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PUMPSANDSYSTEMS.COM
SYSTEMS
OPTIMIZE SYSTEM
PERFORMANCE
4 highly engineered solutions to help
you get the most from your pumps
Component or Cartridge
Choose the Right Seal
How Remote Monitoring
Empowers Plant Employees
Trade Show Preview
Turbomachinery &
Pump Symposia
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EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
aarchibald@cahabamedia.com 205-314-3878
SENIOR TECHNICAL EDITOR: Mike Pemberton
mpemberton@cahabamedia.com
205-314-8279
MANAGING EDITOR: Amelia Messamore
amessamore@cahabamedia.com
205-314-8264
MANAGING EDITOR: Savanna Gray
sgray@cahabamedia.com 205-278-2839
ASSOCIATE EDITOR: Amy Cash
acash@cahabamedia.com 205-278-2826
CONTRIBUTING EDITORS: Laurel Donoho,
Lev Nelik, Ray Hardee, Jim Elsey
CREATIVE SERVICES
SENIOR ART DIRECTOR: Greg Ragsdale
ART DIRECTOR: Melanie Magee
WEB DEVELOPER: Greg Caudle
PRINT ADVERTISING TRAFFIC: Lisa Freeman
lfreeman@cahabamedia.com 205-212-9402
CIRCULATION
AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
lmasaoay@cahabamedia.com 205-278-2840
ADVERTISING
NATIONAL SALES MANAGER: Derrell Moody
dmoody@pump-zone.com 205-345-0784
ACCOUNT EXECUTIVES:
Mary-Kathryn Baker
mkbaker@pump-zone.com 205-345-6036
Mark Goins
mgoins@pump-zone.com 205-345-6414
Addison Perkins
aperkins@pump-zone.com 205-561-2603
Garrick Stone
gstone@pump-zone.com 205-212-9406
MARKETING ASSOCIATES:
Ashley Morris
amorris@cahabamedia.com 205-561-2600
Best regards,
Sonya Crocker
scrocker@cahabamedia.com 205-314-8276
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the
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medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will not be
returned. Volume 23, Issue 8.
THE POWER OF
NON-IMPINGEMENT
H
show great advantages in the transportation
of fluid in general industry, including: oil and petrochemical,
chemical processing, municipal water/wastewater, food and
beverage, pharmaceutical manufacturing, pulp and paper, steel
manufacturing, general industrial and specialty applications.
YDRAULIC DISC PUMPS
SANTEE, CA
619-596-3181
DISCFLO.COM
This issue
COVER
SERIES
AUGUST
Volume 23 Number 8
60
AU G U S T 2 0 15
PUMPSANDSYSTEMS.COM
SYSTEMS
COLUMNS
OPTIMIZE SYSTEM
PERFORMANCE
4 highly engineered solutions to help
you get the most from your pumps
PUMPING PRESCRIPTIONS
14 By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC
Component or Cartridge
Choose the Right Seal
How Remote Monitoring
Empowers Plant Employees
Trade Show Preview
Turbomachinery &
Pump Symposia
Image courtesy
of Hydro, Inc.
68
PRACTICE & OPERATIONS
102
2
8
82
106
107
108
112
This issue
SSPECIAL
PECIAL
SECTION
AUGUST
DEPARTMENTS
84 BUSINESS OF
THE BUSINESS
Precision Agriculture
& Remote Monitoring
Modernize Pump Systems
By Arun Prasath
Frost & Sullivan
86 EFFICIENCY MATTERS
PERFORMANCE OF DRY-START
VERTICAL PUMPS
By Fumitaka Kikkawa & Yoshimasa
Kachu, Mikasa Corp. & Hiroshi Satoh,
Oridea Inc.
90 MAINTENANCE MINDERS
48 THE BASICS OF
COUPLING SELECTION
By Robert Bramer,
95 SEALING SENSE
58 COMPOSITE BEARINGS
26
Understanding System
Efficiency in Motor-Driven
Rotating Equipment
By William Livoti
WEG Electric Corporation
Energy Efficiency of
Compression Packings
in Rotodynamic Pump
Applications
By Henri Azibert
FSA Technical Director
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eqog"vqigvjgt"vq"oggv"{qwt"vqwijguv"ejcnngpigu0
Colfax Fluid Handling delivers what no other pump supplier can
a single source for trusted product brands, the most complete
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Discover the many ways were redefining whats possible.
colfaxfluidhandling.com/redefining
NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
MIKE DUPUIS, JIM SMITH &
LENWOOD IRELAND, EASA
THOMAS DONATO,
ROCKWELL AUTOMATION
Mike Dupuis
NORMAN ZOMBOR,
NETZSCH CANADA, INCORPORATED
EXTON, Pa. (June 25, 2015) NETZSCH Canada,
Incorporated, recently expanded its sales
force by hiring Norman Zombor as western
regional manager for the oil and gas market.
He is responsible for supporting and promoting
Norman Zombor
NETZSCH products in Alberta and British
Columbia. Zombor has a CET in mechanical
engineering and a career of increasing levels of
responsibility in the oil and gas industry. netzsch.com
STEFAN HANTKE,
SCHAEFFLER INDUSTRIAL
SCHWEINFURT, Germany (June 22, 2015)
Stefan Hantke has assumed global management
of sales and engineering of the Industrial
division of Schaefler Technologies AG & Co. KG.
In this new position, Hantke is a member of the
Industrial Divisions Management Board and is
Stefan Hantke
responsible for the global sales management
for rolling and plain bearing components and systems for about
60 industrial sectors. He is also responsible for the 27 Schaefler
Technology Centers (STC) worldwide. Hantke has more than 20 years
of sales and engineering experience in the mechanical engineering
sector, particularly in the ield of bearing and linear technology.
schaeffler.com
John Conway
SMOOTH
H
R
POWERFUL MOTOR
d
Variable speed
motor. None of thee
hammering problemss
common with
h
solenoid pumps.
s.
NATURAL
NA
ATU
PVDF
WETT
WE
TT
WETTED
PARTS
Fo
or o
For
optimum
ch
hem
chemical
resistance.
JAYANTHI IYENGAR,
XYLEM INC.
IP6
P6
66
NEMA
EMA
MA
A 4X
X
]G
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]GY
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YN JU
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JU]
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FULL
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U LL
L
STROKE
A smooth
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helps reduce
the risk of
vapor lock.
PRIMING/
PR
G
DEGASSING
VALVE
riming
Facilitates priming
ure
under pressure
vin
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g
and in removing
e
gas from the
system.
DOUBLE
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UB
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Oversized for increased
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p u mpsa ndsyst ems.c om | Au gu st 2015
10
NEWS
Asahi/America Opens
New Headquarters
LAWRENCE, Mass. (June 11, 2015)
Asahi/America, Inc. oficially opened
its new headquarters in Lawrence,
Massachusetts, on April 23 with a
ribbon-cutting ceremony and open
11
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12
NEWS
EVENTS
ALL-TEST Pro, LLC, Electrical
Reliability Training Seminar
Aug. 10-14, 2015
Holiday Inn Orlando
Lake Buena Vista, Fla.
860-399-4222 / alltestpro.com
5th Annual Pumps Hands-on
Training: Maintenance, Energy
and Reliability Conference
(PumpTec-Israel)
Aug. 18 19, 2015
Tel Aviv, Israel
770-310-0866
pumpingmachinery.com/pump_school/
pump_school.htm
IDA World Congress
Aug. 30 Sept. 4, 2015
San Diego Convention Center
San Diego, Calif.
wc.idadesal.org
TPS 2015
Sept. 14 17, 2015
George R. Brown Convention Center
Houston, Texas
979-845-7417 / tps.tamu.edu
Pumps & Systems Webinar
Presented by Baldor
Sept. 24, 2015
pumpsandsystems.com/webinars
WEFTEC
Sept. 26 30, 2015
McCormick Place
Chicago, Ill.
240-439-2554 / weftec.org
Pack Expo (PMMI)
Sept. 28 30, 2015
Las Vegas Convention Center
Las Vegas, Nev.
