Pump & System - October 2011

The Magazine for Pump Users Worldwide October 2011
pump-zone.com
The Magazine for Pump Users Worldwide
pump-zone.com
October 2011
OUR AGING INFRASTRUCTURE
Pumps in Water Handling Applications
WEFTEC Coverage
circle 100 on card or go to psfreeinfo.com
2 OCTOBER 2011 www.pump-zone.com PUMPS & SYSTEMS
Letter from the Editor
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Pumps & Systems, a member of the Cahaba Media Group, 1900 28th Avenue So., Suite 110, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the right to determine qualications. Annual
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is a member of the following organizations:
M
ost experts agree that Americas infra-
structure needs an upgrade. But
because most of it is buried under-
neath our roads and bridges and cannot be seen,
the questions remain, What needs to be xed?
and Who will pay for it?
Government data veries that more than
half of Americas pipelines were installed before
1970. hese pipelines move water, natural gas
and even hazardous liquids such as gasoline,
diesel and jet fuel. his is only a portion of what
needs to be examined and most certainly is in
need of critical overhaul.
Common wisdom tells us that this is a gov-
ernment issue, but in reality, the 2.5 million
miles of pipeline that move materials across the
U.S. is operated by more than 3,000 dierent
companies. Even with stimulus money invested
and more government funding on the way, the
debate continues over who owns the nancial
burden and who will pay to x the problems.
One thing is certain. When it comes to
addressing the needs of our critical infrastruc-
ture, America is behind the curve. Developing
countries such as China are building new inter-
state highways, airports, high-speed train lines
and state-of-the-art telecommunication net-
works.
On page 25, Pumps & Systems Editorial
Advisory Board member Kerry Baskins, who
leads the water industry business for Grundfos
Pumps USA, examines in-depth the ongoing
issue of Our Aging Infrastructure. For most
Americans, throughout our entire lives, getting
clean water has been as simple as turning on
the tap. If there is a catastrophic failure of our
infrastructure, this will no longer be the case.
Baskins addresses these and other issues, includ-
ing the government and private funding needed
for these upgrades.
It is not an accident that this is the issue
of Pumps & Systems that we take to WEFTEC,
where infrastructure issues are always a topic of
conversation. Come visit us at Booth 1882 in
the South Hall, and let us know what you think
about Americas aging infrastructure, and tell us
what your company is doing about it.
In the meantime, read the informative
articles in our cover series on Pumps in Water
Handling Applications which begins on page
29.
Best Regards,
Michelle Segrest
Editor
msegrest@pump-zone.com
PUBLISHER
Walter B. Evans, Jr.
ASSOCIATE PUBLISHER
VP-SALES
George Lake
glake@pump-zone.com
205-345-0477
EDITOR/VP-EDITORIAL
Michelle Segrest
msegrest@pump-zone.com
205-314-8279
MANAGING EDITOR
Lori K. Ditoro
lditoro@cahabamedia.com
205-314-8269
CONTRIBUTING EDITORS
Laurel Donoho
Joe Evans, Ph.D.
Terry Henshaw
Dr. Lev Nelik, PE, APICS
SENIOR ART DIRECTOR
Greg Ragsdale
PRODUCTION MANAGER
Lisa Freeman
lfreeman@pump-zone.com
205-212-9402
CIRCULATION
Jeff Heine
jheine@cds1976.com
630-739-0900
CIRCULATION & MARKETING
MANAGER
Jaime DeArman
jdearman@cahabamedia.com
WEB EDITOR
Jane Longshore
jlongshore@cahabamedia.com
ACCOUNT EXECUTIVES
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
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vince@pump-zone.com
205-561-2601
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Phone: 205-345-0477 or 205-561-2600

Editorial Advisory Board
Thomas L. Angle, PE, Vice President Engineering,
Hidrostal AG
Robert K. Asdal, Executive Director, Hydraulic
Institute
Bryan S. Barrington, Machinery Engineer, Lyondell
Chemical Co.
Kerry Baskins, Vice President, Grundfos Pumps
Corporation
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, ABS, & President, SWPA
John Carter, President, Warren Rupp, Inc.
Jack Creamer, Market Segment Manager, Schneider
Electric
David A. Doty, North American Sales Manager,
Moyno Industrial Pumps
Joe Evans, Customer & Employee Education,
PumpTech, Inc.
Ralph P. Gabriel, Chief EngineerGlobal, John
Crane
William E. Neis, PE, President, NorthEast Industrial
Sales
Dr. Lev Nelik, PE, Apics, President, Pumping
Machinery, LLC
Henry Peck, President, Geiger Pumps & Equipment/
Smith-Koch, Inc.
Mike Pemberton, Manager, ITT Performance
Services
Bruce Stratton, Product Manager, KLOZURE
,
Garlock Sealing Technologies
Kirk Wilson, Vice President/General Manager,
Integrated Solutions Group, & Vice President
Marketing, Engineering & Technology,
Flowserve Corporation
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In 2009, this approach began with the introduction of the
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SPECIAL SECTION:
VALVES
p
Ball Valve Replacement Increases
Savings
Diane Meyer, Val-Matic Valve & Mfg. Corp.
Rubber-seated ball valve replacement saves energy, money and downtime.
p
Valve Helps Meet Fire Flow Demands
Mark Magda, Singer Valve & J. Keith Malone, Millcreek
Township
Millcreek Township connects to neighboring township with a pressure-
reducing valve with integral backup.
p
Our Aging Infrastructure
Kerry Baskins, Grundfos Pump USA
Water shortages, failing infrastructure, broke governments,
a crumbling municipal bond market and the need for high
subsidies. While the global pump community tools up to
participate in the business of water, the question remains: From where will the
funding come?
COVER SERIES: PUMPS IN WATER
HANDLING APPLICATIONS
p
Progressive Cavity Cake Pumps
in Wastewater Treatment
Daniel Lakovic, seepex, Inc.
Replacing conveyors with pumps improves efciency
and sanitation in an Ohio wastewater treatment plant.
p
Pumping Grit
Graham Hicks, Hayward Gordon Ltd.
Recessed impeller pumps are a solution for grit transfer in wastewater and
water treatment applications.
p
Motors, Drives Improve High-Rise Condo Efficiency
Rick Kirkpatrick, Baldor ElectricA Member of the ABB Group
Signicant energy and money savings are realized when using variable speed
motors controlled with drives.
p
Solving Pump Inlet Problems
Gary L. Cornell, BLACOH Fluid Control, Inc.
Flow and pressure downstream are important, but inlet pump conditions also
require attention during design.
p
The New Wastewater
Robert Domkowski, ITT WWW USA Flygt Group
Modern trash causes big issues for wastewater collection systems.
p
Wastewater Treatment Facility Upgrade Features
CHP System
Alan Wells, P.E., Kleinfelder
Pittseld, Mass., wastewater treatment facility saves money and shrinks
environmental footprint.
p
Liquid Gold
Anand Mugundhu Gnanamoorthy & Laurel Donoho, Frost &
Sullivan
Pumps in the growing global desalination market
p
WEFTEC
Table of Contents
PRACTICE & OPERATIONS
p
VFDs Improve Motor & Pump Control
Christopher Jaszczolt, Yaskawa
VFDs replace mechanical devices and PLCs for lead-lag pump control
p
Smart Motor Management
John Burns & Jeff Woolfolk, Siemens Industry, Inc.
