some of these bearings and is more likely found in particular bearing housing configurations requires thoughtfuland sometimes purely precautionary abatement of unequal pressures inside a bearing housing.
POINT 4
40
REDUCING RISK, SAVING YOUR PUMP
Figure 4: Attempts to apply lubricant in the direction of the arrow (oil flow from left to right) meet with windage (air flow right-to-left) from an inclined cage. The two directions often oppose each other (Source: SKF America, Kulpsville, PA).
Consider the comparison of lubricant application via sump level reaching lowermost bearing elements versus lower oil level needed to prevent oil churning and overheating. Before we progress further into the topic, note how carefully now defunct Worthington Pump Company made sure the pressures surrounding all bearings were equalized. They went through the trouble of drilling balance holes right above the bearings (see figure 5). Do you have balance holes in your pump bearing housings? If not, then why not? Perhaps you dont need them, but then againmaybe you do. Its all about risk reduction.
ower
Vent Connection
Water Outlet Thrust B'R'G Thrust B'R'G Cover Lock Washer Oil Seal
OIL LEVEL Thrust B'R'G Nut Bearing Bracket Drain Oil Drain
FEBRUARY 2013
29
refinery in Sicily. The owners engineers had recorded bearing lube oil in four identical pumps Thrust B'R'G Thrust B'R'G Cover reaching an average of 176 degrees Fahrenheit (80 degrees Celsius) Lock Washer with cooling water in the jacket passages. Oil Seal Without cooling water, the lube oil averaged 158 degrees Fahrenheit (70 degrees Celsius), which OIL LEVEL is 18 degrees cooler (10 degrees cooler Celsius). The bearings now lasted Shaft much longer and we Thrust B'R'G Nut shared these findings with Oil all those that were willing Seal to read, or willing to listen. They were included Bearing Bracket in many books and presentations. Today, forty-five years Oil Drain Drain Water Inlet later, not everybody has acted on the message. That is why cooling water Figure 5: The oil level in this 1960s-vintage housing was set for low-to-moderate speed pumps. Oil throwers create a spray that overcomes windage; the two throwers also prevent oil stratification. Pressure equalization passages are drilled near the top of all bearings issues are listed here (see reference 2). as Point 5. Dont waste this precious resource! By way of overview, we note that rather similar in different bearing Realize, please, that cooling water one of the oldest and simplest methods sizes typically used in process pumps. is very often responsible for actually of oil lubrication consists of an oil bath This allowed these users to focus on reducing the life of rolling element through which the rolling elements a simplified approximation, DN, the bearings in process pumps (see will pass during a portion of each shaft product of shaft diameter (D, inches) reference 4). revolution (see figure 5). times revolutions-per-minute (N, rpm). However, this plowing through Whenever DN exceeds 6000 and so as the oil may cause the lubricant to to avoid risking excessive heat buildup, heat up significantly and should be oil levels reaching the ball center avoided on susceptible process pumps. or the lower third of the lowermost Excessive heat generation results if rolling element are considered a Cooling water can cause dn, the bearing's case diameter (mm) churning risk. In that case, some other bearings to run hot. multiplied by shaft rpm, exceeds a means of lifting oil into the bearing are particular number. That 6-digit number chosen. ranges from 150,000 to perhaps 300,000. It is predetermined by A PRECIOUS RESOURCE bearing manufacturers who estimate Note also the cooling water jacket in at what point churning and heat figure 5. Bearing housing cooling is REFERENCES buildup will exceed desired limits. not needed on process pumps which 1. Taylor, Irving; The Most Persistent PumpThe manufacturers then advocate incorporate rolling element bearings. Application Problems for Petroleum and Power Engineers, ASME Publication 77-Pet-5 (Energy lowering the oil level so that it no Cooling is harmful if it promotes Technology Conference and Exhibit, Houston, longer contacts the rolling elements. moisture condensation or restricts Texas, September 18-22, 1977) In essence, as a certain dn threshold is thermal expansion of the bearing 2. Bloch, Heinz P.; Pump Wisdom, (2011), exceeded, some other means of lifting outer ring (see reference 2). When, John Wiley & Sons, New York, NY (ISBN oil into the bearing must be chosen. in 1967, these concerns were seen to 9-781118-041239). Fortunately, and aiming to stay influence pump reliability, the jacketed 3. SKF USA, Inc.; Bearings in Centrifugal within the inch-system preferred by cooling water passages in figure 5 Pumps, (1995), Publication 100-955, Second pump users in the United States, were left open; the passageways were Edition. a number of users and bearing from then on flooded by the ambient 4. Bloch, Heinz P. and Allen Budris; Pump manufacturers found that the ratios air environment. This no more Users HandbookLife Extension, Third of bearing outside diameters (OD) cooling water decision was reached Edition (2010), Fairmont Press, Inc., Lilburn, GA 30047 (ISBN 0-88173-627-9). and implemented in 1967 at an oil to bearing inside diameters (ID) are
Water Shield
Line Bearing
Oil Thrower
Vent Connection
Water Outlet
POINT 5
30 | FEBRUARY 2013
PUMP solutions
Laying the groundwork for the next generation of centrifuge technology

By michael Kopper and Robert g. havrin, Centrisys Corporation
oday, the decanter centrifuge is the design of choice for pool surface resulted in recycling a portion of the solids back centrifugal thickening. This is due in large part because into clarification section of the bowl. These effects resulted in of the emergence of enabling technologiesthat is, the an inefficient use of the bowl geometry generating thicker cake hydraulic assist method and, to a lesser extent, improved hard solids at reduced capacity and levels of recovery. facing technology. Earlier decanter centrifuges were limited by conveyance efficiency and the impact this had on clarification THE HYDRAULIC ASSIST METHOD capacity. A schematic comparison of the enabling technology The hydraulic assist method (figure 1B) had a number of that resulted in the continuous decanter centrifuge replacing configurations the simplest of which was a circular baffle placed other thickening centrifuges is summarized in figure 1. at the intersection of the cylinder and conical section of the Prior to 1978, decanter centrifuges relied on shallow bowl with a slight annular clearance that selectively transported pool designs and reduced pitch conveyers running at higher thicker solids under the weir. The design was no longer limited differential RPMs by conveyance to discharge soft as cake discharge Figure 1: Enabling technology applied to Cd centrifuges. solids from the was at a greater centrifuge. This is radius than the Figure 1A: Pre-1978 Rotating Assembly Configuration schematically shown centrate discharge in figure 1A. The allowing cake pool depth needed solids to literally to be balanced to flow downhill. maximize buoyancy The impact of this effects but less than type of operation the solids discharge was later termed 8-10 depth to prevent short superpool because degrees circuiting of the feed of the performance to the cake discharge boost achieved. end of the centrifuge. Adjustments were Even then, capacity made incrementally Figure 1B: Post-1978 Hydraulic Assist Modification was limited by the by weir plates with as little as 0.02 inches flat sedimentation (0.05 centimeters) angle (cake solids gradient profile) change in the pool layered inside the diameter. Dual control of bowl characteristic of 10-15 the cake discharge lower viscosity solids. degrees This angle overlapped was now practiced. Course adjustment and interfered with was by weir level the clarification with mechanical conveyance fine tuning the desired cake zone of the centrifuge which takes place in a moving layer at thickness. Further, grit and trash at the periphery of the bowl the inner pool surface. And feed slurry introduction onto the
About the Authors

Michael Kopper is the president and Robert G. Havrin is the director of technology for Centrisys Corporation, an award winning, certified, global provider of separation equipment, parts, repair, and service. Learn more by visiting www.centrisys.us .
32 | FEBRUARY 2013
were conveyed while the biomass conveyed and flowed out of the bowl. The impact on process performance was dramatic. Cake solids were controllable while at the same time the recovery of insolubles increased and at significantly higher flow rates. No polymer performance became the desired mode of operation (50 to 100 percent higher capacity and without the use of polymer for the same size piece of equipment) and when polymer was added, this was seen to further increase the no polymer capacity by 50 to 200 percent with typically less than 2 #/ton db polymer. Concurrently, operation and maintenance were dramatically improved versus the pre-1978 thickening designs. Some of the benefits are listed as follows: 1. Reduced installation costs via a reduced floor space requirement. Specific areas of improvement as follows: a. Higher capacity per square foot of floor space. b. No need for pre-treatment devices such as screens and cyclones in the process layout. c. No need for polymer tanks and the space needed to inventory those supplies. 2. Reduced operating costs. This was primarily seen from: a. Elimination or 70 to 80 percent reduction in polymer costs versus earlier designs. b. Minimal operator attention via simplified process control. In most installations, all that was needed was to look at the cake solids and make a slight adjustment to the differential RPM. 3. Reduced maintenance costs: a. Dramatic extension of time between rebuilds due
to the use of improved hard facing technologies that is, Sintered Tungsten Carbide (STC). b. Many of the initial installations ran 24/7 for years with only occasional shutdowns to periodically grease the conveyer bearings. c. Automated controls with a closed system which eliminated the need to manually clean the equipment.
ORIGINS OF HYDRAULIC ASSIST TECHNOLOGY
The first generation of hydraulic assist technology was known as the Polymizer BD design and manufactured by Sharples. A full range of municipal WAS processes was explored confirming no polymer, commercial performance levels from 18 to 85 gallons per minute (68.14 to 321.76 liters per minute) based on pilot plant testing for the same unit (16 D x 54 L inches; 42.56 D x 137.16 L centimeters). In addition, the unit could run at flow rates up to 120 gallons per minute (454.25 liters per minute) with typically less than 2 #/ton db polymer. For the largest size unit of that time period, the performance difference is summarized in Table 1 as follows: The performance difference was so dramatic, hydraulic assist technology quickly eliminated both VBC and HSD from future market considerations. Further, this design had the ability to both thicken and dewater. In less than five years, however, a new centrifuge technology emerged to challenge the design and was a way around the patent on the hydraulic assist. This technology was the Humboldt Type B nozzle bowl decanter centrifuge.
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PUMP solutions
table 1
Comparison of Hydraulic Assist to Pre-1975 Was Thickening Technology