703-205-0480 / packexpolasvegas.com
Centrifugal And Positive
Displacement Pumps (Basics)
Oct. 28 29, 2015
Pumping Machinery Training Center
Norcross, Ga. / 770-310-0866
pumpingmachinery.com/pump_school/
pump_school.htm
13
14
PUMPING PRESCRIPTIONS
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
15
16
PUMPING PRESCRIPTIONS
References
1. Nelik, L., Pump Repair and Upgrade Standards, pages
16-17, Pumps & System, May 2012
2. Kale R.D., and Sreedhar B.K., A Theoretical Relationship
Between NPSH and Erosion Rate for a centrifugal Pump,
ASME 1994, FED-Vol. 190, Cavitation and Gas-Liquid
Flow in Fluid Machinery
3. Nelik L., How Much Energy is Wasted When Wear Rings
are Worn to Double Their Initial Value?, March 2007
17
REMOVABLE,
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offers just that. The new aggressive self-cleaning wearplate is designed to handle clog-prone
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A lightweight inspection cover allows for easy access to the inside of the pump without
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Trust Gorman-Rupp pumps to keep your operation running smoothly month after month, year after year.
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538
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18
Introducing the
NEW
Affordable Innovation
Its not just the low price, but the incredible built-in features that make
our new Productivity2000 a must-have controller.
Why pay thousands elsewhere for features that are standard for
our newest PLC, including FREE programming software?
5 built-in communications ports right
on the CPU
All the communication you need is built
right in! Modbus TCP/IP, EtherNet/IP, and
serial devices are supported with no additional
modules required!
OLED real-time data displays
View accurate process variable data (current,
voltage and temperature) as well as system
diagnostics on the Productivity2000 hardware
OLED displays. No meter required!
Plus
Effortless PID loops
Flexible tag name
programming
Auto-discovered I/O
Hot-swappable modules
Simple VFD configuration
Built-in data logging
Multiple wiring options
Web server functionality
Small footprint: 7-slot
rack only 10-1/2 wide
AutomationDirect
Productivity2000
Allen-Bradley
CompactLogix
$69.00
P2-04B
N/A
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Power Supply
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$414.50
CPU
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P2-550
$3,160.00
1769-L33ER
16 AC Inputs
$105.00
P2-16NA
$286.00
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16 24VDC Inputs
$69.00
$244.00
8 Relay Outputs
$51.00
P2-08TRS
$301.50
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1-800-633-0405
19
20
Table 3. The annual operating costs for using a control valve to control the flow.
This is the same operating cost calculation for the manual control.
400
125
0.69
0.93
62
8000
0.08
$9,337
Figure 4. A pump system curve showing the pump operating at various speeds.
The pump operating at 1,424 rpm provides 76 feet of head, equal to the process
requirements at 400 gpm.
Conclusion
Passive controls have simple
designs and low installation costs,
but they can have greater process
variability and operating costs.
Active controls can maintain a set
point with minimal changes in the
process variable. These systems
have tighter control that comes
at a higher original cost, but the
operating cost can be much lower.
Ray Hardee is a principal founder
of Engineered Software, creators of
PIPE-FLO and PUMP-FLO software.
At Engineered Software, he helped
develop two training courses
and teaches these courses in the
U.S. and internationally. He is a
member of the ASME ES-2 Energy
Assessment for Pumping Systems
standards committee and the ISO
Technical Committee 115/Working
Group 07 Pumping System
Energy Assessment. Hardee was
a contributing member of the HI/
Europump Pump Life Cycle Cost
and HI/PSM Optimizing Piping
System publications. He may be
reached at ray.hardee@engsoftware.com.
21
Critical Flow
Measurement Solutions
Measuring everything from water in hydraulic fracturing
or mining operations to gases and liquids from wellheads,
the Badger Meter family of flow meter solutions delivers
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as Blancett, Hedland, Preso and more to help you
improve the efficiency and productivity of your most
critical operations.
Visit www.badgermeter.com or call 877-243-1010
today for more information.
Circle
102 on card or visit psfreeinfo.com.
pu mpsa ndsyst ems.c om | Au gu st 2015
22
Rethinking NPSH
Understanding this complex topic can help end users avoid common pitfalls.
Suction Pressure
One of the most common errors
I witness is confusing suction
pressure with net positive suction
head available (NPSH A). Even
people with decades of pump
experience and education seem
to make this mistake. A common
comment is, I do not need to
calculate NPSHA because I have
135 psig of suction pressure.
What they fail to understand is
that the temperature of the fluid in
this case is 350 degrees F. (Please
Rethinking the Concept
assume water as the fluid for all
The responsibility and purpose of
examples in this article.)
the centrifugal pump is to receive
The formula for NPSH A indicates
the liquid that the suction system
delivers and move it downstream.
that 100 percent of the negative
The suction-side system, if properly head caused by the vapor pressure
designed and operated, delivers the of the 350 degree fluid negates
fluid to the pump. The pump does
the positive head contributed by
not reach upstream and retrieve the the pressure of 135 psig. After
fluid, nor is it capable of doing so.
accounting for the losses that
The common misconception
result from friction head, the only
is that the pump will suck the
positive head available to make
fluid from the suction system into
up the remaining energy (bars of
the pump.
signal strength) is the static head.
Perhaps if liquids had tensile
Static head is the energy (bars)
strength characteristics, that could contributed by the elevation of
be remotely possible (I acquiesce
the fluid over the centerline of
that the impeller does create a
the impeller. (Note: This article
small differential pressure at the
does not account for velocity
eye), but the suction-side system
head because of the fractional
must have adequate energy to
contribution and, in this case,
deliver the fluid to the pump. Using flooded suction.)
Augus t 2 015 | Pum ps & S yst e m s
1
2
3
4
5
6
7
23
Vacuum
At the bottom section of most
steam condensers is a collection
area, usually a tank-shaped
reservoir for the condensate
commonly known as the hot
well. In these applications, end
users commonly make errors
determining the correct absolute
pressure when making the NPSH A
calculations. Pumps are subject
to vacuum on the suction side in
many other instances as well.
The error is in the assumption
that the vacuum level is equal to
the absolute pressure. Consider
a condenser with a vacuum level
of 28 inches of mercury (Hg).
Model 701
7011 Grinder
JAM BUSTER
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1-800-928-7867 | www.zoellerpumps.com
24
Visit us at the
Pump Symposium
in Houston
September 15-17
Booth #1136
WEFTEC
in Chicago
September 28-30
Gorman-Rupp Booth #1400
www.nationalpumpcompany.com
Circle 134 on card or visit psfreeinfo.com.
Augus t 2 015 | Pum ps & S yst e m s
25
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A
YA S K A W A . C O M
26
SPECIAL SECTION
Validate Sealing
Systems for Optimized
Performance
Investment at the start of a project can lead to improved
safety, reliability and savings.
BY LARRY CASTLEMAN
TRELLEBORG SEALING SOLUTIONS
27
Image 2. An engineer
completes a
compression test to
ensure performance.
Process Validation
More than a series of tests, validation is a process. It
begins with identifying areas of concern, continues
with testing, and is completed with an analysis and
verication of results. However, during design validation
or development, market forces and conditions do not
always allow for all the possible paths to be considered.
The balance of risk, such as risk of failure mode or system
functionality loss and associated liability, is crucial to
the decision-making process. In scenarios where time
and cost associated with validation are limited, it is
prudent to take into account the right seal functionality
considerations in the equipment.
28
PPC P3-F
Dual Cartridge
Mechanical Seal
Process Workflow
The process ow during a validation exercise
incorporates all signicant factors for consideration.
Even though the amount of crucial elements to consider
for a sealing system may seem overwhelming, many
of these factors provide a practical approach and ow.
Incorporating these important factors can reduce
common mistakes and duplicate common successes.
For starters, eective communication between the
sealing supplier and the end user as well as subsequent
thoughtful and planned action is benecial. While this
approach requires more eort up front, the reward is a
signicantly reduced chance of a negative outcome later.
Taking the critical elements of seals and bearings
into account before the testing phase of the validation
process will optimize the return on investment. The end
result is better overall performance of the process.
www.ppcmechanicalseals.com
Made in USA
Augus t 2 015 | Pum ps & S yst e m s
29
30
SPECIAL SECTION
Component or Cartridge:
How to Choose the Right Seal
The balance between cost and ease of installation should be the
major deciding factor.
