Pump & System - August 2014

OPTIMIZE
PUMPING SYSTEMS
Diligent analysis, rigorous scrutiny
lead to longer system life
AU G UST 2014
PUMP-ZONE.COM
TURBOMACHINERY &
PUMP SYMPOSIA
Trade Show Preview
SEALS & BEARINGS

Tips for Maximizing
PERFORMANCE
6 Considerations
for REFINERY Pump
MAINTENANCE
Well Find It
Before It Fails
Sometimes what doesnt happen matters most.
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From the Editor

T
his month we introduce an exciting, fresh,

modern look to our logo and design that has been
thoughtfully crafted to make the magazine easier for
you to read and navigate. While the look has been
updated, the content remains the same high-quality
technical pumping information that you cant ind
anywhere but in the pages of Pumps & Systems.
It makes sense that we introduce this change with
a focus on the increasingly vital topic of pump system
Michelle Segrest with ITTs Margaret
optimization. Not long ago, the components of a
pumping system were designed separately, purchased Gan at the 2014 Offshore Technology
Conference. The Pumps & Systems
separately and maintained separately. hanks to
team returns to Houston for the
advancements in technology and increased standards Turbomachinery/Pump Symposia in
September.
and awareness and the Hydraulic Institutes development of Pump Systems Matter, today the entire system is examined and modiied to
decrease life-cycle costs and save energy.
On average, industrial pumps operate at less than 40 percent eiciency, and more than
10 percent of pumps run at less than 10 percent eiciency. h is impacts the bottom line.
he cost to pump ineiciently is beyond your wildest imagination, says Mike Pemberton, ITT Performance Services Manager and Pumps & Systems Editorial Advisory Board
member. In the past several decades, pump eiciency has only increased 3 percent by
design. he biggest advantage in increasing eiciency is happening with automation and
controls. he infrastructure is in place, but the question remains, How do we optimize?
his year, Pumps & Systems published a three-part series from HI examining the Department of Energys pump eiciency regulation changes (Jan.-March 2014, www.pump-zone.
com). he series describes how to reduce the burden on U.S. pump manufacturers and support
the DOEs eforts to achieve energy savings and eiciency improvements in the marketplace.
According to Pump Systems Matter, the most likely candidates for optimization are
large systems, systems with high operating hours, problem systems and production-critical systems. he most common red-l ag symptoms are high energy costs, throttle valves
that are generally closed, bypass valves/recirculation lines that are generally open, frequent failures or repair requirements, high operating noise levels (especially at the valve
or pump), vibrations in the system and/or pump assembly, systems with multiple parallel
pumps with the same number of pumps always operating, constant pump operation in a
batch environment or frequent cycle batch operation in a continuous process, and systems
that have undergone a change in function. Learn more by visiting www.pumps.org.
You can ind a wealth of solutions by reading this months cover series, which begins on
page 60. As always, pump eiciency will be a major topic at the 43rd Turbomachinery and
30th Pump Symposia in Houston, Sept. 23 25. Visit the Pumps & Systems team at Booth
514, and tell us about your pump optimization success stories.
EDITORIAL
EDITOR: Michelle Segrest
msegrest@pump-zone.com 205-314-8279
MANAGING EDITOR: Lori K. Ditoro
lditoro@cahabamedia.com 205-314-8269
SR. EDITOR, PRODUCTION & CONTENT MARKETING:
Alecia Archibald
aarchibald@cahabamedia.com 205-314-3878
ASSOCIATE EDITOR: Michael Lambert
mlambert@cahabamedia.com 205-314-8274
ASSOCIATE EDITOR: Savanna Lauderdale
slauderdale@cahabamedia.com 205-278-2839
CONTRIBUTING EDITORS: Laurel Donoho,
Joe Evans, Lev Nelik, Ray Hardee
CREATIVE SERVICES
SENIOR ART DIRECTOR: Greg Ragsdale
ART DIRECTORS: Jaime DeArman, Melanie Magee
WEB CONTENT EDITOR & WEB ADVERTISING TRAFFIC:
Robert Ring
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
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
Vince Marino
vince@pump-zone.com 205-561-2601
MARKETING ASSOCIATES:
Ashley Morris
amorris@cahabamedia.com 205-561-2600
Sonya Crocker
scrocker@cahabamedia.com 205-314-8276
PUBLISHER: Walter B. Evans, Jr.

VP OF SALES: Greg Meineke
VP OF EDITORIAL: Michelle Segrest
CREATIVE DIRECTOR: Terri Jackson
CONTROLLER: Tim Moore
P.O. Box 530067

Birmingham, AL 35253
Editor, Michelle Segrest

Pumps & Systems
is a member of the following organizations:
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the
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will not be returned. Volume 22, Issue 8.
Augus t 2 014 | Pum ps & S yst e m s
EDITORIAL & PRODUCTION
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This issue
AUGUST
Volume 22 Number 8
COVER
60
SERIES
PUMP SYSTEM
OPTIMIZATION
60 STREAMLINED MOTOR
MANAGEMENT SYSTEM BOOSTS
BIOMASS POWER GENERATION
BY Matthias Borutta
Phoenix Contact
Trusted gateway connections allow
for system growth, eiciency and
consistent maintenance at Swedish
paper mill.
64 INTELLIGENT MONITORING
DELIVERS REAL-TIME
PUMP PERFORMANCE DATA
By Mike Pemberton
ITT Pro Services
An energy eiciency and reliability
study helped one plant save $1 million
annually by avoiding downtime.
DEPARTMENTS
COLUMNS
84 EFFICIENCY MATTERS
PUMP ED 101
Smart Air Distribution Systems

Upgrade Traditional AODD Pump
Technology
89 MAINTENANCE MINDERS
6 Reinery Pump Maintenance Tips
69 CLOSE INSPECTION
SOLVES HIGH THRUST BEARING
TEMPERATURE PROBLEM
By Gary Dyson
Hydro Inc.
Careful analysis identiied the issue
with this multistage oil transfer pump.
73 SYSTEM SELECTION CRUCIAL

FOR LONG WASTEWATER
PUMP LIFE
By Lars Bo Andersen
Grundfos Wastewater
94 MOTORS & DRIVES

he Diferences Between Submersible
& Immersible Motors
98 SEALING SENSE
Expansion Joint Selection Optimizes
Piping Systems
102 HI PUMP FAQS

Understand Speciic Speed & Disc
Diaphragm Pump Coupling
20 By Joe Evans, Ph.D.

Pump Tech Inc.
hree-Phase Voltage Variation
& Unbalance
PUMPING PRESCRIPTIONS
26 By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC
Simplify the Equipment
Selection Process
PUMP SYSTEM IMPROVEMENT

28 By Ray Hardee
Engineered Software, Inc.
System Validation & Troubleshooting
GUEST COLUMNS
Driving down investment, energy

and maintenance costs translates
into big savings throughout an
installations lifetime.
36 By Heinz P. Bloch, P.E.

Pushing Fluid Machinery Leads
to Failure
76 REDUCER FITTINGS DECREASE
40 By Amin Almasi
PIPE SIZE TO PREVENT FAILURE
Estimate Pump Installation Costs
By Ross Mahaffey, Aurecon

and Stefanus Johannes van
Vuuren, University of Pretoria
Design of the pump inlet piping can
protect overall operation.
64
Augus t 2 014 | Pum ps & S ys t e m s
Cover photo courtesy of Colfax Fluid Handling
PUMP AND FLUID SYSTEMS
Your business cant run

on a fabrication order.
Power ratings from

2 to 700 hp
We deliver the pump you need without the wait.

0VSVJEQVNQTLFFQZPVSCVTJOFTTNPWJOH'SPNDBVTUJDTUPDSVEFPJMBOEGSPN
DSZPHFOJDUPCPJMJOH PVSQMVOHFSQVNQTEFMJWFSQPXFSBOESFMJBCJMJUZJOUIFPJMFME
GPPETFSWJDF NVOJDJQBM BOEDIFNJDBMJOEVTUSJFT UPOBNFBGFX
Flowrates from
1 to 1,680 gpm
Pressure ratings from
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8IFOZPVPSEFSB8FBUIFSGPSEQSPEVDUJPOQVNQ ZPVHFUNPSFUIBOBGBCSJDBUJPOPSEFS
0VSFYUFOTJWFTUPDLPGQVNQTsJODMVEJOHUIPTFNBEFGSPNQSFNJVNNBUFSJBMT
TVDIBTEVQMFYTUBJOMFTTTUFFM OJDLFMBMVNJOVNCSPO[F BOEDBSCPOTUFFMsFOTVSFT
UIBUZPVHFUUIFQVNQZPVOFFE OPUBGBCSJDBUJPOPSEFS
10,000 psi (207 MPa)
2014 Weatherford. All rights reserved.
Contact and collaborate with us at pumps@weatherford.com
Formation Evaluation
Well Construction
Completion & Stimulation
Production
This issue
SSPECIAL
PECIAL
SECTION
SEALS & BEARINGS
42 CANNED MAGNETIC BEARINGS
50 SELECT SEALS THAT MEET
MINIMIZE CORROSION IN
OIL & GAS PROCESSING
THE CHEMICAL CHALLENGES

OF HPLC PUMPS
By Richard R. Shultz
Waukesha Magnetic Bearings
By Jerry Zawada
Trelleborg Sealing Solutions
Safely immerse motor compressors

in process gas without risking
costly damage.
Abrasive processing and wide

temperature range are some of
the pumping diiculties for highperformance liquid chromatography.
45 THE RIGHT SEAL & LUBRICANT

COMBINATION CAN PREVENT
BEARING CONTAMINATION
54 TREATED CARBIDE SURFACES
By James Wong
Garlock Sealing Technologies
Lip and labyrinth seals provide
protection in harsh oil and
gas applications.
ENHANCE RUNNING
PERFORMANCE
By Mark Slivinski
Carbide Derivative Technologies Inc.
his technology self-lubricates, reduces
friction, and performs in wet or dry
operating conditions.
AUGUST
PRACTICE &
OPERATIONS
106 ENERGY EFFICIENT VERTICAL
TURBINE PUMPS PROMOTE
SUSTAINABLE MINING EFFORTS
By Petar Ostojic
Neptuno Pumps
he computational luid dynamics
process advances highly eicient pump
designs for diicult applications.
110 SPECIFIC PUMP & VALVE

FEATURES SERVE LIQUEFIED
NATURAL GAS APPLICATIONS
By Gobind Khiani
Fluor Canada Ltd.
LNG beneits have increased the
demand for this cleaner burning
fuel and associated production and
distribution equipment.
114 DEWATERING PUMPS HANDLE

2
8
10
80
118
124
128
SAND SLURRIES IN POSTHURRICANE RECOVERY
FROM THE EDITOR

READERS RESPOND
By Mike Bjorkman
BJM Pumps
NEWS
TRADE SHOW COVERAGE
PRODUCT PIPELINE
PUMP USERS MARKETPLACE
PUMP MARKET ANALYSIS
Reconstruction and infrastructure

upgrades require pumps from
durable materials.
EDITORIAL ADVISORY BOARD

THOMAS L. ANGLE, P.E., MSC, Vice President
Engineering, Hidrostal AG
ROBERT K. ASDAL, Executive Director,
Hydraulic Institute
BRYAN S. BARRINGTON, Machinery Engineer,
Lyondell Chemical Co.
KERRY BASKINS, VP/GM, Milton Roy Americas
WALTER BONNETT, Vice President Global
Marketing, Pump Solutions Group
R. THOMAS BROWN III, President,
Advanced Sealing International (ASI)
CHRIS CALDWELL, Director of Advanced
Collection Technology, Business Area
Wastewater Solutions,
Sulzer Pumps, ABS USA
JACK CREAMER, Market Segment Manager
Pumping Equipment, Square D by Schneider
Electric
BOB DOMKOWSKI, Business Development

Manager Transport Pumping and Amusement
Markets/Engineering Consultant, Xylem, Inc.,
Water Solutions USA Flygt
DAVID A. DOTY, North American Sales Manager,
Moyno Industrial Pumps
WALT ERNDT, VP/GM, Crane Pumps & Systems
JOE EVANS, Ph.D., Customer & Employee
Education, PumpTech, Inc.
RALPH P. GABRIEL, Chief Engineer Global,
John Crane
BOB LANGTON, Vice President, Industry Sales,
Grundfos Pumps
LARRY LEWIS, President, Vanton Pump and
Equipment Corp.
TODD LOUDIN, President/CEO North American
Operations, Flowrox Inc.
JOHN MALINOWSKI, Sr. Product Manager, AC
Motors, Baldor Electric Company, A Member of
the ABB Group
WILLIAM E. NEIS, P.E., President, Northeast

Industrial Sales
LEV NELIK, Ph.D., P.E., APICS, President,
PumpingMachinery, LLC
HENRY PECK, President, Geiger Pump &
Equipment Company
MIKE PEMBERTON, Manager, ITT Performance
Services
SCOTT SORENSEN, Oil & Gas Automation
Consultant & Market Developer, Siemens
Industry Sector
ADAM STOLBERG, Executive Director,
Submersible Wastewater Pump Association
(SWPA)
JERRY TURNER, Founder/Senior Advisor,
Pioneer Pump
KIRK WILSON, President, Services & Solutions,
Flowserve Corporation
JAMES WONG, Associate Product Manager
Bearing Isolator, Garlock Sealing Technologies
H ORIZONTAL P UMPING S YSTEMS

Borets Equipment is a HPS horizontal
multistage pump manufacturer that
provides pumping solutions with
exceptional customer service.
SERVICE
Reliable. Quality. Modular.
Horizontal Pumping System (HPS) by Borets Equipment.
Cost-competitive and customizable for your specific application, the HPS equipment
requires less inventory and delivery time than traditional API 610 multistage, vertical
turbine can and reciprocating pump equipment.
Engineered for reliability, modularity, and quick replacement of components, the HPS
pump has a lower life cycle cost, thanks to minimized downtime and low maintenance
Low Pro Design
requirement. The result is a reliable, flexible and innovative pumping system.

You provide the application, well provide the Pump Power and Service.
RELIABLE FLEXIBLE INNOVATIVE

w w w . b o r e t s . c o m / H P S
READERS RESPOND
READERS
responD
A Salute to
Frank Weis,
From the Editor
MARCH 2014
I was sent your article

while I was at the
American Water
Works Association
conference in Boston. hank you so
much for writing this and sharing some
of your thoughts on Frank.
I just wanted to share more with
someone, so I decided to give you more
background. Frank was my irst boss
when I joined Smith and Loveless in
1983, fresh out of graduate school. I
wont go into all the engineering details
I learned from just watching him but
wanted to share the personal side.
I worked for, with and shared lunch
with Frank many days over my next
six years of employment. He treated
everyone the same, from the janitor to
the president of the company. He was
friendly to all, had a great sense of humor, enjoyed pulling pranks on select
employees, and I never, ever saw him be
upset or have a bad day!
We were both alumni of the University of Missouri, and he loved sports,
had coached his kids baseball and basketball teams and loved to talk sports
of all kinds. He shared his knowledge
with any that asked, but he was the
most humble guy I have ever known.
He went about his work with

a quiet determination and knew
exactly what he was trying to
achieve, even if it didnt it with
the views of management at the
moment! He had an amazing
inluence on my professional
and personal life, and I tell stories related to him almost every
week. I left the company in
1989 and moved to Degremont
in Virginia, but his inluence
had more impact on me than
anyone I have worked with since
that time.
I am now back in Kansas City
and was fortunate enough to
attend the 50th anniversary of
Franks work at Smith and Loveless in 2004. As was typical for Frank,
he didnt want it to be a big deal, so the
ceremony was held on the shop loor.
Several former employees attended,
many who had long since retired!
I knew then how unique Frank was
but have understood this even more
in the years that have passed. As great
a man as he was from the engineering and invention side, he was an even
better man overall. he world was a
better place for the time he was here
and for all the individuals that got to
know him.
Andy Mitchell
Director, Business Development
Metawater USA, Inc.
Frank Weis
Pumps & Systems Editor Michelle

Segrest responds:
hank you for reading my column about
Frank Weis (www.pump-zone.com/blog/
salute-frank-weis) and for responding
with these nice comments. he additional
insight into the life of this legendary pump
innovator is greatly appreciated. Frank
Weis was well respected in the pump
industry and will be missed by all who
knew him.
To have a letter considered for Readers

Respond, please send it to Michael Lambert,
mlambert@cahabamedia.com.
10
NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
LARRY LEWIS, VANTON PUMP
HILLSIDE, N.J. (July 10, 2014) The Board of
Directors of the Vanton Pump and Equipment
Corp. voted to name Larry Lewis as the companys
president and chief executive officer. Lewis has
served as Vantons president since 2010. Vanton
Pump and Equipment Corp. supplies chemically
inert, thermoplastic pumps and systems that
solve fluid containment, dosing and transfer
problems. www.vanton.com
SPOTLIGHT
PUMPS & SYSTEMS LAUNCHES
MIDDLE EAST/NORTH AFRICA MAGAZINE
Larry Lewis
DAVID BOEZI, DANFOSS

BALTIMORE (June 24, 2014) Danfoss hired
David Boezi as senior director, strategy and global
platforms. In this role, Boezi will help Danfoss
tailor its high-efficiency compressor portfolio
to respond to changing customer needs that
are being influenced by new refrigerant and
energy-efficiency regulations. Danfoss supplies
David Boezi
technologies that meet the growing need for food
supply, energy efficiency, climate-friendly solutions and modern
infrastructure. www.danfoss.com
DICK SHEAR, MULTI W SYSTEMS

EL MONTE, Calif. (June 20, 2014) Multi W
Systems Inc. announced the appointment of
Dick Shear as general sales manager. Multi
W Systems manufactures and distributes
pump systems, electrical controls and related
engineered machinery. www.multiwsystems.com
BIRMINGHAM, Ala. (July 2, 2014) Pumps & Systems, the leading

magazine for pump users worldwide for more than 20 years, expands its
international coverage of powerful technical pumping information to the
Middle East/North Africa region. The premier issue of Pumps & Systems
MENA will launch in early October 2014. It also will be distributed at the
Pumps & Systems booth Nov. 10, 2014, at the Abu Dhabi International
Petroleum Exhibition & Conference, the regions leading conference
for oil and gas professionals. Pumps & Systems MENA will publish
bimonthly in 2015 following the October 2014 launch and will cover case
studies and technical information in the following industries:
Oil & gas (upstream and downstream)
Water & wastewater
Power generation
Food & beverage processing
Building services
Chemical, petrochemical & refinery
The regular editorial coverage will also include strategic and insightful
market data from respected market research analysts Frost & Sullivan.
The magazine will be supported digitally with a website,
www.pump-zone.com/mena, and a twice-per-month e-newsletter, Pump
Users Digest MENA. Subscribe to the e-newsletter and magazine at
www.pump-zone.com/mena.
Dick Shear
PAMELA HENRY, WEF

ALEXANDRIA, Va. (June 19, 2014) The Water
Environment Federation (WEF) promoted Pamela
Henry to the position of deputy executive
director. Having been with WEF for more than
25 years, Henry is a seasoned leader who will
oversee a number of key organizational programs
including WEFTEC operations and exhibitions,
advertising and sponsorships, marketing,
Pamela Henry
communications and creative services, human
resources, and facilities management. WEF is a not-for-profit
technical and educational organization of 36,000 individual members
and 75 affiliated Member Associations representing water quality
professionals around the world. www.wef.org
CHUCK HULL, 3D SYSTEMS

ROCK HILL, S.C. (June 17, 2014) 3D Systems announced that Chuck
Hull received the 2014 European Inventor Award in the non-European
countries category in recognition of his invention of the threedimensional (3-D) printing technology Stereolithography. Presented
annually by the European Patent Office, the award honors inventors

who made significant contributions to technological progress and
the advancement of society. 3D Systems provides 3-D printing
centric design-to-manufacturing solutions including 3-D printers,
print materials and cloud-sourced on-demand custom parts for
professionals and consumers in materials including plastics, metals,
ceramics and edibles. www.3dsystems.com
EDWARD CRANER, HOLT CAT

SAN ANTONIO, Texas (June 16, 2014) HOLT
CAT named Edward Craner senior vice president,
strategy and marketing. In his new role, Craner
will continue to lead and develop corporate
strategy, marketing and customer experience
initiatives to support sales growth. HOLT CAT
sells, rents and services Caterpillar machines,
engines, generator sets and trucks.
www.holtcat.com
Edward Craner
11
AANNDD
HENRI V. AZIBERT, FSA
FLEX-PRO Peristaltic Metering Pump
Three Models
Available with
Feed Rates
Ranging from
0.1 GPH/.03 LPH
to 158 GPH/600
LPH.
Smooth, Quiet
and Eicient
Pumping Action.
Brushless
Variable Speed
Motor.
Terminal Blocks
in Junction Box
for Remote
Connections.
Patented Tube
Failure Detection,
Patented Safety
Switch, Patented
Method for
Extended Tube
Life.
One or
Two Pump,
Engineered
Skid System is
Available.
WAYNE, Pa. (June 13,

2014) The Fluid Sealing
Association (FSA) announced
the appointment of Henri V.
Azibert as its new technical
director. Pumps & Systems
has partnered with the FSA for Henri V. Azibert
10 years and posted exclusive
Sealing Sense articles in every issue. Azibert
will now coordinate these articles, which provide
the readers of Pumps & Systems with crucial
technical information about mechanical seals,
compression packing, gaskets, expansion joints,
sealing components and molded packing. Azibert
has also joined the prestigious Pumps & Systems
Editorial Advisory Board. FSA is an international
trade association. Members are involved in the
production and marketing of virtually every
kind of fluid sealing device in the world. www.
fluidsealing.com
JOHN DONAHUE, AWWA

BOSTON (June 12, 2014)
In a spirited event at the
conclusion of the American
Water Works Associations
Annual Conference and
Exposition in Boston, John
Donahue, chief executive
John Donahue
officer of North Park, Illinois,
Water District, accepted the ceremonial AWWA
gavel and began his term as president. The gavel
passing ceremony was the culmination of a fiveday conference that drew more than 11,000 water
professionals and water technology providers to
Boston. The American Water Works Association
is the largest nonprofit, scientific and educational
association dedicated to managing and treating
water. www.awwa.org
GREG HEWITT, BALDOR

ELECTRIC COMPANY
WAS
AS
SH DOWN
OW
SONIC-PRO Ultrasonic Flowmeter
NEW!
Sonic-Pro S4 accurately measures

flow using the Transit Time
method. It can be used
with water
containing low
levels of chemicals
and up to 5%
particulates.
Optional
communication
protocols include
Industrial Ethernet,
Profibus and Modbus.
Ultrasonic Transit Time

operation.
Optional factory configuration
for easy installation.
Inline spool piece (inline fitting).
4-20mA and Pulse Outputs.
Special low power mode permits
operation with battery for limited
functions.
NEM
EM
MA 4X
WASH DOWN
WASH
WAS
OWN
W
Advanced communication.
Data logging
Standard 61
5300 Business Drive, Huntington Beach, CA 92649 USA

714-893-8529 sales@blue-white.com
www.blue-white.com www.proseries-m.com
pu mp-zone.c om | Au gu st 2014
FORT SMITH, Ark. (June

9, 2014) Baldor Electric
Company promoted Greg
Hewitt to mounted bearing
engineering manager. In this
role, he will be responsible for
Greg Hewitt
all mounted bearing productrelated engineering and will manage the product
development team in Greenville, South Carolina.
Baldor Electric Company markets, designs and
manufactures industrial electric motors, drives
and mechanical power transmission products.
www.baldor.com
IP
P66
NE
EMA
A 4X
12
NEWS
manager for OPW Engineered Systems. OPW

Engineered Systems provides loading and
coupling systems for the safe and efficient
loading and unloading of critical hazardous
fluids. www.opw-es.com
CHARLES WHISMAN, CH2M HILL

DENVER (June 5, 2014) CH2M HILL announced
that Charles Whisman joined the firm as vice
president and U.S. oil and gas operations
manager for the environment and nuclear
market. CH2M HILL provides consulting,
design, design-build, operations and program
management for government, civil, industrial
and energy clients. www.ch2m.com
Charles Whisman
JOHN MOLNAR,
ARMSTRONG FLUID TECHNOLOGY
Dave Morrow
TORONTO (June 5, 2014) Armstrong Fluid
Technology announced that John Molnar joined
DAVE MORROW, OPW
the company as technical sales representative,
LEBANON, Ohio (June 6, 2014) OPW announced the promotion of
commercial and engineering. In his new role,
Dave Morrow to director of product management for its Chemical &
he will develop and grow relationships with
Industrial business unit. Before this appointment, he was product
engineers, contractors and service dealers in the
Ontario territory.
His main focus
will be working
John Molnar
with standard and
YASKAWA AMERICA, INC. acquired Solectria
BLACKHAWK SPECIALTY TOOLS acquired
configured building
Renewables, LLC
Trinity Tool Rentals
products and design envelope solutions.
July 17, 2014
June 10, 2014
Armstrong Fluid Technology designs,
engineers and manufactures integrated
GE acquired Monsal
FRANKLIN ELECTRIC acquired
solutions within the building-oriented
July 1, 2014
Bombas Leo S.A.
fluid-flow equipment industry. www.
June 9, 2014
armstrongfluidtechnology.com
ACOEM acquired FIXTURLASER
MERGERS & ACQUISITIONS
June 30, 2014
DES-CASE acquired ESCO s sight glass

product line
June 19, 2014
NATIONAL PUMP COMPANY acquired

Bayou City Pump
June 3, 2014

13
AROUND THE INDUSTRY

EXONE to Open Combined
Production Service Center
in Italy
NORTH HUNTINGDON, Pa. (June
19, 2014) The ExOne Company
announced the planned opening of
a new combined production service
center and machine sales center in the
Lombardy region of Italy. Said Omar,
most recently ExOnes European sales
director, will be ExOne Italys managing
director. ExOne provides 3-D printing
machines and printed products,
materials and other services to
industrial customers. www.exone.com
WEATHERFORD Opens
Integrated Colombia
Laboratory
BOGOTA, Colombia (June 13, 2014)
Javier Betancourt, the president of
Agencia Nacional de Hidrocarburos
Colombia, marked the official
opening of the new Weatherford lab in
Bogota, Colombia, during a ribboncutting ceremony. This new facility

provides traditional core and fluid
analysis combined with specialty
services such as shale rock properties,
geochemistry, wellsite geosciences,
frac fluids, drilling fluids and elastomer
testing for progressive cavity pumps.
Weatherford International provides
oilfield products and services across
the drilling, evaluation, completion,
production and intervention areas.
www.weatherford.com
DYNAMIC INDUSTRIES
INTERNATIONAL LLC Receives
SAGIA License
HOUSTON (June 11, 2014) Dynamic
Industries International LLC
announced that its Saudi Arabian office
received its license to operate from
the Saudi Arabian General Investment
Authority (SAGIA). Dynamic
Industries International LLC provides
full-service fabrication, construction
and maintenance services to the

offshore worldwide markets. www.
dynamicind.com
SIEMENS Invests in
Software Grants
RICHMOND, Va. (June 5, 2014)
Siemens announced more than $1
billion of in-kind software grants
for manufacturing programs at
community colleges and universities
in Virginia. The series of in-kind
grants was established as a result of
an industry need for skilled workers
and is designed to support the states
largest industrial employer, Newport
News Shipbuilding, a division of
Huntington Ingalls Industries, and
other companies with local ties such
as Rolls-Royce. Siemens Industry
Sector supplies products, solutions and
services for industrial customers.
www.siemens.com

14
NEWS
AROUND THE INDUSTRY

ABB TURBOCHARGING
Inaugurates Denmark Facility
BADEN, Switzerland (June 4, 2014)
ABB Turbocharging announced a
ceremony that celebrated the opening
of a new service facility in Fredericia,
Denmark. The ceremony also marked

the completion of the amalgamation of
its activities in Norway, Denmark and
Sweden into a single Local Business
Unit. ABB Turbocharging Scandinavia
comprises service stations in Oslo and
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Bergen in Norway, Gteborg in Sweden,

and the new central workshop for
Denmark in Fredericia. Additionally,
the company has two service
engineers and a sales team stationed
in Copenhagen. This geographical
footprint will soon be furthered by a
new service point in Troms, Norway.
ABB Turbocharging manufactures and
services turbochargers. www.abb.com
GRUNDFOS, PUB to Collaborate

on Water Technologies
SINGAPORE (June 3, 2014) Pump
manufacturer Grundfos and PUB,
Singapores national water agency,
have signed a memorandum of
understanding (MOU) to collaborate on
the development of water technologies
and solutions. The MOU sets out to
support PUB in its mission to ensure a
robust and sustainable water supply
for Singapore and to continuously
explore new technologies and solutions
to meet current and future water
challenges. PUB is a statutory board
under the Ministry of the Environment
and Water Resources. It is the water
agency that manages Singapores
water supply, water catchment and
used water. www.pub.gov.sg Grundfos
is a pump manufacturer, offering
water solutions with modular, energy
efficient and intelligent products
and services that can be tailored for
industrial, water utility, water supply,
urban and agricultural applications.
www.grundfos.com
EPA Proposes Guidelines

to Cut Carbon Pollution
WASHINGTON (June 2, 2014) At the
direction of President Obama and after
an unprecedented outreach effort,
the U.S. Environmental Protection
Agency (EPA) released the Clean
Power Plan proposal, which for the
first time cuts carbon pollution from
existing power plants, the single largest
source of carbon pollution in the U.S.
The proposal aims to protect public
health, move the U.S. toward a cleaner
environment and fight climate change
while supplying Americans with reliable
and affordable power. By 2030, the
steps that the EPA is taking will:
Cut carbon emission from the power
sector by 30 percent nationwide
Did You Know?