CONTINUOUS DECANTER PRE 1978 PROCESS PERFORMANCE Feed Rate, GPM/unit max Recovery of Insolubles, % w/w Cake Solids, % w/w ts Polymer Dosage, #/ton db No Polymer Performance Performance with Polymer NA 10-20 0 6 200-300 +90 6-12 600 +85 5-6 1000 90 5-6 No Polymer CONTINUOUS DECANTER HYDRAULIC ASSIST Polymer
MECHANICAL RELIABILITY Downtime Maintenance Costs Operating Costs Medium Medium High Low Low Low Low Low Low
HUMBOLDT TYPE B
The Humboldt Type B nozzle bowl decanter centrifuge was introduced to the market in the early 1980s (see figure 2 schematic). In contrast to the hydraulic assist, the Type B centrifuge was a lower speed, concurrent flow, deep pool design (for thickening only). However, the most unique operating feature was the dual solids discharge mechanism built into the design. The Type B used
a windowed wiper and nozzle in place of the hydraulic assist as well as a steeper angle conical section for discharging the large amorphous trash. The windowed wiper was positioned at the same axial location as the the hydraulic assist but with tighter clearances and a thicker width. The outer radius of the disk had a slot and wiper assembly. The slot opened periodically with the differential rpm to wipe the nozzle clear of any obstruction
Figure 2: humboldt type B thickening centrifuge
30-60 degrees
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before rotating to the open window where bio-solids passed through a restricted orifice. This arrangement allowed nozzle sizes between 0.2 to 0.5 inches (0.51 to 1.27 centimeters) ID to be used on equipment. To further increase capacity, the design gambled on using a steeper cone angle for conveying large amorphous trash and grit from the system. The mid 1980s set the stage for the high water mark of centrifugal thickening technology and innovation. These two designs competed briefly and intensely for several years in high profile, winner take all, sideby-side competitions around the country. In the end, the hydraulic assist design won the battle as measured by the test of time. However, there was insufficient technical evidence to conclude the superiority of one concept over the other. Side-by-side testing filtered through the marketing hype to expose technical weaknesses
in both of the designs. Thus, the stage was set for the next step in the evolution of thickening centrifuges to emerge. However, it did not.
ROADBLOCKS TO INNOVATION
Corporate takeovers, downsizing, and new methods of business management devastated the core competencies of both groups. In short, the philosophy of everyone is going out of business, so the last person standing wins left little resources available for the expensive research needed for centrifuge development. And a dark age emerged in the industry relative to revolutionary product development replaced instead by marketing claims which did little more than re-invent the wheel. The by-product of this stagnation was the loss of market share to gravity belt and rotary drum thickeners. Instead of developing improved technologies, revolutionary designs included marketing claims (a) repeating the mistakes of the past by taking risks on the beach angle to increase the clarification capacity of the design, (b) adjusting the weir level while operating to overcome transient accumulations of trash, and (c) the development of proprietary technologies which worked in theory but rarely delivered in the field. However, these problems are too real to be ignored, and in our next article, we will discuss a new generation of sludge thickening technology: the THK 23, the Centrisys re-interpretation of the synergistic hybridization of the hydraulic assist and Type B continuous decanter centrifuge. REFERENCES
1. Townsend, Joseph R., What the Wastewater Plant Engineer Should Know About Centrifuges, Water and Waste Engineering (November and December 1969). 2. Moll, Richard T. and Letki, Alan G., The Role of Centrifuges in Minimizing/Eliminating the Use of Chemical Additives in Dewatering and Thickening of Industrial Wastes, 34th Annual Purdue Industrial Waste Conference, May 810, 1979. 3. Letki, Alan G., New Developments to Reduce Operating Costs of Centrifuges for Thickening and Dewatering Municipal Sludge, New York Water Pollution Control Meeting, New York City, January 20, 1981. 4. Silverman, Stephen H., The Humboldt Type B Centrifuge: An Effective Tool for Sludge Thickening, Humboldt distributed marketing paper (February 1984).
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PUMP solutions
Harness the Power of Hydraulics

Hydraulically driven submersible pumps offer advantages over electric alternatives
By Andy Falco, hydra-tech Pumps
andy, Katrina, Hugo, and others provide head-shaking reminders of the immense power of water and fluid dynamics. The scenes of cars, houses, or entire neighborhoods being swept aside by rising waters can be terrifying, but the courage of first responders and the resiliency of storm survivors can be equally inspiring. Surely, similar weather events must have played a role in inspiring our forbearersin places like Greece, China, Sri Lanka, and Ancient Rometo harness this liquid energy for positive purposes. This process continues even now. As we learn the lessons of the past, engineers are better able to diagnose problems that may have stymied their predecessorsoften leading to advancements in technology or applying existing techniques in new and exciting ways. In todays demanding applications requiring pumping of water, oil, sewage, sludge, and slurry, hydraulically driven submersible pumps can offer a highly efficient alternative to electric submersible pumps, whether powered by a generator or hard wired to a power grid.
About the Author

Andy Falco is the general manager of Hydra-Tech Pumps. For more information, visit www.hydra-tech.com or call 570.645.3779.
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Solving pumping problems has been an engineering puzzle as old as human civilization, and each society has found an answer suitable to their own environment. Historical records show that the sixth-century Mesopotamians and Egyptians developed irrigation methods based on gravity and water flow. At around the same time, the Chinese designed a dam and reservoir system used to irrigate six million acres of landthe Peony Dam of ancient times, now known as the Anfeng reservoir, is still in existence today. In Sri Lanka, engineers developed the valve tower or valve pit, used to regulate water flow. And perhaps most famously, the Romans used watermills as a source of fluid power and engineered and built the Aqueducts. Much later, the 17th century work of Blas Pascal and the establishment of Pascals Law proved the theory of
A HISTORY LESSON
non-compressible fluids and the manner in which they transfer energy when force is applied. It was two hundred years before Pascals work led engineers in England and Australia to build hydraulic power grids with a central generating location piping water under high pressure to consumers like cranes in dockyards and presses in garments factories. Due to advances in electricity transmission, hydraulic grids fell from favor, but engineers still understood the value of hydraulic power and continued to advance the technology. During the early 20th century when mineral oils and other petroleum based oil began replacing water in hydraulic devices, this new power source became even more prevalent. In the same era, inventors found that using pumps to compress and force hydraulic oils through pump casings was an even more efficient way of using hydraulics. It was not long
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PUMP solutions
before these pumps were coupled to a gas or diesel engine and hydraulic power packs (as we know them today) began powering drive all types of machinery, including submersible pumps. have designs similar to electric submersibles in that the impellers are rotated by motors, but the modern hydraulic prime movers provide flow under pressure to turn hydraulic motors connected to the impellers with system efficiencies of 90 percent or better. A study undertaken by the Manufacturers Resource Center of the campus of Lehigh University found that an electric submersible being run by an engine driven generator will create a footprint of nearly 2000 CO2e, while a like sized hydraulically driven submersible will emit about 25 percent less carbon, or 1500 CO 2e. In more practical terms, the hydraulically driven submersible consumes about 25 percent less fuel while doing the same amount of work. The study found an even more dramatic difference when that same hydraulic submersible was compared to the same electric submersible connected to a grid (carbon footprint equals CO2e). Many would question these findings given the common school of thought that electricity is 100 percent efficient. However, although some electric devices like the incandescent light bulb are 100 percent efficient by themselves, tracing total efficiencies all the way back to the source tells another tale. In grid based systems, the inefficiencies of coal fired electric plants, wind plants, or solar power all have various inefficiencies. And, for both grid based and generator based electric power, transmission line losses due to resistance in the wire account for additional inefficiencies. For example, the US Energy Information Agency estimates that transmission losses average 7 percent in the US grid. In addition to grid losses, engineeringtoolbox.com points out internal electric motor inefficiencies caused by resistance, magnetic energy dissipation, and mechanical losses. For a typical NEMA B designed motor in the 20 to 49 horsepower range the efficiency is 89 percent. When coupled with grid losses, the reasons for the larger carbon impact become more evident.
MODERN FINDINGS
Hydraulically driven submersibles
A MORE EFFICIENT FUTURE
Compare the systems described above with the typical hydraulically driven submersible pump. Many well designed hydraulic systems run at 90 percent efficiency on the hydraulic pump side. These high levels have a lot to do with the work of Pascals Law on the non-compressibility of liquids and its ability to transfer energy on a one-to-one basis. Although mechanical losses do happen in hydraulic pipes, hoses, and motors, in sum the hydraulic systems ability to effectively transfer the stored energy
in a fossil fuel into to mechanical energy surpasses that of the electric pump arrangement. Beyond basic energy consumption calculations are the practical advantages to using the hydraulically driven submersible pumps. The engine coupled hydraulic pump allows the operator to speed up or slow down the submersed impeller and thus the output of the flow of the pump system; this variable speed operation optimizes efficiencies as the system is regulated to meet pumping conditions. On the other hand, electric submersible pumps run either at their constant rated speed or not at all. In addition hydraulic submersible can run dry for long periods of time without fear of thermal overload. And perhaps most importantly the hydraulic submersible creates no shock hazarda danger always present with any electric submersible.
can fill geo-tubes and perform light duty dredging in canals and around boat slips. Having been used in areas as remote as Sierra Leone for creating village water sources to downtown Manhattan as part of the emergency response to super storm Sandy, hydraulically powered pumping
systems continue to build on their reputation as one of the most flexible and efficient means of moving clear water, dirty water and other pumpage. When faced with your next pump purchasing decisions, you should consider the full impact of the system from its effect on the environment to the effect on your bottom line.
VARIED APPLICATIONS
On the maintenance side, hydraulically driven submersibles require no specialized skills or tools for break down service; in most cases they are serviceable by field personnel; and labor costs are reduced since qualified or licensed electrical repair technicians are not needed. In practice, hydraulic submersibles have been used around the world by emergency responders to combat flooding in times of power outages. They are also used deep in mines and quarries for dewatering where intrinsically safe pumps capable of pumping to high heads are required. Several oil recovery companies use these pumps as part of their skimmers systems, using channel or screw impeller pumps to move heavy oils from their skimmers sumps to the barge or recovery bladder. On construction sites, solids handling hydraulic submersibles are popular because they are versatile enough to move a lot of water quickly, pump drillers mud and sludge, or act as booster pumps to help feed long range pumping systems. In the world of mining and dredging, the sand slurry pumps are capable of moving material from a well head in to a remote shaker system, or they can pump out bunkers with float switch operation or they
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DEWATERING solutions
n i g n i r e t a w De y c n e g r e m E an
Flooding Concern
By Jeff Schopperle, Xylem, inc.
and the damage from superstorm Sandy cost an estimated 110 lives and billions of dollars. Flooding water not only creates significant damage immediately, it can also have a long-term impact on buildings. The longer water soaks in, the more damage it will cause to structures and everything they contain. Mold is an important health concern and will grow on wet areas and behind walls. With rising waters, sewage can enter living spaces and the sooner untreated water is moved out the better for all. Experts agree that removing water quickly and as safely as possible is a critical factor in recovery operations following a flood. The National Council for Healthy Housing recommends that standing water be removed as soon as possible. Once the water is out, the building needs to be thoroughly dried and all water damaged articles should be discarded before reconstruction can take place.
looding impacts millions of people across North America. Water is needed for life, but it can also take lives. In the United States for example, 108 people lost their lives in flood-related deaths and the damage from floods totaled $8.41 billion in 2011 alone. That year there were recordbreaking floods along some of the nations largest rivers: the Missouri, Ohio, and Mississippi. Two tropical storm systems impacted densely populated portions of the Mid-Atlantic and the Northeast, hurricane Irene and the remnants of tropical storm Lee. These events, happening just over a week apart in late August and early September, combined to produce thirty-seven freshwater flood fatalities and at least $3.9 billion in direct freshwater flood damages from Virginia to Vermont. In late 2012, flooding impacted millions of people along the Eastern seaboard from hurricane Sandy. Especially hard hit were New Jersey and New York, where millions lost power
About the Author