Data-driven visibility can help protect processes and motors
in key industrial applications.
p
Oil-less Vacuum Technology
Kirsten Petersen Stroud, Thompson Pump
Increased efciency, higher air handling and fast, automatic priming are
provided with new technology.
p
Gain Efficiency Via Volute Design
Concepts NREC
Simplifying the design and analysis of this complex component
p
Turbine Bearing Failure
Keith Schindler & Terry Auger, Toledo Rening
Oil quality assessment causes lubrication issues at a renery.
p
The Case of Action/Reaction
Dennis Rimmel, Sloan Electric
Energy efciency may not always mean total efciency.
p
Mechanical Pressure Measurement
David Gardellin, P.E. Onyx Valve Company
Pressure gauges are a versatile way to monitor pump operation.
p
Proper Alignment of Large Motors & Pumps
Reed Hamm, TECO-Westinghouse
A large utility company confronts alignment of a 5,000-horsepower motor.
DEPARTMENTS
Readers Respond. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Joe Evans, Ph.D.
Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 14
Lev Nelik, P&S Editorial Advisory Board
Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Tom ODonnell, Neptune Chemical Pump Company
Maintenance Minders. . . . . . . . . . . . . . . . . . . . . . . . . 66
John Kozel, Sims Pump Company
FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Product Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
P&S Market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
October 2011
Volume 19 Number 10
The Magazine for Pump Users Worldwide October 2011
pump-zone.com
The Magazine for Pump Users Worldwide
pump-zone.com
October 2011
OURAGINGINFRASTRUCTURE
Pumps in Water Handling Applications
WEFTEC Coverage
18
20
24
30
32
36
40
48
52
60
55
78
100
84
102
90
92
95
98
Hayward is a registered trademark of Hayward Industries, Inc. 2011 Hayward Industries, Inc.
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#5617
Readers Respond
Pump Ed 101,
November & December 2010
Editors note: In the November and
December 2010 issues, Joe Evans Pump
Ed 101 columns focused on a restoration
and coating project that was developed
and presented at WEFTEC 2010. At the
time, the project was not completed.
Now, it is complete and available on www.pump-zone.com.
Go to the Current Issue page for the link.
Sealing Sense, July 2011
In the [tool, under the Inputs/Outputs
sheet] 2) Cost of Capital (PV discount
rate):
What does this mean? Is this not the 100
percent cost of the initial seal purchase?
What is meant by PV discount rate, and
what is the 12 percent based on?

Wim Mourits, Project Manager
EagleBurgmann Netherlands BV
FSA responds:
he Cost of Capital is a nancial term that refers to the
interest rate that a company must pay to borrow the money
needed for a given project. If the company already has the funds
needed for the project and does not need to borrow that money,
then the Cost of Capital represents the income opportunity
lost when the funds are used for the project and not placed in
an alternateand presumably protableinvestment.
he project funds could be placed in an interest-bearing
account, but if used for the project, then that potential interest
will not be realized. he interest rate on borrowed money and
the opportunity lost interest rates are not necessarily the same.
In reality, an individual companys expected rate of return on
a passive capital investment will be lower than its expected
interest rate on borrowed money. However, we have used only
one number in the LCC Tool. For the project to be viable, it
must normally have a higher than the expected rate of return
of the same money on an alternative investment of equal risk.
his is a user-dened eld. It is used to calculate the proj-
ects Present Value over the projects life and is dened by the
user and is often proportional to the time value of money. he
default value for the tool is 12 percent and can be changed.
Dave Casucci, Engineering Manager Cranston
John Crane Inc.
Editors note: he updated LCC Tool is available at www.
uidsealing.com.
Readers Respond, August 2011
I am writing regarding the letter submitted by homas
J. Hill, PE that was published in the August 2011 edition. In
his letter he inadvertently triggered a pet
peeve of mine.
I have been in the engineering profes-
sion for more than 40 years, earning both a
Bachelors Degree (in Nuclear Engineering)
and a Masters Degree (in Mechanical
Engineering). Both of these degrees were
earned using a slide rule, since that was
the only tool available at the time. Our profes-
sors always stressed the subject of signicant digits.
In his letter Mr. Hill reported that he calculated the pump
head as approximately 109.0068 feet (emphasis added). he
use of the word approximately followed by a number reported
to four decimal places is a contradiction in terms. hat may
have been the number reported by Excel, but the inputs he
used were not accurate enough to yield a result to the fourth
decimal. Approximately 109 feet would have been a more
accurate reporting of the results when you consider the accu-
racy of the inputs that were provided. Too often, I see results
provided by young engineers who fail to realize that the accu-
racy of the results is limited by the accuracy of the inputs and
that just because the computer provides results with many dec-
imals that is not the number that should be used. We need to
remember basic engineering principles and respect the concept
of signicant digits.
Albert J. Ugelow, PE, PMP
Tom Hill responds:
As an engineer, I agree with Mr. Ugelow
that it is normally folly to provide four deci-
mal places on a reported value of pump head,
especially when the pump performance data
was totally fabricated, and it consisted entirely
of integer values. he use of four decimal
places on a reported pump head rise is even
less relevant when one considers that instrumentation would
likely be measuring pressure rather than head, and the accu-
racy of pressure measurements on pumps do not warrant the
use of four decimal places. However, the context of my letter
was more at comparing an approximate numerical solution
to an exact analytical solution, which is how mathematicians
frequently distinguish such problems based on their solution
method. When compared to the exact solution of an ana-
lytical problem, the result of an iterative numerical solution
is approximate, regardless of the number of decimal places
used for testing convergence.
For example, computer generated calculations of Pi going
out to 10,000 decimal places are approximate. However,
most engineers would be content to use only four decimal
places for Pi, and the results calculated using this could also be
called approximate.
In the future though, I will try to be more careful when
doing a cut-and-paste from Excel into a word doc, so as not to
report more decimal places than are justied.
P&S
Tom Hill
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P&S News
NEW HIRES & RECOGNITIONS
NIDEC MOTOR CORPORATION (ST. LOUIS, MO.) announced
that it has hired Ed Koepke as the companys new market
manager for water/wastewater, industrial pumping and oil
and gas markets. he new position is a direct result of the
growth of the company and demand for its 100-year-old
agship brand US Motors line of products.
Nidec Motor Corporation is a manufacturer of com-
mercial, industrial and appliance motors and controls.
www.nidec-motor.com
BENTLEY SYSTEMS (RIO DE JANEIRO, BRAZIL)
announced that
Geospatial World
has honored
Greg Bentley,
CEO of Bentley
Systems, with its
Lifetime Achieve-
ment Award at
the Latin Ameri-
can Geospatial
Forum. he award recognizes individuals for their outstand-
ing contributions to geospatial communities worldwide.
Bentley provides architects, engineers, geospatial pro-
fessionals, constructors and owner-operators with software
solutions for sustaining infrastructure. www.bentley.com
AROUND THE INDUSTRY
GODWIN PUMPS (BRIDGEPORT, N.J.) supports emergency
relief eorts
throughout the
East Coast after
Hurricane Irene.
Godwin Pumps
delivered in excess
of 350 Dri-Prime
pumps from
eight East Coast
branches in sup-
port of municipal,
industrial and
recreational ood
relief applications,
including control-
ling water levels
in Citizens Bank
Park, home of the
Philadelphia Phil-
lies. Godwin also
rented dozens of
portable diesel
generators.