Supplies the NGL industry with products for electric motor
and engine-driven pump skids and booster stations.
Engine Management - Murphys Engine Integrated Control System (EICS)
provides a turnkey engine integration package that ensures extended engine life,
optimized emissions and simplied diagnostics.
Controls - Murphy delivers a complete line of annunciators and

controls that can be packaged to provide optimum performance
and advanced functionality.
Gages & End Devices - Murphy has a
For more about Murphys

Natural Gas Liquids products
7-2014
visit: fwmurphy.com/nglps
Phone: 918-317-4100
1311291
robust and value priced line of gages and

sensors, including vibration sensors, level
maintainers, level switches and more.
16
NEWS
AROUND THE INDUSTRY

below 2005 levels, which is equal to
the emissions from powering more
than half the U.S. homes for one year
Cut particle pollution, nitrogen
oxides and sulfur dioxide by more
than 25 percent
Avoid up to 6,600 premature deaths,
up to 150,000 asthma attacks in
children, and up to 490,000 missed
work or school daysproviding up
to $93 billion in climate and public
health benefits
Shrink electricity bills roughly
8 percent by increasing energy
efficiency and reducing demand in
the electricity system
EPAs mission is to protect human
health and the environment.
www.epa.gov
ABAKAN Increases Direct

Ownership in MesoCoat
WEF, IWA Sign Water

Management MOU
MIAMI (June 2, 2014) Abakan Inc.

announced that it has increased its
ownership position in its majority
owned subsidiary, MesoCoat Inc., to a
87.5 percent direct and 89.9 percent
direct and indirect ownership. The
increase is the result of converting an
additional $6.2 million in MesoCoat
investment into equity and exchanging
21 percent of ownership in Powdermet
for 65.3 percent of Powdermets shares
of MesoCoat. Abakan develops,
manufactures and markets advanced
nanocomposite materials, fabricated
metal products and metal composites
for applications in the oil and gas,
petrochemical, mining, aerospace and
defense, energy, infrastructure, and
processing industries.
www.abakaninc.com
ALEXANDRIA, Va. (May 27, 2014)

The Water Environment Federation
(WEF) and the International
Water Association (IWA) signed a
memorandum of understanding (MOU)
intended to accelerate joint work to
grow and disseminate water knowledge
and to serve and advance the global
water profession. WEF is a not-forprofit technical and educational
organization representing water
quality professionals around the world.
www.wef.org IWA is a global network
of water professionals that spans the
continuum between research and
practice, covering all facets of the
water cycle. www.iwahq.org
To have a news item considered, please send the information to Savanna Lauderdale, slauderdale@cahabamedia.com.

18
NEWS
EVENTS
PumpTec-USA
Sept. 10 11, 2014
Georgia World Congress Center
Atlanta, Ga.
770-310-0866
www.pumpconference.com
Turbomachinery/
Pump Symposia
Sept. 23 25, 2014
George R. Brown
Convention Center
Houston, Texas
979-845-7417
pumpturbo.tamu.edu
WEFTEC
Sept. 27 Oct. 1, 2014
New Orleans Morial
Convention Center
New Orleans, La.
www.weftec.org
ere
Wh
ws
Flo
n
o
ati
ov
n
In
International Association
of Amusement Parks and
Attractions (IAAPA)
Nov. 18 21, 2014
Orange County Convention Center
Orlando, Fla.
703-836-4800
www.iaapa.org
PumpTec-Israel
Dec. 3 5, 2014
Jointly with Electricity-Israel
2014 Conference
Eilat, Israel
770-310-0866
www.pumpingmachinery.
com/conference_2014_Israel/
conference_2014_Israel.htm
POWER-GEN International
Dec. 9 11, 2014
Orange County Convention Center
Orlando, Fla.
918-831-9161
www.power-gen.com
NGWA Expo & Annual Meeting
Dec. 9 12, 2014
Las Vegas Convention Center
Las Vegas, Nev.
www.ngwa.org
AHR EXPO
Jan. 26 - 28, 2015
McCormick Place
Chicago, Ill.
www.ahrexpo.com
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20
PUMP ED 101
By Joe Evans, Ph.D.
Pump Tech Inc., P&S Editorial Advisory Board
Three-Phase Voltage
Variation & Unbalance
Last of Two Parts
n my July 2014 column, I

demonstrated that threephase voltage variation can
signiicantly afect several alternating current (AC) motor characteristics. If that variation is large, it
can also reduce motor life. Voltage
unbalance can be an even bigger
problem and is one of the major
causes of premature motor failure.
A relatively small unbalance of
just 2 percent can reduce expected
insulation life by half.
Calculating Voltage
Unbalance
Unlike voltage variation, unbalanced voltage occurs when the
three phases are not at the same
voltage. An example of perfectly
balanced phase voltage is L1/L2 =
460 V, L2/L3 = 460 V and L3/L1 =
460 V. he average voltage is 460
volts.
An example of unbalanced phase
voltage is L1/L2 = 462 V, L2/L3 =
468 V and L3/L1 = 450 V. Again,
the average voltage is 460 V, but the
unbalance is 2.2 percent. Voltage
unbalance is calculated by the following equation:
Percent unbalance = 100 x
(maximum voltage deviation from
average / average voltage)
In the example above, the
maximum voltage deviation from
the average voltage is 10 V (460
minus 450). Motors from member

companies of the National Electrical Manufacturers Association
(NEMA) are designed to tolerate
no more than 1 percent of voltage
unbalance.
Why does voltage unbalance
shorten motor life? One percent of
voltage unbalance can result in 6
to 10 percent of current unbalance.
he phase with the lowest voltage
exhibits the highest current, which
increases the operating temperature of the winding serviced by that
phase. It will also increase the over-
all operating temperature of the

motor. Figure 1 shows the increase
in operating temperature versus
voltage unbalance. As shown, an
unbalance of just 3 percent can
increase operating temperature
by almost 20 percent. At 5 percent
unbalance, operating temperature
will increase by 50 percent.
Temperature Rating
& Insulation Class
Motor operating temperature is the
sum of the ambient temperature
surrounding the motor and the
Figure 1. Overheating because of voltage unbalance
21
Voltage unbalance is one of the major causes of premature motor

failure. A relatively small unbalance of just 2 percent can reduce
expected insulation life by half.
temperature rise due to the motor
load. he temperature rise is usually measured using the resistance
method. Each insulation class has
a speciic temperature rating. For
example, Class F is rated at 155 C
(311 F). he temperature rating is
the maximum operating temperature allowed in order to meet an
average insulation life of 20,000
hours.
Of that rating, 10 C is reserved
for the hot spot allowance. he
resistance method measures the
average temperature rise in the stator windings, but at some places
such as the stator slotsthe
temperature can be higher than the
average measurement. he hot spot
allowance is reserved to protect
these areas. h is reduces the actual
operating temperature (ambient
plus measured average) to 145 C.
For every 10 degrees over 145 C,
insulation life is reduced by half.
For every 10 degrees below 145 C,
insulation life doubles.
Suppose a motor with Class F
insulation operates at an ambient
temperature of 40 C. he measured temperature rise at full load
is 90 C. herefore, the operating
temperature is 130 C. he expected
insulation life would be about
50,000 hours or about 2.5 times
the life at 145 C. But at 3 percent
phase voltage unbalance, the operating temperature increases by 19
percent (155 C) and insulation life
is reduced by 50 percent.
Image 1 shows the windings of
a motor that failed because of high
voltage unbalance. When a motor
loses one phase (single phasing),
the other two phases have to carry
the entire load. As a result, two sets

22
PUMP ED 101
of phase windings are destroyed, and the one that

lost power is unharmed.
Motor Phase Loss & Failure

In the case of unbalance, the winding with the
highest current fails and, usually, the other two
are still functional. In the motor shown in Image
1, one of the phases has failed, one is normal and
the third is beginning to show the efect of higher
temperature. Measuring voltage unbalance and
i xing the cause are much less costly than having
it diagnosed in a motor shop. See Pump Ed 101
in the July 2008 issue of Pumps & Systems for
instructions on diagnosing the cause of unbalanced voltage.
Although correcting voltage unbalance is
always best, a few rules can allow operation in
unbalanced applications. For example, if the leg
with the highest current is under the nameplate
full load amperage (FLA), it will safely operate. If
Image 1. Windings of a motor that failed because of high voltage unbalance.

(Image courtesy of EASA)

23
Visit Booth 1543

43rd Turbomachinery
30th Pump Symposia
Houston, TX
PUMP ED 101
In addition to reduced insulation life, unbalanced voltage

can also increase electrical costs by decreasing motor efficiency.
it is above nameplate FLA but still

within the service factor (SF), it
may still safely operate. As a rule,
if the high current leg is less than
10 percent higher than the average
current, it will probably safely
operate.
A less desirable alternative is
to derate the motors nameplate
horsepower. NEMA suggests
derating horsepower to 75 percent
of nameplate at an unbalance of 5
percent. At 4 percent unbalance,
it is derated to 82 percent. At 3
percent, it is derated to 88 percent,
and at 2 percent, it is derated to 95
percent.
In addition to reduced insulation
life, unbalanced voltage can also
increase electrical costs by decreasing motor eiciency. At 1 percent
unbalance, eiciency remains at
the nameplate nominal eiciency.
However, at 3 percent unbalance,
actual motor eiciency can be reduced by 2 percentage points.
Joe Evans is responsible

for customer and employee
education at PumpTech Inc.,
a pump and packaged system
manufacturer and distributor
with branches throughout the
Pacific Northwest. He can be
reached via his website www.
PumpEd101.com. If there are
topics that you would like to
see discussed in future columns, drop him an email.
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25
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26
PUMPING PRESCRIPTIONS
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
Simplify the Equipment

Selection Process
hen the pump selection

process starts, the
required low of the is
often the only known variable
for an application. For example, a
system must move 2,000 gallons
per minute (gpm) from a holding
tank to another tank or process.
What size pump do should be
installed? he size and pressure of
the piping and the power of the motor must also be determined. his
column helps explain how to make
these decisions.
A = pipe area in square inches

(in2)
In our example,
5 = 2,000 x 0.321 / A
A = 2,000 x 0.321 / 5 =
128.4 in2 pipe area, or 12.8 inch
diameter
h is diameter can round to a 12inch pipe with a velocity of slightly

more than 5 ft/sec.
he next step is to igure out the
amount of pressure in the system
Pump & Piping Size
if the pump is 5,000 feet away
he longer the piping, the more
from the processdischarge. his
pressure its internal friction will
determination is more complicated
generate. A good way to pick a pipe
size is to calculate its diameter from because some hydraulic informaan empirical but simple starting
tion is needed. Several options can
formula. h is will help establish an provide this information: come to
approximate range. Pipe velocity is class, consult a piping friction loss
usually between 5 and 10 feet per
chart or take my word for it that the
second (ft/sec).
losses for cold water at 2,000 gpm
he smaller a pipes diameter, the in a 12-inch, 5,000-foot pipe are
faster luid lows through it. he
about 70 feet.
larger the pipe, the more expensive
With the low and head deterit is. Also, lowing too slowly may
mined, the motor can be sized (see
cause particulate matter to settle
Table 1). Also, an online Eiciency
and clog the line, but lowing too
Estimator, which can be found at
quickly will wear the pipe. he 5
www.mj-scope.com/pump_tools/
to 10 ft/sec range is usually a good
pump_eiciency.htm, ofers useful
starting point. Equation 1 can used formulas.
for a more accurate calculation.
To handle the process speciications, a single-stage pump was seV = Q x 0.321 / A
lected. he Eiciency Estimator calEquation 1 culated that a 42-horsepower and
84.5-percent pump eiciency can
Where:
be expected from a typical pump.
V = velocity in ft/sec
h is number can be conirmed with
Q = low in gpm
quotes from pump distributors.
he Eiciency Estimator also

suggests an impeller size of 9.77
inches. h is measurement is a good
way to roughly verify the appropriate sizes of existing pumps. his
process provides useful preliminary
information for pump selection.
Motor Size
A 1,800-rpm motor speed was
selected for this process because it
is one of the most common motor
speeds in the U.S. he horsepower
recommendation can be rounded to
select a 50-horsepower motor. If the
pump is expected occasionally to
operate outside the curve, choosing
a 75-horsepower leaves a margin of
safety.
Table 1. Sizing motors during pump selection

(Graphics courtesy of the author.)
US Units
Pump low (gpm)
2,000
Total pump head (ft)
70
Speciic gravity (SG)
1.00
Number of stages
Speed (rpm)
Header per stage (ft)
1
1,800
70
Impeller diameter (in)
9.77
Speciic speed U.S. (Ns)
3,326
Speciic speed metric (ns)
64.5
Speciic speed universal (Os)
1.22
Eiciency (%)
84.5
Power (hp)
42
27
If a pump has too little NPSHA, it could experience suction

problems. Too much NPSHA leads to higher contruction costs.
Users must find the right balance.
NPSHA Calculation
he suction side must be considered. My last few columns discussed pump suction performance.
For example, I discussed how the
system afects the operation and
the relationship between the low
(as a percent of the best eiciency
point) and suction recirculation.
Many end users question how much
net positive suction head available
(NPSHA) they need.
If a pump has too little NPSHA, it

could experience suction problems.
Too much NPSHA leads to higher
construction costs. Users must ind
the right balance. My next column
will describe in detail the beginning
of the selection process. For those
interested in how to calculate the
piping losses estimated (70 feet of
head), my Pump School training
covers this in-depth.
Dr. Nelik (aka Dr. Pump) is

president of Pumping Machinery, LLC, an Atlanta-based firm
specializing in pump consulting,
training, equipment troubleshooting and pump repairs. Dr.
Nelik has 30 years of experience
in pumps and pumping equipment. He may be reached at
pump-magazine.com.
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28

By Ray Hardee
Engineered Software, Inc.
System Validation
& Troubleshooting
n the previous article calculating the cost of elements

in a piping system (Pumps &
Systems, July 2014), the energy
consumed and power cost balanced
exactly to demonstrate the process.
Seldom is life that exact. In the
real-world plant, instruments are
subject to inaccuracy, pumps may
be worn, estimates may be of
or the full system may not be
accurately represented in the design
documents.
h is months article demonstrates how cross-validating the
calculated results can ensure the
energy cost balance sheet accurately
relects system operation.
he key to validating the results
is to use multiple means for arriving at the operating cost of each
item in the energy cost balance
sheet. If the energy cost balance
sheet does not add up, troubleshooting skills need to be employed
to discover the reason for the difference.
h is article will continue to
use the example piping system
presented in previous articles (see
Figure 1).
Prioritizing the System

he pump elements provide all
the energy that enters the system.
hat energy is then consumed by
the systems process and control
elements.
If the energy cost balance sheet
does not balance, operators should
begin looking for the source of the
problem. he major energy users
in the system should be examined,

and operators should ind methods to cross-validate the initial
estimates.
Pump Performance
In the example, the pumps low
rate was determined using the
manufacturers pump curve. With

a known low rate, the pump eficiency can be determined from
the curve.
Because the pump eiciency is
used in all energy cost calculations,
ensuring the accuracy of the value
is critical.
Figure 1. Drawing of sample piping system

(Article graphics courtesy of the author.)
Figure 2. An example showing the effect internal leakage has on pump

performance. Because of internal leakage, the installed pump is not
operating as designed.
29
Inaccuracies can occur in

real-life operating conditions. For
example, if the pump has a worn
impeller and excessive internal
leakage, it no longer relects the
pump curves operation.
Figure 2 shows a pump curve for
the process pump along with an
example of the efect that excessive
internal leakage can have on the
pump curve.
Using the calculated head difference of 235 feet (ft), the worn
impeller gives a low rate of less
than the 4,000 gallons per minute
(gpm) used in the previous energy
system balance.
In addition, the eiciency of a
worn impeller would difer from
the manufacturer-supplied test
curve.
h is would result in inaccurate
power consumption and operation
costs calculations.
Operators have other options to
determine the low rate through
the pump, including portable
ultrasonic low meters.
hese meters provide a reasonably accurate low measurement
in a pipeline without physically
changing the piping system.
If the observed low rate on the
temporary low meter equals the
value determined using the pump
head and the pump curve, the low
rate is validated, and the eiciency
is validated by association.
kW = .746
If a power meter is installed on

the motor driving the pump, the
measured kilowatt (kW) value
can be compared to the calculated
power consumed using the pumps

low, head and eiciency values as
show in Equation 1, at the bottom
of page.
XRS
The XRS
SplitSeal
assembles in
four easy sections.
QH
247,000 P M
Equation 1
Where:
Q = low rate in gpm
H = pump head in ft
= luid density lb/ft3
P = pump eiciency
M = motor eiciency
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30
If the power into the motor as

read on its power meter is the same
as the calculated power consumption using Equation 1, the pumps
low, head and eiciency values are
validated.
If a power reading is not available
for the motor, the motors power
consumption can be calculated by
measuring the current and voltage
supplied to the pumps motor, then
using Equation 2. he motors power
factor can be read on its nameplate.
Control Valves
In last months example, the differential pressure across the control
valve was calculated by subtracting
the sum of the head losses of the
process elements from the pump
head. h is approach is easy, but any
errors made in the previous calculations will compound and can greatly
reduce the energy cost balance
sheets accuracy.
Valve manufacturers deine the
operation of control valves based on
tests that are outlined in published
3 V I Pf
P3Motor =
industry standards. Manufacturers
1,000
use the ANSI/ISA-75.01.01 Flow
Equation 2 Equations for Sizing Control Valves
Where:
to size control valves for piping
P3Motor = motor power in kW
systems. he data used in valve
V
= voltage volts
sizing can also be used to calculate
I
= current amps
the diferential pressure across the
Pf
= motor power factor
control valve.
Equation 3 shows the basic forIf the calculated value of motor
mula for valve sizing.
power equals the pumps power conQ
sumption, the pump low, head and
Cv =
P
1 P2
eiciency values are validated.
FP
S
Tank Levels and Pressures

he tanks and vessels make excellent piping system boundaries. he
energy at each tank can be determined by using the elevation of the
liquid level in the tank and pressure
on the liquid surface.
From these values the energy
consumed for the static head component can be easily calculated.
he results can be cross-validated
using installed pressure and level
instrumentation.
he liquid level can be checked
with a sight glass or by manually
measuring the liquid level in the
tank. he pressure in a closed vessel
can be compared using the installed
plant instrumentation, installed
pressure gauges or a temporary pressure gauge.
Equation 3
Where:
Cv = manufacturer-supplied valve
coeicient
Q = low rate in gpm
FP = piping geometry factor (unitless)
P1 = absolute pressure measured
at valve inlet in lb/in2
P2 = absolute pressure measured
at valve outlet in lb/in2
S = luid speciic gravity (unitless)
Rearranging the control valve

sizing equation and solving for differential pressure results in Equation 4.
dP =
Q2S
(CvFP)2
Equation 4
In the example system with a low

rate through the level control valve
of 2,500 gpm, the control valve position is 65 percent. According to the
manufacturers data for the control
valve, the Cv at this position is 391.
he FP of .9996 was calculated
by the manufacturer and included
in the valve data sheet. he speciic gravity of the process luid was
calculated at .993. he low rate
through the level control valve was
measured at 2,500 gpm. Inserting
the values into Equation 4 provides
the diferential pressure across the
control valve.
dP =
Q2S
25002 .993
= 40.6 psi
=
(CvFP)2 (391 .9996)2
Converting the control valves

diferential pressure of 40.6 pounds
per square inch (psi) to feet of luid
results in a head loss of 94.3 ft. his
result for the control valve calculation validates the number from last
months calculations.
Process Equipment
he diferential pressure across the
process equipment was calculated
using the pressure drop data supplied by the manufacturer and the
If the calculated value of motor power equals the

pumps power consumption, the pump flow, head
and efficiency values are validated.
31
Problems that could affect the head loss calculation

include fouling or sedimentation in the pipelines,
partially closed valves, or obstructions in the pipe,
valves or fittings.
Pipelines
In the example, the head loss in the
individual pipelines was calculated,
then used to determine the head
loss in each circuit of the pipeline.
h is requires a large number of
calculations.
he repetitive nature of the calculow rate obtained from the installed validated by installing temporary
lations makes this an excellent task
low element. In the example, the
pressure gauges.
to be performed using a computer.
heat exchanger pressure drop of
Most process equipment has vent Online head loss calculators can be
10 psi was assumed based on the
and drain lines installed for mainfound by performing an Internet
manufacturers supplied data. If the tenance.
search. Commercially available
heat exchanger tubes were fouled
By installing temporary pressure
computer programs can also greatly
due to internal deposit, the actual
gauges on the vent and drain lines simplify the task.
diferential pressure across the heat and correcting the pressure values
Problems that could afect the
exchanger would be greater than
for any diference in elevation of the head loss calculation include fouling
the value used in the energy cost
gaugesthe diferential pressure
or sedimentation in the pipelines,
calculation.
and head loss across the item can be partially closed valves, or obstruche diferential pressure across
measured.
tions in the pipe, valves or ittings.
the process equipment can be
Inaccurate determination of the pipe

32
size or schedule, or inaccurate estimates of the number of ittings or

pipe length can also afect the head
loss calculation.
Total System
If the energy cost balance sheet
does not balance, either the measured plant data or the equipment
ump
s At P
See U posium
m
Sy
903
Booth