Jeff Schopperle is a product manager at Xylem, Inc. For more information on Xylems Rule Evacuator Series, visit www.xylemflowcontrol.com/rule .
Fast water displacement is best done with a mechanical pump. Since most pumps rely on electricity or combustion engine to drive the action that will pull out floodwater, having a power source is critical. In an emergency situation power might be out and fuel sources are often in limited supply and may be needed to drive other emergency gear. In addition, the National Council for Healthy Housing cautions that to prevent carbon monoxide poisoning, generators and fuel powered pumps should only be operated outside of an enclosed space.
Centrifugal pumps consist of three main parts; a motor, a volute, and an impeller. The impeller is a disk with specially designed curved blades that push water coming into the center of the impeller outward. The rushing water is collected on the outside of the impeller in a specially designed chamber called a
volute which guides it to the pumps discharge. This is all powered by the motor which spins the impeller. Manufacturers can produce pumps that perform efficiently under conditions that can vary widelyfrom low flow rates with high head (or back pressure) to high flow rates with low head by changing the curvature of the
The key to moving water from one place to another is energy. But the challenge in an emergency is finding a power source to drive a pump. If the water needs to be pumped out from a basement or the hull of a boat, it will take extra power to move the water up and out to an area of less concern. In an emergency where lots of water needs to be moved quickly, only a powered pump will get the job done. Pumps that have a power source can move water fast and in a large quantity and removing water quickly and efficiently is the main goal. Therefore, its always a good idea to have a back-up plan that will provide power in an emergency. Even though water can be moved by gravity in a process called siphoning, this is typically very slow. To drain by gravity the inlet of a hose is dropped into standing water and the hose is stretched out such that the outlet is lower than the inlet. To initiate the flow suction is required at the outlet end of the hose, which can be done by drawn breath. While this may be an acceptable method to empty a fish tank, its not a very efficient, fast, or even a safe way to get water moving. This is why a backup plan should always include the right kind of pump and a safe and easy way to run it.
FLOOD EMERGENCY DEMAND EFFICIENT PUMPING
Pump efficiency is another important consideration for any emergency plan. One of the most efficient pump designs for water is a centrifugal pump. Centrifugal is based on a Latin phrase that means "fleeing the center," which is a pretty accurate description based on what the pump is doing to the water.
CENTERING IN ON PUMP DESIGN FOR EFFICIENCY
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DEWATERING solutions
blades on the impeller. Another way to think of the head is how high the pump has to push the water, for example a pump designed to pump water out of a well (high head) is hydraulically going to be a lot different from a pump designed to pump water out of a basement (low head). The pump designed to pump water out of a well should be designed so its more efficient at high head and conversely the pump designed to pump water out of a basement should pump efficiently at low head. By zeroing in on the conditions under which the pump is intended to operate designers can ensure that the blades move the water in the most efficient manner possible. Xylems Rule Evacuator Series was designed with this in mind. Although the Evacuator is still capable of pumping water at higher heads, it really excels in work environments
requiring fast, efficient removal of large concentrations of standing or flooding water. It was designed to efficiently pump out flooded basements, drain ditches, boats, and other relatively low head applications.
SELECTING AN EMERGENCY PUMP FOR FAST DEWATERING
Centrifugal pumps offer a simple design that seldom jams or clogs, which means little maintenance and upfront investment. They make a good choice for emergency pumping needs. In an emergency situation for example, a pump might need to be lowered into a confined space, even into an area that cant be seen or that has debris on top of it. Centrifugal pumps can run dry before they are put in the water, which
SPECIFICATIONS Voltage Flow Flow with included hose adapter Amp. Draw Protection Port Configuration Height Width Length Pump Weight Cable Weight Packaged Weight Packaged Dimensions Master Pack Qty.
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EV2000 12 VDC 2000 GPH (7570 LPH) 1700 GPH (7570 LPH) 12 Amps (approx.) Thermal Cut Off (TCO) 1.125 inch outlet (35 mm) (Includes adapter for " garden hose thread) 8" (203 mm) 6" (152 mm) 6 (165 mm) 3 lbs (1.4 kg) 3 lbs (1.4 kg) 7 lbs (3.2 kg) 15" L x 12" W x 10 H (394mm x 317mm x 267mm) 1
EV4000 12 VDC 4000 GPH (113250 LPH) N/A 20 Amps (approx.) Thermal Cut Off (TCO) 2 inch outlet (51 mm) 10" (267 mm) 5" (140 mm) 6 (178 mm) 5 lbs (2.5 kg) 3 lbs (1.4 kg) 9.5 lbs (4.3 kg) 15" L x 12" W x 10 H (394mm x 317mm x 267mm) 1
EV8000 12 VDC 8000 GPH (30283 LPH) N/A 30 Amps (approx.) Thermal Cut Off (TCO) for each motor 3 inch outlet (51 mm) 8" (215 mm) 12" (305 mm) 13 (343 mm) 11 lbs (5 kg) 4 lbs (2 kg) 18 lbs (8.2 kg) 15" L x 12" W x 13 H (394mm x 317mm x 343mm) 1
means they can be lowered into these areas. Once the pump reaches liquid the spinning impeller will start pumping. This means that centrifugal pumps can be used in places where it would be inadvisable to put other kinds of pumps.
A CRITICAL CHOICE
The criteria for selecting a pump to have on hand for an emergency should meet the following requirements: Ability to move the maximum amount of water Use as little power or energy as possible Be rugged in design and function
so that the need for maintenance is negligible Be compact and portable so they can fit into small spaces Be safe and simple to operate in any conditions The Evacuator Series is the portable pump of choice for handling unwanted pools of water in a crisis or anytime.
A PUMP THAT STAYS CALM IN A CRISIS
Developed in response to customer feedback, the Evacuator is a centrifugal pump product line that meets the criteria outlined above and more. The products are backed by Rules forty-five years of operational experience. The Evacuator Series offers high efficiency portable utility pumps. Designed as an alternative to gas, diesel or A/C electric powered portable pumps, the Evacuator Series excels in environments requiring fast, efficient removal of water. In times when power is scarce and water is high, the Evacuator is just the pump to remove or relocate unwanted water. An innovative power connection allows for direct operation from a vehicle's 12-volt battery, using two heavy-duty battery clips, and an inline on / off switch on the cable itself. The Evacuator Series comes in three capacity ratings to move water fast: 2000 gallons (7570.8 liters) per hour, 4000 gallons (15,142 liters) per hour, and a sizeable 8000 gallons (30,283 liters) per hour. The pumps offer a perfect collaboration between size and functionality. When attached to a running vehicles battery the Evacuator draws power directly from the 12-volt battery. A 25-foot (7.62 meter) cable assembly provides ample reach to a basement or boat thats flooded. The Evacuator pumps can all run dry for extended periods and the impeller design lets sand suspended in water be discharged along with liquids. It also has an impact resistant strainer to keep larger debris outside of its inner works. Its rugged ABS plastic housing and bright yellow body make the Evacuator easy to spot. Ideal for dropping into a flooded manhole or other areas where portability and maximum water movement is wanted, the pumps outlet ports can be three inches wide offering a big water displacement capacity. The Evacuator 8000s 30-amp motor has a circuit breaker for added protection and reliability.
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MOTOR solutions
By Robb dussault, Schneider Electric
he International Energy Agency predicts global energy demand will be double that of 2007 levels within the next forty years, and that CO2 Emissions will need to be cut in half to avoid dramatic climate changes (according to the Intergovernmental Panel on Climate Change). Though the anticipated energy growth is expected to come mainly from emerging economies, the US industrial economy is highly sensitive to the imbalance of this energy equation. The US Energy Information Administration has shown that the United States consumes 21 percent of the worlds energy (with less than 5 percent of the worlds population), and a full third of the energy consumed in the United States comes from within the Industrial Segment (figure 1). Transportation This heavy dependence on the 28% worlds energy supply makes the US economy and its industrial base extremely sensitive to future disruptions and price volatility. And volatility in energy prices is quickly entering crisis territory, based on observations from Industrial the past decade (figure 2). 31%
THE KEYS OF ENERGY MANAGEMENT
Energy management in an industrial facility typically starts with an energy assessment, sometimes acquired at no cost from a utility, university, vendor, or DOE program. Because the energy management position of an industrial facility is often only a part-time role of the facilities manager, this energy assessment is commonly followed by a number of energy mitigation efforts targeted to the building systems, such as lighting retrofits, HVAC adjustments, and occupancy sensors. Although this is a logical practice for energy management in commercial buildings, it fails to recognize that as much as 90 percent of energy use within an Commercial industrial facility is in the process. 19% Often, its the organizational structures that limit the scope of energy mitigation efforts: the facilities engineer often has little expertise or influence over production Residential equipment. However, there is 22% a common piece of production equipment where the skills of the facilities engineer do apply: pumping equipment.
Figure 1:
Share of energy consumed by major sectors of the economy, 2008 (Source: US Energy Information Administration [USEIA], Annual Energy Review 2008)
About the Author

Robb Dussault is the offer marketing manager for energy management solutions at Schneider Electric. For more information on Energy Performance, visit www.schneider-electric.com . This article is the second installment in a series exploring new approaches to common pumping industry problems.
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Pumps are a major contributor to energy use within industrial process applications. Figure 3 provides some insight by industry, where energy savings can be realized, and its clear that pumps dominate across the board. It is a little known fact that pumping and pumping systems account for nearly 25 percent of all industrial motor energy use, making them one of the leading sources for curbing energy consumption. Efficient pumping allows for more than 50 percent of energy savings potential in an industrial motors, a fact that many industries have yet to grasp. Reducing energy consumption through pumping equipment can be achieved in three main areas within the process: 1. Adjusting pump duty cycles: Applications where pump duty cycles have wide variance based on system demand. The variance could be a function of system usage demand, process fluctuations or various other varying operating conditions. 2. Compensation for oversized pumps: Pumps are also frequently oversized to allow for anticipated load demand or simply to provide an operational safety factor. 3. Adjusting for pump wear: Pumps also wear over time, two good examples being impeller wear and bearing degradation, which over time will reduce the operating efficiency of the system.
www.elektrimmotors.com Figure 2:
Energy price volatility (Source: USEIA,2008)
1200.00 8.00 7.00 6.00 800.00 5.00 4.00 3.00 2.00 200.00 1.00 0.00
1000.00
600.00
400.00
0.00
73 19 75 19 77 19 79 19 81 19 83 19 85 19 87 19 89 19 91 19 93 19 95 19 97 19 99 20 01 20 03 20 05 20 07 20 09 19
EXAMPLES OF ACTIVE AND PASSIVE ENERGY MANAGEMENT
These challenges can be overcome through a combination of both active and passive energy management approaches:
For example, a passive management approach includes utilizing energy efficient motors, a well-publicized and frequently preferred solution already implemented. Using low consumption switching devices, which can reduce device energy consumed by more than 90 percent versus traditional starting methods.
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MOTOR solutions
Figure 3:
Energy savings potential by industry and application
1. 2. 3.
8000 7000 6000 5000 4000 3000 2000 1000