Godwin Pumpsa direct, wholly-owned subsidiary of
ITT Corporationmaintains a eet of more than 6,000 por-
table rental pumps and 3,200 pieces of related equipment for
dewatering in construction, mining and quarrying; drinking
water supply; and wastewater bypasses in municipal, indus-
trial and environmental markets. www.godwinpumps.com
SERFILCO (CHICAGO, ILL.) announced that it was selected
by the producers of the television show Worlds Greatest!...
from How 2 Media to be featured on the popular television
series. SERFILCO was selected because it is an innovative
company that continues as a family-owned and operated
business. How 2 Media sent a lm crew to visit the companys
facilities in Chicago to get the story behind the business, and
to show the Worlds Greatest!... viewers why SERFILCO
was selected. he award winning program aired on national
cable channels and local networks across the country.
SERFILCO develops and manufactures ltration, liquid
handling and waste treatment equipment. www.serlco.com
SPX CORPORATION (CHARLOTTE, N.C.) announced that
it has entered into a denitive agreement with Clyde Blow-
ers Capital s.a r.l, SCF-VI Oshore L.P., Appleby Nominees
(Jersey) Limited, and certain members of CLYDEUNION
management to acquire CLYDEUNION Pumps.
SPX Corporation is a multi-industry manufacturer of
engineered products and technologies that serve customers
in infrastructure, process equipment and diagnostic tools for
electricity, processed foods and beverages and vehicle ser-
vices. www.spx.com
SEEPEX, INC. (ALEXANDRIA, VA.) will receive the Innova-
tive Technology Award from the Water Environment Fed-
eration (WEF), an international not-for-prot technical and
educational water quality organization. he award will be pre-
sented during a ceremony at the organizations 84th annual
technical exhibition and conference this fall in Los Angeles,
Calif. seepex is being recognized in the solids handling & dis-
posal category for its Smart Conveying Technology.
seepex develops, manufactures and sells progressive
cavity pumps, macerators and control systems.
www.seepex.com
HYDRO INC. (EDMONTON, CANADA)
announced the move of Hydro Scotford (a sub-
sidiary of Hydro Inc., a Chicago-based
corporation) to a newly constructed facility in the Canadian
province of Alberta. his modern 40,000-square-foot facility
equipment that Hydro Scotford uses for pump design, engi-
neering and manufacturing. he new service center has more
than 80-tons of crane capacity and a large training room for
pump users to study topics ranging from basic hydraulics to
vibration and troubleshooting.
Hydro provides pump aftermarket services.
www.hydroinc.com
Greg Bentley receives the Geospatial World
Lifetime Achievement Award.
Godwin pumps in Citizens Bank Park
home of the Philadelphia Phillies
PUMPS & SYSTEMS www.pump-zone.com OCTOBER 2011 9
THOMPSON PUMP AND MANUFACTURING CO., INC.,
(PORT ORANGE, FLA.) announced the appointment of Gajeske,
Inc., Best Line Equipment and Power Equipment Company as
regional sales, rental and service representatives for the hompson
Pump product portfolio in multiple territories across the U.S.
hompson Pump manufactures pumpsincluding wet-
prime trash pumps, dry-prime trash pumps with compres-
sor-assisted or vacuum-assisted prim-
ing systems, sound attenuated pumps,
hydraulic power units with submersible
pump ends, diaphragm pumps, rotary
wellpoint pumps and high pressure jet
pumps. www.thompsonpump.com
ABB (NEW BERLIN, WISC.) announced
that, by exceeding 2,500,000 hours
without a lost-time incident at both
its New Berlin campus and Fort Smith
Drives Center, the drives business of
ABB in the U.S. has proven that these
two key characteristics drive bottom
line performance. he quarter-billion
number sets a record at the campus and
is inclusive of the drives business unit,
along with six additional business units
located there.
ABB produces power and automa-
tion technologies that enable utility and
industry customers to improve their per-
formance while lowering environmental
impact. www.abb.com

VACON, INC., (MEQUON, WISC.)
announced that it entered a three-year
supply agreement with Bristol Com-
pressors International Inc., in Bristol,
Va. his agreement is be to design and
manufacture variable frequency drives
(VFDs) to control Bristol Compres-
sors Benchmark VStar variable speed
compressors.
Vacon develops, manufactures and
sells AC drives. www.vacon.com
SIEMENS INDUSTRY (HOUSTON,
TEXAS) announced a strategic partner-
ship with S&B Plant Services Ltd. to
support companies in the oil & gas,
energy, water and wastewater and
minerals industries. An agreement was
executed to result in an improved abil-
ity to meet market demand with a total
integrated solution based on Siemens
analytical products/services and S&Bs
eld construction/maintenance services. Siemens Industry, Inc.
is the U.S. a liate of Siemens global Industry Sector business,
oering solutions for industrial and infrastructure providers
with six divisions: Building Technologies, Industry Automa-
tion, Industry Solutions, Mobility, Drive Technologies and
Osram Sylvania. www.usa.siemens.com/Industry
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P&S News
UPCOMING EVENTS
SOUTH BY SOUTHWEST ECO
CONFERENCE
October 4 6
Hilton Austin / Austin, Texas
512-467-7979
www.sxsweco.com/attend
WATER ENVIRONMENT FEDERATION
TECHNICAL EXHIBITION AND
CONFERENCE (WEFTEC)
October 15 19
Los Angeles Convention Center
Los Angeles, Calif.
877-933-4734
www.weftec.org
SMRP ANNUAL CONFERENCE
October 17 20
Sheraton Greensboro at Four Seasons
Greensboro, N.C.
703-610-0257
www.smrp.org
CHEM SHOW
November 1 3
Javits Convention Center / New York, N.Y.
203-221-9232 / www.chemshow.com
NATIONAL GROUNDWATER
ASSOCIATION EXPO
November 29 December 2
Las Vegas Convention Center
Las Vegas, Nev.
800-551-7379
www.groundwaterexpo.com
POWER-GEN
December 13 15
Las Vegas, Nev.
918-831-9160
www.power-gen.com
AHR EXPO
January 23 January 25, 2012
McCormick Place Convention Center
Chicago, Ill.
203.221.9232
www.ahrexpo.com
WQA AQUATECH USA
March 6 9
Las Vegas, Nev.
630-505-0160
www.wqa.org
TEXAS WATER
April 10 13
San Antonio, Texas
512-251-8010 / www.texas-water.com
OFFSHORE TECHNOLOGY CONFERENCE
(OTC)
April 30 May 3
Reliant Park / Houston, Texas
972-952-9494 / www.otcnet.org
INTERPHEX
May 1 3
Jacob K. Javits Convention Center
New York, N.Y.
203-840-5897 / www.interphex.com
WINDPOWER CONFERENCE &
EXHIBITION
June 3 6
Georgia World Congress Center
Atlanta, Ga.
202-383-2500 / www.windpowerexpo.org
To have an event considered for Upcoming
Events, please send information to Lori Ditoro
at Pumps & Systems, P.O. Box 530067,
Birmingham, AL 35253, 205-314-8269,
lditoro@cahabamedia.com.
P&S
Dovers Pump Solution Group (PSG) is committed to
providing low life cycle cost for your industrial and
municipal water & wastewater treatment needs.
NEPTUNE chemical pumps ofer solutions for dos-
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the water quality event
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Fluid Technologies:
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GORE and design are trademarks of W. L. Gore & Associates. 2011 W. L. Gore & Associates.