(pumps, process components or

control valves) could be causing the
problem.
To conirm the accuracy of the
measured data, check to see that
the instruments are calibrated. he
instrumentation department can
also make sure the instruments
are accurately reading the process
parameters.
he irst step is to check for
cavitation throughout the whole
system. Cavitation is caused when
the local pressure drops below, then
rises above, the vapor pressure of
the process luid. Some of the luid is
converted from liquid to vapor. he
vapor bubbles take up extra space
in the low stream, which causes a
reduction in the mass low rate.
All standards and calculation
methods used to determine head
loss assume single phase low. If
cavitation occurs, the calculated results will not accurately relect what
is happening in the system.
Cavitation is especially troublesome in pumps and control valves.
It can be a major source of maintenance problems and should be corrected prior to performing a system
assessment.
Next, the interaction of the
systems components should be
examined. he best way to accomplish this is to compare the current
observed values with previous
observed values.
For example, the average valve
position of the level control valve
increased over time from 65 percent
open to 71 percent open. he rest of
the measured plant data remained
the same.
Using Equation 4, the head
loss across the level control valve
decreased from the original 94 ft of
loss to 71 ft. he only explanation
for this change is that the head loss
across the process element increased
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34
from the manufacturers published

value of 23 ft to 46 ft. his is a clear
indication of fouling in the process
equipment.
Conclusion
Gaining a clear picture of how a
piping system operates is key to assessing the system.
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Because most operating plants do

not have suicient installed plant
instrumentation to provide all the
data needed for the calculations,
many of the values must be calculated using other well-established
methods.
By performing the calculations
and comparing them to available
operating data, operators can determine how the system is currently
operating.
h is information allows operators to correct any problems that
adversely afect system operation
and perform an accurate assessment of the piping system by
completing an energy cost balance
sheet.
My next few columns will investigate a variety of plant systems.
hey will demonstrate what can be
gained with a better understanding
of system operation and what can
be done to reduce operating, maintenance and capital cost within
piping systems.
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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@eng-software.com.
36
GUEST COLUMN
By Heinz P. Bloch, P.E.
Pushing Fluid Machinery Leads

to Frequent Failures
Second of Four Parts
espite their simplicity,

centrifugal pumps often
experience repeat failures
that even seasoned maintenance
and reliability professionals have
trouble preventing. h is four-part
series explains the reasons behind
repeat pump failures and uses a
real-world ield example involving
boiler feedwater pumps. Deviations from best practices or oversights can range from seemingly
insigniicant to stunningly elusive.
hese can combine and often cause
costly failures.
Operating Diferent
Pumps in Parallel
he negative experience of a
metal producing facility best
demonstrates the consequences of

year to meet the plants production
operating pumps beyond their apneeds. he system has operated in
propriate low ranges. h is example this way since being commissioned
serves as a reminder of the merits
ive years ago.
of conducting in-depth
reliability reviews before Figure 1. Pump manufacturers usually plot only the net positive suction
head required (NPSHR) trend associated with the lowermost curve. At that
buying process pumps.
point, a head drop or pressure fluctuation of 3 percent exists at BEP flow.1
h is case history extends
to the remaining parts of
this series.
he operating data of
the plants installed instrumentation is shown
in Figure 1. he low rate
into the destination tank
averages 2,500 gallons
per minute (gpm) to
maintain the tank level.
h is system currently operates for 8,000 hours per
Figure 2. A typical head-versus-flow performance curve
Image 1. This riveted cage bearing failed because of axial (rotor thrust) overload.
(Article images and graphics courtesy of the author.)
37
h is case history is one of

many examples that validate the
importance of examining the
low-versus-head characteristics
(the H/Q curves) of pumps. Such
examinations are needed during
the procurement phase of new
pumps and the troubleshooting of
installed but failure-prone process
pumps.
Seven boiler feedwater (BFW)
pumps were installed in the metal
producers boiler house. Two of the
facilitys seven pumps came from
Vendor A, two from B and three
from C. he respective H/Q curves
from vendors A, B and C were not
identical. By 2009, these pumps
had failed often and randomly. he
need for a thoroughly experiencebased failure analysis was recognized. he analysis pointed to
hydraulic and mechanical issues.
hrough the years, this facility
routinely ran several BFW pumps
in parallel. Fear of failure may
have prompted operating four
pumps in parallel when only three
were required to provide a speciic
low rate. If running three pumps,
each pump could have operated
closer to its BEP, but operating
four pumps led to a greater failure
risk. In other words, one or more
of these four pumps operated in
the questionable or forbidden lowlow and high-internal-recirculation range illustrated in Figure 1.
Low-Flow Range
At least two of the pumps had
l at H/Q curves, similar to the
curve in Figure 2. Running in
the low-low range forced one or
both pumps into the l at portion
of their respective performance
curves. When operating in the l at
range, even a small change in head
(a small change in p) results in
large diferences in throughput.
Controlling and equalizing load

sharing would be diicult.
In addition, the internal
pump clearances opened as time
progressed. his explanation was

in line with the recent escalated
failure frequencies. It led to the
recommendation of investigating
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Manufactured in 35 sizes, standard materials
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38
GUEST COLUMN
the minimum low allowed for these

high-suction-energy, BFW pumps.
he concept of high suction energy
and what it means in terms of the
required net positive suction head
available (NPSHA)/net positive suction head required (NPSHR) ratio
and/or reduced allowable operating
range is thoroughly explained in
References 3 and 4.
Internal wear and operation at
lower-than-designed low afect
the hydraulic thrust acting on a
pump rotor. his often contributes
to thrust bearing failures similar
to the one shown in Image 1 and
might even explain the excessive
wear on the worm wheel of one of
the shaft-driven lube oil pumps. In
general, rolling element bearings
with riveted cages should be avoided
in process pumps. Part hree of this
four-part series will explain why

this is recommended.
References
1. Taylor, Irving, he Most Persistent
Pump-Application Problems for Petroleum
and Power Engineers, ASME Publication
77-Pet-5 (Presented at Energy Technology
Conference and Exhibit, Houston, Texas,
September 18 22, 1977).
2. Bloch, Heinz P., Pump Wisdom: Problem
Solving for Operators and Specialists, John
Wiley & Sons, Hoboken, N.J., 2011.
3. Bloch, Heinz P. and Alan R. Budris, Pump
Users Handbook, 4th Edition, Fairmont
Press, Lilburn, Ga., 2013.
4. ANSI/HI9.6.3-1997, Allowable Operating
Region, Hydraulic Institute, Parsippany,
N.J.
5. SKF USA, Inc., Publication 100 955,
Bearings in Centrifugal Pumps, Version
4, p. 20, Kulpsville, Pa., 2008.
6. Bloch, Heinz P., Practical Lubrication for
Industrial Facilities, 2nd Edition, Fairmont
Press, p. 179, 2009; Mechanical Seals
in Medium-Pressure Steam Turbines,
presented at the ASLE 40th Annual Meeting in Las Vegas, Nev., May 1985 (later
reprinted in Lubrication Engineering,
November 1985).
Heinz P. Bloch has been a professional engineer for almost 50 years.

He holds a BSME and an MSME
degree (cum laude) from New Jersey
Institute of Technology and retired as
Exxon Chemical Companys regional
machinery specialist. He authored or
co-authored 18 comprehensive textbooks dealing with lubrication and
fluid machinery topics and published
more than 570 technical papers or
articles. Bloch has taught reliability
improvement and maintenance cost
avoidance subjects on six continents. He continues to write for trade
journals and advises and teaches
machinery reliability improvement
subjects. He may be reached at
heinzpbloch@gmail.com.
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40
GUEST COLUMN
By Amin Almasi
Estimate Pump Installation Costs
ost estimation errors are

common in a variety of
projects. Recent studies
have shown the cost of machinery
can represent 20 to 35 percent of
a processing and manufacturing
projects total cost. he estimated
costs for new plants and particularly new pump installations are
very uncertain and have increased
in recent years.
he following concepts minimize
the cost of pump installations:
Maximizing the extent of
manufacturing and installation
in the shop environment
Simplifying a pump packages
transportation and installation
Providing modularized components that are easy to change
Reducing on-site personnel
supports and encouraging unmanned operation
Eliminating as many standby
pumps as possible
Very limited literature is available on pump cost estimation. h is
column will focus on the cost estimation of the pump installations in
diferent projects.
Pump Installation
Cost Estimate
Historical data could inform pump
installation cost estimation models
within certain limits. Results have
shown a large cost diference between diferent regions.
he economies of concentration
play an important role in cost.
Cost studies have indicated that
pump installation cost components

usually have economies that are
to scale to pump unit capacity and
pump train size.
he cost estimation of a pump
unit or installation in a plant
cannot be fully accurate, with the
exception of the material cost,
particularly the cost of a pump
package. h is cost can be estimated
from the pump packages vendor,
and the cost of materials could be
obtained from suppliers. However,
other cost estimations are relatively
inaccurate. Labor costs have much
larger cost overruns compared to
other cost components.
he following estimation concept
can be employed for a pump unit or
installation:
(Pump Unit Cost) = A (Pump
Package Cost) + B
he factor A is assigned for all
auxiliaries and accessories required
for each pump package such as
the foundation, civil works, piping
and additional steel structures for
each pump package. his factor is
usually between 1.3 and 2.5. he
pump package cost includes all
skid-mounted facilities such as the
driver and lubrication oil system.
he factor B is assigned for all

auxiliaries and accessories required
for each pump unit, such as unit
piping, unit utilities, protection
systems, unit pit/drain, unit electrical facilities, safety equipment,
unit steel structures and unit civil
works.
Because the cost underestimating
error is generally larger than the
overestimating error, proper safety
margins for factors A and B are
always encouraged.
he cost is also a function of the
project size or the pump system
capacity. A proper set of factors
should be developed for a deined
range of the pump unit size and
capacity for a region.
Environmental conditionssoil,
terrain, cost of living, population
density, economies of scale, noise
limits, applicable codes and distances from pump suppliescould
afect the installation cost estimation and should be considered when
the cost factors are estimated.
Other Costs
Studies on recent pump installations have shown that the cost
of civil works (site developments,
foundations and others) are about 9
to 20 percent of the total cost.
Cost studies have indicated that pump installation cost

components usually have economies that are to scale to
pump unit capacity and pump train size.
41
hey have also shown that the cost

of installation can be approximately 7 to 11 percent of the total
cost.
he required man-hours for the
installation and commissioning of
pumps can vary signiicantly. For
packaged pumps, the following
indications should be noted:
For large pump packages (more
than 1 megawatt (MW)), the
installation and commissioning man-hours could be
between 300 and 900 hours.
For small pump packages (less
than 1 MW), the installation
and commissioning man-hours
could be between 100 and 300
hours.
Case Study
he irst case study is presented for
a 6 MW pumping unit. he costs
of electric motor-driven pump
packages are obtained in millions
of U.S. dollars (MUSD):
A 3 MW pump package:
0.9 MUSD
A 1.5 MW pump package:
0.6 MUSD
A 0.8 MW pump package:
0.45 MUSD
A proper set of factors should be developed

for a defined range of the pump unit size
and capacity for a region.
he factor A is estimated at
1.67 for these pump packages. he
factor B is estimated at 1.5 MUSD
for a 6 MW pump unit. Table 1
compares the cost of these diferent options.
As shown, smaller pumps considerably increase costs. A greater
number of smaller pumps is more
expensive than using a single large
pump.
he second case study is presented for small pump installations. he following two options
are considered:
Option 1: A 320 kW pump,
$52,000
Option 2: A 200 kW pump,
$42,000
he factor A is estimated at
1.49 for these small pump packages. he factor B is estimated at
$45,000 for Option 1 and $34,000
for Option 2.
Table 1. Costs of different pump arrangement options

(Article graphics courtesy of the author.)
Pump Unit
Rough Cost of
Packages (MUSD)
Rough Total
Cost (MUSD)
Rough Cost
Ratio
23 MW
1.8
4.5
41.5 MW
2.4
5.5
1.2
80.8 MW
3.6
7.5
1.7
Table 2. Cost analysis for two options of small pumps
Pump Option
Package Cost
Installed Cost Rough Cost

Ratio
Option 1: 320 kW
$52,000
$122,000
Option 2: 200 kW
$42,000
$97,000
0.80
Table 2 shows the cost analysis

for two options of small pumps.
Based on Table 2, only about 20
percent total installed cost reduction could be expected for a pump
38 percent smaller in size. Large
pumps have economies of scale
and low unit cost. In other words,
unit costs of pump installations
usually decrease as pump size
increases.
Amin Almasi is a rotating

machine consultant in Australia.
He is a chartered professional
engineer of Engineers Australia
(MIEAust CPEng Mechanical)
and IMechE (CEng MIMechE)
and a Registered Professional
Engineer in Queensland. He specializes in rotating machines
including centrifugal, screw and
reciprocating compressors; gas
turbines; steam turbines; engine
pumps; subsea and offshore rotating machines; LNG units; condition monitoring; and reliability.
Almasi is an active member of
Engineers Australia, IMechE,
ASME, Vibration Institute, SPE,
IEEE and IDGTE. He has written
more than 80 papers and articles
dealing with rotating equipment,
condition monitoring, offshore
and subsea equipment, and reliability. Almasi may be reached at
amin.almasi@ymail.com or +61
(0)7 3319 3902.
42
SPECIAL SECTION
SEALS & BEARINGS
Canned Magnetic
Bearings Minimize
Corrosion in
Oil & Gas Processing
Safely immerse motor compressors in
process gas without risking costly damage.
BY RICHARD SHULTZ
WAUKESHA MAGNETIC BEARINGS
ctive magnetic bearing (AMB) reliability and availability levels have surpassed oil bearings after 10 years
of technological advancements. hese advances have
made an impact on the industry, drawing attention
from major original equipment manufacturers globally.
In 2002, an oil and gas processing company required a bearing for a hermetically sealed integral motor compressor. he
natural gas from the well contained hydrogen sulide, which
lead the company to pursue a corrosion-resistant canned
bearing. Finding a reliable bearing for this hermetically sealed
integral motor compressor was a challengebut one worth
the cost. he solution included sealed bearings and electrical
connectors, which eliminated the need for a costly enclosure
surrounding the motor compressor. Installing the motor
compressor outdoors, without a building or enclosure, saved
the company signiicantly in capital expenditures. he hermetic
sealing of the bearings and motor compressor also ensured that
emission limits were not exceeded for sites in which operating
licenses limited hydrocarbon emissions.
Process Gas Immersion

Magnetic bearings are an efective solution for many oil and gas
applications because they can be immersed in the process gas. A
Augus t 2014 | Pum ps & S yst e m s
canned magnetic bearing with metallic lined stators

segregates the electrical connections and windings
from the corrosive gas. Canned bearings allow for
the placement of the magnet core and windings
behind an impervious pressure-rated barrier
constructed of corrosion-resistant alloy or other
nonmetallic material.
Special alloys ensure that the bearings will not
corrode, protecting the inside of the machine from serious
degradation.
With canned AMB designs, the metallic can separates the
pressurized volume inside the machine from the cavity and
ambient pressures and protects against leakage to the machines
exterior. he metallic can must withstand the maximum pressure inside the machine, which is equal to the cans diferential
pressure.
A proper design of the metallic can and backing system is
crucial to survive all the temperature and pressure conditions
that the AMBs will encounter during operation.
In one 2006 oil and gas installation, the system has
operated safely in its environment. After 25,000 hours, the
units operation provides 99.9 percent availability to its end
user. In addition, the canned bearings temperature ratings
43
Because they can be immersed in process gas without

corroding the electrical connections, canned magnetic
bearings offer oil and gas end users a significant advantage.
(Article images and graphics courtesy of Waukesha.)
EOG location
memphis, tnks jkask
Figure 1. A plot of in situ pH against the partial pressure of hydrogen

sulfide shows increasing corrosion from Regions 0 (no effect) to 3 and
beyond (highest propensity for SSC).
reached 165 C. Other canned bearings have reached 130

C in similar applications.
Managing Corrosion Risks

Magnetic bearings must conform to the corrosion safety
standards for oil and gas applications, such as National
Association of Corrosion Engineers (NACE) MR0175. he
bearings electrical components are protected from process
conditions, including chemical attack by process gas and
condensates. he motor compressor can eliminate the use
of dry gas seals, avoiding natural and sour gas damage to
the environment.
Figure 1 has been adapted from NACE MR0175. It
details regions of increasing sour gas corrosion to metal
alloys used in oil and gas processing equipment. Corrosion
is deined by reference to sulide stress cracking (SSC).
p u mp-zone.c om | Au gu st 2014
44
SPECIAL SECTION
SEALS & BEARINGS
Figure 1 shows in what levels of sour gas

service sealed and canned designs may
be applied while still expecting a reasonable service life, based on documented
corrosion rates. he dividing line corresponds to a concentration of about 600
parts per million of sulides.
A rotor system inside a pressure vessel

also helps cool the motors and bearings
and provides electrical connections that
penetrate the pressure vessel.
Erosion and corrosion can cause
costly damage to a machines interior.
Canned and corrosion-resistant auxil-
A canned magnetic
bearing segregates
electrical connections
and windings from the
process gas.
PumpWorks 610
delivers.
iary bearings ofer a beneit to the oil

and gas industry, in which environmental regulations continue to increase.
hese bearings can be applied in the
manufacturing of integral motor compressors, externally driven compressors
and turbo expanders.
Richard Shultz is the design engineering

manager for magnetic bearing systems at
Waukesha Magnetic Bearings. He has 20
years of industrial experience designing
magnetic bearing systems and auxiliary
bearing systems, specializing in rotordynamics and control system design. He
recently instructed at the Magnetic Bearing Short Course
at the Texas A&M Turbomachinery Symposium and the
Middle East Turbomachinery
Symposium in Qatar.
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45
The Right Seal & Lubricant

Combination Can Prevent
Bearing Contamination
Lip and labyrinth seals provide protection
in harsh oil and gas applications.
BY JAMES WONG
GARLOCK SEALING TECHNOLOGIES
Figure 1. Formation of meniscus of oil under the lip

(Article graphics courtesy of Garlock Sealing Technologies.)
ithin the oil and gas industry, the rotating shafts

of equipmentsuch as pumps, motors, compressors, gearboxes and turbinesperform an essential function in both upstream and downstream
applications. his rotating equipment ensures process low and
the safety of employees and the surrounding community.
Bearings are critical to the reliability of rotating equipment.
If they fail, the equipment has to be repaired or replaced.
Because they support the shaft, bearings are prone to wear
and damage. Lubrication starvation and contamination are
the principal factors that cause premature bearing failure, so
systems have been developed to prevent these issues.
Methods for sealing the gap between a rotating shaft and
the stationary bore have evolved with advances in lubrication
and lubrication delivery systems. Selecting the right seal for a
lubrication system will yield the best bearing protection. Lip
seals and labyrinth seals, also known as bearing isolators, are
the most common solutions.
Lip seals are unidirectional contact type seals. heir geometry is important for maintaining an optimal radial load on
the shaft to develop a meniscus of oil on which the lip can ride,
which reduces friction and wear on the shaft and lip (see Figure 1). Depending on the direction of the installed seal, it will
either prevent egress of lubrication or ingress of contamination
(see Figure 2).
Bearing isolators are non-contact seals that provide bidirectional sealing capability. heir construction includes two
Figure 2. Direction determines lubricant retention or contaminant exclusion .
46
SPECIAL SECTION
SEALS & BEARINGS
components that rotate independently of each other. he stator

remains with the bore, and the rotor rotates with the shaft. Between the stator and rotor is the labyrintha small, contorted
pathway that prevents the egress of lubrication and ingress of
contaminants at the same time (see Figure 3).
Grease Purge
Grease is an easy lubricant to apply and maintain, and it can be
used to prevent contamination. Its consistency makes it easy
to seal within bearing chambers. Most equipment designed for
grease lubrication is equipped with a purge stream. his allows
fresh grease to be pumped into the bearing chamber, replacing
degraded or contaminated grease. Grease purging is a common
practice, but should only be carried out with an understanding
of the grease lows efect on the seal.
Lip seals are suitable for use with grease lubrication, since only
one seal installed facing the external environment is typically
needed. h is coniguration prevents contamination of the grease
by water or dirt and allows it to be purged under the lip if the
discharge port becomes plugged or otherwise obstructed. Lip
seals are rarely installed with the lip oriented toward the grease.
Applications in which no grease should ever escape the seal, such
as those in the food industry, are exceptions. In these instances,
a metal case lip seal or cover plate that helps retain the seal in
the bore is recommended. his helps prevent the seal from blowing out from purge pressure of the grease.
Operating temperature is an important consideration when
selecting lip seal material. Because grease does not dissipate heat
as well as oil, adding another 100 degrees Fahrenheit to the operating temperature is recommended to ensure that the material
can withstand the heat.
Bearing isolators are also suitable for use with grease lubrication. hey can retain grease within the bearing chamber even
during purging. Because of the consistency of grease, the level of
lubrication is not a concern. Bearing isolators are customizable.
If the equipment does not have a grease discharge port or if the
port is obstructed, a special bearing isolator can be designed to
purge the grease through the isolator itself (see Figure 4).
Oil Bath
Oil bath/splash is the simplest type lubrication system. It
requires only minimal maintenance. A side glass or dip stick
should be provided with these systems to ensure that the proper
level of lubrication is maintained. he level typically should be
at the center of the lowest rolling element of the bearing. With
each rotation of the shaft, the rolling elements distribute the oil
within the bearing.
h is poses a problem for lip seals. Depending on the size of the
bearing and the speed of the shaft, the lip could be starved of oil
and unable to develop a meniscus. his means that the lip would
contact the shaft, grooving it and reducing the seals life.
Bearing isolators are designed for this type lubrication system.

In addition to labyrinths that prevent the escape of lubrication,
they have drain ports to capture excessive oil splash and drain it
back to the sump. With the smaller footprints of todays pumps,
the distance between the bearing and the back of the seal is
reduced, creating a more aggressive splash onto the bearing
isolator. As a result, manufacturers have redesigned drain ports
to capture more lubrication and direct it back to the sump.
Oil Mist
Oil mist is becoming a popular lubrication system, especially
in the oil and gas industry. Oil mist systems are approved by
the American Petroleum Institute (API) 610 speciication for
centrifugal pumps for the petroleum, petrochemical and natural
gas industries.
An oil aerosol is dispersed within the bearing chamber to
lubricate the bearings. If not vented properly or applied in a
closed-loop oil mist system, the pressure will increase within
the bearing chamber. h is increased pressure makes capturing
the mist within the bearing housing diicult because the higher
pressure in the bearing chamber attempts to obtain equilibrium,
carrying the oil mist into the environment.
Figure 3. Components of a bearing isolator with the

labyrinth pathway highlighted in yellow
47
Figure 4. Custom bearing isolator with purge stream
Lip seals are not recommended because the mist may not be conducive to the
formation of an oil meniscus under the lip, resulting in friction and heat that will
groove the shaft and damage the seal. Speciically, API 610, 11th Edition, Paragraph 6.10.2.6 states that lip-type seals shall not be used with oil mist systems or
any other type lubrication system in API pumps.
he same paragraph stipulates that labyrinth- or magnetic-type end shields
should be used. Magnetic-type seals work like face-type mechanical seals. Two
smooth faces, lapped within two light bands are mated. Force is applied across the
faces either by springs or magnets. he face material could be bronze, carbon or
ceramic depending on the application temperature, since the seal generates
additional heat as the two faces rub against one another.
Labyrinth seals, such as bearing isolators, could be used, but without modiication or additional features, they cannot hold back the pressurized oil mist. One
way to combat this is the addition of a mechanism to block the pathway to the environment. h is could be an O-ring, felt or a molded polytetraluoroethylene ring
in diferent cross-sections. hese rings are strategically placed along the labyrinth
and typically have frictional contact with either the isolator or the shaft.
Recent advances in bearing isolators include the ability to be used in submerged
or looded conditions. hese hybrid bearing isolators combine the beneits of a
non-contact, labyrinth-type seal and a contact-type seal to hold a full head of lubrication (see Figure 5). his makes them suitable for use in oil mist applications to
prevent the mist from migrating into the atmosphere. Operators should note that
these hybrid bearing isolators could be made of steel, which is a sparking material.
Disinfect
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48
SPECIAL SECTION
SEALS & BEARINGS
Conclusion
Seals and lubrication systems can be combined in many ways. he wrong pairing can
lead to premature bearing failure, downtime, lost production, shorter maintenance
intervals, and costly equipment repairs and replacement.
t the
130 a sium
th #1
y Boo rbo S y mpo
b
p
Sto
n
/ Tu
ousto
Pump
2014 Show in H
Figure 5. Hybrid bearing isolator with contact

points within the labyrinth to retain oil mist or a
full head of lubrication in flooded condition
James Wong is the associate product

manager for the bearing isolator product line
at Garlock Sealing Technologies. He has extensive experience in industrial sealing technology in dynamic and static applications.
He started his career as a product engineer
designing and testing seals for dynamic
application, including field experience solving challenging applications. Currently, he
manages the entire bearing isolator portfolio
at Garlock. His name appears on several
patent and technical articles pertaining to
bearing isolators. Wong also has
presented in seminars around
the world on the subject of
bearing protection. He may be
reached at james.wong@
garlock.com.
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50
SPECIAL SECTION
SEALS & BEARINGS
Select Seals
That Meet
the Chemical
Challenges of
HPLC Pumps
Abrasive processing and wide
temperature range are some
of the pumping diculties
for high-performance liquid
chromatography.
BY JERRY ZAWADA
TRELLEBORG SEALING SOLUTIONS
igh performance liquid chromatography (HPLC) is a

chemical analysis technique with wide applications,
from food and medical safety to manufacturing.
HPLC can detect vitamin D levels in blood serum or
performance enhancing drugs in urine. he technique has even
been used to synthesize blood and determine DNA evidence in
forensic investigations.
In biotechnical and pharmaceutical manufacturing, HPLC
enhances the production process by increasing separation
eiciency, improving resolution and shortening analysis time.
Instrumentation and system automation have evolved to keep
pace with the quality of materials that support HPLC and its
applications.
How HPLC Works

HPLC passes a liquid sample through a column of a particular
absorbent solid material that reacts at divergent rates from an
In HPLC applications, the

use of seals that offer low
coefficients of friction and
robust dynamic and static
sealing is recommended.
(Article images courtesy of
Trelleborg Sealing Solutions.)
analyzing solvent. he rate of reaction and how the solution

separates identify the original components. his technique can
determine all the materials in a solution based on known reactions to base chemicals and solid state materials.
HPLC instruments include a sampler, pumps and a detector.
he sampler brings the mixture samples into the mobile phase
stream, which carries it into the column. he pumps deliver the
desired low and composition of the mobile phase through the
column. Some mechanical pumps mix multiple solvents in ratios changing over time, creating a composition gradient in the
mobile phase. he detectorultraviolet-visible spectroscopy,
photodiode arrays (PDAs) or mass spectrometry are commonly
51
Long-lasting instrumentswith lifespans from five to

20 yearshave led to instrument maintenance repair organizations
having a more common role in HLPC instrument upkeep.
usedgenerates a signal proportional

to the amount of sample component
emerging from the column and allows for
quantitative analysis of the sample components. Instrument control software
usually ties into the HPLC instrument
and provides data analysis. Additionally, a high scan-speed detector capable
of collecting enough data points across
an analysiss narrower peaks has often
improved the production process.
HPLC Pumping Challenges