D D AN TS ND S . LS UC ER A CT AN TS ISC S R A D D P DU UM UC M CT THENT IC O N S A M PR & DU AN P RO LE OD O E E CT TIONT R P O PR BE RO C & IPM ODDU CHIED TA ME D R I QU B P O O L R T AL IE P L F E N L U O U A P O R TIC RO E PR AL SP EQ C T RIC AS ED AN T PL ELEC DR TR EC N L E KI
Pump system Compress. air sys. Motor upgrade Motor downsizing Replace vs. rewind Fan system Other processing systems
Energy consumption data in the context of relevant production data Dynamic forecasting and modeling of energy usage tied to production plans and process settings The capture of energy events along with analytical tools to facilitate the elimination of the root causes of those events.
If we consider energy in the context of production data, combining real-time energy data with real-time process data, operations personnel are able to visualize and understand the relationships between various aspects of energy and production.
Use of Variable Frequency Drives (VFDs) Especially on centrifugal pumps, VFDs allow you to match varying loads. VFDs represent tremendous energy savings potential in the process, due to what are called the affinity laws, which summed up state that: Flow is proportional to motor speed Pressure is proportional to the motor speed squared Power is proportional to the motor speed cubed. Continuous Optimization of Process Energy An active energy management strategy, this provides for system profiling at optimum operating points, and constant monitoring and follow up to provide feedback on system deviation. For example, Energy Performance from Schneider Electric is a system that provides for this optimization. Systems like Energy Performance can yield efficiency gains of up to 15 percent for energy intensive processes. These systems deliver tremendous value to end users with large pumping loads by providing:
Once this energy usage information is integrated properly to key process data, operations personnel can clearly and fully understand important relationships between energy and the process that drive consumption variability. Once these relational comparisons are made, quality teams can determine where the largest variability exists and work to normalize performance around best in class benchmarks. Additionally, the use of regression analysis techniques and standards established by ASHRAE guideline 14, systems like Energy Performance can model energy usage based upon criteria such as weather conditions, production plans and process set points. This tightly correlated model and resulting dynamic forecast allow operations personnel to establish a framework that defines normal operation, and subsequently identify energy consumption intervals that are abnormal or that fail to meet the minimum efficiency requirements. This forecasting methodology can either be applied to the entire process, or to single, large pieces of equipment, such as a high kilowatt pump. When applied to a single large piece of equipment, the dynamic energy forecast for that piece of equipment can be compared to actual energy use, in real time. If the actual energy usage trends above the dynamic forecast, maintenance personnel can be alerted to potential nascent failure conditions before an unplanned process shutdown occurs.
NORMALIZE ENERGY CONSUMPTION TO BENCHMARK FACILITIES
table 1:
Typical Energy Performance benefits
COMPANY DESCRIPTION HEAVY CONSTRUCTION EQUPIMENT MANUFACTURING BATTERY MANUFACTURING PAPER MILL SILICON WATER MANUFACTURING ELECTRICAL PRODUCT MANUFACTURING MUNICIPAL WATER/WASTEWATER
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PROCESS DESCRIPTION
Discreet Process, Assembly Teams Discreet Process, Assembly Teams Continuous Process with Co-Generation Batch Process Discrete Process, Fabrication and Assembly Continuous Process, Distributed Arch.
SOLUTION SUMMARY
Energy Performance for Electric, Gas, Water Energy Performance for Electric, Gas, Water Energy Performance With Cost Allocation and Billing Energy Performance With Cost Allocation and GHG Energy Performance Energy Performance with PQ and GHG
ESTIMATED BENEFITS
12% ROI 14% ROI 18 Month Payback 15% ROI 16% Utility Savings 28 Month Payback 22 Month Payback

Energy events, or a period of energy consumption that is above the established standards of normal, can be identified and captured by using a system like Energy Performance. When an energy event occurs, the system captures all of the relevant process data. In short, an energy event is a period of energy consumption that is above the standards established as normal or acceptable. Any time an energy event occurs, Energy Performance can capture all of the energy and process data relevant to the event. In order to identify energy events, we must first understand the typical behavior of the end user's industrial process in terms of energy consumption per unit of process output, often referred to as energy intensity. Excess consumption is then understood to be defined as energy intensity that is above the normal range or band of consumption behavior. Consider the hypothetical example of an energy over-consumption event and the data that would be captured for analysis. In such an example, Energy Performance would capture the start and stop time, duration, overconsumption, classification, cause, shift, and crew associated with the event. Some examples of pump-related causes of energy events are 1. 2. Suction cavitation due to lowpressure/high-vacuum conditions Discharge cavitation due to extremely high discharge pressure, normally occurring
www.elektrimmotors.com
INDUSTRIAL MOTOR ENERGY USE Other 4.3% Pumps 24.8% Material Processing 22.5%
SAVINGS POTENTIAL Other 12.5%
Compressed Air 27.0%
DEFINING ENERGY EVENTS
Fans 13.7% Compressed Air 15.8%
Material Handling 12.2% Refrigeration 6.7% Pumps 50.5%
Fans 10.0%
Figure 4:
Energy use and energy savings potential by application (Source: DOE Office of Industrial Technology)
3.
4.
when a pump is running at less than 10 percent of optimal efficiency point Concurrent operation of shortduration pump loads such as backwash pumps along with base-load commonly running pump loads Failure to monitor and optimize use of system-wide storage capabilities, thereby operating pumps more often than necessary for system mass balance
15 percent while driving continuous improvement to energy efficiency. In order to implement an Energy Performance system, an industrial site must capture energy metering information for the parts of the process that consume the most energy. This metering data must be fed in real-time, along with process control set-points into a database for real time analytics and reporting. Energy Performance solutions are specific to the client needs and existing infrastructure.
As these records are captured and stored, a quality engineer can then perform an FMEA analysis that will identify and correct the processrelated causes of the energy events. As energy events are better understood and minimized or eliminated, the operations team can achieve active energy management savings of up to
Figure 5:
Energy Management Process Flow
ENERGY AUDIT & MEASURE
Fix the basics
Optimize through automation & regulation

Pump control, optimization software, process control, variable speed drives...
NEMA Premium Efficiency motors, insulation material, power factor correction
Typical return on investment (ROI) figures for production energy optimization range from 20 percent in areas with high energy per-unit costs to 10 percent in areas with lower per-unit energy costs. Some examples along with key terms are shown in table 1: As energy becomes an increasingly valuable commodity, the need to effectively measure, monitor and manage consumption will continue to be viewed as an integral part of all process systems. Because pumps represent such a significant part of the energy consumed, whether in industry, buildings, or infrastructure; and an even greater target for energy Monitor, optimization, they will maintain, continue to be a focal improve point to drive energy reduction via the process Meter installation, monitoring energy optimization services, EE analysis software process.
FEBRUARY 2013
BENEFITS FOR THE FUTURE
47
Cool, Calm, and ColleCted

An analysis of a circulating water pump system
By William livoti, WEg Electric Corporation
n this analysis, the circulating water system provides cooling water for a combined cycle power plant that swings load from 150 megawatts to 785 megawatts. The system has three 900 horsepower, 444 rpm vertical, mixed flow Ingersoll Rand model 50 APMA, single stage circulating water pumps that generate 85,234 gallons (322,646 liters) per minute at 32 feet of head (at design point). The pumps are coupled to an Allis Chalmers 900 horsepower, 4160 volt high pole count induction motor. The pumps feed a common manifold flow is controlled by a motor actuated butterfly valve at the discharge of each pump. Based on customer historical data MTBR (mean time between repair) for motors is approximately three years, mode of failure is unknown, and MTBR for pump is unknown. The reasons for the analysis / improvement are as follows:
POWER GENERATION solutions
The system has three 1/3 capacity circulating water pumps designated north, central, and south. The subject units provide cooling water to the main turbine condensers and also supply suction pressure to the low pressure general service cooling water pumps. The circulating water pumps draw suction from a self contained canal system (system contains 250 million gallons of water) and lake (added in 2001). The canal system (original design) contains approximately 144 50 APMA circulating water pump pumps with four spray heads per pump. Cooling water is being recycled constantly, moving in and out of the plant in a closed loop. At full load, it takes approximately 12 hours to complete one cooling cycle (turnover of cooling water). The circulating water system also provides water to the general service Plant cannot achieve water pumps, said system full load due to lack contains five 6 x 8 x of cooling capacity. 17 Goulds model 3405 Cooling water capacity / supply has pumps generating 1800 Spray heads / pumps and cooling channel inlet for circulating water pumps been an issue since gallons (6813.7 liters) per minute at 260 feet commissioning. of head (at BEP). Demand placed on the circulating water Corrosion damage of upper condenser tubes has become a issue. system by the general service water pumps is unknown. This Frequent motor failures. demand fluctuates depending on needs of service water and Excessive vibration. ultimately affects circulating water cooling capacity.
CURRENT SITUATION OF THE CIRCULATING WATER SYSTEM
About the Author

William Livoti is the power generation business development manager for WEG Electric Corporation. With over thirty years of experience in the pump industry designing, field testing, repairing, and troubleshooting mechanical seals, compressors, and pumping systems, William is an active member of ASME, Vibration Institute, IEEE, PCIC, Power Engineering Society, Hydraulic Institute, and HI working groups and has served the vice chair on the board of directors of Pump Systems Matter. Mr. Livoti has just completed a book on System Optimization Guidelines with the Hydraulic Institute and is currently preparing a book on Power Plant Process Guidelines for Pumping Systems.
48 | FEBRUARY 2013
POTENTIAL ROOT CAUSE Root Cause