I
f you work for an engineering rm, manufacturer or the
government, you probably have access to software that
assists with the design of pumping and piping systems.
Programs such as AutoCad, Solid Works and other computer
aided design (CAD) systems are indispensible when design-
ing mechanical equipment and packaged systems. Hydraulic
design programs such as Pipe-Flo and AFT Fathom are also
useful, especially for more complex pumping applications.
Many people are unable to take advantage of these tools
due to the licensing fee. Fortunately, free or nearly free ver-
sions are available, and some are provided by the companies
that sell them. hey are often a limited or less sophisticated
version but can still meet many design requirements.
I will briey review several with which I am familiar and
provide the Web links for further investigation. If you have
experience with these or others please send your comments to
Managing Editor Lori Ditoro (lditoro@cahabamedia.com).
CAD Programs
One of the newer programs to hit the Web is Google
Sketchup. It is a somewhat limited version of Sketchup Pro
and is available for free download. It has an intuitive interface
and oers amazing drawing features. he list of plug-ins and
add-ons grows daily and the library of 3D objects is exten-
sive. Visit http://sketchup.google.com for an overview.
Another that has received good reviews is progeCAD
2009 Smart. It is described as an AutoCad clone, and the
free version oers most of the features of the progeCAD Pro
version. It supports both 2D and 3D drawing and has more
than 11,000 pre-drawn blocks and symbols. If you have any
problems, you can join an online user forum. he only nega-
tive is that there have been no .DXF le (AutoCad compat-
ible) revisions since 2009. For more information and usage
restrictions visit http://www.progesoft.us/index.pl?id=3985 .
For more, visit the following links sites:
http://freecad.com/
http://www.freebyte.com/cad/cad.htm
http://www.cadazz.com/free-cad-software.htm
Hydraulic Design Programs
Engineered Software in Olympia, Wash., sells Pipe-Flo, a
popular piping system design program. It also hosts online
catalogs and provides pump selection software for more than
100 manufacturers in the U.S. and worldwide. he online
version does a simple design point search and allows for
the calculation of total dynamic head (TDH) at the design
point. Users can select pipe diameter, material, length and
ow rate plus elevations, ttings and valves.
Once all are selected, the TDH is calculated. his free
version models only a single piping element but it can meet
the needs of simple piping applications. Visit http://www.
eng-software.com/pml/default.aspx to see if your pump
manufacturers catalog is part of the online pump selection
system and download the program.
Some of the subscribing manufacturers oer a CD ver-
sion so performing the download is unnecessary. Hydromatic
Pumps oers it on its site. Visit http://www.hydromatic.
com/EngineeredResourcePage_ENG_SoftwareUpdates.aspx
to order the CD version of H2O Optimize 9.0.
EPANET, a public domain program from the EPA,
helps water utilities maintain and improve water quality and
distribution systems. It tracks the ow and pressure in simple
and complex systems and is not limited to a xed number
of pipes, branches and nodes. It uses the Hazen-Williams,
Darcy-Weisbach or Chez-Manning equations for head loss
calculations and includes minor losses for bends and ttings.
It models constant or variable speed pumps, many
valve types and storage tanks and will assist with pipe, pump
and valve placement and sizing. It employs a dynamic link
library (DLL) that allows users to customize it and runs on
Windows 95, 98, NT and XP. Several of my associates use
EPANET and give it a good grade. For more information,
visit http://www.epa.gov/nrmrl/wswrd/dw/epanet.html
Pump System Improvement Modeling (PSIM) was
developed by Applied Flow Technology (AFT) as a Pump
Systems Matter (Hydraulic Institute) tool. Built on AFT
Fathom, it is a well-accepted pipe ow analysis program.
PSIM models both centrifugal and positive displace-
ment pumpsincluding sizing, variable speed, viscosity cor-
rection, power calculations and energy usage. It also has the
ability to model dierent types of uids (other than water)
and can model piping networks (up to twelve pipe elements).
Visit http://www.aft.com/products/PSIM.php. Several indi-
viduals who have used PSIM, give it very good marks.
P&S
Joe Evans, Ph.D.
Free (and Nearly Free)
Modeling & Design Software
Joe Evans is responsible for customer and employee educa-
tion at PumpTech, Inc., a pumps and packaged systems
manufacturer and distributor with branches throughout the
Pacic 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.
Pump Ed 101
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T
his column presents a discussion between myself and
pump users regarding some of their questions, con-
cerns and preferences about materials of construc-
tion that they consider for their applications. Some of this
feedback comes from previous articles published in Pumps
& Systems.

Dear Dr. Nelik,
I enjoyed your recent article about using a specialty
material to help improve the e ciency and reliability of a
multistage pump. I was interested in your selection of the
Graphalloy material. I have used Vespel CR6100 to reduce
running clearances for e ciency gains and rotor stabil-
ity improvements. Do you have experience using Vespel?
If so, what comparisons can you make between this and
Graphalloy? When would you recommend one over the
other? Any experiences you can share would be greatly
appreciated.
Lee M. Posey
Lev Nelik responds:
A great multitude of materials can be used for pump
bushings, including metals (bronze, hardened steels), hard
coatings, non-metals (thermoplastics, thermosets, compos-
ites) and ceramics. All have benets and shortcomings, such
as resistance to temperature, thermal or mechanical shock,
machinability, galling resistance, dimensional stability, swell-
ing, chemical resistance, abrasive resistance and price.
It would be good to have a three-dimensional tabula-
tion listing these materials on one column (say, horizontal),
versus properties on the other (vertical), and application
(pumped uid) inside the table, for some sort of visual pick-
and-choose guide. I am not aware of such table.
In practice, it is di cult to select an all-around best
choice. he main reason is unfamiliarity of the end users with
the multiple products that exist and users being cautious
against over-zealous salesman trying to sell them a bushing
material for their application which may not be appropriate
for what they pump.
Pump manufacturers have a less biased approach to
this because they are willing to apply any material that the
end user asks for (reective in price). hey also may go on
their own experience with (usually a limited number of )
material(s). If they do not hear anything bad about the mate-
rial from the eld, good enough. No news is good news!
One needs to have a good survey of the cross-section
of interested parties: material manufacturers, pump suppliers
and end users to produce and compile such a table. During
my days with Goulds Pumps Engineering, we produced such
tabulation, trying to reect our experience and knowledge.
Although it was limited, it provided us with some degree
of judgment when applying one material or another to dif-
ferent applications. Other pump companies probably have
similar, internally-generated selection guides, but little is
actually published. To be truly unbiased, such compilation
would have to include a wide spectrum of parties, with often
unavoidably biased commercial interests.
My personal choice of Graphalloy, as presented in the
article you read, was based on what I knew from my own
experience. With limited knowledge of alternatives, some of
which perhaps could work just as well but unfortunately not
known to me, I made this choice.
In my younger days with Ingersoll-Rand, Graphalloy
was also used for liquid CO
2
, at multi-stage pumps, with
high pressures and low temperatures and with poor lubric-
ity and viscosity. Knowing it handles CO
2
is a good reason
for me to review its potential for other applications. hat is
how it works for most people: we use what we know works.
I have a section for feedback at: www.pumpingmachinery.
com/pump_magazine/maintenance/maintenance.htm (sec-
tion: Materials) which will be used to collect feedback and
is available for the end users as. It is in its infancy, but as the
information develops, it might evolve into a useful materials
comparison resource. hank you for your question. Perhaps
you have started a good information exchange on materials.