All piston pumps have multiple replacement parts, such as check values, piston
seals and pump piston rods. When working with HPLC instruments, biotechnical
and pharmaceutical manufacturers pay
close attention to the parts and materials
entering their supply chain in terms of
their pumping needs.
Seals in HPLC pumps must deliver
exceptional leak tightness, high resistance to wear and tear, low coeicient
of friction and no extrusion into gaps.
An HPLC pump seal should withstand
aggressive and abrasive processing and
ofer excellent temperature capabilitiesoperating in a range from -253 C to
300 C (-423 F to 572 F). Recommended
seals can work at high speeds up to 15
meters per second (49 feet per second).
Check valves (inlet and outlet) prevent
low from a high-pressure area into the
low-pressure area inside the HPLC pump
head. As a result, the pumps piston can
deliver a mobile phase low through
the column at high pressure. A properly
functioning check valve opens and closes
quickly and provides a secure seal across
a wide pressure range. Check valves in
HPLC pumps fail more often than other
HPLC parts, such as pistons or piston
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SPECIAL SECTION
SEALS & BEARINGS
seals, because they are exposed to repeated mechanical stress at

high pressure. Failed check valves are also diicult to identify.
Unlike external pump leaks, internal pump leaks do not lead to
a substantial drop in pressure, and HPLC software programs will
not detect them.
Service Kits Increase Longevity

Long-lasting instrumentswith lifespans from ive to 20
yearshave led to instrument maintenance repair organizations
(MROs) having a more common role in HLPC instrument upkeep. MROs now make service kits for HPLC part replacements
because of instrument longevity. For example, pump manufacturers and MROs can remove metallic
spring energizers from an HPLC system
because the energizer can afect production
results in some cases.
Some MROs have developed specialized
kits based on consults with operations personnel to determine what parts, supplies and
packaging requirements will ensure a customers instruments and machines continue
to run smoothly. hese organizations partner
with material suppliers to eiciently manage
inbound and outbound logistics through supply chain services.
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he Future of HPLC
HPLC is the largest product segment in the
analytical instruments industry. he technology serves several industries for research
and development purposes, quality control
and process engineering applications. Improvements in system automation, robotics
and instrument design are propelling growth
in the HPLC market.
China and India are driving the market for
analytical instruments in Asia, with Latin
America ofering good growth prospects. he
rise in drug discovery and generic pharmaceutical production, as well as rapid industrialization, has fueled the HPLC market in
these regions. Industry research forecasts the
HPLC pumps market crossing the $100 million mark in 2014.
he global market for HPLC systems and
supporting accessories is projected to reach
$3.7 billion by 2015.
Jerry Zawada is life sciences segment

manager for Trelleborg Sealing Solutions.
He has worked with Trelleborg
for more than 14 years and
was previously vice president
for a startup life sciences
company. He may be reached
at tssusa@trelleborg.com.
53
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2014 Schneider Electric Industries SAS. All trademarks are owned by Schneider Electric Industries S.A.S. or their affiliated companies. twww.schneider-electric.com
t 998-1207451_US
| Au gu st 2014
3 Ready-to-use
54
SPECIAL SECTION
SEALS & BEARINGS
Treated Carbide
Surfaces Enhance
Running Performance
This technology self-lubricates, reduces friction
and performs in wet or dry operating conditions.
BY MARK SLIVINSKI
CARBIDE DERIVATIVE TECHNOLOGIES INC.
n article in the June 2009 issue of Pumps & Systems

detailed a new technology to treat the surface of
silicon carbides. he treatment is not a coating and
not homogenous with depth. Since the publication of
this article, independent parties have tested the treatment and
returned the results from several applications.
h is article summarizes some of those tests.
Background
he technology involves treating a inished
silicon carbide (SiC) component with a speciic
chemistry that etches the silicon from the surface of the SiC and leaves behind the carbon.
h is process occurs at the nanoscale. he
silicon is removed, and the carbonwhich was
initially reacted with the silicon and sintered
into the SiC substrateremains in its original,
covalently-bonded crystal lattice. During the
reaction, the carbon further reorganizes into
various nanospecies and creates a treatment
zone as shown in Image 1.
hese transmission electron microscope images are taken at diferent depths within this
treatment zone. Its outer zone is mostly planar
graphite and disordered carbon, giving the sur-
face a controllable, low coeicient of friction in the range of 0.08

to 0.12. Nanocrystalline diamond combined with the carbon
and graphite emerges further down into the surface. Eventually,
all these constituents merge with the virgin SiC, where SiC and
all carbon nanospecies are present.
Image 1. Transmission electron microscope images taken at different depths within the
treatment zone (Article images and graphics courtesy of Carbide Derivative Technologies.)
55
Compared with current sealing surface solutions, the resulting treated

surface runs cooler, longer and withstands significant periods of dry
running. It has never delaminated during 25 years of rigorous testing.
As the surface runs in, it operates at the

robust zones in which graphite, carbon
and nanocrystalline diamond provide
a tough,low-friction running surface.
Because it is not a coating, and the carbon
is covalently bonded to itself and the
supporting SiC substrate, this technology cannot delaminate, spall or peel of.
Compared with current sealing surface
solutions, the resulting treated surface
runs cooler, longer and withstands
signiicant periods of dry running. It has
never delaminated in 25 years of rigorous
testing.
he 2009 article showed results from
l ashing hot water tests. Specimens in
that series were run for 24 to 100 hours
at 250 F and 140 pounds per square inch
(psi).
he specially treated specimens exhibited minimal wear scars on the mating
rings between 1.7 and 4.4 micrometers
(m), but the untreated SiC specimens
wear scars were between 47 and 173 m.
Furthermore, the specially treated surfaces were still smooth, but the untreated
surfaces were heavily grooved.
New Tests
All the recent tests, detailed in this section,
had the hard/hard running combination of
a treated SiC surface against another SiCtreated surface.
Mechanical Seals
A seal pair was run in rigorous water test
in conditions that typically damage sealing faces, as shown in Figure 1. he water
test lasted for 350 hours. Next, the pump
was drained, and the seal was run for
another 75 minutes in dry nitrogen before
a temperature spike stopped the test. h is

56
SPECIAL SECTION
SEALS & BEARINGS
test proved extensive wet- and dry-running capabilities,

even after running under rigorous wet conditions. No leakage occurred throughout the combined test.
h is mechanical seal test included stressful water conditions followed by dry nitrogen conditions. Most demonstrations in stressful water conditions, including deionized
water, caused the water to l ash or simulate other intermitImage 2. The treated thrust plate (left) and thrust pads (right) with no
discernable wear at twice the normal maximum load
tent dry and high-temperature running conditions. hese
tests, which typically destroy plain SiC sealing faces, have
hey also survive extended l ashing or dry-running conditions
ranged in duration from 24 to 1,000 hours. Treated sealing
for much longer than other solutions. Field examples have shown
faces survive such conditions with smooth faces even after the
that this technology lengthens the running life in lashing
rigors of the test.
hydrocarbon service by a factor of 12. Since the surfaces remain
Dry nitrogen is diicult to seal with plain, fully contacting seal
smooth even after l ashing or dry running, they survive through
faces. he 2009 article showed that treated surfaces actually ran
process upsets that would normally require shutdowns for pump
with lower friction in pin-on-disc tests than in ambient air. Several
repair because of seal damage. his is because the treated seal
mechanical seal tests in dry nitrogen have been conducted. Some
faces stay smooth and enable the pump to recover, be rewetted
were fully dry, without the pump being wet before the dry running.
and run after a process upset without the seal leaking.
Specialized treatment for silicon carbide surfaces has survived tests
Emissions are directly proportional to seal wear. he low wear
in dry air or nitrogen for durations ranging from 45 minutes to four
and resistance to grooving of treated seal faces also provides
hours at aggressive pressure velocity conditions of between 6,000
signiicantly lower fugitive emissions for single-seals. All these
and 80,000 psi-feet/minute (ft/min). he surfaces typically did not
groove. hey remained smooth and continued to provide a good seal- features lengthen plant maintenance cycles.
ing surface. hese tests demonstrate that treated seal faces run well
in dry air or nitrogen environments. his performance characteristic Bearings
he treatment also enhances the performance of bearings. One
can provide long-running life for pure dry mixer seals and lightly
manufacturer demonstrated improved dry startup capability in a
loaded safety seals.
hydrodynamic bearing contained in a downhole pump. In operaAnother mechanical seal example tested automotive water
tion, the pump runs dry for ive to 10 seconds at startup before
pump seals. he industry standard stress test for these products
dirty water loods the bearing chamber. A test was performed
includes a 15-minute dry-running test. he seal face materials
in dirty water with 35 stop/starts25 forward and 10 reverse.
currently used in this industry have diiculty meeting this stanWhile this test typically destroys SiC hydro pads and thrust
dard. Figure 2 shows the results of a seal assembly subjected to
ive tests, at increasing shaft speeds, for one hour and 15 minutes plates, the treated components were unharmed. he components
were able to be reused in another pump and placed into service.
of total dry-run time. he seal assembly was allowed to cool to
ambient temperature between runs. Some
tests of the untreated assemblies were
Figure 1. Results of a mechanical seal tested for 350 hours in water
stopped before 15 minutes had elapsed.
followed by 75 minutes of running in dry nitrogen
he results showed erratic temperature
behavior from the untreated seal rings
and damage to the elastomer bellows. he
cumulative wear from the ive tests was
a 20-m wear scar on the mating ring. In
contrast, the treated seal faces ran at low
temperatures with normal trends. he
proi lometry showed no discernible wear,
and the seals did not leak under a 25-psi
air pressure leak test.
hese results demonstrate that treated
seal faces enable dramatically longer run
times in normally lubricated situations.
57
While treated components have not been tested in the sleeve bearing
parts of mag-drive pumps, it is expected that they would protect
equipment from damage during dry running.
Image 2 shows the results of a hydrodynamic bearing test
with treated components. he test was conducted in water with
a load that increased incrementally until twice the normal
load-bearing capability was reached. As the image shows, the
components experienced no discernible wear. Proi lometry
measurements also showed no discernible wear. he assembly
may have been able to support even higher loads.
While treated components have not been tested in the sleeve
bearing parts of mag-drive pumps, it is expected that they
would protect equipment from damage during dry running.
Specially treated SiC components have been demonstrated to
run well when mated with certain metallic components. his
lexibility makes the technology ideal for protecting mag-drive
pumps with either metallic or carbide shafts from damage during dry running.
ere
Wh
ws
Flo
n
o
i
at
ov
n
n
I
The
Conclusion
h is technology allows an improved running surface to be
synthesized on a inished SiC component in a net shape, size
and roughness process that does not add any new material or
require post-treatment polishing. he surface derives from the
virgin SiC, where the silicon is etched out of the surface while
the carbon already contained in the SiC stays in its original crystal lattice and transforms into carbon nanospeciesincluding
planar graphite and nanocrystalline diamond.
he resulting surfaces demonstrate the ability to run for
extended periods wet, dry and during l ashing. After operating in demanding conditions, the surfaces are still smooth and
able to seal. h is technology allows luid-handling equipment to
be rewetted and run after process upsets without stopping the
luid loop to repair damaged mechanical seal rings. Because of
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58
SPECIAL SECTION
SEALS & BEARINGS
decreased friction, seals employing this

Figure 2. Results of multiple 15-minute dry-running tests on the same seal
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allows long duration and quiet running for
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capability for hydrodynamic bearings can
be substantially increased, and dry running capability for sleeve bearings can be
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All these beneits are possible with
hard/hard surface pairings. he technology can have a positive impact on plant maintenance cycles, equipment mean time
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60
PUMP SYSTEM OPTIMIZATION
Streamlined Motor
Management System
Boosts Biomass
Power Generation
Trusted gateway connections allow for system
growth, eciency and consistent maintenance
at Swedish paper mill.
BY MATTHIAS BORUTTA
PHOENIX CONTACT
aper production requires large amounts of power. he

Smurit Kappa plant in Pite, Sweden, uses its own biomass boilers to meet part of its energy needs. he cleaning system in place for the high-performance steam generator
includes a specialized motor management solution to ensure
uninterrupted motor operation.
At the Smurit Kappa Kraftliner Pite paper plant in northeast Sweden, 520 employees produce about 700,000 metric
tons of Kraftliner paper per year. Kraftliner is a special type of
raw paper made of fresh ibers and serves as the base material
for manufacturing high-quality corrugated cardboard packaging. he Swedish plants annual power consumption is about
520,000 megawatt hours (MWh). Biomass boilerswhich burn
organic material such as wood generate 58 percent of that
power, creating added value through eiciency and sustainability..
he Pite production site consists of a pulp mill with two
soft-pulp digesters and one hardwood digester and a paper
mill with two paper machines. Two boilers produce the energy
needed for the mill. One recovery boiler combusts the black
liqueur from the process, and a biomass boiler uses mostly the
bark from the wood-handling system. he steam from the boiler
passes across two steam turbines that generate more than half
the electricity required by the mill. h is self-produced electricAugus t 2014 | Pum ps & S yst e m s
ity is a green option because fossil fuel is

only required during the startup process.
Lower Costs for Cleaning Routines

A special steam cleansing technology boosts
the eiciency of the power generation system. A high-performance
boiler must be kept clean, ensuring high-eiciency degrees, high
availability and minimal ash corrosion. Pressurized steam dissipates the soot, increasing the eiciency compared with conventional methods.
he cleansing technology also permits cheap, aggressive fuels
for natural, eicient powering. he boilers are cleaned with
automatic motorized 8-meter-long cleaning lances that spray
pressurized steam onto the boilers heat surfaces. A specialized
motor management program controls and monitors the motors
during this cleansing process.
Eiciency & Maintenance Challenges
he previous electrical drives in Smurit Kappas high-performance boiler were complex and diicult to use. he system
required mechanical contactors for reversing the rotational
direction of the steam cleansing systems motors and digital
outputs for clockwise and counterclockwise control.
61
Smurfit Kappa Kraftliner Pite in northeast Sweden is one

of the Smurfit Kappa groups 350 production sites. (Article
images and graphics courtesy of Phoenix Contact.)
Analog inputs handled the power input,

and digital inputs analyzed the return
signals. Wire connected all the devices and
individual switching cabinets.
Documentation and controller programming were time-consuming with the existing system. Adding drives to the setup was
a major undertaking that required expert
project management.
In addition, the switching cabinets left
little room for new additions. Consistent
maintenance was not efective because
of multiple componentssuch as drives,
input/output (I/O) modules, measuring sensors, terminal blocks and contactors.
he existing systems drives were threephase asynchronous motors. A screw
conveyor moved the lance in and out of the
boiler to blow the soot of surfaces.
The Pite site produces about 700,000

metric tons of Kraftliner paper per year.
62
COVER
SERIES
Each screw conveyor was itted with two mechanical or

inductive limit switches. When the screw conveyor reached the
end or start position, the rotational direction had to reverse.
he limit switches were prone to dirt build-up, which made
their signal information for reversing the rotational direction
less reliable. Inadequate cleaning could, in a worst-case scenario, damage or destroy the motor.
3.
Fewer Wires, More Space

he new motor management system provided several advantages to the steam cleansing system. he program, which included
motor management, hybrid motor starters and a ieldbus gateway, detected worn sootblowers before failure.
Fewer I/O modules were required, reducing wiring and documentation, and the compact device dimensions opened more
installation space.
Bus gateways allowed for system expansion during system
operation. he gateway forwarded the process data from multiple
motor management modules to the control unit, while electronic
motor management units (EMMs) handled monitoring and drive

protection with active power monitoring.
he solution also included hybrid motor starters, which provided
non-wearing motor switching. Relays and the system cabling solution quickly and reliably coupled the ield devices to the controller.
No Need for More Sensors

he 22.5-millimeter electronic motor management unit has
built-in current transformers to directly read input currents up
to 16 amperes.
If the applications output is higher currents, other EMM modules read them in combination with external current transformers.
he range of available components works for all power ratings.
Because the EMM can be easily inserted on the existing motor cable, the operator was provided access to all the measurements for easy and cost-efective motor and system monitoring. he ease of installation eliminates the need for additional
sensors. he module can retroit existing systems, keeping the
system up-to-date with all current status values.
Figure 1. Network integration of the motor manager as shown in a
Profibus structure
The steam cleansing system uses high-pressure steam to blow the

soot off the high-performance boilers heating surfaces.
The motor management units compact dimensions
save considerable space compared with similar components.
The switching cabinets contain a solution that

includes motor management, hybrid motor starters
and a fieldbus gateway.
63
Motor management supplies the data for any application, such as

monitoring and protecting pumps, controlling valves or tool machines, or
analyzing the systems power consumption.
Separate mechanical or non-wearing semiconductor contactors

switch three-phase loads. he digital output of the motor management modules implemented on- and of-switching. Motor management supplied the data for any application, such as monitoring and
protecting pumps, controlling valves or tool machines, or analyzing
the systems power consumption.
he choice of control system connectionwhether independent
or ieldbusdoes not impact the systems data collection.
Trusted Connections
hrough the programs ieldbus gateway, which is certiied according
to European Norm 50170 as speciied by Decentralized Peripherals,
level V1, 31 motor management modules can be connected to each
other. he pluggable design means no wiring is needed (see Figure
1). All process data is transferred to the control system.
he ieldbus gateway also supports a fail-safe. If any malfunctions occur, the switching behavior can be modiied. he gate-
way also features additional digital inputs and outputs. If communication is based on the Proibus DVP1 system, the device is
connected to the network using a general station description.
In addition, the system support permits increased lexibility
for the entire system: parameter setup, monitoring and diagnosis of the motor management devices.
Matthias Borutta studied electrical engineering with a
focus on measuring technology at the Gttingen University
of Applied Sciences. In 2000, he wrote his final thesis in the
field of automation. Since 2001, he has been
product manager for electronic load relays
and solid state relays in Product Marketing
ELR for Phoenix Contact. He may be reached
at mborutta@phoenixcontact.com or
+49 5281 946-3112.
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64
COVER
SERIES
Intelligent Monitoring
Delivers Real-Time
Pump Performance Data
An energy eciency and reliability study helped one plant
save $1 million annually by avoiding downtime.
BY MIKE PEMBERTON
ITT PRO SERVICES
he years leading up to the new millennium saw a rapid evolution of industrial communication networks from analog to
digital. By 2000, information technology tools were becoming
integrated into luid handling products and systems. his marked
the beginning of pump and automation technology convergence.
Process instruments, control valves and stand-alone controllers developed from individual hardware units to microprocessor
embedded devices that could be digitally linked into a computerbased process management system. Intelligent pumps also joined
the march forward in 2000. Today, smart centrifugal pumps with
variable frequency drive (VFD) controls are becoming an integral
component of the industrial process automation architecture.
Hard-wired communication systems in ield devices are being
replaced by wireless communication as the new standard. What
does this communication revolution mean for the traditional
pump and automation industry?
he migration from hardware to software enables new services
that were practically undeliverable in the past. Widespread
information low from process assets helps plant operators make
better life-cycle-cost decisions and perform true predictive maintenance in real time, without needing to collect data manually.
hese changes drive stakeholder innovation and proitability.
he old paradigm of business gives way to the life-cycle-costing
approach. Organizational structures and stakeholder perceptions
are changing. Suppliers are moving from selling commodity
products and services to rendering unique, value-added services
that are highly customized.
While all this may seem vague, new approaches are becoming part of industrial automation and luid handling systems
practice and management. he plan-do-check-and-act cycle now
should mean making sound inancial decisions that win today
and in the future rather than irst cost decisions that win today
and fail decidedly in the future.
As an example of these changes, consider one pulp mills maintenance strategy for dealing with a vat dilution pumping system that
was causing repeated component and system failures and process

downtime. his approach included looking at the system holistically
and also considered the use of more intelligent components. Decisions were ultimately made based on life-cycle costs.
Case Study
Regular pump breakdowns and undue wear resulting from heavy
control valve throttling can cost companies millions each year.
Widespread information flow from process assets helps plant operators

make better life-cycle-cost decisions and perform true predictive
maintenance in real time. (Article images courtesy of ITT Corporation.)
65
66
COVER
SERIES
In one case study from 2001, a paper mill bleach plant was sufering inancial losses from an oversized pump. After assessing the
problem, plant personnel contacted a plant operation specialist.
he mills energy team determined that nearly two-thirds
of the facilitys valves were less than 50 percent open. Many of
them were less than 25 percent open. One key pump system had
a capacity of 6,500 gallons per minute (gpm), but the average

load was only 2,750 gpm52 percent of total capacity. he peak
low demand was only 5,200 gpm.
he 10-inch ball-valve installed in a 14-inch discharge line was
undersized. he large pressure drop and associated vibration were
causing valve wear, pipe cracks, gasket leaks and frequent downtime. Also, it was diicult to keep the control
loop tuned, which required manual operation
of the modulating valve. he pump experienced almost 10 failures per year, all of which
occurred while the pump was running and
during startup and shutdown.
A pump is more susceptible to catastrophic damage during startup and shutdown
than at any other time. his is primarily
because of large pressure changes and water
hammer across the pump system components. But the initial shock to the system
upon startup involved more than pressure.
here was also thermal shock from 220 F
(104 C) i ltrate entering the pipes when the
pump motor was started.
he mills reliability engineers conducted
a thorough examination of the system. hey
determined that automated gate valves,
which open slowly as pipes warm to avoid
thermal shock and cracking, plus new operating procedures would provide incremental
improvements and a reduction in failures.
In addition to the gate valve automation,
the plant operation specialist recommended
installing a low-voltage motor and VFD, operated in pressure control mode, for the three
vessels the pump was feeding.
Stabilizing the control loops and reducing pressure inside the system turned a
frequently failing pump into a properly
functioning component of the system. he
bleach plant witnessed $18,000 in energy
savings in 2002. Energy savings in the same
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A Systems Approach
Plants havent been clamoring to invest in
eiciency for several reasons. One is simply
a lack of experience with the methods and
techniques used to raise eiciency.
67
When components break, operators tend to buy what they think

from BEP and impeller diameter. If a mill optimizes 30 percent
already works to replace them.
of existing pump systems, overall mill process availability will
When deciding to modify systems, eiciency improvements
dramatically increase while pump seal and bearing failures will
may feel unnecessary. No one wants to interrupt day-to-day
signiicantly decrease.
operation of the plant to overhaul functioning equipment or
Reliability improvements can be predicted, and past work
systemsespecially if they arent part of the plants specialized orders and CMMS records can be used to estimate annual
production equipment. However, critical
subsystem issues in many plants have too
long been ignored. Engineers and suppliVisit us at the Pump Symposium
ers are still oversizing pumps, for a variety
Houston, TX | September 23-25
of reasons. Some prepare for increased deBooth #430
mand, imagining future capacity increases
that never come.
Pump optimization activities allow an
increase in the level of condition monitoring through broader use of intelligent motors, pumps with embedded chips, VFDs
and wireless vibration monitoring. hese
tools ofer real-time information on pump
system performance.
Pumps are not considered to be an integral component of the process automation
architecture. As a result, plant information systemssuch as distributed control
systems (DCS) and computerized maintenance management systems (CMMS)
typically lack continuously monitored
asset data for diagnostic use.
Although the DCS monitors most of
the key process parameters required
for traditional process control, up to 60
percent of the pump systems lack a low
measurement on the discharge line. For all
practical purposes, almost all of the work
orders and asset information is manually
entered into the CMMS.
Furthermore, other underlying assets,
including compressors, blowers, fans
and control valves, are rarely connected
to the CMMS. he lack of information
is a missing link in an e-manufacturing
strategy. It can mean that large potential
cost savings go unrealized. According to
the ARC Advisory Group, up to 40 percent
of manufacturing revenues are devoted
to maintenance and up to 60 percent of
scheduled maintenance checks and motorProud Member of the
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driven systems are unnecessary.
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With consideration given to proper
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68
COVER
SERIES
maintenance costs. In many cases, process control

beneits can be identiied in terms of reduced raw
material variability, and life-cycle-cost savings can
be estimated based on current costs compared with
optimized costs.
Making decisions based on long-term operating
costsrather than keeping a large safety margin
that allows unnecessarily high flow production
will create an opportunity for the plant of the future. This kind of plant will be available, adaptable
and sustainable as required. This thought process
needs to be implemented and is increasingly becoming a regulatory requirement.
Mike Pemberton is the Energy & Reliability program manager for ITT PRO Services, Plant Performance Services. He is a member of the Hydraulic
Institute (HI) and served as co-chairman of the
Pump Systems Matter education committee. He is also co-editor of the
HI guidebook, Optimizing Pumping
Systems: A Guide to Improved Energy Efficiency, Reliability and
Profitability.
The latest advances in technology offer

real-time information on pump performance,
helping plant operators make more informed
decisions related to their service.
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69
Close Inspection Solves