Frequency of Starts/ Stops
VERIFICATION PLAN How to Check

Review plant data, determine trend circulating water pump operating data. Procedure as defined in this document. Review / witness start-up and shut-down, capture vibration and motor data. Review operating history of plant. Disassembly and inspect motor. Performance test pumps in various operating configurations (1,2, & 3 pumps in service).
Description
Starts and stops are very hard on this type of pump system and can result in damage to pump, motor and intake structure. Faulty or improperly operated valve can push to pump into a undesirable operating condition. Incorrect start-up procedure can result in high vibration and damage to system components. System requirements changed from original design, system demands more flow which requires additional hp. Rebuild procedure would have a direct impact on the motor reliability. Insufficient number of pumps in operation or one pump operating in a throttled condition will force the pump/motor into an off design condition. If the rotor and bearings are not centered in the stationary components there is a potential for contacting as well as imparting additional load on the motor. Undersized motor will result in elevated operating temperature and reduced motor life.
Results
Pumps now experience high number of starts and stops as plant operation has changed.
Valve Malfunction Start-up and Shutdown Procedure Load / System Requirements Quality of Motor Rebuild Multiple Pump Operation
Faulty valve (center pump) was identified. Testing confirmed start-up procedure has been modified from plant operation manual. From initial commissioning until late 2004 the plant had minimal run. In 2005 the plant began frequent operation and load. Disassembly and inspection indicated the pump repair was sub-standard. Testing confirmed that the three pump in parallel operation (valves 100% open) the pumps operate close to design. However the motors operate in the service factor.
Stator / Rotor Centrilization
Disassemble and inspect.
Inspection verified lack of rotor centralization.
Motor Sized Properly
Obtain motor load over range of operation.
Testing confirmed motors are operating in service factor.
Root Cause Verification Matrix
There has been a recent motor failure on the South pump prompting the analysis. This motor was removed for disassembly, inspection, and repair. The pump was not pulled for evaluation. Additional testing with all three pumps in service was scheduled for a later date.
80
70
60 Head (Feet), BHP X .01
50
40
30
20
10
0 0
System with Two Pumps in Service Calibrated analog pressure gauges were attached to the center and south pumps discharge flanges. A Panametrics flow meter was installed on the discharge piping of the center pump. A flow rate was not able to be obtained. Pipe internal Circulating Water Pumps 4/4/07 scale was apparently dispersing the sound Model: 50 APMA transducers signals. End Speed: 440 user electricians obtained 100 motor amperage with 90 clamp-on meters at the pump motor leads and 80 pump performance was calculated at several 70 valve positions. The south, center, and 60 Rated Point north pumps operating 85234 GPM @ points were plotted on the 50 32 FT design curve. Pump flows 40 Estimated were estimated based on Estimated Operating Operating Point calculated discharge head Range Center Pump Center and North 30 30% Valve with the assumption that Pumps 100% Valve the pumps are operating 20 close to (slightly below) the curve. 10 Pump motor vibration was recorded with a CSI 0 2130 signal analyzer. The 20000 40000 60000 80000 100000 120000 Flow (GPM) vibration levels were low and in the acceptable Total Discharge Head BHP Field Tested Head Field Tested BHP range for a pump of Rated Point Efficiency Field Tested Eff. this design.
Percent (%), Feet (NPSH)
ANALYSIS
FEBRUARY 2013
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Circulating Water Pumps 4/4/07
80 70 Model: 50 APMA Speed: 440 100 90 80 60 Percent (%), Feet (NPSH) 70 Head (Feet), BHP X .01 50 Rated Point 85234 GPM @ 32 FT Estimated Operating Point Center Pump 30% Valve 60 50 40 30 20 10 10 0 120000
BRIEF SUMMARY
Equipment in question was commissioned in 1979; however, said system has approximately three years actual run time due to long term cold stand-by status. Each circulating water pump and motor set has been rebuilt at least once since 1979. The south circulating water pump motor is currently out for second repair. Plant did not receive pump or system curve data upon commissioning of plant. Plant performance was never documented / verified. Corrosion damage of upper condenser tubes has become an issue. Cooling water capacity / supply has been a issue since commissioning. Lack of cooling capacity has prevented plant from making full load. Two vacuum pumps are required to charge condensers, currently only one vacuum pump in service, unit in service has a bad motor bearing. Most recent vibration routes were obtained by plant personnel on 5/06 South unit displayed high vibration, resulting in shut down.
40
30
20
Estimated Operating Range Center and North Pumps 100% Valve
0 0 20000 40000 60000 Flow (GPM) Total Discharge Head Rated Point BHP Efficiency Field Tested Head Field Tested Eff. Field Tested BHP 80000 100000
Test Results A faulty valve on the center pump forced the unit back on the curve. After correcting this condition, the test was repeated with both pumps operating with valve in full open position as noted on pump curve. With two pumps in operation the pumps operate to the right of the pump performance curve. At this point, additional testing was rescheduled until the repair was completed on the south unit and flow instrumentation installed for more precise flow readings. South Motor Inspection The south motor is an Allis Chalmers, 900 horsepower, 440 revolutions per minute, 4000 volts, and 128 amps. Upon disassembly of the motor, a rub between the stator and rotor was immediately identified. This rub was on one side of the stator and all the way around on the rotor.
50 | FEBRUARY 2013
The upper bearing carrier indicated that the carrier was repaired in the past with a metal sleeve. This sleeve has become loose. This loose sleeve most likely added to the failure condition by allowing some movement of the upper bearing. There were no findings of damaged bearings (upper or lower). All grease was intact and no signs of heat damage within bearings at all. The frame was found to be poorly constructed. The construction only allows for support at the stator end plates (which are then welded to the frame). This does not allow any center support (and per previous history has been braced / welded and repaired in the past). The stator bore was checked the sizes varied and found the stator ID to range from 35.986 to 36.023 inches (91.41 to 91.5 centimeters) and up to .037 inches (.94 millimeters) of size variation. It should be noted here the average air gap is around .055 inches (1.4 millimeters) An evident rub between the stator and rotor. per side. It was also
Pump no. Center Circular motor

Location
OB Hor - Parall to disch OB Vert - Perpend to disch OB Axial IB Hor - Parall to disch IB Vert - Perpend to disch
Pump no. north Circular motor

Location
OB Hor - Parall to disch OB Vert - Perpend to disch OB Axial IB Hor - Parall to disch IB Vert - Perpend to disch
Magnitude Freq Spikes In Seconds

0.031 0.038 0.028 0.026 0.013 2X, 3.5X, 8X 3.3X, 7X, 16X, 21600 4X, 8X, 21600 4X, 16X 2X, 4X, 16X
Magnitude In Seconds
0.054 0.048 0.043 0.048 0.027
Freq Spikes
1X, 3.5X, 8X, 21600 4X, 8X, 16X, 21600 4X, 5X, 8X, 11X, 12X, 21600 3.6X, 16X 4X
NOTES: Pump Speed 440 RPM 8X = 3600 CPM, 16X = 7200 CPM Imp Vane Count = 4
discovered that the stator had other rub marks from a previous failure. From the evidence present, it appears the rotor has been bumping the stator iron for some time. Findings could suggest that this condition was caused by uneven alignment of motor parts. In other words the center line of the stator bore (which would have been unclear after the first failure / rub, could have been misunderstood). This, in conjunction with the upper and lower end bells and bearing housings aided the internal misalignment to the point where it allowed the rub to occur again. On start up (when magnetic forces are greatest) at the tighter air gap the forces are so great to cause a deflection within the motor. This deflection comes from the rotor which magnetically tries to move to close the uneven gap. This is propagated from thermal heat expansion and the condition worsens over time.
and in parallel (three units). Valve positioning was monitored (during startup and shut-down of each pump) as well as discharge pressure, amperage, flow, and motor / pump response during shut down and start-up. The discharge pressure was captured at the pump and in the control room. Motor amperage, pressure, and flow were obtained at the DCS control room. Observations With pumps in parallel, the south pump failed to vent properly, discharge pressure dropped to 5psi, and amperage fluctuated. It appears the vent valve is faulty.The start-up sequence/valve positioning/actuation is incorrect resulting in reverse rotation of static pumps. The total calculated flow parallel operation is 248,000 gallons (938,782 liters) per minute, and the design flow parallel operation is 254,425 gallons (963,103 liters) per minute. All three pumps operating in service factor in parallel operation. The south pump vent malfunctions preventing pump from achieving design flow.
PUMP START-UP AND SHUT-DOWN PROCEDURE
According to the plant operating manual the circulating water pumps start-up procedure as follows: Start-up Motor Operated Valve (MOV) at Pump outlet is fully closed or 10 percent open. Start motor - Allow pump to come up to speed and near shut off pressure (30 seconds to 1 minute). Slowly open the MOV (approximately 5 minutes to achieve full open position). Shut-down Motor Operated Valve (MOV) is fully closed. De-energize motor. The start-up and shut-down sequence of any pumping system is very harsh on the pump. This is due to the time it takes for the system to achieve hydraulic stability. In the case of a long discharge, such as the application in question, the
PUMP SYSTEM TEST WITH THREE UNITS IN SERVICE
Test Procedure (Plant Off Line) Each pump was operated individually
Loose sleeve on the upper bearing carrier.
FEBRUARY 2013
51

hydraulic transient could last for 20 to 30 minutes. This transient condition can and will have a negative impact on the pump, motor and intake structure. By maintaining a closed or partially open valve for these longer periods of time, it is likely that there will be unavoidable damage to the pump and system (motor, valves, piping, supports and structure). Additionally, if the MOV actuate too fast or malfunctions or if the system is not properly vented, water hammer can occur. This anomaly will also result in severe damage to the pump and system. Typical damage from these events: Piping failure Broken pump shafts Motor damage Structural damage Broken pipe hangers and or supports
Discharge valve sequencing set incorrectly (valve 25 percent open) during start-up and shut down, resulting in reverse rotation condition of parallel pumps.
NORTH PUMP
Time
1:20 1:21 1:22 1:23 1:24 1:26 1:27 1:28 1:29 1:32 1:33 1:34 1:36 1:37 1:39 1:41 1:42 1:44 1:47 1:50 ?? Run Run 80,000 gpm 16 14.5 11.69 13 12 13.7 3/5/2007 10 120 125 120 130 Off 130 130 Run Run Run Start Run Run Run Run 93,000 gpm 11.98 12.5 12.5 12.39 120 120 120 120 Run Run Run Run
CENTER PUMP
Amp
Off
CENTER PUMP
Amp Flow Pressure Amp
Flow
Pressure
Flow
Pressure
17 93,000 gpm 12.5 11.8 12
120 120 120 120 Start 93,000 gpm 1711:15 12:15 15.78 13.4 Run 80,000 gpm Off 16 14.5 125 125 130 130 130 130
14 88,000 gpm 13.4 16 14.5 13 12
130 130 130 130 125 120 Off
north Pump Solo Run

Existing
Pump Efficiency Motor Rated Power Motor Shaft Power Pump Shaft Power Motor Efficiency Motor Power Factor Motor Current Motor Power Annual Energy 79.8 900 829,6 829.6 95.9 77.6 120.0 645.4 5653.6
north Pump in Parallel

Existing
Pump Efficiency Motor Rated Power Motor Shaft Power Pump Shaft Power Motor Efficiency Motor Power Factor Motor Current Motor Power Annual Energy Annual Cost 78.3 900 917.2 917.2 95.8 79.3 130 714.5 6258.89 312.9
Optimal
85.0 900 779.1 779.1 95.1 73.3 120.5 611.5 5356.4
Units
% hp hp hp % % amps kW MWh
Optimal
88.0 1000 815.8 815.8 95.1 72.2 128.0 640.2 5608.2 280.4
Units
% hp hp hp % % amps kW MWh $1000
Center Pump Solo Run

Existing
Pump Efficiency Motor Rated Power Motor Shaft Power Pump Shaft Power Motor Efficiency Motor Power Factor Motor Current Motor Power Annual Energy Annual Cost 76.4 900 829.6 829.6 95.9 77.6 120.0 645.4 5653.6 282.7
Center Pump in Parallel

Existing
Optimal
84.6 900 749.5 749.5 95.0 72.5 117.2 588.3 5153.9 257.7
Units
Optimal
86.6 1000 793.2 793.2 95.0 71.6 125.5 622.7 5454.4 272.7
Units
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South Pump Solo Run