At the request of Lev Nelik, Gilberto Lunardiapplica-
tions engineer (Kalrez & Vespel), DuPont Performance
Polymersresponds:
Your inquiry on Vespel has been forwarded to us by
Dr. Nelik. Among the dierent families of Vespel prod-
ucts, CR-6100 is the one specically recommended for use
in centrifugal pumps. Process conditions are important fac-
tors to consider when selecting a bushing material in each
application. Vespel CR-6100 exhibits a unique combination
of properties and attributes like non-galling operation, self-
lubrication, high wear resistance, ability to reduce running
clearances, large temperature range, broad chemical resis-
tance, non-brittle, shock resistance and ease of machining.
his unique dierentiation compared to other nonmetallic
materials allows Vespel CR-6100 to perform in a broad vari-
ety of process conditions. Some of these properties are also
Dr. Lev Nelik, P.E., P&S Editorial Advisory Board
Materials of Construction
Pumping Prescriptions
found in other nonmetallic bushing materials. It is important
to understand the process conditions in each application to
select the best material for each individual case. For example,
you may not use Vespel CR-6100 in temperatures above 550
degrees F, and may not be able to use some metal-graphite com-
posites in acids that would attack the metal or use PEEK-based
composites in contact with alkaline media.
Gilberto Lunardi
Applications Engineer Kalrez & Vespel

Dear Dr. Nelik,
First, thank you for encouraging the dialogue about non-
metallic materials. I have been working with DuPont Vespel
CR-6100 for the past 13 yearsfor four years as one of the
rst customers when I was a rotating equipment engineer at
a renery in California and for the past seven years represent-
ing Vespel CR-6100. I currently represent Vespel CR-6100 in
EMEA (Europe Middle East Africa).
he most important thing is for users to recognize the
value of installing nonmetallic wear rings with reduced clear-
ance. Even after 20 years of experience with nonmetallic wear
rings, 98 percent of pumps used in industry continue to use
metal wear rings with larger clearances. hese pumps with
metal rings run with lower reliability, less e ciency and are not
as safe as pumps tted with nonmetallic wear rings. I would
encourage users to recognize the value of nonmetallic wear ring
upgrades for their pumps, learn about the various options and
select the material they believe will provide them with the best
reliability.
As for providing users a guide of which materials to chose,
I would point to API610 11th Edition, Table H.3. It includes
the most commonly used composite materials for industrial
pump applications: Vespel CR-6100 (under the cumbersome,
non-commercial description of PFA/CF reinforced composite
20% mass fraction random x-y oriented carbon ber), poly-
etheretherketone (PEEK) based composites and impregnated
graphite materials. he table provides acceptable operating
conditions in terms of temperature and dierential pressure.
hese limits are based upon feedback from the pump users
community, and the API committee is working to expand and
improve the table with each successive edition of the standard.
Beyond the temperature and pressure limits in table H.3,
users should consider the following material characteristics:
Coe cent of thermal expansion, chemical compatibility, lim-
iting PV (pressure-velocity ratio), creep resistance, wear rate,
impact resistance, thermal shock resistance, machining and
installation characteristics, and for composite plastics, glass
transition temperature. For a specic application, other proper-
ties may come into play, but the above list should be a good
starting point for most centrifugal pump applications. Users
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Pumping Prescriptions
need to consider the full range of properties as the long-term
performance of nonmetallic materials is not driven by one or
two factors but a combination of a wide range of properties.
One nal note, in your original response to the user, you
suggest that users look to the pump OEM as an unbiased source
of information. In some cases, this will be true, but not always.
Robert Aronen, Boulden International
Dear Lee,
Graphalloy has been used by Valero facilities for many
years for various applicationsincluding pumps for boiler feed
service, hydrocarbons, liquid gases and vacuum tower bottoms.
Compared to plastics, Graphalloy has some key advantages:
It has dimensional stability and heat-
transfer capabilities. It is not just
dimensionally stable in one or two
directions but experiences no creep,
even under high loads.
It is self-lubricating and has run-
dry capabilities. It can outperform
plastics as it is a run-dry material
that survives loss of pumpage opera-
tion for prolonged periods without
damage or preventing pump restart
Graphalloy is non-galling.
Graphalloy has a constant coe cient
of friction.
Clearances using Graphalloy can
be reduced to lower vibration levels
and reduce cavitation with no risk of
galling.
It does not swell or cold ow (in any
direction) and can be submerged in
liquids.
It has a wider temperature range
than plastic. It performs in cryogenic
temperatures and is used in pump
applications up to 750 degrees F
(and much higher in non-oxidizing
environments).
Graphalloy can also be machined to
your specications or semi-nished
sizes to minimize subsequent
machining.
It has been used for more than 50
years in multistage pumps, moving
uids from super critical ethylene to
heater drain condensate to bottoms
pumps.
Eric Ford,
Graphite Metallizing Corporation
P&S
Dr. Nelik (aka Dr. Pump) is presi-
dent of Pumping Machinery, LLC,
an Atlanta-based rm specializing
in pump consulting, training, equip-
ment troubleshooting and pump
repairs. Dr. Nelik has 30 years of
experience in pumps and pumping
equipment. He can be contacted at
www.PumpingMachinery.com.
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Special Section: Valves
L
ocated in northwestern Ohio, the City of Findlay is
the epicenter of Hancock County. Built in 1931, the
Findlay Water Treatment Plant (WTP) was upgraded
in 1965 and again in 1984. he Findlay WTP serves the
40,000 residents of the greater Findlay area and supplies an
average of six million gallons of potable water per day and
approximately 22,000 million gallons annually.
Water is pumped from the Blanchard River into the
treatment plant, and then the raw water surplus is pumped
into the Findlay Reservoir located three miles southeast of
the Findlay WTP. he water in the Findlay WTP is treated
and stored in the clear well and two, elevated storage tanks.
Upon demand, potable drinking water is pumped to resi-
dents of Findlay using ve motorized pumps ranging from
100 to 300 horsepower.
The Problem
Each of the ve pumps used at the WTP has a rubber-seated
ball valve. hree are 10 inches and the remaining two are 12
inches. he seats on four of the ve previously installed ball
valves continually failed, leaked and were in constant need
of repair.
After months of reworking and machining the seats, the
Findlay WTP received what it hoped would be a nal quote
from the manufacturer for the signicant but necessary
repairs. Unfortunately, the cost to repair each valve was more
than half the cost of completely replacing it with a new valve.
Instead of the costly repairs, the WTP proposed
a trial replacement of one of its faulty valves
with a new type of rubber-seated ball valve.
The Solution
he new rubber-seated ball valve was precisely
the solution: a reliable valve for surge control in
a pumping application. For pumping systems
in which surge control is critical, a pump con-
trol ball valve is typically used. he ball valve
is wired to the pump controls and provides
adjustable opening and closing times in excess
of the system critical surge period.
Stable operating times are essential in con-
trolling surges in pumping systems. he ball
valves inherent ow characteristics are highly
suited to control ow and pressure. Equal
Ball Valve Replacement
Increases Savings
Diane Meyer, Val-Matic Valve & Mfg. Corp.
Rubber-seated ball valve replacement saves energy, money and downtime.