BY EUGENE VOGEL
EASA
Liquid Pumpage
Vaporized Liquid
Rotating Shaft
31
Image 1. Component
(left) and cartridge (right)
mechanical seals
32
SPECIAL SECTION
Dual Seals
Image 2. A cartridge dual mechanical seal
Dual seals are effective
solutions for many pumping environments and
applications that are tough on seals, including high
temperatures, high pressures and foul pumpage laden
with abrasives. Dual seals have a chamber between the
seals into which barrier fluid can be pumped to provide
cooling, lubrication and protection from abrasives in
the pumpage. While redesigning a single-seal pump to
accept dual component seals would be challenging, the
precision components of a cartridge mechanical seal can
be designed as a dual seal that can easily fit in the same
space as a single component seal (see Image 2).
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Augus t 2 015 | Pum ps & S yst e m s
33
Impeller Adjustment
Some pumps, particularly those with semi-open
impellers, require periodic adjustment of the impeller
face clearance. Users can make this adjustment by moving
the pump shaft axially, which can change the tension on
the seal. On a component seal, resetting the seal tension
requires signicant disassembly of the pump. Most
cartridge mechanical seals have retaining devices that
can be reinstalled to align the stationary and rotating
elements. This makes it easy to reset the seal tension after
the impeller face clearance has been adjusted.
Split Cartridge Mechanical Seals
Replacing a mechanical pump seal, component or
cartridge usually requires pump disassembly. One way
to avoid this is to use a split seal. The faces and other
circumferential components are split in half so they can
be installed without disassembling the pump. Since each
circumferential component must be properly tted and
joined together, installation of split component seals can
be problematic and requires a high degree of technical
ability. If any mistakes are made, the seal wont work.
Recent developments in seal technology have led to
the production of split cartridge mechanical seals, which
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sales@tfsealsusa.com
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10620 Stebbins Cir, Suite E
Houston, TX 77043
34
SPECIAL SECTION
How to Interpret
Published Sealing Data
Gasket information and the tests used to generate it can help
users make the best possible equipment selections.
BY JIM DRAGO
GARLOCK SEALING TECHNOLOGIES, LLC
Image 1. A technician tests a gasket for leak tightness using DIN3535 method and equipment. (Images and graphics courtesy of
Garlock Sealing Technologies, LLC)
35
Seal Composition
Temperature
Minimum
Maximum
Continuous maximum
Pressure
PxT
Maximum for 1/32 inch, 1/16 inch (0.8
millimeters, 1.6 millimeters)
For 1/8 inch (3.2 millimeters)
Filled Restructured
Polytetrafluoroethylene (PTFE)
Compressed Inorganic
Fiber
-450 F (-268 C)
--500 F (260 C)
-100 F (-75 C)
700 F (370 C)
400 F (205 C)
-100 F (-75 C)
800 F (425 C)
550 F (290 C)
400,000 psig x F
(14,000 bar x C)
250,000 psig x F
(8,600 bar x C)
275,000 psig x F
(9,600 bar x C)
--0.22 ml/hr
0.2 ml/hr
0.6 ml/hr
0.2 ml/hr
1.0 ml/hr
<0.015 cc/min
0.05 cc/min
0.05 cc/min
Compressed Aramid
Fiber
18%
21%
15%
7-12%
7-17%
7-17%
>10%
50%
>50%
2,000 psi
(14 Newtons per square millimeter
(N/mm2))
2,250 psi
(15 N/mm2)
1,500 psi
(10 N/mm2)
36
YOUR
BEARINGS
COULD BE
DOING
MUCH MORE
FOR YOU.
Circle 135 on card or visit psfreeinfo.com.
800.675.9930
www.nskamericas.com/aip
37
38
SPECIAL SECTION
Dust Contamination
Dust in the production environment is a major problem
for bearings. Heavy dust is made of particles as small as
50 microns that can become airborne.
Because they fall at about 200 millimeters per
second, these particles are unlikely to move beyond the
production area. Heavy dust is readily seen as a cloud with
the naked eye.
Light dust, which is smaller than 50 microns in size,
may stay in the air for more than 30 minutes. This type
of dust can travel well beyond the manufacturing site,
although it is commonly seen as a ne coating when it
settles on machinery, bearing housings and other surfaces.
Image 1. Three months after running, the air purge still keeps
dust away from the stator to rotor interface.
39
40
SPECIAL SECTION
Lubrication Issues
Improper lubrication accounts for about one-third of
all bearing failures. Poor lubricant viscosity, prolonged
service or infrequent changes, excessive temperature,
using the wrong type of lubrication or over-lubrication
are common problems. External contamination is another
major cause of compromised performance of the lubricant.
Creating optimum lubrication conditions is a
balancing act between over-lubrication and underlubrication. Both create a problem as do contamination
or the use of a lubricant not suited to the equipment.
Consistency, viscosity, oxidation resistance and antiwear characteristics all play a role in the selection of
a lubricant. Usually, the application will dictate the
amount, type and frequency of lubrication needed.
41
Conclusion
When all of the issues that cause bearing failure are
addressed, bearings should have a long, trouble-free
life. Taking steps to address these problems before they
happen can result in signicant cost savings. Bearings
are precision elements and require an ongoing supply of
clean lubricant in the appropriate amount to ensure long
equipment life and low maintenance. Modern labyrinth
bearing protectors have been shown to prevent the entry
of contaminants, as well as the loss of lubricant.
References:
1.
Bloch, Heinz; Pump Users Handbook: Life Extension 2011
42
SPECIAL SECTION
43
44
SPECIAL SECTION
MC r
e
Chicago,, Illinois
C
45
IIn rigorous
i
clog
l testing,
t ti Barnes
B
SH clog-resistant
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it t
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pu mpsa ndsyst ems.c om | Au gu st 2015
46
SPECIAL SECTION
BOOTH #3206
47
rtners
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STANDING BESIDE OUR CUSTOMERS
For 50 years DP Pumps has been
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consistent premium quality, have access
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Download our
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Represented by Global Pump Marketing
48
SPECIAL SECTION
The Basics of
Coupling Selection
Users should consider these important factors when
choosing the best equipment for their applications.
BY ROBERT BRAMER
FISCHER PROCESS INDUSTRIES
HP =
T(n)
63025
Equation 1
Where
HP = horsepower
T = torque (inch-pounds)
n = shaft speed
Service Factor
Service factor is an application- and coupling-dependent
multiplier that should be factored into sizing data. It is a
buer between the torque capacity used to size a coupling
and what happens in the real world.
For example, if a pump requires 500 inch-pounds (in-lb)
of torque and the coupling manual recommends a 1.2
service factor, the coupling would be sized for 600 in-lb
(500 in-lb x 1.2 = 600 in-lb). This is to help compensate for
application details such as shock loads, type of driver and
49
Fail Safe
A fail-safe coupling will transmit power even after the
element fails, because part of both hubs operates in the
same plane. A jaw coupling is an example of a fail-safe
coupling. Alternatively, couplings that are not fail-safe
are also available. When the element fails, these couplings
will no longer transmit power, because no part of the hubs
operates in the same plane.
Load Characteristics
Users should always know the load characteristics for
their pumps. Are uniform or non-uniform loads expected?
Is this a variable-torque (centrifugal pump) or constanttorque (positive displacement) application?
Starting torque is particularly important. Progressing
cavity pump applications are a prime example of an
50
www.ksbusa.com
Valves
Service
51
sotera.com/aod
pu mpsa ndsyst ems.c om | Au gu st 2015
Misalignment
Shaft misalignment includes parallel oset,
angular oset and a mixture of the two (see Figure
1). Coupling manufactures often talk about the
misalignment their coupling can tolerate. Just
because the coupling can handle the misalignment
does not mean that the pump can. For example,
a popular model elastomeric coupling used in the
pump industry can handle more than 0.060 inches of
parallel oset. However, the installation, operation
and maintenance (IOM) manual for the pump to
which the coupling is being mounted indicates that
the manufacturer only recommends 0.005 inches
of parallel oset. The coupling can tolerate more
than 12 times the parallel oset that the pump is
recommended to handle. Improper alignment will lead
to bearing and seal issues down the road. Taking the
necessary time to align their pump assemblies before
putting them into service will help save plants money
in the long run.