Existing
South Pump in Parallel

Existing
Optimal
84.6 900 749.5 749.5 95.0 72.5 117.2 588.3 5153.9 257.7
Units
Optimal
88 1000 849.1 849.1 95.1 73 131.7 666.2 5836.0 291.8
Units
ANALYSIS (SUMMARY OF RESULTS)

SUGGESTED COUNTERMEASURES (SHORT TERM): Re-pRogRam pump startup and shut down sequence to prevent reverse rotation condition. This action would include valve positioning and valve activation versus pump activation. RESULT: Eliminate motor damage (cracked stator block, rotor damage, etc.)
100 90 80
80
70
RepaiR/Replace faulty vent valve on South Pump. RESULT: Stable pump, motor operation.
Percent (%), Feet (NPSH)
60 Head (Feet), BHP X .01
North and South Pumps (3) Units in Service Rated Point 85234 GPM @ 32 FT Estimated Operating Point Center Pump 30% Valve Central Pump (3) Units in Service
70 60 50 40 30 20
50
40
TRack/documenT motor stator temperatures during parallel operation. RESULT: Verification temperature is within motor design limits. disassemble and inspect and repair MOVs at all three pumps. RESULT: Reliable valve operation, better system control. SUGGESTED COUNTERMEASURES (INTERMEDIATE TERM): model circulating water pump system over full range of operation, develop system curve. RESULT: This data will provide the information necessary to establish required flow to meet plant full load condition and identify potential opportunities to improve efficiency/reliability of system. based on new sysTem CURVE and load requirements replace motors with a more robust design and required horsepower rating. RESULT: improved plant efficiency as well as uptime, availability and reliability.
30
20
Estimated Operating Range Center and North Pumps 100% Valve
10
10 0 120000
0 0 20000 40000 60000 Flow (GPM) Total Discharge Head Rated Point BHP Efficiency Field Tested Head Field Tested Eff. Field Tested BHP 80000 100000
POTENTIAL ROOT CAUSE

Frequency of Starts/Stops Multiple Pump Operation Valve Malfunction Start-up and Shut-down Procedure Load / System Requirements Quality of Motor Rebuild Motor Stator / Rotor Centrilization Motor Sized Properly
CONCLUSIONS FINDINGS
Pumps now experience high number of starts and stops as the plant operation has changed. Testing confirmed that with three pump in parallel operation (valves 100% open) the pumps operate close to design. However the motors operate in the service factor. Faulty valve was identified. Testing confirmed start-up procedure deviates from plant operating / data manual. Modified procedure has negative impact on equipment. From initial commissioning until late 2004 the plant had minimal run. In 2005 the plant began frequent operation and load swings. Disassembly and inspection indicated the pump repair was sub-standard. Inspection verified lack of rotor centralization. Testing confirmed motors are operating in service factor.
Root Cause?
Yes
Contributing Factor?
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes Yes Yes
Yes Yes Yes
FEBRUARY 2013
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PROCESSING solutions
The BlockBuster
Rises to the Challenge

Circumferential piston pump increases productivity and consistency demands for bakery
By Jeff Best, BestPump ltd.
rustrated by the numerous profitsapping problems experienced in the preparation of butter for cake mix, the management team of a prominent bakery has installed a system that has streamlined and stabilized their production. Bakery Operatives can now rely upon an on-demand supply of tempered, ready-for-mixing butter. Many disruptions to production have been eliminated including damage to mixers, inconsistent batches, and various other issues typically encountered when working with awkward bulk solidsin this case, chilled 55 pound (25 kilogram) butter
blocks ranging from 37.4 to 50 degrees Fahrenheit (3 to 10 degrees Celsius) in temperature.
THE BLOCKBUSTER
This butter handling system, nicknamed the BlockBuster, is the flagship product of the pump and processing specialist BestPump. The systems modular design allowed the end user to specify a bespoke solution with features such as multi-block
conveyor, twin auger configuration, and variable flow rates handled by a positive displacement circumferential piston pump. The system discharges perfectly conditioned butter strands via a special
About the Author

Jeff Best is the managing director of BestPump Ltd., whose customer base includes organizations like small breweries and dairies to huge multi-national manufacturers. He can be reached at jeff@bestpump.co.uk. For more information, visit www.bestpump.co.uk or call 44.0.1236.756.900.
54 | FEBRUARY 2013
shower head extruder at a flow rate of 100 pounds (50 kilograms) per minute but is capable of much higher capacities if required. The need for an automated solution like this was identified several years ago by BestPump. It was clear that food manufacturerseven market leaderswere using various inefficient and, in some cases, archaic methods to get butter out from cold storage and into a ready-to-mix condition. Having witnessed the problems at first-hand, the BlockBuster design concept came directly from the BestPump Engineering Team. Their comprehensive product conditioning and rheology knowledge base resulted in a solution that is made specifically to solve bulk product handling problems.
A COMMON PROBLEM
Butter is such a common ingredient, yet a satisfactory solution for handling butter seemed out of reach. The health and safety risks involved in moving and lifting heavy blocks are obvious and then there is the huge amount of work that has to go into the butter prior to mixing. Both of these challenges need
to be overcome before considering the batching accuracy and ingredient conditioning for product consistency. From previous experience with installations in the United Kingdom, North America, and Australia, BestPump came to realize that these problems are universal. Customers demonstrated all sorts of butter-handling methods that ranged from melting to chopping to just beating the living daylights out of the block product yet nothing gave satisfactory results. The BlockBuster system results in safe employees and consistent and reliable products. The latest BlockBuster model features an ultra-compact design and smaller footprint compared to previous versions. The new design uses fewer specialized components, has a shorter lead time, and the complete system now requires a smaller capital expenditure. Even the installation and commissioning times are minimized. The system was ready to run, including the training of operators and maintenance staff, in less than one day. Other enhancements include a lowered table-top form factor for safer loading and a simplified strip-down procedure for more efficient hot wash
cleaning. Disassembly is safe and easy with the augers being removed using an innovative removal system and trolleyno heavy lifting is necessary. BestPump has been deploying similar systems since 2004 and has yet to log a single maintenance or performance issue. End users have realized complete payback within a timeframe of months due to the numerous savings afforded by automation. From a cleanliness perspective, ongoing microbiological checks continue to certify that the system is sanitary and bug-free.
THE BLOCKBUSTER ADVANTAGE
As operating costs increase and margins decrease, supermarkets and leading brands are demanding higher product quality and greater levels of productivity and the BlockBuster appears to tick all the boxes. The machine is robust and built to the highest standards. The benefits to high-volume consumers of block product like fat or butter include product consistency, easy repeatability of recipes, minimal product waste, workforce efficiency, employee safety, easy cleanability, low maintenance, and no more broken mixers!
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VALVES & CONTROLS solutions
By Jim delee, Fluid Components international
umps are all too frequently one of the most overlooked and abused pieces of equipment in process automation, yet nothing moves without them and a process becomes inefficient when they dont operate properly or completely shutFigure 1 down. While it is convenient to blame the pump manufacturer, more often than not the process or the surrounding equipment configuration is the problem. Optimizing your process for productive operation, including the pump, and protecting the pump against common hazards, are two of the smartest ways that engineers and technicians can help their plant operations. These efforts will improve endproduct or batch quality, cut the material costs, eliminate waste and reduce maintenance costs. Taking good care of your pump always delivers a positive payback and there are some simple strategies that can be employedstarting with an analysis of process media flow rates.
Controlling material flow ensures that pumps operate efficiently, moving stock or products with the least possible expenditure of energy while reducing maintenance requirements and extending life. Failing to control material flow adequately can lead to some unwanted conditions, such as cavitation, or pump bearing failure, or even seal failure. The first problem cavitationcan reduce capacity or even cause quality problems. Losing a bearing or a seal can lead to pump shutdown, possibly process line shut-down and the unfavorable conditions could get worse the further you take this type of scenario. Protecting your process and pump starts with analyzing the flow to make sure the media is flowing regularly at the pressure required by the pump with a minimum headloss. Any number of process conditions can cause irregular flow, such as turbulence, temperature changes, unwanted air ingestion, etc. The problems of irregular flows and turbulence, in particular, can be especially challenging to solve because eliminating the root causes are often difficult to impossibleso you need a workaround strategy. Nothing can damage a pump faster than the build-up of heat from low flow or dry running conditions, which occurs when liquid flow dramatically slows down or stops flowing altogether through the line or the pump. When the liquid
ANALYZE THE FLOW
PROTECTING YOUR PROCESS
Plant overview
With todays focus on turning plants into 24/7 lean operations, the pumps in most plants are running near capacity to keep up with material through-put objectives and demand in many industriessuch as petrochemicals. One of the most common hazards to efficient pump operation is irregular material flow, which can result in three negative conditions: (1) flow turbulence, (2) low flows, or (3) dry running conditions.
About the Author

Jim Delee is a senior member technical staff for Fluid Components International. For more information about FCIs line of flow switches and other instruments, visit www.fluidcomponents.com .
56 | FEBRUARY 2013
isnt there to provide cooling, the heat can destroy a pumps bearings or seals. If repair is even possible, it is going to be a very expensive Figure 2 proposition. Of course, such dramatic failures also often ruin the material being processed or reduce process line capacity.
For proper and efficient operation, pumps require a stable upstream flow profile in the pipeline before liquid enters the pump. Irregular flows often result in cavitation, a condition where cavities form in the liquid at the point of pump suction. A commonly cited industry pump installation guideline suggests at least 10 diameters of unobstructed pipe be Vortab inline and elbow flow conditioners placed between the point of pump suction and the first elbow or other disturbance. Obstructions and/or corrosion in a pipe can change the velocity of the media and affect its pressure as well.
ELIMINATING IRREGULAR FLOWS
When plant real estate restrictions result in the placement of elbows, valves or other equipment that are too close to a pump, these other devices can create swirl and velocity profile distortion in the pipeline (as well as pressure changes). These disturbances can result in excess noise and cavitation, resulting in reduced bearing and/or seal life. An inline or elbow flow conditioner can be installed upstream from your pump to ensure an optimal flow profile for efficient operation. Isolating the effects of velocity profile distortions, turbulence, swirl and other flow anomalies in your pipeline will result in a repeatable, symmetric, and swirlfree velocity profile with minimal pressure loss. Creating a relatively more benign operating environment helps increase pump life. The conditioned flow stream enters the pumps impeller in a uniform and equally distributed pattern, optimizing pump efficiency and
FEBRUARY 2013
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VALVES & CONTROLS solutions