New rubber-seated ball valve, installed
Figure 1. Inherent ow characteristics of different valves
percentage valves, such as the rubber-seated ball valve used at
the Findlay WTP, uniformly changes the ow rate during the
full travel.
Figure 1 provides the inherent ow characteristics of dif-
ferent valves whose data is expressed in terms of ow coe cient
(Cv) at percentages of the valves position. he most desirable
ow characteristic for surge control is equal percentage, as pro-
vided by the ball valve.
Features & Characteristics
he replacement ball valve was devel-
oped with more than 50 years of com-
bined engineering, manufacturing,
application and design experience. It
features a seat retention system that pro-
vides positive mechanical retention of
the valve seat while allowing easy adjust-
ment or replacement.
Both single and double-seated valves
are available for sealing in one or two
directions. When fully open, the resilient
seat is completely out of the ow stream.
All these valves are interior and exterior
coated with NSF 61 fusion bonded
epoxy per AWWA C550 for the high-
est level of corrosion protection ensuring
smooth ow surfaces and long life.
An important characteristic of
valves in water pumping systems that
is often overlooked is the valves ability
to minimize energy consumption. his
valve is ideal when energy savings are a
priority. When fully open, the valve pro-
vides a 100 percent clear ow area equal
to the valve size. herefore, the valves
head loss is equal to an equivalent length
of pipe and will represent a signicant
savings in pumping costs.
his valve consumes less than 1
percent of the energy that a globe-style
control valve consumes. Larger systems
and systems operating at higher veloci-
ties will provide even greater savings.
The Results
he initial 12-inch rubber-seated ball
valve impressed the Findlay WTP with
its performance and energy savings.
Subsequently, two 10-inch valves were
installed with air-powered vane pneu-
matic actuators. According to Findlay
WTP Supervisor, Je Newcomer, Since
the Val-Matic EnerG Ball Valves were
installed, they have been maintenance-
free and working out great.
his classic water treatment plant rehabilitation project
not only generated energy savings, it eliminated the downtime
necessary to repair the leaking seats.
P&S
Diane Meyer is the marketing manager at Val-Matic Valve
& Mfg. Corp. She can be reached at 630-941-7600 or at
dmm@valmatic.com.
We invite you to visit our redesigned website at www.ruhrpumpen.com
and contact us at info@ruhrpumpen.com
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T
he Millcreek Township Water Authority
(MTWA) near Erie, Penn., was created in
1974 to provide water to the rapidly grow-
ing Millcreek Township customer base. he MTWA
purchased several small water systems that have been
upgraded and grown to 112 miles of pipeline ranging
in size from 2 to 24 inches with 10 pump stations to
maintain water pressure, ve water towers for storing a
total of 5 million gallons and one groundwater well. he
water distribution system has elevation changes of about
400 feet and an average daily ow of approximately 2.5
millions of gallons per day (MGD). With 7,300 cus-
tomers and growing, it is essential that the Township of
Millcreek continues to maintain an eective and reliable
water system.
Taxed Capacity
Recent growth in the Peach Street commercial district,
the main shopping and restaurant area of Erie County,
had taxed the capability of MTWAs Peach Street Pump
Station. his station provides water to the neighbor-
ing communities of Summit Township and McKean
Township. MTWA retained the consulting rm of Hill
Engineering, Inc., to evaluate the future demands of the Peach
Street pressure district and to develop a long-term plan to meet
those needs.
The Long-Term Plan
he Hill Engineering report recommended construction of
a larger Peach Street Pump Station with greater capacity and
the construction of more distribution system storage to meet
re demands. Construction of these improvements would take
years to plan, design and build. Interim upgrades were essential
to make it through the next few years.
he owners of the Millcreek Mall, (the largest shopping
center in the area) approached MTWA, requesting to be con-
nected to Millcreeks system to avoid costly repairs to its own
private water tower, which was in need of an upgrade. MTWAs
Peach Street Station could provide the Mall with su cient
water to meet its daily demands, but the availability of adequate
re ow from the station could not be guaranteed.
Short-Term Solution
he solution was to develop a reliable interconnection between
the Millcreek system and the Summit system, so that the Summit
Township Water Authoritys (STWA) existing Waterview water
storage tank could automatically backfeed into the Millcreek
system in the event of a re or loss of electric power at MTWAs
Peach Street station. A manually operated pressure reducing
valve (PRV) had been installed years before to provide emer-
gency backow, but it was not 100 percent reliable.
In addition to being a single (non-redundant) device, the
valve was located in a buried vault. Its activation required an
operator to be present to open a gate valve. With a pressure
dierential of about 100 psi at the interconnection point, an
Valve Helps Meet Fire
Flow Demands
Mark Magda, Singer Valve, & J. Keith Malone, Millcreek Township
Millcreek Township connects to neighboring township with a pressure-reducing valve
with integral backup.
Double-diaphragm PRV in the heated enclosure
automatically operated, fail-safe PRV was needed to avoid
damage in the event of valve failure. Installing two PRVs as
a safety backup was considered as a safety backup, but that
would add cost and double the maintenance required. A pres-
sure reducing valve with integral backup (PR-SM), was the best
solution. he new control valves have a second and indepen-
dent operating system superimposed upon the standard pri-
mary system. Under normal pressure reducing conditions, the
primary pilot senses the downstream pressure through a con-
nection at the valve outlet. Under owing conditions, the pilot
reacts to small changes in pressure to control the valve position
by modulating the pressure above the diaphragm in the lower
operating chamber. he downstream pressure is steadily main-
tained at the pilot set point that is adjustable.
Should the primary pilot system and/or main valve fail
to control the downstream pressure, the independent back-up
pilot system will begin to operate. It controls the pressure above
the diaphragm in the second operating chamber. he back-up
pilot is set slightly higher than the primary pilot. he forces
now operating in the top chamber assume control of the inner
valve assembly and maintain pressure reducing control.
he secondary pilot continually senses the downstream
pressure. Should there be a rapid rise in downstream pressure,
the secondary pilot will respond quickly and pressurize the top
chamber. his will complement the primary pressure reducing
controls and provide faster response. he installation took
about two weeks to complete once the materials were on hand.
his project has allowed MTWA to maintain water pres-
sure to its customers and the Millcreek Mall continuously, even
during power outages.
P&S
Mark Magda is the general operations
manager for Singer Valve. He has more
than 11 years of experience in the munici-
pal water/wastewater industry and has
worked with Non-Revenue Water (NRW)
water loss leakage pressure management
programs. He can be reached at mark@
singervalve.com.
J. Keith Malone is the water operations
superintendent for the Millcreek Township
Water Authority. He has more than 15
years of experience in the utility construc-
tion and construction industries and has
been integral in upgrading pumping sys-
tems with VFDs and coordinating the
installation of a SCADA system. Malone can be reached at
kmalone@millcreektownship.com.
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I
n the time it takes to read this sentence, a signicant water
line will rupture somewhere in the U.S. hat is because,
according to the Environmental Protection Agency (EPA),
somewhere in the U.S., a water line ruptures every two seconds.
In Washington D.C. alone, a pipe break occurs every day.
he water main breaks in the U.S. are not ordinary faucet
drips. While we have all seen water line ruptures that have
caused wet streets and small sink holes, increasingly, areas are
experiencing the kind of water main breaks that require evacu-
ation and rescue via boats and helicopters.
he U.S. Geological Survey estimates that the annual
water lost from distribution systems is 1.7 trillion gallons, at a
national cost of $2.6 billion per year. hat is the drinking water
side. here are also 75,000 sanitary sewer overows each year
in the U.S., resulting in the discharge of 3 to 10 billion gal-
lons of untreated wastewater. his can certainly all be expected
from a water infrastructure that has been evaluated and graded
a D-minus.