52
SPECIAL SECTION
Image 1. The first set of seals were removed from a natural gas compressor after
11 years in service. (Images and graphics courtesy of Quadrant)
53
Table 1. The two sets of seals used in the evaluation and their descriptions
B-Case (2)
C-Case
C-Case
C-Case
C-Case
8th Stage
2nd Wheel
5th Wheel
4th Wheel
5th Wheel
7th Wheel
2nd Wheel
D-029-100029
D-029-126-002
(possibly)
TCE Part
Number
C-029-126-002
D-029-164-005 D-029-100-029
D-029-100029
Nova Serial
Number
120201187
120201103
Not identified
120201090
Not
identified
120201187
Marking on
Part
Not identified
14388 K201C
#5
lower
14387 K201C
#4
lower
14386 K201C
14389
K201C #7
Not identified
Size
15.242" OD x
12.6"
ID x 2.226
18.057" OD x
16.4" ID
x 1.180
11.623" OD x
10.0"
ID x 1.562
11.623" OD x
10.0"
ID x 1.562
11.623" OD
x 10.0"
ID x 1.562
15.242 OD x 12.6 ID x
2.226
Seal Config
2-segment
shaft
seal
2-segment
impeller
seal
2-segment
shaft
seal
2-segment
shaft
seal
2-segment
shaft
seal
2-segment shaft
seal
Material
Torlon 4540
Torlon 4540
Torlon 4540
Torlon 4540
Torlon 4540
Torlon 4540
Temp
Exposure
47 to 60 C
49 to 64 C
44 to 57 C
49 to 64 C
61 to 77 C
31 to 45 C
11 yr
11 yr
11 yr
11 yr
11 yr
15 yr
Time in
Service
54
SPECIAL SECTION
Table 2. The results of the mechanical property testing for both the 11-year-old and 15-year-old polymer labyrinth seals
Seal Set 2
15 Years in Service
Duratron T4540
Baseline (1)
B-Case(2)
C-Case
C-Case
C-Case
C-Case
8th Stage
Recent
Production
2nd
Wheel
5th
Wheel
4th
Wheel
5th
Wheel
7th
Wheel
2nd Wheel
Specific gravity
ASTM
D792
1.47
1.47
NA
NA
NA
NA
1.47
Tensile strength,
psi
ASTM
D638
10,516
9,416
NA
NA
NA
NA
10,323
Elongation at
yield, %
ASTM
D638
3.40
2.23
NA
NA
NA
NA
3.34
Elongation at
break, %
ASTM
D638
3.40
2.23
NA
NA
NA
NA
3.34
Tensile modulus,
psi
ASTM
D638
608,843
634,536
NA
NA
NA
NA
NA
Flex strength,
psi
ASTM
D790
11,864
13,217
NA
NA
NA
NA
9,160
Flex modulus,
psi
ASTM
D790
546,492
608,581
NA
NA
NA
NA
687,283
Compressive
strength, psi
ASTM
D695
23,606
21,140
21,475
21,136
20,345
21,860
22,132
Compressive
modulus,psi
ASTM
D695
346,670
433,450
437,000
450,000
454,160
456,440
376,060
DSC Tg, oC
ASTM
D3418
281
280
NA
NA
NA
NA
272
Moisture content
at time of
testing, %
ASTM
D570
Dry
0.47
NA
NA
NA
NA
0.58
(1) Quadrant production sample data based on averages between 18 x 11 x 6 and 12 x 3.5 x 6 tubular bars
(2) B-Case, 2nd wheel was the only component large enough to allow for a full-sized machined tensile bar, which allowed for tensile strength, elongation
and modulus data. As a result, only compressive data was generated on the other samples.
55
Results
The property values of both the 11-yearold and 15-year-old compressor seals
revealed consistent performance
compared with standard data for
the product.
For the 11-year-old seals, the tensile
strength and elongation properties of
the B-case sample were a little lower
than baseline, but the tensile modulus
was higher. The lower properties
were due to slight embrittlement
during service.
The exural and compressive
properties were higher than current
production, which can also be attributed
to embrittlement. The glass-transition
temperature (Tg) of the 11-year-old
material remained steady at 280 degrees
C, at which no major degradation of
the polymeric structure occurred. The
compressive strength and modulus
values were also tightly packed and
within a 7 percent spread, showing good
data integrity among the returned seals.
For the 15-year-old seal, both tensile
and compressive data matched closely to
Simple, Reliable
Efficient
Vapor Recovery? LPG Transfer? Natural Gas Boosting?
The answer is the FLSmidth Ful-Vane rotary vane compressor!
Built robustly for long service life, it has only three moving parts. Combined with low operating speeds
which minimizes wear and vibration, it is designed to not only outlast other compressors, but save you
money on power and maintenance costs.
Suitable for natural gas, are gas, bio gases, LPG vapor, and ammonia refrigeration
Carbon ber vanes last longer than traditional blades
Variable ows with VFD and/or bypass
Single stage to 3000 SCFM, two-stage to 1800 SCFM
Discharge pressures to 250 PSIG
Made in the USA for over 80 years
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Circle 152 on card or visit psfreeinfo.com.
pu mpsa ndsyst ems.c om | Au gu st 2015
56
Image 3. For seals from the B-case sample, tensile strength was
lower than baseline, but tensile modulus was higher.
57
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58
SPECIAL SECTION
Composite Bearings
Resist Wear in Circulating
Water Pumps
A thermoplastic composition in abrasive applications helped
bearings meet end user specications.
BY GREG GEDNEY
GREENE, TWEED & CO.
The Challenge
The nuclear plant engineering team requested that the
pump manufacturer add a low-ow/ush alarm to the
upgraded pumps. The alarm would trigger when the
ush drops below 5 gallons per minute (GPM) of ow to
the bearings. The bearings in the pump must survive 15
minutes of low-ow/ush conditions to give the operators
adequate time to respond.
Although the pump OEM was condent the bearings
would survive for 15 minutes under low-ow/ush
conditions, sucient data was not available to conrm
the composite bearings performance.
Figure 1. The test matrix shows the results of using the testing rig.
59
Table 1. The inner diameter of the bearings measured in inches () and millimeters (mm) before and after testing
Before Test
Inner Diameter
Inner Diameter
Inner Diameter
Inner Diameter
Bearing 1
Bearing 2
Bearing 3
Bearing 4
The Solution
A test program was developed to conrm the bearings
ability to survive in the end users condition. The
programs objective was to verify that the running
clearance would remain within an acceptable limit (less
than two times the original clearance) after a 15-minute
dry run, using the same operating conditions as the
vertical pump.
The Results
Four bearings were tested on a horizontal testing rig.
Multiple tests were run on the four bearings, each for a
specied amount of time (15, 30 and 60 minutes). The
bearings demonstrated outstanding wear resistance
FRANKLIN INTRODUCES
NEW HIGH HEAD GRINDERS
Designed to handle the tough demands of higher head conditions found in many
low pressure sewage applications. Utilizing the same reliable patented cutter
system at 414,000 cuts per minute, these new units incorporate 2 impeller stages
for efficient pumping of sewage slurries up to 200 feet. With only 16 full-load
amps, these units are not only the solution to many demanding applications,
but also replace other grinder units failing to meet requirements.
60
Optimize High-Energy
Pumps With Improved
Impeller Design
As new design and manufacturing technologies are
developed, end users can aordably upgrade their
systems and verify better performance.
BY BOB JENNINGS & DR. GARY DYSON
HYDRO, INC.
61
Image 1. Much research has pointed to opportunities for cost savings by
optimizing pumping equipment. (Images and graphics courtesy of Hydro, Inc.)
COVER
SERIES
PROTECT PUMPS
PUMP POWER
VALVE CLOSING
PUMPING
AMPS
POWER
62
FULL LOAD
No Sensitivity
For Low Loads
NO LOAD
VALVE OPENING
NO FLUID
FULL LOAD
63
ROTALIGN Ultra IS
or bearing failures,
fail
and increased power consumption.