Figure 3 extending bearing life while at the same time decreasing noise and cavitation. When faced with less than ideal piping configurations, an inline or elbow flow conditioner will eliminate all upstream straight run requirements for pumps, compressors, flow meters, and other critical process equipment. Tab type flow conditioners, such as the Vortab Flow Conditioner, have proved successful in these applications. Other flow conditioning technology choices, including tube bundles, honeycombs, and FLT93 Flow Switch perforated plates, may also be considered depending upon the specifics of the FlexSwitch FLT93 Series, with its no application. moving parts design, offers a highly The inline or elbow flow robust scheme for pump protection conditioners profile conditioning tabs with its dual alarm capability. produce rapid crossstream mixing, With Alarm 1, the switch will detect forcing higher velocity regions to a low flow situation anywhere between mix with lower velocity regions. The 0.01 and 3 feet per second (FPS) shape of the resultant velocity profile (0.003 to 0.9 meters per second MPS). is flat and repeatable regardless This low flow alarm can be regarded of the closecoupled upstream flow as a pre-warning signal for the control disturbances. system or operator. The system or Incorporating anti-swirl mechanisms operator can then decide to keep the into the design of the flow conditioner pump running or to shut it down. If an Alarm 2 occurs because the eliminates the swirl condition typically feed line to the pump is running dry, seen exiting 90-degree elbows. The this condition would be an emergency result is a flow stream that enters the signal to shut down the pump pump in such a way that it maximizes immediately because the bearings now the efficiency of its operation and see gas instead of a liquid as a heat reduces stress. In addition, the tapered transfer media. In such situations, the design of the anti-swirl and profile temperature of the bearings may rise conditioning tabs make them immune very fast. Using a flow switch prevents to fouling or clogging. permanent damage to the pumps PUMP FLOW MONITORING bearings that will require an overhaul Eliminating the damage caused by a of the pump before more damage low flow or a dry running condition occurs. can be achieved by installing a point The FLT flow switch is a dual-function flow switch in the process loop. instrument that indicates both flow Combination point flow switches will and temperature, and/or level sensing in a single device. It can be specified detect not only a low flow situation, but also detecting a dry running in either insertion or in-line styles for pipe or tube installation. With the FLT, condition. This capability allows the control system or operator to a single switch monitors your direct take corrective measures before the variable interest, flow, and temperature simultaneously with excellent accuracy bearings of the pumps are overheated and reliability. The dual 6A relay and fail. There are many types of point outputs are standard and are assignable flow switches available. The FCI to flow, level or temperature.
58 | FEBRUARY 2013
In selecting a flow switch for pump protection or any application, the first step is choosing the appropriate flow technology. There are multiple flow switch sensing technologies available, and the major ones now include Paddle Piston Thermal Mass Pressure Magnetic Reed
CHOOSING A FLOW SWITCH
Each of these technologies have their advantages/disadvantages, depending on the media and your applications requirements. Some may be the only choice in certain media for your application. By looking at these factors, as well as your plants layout, environmental conditions, maintenance schedules, energy cost and ROI, you will quickly be able to narrow the field to one or two best choices.
CONCLUSIONS
When designing new plants or retrofitting old ones, be sure to consider pump requirements. Optimizing your process with your pumps in mind offers a wide range of benefits: higher capacity, improved quality, lower energy costs, reduced maintenance, increased equipment (pump) life. One of the most common pump problems is irregular flows caused by turbulence that frequently results when the minimum pipe straight runs required between the point of pump suction and elbows, valves or other equipment are either ignored or pushed to the limits. Inserting a flow conditioner frequently eliminates turbulent flow issues. Dont forget to protect your pump from accidental low flow or dry running conditions, which can lead to bearing or seal loss requiring expense repairs. Inserting a dual alarm flow switch in your process loop not only protects the pump from damage, but will alert you to a potential problem and let you make adjustments before a shutdown is necessary.
SEALING solutions
No Seals? No Problem!
Non-metallic drum pump is a sealless solution evacuating hazardous and corrosive fluids
By Ken Comerford, vanton Pump and Equipment Corp.
chain is only as strong as its weakest link. Likewise, when evacuating hazardous fluids from chemical processing facilities or corrosive byproducts from industrial plants, a pump is only as strong as its weakest component. Often, operators are faced with the frustrating dilemma of watching high-dollar equipment bog down or go offline for repair because supposedly cost-saving components fail. Large investments in pumps and motors seem useless when penny wise and pound foolish seals or valves cannot withstand the regular flow of acids, caustics, salts, chlorides, and reagent grade chemicals common to most processing tasks.
The obvious answer would be to invest in higher-end components, but look closer. What if the solution not only meant spending less on seals but spending nothing at all? What if you changed the question from how do I stop a leak? to why do I need a seal?
THE FLEX-I-LINER
Portable, non-metallic Flex-I-Liner rotary peristaltic pump from Vanton evacuates drums containing acids, caustics, solvents, salts, chlorides, reagent grade chemicals, and viscous fluids with no corrosion of the pump or contamination of the fluid.
The portable, non-metallic Flex-I-Liner rotary peristaltic pump from Vanton Pump and Equipment Corp. answers that question by saying, you dont! Nor does an evacuating pump need valves that inevitably clog or fail when faced with harsh chemicals. Because Flex-I-Liner does not incorporate these components in the pumps design, engineers at Vanton have provided end users with a new, long-term solution to a chronic problem.
About the Author

Ken Comerford is the vice president of Vanton Pump and Equipment Corp. Vanton pumps operate in over seventy-five countries across all industries in which corrosive or ultra pure fluids are handled including water and waste treatment, pollution control, metal finishing, chemical processing, pulp and paper, mining, and semiconductor manufacturing. For more information, call 908.688.4216 or visit www.vanton.com.
60 | FEBRUARY 2013
The Flex-I-Liner evacuates drums and totes containing hazardous fluids and harsh chemicals, without corrosion of the pump or contamination of the fluid. The pump is suitable for flows from 0.33 to 10 gallons per minute and pressures to 20 psig at temperatures to 180 degrees Fahrenheit (82 degrees Celsius). The Flex-I-Liners self-priming design has no seals to leak or valves to clog, and can run dry for extended periods without damage. Compact in size with integral handle, it fits on traditional drum lids without protruding, and has sufficient lift characteristics to operate from the floor, skid, or stand. Only two non-metallic parts contact fluid: a thermoplastic body block, and an elastomeric flexible liner that can be replaced in the field without special tools. The rigid body block is of solid polypropylene, UHMW polyethylene, or PTFE, and the molded flexible liner of natural rubber, Neoprene, Buna-N, Hypalon, Viton, or Nordel elastomers, eliminating corrosion or contamination associated with metal pumps. Being able to choose from a wide choice of thermoplastics and elastomers in which these pumps are available is key to their accomplishing their task. Variety in the Flex-I-Liners construction permits its use over the full pH range and for an extensive list of corrosive, volatile, and viscous fluids. Should a new fluid handling task arise at a chemical processing plant or a new byproduct need be removed, facility operators can remain confident that they can match the right materials of construction to handle the fluid being pumped. A rotor mounted on an eccentric shaft oscillates within the flexible liner, imparting a progressive squeegee action on the fluid trapped in the channel between the liner and the body block. Flanges on the flexible liner are pressed to the side of the body block by concentric grooves on the bracket assembly and the cover plate, isolating the fluid to the channel. Vanton also manufactures horizontal and vertical centrifugal pumps with all fluid contact components of inert thermoplastics, for flows to 1150 gallons per hour (261 m3/h) and heads to 185 feet (56 meters) at temperatures to
275 degrees Fahrenheit (135 degrees Celsius), as well as integrated nonmetallic pump/tank systems from 60 to 5000 gallons (227 to 18,927 liters).
THE POWER OF IDEAS
ADDITION BY SUBTRACTION
Even though pump engineers cannot design their way out of every persistent problem, Vanton believes some ideas have the power to change previously
held limits and open the possibilities to new options. Of course, adequate seals and reliable valves are necessary components in most pump systems, but for those situations where a sealless option offers consistent benefits, like transferring, dosing, or evacuating harmful acids, caustics, and other hazardous fluid materials, an option like the Flex-I-Liner makes perfect sense.
MANY FORMS, ONE PURPOSE
FEBRUARY 2013
61
MODERN PUMPING products

mAStER Bond
Super gel 9
Featuring softness and resilience, Master Bond Super Gel 9 is a urethane modified epoxy gel that can be employed in a variety of applications. Super Gel 9 has an exceptionally low Shore A hardness of about 5-10. This softness allows it to be easily repairable making it ideal for retrieving components with a sharp knife or razor blade. It will not shatter during this process. These properties also enable Super Gel 9 to withstand rigorous thermal cycling and thermal/mechanical shock. This product has a two to one mix ratio by weight or volume, along with a low viscosity and exotherm enabling it to be cast in larger sections up to 2 to 3 inches thick. Super Gel 9 bonds well to an array of substrates, such as metals, glass, ceramics, and many rubbers and plastics. It has a long working life of seven to nine hours depending on the mass that is mixed (the smaller the mass, the longer the working life). For more about the full line of Master Bond thermal cycling resistant adhesives, contact James Brenner, marketing manager, at jbrenner@masterbond.com or by calling 201.343.8983.
vAl-mAtiC
AWWA Swing Check valve

Val-Matics AWWA Swing Check Valve incorporates design features to provide energy savings, ease of maintenance, and extended valve life. Designed for municipal and industrial water and wastewater applications, the valve is available with three field adjustable closer options: Lever and Weight, Air Cushion, or Lever and Spring. The Swing Check Valve features a 100 percent unrestricted flow area for energy savings and a full-access domed cover with vent port for ease of maintenance without removing the valve from the line. Other features include heavy duty stainless steel shafts and replaceable body seats, replaceable resilient seats with integral O-ring sealing beads for positive seating, and NSF/ANSI 61 fusion bonded epoxy coating on the interior and exterior for corrosion resistance. For more information, contact Alissa Kantola, marketing project coordinator, at 630.941.7600 or ajk@valmatic.com.
hAYWARd FloW ContRol

Pmd4 and PmS4 Pneumatic Actuators
Hayward Flow Control is proud to announce the launch of their GF-PP (glass filled polypropylene) PMD4/PMS4 Series Pneumatic Actuator line. The PMD4/PMS4 features a GF-PP housing that provides the actuator superior corrosion resistance and performance in environments and atmospheres where most metal actuators cannot. With the GF-PP material, the PMD4/PMS4 actuators are also very robust, lightweight and compact, allowing for ease of installation. The PMD4/ PMS4 Series are available in several sizes for use with Hayward ball valves up through 6inches, and butterfly valves through 4 inches. Available in both double acting and spring return designs, the PMD4 has a torque range at 80 psi supply, from 125 in-lbs to 500 in-lbs, whereas the PMS4 features a range of 44 in-lbs to 230 in-lbs. All sizes have NAMUR VDI/VDE 3845 mounting for solenoids and ISO5211 mounting base. Additional options include solenoid valves for double acting air-toopen and close, solenoid valves with optional voltages, auxiliary switch control, and cycle speed controls. For more information, contact Hayward Flow Control at 888.429.4635 or by email at hflow@haywardnet.com; also visit www.haywardflowcontrol.com.
RotoRK FlUid SYStEmS