Approximately 1 million miles of water lines and 800,000
miles of buried wastewater (sewer) lines are located in the U.S.
Our Aging Infrastructure
Kerry Baskins, Grundfos Pumps USA
Water shortages, failing infrastructure, broke governments, a crumbling municipal
bond market and the need for high subsidies. While the global pump community tools
up to participate in the business of water, the question remains: From where will the
funding come?
Underground infrastructure was mostly developed during three
main time periods due to population growth and movement
in the late 1800s, pre-WWI and post WWII eras. Pipes con-
structed in each of these time periods will begin to fail over
the next couple decades due to age, materials used, inadequate
design, poor installation and soil and water content. Pipes
have life cycles that can range from 15 to more than 100 years
depending on material and environmental factors.
he piping issue alone is staggering. However, many addi-
tional components make up water systemsincluding re
hydrants, valves, tanks, pumps, motors, mixers, lters, sensors,
meters and vaults. While static components, such as piping, are
susceptible to ground movement, freezing, thawing, corrosion,
tree roots, etc., rotating equipment longevity is susceptible to
many of the same inuences in addition to wear and techno-
logical obsolescence.
he World Economic Forum Global Risks Report for
2010 highlights the fact that under investment in the worlds
critical infrastructure is one of the biggest global threats. Global
infrastructure investment needs will be a staggering $35 trillion
over the next 20 years. According to he World Bank, in the
U.S. about $2.2 trillion will be needed over the next ve years
to address the problem.
The Price of Water
Consider for a moment the 2009 gures for the average water
use for a family of four in the U.S.:
Average monthly water consumption: 18,000 gallons
(24 hundred cubic feet HCF)
Average cost per HCF: $1.50
Average monthly water bill: $36
Average monthly sewer bill: $15
Total average monthly water bill: $51
hese gures are based on services from small municipali-
ties. Many larger municipalities have tiered water rate struc-
tures with increasing prices based on usage past a standard
family consumption expectation. Ideally, municipalities would
prefer to fund their operating budgets and capital expenditure
needs through revenue receipts. However, the average home-
owner regards water as a right as opposed to a resource that
requires signicant investment before it arrives clean and safe
from the tap.
While in some of the more arid areas of the U.S., water
pricing is creeping up in an attempt to narrow the gap between
revenue and spending, many municipalities simply do not gen-
erate enough revenue from the billing of drinking water use
or the processing of waste to cover operating costs, equipment
upgrades, expansions or catastrophic failures. Most people still
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believe that water is plentiful and inexpensive and do not give
a second thought to the fact that the water in our toilets is as
clean and drinkable as that coming from our faucets.
When the topic of infrastructure spending comes up in
many town halls, residents consider a price hike in water as
absurd if not insulting because, for most of our lifetimes, water
has been provided plentifully and inexpensively. Tangible prob-
lems such as street repairs, new rail systems, and new parks
translate to successful urban planning and development. It is,
therefore, no wonder that people become surprised when water
infrastructure fails and a home is swallowed in a sink hole.
he money for preventative maintenance rarely hits municipal
budgets.
Water pricing is largely determined by these factors:
demand, cost of transport from the source, amount of treat-
ment required and the amount of available subsidy. On aver-
age, 40 percent of municipal suppliers do not charge enough
for water to meet their basic operation and maintenance costs.
Funding Infrastructure
Clearly, if infrastructure could be repaired and leak rates mini-
mized, additional savings could be realized that would aord
many municipalities the opportunity to become more self sus-
tainable. However, signicant investment must be made just to
arrive at a point that this can occur.
For many years, the low price consumers pay for water
has been subsidized through municipal bonds, which on aver-
age make up 60 percent of a municipalitys nancing needs,
with earnings accounting for 20 to 30 percent of the dier-
ence followed by grants and other loans. However, this fund-
ing source is now severely challenged. Standard & Poors, in a
report released on July 21, 2011, indicated that a downgrade
of the U.S. credit could severely disrupt the municipal capital
markets, making it more of a challenge for some public issuers
to receive nancing.
Another source of funding is the privatization of water
works. By contrast, privatized water works must derive as much
of their revenue as they can from earnings, which on average
with private rms is only 40 to 50 percent. he rest is made
up through stocks and taxable bonds, industrial revenue bonds
and other sources. Proponents of privatization argue that this
avenue is needed to bring more private money into infrastruc-
ture needs, whereas opponents of privatization argue that, inev-
itably, privately owned water works must raise prices to make
the venture attractive and viable.
In 2007, U.S. Senators Christopher Dodd and Chuck
Hagel proposed a National Infrastructure Bank. However, this
initiative is also one of substantial leverage and would rely heav-
ily on an already over-burdened global debt market.
Increasingly, many believe the answer to the problem of
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funding water infrastructure can be found simply in the price
paid for water. he American Water Works Association, one
of the foremost voices in the water industry, has committed as
an organization to the principle belief that utilities should be
self-sustaining through their rates. A true landed cost analysis
of water, when infrastructure needs are taken into consider-
ation, would reveal a price point well above the current national
average.
Where Does This Leave the Pump
Industry?
he failing infrastructure must be addressed, and signicant
spending will inevitably occur. However, we can expect the
business environment to change. he price of water will likely
continue to increase, and with that, engineers will look to sup-
pliers who can deliver e ciency, energy savings and sustainable
equipment that is reliably leak free. Privatization will continue
to expand and traditional equipment suppliers will not only
manufacture and supply equipment but will also own and
operate the water plants.
he pump industry will also evolve into suppliers oering
more holistic solutions to the water infrastructure issue and not
just a mechanical means of moving the water through the pipes.
As traditional pump companies continue to tool up for the
gathering storm of infrastructure needs, we will see some com-
panies completely change in corporate identity as they become
experts in pumping water, and treating, ltering, cleaning and
reusing it.
P&S
Reference:
1 www.epa.gov
2. www.nytimes.com/2010/03/15water.html
3. www.suite101.com/contenct/
fragile-water-infrastructure-in-the-us-a210288
4. www.waterworld.com/index/display/article-display/6975580767/articles.
water-wastewater
5. AWWA Journal, April 2010
6. www.leakbird.com
7. www.earth-policy.org/plan_b_updates/2007/update64
8. http://www.circleofblue.org/waternews/2010/world/
the-price-of-water-a-comparison-of-water-rates-usage-in-30-u-s-cities/
9. http://www.bondbuyer.com/news/-1029733-1.html?ET=bondb
uyer:e3813:2050007a:&st=email&utm_source=editorial&utm_
medium=email&utm_campaign=BB_intraday_080611
10. http://reason.org/les/4ae2b80350813f066fbae6baa3d98b7c.pdf
Kerry Baskins is vice president at Grundfos Pumps USA
and leads Grundfos water industry business in the U.S. He
is a member of the Pumps & Systems Editorial Advisory
Board. He can be reached at kbaskins@grundfos.com.