A PRFTECHNIK product
Laser Alignment, Flatness,
Straightness and more!
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305.591
64
Measurement
Per Pump
Per System
GPM
40,000*
160,000*
TDH
185
185
Efficiency
0.74
0.74
Brake horsepower
2,525
10,101
kilowatts (kW)
1,884
7,536
8,400
8,400
kW rate
$0.07
$0.07
$1,107,792.00
$4,431,168.00
Measurement
Per Pump
Per System
GPM
48,333*
TDH
160
160
Efficiency
0.89
0.89
2,194
6,582
Brake horsepower
144,999*
kW
1,637
4,911
8,400
8,400
kW rate
$0.07
$0.07
$962,556.00
$2,887,668.00
$ 4,431,168.00
$ 2,887,668.00
$ 390,000.00*
Total Savings
$ 1,153,500.00
* Number excludes the regular repair cost(s) normally incurred for this equipment.
Conclusion
Signicant energy savings opportunities exist in every manufacturing
facility worldwide, particularly with pumping systems that:
use pumps driven by 200 horsepower and above
are primarily providing cooling water
include demands proportional to the plant throughput
are used for batch operations
have inherent delays or production slowdown
currently use dump valves or bypass lines
feature uctuating system loading
Augus t 2 015 | Pum ps & S yst e m s
65
66
COVER
SERIES
Visit us at
Booth# 1928 at
the 2015 Pump/
Turbo Symposia
TE
C
H
P
N
M
O
U
LOG
P
E
Y
EXPERTS
TH
67
MS
E
T
S
Y
S
adin
The Le
azin
g Mag
e for P
ump U
id
orldw
sers W
TM
The Cost
of Clean
Water
How pumps play a role in the
WATER-ENERGY NEXUS
IFT OF
EX CL
A
CO V ER
U SI V E
ING . C OM
E A MP UMP
OM
G E FR
ZA M BI
A LA
A & M
WI
FOOD PROCESSING
BUILDING SERVICES
S U R V IV
THE A
STATE
OF
C H E M I C ANAL
JAN UAR
P O W E R G E N E R AT I O N
UP S T R
ALSO INSIDE THE NEW OIL MARKET: What Can Operators Do to Improve Efciency?
Y
O LO G IT IE S
TE C H N
UN
P U M P G ES C O M M
N
A
H
C
Y / F E BRU
ARY
CLEAENR
WAT
| 2 015
THE G
A L OF T
H E F IT T
IAL LI
ES
RTIFIC
THE OI
F T E VO
LU
TION
L & GA
S INDU
STRY
REPORT
GAS PO
WERS
FR ACKIN
G UNITS
SHOW
PREVIEW
IN THE
MARCE
: SOUT
LLUS SH
HWES
TE RN
ALE
PETROL
EUM SH
ORT CO
URSE
TURAL
TR ADE
COMPREHENSIVE COVERAGE
RELEVANT CONTENT
CASE STUDIES
WORLDWIDE NEWS
TECHNICAL ARTICLES
To subscribe to our print or digital editions and to sign up for our e-newsletters,
visit our websites and click on SUBSCRIBE.
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PUMPSANDSYSTEMS.COM/MENA
UPSTREAMPUMPING.COM
68
COVER
SERIES
1.
69
Image 1. Calculating NPSHA
3. NPSH
70
COVER
SERIES
6.
PROTECT
your Pumps,
Mechanical
Seals and
Bearings
Free
Technical Support &
Used Oil Analysis
Summit
Industrial Products
800.749.5823
www.klsummit.com
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Augus t 2 015 | Pum ps & S yst e m s
71
Conclusion
Cavitation is unavoidable in pump
operations. Understanding how to reduce
it using NPSH calculations is necessary to
maintain pump functionality and health.
Although methods and materials are
available to reduce the eects of cavitation,
the truth is that cavitation will always be
present. Proper management of cavitation
to prevent damage is the end goal.
72
COVER
SERIES
Engineered Composites
Oer Opportunities for
Upgrading Equipment
These pumps prevent equipment from corroding, provide lower
costs and increase eciency.
BY JOHN A. KOZEL
SIMS PUMP VALVE COMPANY, INC.
73
Pump Optimization
Too often, a pump is purchased
for a specic performance but
when put into service, it operates
at a point completely dierent
from the original design point,
or BEP, because of the system
requirements. The pump operating
away from the BEP also causes
problems such as excessive noise
and vibration, shaft oscillation,
cavitation, and premature wear
and failure of the mechanical
seals, bearings, rings, sleeves
and impellers.
In extreme cases, the pump
shaft will break right behind the
impeller from the excessive radial
forces that occur when a pump is
operated away from the original
design point.
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74
COVER
SERIES
75
Improved Efficiency
In 2015, tremendous eort has been put forth to reduce
energy consumption. The Department of Energy (DOE)
and the Hydraulic Institute have been working together
to reduce the energy consumption of pumps, motors and
pump systems. Engineered composites can contribute to
this eort. By re-engineering the pump/impeller design,
they can signicantly reduce energy consumptionin
some cases by 20 percent.
Equipment Longevity
In addition to improved eciency, engineered composite
impellers oer many advantages over traditional products
cast from metal. They do not corrode, are lightweight,
can run with tighter clearances, are designed for high
eciency, and are not subject to casting defects or
76
COVER
SERIES
Reduced Wear
The new alternative composite solutions
for impellers and rings are ideal for new,
repair or retrot applications. Engineered
impellers and rings are lightweight and do
not corrode.
Wear of other pump partsincluding
the pump casingis greatly reduced
because of the engineered impellers
balance, light weight, self-lubrication,
sealing, and resistance to corrosion, erosion
and cavitation. This means far less expense
for replacement of parts and downtime.
Image 4. This composite pump was re-engineered into a two-stage structural composite
pump with single-suction impellers. It is approximately 11 percent more efficient than the
original metallic pump (before corroding).
Maximized Performance
Because of new technologies, structural
composite impellers are computerengineered and precision-machined. The
impeller vane geometry can be engineered
using computational uid dynamics (CFD)
techniques and programmed to maximize
eciency and performance. Problems
such as recirculation, radial thrust and
cavitation can be minimized or eliminated
by using structural composite impellers
instead of the traditional
metallic ones. Impeller vane shapes can
easily be modied to provide the best
vane shape for specic applications and
performance requests.
Corrosion, erosion, cavitation, rotor
imbalance and leakage between the wear
rings, casing rings and interstage bushings
are major contributors to the loss of
pump eciency. Damage from corrosion,
erosion and cavitation quickly destroys
the metallic pump parts. Because of the
self-lubricating characteristics of many
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Augus t 2 015 | Pum ps & S yst e m s
77
John A. Kozel is president and CEO of SIMS Pump Valve Company, Inc.
He may be reached at 201-792-0600 or at
simsite1@aol.com. For more information, visit simsite.com.
78
COVER
SERIES
Electrical
Inspections
Reduce Cost of
Ownership
Oine and online testing can improve
reliability and reduce downtime.
BY JAMES JETTE
Offline Testing
During a motor inspection, several tests are performed
on the stator windings. A multimeter can be used to test
Augus t 2 015 | Pum ps & S yst e m s
79
80
COVER
SERIES
Online Testing
The most exciting new development in the world of pump
electrical maintenance is the development of online
testing. This new breed of instruments can be attached
to a pumping system to monitor the pump and motor
while they are running. The temperature, vibration, ow,
pressure, power and electrical waveforms can be analyzed
using online testing.
On the motor side, users can detect problems with
incoming power, bearings, stator shorts, and dirty or
wet windings. On the pump side, the intake pressure,
discharge pressure, uid temperature, ow rate, bearing
condition and vibration can be measured.
Another feature of online testingknown as data
loggingis the ability to collect measurements over a
period of time. The majority of pump system problems
happen when an operator is not presentthe ghost
failures that occur in the late hours of the night. Data
logging can monitor multiple channels of information
for long periods of time to capture these events as they
happen. Examining data logger records collected over
extended periods can also reveal trends that point to
Monitor them.
SKFs EXP4000 and
NetEP dynamic motor
monitoring solutions
reveal adverse impacts
variable-frequency
drives have on motors,
and they can help you
optimize performance
of those VFDs.