Rotary Pneumatic Actuator
Rotork-Hiller, the specialist manufacturer of pneumatic and hydraulic valve actuators for the nuclear industry, has successfully completed the full qualification of a new scotch yoke rotary pneumatic actuator to the latest industry standards. Designed for the operation of ball, butterfly, and plug valves, the actuators are available with a comprehensive torque range and control solutions to meet customer specifications. The compact and rugged design is suitable for harsh environmental conditions and has been supplied for nuclear power projects in countries including China and the USA. Rotork-Hiller rotary actuators meet safety critical applications found in the nuclear power industry and are manufactured under a quality assurance program in compliance with the requirements of 10CFR50 Appendix B, 10CFR21, NQA-1 and ANSI N45.2. For more information contact Sarah Kellett at sarah.kellett@rotork.com or visit www.rotork.com/en/product/index/hiller.
62 | FEBRUARY 2013
tREBoR intERnAtionAl
maxim 50 Aodd Pump
The Maxim 50 air-operated double-diaphragm pump is ideal for aggressive, high purity applications. Its unique construction contains no metal parts or elastomer O-ring seals and includes a fluid path that consists of all PTFE and PFA materials; providing reliable, contamination-free operation at temperatures up to 356 degrees Fahrenheit (180 degrees Celsius). The Maxim 50's revolutionary design allows the pump to be configured for specific applications. You may select from three control base options: recirculation, chemical delivery, or external control. The recirculation and chemical delivery configurations are self-contained while the external control base option allows for pump operation via existing air control systems or by PLC/PC control using fiber optic inputs from the pump; suitable for either recirculation or chemical delivery applications. For more information, visit www.treborintl.com.
nov mono
EZstrip transfer Pump

Recognized as the biggest leap forward in progressing cavity pump design for thirty years, the EZstrip transfer pumps were designed to incorporate all the best aspects of NOV Monos popular and thoroughly proven Compact C Range pumps. The EZstrip technology on which they are based provides a quick and easy way to disassemble, de-rag, and maintain the pump insitu. This can dramatically reduce the time needed to replace a rotor, stator, coupling rod, and drive train by up to 95 percent cutting the typical day-long maintenance operation down to just 30 minutes. The EZstrip pumps can be installed in new plants or retrofitted into existing Compact C applications. Electrical disconnection is not required, while suction and discharge pipes remain untouched. No special tools or skills are required for normal de-ragging operations. All pumps provide dry run protection, during which operational parameters remain unaffected. Both cast iron and stainless steel versions are offered, plus an option to incorporate WRAS-compliant elastomers, a preassembled drive train, and a two-year warranty. For more information on Mono pumps and associated equipment, visit www.mono-pumps.com.
SAndPiPER
Air/Filter Regulator
SANDPIPER, a leading brand in the world of air operated double-diaphragm (AODD) pumps, recently launched a new and improved line of Air Filter/Regulators and Lubricators. Features of the improved product line include a liquid filled pressure gauge as well as a full line of accessories such as lockout valves and mounting bracket kits. These reliable point-of-use Air Filter/Regulators have been specifically developed for air operated double diaphragm (AODD) pumps to reduce maintenance and lower operating costs. The addition of a Filter/ Regulator will help prevent dirty, wet and contaminated compressed air from decreasing the performance of your AODD pump. SANDPIPER recommends the use of a Filter/Regulator with every pump. For additional information, review the Air Filter/Regulator flyer located on the SANDPIPER website, www.sandpiperpump.com.
Smith & lovElESS
PiStAWorks headworks System

Smith & Loveless Inc. has shipped its first PISTAWorks Headworks System, the latest innovation offering four headworks processes on one skid package. The PISTAWorks system will service a governmental training facility in Minden, Louisiana. The pre-engineered, packaged, headworks system combines screening, grit removal and grit washing into one integrated system. The complete PISTAWorks system is preassembled and shipped direct to the job site on one truck, significantly reducing field installation costs while allowing for a compact footprint. All equipment components are constructed of stainless steel and utilize multiple patented technologies. PISTAWorks operates peak system flow capacity from 0.5 MGD to 7.0 MGD depending on the model. For complete sizing data information or to find a Smith & Loveless treatment sales representative, call 800.898.9122 or visit www.smithandloveless.com.
FEBRUARY 2013
63
PUMPING trends
What Comes Next?

Nidecs Tim Albers on government regulation, industrial standards, and the global customer base of the future
idec Motor Corporation, and its flagship brand US Motors, is actively expanding its client base around the world. As the company intensifies its influence in new markets for products like the TITANII vertical motor, Tim Albers, Nidecs director of marketing for industrial motors and systems, talked with Modern Pumping Today about the opportunities and challenges that arise. modern pumping Today: what are todays pump users asking for in a motor? what are you hearing from your customers? Tim Albers: One item that seems to cut across all markets is a motor that is truly inverter duty. I am not just saying that because of the new inverter duty vertical high thrust motor we recently introduced, but it is truly across the pumping industry: verticals, horizontals, and low and medium voltage in many markets. Inverters allow systems to be optimized, but induce stresses on motors not encountered in non-inverter applications. One other item is efficiency. The Department of Energy is working toward regulating pump efficiency. This initiative and the continued push to increase overall efficiency keeps motor efficiency in focus. As an example, premium efficiency is gaining support in some segments that are not currently regulated, such as in the submersible pump market. mpT: How do you reconcile the needs of domestic and international customers? Tim Albers: The trend is moving toward harmonization of standards across the world. However, two unique standards still exist, IEC and NEMA, with the IEC standard being predominant in the world. Nidec is specifically working through acquisition and new product development to expand our IEC product lines and continues to enhance and develop new NEMA products. mpT: when you look ahead to new products, which areas have the highest ceiling in the future? Tim Albers: We are increasing power range, efficiency, and reliability in our products. The addition of grounding rings to motors is a great example of adding to longevity. It was brought about by a change in technology that allowed for cost effective installations. The global manufacturing base to cover current power range usage is pretty well covered in the world. It is really a function of adding the product to a portfolio such as Nidec did when we purchased ASI in Italy. ASI gave Nidec the ability to build product above power levels that resided in the Nidec portfolio.
64 | FEBRUARY 2013
Many things are happening in motor efficiency and the most prominent is the EISA legislation that went into effect in December of 2010 to set the efficiency standard for general purpose motors at the NEMA Premium level. The question really is What comes next? An example of what may be next would be the Department of Energy considering whether or not to apply the NEMA Premium standard to a much broader range of motors currently regulated at the EPACT level. This includes Close Coupled Pump motors and if approved will have a large effect on the pumping industry. For fractional motors, the Department of Energy has recently regulated Open Dripproof motors in the horsepower through 3 horsepower range of single and three phase designs. mpT: nidec has recently expanded its line of TiTanii motors to include the 5812 and 5813 frame vertical motors. what are the main needs in water treatment and processing that youre meeting with this product? Tim Albers: The needs being met are different between the 5812 and the 5813. The 5812 is a new TEFC motor and offers the highest horsepower available for a high thrust vertical motor in a TEFC enclosure. The biggest advantage for this motor is in severe environments. Some severe environment applications include process water and wastewater in mining and pumping in coastal areas such as for desalination systems. The 5813 range of product already exists and the real game changer is the lead time reduction as the design is a WPII enclosure in a cast versus fabricated frame. mpT: How does a cast iron frame benefit nidecs production of these motors? what can customers expect? Tim Albers: A few advantages include a shorter lead time, packaged solutions such as the WPII add on as well as increased consistency of the product. We have moved from fabricating each frame from scratch to adding a Min/Max type of KANBAN for 5813 frames to lower lead time for manufacturing. Electrical performance really does not change. Mechanical features become more consistent. That helps the pump manufacturers when calculating the Reed Critical Frequency of the pump and motor system. mpT: its easier for end users to communicate with manufacturers today than ever before. Does greater communication equal greater clarity? How can manufacturers ensure they separate the signal from the noise? Tim Albers: Great question. A qualified, technically competent sales force and application support are still very relevant. Online tools continue to be improved, but when an end user has a problem, people are still key. Up front application work can be supported by online tools, but the noise really is sorted out by well-trained people.

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modERn todAY

PRoviding SolUtionS FoR thE WoRldWidE PUmP indUStRY FEBRUARY 2013

PUMPS AND ENERGY

DEWATERING IN AN EMERGENCY HARNESS THE POWER OF HYDRAULICS INSIST ON BETTER PUMPS

10 Unraveling a Super-Synchronous Pump vibration issue 18 Solving a very dirty Problem

industry news trade Show Profile Case Studies

22 A new hope for a Common Water treatment Plant Problem

Water & Wastewater Solutions

26 insist on Better Pumps

32 history Repeats itself

36 harness the Power of hydraulics

44 Pumps and Energy Performance

P.O. Box 660197 | Birmingham, Alabama 35266

48 Cool, Calm, and Collected

Power generation Solutions Processing Solutions

54 the BlockBuster Rises to the Challenge

56 monitor Your Pump for Process Efficiency 60 no Seals? no Problem! 62

valves & Controls Solutions Sealing Solutions

64 What Comes next?

modern Pumping Products Pumping trends

312 Lorna Square | Birmingham, Alabama 35216 T: 866.251.1777 | F: 205.824.9796

PATTERSON PUMP COMPANY PARTNERS WITH PUMPSCOUT.COM

TRADE SHOW profile

Expect the Unexpected at MEOS 2013

U nraveling a S Uper -S ynchronoUS ib n i SSUe at on ti p Ump V Vibration ra io br Vi

About the Authors

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Autospectrum (Signal 2) - Mark 1 (Real) \ FFT Analyzer

1x rpm 1.59x rpm

Cursor values X: 94.875 Hz Y: 0.229 in/s

OBB Vertical Overall: 0.38 in/s RMS

IBB Proximity Probe Y: 9.1 mils pk-pk @95 Hz

Amplitude (mils pk-pk)

Amplitude (mils pk-pk)

Pump IBB X 1x rpm 1x rpm

Amplitude (mils pk-pk)

Amplitude (mils pk-pk)

Shaft position in time (seconds)

Shaft position in time (seconds)

THIS SecTIon SponSored by

Operating Deflection Shape (ODS)

3D View BLK: ODS 01 REC 0 Freq: 94.8 Hertz [Complex]

X View BLK: ODS 01 REC 0 Freq: 59.4 Hertz [Complex]

Y View BLK: ODS 01 REC 0 Freq: 59.4 Hertz [Complex]

Figure 9: Four stills from the ODS animation.

Experimental Modal Analysis (EMA)

Experimental modal analysis (EMA) testing was performed

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Superior check valves should ...

Manufactured in West Des Moines, Iowa, USA 515-224-2301 www.checkall.com

Autospectrum (Signal 8) - Mark 1 (Magnitude) \ FFT Analyzer

A POTENTIAL SOLUTION WAS AT HAND

Cursor values X: 59.250 Hz Y: 8.510m in/s

OBB Vertical Overall: 0.05 in/s RMS

THE SOLUTION WAS VERIFIED AS EFFECTIVE

Autospectrum (Signal 3) - Mark 1 (Magnitude) \ FFT Analyzer

Cursor values X: 59.250 Hz Y: 0.404 mil

~110 Hz IBB Proximity Probe Y: 1.1 mils pk-pk @59.3 Hz

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Radial Proximity Probes

~9.5 mils pk-pk

Radial Proximity Probes

~2.1 mils pk-pk Mostly Run-Out