High Thrust Bearing
Temperature Problem
Careful analysis identied the issue
with this multistage, oil transfer pump.
BY GARY DYSON
HYDRO INC.
multistage BB5 dif user machine in oil transfer service

in the Middle East had been in operation for many years
without problems. After a routine maintenance strip
down and rebuild, the pump experienced a high thrust bearing
temperature of 105 C, which caused it to alarm and shut down.
he temperature range had previously been 75 C to 85 C.
h is case study describes the method used to solve the high
bearing temperature problem and outlines the low physics
that contributed to the high thrust bearing temperature. he
customer contacted an engineering services company after the
original pump manufacturer failed to remedy the problem.
he companys forensic approach to this problem involved two
distinct methodologies:
Diligent and in-depth analysis of site data relating to
the problem
Rigorous scrutiny and analysis of the pump geometry and

build against the background
he engineering services company identiied several scenarios

that could cause this temperature rise, then narrowed down the
list to establish a root cause.
Site Data Analysis

he behavior of thrust bearing pads during startup is seldom
investigated. he temperature rise of the pads can be attributed
to two distinct causesthrust developed during startup and
environmental and oil conditions (see Figure 1).
he signiicant inding from this data was the temperature
rise associated with thrust. he pump could not achieve the
temperatures measured prior to maintenance in its current
condition. he total thrust bearing temperature includes the oil
temperature and environmental conditions.
Figure 2. Meridional flow interactions of a pump running at
partial capacity
Figure 1. Behavior of thrust bearing pads based on thrust and

environmental conditions (Article images and graphics courtesy of
Hydro Inc.)
70
COVER
SERIES
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Based on comparisons with previous site data, both the thrust and oil cooling had
altered. Analysis of the temperature data at the motor bearings, which were experiencing oil temperature increases of 10 to 15 C, further supported the conclusion.
Pump Analysis
Analysis of the pump build procedures also revealed that a change in thrust quantity was causing a high pad temperature. h is machine can be susceptible to thrust
changes due to the axial position of the impeller with respect to the dif user.
he engineering services company investigated the build process and discovered
that the original bearing housing had not been used in the rebuild. he axial position of the rotors had not been reset correctly, unlike the bearing clearance.
h is machine has an adjustment ring behind the thrust collar that is used to
account for build tolerances in the components stack. Fitting the new bearing assembly afected the rotor positioning. he adjustment ring had been reitted without
ensuring that the rotor centralization had been carried out correctly.
he direction of the thrust further complicated the scenario. hrust bearings
on this machine are designed to run with the thrust on the inboard pads. When a
pump runs back to a lower low, a thrust reversal afects the outer pads.
Although this pump was not running at its best eiciency point, its operating low was not reduced enough to cause a thrust reversal. Scrutiny of site data
indicated that this pump had always thrust to the outboard pads regardless of any
process changes over time.
Some pump manufacturers ine-tune the thrust behavior of their machines by
adjusting the size of the balance drum and bush based on their initial performance
test results. If this process is too time-consuming, manufacturers adjust the axial
position of the rotor with respect to the dif user to modify the thrust and bearing
temperature.
h is rotor setting data is easily overlooked on rebuild, especially since the actual
rotor centralization is rarely checked on strip-down. his means it cannot be restored after a component change.
Hydraulic Instability and Hydraulic hrust
As a pump operates at partial capacity, the low becomes increasingly unstable. Both
the impeller and rotor experience an increase in unsteady low interchange.
Traditionally, this low regime interaction has been illustrated as in Figure 2 in
the meridional plane (see page 69). Although this image is helpful in understanding
the low physics, the true picture is far more complex.
Figure 3 illustrates the complex nature of the low that develops within the impeller when the pump operates at extreme part load. Point A illustrates the development of a discharge vortex that commences on the hub at the impeller discharge.
Point B illustrates the boundary of this interaction with the inlet backlow recirculation within the impeller eye. his inlet backlow recirculation is also illustrated
in detail in Figure 4.
At partial capacity, the low exits the impeller eye at the hub inlet angle and spirals down the suction channel impinging on splitters of the previous stage.
he meridional view clearly depicts these two unstable low interactions with the vortex that exists within the gap between the channel ring and impeller shroud (see Point C
in Figure 2, page 69).
h is vortex accounts for the developed thrust within this pocket. Any disruption
to this vortex leads to a more unpredictable thrust regime.
71
Figure 3. Complex flow interactions of a pump running at partial capacity
Figure 4. Illustration of 3-D inlet backflow recirculation

72
COVER
SERIES
he centralization efect of the rotor within

this channel inluences both the development
and speed of this vortex. he space available
for the vortex is either increased or decreased
so boundary layer efects begin to dominate.
Figure 5. Rotor with poor centralization
Solution
The solution to the high thrust bearing
temperature problem lay in a combination
of contributing factors, each needing indepth understanding of pump technology
and flow physics.
The following actions returned the pump
to an acceptable temperature:
Oil temperature correction: A thermostatic valve was disabled during pump removal. On commissioning, this valve was
left in an inoperable position, which kept
the oil from passing through the cooler.
he engineering services company identiied the problem and
returned the valve to the appropriate setting.
Rotor centralization: he rotor centralization had been adjusted to of-center by the original equipment manufacturer
to limit the thrust on the outer pads (see Figure 5). he engineering services company restored the rotor to the correct
position relative to the dif user, which put the thrust bearing
temperature within an acceptable range.
Thrust compensation modification: The
engineering services company is now
suggesting modifications to the machine
to correct the thrust balance based on
the actual site operating conditions. This
new thrust compensating modification
will be designed to ensure the thrust is
on the inner thrust pads, giving the bearing an extended operating range.
h is case study illustrates the problems
that can arise if a meticulous approach is
not adopted for even a routine maintenance
activity. Severe operational problems can be
prevented by repair practices that diligently
record every aspect of the pump repair.
Dr. Gary Dyson is managing director with

Hydro Global Engineering Services. He has a
Ph.D. from Cranfield University and 30 years of experience in the pump industry in
senior positions with many
manufacturers. His expertise
includes pump hydraulic
performance, design and
reliability improvement.
73
System Selection
Crucial for Long
Wastewater Pump Life
Driving down investment, energy and maintenance
costs translates into big savings throughout an
installation s lifetime.
BY LARS BO ANDERSEN
GRUNDFOS WASTEWATER
ife-cycle cost calculations for wastewater installations can produce huge savings over time
for wastewater companies. he life-cycle costs
summarize the total cost of a wastewater installation,
and the pump system plays a major role. It is the key
element to ensuring the installations long-term costefectiveness.
Total lifetime costs normally include planning,
design, purchasing, investment, installation, commissioning, energy, maintenance and operation, and
downtime costs. A system can also incur environmental and disposal costs at the end of its lifetime. he
pump system has the highest impact on the lifetime
cost of the wastewater installation. However, only
three of the costs listed above play a signiicant role
in the pump systems contribution to life-cycle costs:
investment, energy and maintenance.
Involve different people to ensure that all aspects of the pump purchase are
considered. (Article images and graphics courtesy of Grundfos.)
Investment
he initial procurement cost is often seen as the best way to
ensure low cost. Meeting investment budgets means keeping
in mind that the cost of operation, maintenance and disposal
could be ive to 20 times higher than the initial investment.
h is is why municipalities and contractors increasingly consider the requirements for performance, reliability and energy
consumption when purchasing a pump system.
Energy
Decision makers might think that the energy cost of the pump
is easy to calculate. But many things must be considered when
determining the energy cost of a pumpsuch as wear, variable
load, installation and clogging.
If the wrong wastewater pump is chosen, the media content
leads to wear, costly breakdown and 3 to 5 percent lower eficiency for every year the pump is not maintained.
74
COVER
SERIES
The design of the pump impeller is a key issue because a simple design with
large free passage and no inserts or moving parts will wear less than a design
without these features, thus ensuring a high efficiency over the pump lifetime.
Most pump brands make it possible to restore eiciency loss.

Some have a replaceable wear ring, while others have built-in trimming that allows adjustment of the impeller clearance using outside
bolts. Because wear also afects non-replaceable parts of the pump,
full restoration of eiciency is impossible.
he design of the pump impeller is a key issue, since a simple design
with large free passage and no inserts or moving parts will wear less
than a design without these features, thus ensuring a high eiciency
over the pump lifetime.
he pumps duty point is seldom constant and varies over the
course of a day, a year and a pumps lifetime. Users should look
for a pump with a lat eiciency curve. h is ensures high eiciency over a wide duty range and determines whether the pump is
using a variable speed drive. If the pump is running with variable
speed, a pump with a duty point to the right of the curve should
be selected. When adjusting the speed downward, the pumps
duty point moves to a part of the curve with higher eiciency.
he energy saved when operating with a variable speed drive depends heavily on the system curve. he savings potential decreases
if the static head is small compared to the friction losses. It increases
in a system with large friction losses compared to the static head.
A variable speed drive can also signiicantly inluence the clogging
frequency of the pump, as the water velocity might fall below the
self-cleaning velocities in the system.
When installing a pump system, measures should be taken
to avoid leakages, especially where the connection between the
pump and the installation equipment is metal-to-metal (see Figure 2). hese connections become more susceptible to leaks as the
system gets older. Seals or gaskets should be placed at all joints.
More leakages mean a greater loss of energy.
Figure 1. Wear of impeller clearances with different impeller designs
A small diameter in the rising main leads to increased head

requirements and energy consumption, because small pipes amplify
the pipe friction losses of the installation. A small rising main also
increases the leakage low. To avoid high losses, the water velocity
through the pipes should be kept low. he exact maximum velocity
depends on the length and roughness of the pipes, but as a rule, the
velocity should not exceed 3 meters per second (m/s).
Avoiding velocities that are too low is also crucial. Low velocities can cause sedimentation and deposits to build in the pipes,
increasing friction losses and energy consumption. Manual pipe
cleaning may become necessary to clear the pipes, adding to
maintenance costs.
For horizontal rising mains, a minimum of 0.7 m/s is recommended, while a vertical rising main should be dimensioned for a
velocity of no less than 1 m/s. his is especially important in pump
systems with variable operation. Variable speed drives can heavily
inluence water velocity, so take care that the pump is not always
running at a low speed. he self-cleaning velocity in the pipes otherwise might not be achieved.
More than installation clogging, impeller design relates
directly to energy cost. he improved nonclogging capability of
an impeller is normally achieved by using semi-open impeller
designs, but these designs cause eiciency loss.
New developments now combine the best of both worlds by having nonclogging, high-eiciency impellers with large free passages,
no inserts and no moving parts.
Figure 2. Conventional pump with metal-to-metal discharge connection
75
Maintenance
Maintenance costs are often diicult to estimate.
Planned maintenance costs will vary depending on many different factors, such as:
Pump value
Pump maintenance costs
Operational experience
Pump failure consequences
Pump failure probability
System design
its service friendliness. To determine the cost of the repair,

take into account the following:
Maintenance to be performed on the pump
Time required for maintenance activity
Number of personnel involved
Spare parts cost for maintenance activity
Fast spare part availability also ensures that unplanned maintenance can be conducted quickly and reliably.
With small, inexpensive pumps or pumps that are diicult to

maintain due to their placement, planned maintenance activities
might be kept to a minimum, while large, expensive pumps might
get the full range of planned and predictive maintenance.
Stocking recommended spares can make planned maintenance
less expensive and more intuitive for operators. his allows worn
parts to be changed without special tools or training. Choosing
a pump with built-in analogue sensors allows monitoring of the
pumps condition and enhances maintenance planning.
Unplanned maintenance costs can be easily predicted
based on an operators familiarity with the pump brand and
Lars Bo Andersen has worked at Grundfos for the past 18

years in various positions. Starting as a product engineer
in 1996, he progressed to project manager
to develop pump selection tools supporting life-cycle cost calculations according to
best practices from EuroPump and the U.S.
Hydraulic Institute. He is currently the global
product manager for wastewater based in
Bjerringbro, Denmark.
Misalignment
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Mis
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76
COVER
SERIES
Reducer Fittings Decrease Pipe

Size to Avoid Failure
Design of the pump inlet piping can protect overall operation.
BY ROSS MAHAFFEY, AURECON
AND STEFANUS JOHANNES VAN VUUREN
UNIVERSITY OF PRETORIA
FIRST OF TWO PARTS
Figure 1. Difference between eccentric and concentric reducers

in pump inlet piping (Article graphics courtesy of the authors.)
he design of pump inlet piping deines the resulting hydraulic conditions experienced at the pump
inlet/impeller. If the design fails to produce a
uniform velocity distribution at the pump inlet, noisy
operation, random axial load oscillations, premature
bearing or seal failure, cavitation damage to the impeller
and inlet portions of the casing, and occasional damage
on the discharge side due to liquid separation can occur.
Any of these issues could lead to pump failure (ANSI/
Figure 2. Calculation of reducer angles
HI 9.6.6., 2009). Part of the pump inlet piping design
includes the selection of reducer itting type.
A reducer itting is typically used in pump station
pipe work to reduce the size of the suction pipe to match
the size of the pump suction end lange. Reducer ittings used in pump inlet pipe work are divided into two
typesconcentric and eccentric reducers. he two types
of reducer ittings can be described as:
Concentric reducerhe reduction of the pipe size is

achieved by decreasing the diameter of the itting at
a constant rate over a speciied length, maintaining
symmetry around the itting (see Figure 1).
Table 1. Minimum straight length required before suction inlet
Eccentric reducerhe reduction of the pipe size is achieved

Number of pipe diameters a
by decreasing the diameter of the itting at a constant rate
over a speciied length, maintaining one side of the itting
Reducer
Concentric
Eccentric
horizontally (see Figure 1).
1 pipe size reduction
0 (<10) b
0 (<20) b
Design guidelines, pump operating manuals and design

standards mostly prescribe the selection of an eccentric reducer
with the l at side on top for horizontal low to the pump. h is
coniguration prevents air pocket accumulation at the upstream
end of the reducer (see Figure 1). he non-uniform velocity distribution results from the acceleration of low along the eccentric
reducers sloped side resulting in an unbalanced force that is not
addressed. An unbalanced force on the impeller could lead to
potentially detrimental radial thrust harmonics.
0 (<20)
1 (<30)
1 (<20)
2 (<30)
2 (<20)
3 (<40)
3 (<30)
4 (<40)
a Minimum required straight pipe length before pump suction inlet = diameter x
number of pipe diameters
b he angles given are the maximum per side for standard commercial ittings.
Nonstandard ittings having a greater angle per side should use the number of pipe
diameters corresponding to that angle, regardless of the number of pipe reductions.
77
A reducer fitting is typically used in pump station pipe work

to reduce the size of the suction pipe to match the size
of the pump suction end flange.
Abstract from the Design Standards

ANSI/HI 9.6.6 American National Standard for Pump Piping
for Rotodynamic Pumps (P4, 2009) speciies the following for
the selection of reducer type in pump inlet piping: A concentric
reducer is recommended for vertical inlet (suction) pipes or
horizontal installations where there is no potential for air vapor
accumulation.
Eccentric convergent reducers are normally used for horizontal installations where there is potential for air vapor accumulation. he l at side shall be located on top, unless the inlet (suction) line approach from above, in which case either a concentric
reducer or eccentric convergent reducer (with the lat side on the
bottom) should be used.
ANSI/HI 9.8 American National Standard for Pump Intake
Design (P21, 1998) states, here shall be no low disturbing
ittings (such as partially open valves, tees, short radius elbows,
etc.) closer than ive suction pipe diameters from the pump.
Fully open, non-low disturbing valves, vaned elbows and reducers are not considered low disturbing ittings.
h is standard eliminates any reference to the possible low
distribution that could be generated by the reducer. his standard (P28, 1998) also requires that, Time-averaged velocities at
the pump suction in a piping system shall be within 10 percent
of the cross-sectional areas average velocity.
h is requirement can be used to assess the extent of low
disturbance caused by a reducer. ANSI/HI 9.8 also recommends
a maximum low velocity of 2.4 meters per second (m/s) in the
suction pipe work.
ANSI/AWWA C208 American Water Works Association Standard Dimensions for Fabricated Steel Water Pipe Fittings (P7,
2008) directs the length of a reducer (Lr) to be calculated with
the following formula.
Unbalance is amongst
Unb
a
the most common of reliability problems
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305.5

78
COVER
SERIES
L r = 4 (DL Ds)
Equation 1
with the method in Figure 2 to compare it to the requirements in

Table 1. he calculated angles are:
ANSI/AWWA C208 Eccentric Reducer Angle = 14.04
ANSI/AWWA C208 Concentric Reducer Angle = 7.13
Where:
Lr = Length of the reducer
DL = Larger pipe diameter
Ds = Smaller pipe diameter
he minimum number of straight pipe lengths required is

determined by the number of pipe reductions, regardless of the
he reducer angles for the ANSI/AWWA C208 were calculated
reducer angle staying constant. For a single pipe reduction, the
standard ANSI/AWWA C208 reducer has no
requirement for downstream pipe lengths
before the pump.
Motors | Automation | Energy | Transmission & Distribution
In the second part of this series, the recommendations presented in ANSI/HI 9.6.6
will be assessed using computational luid
dynamics and compared to the ANSI/HI 9.8
and ANSI/AWWA C208 requirements.
Pump Genius
Pump Process Control Software
Pump Genius is designed to reduce system operation and maintenance
costs while increasing process accuracy and protection. The software
provides multiple pump control and protection, as well as system
monitoring and protection. Pump Genius can be applied to any system
that requires constant flow or pressure.
Reduce your pump system operation and maintenance cost
Increase accuracy and protection
Control up to 6 pumps dynamically alternated and controlled
To learn more about

Pump Genius or to
locate a WEG Distributor
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References
1. ANSI/AWWA C208-07. 2008. Dimensions for fabricated steel water pipe ittings. American Water Works
Association, Denver.
2. ANSI/HI 9.8-1998. 2000. American National Standard for pump intake design. Hydraulic Institute, New
Jersey.
3. ANSI/HI 9.6.6-2009. 2009. American National
Standard for rotodynamic pumps for pump piping.
Hydraulic Institute, New Jersey.
4. VAN VUUREN, S.J., VAN DIJK, M and STEENKAMP,
J.N. 2004. Guidelines for efective de aeration. WRC
Report No. 1177/2/04. Water Research Commission,
Pretoria.
Ross Mahaffey is a professional engineer at Aurecon, an international group

of consulting engineers, where he is the
lead 3-D design engineer for pipelines
on a large bulk water transfer system in
South Africa. He is a civil engineering
graduate from the University of Pretoria
and has a postgraduate
degree in water resource
engineering. He may be
reached at
ross.mahaffey@
aurecongroup.com.
1-800-ASK-4WEG
or visit
www.weg.net/us
Transforming energy into solutions.

2014 WEG Electric Corp.
Stefanus Johannes van Vuuren holds an

MBA and Ph.D. in engineering from the
University of Pretoria. He has worked with
the Department of Water Affairs, Windhoek Municipality, consulting engineering
firms, contractors and
international academic
institutions. He may be
reached at
fanie-vanvuuren@up.ac.za.
87th Annual Water Environment Federation Technical Exhibition and Conference

New Orleans Morial Convention Center | New Orleans, Louisiana USA
Conference: September 27 October 1, 2014 | Exhibition: September 29 October 1, 2014
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80
TRADE SHOW COVERAGE
PUMP & TURBO

43rd Turbomachinery
30th Pump Symposia
he 43rd Turbomachinery & 30th Pump Symposia feature a technical program

and international exhibition, complete with full-size equipment and hundreds of
companies. his is the only meeting organized by users for users. he members
of the Advisory Committee are recognized leaders in the rotating equipment and power
generation community. he event promotes professional development, technology
transfer, peer networking and information exchange among industry professionals. For
more information, please visit pumpturbo.tamu.edu.
FEATURED TECHNICAL PROGRAM
Lecture P4: A Lateral

Rotordynamics Primer on
Electric Submersible Pumps
(ESPs) for Deep Subsea
Applications
Discussion Group P11: Subsea

Pumps and Drivers
Discussion Group P1/T1:

Monitoring Vibration and
Other Critical Machine
Conditions
Tutorial P10: So What Did We

Learn About Pumps During the
Past 20 Years?
Pump Case Study (Session 18)
Sept. 22 25, 2014

George R. Brown Convention Center
Houston, Texas
Exhibition Hours
Tuesday, Sept. 23
Noon 2 p.m.
2:30 p.m. 7 p.m.
Wednesday Sept. 24 Noon 2 p.m.
2:30 p.m. 6:30 p.m.
Thursday Sept. 25 9:30 a.m. Noon
Top 10 Reasons to Attend Pump & Turbo 2014

1. Network with industry professionals
Meet with more than 5,500 turbomachinery
and pump professionals gathered together
in one location. Last year, 91 percent of
attendees said attending was important or
very important to establishing their contacts
in the industry.
2. Learn about new technologies
Attend lectures to learn about cutting-edge,
emerging turbomachinery or reciprocating
compressor technologies that have been
successfully ield tested.
3. Have questions answered on the spot
Whether it is a troubleshooting question
for a current vendor or a question to an
expert about the efectiveness of condition
monitoring on rotating equipment, the
symposia provide answers.
4. Leverage your training budget

Choose from more than 100 technical sessions
to attend. Industries covered include oil and
gas, chemical and petrochemical, mining and
minerals, water, power, and manufacturing
and repair.
5. Talk to the experts
Beneit from face-to-face interactions
with more than 200 industry experts who
will lead the technical program and with
representatives from more than 320 exhibiting
companies ready to discuss their products or
services.
6. Find solutions to existing problems
In addition to meeting with company
representatives in the exhibit hall, attendees
can talk about their problem in a discussion
groupa forum to address problems
attendees bring to the loor and ind solutions
to those problems through dialogue.
7. Bank on a history of success

his year marks the 43rd Turbomachinery and
30th Pump Users Symposia.
8. Gather information for purchases
he exhibit hall features full-sized equipment,
knowledgeable representatives and more than
320 companies.
9. Beneit from an event designed with
the user in mind
Pump & Turbo is developed for the industry, by
the industry. An advisory board, comprised of
leading experts from more than 50 companies,
selects the technical program speciically to
address industry needs.
10. Tap into the energy capital of the
world
Houston is home to more than 5,000 energyrelated irms, and it has a broad industrial
base in the energy, aeronautics and technology
industries.
S P O N S O R E D
C O N T E N T
Flux Drive Introduces the

SmartCOUPLING
TM
The Worlds First Coupling To Combine Energy

6DYLQJVDQG0DLQWHQDQFH%HQHWV
Right-size your pumps!
he US Dept. of Energy and leading pump
industry professionals agree that nearly
all pumps are oversized to some degree.
As pump systems are designed, Excess
Capacity Margin (ECM) is added to the
base low requirement - either to compensate for increased future demand or simply
as a safety margin.
Unfortuntately, ECM leads to excess
energy consumption. Because the pump is
sized to provide more low than is initially
required, operators often resort to using
discharge throttling valves or even recirculation loops both of which are extremely
ineicient. Variable speed drives may be
an alternative, but they can be complex,
unreliable, and expensive - and are simply
overkill if a ixed lower speed/low is all
thats required.
Out of the box speed control and
energy savings!
Enter the Flux Drive SmartCOUPLING!
Designed as a drop-in replacement for
grid, gear, elastomeric, and other lexible
couplings, the SmartCOUPLING transfers torque across an air gap by means of
magnetic induction. Magnetic torque
transmission provides inherent soft-start
beneits (reducing start-up amps) but also
allows the coupling to be conigured for a
lower pump speed.
Air gap spacer shims can be installed to
increase the distance between the induction rotors and the permanent magnets.
he larger the air gap, the slower the load
will operate. On centrifugal loads such as
most pumps, fans and blowers, this results
in signiicant energy savings. Just a 10%
reduction in pump speed can easily result
in more than 20% energy savings! If a
return to maximum low is needed in the
future, the air gap spacers can simply be
removed.
Misalignment correction for increased

seal and bearing life!
Energy savings isnt the SmartCOUPLINGs
only beneit. As experienced pump engineers know, misalignment is the leading
cause of premature seal and bearing failure
leading to costly downtime and recurring
maintenance expenses.
Because the SmartCOUPLING separates the motor from the load via an air
gap, vibration from misalignment is eliminated. In fact, the coupling can accommodate up to 0.100 (and more with air gap
spacers installed) in parallel, angular, or
axial misalignment with no adverse impact
on torque transmission. he coupling
also acts as a shear pin during load seizures and restrictions, allowing the motor
to break away from the load magnetically
instead of causing permanent damage to
motor & load shafts or couplings.
Unlike other forms of lexible couplings, the SmartCOUPLING has no
wearable parts to replace. here is absolutely no ongoing maintenance requirement once the coupling is installed. It
literally never wears out!
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Reliability!
Balancing demands for both eiciency and
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a challenge for any maintenance professional. Flux Drive is here to help with
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both objectives. Contact us at info@luxdrive.com or visit www.luxdrive.com for
more information.
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>> INTRODUCING
Pumps & Systems MENA

Pumps & Systems MENA provides timely and powerful technical
information to end users in the expanding pump industry of the
Middle East and North Africa region.
INDUSTRIES COVERED
Oil & Gas (upstream and

downstream)
Water & Wastewater
Power Generation
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Chemical, Petrochemical &
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Plus market analysis in each
issue from global consultancy
irm Frost & Sullivan
DISTRIBUTION
he printed magazine
will be distributed to
15,000 subscribers in:
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United Arab Emirates
Content will focus on these and other
Middle East and North African countries.
CONTENT INCLUDES
Case Studies
Technical Articles
Relevant Regional News
New Products
Ancillary Equipment
motors & drives, seals,
instrumentation, bearings,
valves, compressors and engines
Design. Repair. Efficiency. Maintenance. No one covers the many facets of the pump and rotating
equipment industry like Pumps & Systems. Engineers, operators, consultants and maintenance professionals
who read our magazine know we are the number one source for technical pump information. Now, were taking
our coverage to the expanding Middle Eastern/North African region. Pumps and the systems surrounding them
are crucial to the economy and growth of this part of the world. Pumps & Systems MENA covers pumps and
related operations in every issue, bringing relevance and clarity to end users worldwide.
Pumps & Systems mena

will publish six times
in 2015.
PREMIERS
OCTOBER
2014
SUBSCRIBE NOW
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84
EFFICIENCY MATTERS
Smart Air Distribution Systems Upgrade

Traditional AODD Pump Technology
Head-to-head comparisons show decreased compressed air use and enhanced flow.
By Carl Glauber
or more than 50 years, airoperated, double-diaphragm