REGISTER
44TH TURBOMACHINERY & 31ST PUMP SYMPOSIA
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Comprehensive
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Circle 163 on card or visit psfreeinfo.com.
Augus t 2 015 | Pum ps & S yst e m s
83
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84
Food Security
One of the key challenges the
world faces today is population
growth, particularly in developing
countries. According to a recently
released report from the United
Nations, the worlds 7.2 billion
people will increase to 8.1 billion
by 2025 and 9.6 billion by 2050.
Most of that growth will occur
in developing regions, which are
projected to increase from
5.9 billion in 2013 to 8.2 billion
in 2050. The current food
production rate, however, falls
significantly short of meeting this
increased need.
Th is deficit is pushing farmers
to adopt better technologies that
will meet the increasing demand
and to optimize resources with
minimum waste. Adoption of
precision agriculture, particularly
in developing regions, can play
Augus t 2 015 | Pum ps & S yst e m s
Precision Agriculture
Built on location-based
technologies such as global
positioning systems (GPS) and
geographic information systems
(GIS), precision agriculture has
transformed the way farming is
conducted. It enables farmers to
monitor fleets remotely, conduct
soil analysis, monitor yield or
create customized maps to target
each area of a field uniquely. It
ensures better crop yield and
output efficiency, enabling high
profitability with optimum use of
available resources.
Emerging countries are
expected to invest heavily in
85
Remote Monitoring
New technologies will enable
multiple innovative applications
that change the way we live,
communicate and conduct
business. In 2015, the number of
connected devices is around 8.5
billion, and the installed base of
connected devices and machines
is expected to grow to 50 billion
units by 2020.
Remote monitoring is crucial
and intensive in agriculture.
In farming, water levels, soil
conditions and temperature
require continuous examination.
On the plant side, yield
monitoring and weed monitoring
are closely related key metrics.
Conserving water is a vital part
of farming. Water monitoring
and management are critical to
ensure this resource is allocated
effectively and used efficiently.
Farmers spend approximately
one-third of their time traveling
to inaccessible or distant places to
Adapt:
Conservation
agriculture
g
Develop:
Sustainable
agricultural
practices
Food
Security
Improve:
Agricultural
productivity
Utilize: Better
water
management
systems
Conclusion
The modern agriculture
industry provides a wide range
of opportunities for remote
monitoring and control. Water
conservation is a major challenge
for farmers, and because of
new regulations in water usage,
farmers are looking for better
ways to use available resources.
The growing awarenesscoupled
with technology savvy farmers
will increase the rate of growth of
precision agriculture at automated
farm processes.
86
EFFICIENCY MATTERS
Image 1. In order to fashion a handling and transfer operation that optimizes reliability, efficiency and safety, many chemical
processors are making the decision to install internal gear pumps. (Images courtesy of PSG)
87
industrial manufacturing
operations, positive displacement
internal gear pumps can offer
precise and consistent transfer of
demanding fluids.
Chemical processing and
manufacturing is one of the most
complex industrial operations. The
chemical manufacturing process
is so intricate that it is comprised
of several unit operations,
from cracking, distillation and
evaporation, to gas absorption,
scrubbing and solvent extraction.
Within that family of unit
operations, fluid transfer
touches every stage of the
manufacturing process and is vital
for overall process success. Often
oversimplified as transporting
fluid from one point to another,
fluid transfer in chemical
manufacturing is much more.
Fluid transfer includes a
spectrum of applications, with
responsibilities all along the
chemical production chain. For
example, thin or viscous raw
materials can be transferred to
storage tanks or blending and
mixing tanks. Final formulations
can be transferred to holding
tanks, and finished products can
be loaded into intermediate bulk
containers (IBCs) for delivery or
consumer packaging.
In many cases, chemical
manufacturing processes require
the use of dangerous substances,
such as strong acids, caustics,
solvents, resins and polymers.
Despite their inherent danger, these
are necessary for the manufacture
of thousands of consumer goods
or to facilitate other industrial
processes. The challenge when using
dangerous chemicals is to construct,
handle and transfer them in a safe
and reliable way.
Fortunately for chemical
processors, positive displacement
Image 2. No acid, polymer, resin or caustic has the same handling characteristics, which
makes pump versatility a primary concern for chemical processors. These internal gear pumps
overcome many handling concerns by featuring a method of operation that can successfully
and safely transfer fluids of differing viscosities and chemical makeups.
re
he
ati
ov
Inn
s
low
nF
Improve
Reliabilityand
Versatility
G-Series
Best-in-class delivery
Interchangeable with
competitive models
Flexible design for easy installation
Multiple seal options available
Available in cast iron and
stainless steel
PSG
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Grand Terrace, CA 92313-5651
P: +1 (909) 422-1731
psgdover.com
88
EFFICIENCY MATTERS
info@cd-adapco.com
www.cd-adapco.com
89
Chrishelle Rogers is the global gear pump product manager for Maag
Industrial Pumps, Grand Terrace, California, and PSG, Oakbrook Terrace,
Illinois. Rogers can be reached at 909-222-1309 or chrishelle.rogers@
psgdover.com. For more information, visit psgdover.com.
90
MAINTENANCE MINDERS
91
The debris from the broken bolts could have caused a catastrophic
failure of this compressor and could have resulted in the
compressor requiring a complete overhaul.
92
Efficiency Standards as
Defined by EISA
For each general-purpose
rating (Subtype 1) from 1 to
200 horsepower (HP) that was
previously covered by EPAct, the
law specifies a nominal fullload efficiency level based on
National Electrical Manufacturers
Association (NEMA) premium
efficiency as shown in NEMA MG
1, Table 12-12. All 230- or 460-volt
(and 575-volt for Canada) motors
currently under EPAct that were
manufactured after December 19,
2010, must meet or exceed this
efficiency level.
General-purpose electric
motors (Subtype II) not previously
Motor Losses
Losses in a motor include stray
losses, rotors, stators, core losses
and fan design (windage).
To make a motor more efficient,
a manufacturer must add more or
better material. These additions
and adjustments could include
more active material such as
copper in the winding, a longer
stator, rotor cores and improved
electrical steel (silicon steel is
used for the stator and rotor). A
93
System Efficiency
Energy-efficient motors can also
improve system efficiency, but
end users must consider the
following factors:
Motors meeting higher
efficiencies tend to run faster
than their less efficient
counterparts.
Matching speeds to application
need (such as pump flow) is
important to consider.
Case Study
The following case study graphically
illustrates the impact of a premiumefficient motor in a centrifugal
pumping application.
Figure 1 (page 92) provides four
separate scenarios for reducing
energy consumption in a cooling
tower pumping system. The
portrayed system is a typical closed
loop configuration where the
discharge is being throttled over a
range of operation. The system in
this example operates 24/7, 365
days per year. At this particular
load point, that means it operates
70 percent of the timeor 6,250
hours per year.
Columns 1 and 2 in Figure 1
indicate the various components
factored into the system efficiency
calculation. Column A is the
base condition where the system
operates 50 percent of the time.
The component efficiencies for the
VFD and gearbox are at 100 percent
because they were not used.
Under the base condition,
the total power required is
approximately 1,777 HP; almost
356 HP is being lost (wasted) across
a control valve. In addition, the
pump is operating back on the curve
at 65 percent efficiency. Under
these conditions, the total system
efficiency is 49 percent.
Column B provides the new
operating conditions with the
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94
Figure 1. Four separate scenarios for reducing energy consumption in a cooling tower pumping
system (Courtesy of WEG)
SEALING SENSE
95
96
SEALING SENSE
Power Consumption
While the final test procedure
produced good correlation of
results in terms of packing leakage,
temperature and post-test packing
condition, the one performance
aspect that continued to cause
debate was frictional level and
power consumption. Throughout
the round-robin test program
the results reported for frictional
torque or absorbed power showed
significant variability, partly
because of the different methods
used to measure it.
This uncertainty about packing
friction is concerning, because the
generally accepted wisdom is that
Figure 2. Results from round-robin 5
Test Rig
The test rig is designed to test
both compression packings
and mechanical seals so direct
comparison can be made under
the same conditions (see Image
1, page 98). A torque meter is
used to record the mechanical
seal or packing friction on the
shaft. Measurements of torque,
temperature and leakage levels are
97
98
SEALING SENSE
Initial Testing
After initial trials to validate
the equipment functionality and
accuracy of the monitoring devices,
the first tests were carried out on
the same graphite/ePTFE packing
that had been widely used during
the earlier test program.
Testing was conducted at
different rotational speeds and
pressures, with varying target
leak rates. For direct comparison,
a typical unitized, single-spring
elastomer bellows mechanical seal
was also tested under a range of
conditions. It is an unbalanced
mechanical seal with carbon
graphite versus chromium oxide
seal faces.
The measured torque is plotted
for different water pressures, in
the case of the packing with the
associated shaft leak. During these
tests, the gland leak rate was of the
same order of magnitude as that of
the shaft.
These results were unexpected. The
figures for packing were much lower
than predicted and were of the same
order of magnitude as, and generally
lower than, the mechanical seal.
Of course, a degree of leakage must
be tolerated when using packings,
and the lubrication afforded by
the leaking fluid will reduce the
friction. But even when the leak
rate is extremely low, as in the case
at 6 bar and 1500 rpm, the friction
recorded was the same as that for the
mechanical seal at a lower pressure.
Rigorous checks were carried out
to ensure the accuracy of the results.
In particular, the measurement
range of the torque meter was
revised to ensure accuracy at these
much lower torque levels, and it
was verified that the torque levels
Further Tests
A further series of tests was carried
out on two other packing types and
four mechanical seal variants. The
packings were a lubricated natural
ramie fiber, which would normally
be used where higher leakage would
be acceptable, and a synthetic
aramid yarn packing.
The mechanical seals were one
unbalanced and two balanced
component seals and a cartridge
balanced seal. They were chosen
to represent a cross section of
commonly used designs. These
featured carbon graphite versus
silicon carbide seal faces. This face
combination is typically chosen for
its low coefficient of friction. The
designs had different balance ratios,
and two had a composite narrow
seal face and the other two had a
monolithic narrow seal face.
All tests in this sequence were
carried out at 6 bar pressure. The
comparative results are shown in
Figure 3.
Some of the results for the
mechanical seals were unexpected.
The unbalanced mechanical seal
showed lower torque than the
balanced O-ring pusher seal.
The difference can most likely
be explained by the fact that the
face profiles are different for the
composite seal face of the balanced
seal than the monolithic design of
the unbalanced seal.
Typical thermal deflections are
different for these variations in
design. The composite faces tend to
have a divergent profile with outside
contact, while the monolithic
face tends to have a convergent
profile with good fluid penetration
between the faces. The pressure
drop between the seal faces is
99
Theoretical Considerations
The formula that has long been used
to calculate power consumption
from compression packing systems is
as follows:
P= Pp x RPM x D x x A p x F
Where
P
= Power (HP or kilowatts,
depending on units used)
Pp
= sealed pressure
RPM = rotational speed
D
= shaft diameter
= coefficient of friction
between the packing and
the shaft
Ap = packing contact area
F
= factor, depending on
units used
This formula is similar to the
one used for mechanical seals,
which has been shown to give
a good approximation to power
consumption levels.
Recognized approximations in
the packing formula are that it
does not take account of lubricant
levels, actual packing compression,
type of liquid sealed, viscosity or
temperature. But it can provide a
figure for the amount of energy
consumed by the packing. It tends
to give power consumption levels
Figure 3. Tests at 6 bar
Further Work
Some further test work is planned
on other packing types. The major
thrust of this work is to develop
a mathematical model that will
provide an accurate tool for the
calculation of packing power
consumption. A revised formula
will be finalized once testing is
completed.
The unquestioned switch from
compression packing to mechanical
seals to save energy in sealing
systems must be reconsidered.
Users must take many factors into
account when using one technology
versus the other, including periodic
maintenance, the availability of
trained maintenance personnel
and permissible leakage levels.
But frictional energy saving is not
as important as conventionally
viewed. The choice of which
technology to use must encompass
all aspects of performance based on
real results rather than perception.
Acknowledgements
The author would like to express his
appreciation to all of the ESA and
FSA member companies involved
in this project, in particular the
members of the joint ESA/FSA
Packings Technical Task Force and
David Edwin-Scott of the European
Sealing Association (UK), and Didier
Fribourg of the Technical Center
for Mechanical Industries CETIM
(France).
Next Month: How to Achieve
Zero Emissions with Mechanical
Seals
We invite your suggestions for article topics as
well as questions on sealing issues so we can
better respond to the needs of the industry.
Please direct your suggestions and questions to
sealingsensequestions@fluidsealing.com.
100
HI PUMP FAQS
101
U N M AT C H A B L E E X P E R I E N C E
I N F L OW C O N T RO L
TRANSACTIONS
(EZMH%/EOEVIOE
Managing Principal
GN$NSVHEROREYJJGSQ
Senior Associate
HOEOEVIOE$NSVHEROREYJJGSQ
102
Challenges
A remote Wisconsin sand mine
experienced pump deterioration
from the abrasive sand. Because
of the harsh Midwest winters,
the mine only operates from
April 1 to Thanksgiving. During
operating season, the plant is
scheduled to run 24 hours per day
to maximize production.
Patented Solutions
A pump distributor working
with the plant operator offered a
103
Images 2 and 3. Because of harsh Midwest winters, the mine only operates from April to November, when the plant is scheduled
to run 24 hours per day. The constant operation requires reliable equipment with superior solids-handling capability.
Additional Features
The pump also features a drypriming system with a vacuum
assist. If the pump loses prime,
the system engages the assisting
vacuum pump to draw sand into
the volute. When normal operation
resumes, the system disengages.
Unlike a venturi system, this
dry-priming method does not
materially affect efficiency.
An oil reservoir can lubricate the
pumps seal faces if it loses prime.
With the dry-priming vacuum,
the system protects the seal faces
from heat and cracking that could
occur without pumpage to lubricate
it. When the system reprimes,
the gland disengages. The system
Millions Saved
Since installation in March 2014,
the plant has run continuously.
With the previous turbines, the
plant would have experienced
at least 60 hours of downtime.
Processing more than 600 tons an
hour meant the plant would have
lost the opportunity to process
more than 36,000 additional tons
of sand in a year. With high-quality
hydraulic fracturing sand selling at
more than $50 a ton, the new
pump helped save more than a
$1.5 million dollars of downtime
losses in a year.
104
hile instrumentation
and monitoring
software are widely used
in manufacturing facilities around
the world, these tools alone will not
solve every production problem.
In addition to software and other
resources, the field workforce
plays a major role in the overall
effectiveness of a plants reliability
strategies.
This is especially true in the
pump industry because pumps are
frequently located in remote or
difficult-to-access locations. For this
reason, instrumentation and remote
monitoring software must be
combined with tools that empower
the field workforce to manage and
maintain systems reliably and
efficiently. This comprehensive
strategy can help field workers
increase their knowledge of system
processes and procedures, analyze
important equipment information,
and make well-informed decisions.
The Importance of
Remote Monitoring
A comprehensive reliability strategy
is vital because two primary
elements make up nearly 80 percent
of the total cost of ownership (TCO)
of pumps: energy consumption
and maintenance activities (see
Figure 1). A variety of pumping
Augus t 2 015 | Pum ps & S yst e m s
105
Improving Predictive
Maintenance
Predictive maintenance can be
custom-designed for a users
specific system, built from regular
observation and recordkeeping
that can reveal trends and uncover
anomalies. When equipment is
commissioned, a facility may
create a pump health log to use as
a baseline for alarms and required
maintenance triggers during the
lifetime of the system. End users
can leverage this historical data
to take future actions to optimize
their operational efficiency.
With minimal investment using
standard features built into a
variable frequency drive (VFD) or
other smart motor control system,
users can greatly expand reliability
and reduce operational costs. For
reference, users should remember
that pump equipment purchase
prices are estimated to account
for only 10 percent of the overall
lifetime expense of the system.
106
PRODUCTS
Grinder Pump
SEEPEX
introduces
Smart Conveying
Technology (SCT),
the innovative
technology for
progressive
cavity pumps.