(AODD) pumps have played
a role in many companies modern
global manufacturing and luidhandling operations.
he original pump concept has
changed little over time and works
because of its simple operation and
construction.
With a major focus on operating
improvements and cost reductions
from businesses, AODD pump
manufacturers have introduced
new air distribution systems (ADS)
to increase pump eiciency and
meet these demands. he new ADS
technologies range from electronic
controls to mechanical innovations. However, the resulting savings in compressed air usage and
increase in pump eiciency vary
for each system.
his article presents the results of
head-to-head comparisons of AODD
pumps with diferent ADSs and the
inal data acquired during those
tests. he results help illustrate the
impact that diferent ADS technologies have on air consumption,
energy use and overall low rate.
energy costs, facility operators understand that the initial purchase

and installation of a new pumping
system is only a small part of the
total cost of ownership (TCO) and
operation. he routine costs of energy and maintenance remain the
primary cost drivers in the TCO.
Much like cars, pumps can be
rated according to eiciency. he
goal is to use the least amount of
air to pump the greatest amount of

product. he ultimate objective is
to reduce the rate of air consumption in relation to the product low
rate and minimize the amount
of air that is not creating product
yield (therefore, wasting energy)
during the pumping cycle.
If attained, this combination can
positively impact an operations
bottom line. he proitability is
he Challenge
In AODD pump operations, energy
use is directly related to the rate at
which the pumps use air to drive
each stroke during the pumping cycle. With increasingly high
Manufacturers have introduced new air distribution systems to improve AODD pump efficiency. (Article
images and graphics courtesy of Wilden.)
85
Although the technology is more than 50

years old, AODD pumps can still be made
more efficient by recent ADS evolution.
to cut of the air supply prior to

the end of the stroke. h is can
result in erratic and sometimes
wasteful low rates during the
learning period.
During the time period from
the end of each stroke to the
completed shift of the valve, the
air is allowed to overi ll the
air chamber without any corresponding displacement of luid.
h is volume of compressed air is
entirely wasted.
he mechanically actuated
method is a simple and extremely
efective way to control the air
with each stroke and prevent
wasteful overi lling.
he air is constantly mechanically controlled to maximize eficiency, minimize complexity and
maintenance considerations, and
allow for operation in explosive
and submerged pumping environments.
he Controlled Comparisons
To create real-world conditions to
measure the efectiveness of different ADS technologies industrywide, a controlled, objective
head-to-head test was arranged
comparing several AODD pumps
that were itted with traditional,
electronically controlled and mechanically actuated ADSs. Common conditions of service that are
seen in the ield were replicated in
the laboratory.
The all new...
Achieves up to a 60% savings in

air consumption over competitive
AODD pump technologies
More yield per SCFM
Easy to maintain (fewest ADS parts
of any AODD pump competitor)
See the proof at

profloshift.com/proof

Grand Terrace, CA 92313-5607 USA
T: +1 (909) 422-1730 F: +1 (909) 783-3440
www.wildenpump.com
determined by the volume of air

being consumed and the energy
required to compress it.
In addition to wasting energy,
air overi lling unnecessarily
stretches the diaphragm. h is
stretching produces excessive
diaphragm wear, resulting in more
frequent replacement and downtime and increased operating
costs. Although the technology
is more than 50 years old, AODD
pumps can still be made more
eicient by recent ADS evolution.
hese developments better control
the air low and prevent wasteful
air overi lling, which reduces air
consumption and operating and
maintenance costs.
Two primary methods control
air low and prevent overi lling
by cutting of the air supply to
the air chamber before the end
of the pump cycle: electronically
controlled and mechanically actuated ADSs.
he electronic control method
has two shortcomings. First, the
electronics raise an additional set
of maintenance and operational
concerns, including the prohibition of their use in explosive
environments, such as mines, and
an inability to be submerged.
Second, electronic ADS technology requires a learning period
of 30 to 40 seconds during which
it monitors the operation of the
pump before it can estimate when
Introducing the worlds most energy efficient

pump in its class. Period.
EFFICIENCY MATTERS
86
e-newsletters
news!
PUMP USERS DIGEST

To better serve our readers, this month
weve consolidated our Pump Industry
Insider e-newsletter with Pump Users
Digest. Readers will receive the same
relevant industry coverage, along with
reports of contracts and mergers and
acquisitions. To subscribe, visit
pump-zone.com/e-newslettersubscription-form.
PUMP USERS DIGEST MENA

To complement the October launch of
Pumps & Systems MENA, we have introduced a brand new e-newsletter, Pump
Users Digest MENA. Like the magazine,
this targeted e-newsletter covers the
pump and rotating equipment industry
in the Middle East and North Africa.
To subscribe, visit pump-zone.com/
mena.
SUBSCRIBE
TODAY!
h is simulated application required each pump to produce a low

of 320 liters per minute (lpm)85
gallons per minute (gpm)against
a head pressure of 2.1 bar (30 psi).
To achieve a fair comparison between these competing pumps, each
pump was run at the inlet air pressure
needed to meet the common condition of service. Air-consumption data
was then recorded (see Table 1 for the
results for four pumps).
he Solution
The data gathered in the objective
AODD testing show that Pump
Dwhich used the ADS that
restricts air flow into the filling
air chamber to minimize wasted
compressed airhad better
performance in all three points of
measurement.
It had the lowest air consumption in standard cubic feet per

minute (SCFM), the lowest strokes
per minute and the highest volume
of luid pumped per SCFM.
Pump D averages an overall 30
percent reduction in air consumption
compared with Pumps A, B and C.
It also provides the largest reduction in air consumption among the
four pumps while still managing
the best overall volume of luid
moved per stroke, requiring the
fewest strokes per minute.
he air-restricting ADS in Pump
D is a new way to look at how pneumatic pumps operate.
To combat overi lling, the ADS
used in Pump D restricts the air
low into the i lling air chamber at
the end of the pumps stroke, which
minimizes the compressed air that
Table 1. In a controlled head-to-head laboratory test comparing eight AODD pumps operating
under common parameters seen in the field, this sample of four illustrates Pump Ds standout
results and the wide range of energy and strokes required to achieve similar fluid output.
87
The air control spool prevents overfilling

without reducing product yield.
is wasted. he air control spool of

this ADS meters the air to prevent
overi lling without reducing product yield.
he result is decreased air
consumption with maximum
operational eiciency and low
rates. Unlike the electronic ADS solution, Pump Ds ADS requires no
electrical power source and has no
delayed learning period after each
startup.
Conclusion
Although reliably used in applications for more than 50 years,
AODD pumps can be enhanced
to deliver greater eiciency and
cost savings through improved
ADS technology that prevents air
overi lling.
While end users understand that
AODD pumps featuring new ADS
technologies can deliver results
that support their shrinking budgets and operating margins,
Table 2. Pump Ds ADS saves air consumption and energy while maintaining desired flow rate.
100
90
80
71.8
65.8
70
49.5
50
42.6
40
30
20
10
0
Pump A
Pump B
Pump C
Pump D
SCFM
60
88
EFFICIENCY MATTERS
This ADS addresses the overfilling waste of traditional AODD

pumps, providing considerable savings by decreasing air
consumption while maintaining the same fluid-volume output.
ARE YOUR PUMP

OPERATING SAVINGS
REALLY AN ILLUSION?
Pump Ds ADS sets it apart from

the competition.
h is ADS addresses the overi lling waste of traditional AODD
pumps, providing considerable
savings by decreasing air consumption while maintaining the same
luid-volume output. h is ADSs
lower strokes-per-minute rate
compared with the other systems
delivers maintenance advantages
because of the minimized wear and
tear during operation.
Carl Glauber is the Diaphragm

Pump product manager for
Wilden Pump & Engineering Co.,
LLC, Grand Terrace, California, a
manufacturer of AODD pumps.
He may be reached at carl.
glauber@wildenpump.com or
718-213-7602.
Unless youre considering Total Cost of

Ownership in your operations, the savings
promoted by your diaphragm pump
supplier may be smoke and mirrors.
ARO is the true leader when you
calculate the different factors associated
with pump applications such as price,
energy usage, repair cost and downtime.
Flow rates up to 275 GPM (1041 LPM)
Contact ARO to reveal your

Total Cost of Ownership.
ARO Tech Support: 800.483.4981
E-mail: arohotline@irco.com
arozone.com

For more information, visit

www.wildenpump.com. Wilden
is an operating company
within Dover Corporations
Pump Solutions Group (PSG),
Oakbrook Terrace, Illinois. PSG
is comprised of several pump
companiesincluding Abaque,
Almatec, Blackmer, Ebsray,
Finder, Griswold, Maag, Mouvex,
Neptune, Quattroflow and
Wilden. For more information,
visit www.psgdover.com.
To view a video documenting
the laboratory pump demonstration, visit
www.profloshift.com/proof.
MAINTENANCE MINDERS
6 Refinery Pump Maintenance Tips

Outside lubrication experts help improve protocols and minimize downtime.
By Marcus Pillion
Colfax Fluid Handling
ew industries can tolerate the

unscheduled downtime of
critical equipment. In reinery
operations, it can have particularly serious implications. For an
operation that runs 24 hours per
day year-round, the lossesin both
production and proitabilitycan be
staggering.
Rotating equipmentpumps, motors, compressors and pillow block
bearingsrepresents a key reinery
component that, without proper
planning, can become a reinerys
Achilles heel. his article presents
six tips that help prevent unscheduled downtime because of rotating
equipment failure.
cally double-ended or double-suction

to achieve higher low rates.
he screw pump design better
handles luids with more solids
content and a product viscosity
range from 0.5 to more than 1 million centistokes. In reineries, screw
pumps provide lexibility and quick
payback to owners.
Lubricants
2 Decontaminate
Every piece of rotating equipment in a reinery needs lubrication.
At some point, lushing, varnish

removal, reservoir maintenance and
luid replacement will be required.
Particle contamination is the biggest
threat to rotating equipment lubrication and a leading cause of bearing
failure.
A reinerys maintenance staf is
responsible for its lubrication program, but these specialists also have
other duties. A lubrication program
can divert time and money from operations. Successful rei neries often
in the Right
1 Invest
Equipment
Flexibility is the key. What may have
been the right equipment in the
past may not be the right equipment
today. Many facilities were originally designed to handle a certain
luid and have pumps and peripheral
systems designed to accommodate
that luid.
Today, diferent feedstocks in a
wide array of viscosities ofer price
and proitability advantages. A reinery must accommodate the diversity.
Retroitting the right pumps and
related equipment into existing operations improves eiciency. Larger,
two-screw pumps can work better
than a battery of smaller, specialized
pumps in some applications. Twoscrew pumps are rotary, self-priming
positive displacement pumps, typi-
Rotating equipmentpumps, motors, compressors and pillow block bearingsrepresents a

key refinery component that, without proper planning, can become a refinerys Achilles heel.
(Article images courtesy of Colfax Fluid Handling.)
89
90
MAINTENANCE MINDERS
partner with a irm specializing in

Be Honest with
lubrication maintenance. External
Outside Experts
lubrication experts have experiAny partnership with an external
ence that allows them to anticimaintenance i rm should be
pate issues before they occur.
based on candor and trustlike
that of a patient and doctor. A

lubrication expert can only help
a rei nery if the facilitys maintenance personnel willingly shares
information on current and past
equipment operations.
Has a single pump or motor
been a problem in the recent
past, or does it create a recurring issue? Do certain systems
respond diferently during
temperature changes? Honest
communication is critical from
The most common cause of failure during

the lubrication of rotating equipment and
bearings is particle contamination.

91
the beginning for an efective

maintenance program.
A well-equipped lubrication
partner will know what to ask
during the auditthe i rst step
toward a partnership. Rei nery
maintenance staf members
should brace for some tough
questions. he more raw data
the maintenance experts have
available, the faster the audit can
be completed. Afterward, the
rei nery will be one step closer
to its maintenance goal: clean,

contaminant-free lubricants
delivered in the right amount, at
the right time, for every piece of
rotating equipment.
A lubrication maintenance
program built on trust goes
beyond the basics. he program
overlooks nothing in the lubrication process, even considering

92
MAINTENANCE MINDERS
intangibles such as a facilitys

employee safety program. Rei neries reap the beneits: new
lubricants; new delivery methods; and longer, more sustainable
lubricant life.
ink Outside the Box

4h
Facility maintenance managers often understand their lubricant needs. However, an expert
may recommend new lubricants
that can help optimize rotating
equipment operation.
Changing to oil mist lubrication is an example. Oil mist is
not new. he lubrication method
has been around for nearly half a
century. Newer oil mist systems
have replaced their older, more
wasteful ancestors, delivering
precise lubrication that extends
bearing life compared with al-
Regularly scheduled inspections are required to ensure that a pre-planned

maintenance program satisfies the refinerys operation requirements.
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
Find out more at www.flsmidth.com/compressors

ternative lubrication methods.

Rei nery owners and personnel
should consider outside suggestions. At the same time, they
should pay more attention to
the ordering, storage, handling,
disposal and recycling of the
facilitys lubricants.
Often overlooked, improper
storage and handling can introduce contaminants to the lubrication system that may cause
facility-wide problems.
Regular
5 Schedule
Inspections
After the maintenance partner
develops a lubrication plan, the
next step involves regularly
scheduled inspections. he results determine how the maintenance program will be revised
and updated. he plan becomes
a living document that adapts as
rei nery conditions change and
new equipment and operations
are added.
93
LEADING
THE INDUSTRY
Regular inspections also help
rei neries manage their sustainability programs, essential to any
modern-day oil and gas processing operation.
Leakage oil reclamation services alone can ofer bottom-line
beneits that include identifying
high lubricant use areas for reclamation and establishing puriication methods through i rst- and
second-stage i ltration.
A properly documented,
veriied program is critical to
complying with Environmental
Protection Agency and safety
standards.
the Global
6 Join
Community
A partnership with a rotating
equipment and lubrication expert
can pay of and help rei nery personnel learn best practices from
around the globe. What works
for a rei nery halfway around the
world may be the remedy to a
diicult problem plaguing other
facilities. Relying on a partner to
provide new ideas to optimize a
facilitys rotating equipment is
a value-added service that can
beneit the rei nery in the future.
Marcus Pillion
is the director
of engineering
and marketing
for the reliability
services division
of Colfax Fluid
Handling, which owns and operates COT-Puritech, LSC, Sicelub
and Total Lubrication Management. He may be reached at
marcus.pillion@
colfaxfluidhandling.com.
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Read Our Drillers

Mud Case Study:

94
MOTORS & DRIVES
The Differences Between Submersible

& Immersible Motors
How do end users choose, and what are each types ideal applications?
By Bobby Bowen
Baldor Electric Company
otor manufacturers routinely answer questions

about the diferences
between submersible and immersible motors and the applications
best served by each design. While
end users ultimately decide which
motor best its their need, this article explains how the designs differ and provides information that
will help end users make informed
decisions.
cast iron frames and end plates.

Most motors come standard with
316 stainless steel hardware and
416 stainless steel shaft material.
Submersible designs are available
for hazardous and nonhazardous
locations. An example of a hazardous location is a sewage application
where l ammable gases might be
present. hese locations require
an explosion-proof motor design.
Explosion-proof motors are UL
(Underwriters Laboratories) listed
Submersible Motors
and CSA (Canadian Standards AsMunicipal and industrial wastewa- sociation) certiied for Division 1,
ter markets use submersible moClass 1, Groups C and D with a 1.0
tors for both wet and dry pit appli- Service Factor and T2A temperacations. hese are totally enclosed, ture code.
non-ventilated (TENV) motors.
Submersible motors use cast
Wet pit motors use the eluent for iron frames that are precision
cooling and are designed to run
machined for tight its between
continuously while submerged.
the parts. Machined its have
hese standard designs are also
grooves with O-rings to prevent
rated to run in air for 15 minutes
water ingress to the motor. An
when conditions require it.
epoxy i lled, non-wicking cable cap
hese motors can also be deassembly protects the motor from
signed for continuous operation in moisture that could enter through
dry pit applications by de-rating
the opposite drive end of the moa larger horsepower motor frame.
tor. Typically, two separate cables
h is allows the motor to dissipate
exit the cable cap epoxy potting
heat while running continuously in compound; a four conductor power
a dry pit application that only excable and a ive conductor control
periences looding under unusual
cable. Standard lengths vary from
conditions, such as heavy rains or
25 to 30 feet, but other lengths are
a backup in the system.
available upon request. h is cable
Submersible motors are rugged
should never be used to lift the
and corrosion resistant, makmotor.
ing them suitable for demanding
he drive end of submersible moapplications. he motors have
tors is a critical part of the design.
Since the motors are designed to

run continuously while submerged
in water or eluent, they include
features to keep water out. An oil
i lled chamber and a mechanical
Many submerged motors rely on

the effluent to stay cool and run
continuously while submerged. (Article
images courtesy of Baldor Electric
Company.)
95
Moisture probes are necessary because seals

wear, and the potential for moisture to enter the
motor increases over time.
motor increases over time. h is

sensing system, consisting of two
probes with a resistor between
them, is placed in the oil inside
the endplate. he probes are connected to a customer-supplied
control module that sounds a
warning alarm or shuts down the
motor if a change in resistance is
detected. h is ensures that the
motor is shut down before any
damage occurs. Worn seals will
need to be replaced.
h is motor coniguration is
predominantly used for applications in which the motor will be
submerged at all times.
Immersible Motors
Immersible motors, on the other
hand, are speciically designed to
be operated in a dry environment
that might lood under unusual
circumstances. One companys
immersible design was developed
for an end user who needed a
more cost efective alternative
to the more expensive, oversized
submersible frame motors used
for continuous in air operation.
Immersible designs use TENV
enclosures in smaller frames and
totally enclosed blower cooled
(TEBC) enclosures on larger
frames. hey have a sealing system that allows reliable operation
for two weeks while submerged
under a maximum depth of 30
feet of water. he immersible
design has been proven with ex-
seal serve this function. Also,

a moisture monitoring probe is
used to detect moisture entering
the chamber.
he drive endplate has a special
design that includes a chamber
i lled with oil. he oil acts as
a barrier to trap moisture and
provide suicient time for shut
down if water enters the motor. It
also lubricates the upper part of
the mechanical seal.
he mechanical seal keeps
moisture out of the motor.
Some companies use a Type 21
mechanical seal as its standard
submersible motor seal. h is
seal uses an inner and outer
seal arrangement. It has both a
stationary face and a rotating
face. As previously stated, the
upper part of the mechanical
seal is lubricated by the oil in the
endplate chamber. However, the
lower part is lubricated by the
pumped liquid. Carbon ceramic
is the standard seal face material and is used in applications
with relatively clean eluent.
Tungsten carbide, which is used
with more viscous luids, is the
most popular seal face material.
For the most demanding slurry
type applications, seal faces with
tungsten carbide are an option.
Pump manufacturers specify
what type seal is necessary.
Moisture probes are necessary
because seals wear, and the potential for moisture to enter the
96
MOTORS & DRIVES
tensive tests, including disassembly

and inspection to ensure dryness
and structural integrity.
he TEBC design runs continuously in air and has a separate
horsepower motor running an
external fan for constant velocity
cooling. An end user-supplied loat
switch turns of the blower motor
if the water reaches a level near the
cooling fan. he opposite drive end
is totally enclosed, and the fan and
blower motor are mounted separately to ensure that moisture will
not enter the motor from the opposite drive end. hese motors are
also built with precision machined
cast iron frames and endplates with
grooves and O-rings to prevent
water ingress to the motor.
Immersible designs have a sealing system that

allows reliable operation for two weeks while
submerged under a maximum depth
of 30 feet of water.
he drive endplate is designed to
keep moisture out by using a dual
oil seal coniguration that is packed
with heavy, moisture resistant
grease. h is endplate does not have
an oil chamber like the submersible
design.
Another mechanical feature
of the immersible design is an
explosion-proof style conduit box
that uses a sealing compound and a
non-wicking epoxy-sealed cable as-
sembly to prevent water from

entering through the electrical connection at the motor. hese motors
use the same power and control
cable coniguration as the submersible motor design. Other standard
features include: two normally
closed thermostats, motor space
heaters and a regreasable lubrication system.
Lastly, the immersible design has
the beneit of reducing costs over
the traditional immersible pump
coniguration, which uses a nonimmersible vertical pump motor
mounted more than 20 feet above
the pump and employs a jack shaft
to reach it. he immersible motor mounts directly to the pump.
h is coniguration eliminates the
construction and installation costs
incurred by building a motor support structure.
Conclusion
Application conditions should be
the deciding factor between immersible and submersible motors.
Immersible designs are more cost
efective, but the submersible design is a better it in an application
that requires continual submergence.
Immersible motors are specifically designed to be operated in a dry

environment that might flood under unusual circumstances.
Bobby Bowen is a marketing product specialist, Definite Purpose Motors, for Baldor Electric Company. He
has been with Baldor since 2001 and
has held the positions of mechanical
designer, applications specialist and
international sales engineer.
An Indispensable Resource
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2014
January/February
Technolo
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May/June 2014
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98
SEALING SENSE
Expansion Joint Selection Optimizes

Piping Systems
Different material and design combinations offer application-specific advantages.
By Lloyd Aanonsen
FSA member
hen discussing expansion joint selection, the

conversation typically
focuses on the quality, durability
and capabilities of the expansion
joint. However, the expansion
joints role in the overall energy
eiciency and optimization of the
piping system is often overlooked.
All piping systems require some
degree of lexibility. Inadequate
lexibility can lead to a catastrophic
system failure that could even be
life-threatening, making lexibility an important consideration in
expansion joint selection.
Rubber expansion joints provide
maximum lexibility with their
resilient construction and alldirectional movement capability.

Rubber expansion joints can handle
axial, lateral, angular and torsional
movements. hey can also absorb
vibration and accommodate piping
misalignment.
he rubber expansion joint provides these beneits in the smallest
space possible, reducing the piping
systems size and overall footprint
for greater overall energy eiciency
and system optimization. h is level
of performance cannot be achieved
with alternatives such as large pipe
loops, metal expansion joints or
grooved couplings.
A typical expansion joint (Article images courtesy of FSA.)
Section-by-Section System
Optimization
he expansion joint selection and
application process often requires a
systematic and sometimes tedious
approach. First, the proposed piping
should be divided into individual
sections (straight runs or L- or
Z-shaped bends) by choosing tentative anchor locations. Each section
can then be optimized and later
rejoined with the complete piping
system, resulting in a completely
optimized, eicient system. h is
process will require additional consideration for the following:
Capabilities and limitations
of diferent anchor types,
including main, directional or
intermediate
Piping code (ASME B31.1,
ASME B31.3 or others)
Location of various equipment,
branch connections and space
restrictions
Available support structure and
load limitations on piping and
equipment
Operating conditions including
temperature and pressure
Amount of thermal and/or external movements anticipated
Need to absorb noise and vibration and to compensate for
misalignment
Need to provide access to piping
and equipment
Need to absorb shock loads
Required cycle life
Capabilities and limitations
99
of diferent expansion joint

designs, including unrestrained and restrained arrangements
Unrestrained Designs
Unrestrained designs are the simplestand often most economicalsolution to expansion joint
selection.
hese designs primarily relieve
thermal stresses in rigid piping
The unrestrained expansion joint will

commonly have a cycle life
in the tens of millions.
systems by absorbing axial movement. he use of main anchors

with numerous guides at speciic
spacing becomes critical.
Lateral movements can be

achieved by using a directional
main anchor. he unrestrained expansion joint will commonly have
a cycle life in the tens of millions.
A single-arch unrestrained rubber expansion joint
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100
SEALING SENSE
It also reduces noise and vibration, compensates for misalignment, and absorbs shock and anchor loading, provided the support
structure and adjacent equipment
does not have loading limitations.
he joints can also provide access
to piping and equipment when
a self-retracting design or an
adjustable installed length is not
required.
Although this type of piping
system uses a very traditional
approach, other solutions are
more eicient and eco-friendly.
hese systems tend to occupy a
signiicant footprint and require
more piping and greater support
structure.
Restrained Designs
An alternative approach that uses
restrained designsincluding
universal, hinged, gimbal, pressure
balanced and dismantling expansion jointsmay be used to absorb
axial, lateral, angular, torsional and
combined movements. he pressure
thrust forces in these designs are
often self-restrained, allowing for
intermediate anchors and fewer
guides. hese designs are extremely
Universal restrained design
Restrained designs offer many of the same benefits

of unrestrained designs, but they have improved
energy efficiency and system optimization.
helpful with space or structural

limitations or with load limitations on piping and equipment.
A universal restrained design, for
example, relieves thermal stresses
in perpendicular runs by absorbing
lateral movements.
Restrained designs ofer many of
the same beneits of unrestrained
designs, but they have improved
energy eiciency and system
optimization. Restrained designs
can also provide access to piping
and equipment in a self-retracting
design while allowing for additional
adjustments to the installed length.
hese systems tend to have a much
smaller footprint because the piping length, pumping requirements
and need for structural support are
greatly reduced.
Conclusion
Each expansion joint arrangement
has characteristics that make it particularly suitable for a given application. In some cases, two or more
solutions may be possible, allowing
the designer to maximize energy
eiciency and system optimization.
While the arrangements covered in
this article are the most common,
a combination of materials and designs is available to create the most
efective solution for even the most
demanding application.
Next Month: What are the
beneits of the new plan 03?
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@luidsealing.com.
102
HI PUMP FAQS
Understand Specific Speed & Disc Diaphragm

Pump Coupling
By Hydraulic Institute
What are some

differences between
specific speed and
suction specific speed for
a rotodynamic pump?
he Hydraulic Institute deines
speciic speed as an index of pump
performance (developed total head).
It is determined at the pumps best
eiciency point (BEP) rate of low,
with the maximum diameter impeller
and at a given rotative speed. Speciic
speed is expressed by the following
equation:
0.5
ns = n(Q) 0.75
(H)
suction operating characteristics.