In addition to the one-stage design for pressures up to 4
bar (60 psi), SCT is now available in a two-stage design
for pressures up to 8 bar (120 psi). SCT is a customized
solution that is efficient, economical and environmentally
friendly. SCT delivers enhanced pump performance with
a longer component service life and easy maintenance,
reducing maintenance time by up to 85 percent.
Circle 201 on card or visit psfreeinfo.com.
Multi-Purpose Accelerometer
ClearView Filtrations
patented fi lter assemblies
allow visual inspection
of the fluid being fi ltered,
the fi lter element and the
particles fi ltered out of the
fluid system. This is done in
seconds without draining,
leaking or the loss of fluid
and without unbolting or
loosening any fasteners or
fittingseven when fi ltering
non-transparent fluids. ClearView Filtration helps
determine if particles are from normal use or engine or
fluid system components excessively wearing.
Circle 203 on card or visit psfreeinfo.com.
SPM Instrument,
Sweden, announces
the DuoTech, a multipurpose accelerometer
for vibration and shock
pulse measurement.
In the DuoTech
accelerometer, two of the
most widely used and
successful methods for monitoring mechanical condition
come together: vibration and shock pulse measurement.
The combination of the patented HD enveloping and SPM
HD measuring techniques provides maximum flexibility,
enabling superior lubrication and bearing monitoring
covering the entire bearing deterioration process.
Circle 204 on card or visit psfreeinfo.com.
Compact
Pressure Transducer
Solids
Measurement
Ashcroft Inc. announces the
new G3 pressure transducer,
which offers 316L stainless steel
wetted material and absolute
pressure measurement to fulfi ll
unique OEM sensor requirements.
Available in ranges from 0/5
through 0/300 psi and vacuum,
the application-friendly G3
is enhanced by a broad choice
of pressure and electrical
connections and outputs. This compact transducer is
constructed to stand up to shock and vibration while
providing stable pressure readings over an extended life.
Circle 205 on card or visit psfreeinfo.com.
Mechanical Seals
Colonial Seal
Company, a
New Jerseybased specialty
distributor of
standard and
custom sealing
solutions,
announces a range
of new design or replacement mechanical seals. This
includes elastomeric bellows seals, conical spring O-ring
mounted seals, parallel spring diaphragms, balanced
diaphragm seals, parallel spring O-ring mounted seals,
wave spring type seals and water pump type seals.
Circle 206 on card or visit psfreeinfo.com.
To have a product considered for our Products page, please send the information to Amy Cash, acash@cahabamedia.com.
107
Adve r t ise rs
Advertiser Name
Page
RS#
Advertiser Name
169
168
122
118
101
102
170
192
152
119
123
153
103
124
171
120
104
172
125
105
106
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163
154
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164
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107
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100
166
151
155
131
174
173
132
161
175
176
121
133
134
177
178
135
147
156
136
Page
RS#
Advertiser Name
87
75
41
16
37
109
29
66
57
44
110
BC
109
110
97
80
12
109
76
107
70
110
157
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139
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179
110
149
116
140
180
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188
193
117
158
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190
142
182
Page
RS#
69
33
79
64
110
111
111
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110
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101
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148
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191
159
183
184
185
144
112
186
187
145
113
114
160
167
189
115
146
108
108
Technologically
Advanced Epoxies
Less downtime.
Longer seal life.
More predictability.
800.366.1006 www.balseal.com
Circle 170 on card or visit psfreeinfo.com.
POLYMER BASEPLATES
COMPARED TO STEEL, THEYRE
RE FLAT OUT THE BEST!
Hackensack, NJ 07601 USA
+1.201.343.8983
main@masterbond.com
www.masterbond.com
CALL TODAY!
877-712-BASE (2273)
WWW.BASETEK.COM
Circle 192 on card or visit psfreeinfo.com.
MOTOR
PLUGS
QUICKLY CONNECT
& DISCONNECT POWER
OFF
Button
Circle 171 on card or visit psfreeinfo.com.
Safety Shutter
S
univeRsalPoweRCell
OneSizeAdjustsfor
AllMotors,FromSmall
upto150HP
WorksonVariableFrequency
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10timesmoresensitivethan
justsensingamps
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CallnowFoRyouRFRee30-daytRail
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e)
109
Important Properties of
LobePro Rotary Lobe Pumps
Capacities 0- 2, 656
Low shear
GPM (0-604 m/hr)
Measured Flow
Self priming to 25 wet Low pulsation
Discharge pressure to Space-saving,
compact design
175 psi (12 bar)
ask about
Smooth operation,
low pulsation,
steady ow in
direct proportion to speed
Low to high solids content, abrasive material, shear sensitive
Pressures: To 1080 psi; special designs to 3400 psi
Capacities: A few gph up to 2,200 gpm
NETZSCH Pumps North America, LLC
Viscosity: 1 mPas up to 3 million mPas
1-610-363-8010
Temperatures: 5 F to 570 F
PUMPS@netzsch.com
Maintenance friendly, low life-cycle cost
www.netzsch.com
110
Model 2196
Green Bay, WI
www.SUMMITPUMP.com
Solve
dry start
problems with
Vesconite Hilube
bushings
Increase MTBR
No swell
Low friction = reduced
electricity costs
Quick supply.
No quantity too small
Tollfree 1-866-635-7596
vesconite@vesconite.com
www.vesconite.com
Circle 183 on card or visit psfreeinfo.com.
111
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EXECUTIVE SEARCH/RECRUITING
CRTTP@comcast.net
713.871.1063
www.deepbluepumps.com
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Specializing in placing:
General Management Engineering
Sales & Marketing
Manufacturing
DAN BOLEN JASON SWANSON
CHRIS OSBORN
9741 North 90th Place, Suite 200
Scottsdale, Arizona 85258-5065
(480) 767-9000 Fax (480) 767-0100
Email: dan@danbolenassoc.com
www.danbolenassoc.com
Circle 172 on card or visit psfreeinfo.com.
112
an increase of 64,000 in
professional and business
services. In the irst half of the
year, manufacturing has added
an average of just over 6,000
workers per month. Nonfarm
employment increases averaged
more than 250,000 per month
for the past 16 months and
surpassed 200,000 in 14 of the
Source: Capital IQ and JKC research. Local currency converted to USD using
past 16 months.
historical spot rates. he JKC Pump and Valve Stock Indices include a select list of
publicly traded companies involved in the pump and valve industries weighted by
he Census Bureau reported
market capitalization.
that total construction
commercial production include
spending rose 0.8 percent
Reference
Mexico, Poland, Algeria, Australia,
in May while rising 5.9 percent
1. he S&P Return
Colombia and Russia.
during the irst ive months of the
igures are provided
On Wall Street, all indices were
by Capital IQ.
year. It is up 8.2 percent over 2014.
down for the month of June. he
New home sales activity was at its
highest level in seven years in May. Dow Jones Industrial Average lost
Private nonresidential construction 2.2 percent, the S&P 500 Index
Jordan, Knauf
was down 2.1 percent, and the
increased 1.5 percent during the
& Company is an
NASDAQ Composite declined 1.6
month and is up 12.7 percent
investment bank
based in Chicago,
percent. For the second quarter
year over year.
Illinois, that
of the year, the Dow declined 0.2
As of last year, only four
provides merger and
percent
and
the
S&P
500
lost
countries were producing
acquisition advisory
0.9 percent, while the NASDAQ
commercial volumes of either
services to the
pump, valve and
gained 1.8 percent. Concerns about
crude oil from tight formations or
iltration industries.
Greeces bailout program and
natural gas from shale formations
Please visit
referendum on whether to accept
according to the U.S. Energy
jordanknauf.com for
terms demanded by its creditors
Information Administration and
more information.
afected investors. Despite a rise in
Advanced Resources International
Jordan Knauf &
Company is a member
consumer spending, upbeat housing
Inc. Along with the U.S. and
of FINRA.
Canada, Argentina and China have data and encouraging retail sales,
the Federal Reserve Bank indicated
recently begun production of this
it will increase interest rates at a
type. Other countries that have
slower pace than it expected earlier
started to explore shale and tight
These materials were
prepared for informational
this year.
oil but are still short of reaching
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