It is determined at the BEP rate of
low with the maximum diameter
impeller. (Suction speciic speed
is an indicator of the net positive
suction head required [NPSH3]
for given values of capacity and
also provides an assessment of a
pumps susceptibility to internal
recirculation.) Suction speciic
speed is expressed by the following
equation:
0.5
S = n(Q) 0.75
(NPSH3)
Where:
S = suction speciic speed
n = rotative speed, in revolutions
per minute
Q = low rate per impeller eye
measured in U.S. gallons per minute
(cubic meters per second)
Where:
ns = speciic speed
n = rotative speed measured in
revolutions per minute
Q = total pump low rate measured
in U.S. gallons per minute
(cubic meters per second)
Figure 1. Mechanically coupled disc diaphragm
H = head per stage
measured in feet (meters)
It should be noted that
when calculating speciic
speed using units of cubic
meters per second for low
rate and meters for head per
stage, 51.6 is the conversion
factor for speciic speed in
U.S. gallons per minute and
feet (metric 51.6 = U.S.
customary units).
he usual symbol for
speciic speed in U.S.
customary units is Ns.
Suction speciic speed
is an index of pump
= total low rate for single suction

impellers
= one half of total low rate for
double suction impellers
NPSH3 = net positive suction head
required in feet (meters) that will
cause the total head (or irst-stage
head of multistage pumps) to be
reduced by 3 percent
When suction speciic speed is
calculated using cubic meters per
second and meters, the conversion
factor to suction speciic speed in U.S.
gallons per minute and feet is 51.6.
he U.S. customary symbol Nss is
sometimes used to designate suction
speciic speed.
For more information about
speciic speed and suction speciic
speed, see ANSI/HI 1.1-1.2
Rotodynamic (Centrifugal) Pumps for
Nomenclature and Deinitions.
103
How do mechanically
coupled and hydraulic
coupled disc diaphragm
pumps differ?
A mechanically coupled disc
diaphragm liquid end contains a
lexible, round diaphragm, which is
clamped at the periphery and in direct
contact with the process liquid being
displaced (see Figure 1, page 102). his
type of design is inherently leak free.
he diaphragm material is typically
a luoropolymer, elastomer or
luoropolymer-elastomer composite.
Figure 2. Hydraulic disc with contour plates
Figure 3. Hydraulic disc with diaphragm positioning valve
A connecting rod is connected directly

to the diaphragm. he diaphragm is
not pressure balanced because the
process pressure is acting on one side
of the diaphragm and atmospheric
pressure is acting on the other side.
his results in higher stress levels
in the diaphragm. herefore, these
pumps are typically used for lower
pressure applications. In operation,
the process liquid is admitted through
the suction check valve as the
diaphragm/connecting rod assembly
moves away from the wet end. As
this happens, the suction check valve
closes and the discharge check valve

opens, discharging liquid.
A hydraulic coupled disc diaphragm
liquid end contains a lexible, single
or double coniguration diaphragm,
clamped at the periphery and in direct
contact with the process liquid being
displaced (see Figure 2). his liquid
end design is also inherently leak
free. Liquid end designs featuring
lexible metallic diaphragms are
available. hese diaphragms are used
in applications where severe operating
conditions prohibit the use of
luoropolymer or other elastomers.
In operation, the diaphragm is
moved by a hydraulic luid, which
is displaced by a reciprocating
plunger or piston. he stresses in
the diaphragm are minimal because
the process pressure acting on one
side of the diaphragm is balanced
by the hydraulic pressure acting on
the opposite side. he process liquid
is admitted through the suction
check valves as the diaphragm moves
rearward. As the diaphragm moves
toward the wet end, the suction check
valve closes, and the discharge check
valve opens and discharges liquid.
Liquid end designs may include
provisions such as contour plates,
springs or diaphragm positioning
hydraulic control valves to ensure the
diaphragm does not move beyond its
elastic limits (see Figure 3).
For additional information
regarding various controlled-volume
metering pumps, see ANSI/HI 7.1-7.5
Controlled-Volume Metering Pumps for
Nomenclature, Deinitions, Application,
and Operation.
HI Pump FAQs is produced by the Hydraulic
Institute as a service to pump users,
contractors, distributors, reps and OEMs. For
more information, visit pumps.org.
S P O N S O R E D
C O N T E N T
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ulzer has long been a leading service provider for

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into a single Rotating Equipment Services division. The
new division combines services for pumps, motors,
generators, turbines, and compressors, and expands
Sulzers geographical footprint to over 100 service centers
worldwide.
As a third-party service provider, Sulzer aims to offer
customers an alternative approach to maintenance,
repair, overhauls and upgrades. By leveraging combined
capabilities and integrated service centers, Sulzer is able
to provide customers with a single access point for service,
eliminating the need to source separate vendors for varying
types and brands of rotating equipment.
Pumps
No matter how simple or complex the machine, Sulzer
is dedicated to improving customers pumping systems
and operational reliability. At our expansive network of
service centers, an expert team of engineers and repair
staff respond to industry needs and focus on ensuring the
highest performance for your equipment. Pumps services
www.sulzer.com
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Sulzer is recognized as a technically advanced service
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Phone +1 713 567 2700
www.sulzer.com
106
PRACTICE & OPERATIONS
Energy Efficient Vertical Turbine Pumps

Promote Sustainable Mining Efforts
The computational fluid dynamics process advances highly efficient pump
designs for difficult applications.
By Petar Ostojic
Neptuno Pumps
nergy is a strategic input for

the mining industry in Latin
America and worldwide.
Mining requires large amounts
of energy, which drives up total
operational costs. In Chile, mining
companies consume 34 percent of
the total energy produced in the
country and spend approximately
20 percent of their total income on
electricity costs.
According to oicial mining
sources, the copper mining industry is expected to consume 41.1
terawatt-hours (TWh) in 2025, an
increase of 95.5 percent from 2013.
New projects alone will consume
36.2 percent by 2025.
he worlds biggest copper companies use concentration plants
which are energy intensive and use
the worlds biggest pumpsas their
main production process. In 2013,
concentration plants represented
48.6 percent of the total energy
consumption for the copper mining industry, which is expected to
increase to 64.2 percent by 2025,
reaching 26.4 TWh.
Water is another major concern
in the mining industry. Freshwater
restrictions from scarcity or government policy will have an impact
on water availability for future
mining projects. Because of these
restrictions, desalination plants
Image 1. Vertical turbine pump designed using CFD
and seawater pumping systems are

also expected to reach 6.2 TWh,
representing up to 15 percent of the
industrys total energy consumption.
Pump Stations
Several studies have shown that
pumps account for approximately
25 to 32 percent of total motor
energy consumption on an average
industrial site. Governments from
diferent mining countries are considering applying strict energy eiciency policies to mining companies.
hese policies will seek signiicant
reductions in carbon emissions and
immediate optimizations (up to 10
percent in Chile, the worlds largest
copper producer).
In recent years, motor manufacturers have accomplished great results regarding energy eiciency, up
to 96 percent. However, this has not
been the case for the pump industry.
In this new energy-eicient and
carbon-reduction scenario, pump

designers and manufacturers will
play a key role in delivering highly
eicient pumps. Energy represents
up to 90 percent of a pumps life
cycle cost, making pumps and pump
stations a huge opportunity to improve energy eiciency and reduce
carbon dioxide emissions in the
mining industry.
Vertical Turbine Pumps

Vertical turbine pumps (VTP) are
some of the most versatile and reliable pump designs in the turbomachinery industry. heir minimal
space requirement, highly eicient
semi-axial design and pro-gravity
vertical arrangement have made
this type pump popular in several
industries, particularly mining because of their compact size and ease
of maintenance.
In recent years, engineering and
design capabilities have improved
through mechanical and hydraulic
107
simulation software, advanced

manufacturing technologies
such as three-dimensional (3-D)
printing and computer numerical control (CNC) machining as
well as the extensive use of
special metallurgies. hese
changes have allowed
pump manufacturers to
take this pump type to a
new level. Engineers can custom design vertical turbine pumps,
such as high-head/capacity pumps
or pumps for the transportation
of highly corrosive and abrasive
luids for heavy-duty applications,
while maintaining the designs
highly eicient characteristics and
operational advantages.
Energy-Eicient
Pump Design
Hoping to increase its production,
one copper producer decided to
double its concentration plants

reclaim water pumping capacity.
However, the water quality was a
challenge for most pump manufacturers. he water had a high solids
content concentration, about 20
percent, and high concentrations of
chlorides, about 60,000 milligrams
per liter (mg/L).
he companys previous pumping
station consisted of 10 standard
short-set vertical turbine pumps
with a capacity of 1,500 cubic
meters per hour (m3/h) and a total
dynamic head of 80 meters (m).
Each cast-iron pump had eiciencies below 80 percent. h is pump
coniguration was a poor it for
this highly corrosive and abrasive
application, requiring operators
to repair and replace these pumps
every three to ive months.
Assisted by computational luid
dynamics (CFD) and inite element
Image 2. Vertical turbine pump completely casted in duplex 2205 stainless steel (Article images
courtesy of Neptuno Pumps.)
analysis (FEA), a pump manufacturer custom designed a vertical

turbine pump that met all the requirements for this abrasive service
(see Image 1).
he pump was designed for a capacity of 3,100 m3/h and a total dynamic head of 90 m, obtaining an
eiciency of 85 percent. Because of
the highly abrasive potential of the
water, the pump was designed to
run at a low speed of 995 rotations
per minute (rpm) or 50 hertz. he
low speed diminished the abrasive
wear of its internal parts, which
in the case of centrifugal pumps,
is known to be proportional to the
cube of the particles low velocity.
Because the pump was for a
short-set application, some special
design considerations were necessary to guarantee reliability and
long operational life. All the bearings and wear rings use advanced
polymeric materials with better
lubrication properties. An independent axial thrust bearing assembly
supports the pumps thrust and
protects the motor from any damage during startup and operation.
Flanged column pipes ensure pump
and shaft straightness during
operation. A reinforced suction bell
and strainer minimize suction submergence and prevent the entrance
of large solid particles.
To protect the pump from the
highly corrosive and abrasive water,
duplex 2205 stainless steel was
speciied for all the wet parts of
the pump design. his material is
a combination of austenitic and
ferrite stainless steel. It is ideal
for chloride-containing environments because of its resistance for
localized corrosion types such as
intergranular, pitting and crevice.
Because of this feature, it provides
a better performance than 316L or
108
317L stainless steels. It is also resistant to chloride stress corrosion

cracking (SCC), so it was the right
choice for this highly corrosive application (see Image 2).
High resistance to fatigue, abrasion and erosion also made the material suitable for this project. Its
combination of moderate hardness
and high toughness is ideal for the
pumping of water with high solid
concentration.
he internal geometry of this
CFD-validated pump design was
then 3-D printed directly from
the 3-D computer-aided design
(CAD) i les to strictly maintain all
of its mechanical and hydraulic
characteristics, which ensure its
highly eicient performance. h is
3-D printed pump model was cast
using advanced investment casting
technologies by the pump manufacturer in-house to guarantee perfect
reproduction and a smooth surface
inish, both signiicant factors
when striving for high eiciency.
he pump was then assembled
and tested. Results showed that the
error between CFD simulation and
the actual pump performance test
was lower than 3 percent. h is

was well within the 5 percent
allowable tolerance that ISO
9906 for pump performance
tests speciies for eiciency in its
Grade 2B.
he installation of these
pumps allowed the end user to
double reclaim water pumping
capacity, reaching approximately
31,000 m3/h, with 50 percent
fewer pumps than would have
been required with the previous
pump model. he new model increased the users system reliability with a heavy-duty metallurgy
capable of withstanding this highly
abrasive and corrosive application
for 10 to 12 months before repairs
or replacement become necessary.
he pump system eiciency showed
an improvement of approximately
5 percent, reducing energy costs as
well as carbon dioxide emissions to
the atmosphere (see Image 3).
Sustainable Mining
Energy eicient vertical turbine
pumps are the future for the mining industry because they address
two major issues for todays sus-
tainable mining: energy and water.

New design and manufacturing
technologies, such as CFD/FEA
simulations and 3-D printing, play
a key role in delivering energy-eicient vertical turbine pumps. hese
pumps can help mining companies
operate sustainable processes and
save them money by improving
their systems reliability and reducing energy costs. hey also demonstrate a focus on the environment
and the mines surrounding communities by reducing the carbon
emissions of the pumping systems
across their entire process.
109
Image 3 (far left). Three vertical turbine pumps in the Andes

Mountains, each with a 3,100-m3/hcapacity
Image 4 (left). 1,500-horsepower vertical turbine pumps operating in
parallel in northern Chile at one of the worlds largest reclaimed water
systems
Image 5 (above). Vertical turbine pump arriving at a high-elevation
copper mine in northern Chile
Petar Ostojic is the project and product manager at Neptuno

Pumps based in Iquique, Chile. He earned his Master of Science
in mechanical engineering from the University of WisconsinMadison. Ostojic may be reached at projects@neptunopumps.
com or +56 57 424685. For more information, visit
www.neptunopumps.com or follow the company on
Twitter, @NeptunoPumps.

110
Specific Pump & Valve Features Serve Liquefied

Natural Gas Applications
LNG benefits have increased the demand for this cleaner burning fuel and
associated production and distribution equipment.
By Gobind Khiani
Fluor Canada Ltd.
iqueied natural gas (LNG) is

natural gas in a liquid form
that is clear, colorless, odorless, non-corrosive and non-toxic.
It is produced when natural gas is
cooled to minus 259 F (-161.66 C)
through a process known as liquefaction.
During this process, the natural
gaswhich is primarily methane
is cooled below its boiling point, and
certain concentrations of hydrocarbons, water, carbon dioxide, oxygen
and some sulfur compounds are
either reduced or removed.
LNG is less than half the weight
of water. If spilled on water, it will
loat and then immediately vaporize
if under atmospheric pressure.
Cost
On average, LNG costs about 50
percent less than gasoline or diesel
fuel and delivers the same power
and performance. According to the
Federal Reserve Economic Database,
in 2010, the U.S. spent $552 billion
on oil alone, and 61 percent of that
was imported. A 50-percent savings
could bring many beneits.
Emissions
Natural gas is the cleanest burning
fossil-based fuel with 50 percent
lower CO2 emissions than the next
best option. LNG burns almost completely, leaving only a small amount
of carbon dioxide and water behind
(CH4 + 2O2 = CO2 + 2H2O).
LNG produces up to 90 percent
LNG Uses
lower emissions than gasoline or
LNG has been used as a clean burn- diesel. LNGs reduced amount of
ing alternative in power plants and
greenhouse gases makes it the cleanin thousands of vehicles for decades. est internal combustible fuel for our
With the substantial growth of
environment. It also burns cleaner
the LNG fuels industry around the
inside engines, resulting in fewer
world, the opportunity to use LNG
oil changes and less maintenance.
as a cleaner and lower-cost vehicle
By replacing the traditional diesel
fuel in transportation leets and
engine of one 18-wheeler with an
heavy horsepower equipment conLNG engine, its carbon footprint
tinues to grow.
reduction is equivalent to removing
324 automobiles from the road.
LNG Beneits
LNG has many beneits when comSafety
pared with other fossil fuels. It is
LNG is lighter than air. In the event
less expensive, has fewer emissions, of a spill, LNG disperses quickly,
and is safer and less likely to ignite.
unlike petroleum-based fuels that
pool on the ground and create a ire

hazard. It also has a higher ignition
temperature, making it less l ammable than gasoline or diesel. In
addition, LNG is non-toxic and nonThe LNG process
Transportation
Treatment
Condensate
Removal
CO2 Removal
Dehydration
Mercury & H2S

Removal
Refrigeration
Liquefaction
Storage &
Loading
Transportation
& Marketing
111
corrosive and will not contaminate

ground water.
Abundance
Canada and the U.S. sit above large
natural gas reservoirs. Some analysts believe that these reservoirs
contain four times the energy held
in the oil ields of Saudi Arabia.

During the last ive years, shale
reservoirs have revealed natural gas
deposits that doubled previously
estimated recoverable reserves.
Other Beneits
Additional LNG beneits include:
RangeLNG is the only op
tion for a truck that needs to
travel more than 200 miles.
Compressed natural gas (CNG)
trucks must add multiple tanks,
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
Jordan, Knauff & Company is a knowledgeable and

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which increase the vehicles

weight and cost to attain the
same range as an LNG truck.
PressureLNG systems operate at lower pressure than CNG
[25 to 200 pounds per square
inch (psi) for LNG versus 3,600
psi for CNG].
StorageAs much as 2.5 times
more LNG can be stored in the
same space as conventional
CNG systems, increasing fuel
eiciencies and range.
HorsepowerLNG ofers
engines that are more than 400
horsepower.
Fuel economyLNG provides
better fuel economy. CNG is
historically 12 to 18 percent
less eicient.
WeightLNG is denser than

CNG, so more fuel can be stored
in smaller, lighter tanks that
increase eiciencies.
Fueling speedLNG fuels as
fast as diesel, at 40 gallons per
minute. CNG slow i ll takes 6
to 8 hours and fast i ll takes 30
to 45 minutes. In addition, only
half of the tank can be i lled
because of heat and pressure
buildup. If a leet operates more
than one shift, CNG is not a
viable fuel because the vehicles
will take too long to fuel.
Design Features of Pumps

Used in LNG Applications
Pumps used in LNG service are
integrally mounted on the same
shaft as the motor, which is
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112
submerged without coupling or

mechanical seals in the LNG liquid.
For a retractable in-tank application,
the pumps can be installed inside
the LNG storage tanks in vertical
pump columns with foot valves at
the bottom. h is removes the possibility of tank leakage because of
piping or other external problems.
he pump retraction system permits
the unit to be safely removed from
an operational tank without venting
gas vapor to the atmosphere.
By enclosing the entire unit
within a suction vessel built to an
appropriate pressure vessel code,
such as American Society of Mechanical Engineers Standard VIII,
the system becomes safe and simple.
he pump is factory aligned. It has
no couplings and no auxiliary piping
for seal purge, bearing cooling or
lubrication. h is makes it a lightweight, uncomplicated installation.
Key factors to consider for LNG
application pumps are:
Lubrication and cooling systems
hrust equalizing mechanism
Bearing coniguration
Junction box assembly and electrical penetration
Cryodynamic inducer design
Vibration monitoring system
By replacing the traditional diesel engine of one

18-wheeler with an LNG engine, its carbon
footprint reduction is equivalent to removing
324 automobiles from the road.
do not decompose or deteriorate

done to achieve bubble-tight zero
during a plant ire. he edge of the
leakage when closing a valve. Afmetal seat retainer preloaded by the
ter machining a seat to achieve
seat spring comes into contact with
mirror inish the seat is lapped
the ball (in a ball valve) to shut of
on the lapping machine.
the line luid to minimize internal
Stem binding prevention
leakage through the valve bore. he
h is is achieved by having a back
seat retainer also compresses. he
seat in PTFE + PFA (form of luolexible graphite retainer packing
ropolymer) construction bush.
prevents luid leakage between the
Low emission type packing
valve body and the seat retainer.
h is helps avoid compression
A bidirectional low sealing
creep stress thats caused while
mechanism is employed so that
packing stem with packing.
each of the upstream and down Designhe design needs to
stream seats of the valve adequately
accommodate the prevention of
contacts the ball with a seat spring.
abnormal pressure within the
Line pressure further maintains this
cavity. It should also be designed
contact method. he cavity pressure
to have little to no pressure loss
relief is designed to avoid trapped
and be ire-safe.
volatile liquid releasing into the
downstream low.
Gobind Khiani is a professional
Key factors to consider for valves
engineer with Fluor Canada Ltd. He
in LNG applications are:
has been in the energy and power
Extension bonnethe
business for more than 18 years
thermal conduction and heat
Design Features of Valves
and has worked in three countries
transmission from the low
Used in LNG Applications
(the U.K., United Arab Emirates and
temperature
l
uid
should
be
Valves used in LNG service are
Canada) with more than 10 years in
suppressed to a minimum while
designed with an extended bonnet to
the Western Canadian oil and gas
a cooling efect is provided. he
avoid freezing the packing at operating
industry based in Calgary, Alberta.
packing
is
not
exposed
to
the
low
temperatures. his allows operations
temperature
liquid,
and
a
secure
He graduated from the University
to cycle valves as required. Valves
seal is achieved.
of Poona in India and completed
manufactured for cryogenic applicahis masters in materials and metions should comply with type tested to Surface hardening treatmentTreatment with stellite
chanical engineering from Schulich
British Standard 6364 or an equivaalloy is recommended for better
School of Engineering at the
lent standard. Nonmetallic materials
performance.
University of Calgary, Alberta. He is
should be restricted to polytetraluoro Cavity pressure reliefh is
a registered professional engineer
ethylene (PTFE) and graphite.
feature should be included.
in the provinces of Alberta and SasFire-safe design to prevent
katchewan. Khiani can be reached
internal leakage is achieved by us Seat lappingSeat lapping is
at gobindkhiani@gmail.com.
ing resilient sealing materials that
113
114
Dewatering Pumps Handle Sand Slurries

in Post-Hurricane Recovery
Reconstruction and infrastructure upgrades require pumps made from durable materials.
By Mike Bjorkman
BJM Pumps
hen dealing with a

construction site that
is underwater or where
the water table is just above sea
level, contractors must ensure
that the excavation stays dry and
safe for workers. h is can be even
more challenging in locations with
conditions afected by water depth
and complications like silt and
sand.
Additionally, these diicult conditions may vary during seasonal
weather or with the tides. Contractors need to investigate historical
data and monitor luctuations in
water levels and speeds of low to
decrease the risks for workers and
ensure the success of the project.
he contractor must decide
what pumping equipment to use
based on the hydraulic conditions.
Jobsite conditionssuch as low
required to mitigate water seepage,
depth of a cofer dam and solids
contentinluence this decision.
he contractor usually chooses
between self-priming centrifugal
pumps or submersible pumps.
Self-Priming
Centrifugal Pumps
One weakness of end-suction
centrifugal pumps is their poor
performance when the liquid is
below the pump centerline. Liquid
must be delivered to the pump
so the process can begin. Air on
the suction side of the pump (the
piping and pump casing) needs to
be completely evacuated. If any

air remains in a centrifugal pump,
the pump becomes air bound and
incapable of functioning.
he self-priming centrifugal
pump, a specialized end-suction
design, creates a vacuum at the
impeller eye to continuously
remove air from the suction line.
he pump cannot compress the
air during the priming phase, so
the air must be allowed to escape
through the discharge. As air is
removed, atmospheric pressure
forces water through the suction
piping to the pump, allowing the
pump to operate.
h is self-priming process occurs
automatically once the pump is
started with the initial quantity

of liquid. Sand or solids in the
pumped liquid can complicate the
priming process. he practical
suction lift limit for self-priming
pumps is about 8 meters (26 feet)
of liquid under ideal conditions.
Self-priming centrifugal pumps
have disadvantages. Any small
vacuum leaksuch as sealing
areas around connectors in the
suction line or pump sealscan
prevent the unit from priming.
he pump will continuously
pull air from the leak instead of
the air in the suction line, which
keeps the priming cycle from being
completed. hese leaks are a common cause of priming failure. hey
Rebuilding and damage repair after a hurricane or major storm can take years of hard work
and millions of dollars to complete. (Article images courtesy of BJM Pumps.)
115
A storm surge attacks a seawall that protects a coastal city.
can be very small or invisible to the

naked eye but still prevent priming.
he diameter and length of the
suction hose or pipe can also afect
the priming cycles length of time
because of the volume of air that
must be evacuated during pump
priming. h is extended priming
time can also add heat to the liquid,
which further extends prime time.
Self-priming pumps need to be
as close as possible to the water
source. A location directly above
the cofer dam with few restrictions
reduces friction. h is can present
problems, depending on the excavation location.
Once the pump is primed and
moving luid, it will require adequate net positive suction head
(NPSH) to continue pumping without suction limitations.
Without suicient NPSH, a selfpriming centrifugal pump can ex-
perience cavitation and lose prime.

Lifts through long suction lines,
especially lines containing obstructions, can be plagued by cavitation
problems that cause unacceptable
noise levels and possible equipment
damage.
If a self-priming pump must lift
water 15 feet or more from the
source to the pumps suction, the
pump capacity could be decreased
signiicantly.
Most self-priming centrifugal
pumps in remote applications
have engine drives. hese drives
can present their own operational
issuessuch as maintaining fuel
levels for long run times, the engine oil condition and other prime
mover maintenance issues.
Submersible Pumps
Submersible pumps ofer many
operational and application advan-
tages. hese pumps are submerged

directly into the water for immediate use and unit cooling. h is
eliminates priming challenges and
extended prime times.
No worker intervention is required. he pump is fed without the
need for a suction line.
Submerged pumps are quiet. Cavitation is rare and occurs primarily
when the sump is too small for the
installed submersible pumps size.
hey are also lighter weight and
portable.
he versatility and low maintenance of submersible pumps make
them an ideal option for dewatering service. No regular maintenance is necessary.
Submersible pumps usually need
to be fully submerged. he water
around a submersible pump actually cools the motor.
116
Dewatering pumps keep construction sites dry in high water table areas.
Case Study:
Reconstructing Galveston
he sea level along the Gulf Coast
is rising faster than most places
on the globe. Galveston, Texas,
has experienced a 3-foot rise since
the disastrous lood of 1900 that
killed thousands of people.
One of the toughest jobs in
rebuilding the infrastructure of a
city that is just a few feet above sea
level is keeping water out of the
construction siteparticularly water that is laden with sand. Pumping a water/sand slurry is tough on
pumps, especially aluminum dewatering pumps. Boyer Construction

experienced this condition while
working in Galveston.
Galveston Island, located in
Southeast Texas, runs west to
east and is slightly tilted to the
northeast end, where the city of
Galveston is located. he north
side of the island opens up to a
protected harbor, and the southern
side faces the Gulf of Mexico.
Before the 1900 hurricane
which still holds the record of
the most deadly natural disaster
in American history with 6,000

deathsthe highest point in
Galveston was 9 feet above sea
level.
After the 1900 hurricane, a
17-foot high, 3-mile long seawall
was built to protect the city and
its people from other storms. he
entire city was raised to the edge
of the seawall. hen the island was
sloped down 8 feet above sea level
on the north side, so that water
rising over the seawall would drain
into the bay. h is engineering feat,
which took more than 10 years,
117
One of the toughest jobs in rebuilding the infrastructure of a city

that is just a few feet above sea level is keeping water out of the
construction site particularly water that is laden with sand.
was accomplished by pumping a

sand and seawater slurry under existing buildings to raise the island.
he seawater ran of, leaving the
sand and building up the island.
Since then, Galveston has experienced other hurricanes, but none
have had the same impact as the
great 1900 storm.
In September 2008, Hurricane
Ike devastated Galveston Island
along with the Bolivar Peninsula
and Gilchrist, Texas, with sustained winds of 110 miles per
hour, and a 22-foot storm surge.
Property damage was estimated at
$29.5 billion, and 135 people died
in the U.S. because of the storm.
he downtown area of Galveston
had 6 feet of standing water in the
aftermath.
As is always the case after a hurricane impacts a populated area,
the rebuilding and damage-repair
efort took years of hard work and
millions of dollars. One of the
companies that worked to rebuild
Galveston was Boyer Construction.
Boyer Construction is a 20 yearold construction and engineering
company specializing in civil,
electrical, mechanical and inland
marine construction projects.
Based in northwest Houston, more
than 250 engineers, master electricians and plumbers, equipment
specialists, and skilled fabricators,
have worked on rehabilitation and
infrastructure replacement projects
throughout southeast Texas.
Many of those projects, including those in Galveston, required

dewatering pumps on cofer dams
and large excavation jobs. hese
demanding services require continual operation, pumping water
that is often laden with silt and
sand. he combination of continual
cycling with salt and brackish water
minimizes the life of most dewatering pumps.
Looking for help in keeping their
dewatering pumps from wearing
and failing, Boyer Construction
contacted a pump specialist. he
expert recommended a series of
hard metal dewatering pumps.
he chosen pump ofered the
low range and high lifts required
for a broad spectrum of applications. From 2 horsepower with
lows up to 180 gallons per minute
(gpm) and heads up to 55 feet to 10
horsepower with lows up to 475
gpm and heads up to 117 feet, the
series of pumps is designed and
constructed for harsh services. he
impeller and wear plate are made
of abrasion resistant chrome iron,
while the agitator and volute are
constructed of hardened ductile
iron, making the pump appropriate for the salt/sand slurry and
solids-laden water Boyer Construction would encounter. he integral
agitator is designed to mix settled
solids with pump water to maintain
a steady solids concentration and
discharge volume.
Conclusion
Every jobsite has a speciic set of
pumping conditions. Selecting the
optimum pump for the service
takes the collaboration of a competent contractor and a hydraulic
specialist. he right choice of
equipment can make a substantial
impact on the timely completion of
the project and the end users bottom line results.
Mike Bjorkman is vice president of
BJM Corp. and has more than 30 years
of experience in the pump industry.
He serves as director of marketing
and IT for BJM Pumps, LLC, and All
Test Pro, LLC. Both companies are
subsidiaries of BJM Corp. He may be
reached at 860-399-5937.
BJM Pumps supplies electrical
submersible pumps to industrial
and municipal markets throughout
the U.S., Canada and South America.
For more information, visit www.
bjmpumps.com.
Boyer Contractors and Engineers
provide timely and cost-effective
solutions for the rehabilitation and replacement of infrastructure. For more
information, visit www.boyerinc.com.
Pumps of Houston is a distributor
of water and wastewater pumping
equipment that provides customerdriven solutions. For more information, visit www.pumpsofhouston.com.
118
PRODUCT PIPELINE
Vibration Analyzer
Portable Gas Detector
SPM Instrument Inc.

he Leonova Emerald is a compact,
powerful vibration analyzer in a
carbon iber reinforced casing for
the harshest environments. Fast
Fourier transform vibrations plus
shock pulse for bearing analysis,
infrared temperature, laster tachometer, an electronic
stethoscope, voice recording and user friendly software
are ofered with this monitoring instrument.
Circle 201 on card or visit psfreeinfo.com
Gas Clip Technologies Inc.

he Multi Gas Clip (MGC) Pump
portable multi-gas detector has an
internal pump that can run for a work
week without a charge. Low-power
photometric technology allows the
MGC Pump-IR to run ive days without
having to recharge the battery and
only requires calibration in six-month
intervals.
Reverse Osmosis System
Carbon Dioxide Detector
KSB
he SALINO Pressure
Center combined four
main components
into a single, compact
reverse osmosis system:
a high-pressure pump,
an energy recovery
device, a booster pump and an electric motor. h is fourin-one technology and its space-saving design make the
SALINO Pressure Center ideal for decentralized use in
small- and medium-sized containerized systems.
Dwyer Instruments Inc.

he new Series CDTA
communicating detector
combines carbon dioxide,
humidity, temperature,
occupancy override and
temperature set point
measurements in one
compact device. Carbon dioxide measurements are taken
using Dwyers Single-Beam, Dual-Wavelength NonDispersive Infrared sensor. Humidity is measured using
a capacitive polymer sensor, and the temperature is
recorded by a solid state band gap sensor.
Plunger Pump
Circle 205 on card or visit

psfreeinfo.com
Control Valve
CAT Pumps
he company engineers
high-pressure triplex
pumps that feature
lubricated and cooled
seals for maximum
service. Concentric, highdensity, polished, solid
ceramic plungers provide
a true wear surface that
extends seal life. he 316
stainless steel manifolds
are designed for strength
and corrosion resistance.
Singer Valve
Single rolling diaphragm (SRD)
technology has been added
to the 106/206 PGM Valve
Series. he 106/206 PGM Series
Control Valves are designed for
particularly sensitive applications
or situations in which the
valves are diicult to access
and maintain. hey provide an
integral back-up control and the
ability to signal should the desired function move oflimits. hey can also provide an independent override.
Butterfly Valve
Hayward Flow Control
he patent-pending BYV Series Butterly Valve incorporates advanced thermoplastic design and
construction for butterly valves. Available in multiple thermoplastic materials and sizes from 2
to 12 inches/DN50-300, the BYV Series has a robust, one-piece body construction and is lighter
weight than metal valves of equal size.
Aug us t 2 014 | Pum ps & S yst e m s
119
Cooling Water Pump
Complete Service and Repair of

Electric Motors through 19,000
Horsepower and 13,800 volts.
Large Motor Repair
Sulzer Pumps Ltd.

he cooling water pump (CWP)
range type SJT/SJM are
engineered-to-order, singlestage, mixed-low vertical pumps
with semi-open impellers,
available in sizes starting from
750 millimeters (30 inches) up
to 1,800 millimeters (72 inches)
nominal impeller diameter and
for speciic speeds (nq) between
90 to 155 (NS 4,639 to 7,990).
hey are mainly designed as
cooling water pumps for power
applications but can also be used
in the water market and other
markets.
High Voltage Testing

12 diameter VPI system
Large Ovens & Cranes
Motor Storage and
Management
Rewinding thru 13,800V
Inman Electric motors has been a leader in innovative electrical apparatus
service since 1967. Our 70,000 sq. ft. service shop features state-of-the-art
production and testing equipment to provide our customers with the highest
quality of repaired electric motors. We offer complete sales, service and
repair of electric motors through 19,000 horsepower.
Call Inman Electric Motors today!
Phone: (815) 223-2288

FAX: (815) 223-7108

314 Civic Road, La Salle, IL 61301
www.inmanelectric.com
Gauge Protection
Ashcroft
he company ofers a protective
rubber boot for lower connected
types 1000, 1005, 1005P, 1005S,
1005P-XUL and 1005M-XRG
commercial pressure gauges. In
addition to the patented shockresistant Power-Flex movement,
the boot provides added
protection if the gauge is struck
while installed or dropped during
portable use.

120
PRODUCT PIPELINE
Metering Pump
Circle 214 on card or

visit psfreeinfo.com
Cake Pump
White Knight Fluid Handling Inc.
he PEM050 electronic metering pump
was released for chemical replenishing,
blending, dosing and spiking
applications. he PEM050 electronic,
stepper-controlled metering pumps
dispense up to 50 milliliters of highpurity chemical with 0.01 percent
repeatability at high pressures (60 to
80 psi). hey feature PTFE luid paths
and fully supported rolling diaphragms
to maximize chemical compatibility
and discharge pressure capabilities.
Moyno Inc.
he EZstrip Cake Pump
features a specially
designed feed chamber that
can easily be disconnected
allowing access to the
rotating assembly. he
rotor can be separated from
the conveyor allowing for the removal of the rotor and
stator all within its own assembled length. With quick
and easy disassembly, maintenance time is reduced by
more than 93 percent for signiicant cost savings.
Hydraulic Axial-Piston Pump

Bosch Rexroth
he new A15VSO hydraulic axial-piston pump combines lower noise emissions with
improved eiciency. It can meet pressure requirements up to 420 bars and recover
potential energy during pump/motor operation. Equipped with a universal through
drive, the A15VSO integrates into the Rexroth line of products and simpliies the process
of combining diferent pumps.
REASONS
TOP
5
1.
2.
3.
4.
5.
Why You Cant Miss

G IL 2014: S IL ICON VAL L EY
The Global Community of Growth, Innovation & Leadership
GIL 2014 Keynotes Include:
September 15 -17, 2014

The Fairmont, San Jose, CA
Frost & Sullivan Executive Events Are Over 80% Interactive

The Convergence of Industry Leaders All In One Place
Top Speakers Sharing Thought Leadership
The Daily Networking and Team Building Events
Location...Silicon Valley is one of the world's busiest hubs,
and the capital of this high-tech mecca is San Jose
Pumps & Systems magazine subscribers

receive $500 Off through August 31, 2014
Use code pumpsys500 at checkout.
Joseph Bradley
Managing Director, Internet
of Everything Practice
Cisco Consulting
Services
For more information or to register, go to:
growthinnovationleadership.com
Ingrid Vanderveldt
Entrepreneur-in-Residence
Dell

121
Solar Roof Pump
Mechanical Seal Primary Rings
Roof Sentinel
Solar Roof Pump XD was designed
as an auxiliary pump for older
buildings that have standing
water. It is the irst auxiliary
solar roof pump on the market
with patent-pending smart chip
technology and cold weather
protection. he Roof Sentinels over-sized 20-watt solar
panel uses the sun to power its 400-gph pump. It has a
battery back-up system that can pump water up to 30
days without any sunlight.
Metallized Carbon
Corporation
he company announced
mechanical seal primary
rings for sealing refrigerants
and other low-viscosity
liquids. he Metcar Grade
M-44, antimony-impregnated, carbon graphite primary
seal rings self-polish allows the seal faces to run in the
required close proximity. he rings are ideal for use
with Freon refrigerants, liquid oxygen, liquid carbon
dioxide, propane, ethylene and acetone.
Intelligent Monitoring
Waukesha Magnetic Bearings
he Automated Commissioning System is now available. he system allows a magnetic
bearing system to be commissioned into operation without the presence of an active
magnetic (AMB) specialist. Featuring computer-based automation, the Automated
Commissioning System is faster than hands-on commissioning procedures. he systems
computer automation delivers automatic collection and archiving of essential data, which
ensures reduced time required for planned maintenance.
ANSI/HI Standards by Subscription

Unlimited Access to Standards 24/7
ANSI/HI Standards by Subscription are
available in the following eight packages:
Rotodynamic (Centrifugal)
Rotodynamic (Vertical)
Rotodynamic (Centrifugal & Vertical)
Positive Displacement
Rotodynamic (Centrifugal) & Positive Displacement
Rotodynamic (Vertical) & Positive Displacement
Complete Set: Online
Complete Set: Hardcopy & Online
Order the web-based

subscription package for
your application now at:
eStore.Pumps.org/subscriptions

122
PRODUCT PIPELINE
Diaphragm Pump

psfreeinfo.com
Dewatering Pump
All-Flo Pump Company
he new High Purity PTFE air
diaphragm pump operates at a
maximum temperature of 248
F (120 C) and is available in
six sizes from inch through
2 inches. his pump includes a
single-piece PTFE diaphragm,
integrated vibration pads and a
housing machined from a solid
PTFE block. he High Purity
PTFE pumps are available with
diferent connection ports.
Atlas Copco Portable

Energy
he company announced an
expansion of its dewatering
pump solutions with the
introduction of a new range
of diesel-driven portable
pumps. he 4-, 6- and 8-inch
dry-prime unitsPAS 4, PAS 6 and PAS 8are best
suited for transporting or lifting water with abrasive
solids in suspension. he PAS 4, PAS 6 and PAS 8 have
an operating low range of 50 to 600 cubic meters per
hour with a maximum head of up to 37 meters. heir
solids-handling capacity reaches up to 76 millimeters.
Electric Motor
Ball Valve
Baldor Electric
Company
Part of a new line,
the Large AC-GPM
induction motor, is
available up to 1,500
horsepower (HP).
Large AC-GPM motors
are available in stock
ratings of 250 to 1,000 HP, 2,300/4,000 volt, totally
enclosed fan cooled (TEFC), foot-mounted designs.
Custom motors are available in 250 to 1,500 HP; 460,
575, 2300/400 volt; TEFC foot-mounted designs.
Val-Matic
QuadroSphere Trunnion Ball
Valve handles ly ash water/slurry,
river water, pump isolation,
crude oil, low steam pressure and
natural gas lines. he multiple
low paths through the valve and
the contoured recessed surfaces
of the ball provide self-lushing
to prevent clogging by avoiding
high scale and solids build up.
he abrasion-resistant ball design is ideal for severe
applications typical of the power industry.
Air Quality Monitor

psfreeinfo.com
Electrical Tester
E Instruments
he AQ Comfort is made for
the HVAC professional. he
all-in-one instruments provides
the latest in indoor air quality
monitoring and real-time
data logging for IAQ analysis
in homes, schools, oices
and more. he AQ Comfort
model measures carbon
dioxide, temperature, percent
RH, dew point and wet bulb.
he magnetic rubber boot is
included. he instrument is
designed and made in the U.S.
Milwaukee Tool
he company ofers two new auto
voltage/continuity testers. For
accurate troubleshooting, the new
units measure voltage, continuity
and resistance with great precision.
he Milwaukee units deliver
measurements down to the
decimal and display them on an
easy-to-read LCD screen. he units
automatically determine whether to
test for voltage or continuity and also
identify alternating-current or directcurrent voltage.
123
Hydronic Pump
Circle 222 on card or

visit psfreeinfo.com
Slurry Tanks
AquaMotion Inc.
A new three-speed hydronic pump
(AM10) is designed to provide a more
energy eicient and less expensive
circulator. he rugged three-speed
AM10 circulator is ideal to replace
all circulators up to 26 gallons
per minute. he four-bolt lange
for mounting in-line or 90-degree
rotation capability make the AM10
ideal for replacement service pumps
in most installations.
Sodimate Inc.
heir custom-fabricated
slurry tanks come equipped
with a mixer, waterboard
(with solenoid valves and low
meters), level control system,
and all connections necessary
for slurry pumping and draining. Typical fabrication
materials include high-density polyethylene (HDPE),
stainless steel or iber glass, and volume can range from
130 to 750 gallons.
To have a product considered for Product Pipeline, please send the information to Michael Lambert, mlambert@cahabamedia.com.
Advertisers
Advertiser Name
Page
RS#
A. W. Chesterton Company . . . . . . . . . . . . . . 14
ABZ, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
ADIPEC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Advanced Engineered Pump, Inc. . . . . . . . .127
ALMATEC, Part of Pump Solutions Group 18
Badger Meter, Inc. . . . . . . . . . . . . . . . . . . . . . .39
Bal Seal Engineering Inc. . . . . . . . . . . . . . . .124
Baldor Electric Company . . . . . . . . . . . . . . . .25
BaseTek, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . .93
BJM Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
BLACOH Fluid Control, Inc.. . . . . . . . . . . . . .95
Blue-White Industries . . . . . . . . . . . . . . . . . . .11
Borets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Burns Dewatering Services, Inc. . . . . . . . . .127
Carbide Derivative Technologies, Inc. . . . .124
Carver Pump Company . . . . . . . . . . . . . . . . . .37
Comercializadora FEOC S.A. de C.V . . . . . .109
Conhagen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Continental Pump Company . . . . . . . . . . . .124
Dan Bolen & Associates, LLC . . . . . . . . . . . .124
Dickow Pump Company . . . . . . . . . . . . . . . . .55
DSI Dynamatic . . . . . . . . . . . . . . . . . . . . . . . . .13
Environmental Gasket Co., Ltd. . . . . . . . . . .12
EnviroPump and Seal Inc.. . . . . . . . . . . . . . .125
FCX/Pump Pros . . . . . . . . . . . . . . . . . . . . . . . .35
Flowrox Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . .38
FLSmidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
FluxDrive Incorporated . . . . . . . . . . . . . . . . .81
Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . . .120
Fullo Specialties Co. . . . . . . . . . . . . . . . . . . .119
Garlock Sealing Technologies . . . . . . . . . . . BC
Godwin, a Xylem brand . . . . . . . . . . . . . . . . . . 52
GPM USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Graphite Metallizing Corporation . . . . . . .121
Greene Tweed & Company . . . . . . . . . . . . . . . 17
128
300
106
301
129
103
302
104
162
163
173
126
105
303
304
131
179
132
305
306
133
134
135
307
125
136
164
124
161
165
109
137
138
166
110
Advertiser Name
Page
RS#
Highland Foundry, Ltd.. . . . . . . . . . . . . . . . . .31

Hoosier Pattern . . . . . . . . . . . . . . . . . . . . . . . . 16
Houston Dynamic Service, Inc. . . . . . . . . . .125
Hydraulic Institute . . . . . . . . . . . . . . . . . . . .121
Hydro, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC
Ingersoll Rand/ARO. . . . . . . . . . . . . . . . . . . . .88
Inman Electric Motors, Inc. . . . . . . . . . . . . .119
Jordan, Knauf & Company . . . . . . . . . . . . .111
KTR Corporation . . . . . . . . . . . . . . . . . . . . . . .23
Load Controls, Inc.. . . . . . . . . . . . . . . . . . . . . . 24
Load Controls, Inc.. . . . . . . . . . . . . . . . . . . . .125
LobePro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
LUDECA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .75
LUDECA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .77
Maag Automatik, Inc. . . . . . . . . . . . . . . . . . . .99
Magnatex Pumps, Inc.. . . . . . . . . . . . . . . . . .109
Master Bond Inc. . . . . . . . . . . . . . . . . . . . . . .124
Meltric Corporation. . . . . . . . . . . . . . . . . . . .125
Mouvex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Murphy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
National Pump Company . . . . . . . . . . . . . . . .67
NETZSCH Group . . . . . . . . . . . . . . . . . . . . . . .27
NOC Ningbo Ocean Fine Ceramic
Technology Co., Ltd.. . . . . . . . . . . . . . . . .126
NSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Orion Engineered Seals, LLC . . . . . . . . . . . . .72
Pinnacle Flo, Inc. . . . . . . . . . . . . . . . . . . . . . . .87
Pinnacle Flo, Inc. . . . . . . . . . . . . . . . . . . . . . .127
Pioneer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pump Solutions Group . . . . . . . . . . . . . . . . . .85
PumpWorks 610 . . . . . . . . . . . . . . . . . . . . . . . .44
R+W America. . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Revere Controls . . . . . . . . . . . . . . . . . . . . . . .111
Rogers Equipment Sales, Inc.. . . . . . . . . . . . .70
Ruhrpumpen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Scalewatcher . . . . . . . . . . . . . . . . . . . . . . . . . .125
139
140
308
174
100
141
167
175
111
143
309
325
144
145
176
180
310
311
146
108
147
148
312
149
168
172
324
113
169
130
150
178
170
112
313
Advertiser Name
Page
RS#
Scenic Precise Element Inc. . . . . . . . . . . . . .126

Schaeler.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Schenck Trebel Corp. . . . . . . . . . . . . . . . . . . . .48
Schneider Electric . . . . . . . . . . . . . . . . . . . . . .53
seepex, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SEPCO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
SEPCO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
SERO Pump Systems, Inc.. . . . . . . . . . . . . . .126
Sims Pump Co. . . . . . . . . . . . . . . . . . . . . . . . . .65
Sims Pump Co. . . . . . . . . . . . . . . . . . . . . . . . .127
Skinner Power Systems, LLC . . . . . . . . . . . . .32
Solcon USA LLC. . . . . . . . . . . . . . . . . . . . . . . . .71
St. Marys Foundry . . . . . . . . . . . . . . . . . . . . .126
Standard Alloys . . . . . . . . . . . . . . . . . . . . . . . .63
Sulzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Summit Industrial Products . . . . . . . . . . . . .34
Summit Pump, Inc. . . . . . . . . . . . . . . . . . . . .126
Teikoku USA, Inc. . . . . . . . . . . . . . . . . . . . . . . .90
Titan Manufacturing, Inc. . . . . . . . . . . . . . . .99
Trachte, USA . . . . . . . . . . . . . . . . . . . . . . . . . .127
Tuf-Lok International . . . . . . . . . . . . . . . . . .127
United Rentals . . . . . . . . . . . . . . . . . . . . . . . . .33
Varisco USA Inc. . . . . . . . . . . . . . . . . . . . . . . .127
Vaughan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IBC
Vertilo Pump Company . . . . . . . . . . . . . . . .127
Waukesha Bearings . . . . . . . . . . . . . . . . . . . . .21
Weatherford . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WEFTEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
WEG Electric Corp . . . . . . . . . . . . . . . . . . . . . . . 3
WEG Electric Corp . . . . . . . . . . . . . . . . . . . . . .78
Wilden . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Yaskawa America, Inc . . . . . . . . . . . . . . . . . . .49
Zoeller Company. . . . . . . . . . . . . . . . . . . . . . . .22
314
114
151
115
152
153
315
316
116
317
154
171
318
155
101
156
319
159
177
320
321
117
322
118
323
142
119
120
121
160
157
123
158
* he Index of Advertisers is furnished as a courtesy, and

no responsibility is assumed for incorrect information.
124

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345 Lincoln St.

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Wear plates and housing

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126

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Augus t 2 014 | Pum ps & S yst e m s
127
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www.pump-zone.com/pumps-systems-tour

128
PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

By Jordan, Knauff & Company
Figure 1. Stock indices from July 1, 2013, to June 30, 2014
he Jordan, Knauf &

Company (JKC) Valve Stock
Index was up 18.5 percent
during the last 12 months, staying
close to the broader S&P 500 Index,
which was up 21.3 percent. he
JKC Pump Stock Index was up 34.9
percent for the same time period.1
he Institute for Supply
Managements Purchasing Managers
Index (PMI) was 55.3 percent in
June, a slight decrease of 0.1 percent
from May. he New Orders Index
increased 2 percent to 58.9 percent,
and the Production Index fell 1
percent to 60 percent.
he U.S. Commerce Department
reported that the gross domestic
product (GDP) declined by 2.9
percent during the irst quarter of
2014. his is a much larger decline
than previously estimated in May.
Signiicant declines in nonfarm
inventory investment and net
exports, as well as nonfederal
government spending, business
investment and housing investment,
contributed to the GDP decline. In
the fourth quarter of 2013, GDP
grew by 2.6 percent.
he U.S. Bureau of Labor
reported that total nonfarm payroll
employment increased by 288,000
in June, and the unemployment
rate decreased to 6.1 percent. Led by
growth in professional and business
services, retail trade, food and
beverage, and health

care, the job gains
were widespread.
he manufacturing
sector added 16,000
jobs in June with
all of the increase
occurring in the
durable goods area.
Employment gains in
April and May were
Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates.
29,000 higher than
he JKC Pump and Valve Stock Indices include a select list of publicly-traded companies involved in
the
pump and valve industries weighted by market capitalization.
previously reported.
During the past three
months, job growth has averaged
Reference
four years, the Gulf of Mexicos
1
he S&P Return
272,000 per month.
production share has declined from
igures are provided
U.S. crude oil production was an
27 percent to 17 percent.
by Capital IQ.
estimated 7.4 million barrels per day
On Wall Street, the Dow Jones
(bpd) in 2013, according to the U.S.
Industrial Average gained 0.7 percent
Energy Information Administration, for the month of June, while the S&P
Jordan, Knauf
& Company is an
and is forecast to grow to 8.4 million 500 Index gained 1.9 percent and
investment bank based
bpd this year and 9.3 million bpd in
the NASDAQ Composite rose 3.9
in Chicago, Ill.,
2015. Previously, the highest annual percent. Technology, media, inancial
that provides merger
average production was 9.6 million
and small-cap stocks all increased
and acquisition
bpd in 1970.
during the month. Investors were
advisory services to
the pump, valve and
Combined crude oil production
encouraged by the European Central
iltration industries.
from Texas and North Dakota
Banks stimulus measures to aid the
Please visit www.
reached 4 million barrels per day
Eurozones recovery and positive
jordanknauf.com for
in April and now accounts for
economic data in the U.S. For the
further information
on the irm. Jordan
48 percent of the countrys oil
irst half of 2014, the Dow, S&P 500
Knauf & Company is a
production. In April 2010, these
and NASDAQ were all up with gains
member of FINRA.
two states produced only 26 percent
of 1.5 percent, 6.1 percent and 5.5
of U.S. production. During the
percent, respectively, with airline,
past three years, Texas has more
pharmaceutical and utilities stocks
than doubled its production, while
gaining the most.
These materials were
prepared for informational
North Dakota has nearly tripled
purposes from sources that
are believed to be reliable
its production. During the past
Figure 2. U.S. energy consumption and rig counts
Source: U.S. Energy Information Administration and Baker Hughes Inc.
Figure 3. U.S. PMI index and manufacturing shipments
Source: Institute for Supply Management Manufacturing Report on

Business and U.S. Census Bureau
but which could change

without notice. Jordan,
Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or completeness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
any investment offering or
deployment of capital.
Vaughans Rotamix System sets the standard for hydraulic mixing, providing the customer with
lower operating and maintenance costs, more efficient breakdown of solids and Vaughans
UNMATCHED RELIABILITY. Its perfect for digesters, sludge storage tanks, equalization basins
and other process or suspension type mixing applications.
- Over 1000 installations worldwide
- Optimizes solids contact with its unique dual rotational zone mixing pattern
- 10 Year Nozzle warranty
See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP
LIQUIDYNE seals
Secure pump performance
to protect your core business
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info.seals@ihcmerwede.com
als@ihcmerwede.com
/
/

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From the Editor

his month we introduce an exciting, fresh,

PRINT ADVERTISING TRAFFIC: Lisa Freeman

AUDIENCE DEVELOPMENT MANAGER:

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Motors | Automation | Energy | Transmission & Distribution | Coatings

WEG Rolled Steel Line

Features that make a difference:

rated for 60 Hz and 50 Hz @ 190-220/380-415 V

ventilation system for cooler operation

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box is rotatable in 90 degrees increments for easy installation

ingress protection is standard

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coded leads for easy installation

Please contact your authorized WEG distributor or go to weg.net/us for further

Transforming Energy into Solutions

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Smart Air Distribution Systems

73 SYSTEM SELECTION CRUCIAL

94 MOTORS & DRIVES

102 HI PUMP FAQS

20 By Joe Evans, Ph.D.

PUMP SYSTEM IMPROVEMENT

Driving down investment, energy

36 By Heinz P. Bloch, P.E.

76 REDUCER FITTINGS DECREASE

PIPE SIZE TO PREVENT FAILURE

Estimate Pump Installation Costs

By Ross Mahaffey, Aurecon

Cover photo courtesy of Colfax Fluid Handling

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Completion & Stimulation

SEALS & BEARINGS

42 CANNED MAGNETIC BEARINGS

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THE CHEMICAL CHALLENGES

Safely immerse motor compressors

Abrasive processing and wide

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Pump & System - August 2014

Pump & System - August 2014