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PUMPS IN WATER
HANDLING APPLICATIONS
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Cover Series: Pumps in Water Handling Applications
A
Delaware, Ohio, wastewater treatment plant needed
a solution to replace its conveyer system. Delaware
is a small Ohio city located about 30 miles north of
Columbus. he citys 34,000 residents rely on a functioning
wastewater treatment system as they continue to grow through-
out the next decades. Delaware retains its small town vibe while
also oering the benets of a major city. Business is growing, so
the need for wastewater treatment will grow with it.
he treatment plant in Delaware is responsible for all
domestic and industrial wastewater from within the city along
with the disposal of the sewage sludge produced during the
wastewater treatment process. he expanded facility is capable
of handling 10 million gallons per day. After the solids separa-
tion, the sludge is belt pressed to an approximate 20 percent
solids content.
The Problem
Conveyers are costly and di cult to maintain due to their
many moving parts. Previously, the dewatered sludge fell onto a
conveyer which would transport the sludge into dump contain-
ers, which would later be hauled to a landll. he rectangular
dump containers would frequently have to be moved with a
front-loader to assure proper distribution of sludge. he con-
veyors were messy. Dewatered sludge would often fall onto the
oor and require clean up. Odor was also a problem, making
this a dirty job that even Mike Rowe would avoid.
Conveyor upkeep was tedious and expensive. Many
moving parts mean that there is a higher chance of something
eroding and breaking. It is impossible to stock all the parts and
ordering replacements can take a long time and is expensive.
The Solution
he operators at the plant contacted a local distributor. After
analyzing the problem, distributor and engineers from a pro-
gressive cavity pump (PCP) company came to the conclusion
that a load cell controlled progressive cavity cake pump was a
potential solution. When compared to a conveyer, the pump
would result in a $1,500 per square foot capital cost savings.
he distributor worked closely with Dwight Miller and Gerald
Glenn from the city of Delaware to congure this solution. An
open hopper pump was installed. It has a conveying capacity of
14 to 18 gallons per minute. he pump can handle up to 35
percent dry solids content.
Progressive Cavity Cake
Pumps in Wastewater
Treatment
Daniel Lakovic, seepex, Inc.
Replacing conveyors with pumps improves efciency and sanitation in an Ohio
wastewater treatment plant.
The progressive cavity cake pump with a reinforced hopper
he feed screw moves the cake into the compression zone at a rate that
is three times greater than the physical capacity of the pumping elements.
he high shear of the feed screw and circulation of the thixotropic sludge
reduces the apparent viscosity, so it is easier and more e cient to pump.
A custom hopper was installed for full containment of dewatered sludge
coming from the belt press.
his cake pump was tted with load cell sensors on a specially designed
base plate. he sensors were integrated
into a VFD and proportionally con-
trolled by a panel that totalizes and
buers the signals coming from the
load cells. he speed of the pump is
adjusted according to the weight within
the pump hopper. At higher levels, the
speed increases. At lower levels, the
pump slows. No operator is required to
monitor the operation of the pump. A
thermally actuated sensor is installed in
the pump stator to prevent any run-dry
damage. he sludge is moved through
six-inch pipe to the dump containers. A
series of valves allows operators to evenly
distribute the sludge within the con-
tainers without using heavy equipment,
eliminating the need for a front loader.
In this case, the dewatered cake
travels through about 15 feet of pipe.
In other instances, the distance may be
greater. he pump manufacturer for
this situation would oer a boundary
layer injection system, which includes
an injection ring and a metering pump.
When polymer solution from the belt
press day tank is used as a boundary
layer, pressures from pipe friction losses
can be reduced by more than 80 percent.
Once installed, operators noticed
that due to the length of the custom
hopper, additional reinforcement was
needed. he problem was solved by
adding the reinforced hopper.
The Successful Results
Glenn says, Im glad these machines
are working for us now. Before (with the
conveyors), it seemed we were doing all
the work anyway.
he pump has been running prob-
lem free for two years, with the only
maintenance being a recent change
of the stator. he PCP has eectively
contained the odor, solved the dump
container issue and reduced capital and
maintenance costs and down time.
P&S
Daniel Lakovic holds a BS in International
Business from Wright State University. He has
worked for seepex, Inc. for two years in the role
of assistant to the president, performing roles
such as marketing management, pump develop-
ment, rental pump program and special events.
Lakovic can be reached at dlakovic@seepex.net.
G
rit is highly abrasive. Selecting
pump materials of the correct
construction and hardness is
critical to ensure long pump wear life. For
wastewater treatment plants, grit is typi-
cally dened as an inorganic solid, and
it can be made up of sand, gravel, cinder,
glass and other heavy inorganic material.
he major abrading component of grit is
silica sand. As a guide, the typical hard-
ness of silica sand is in the Brinell harness
number (BHN) range of 570 to 590. For
water treatment plants, where the water
source is a river, similar solids will enter
the plant during higher river ow rates,
which can increase water turbidity.
he amount of grit entering these
plants varies. However, both facilities
must remove it as soon as possible to
alleviate erosive wear as the process water
moves through the plant for treatment.
Grit removal systems are provided in
many dierent forms, and all require pumps for the disposal of
the inorganic solids.
Design Requirements for a Grit Pump
With grit (silica sand) being so abrasive, what is paramount
in selecting an appropriate pump is its ability to stand up to
erosive attack. Historically, the design of choice has been a
recessed-impeller or vortex centrifugal pump. his style oers
the benet of operating without the requirement of close impel-
ler clearances, being available in hard metal construction and
having performance minimally impacted when wear occurs.
hese all add up to long pump life.
Two basic styles of recessed-impeller pumps are available,
radial vane and cup type. Both designs have been used in grit/
slurry applications for more than 30 years and are industry
proven. hey are oered in hard metal construction with extra
thick wet-end components. he dierence in their wet-end
designs is ultimately dictated by the hydraulic ow path through
each pump, which in turn dictates where
the brunt of the wear will occur. For true,
recessed-impeller pumps it is expected
that roughly 80 to 85 percent of the ow
through the pump will not come in con-
tact with the impeller. he distinguishing
factor between the two designs is where
the ow that does come in contact with
the impeller is directed.
For a radial vane design, this ow will
be directed out to the impeller periphery
making this area the predetermined point
of wear. For true heavy duty radial vane
recessed impeller pumps, the casing will
not suer this wear as it is protected by an
independent heavy duty peripheral wear
plate assembly.
With this pump design, wear does
not occur at the suction area of the casing
so a single piece casing is used. In contrast,
for a cup-type design, the ow that comes
into the impeller gets directed back to the
suction of the pump by the impellers cup prole, making this
area the predetermined point of wear. he casing is, therefore,
provided in two pieces so that the end user does not have to
replace the entire casing when this area wears.
With both designs, key requirements must be met, such as:
Pumping Grit
Graham Hicks, Hayward Gordon Ltd.
Recessed impeller pumps are a solution for grit transfer in wastewater and water
treatment applications.
he pumps wet-end materials of construction must be
harder than the hard abrasive
hick wet-end components (those items coming in contact
with the uid)
Must have a sacricial component so that the entire casing
does not have to be replaced
Keep pump and tip speeds down to acceptable levels
Materials of Construction
First, and foremost, is having the pump
wet end manufactured from a mate-
rial harder than the hard abrasive.
Historically, this has been Ni-hard
(ASTM A532 Class 1). Ni-hard is a
nickel/chromium (Ni-Cr) cast iron. his
materials microstructure reveals an iron
carbide precipitate in a matrix of pri-
marily martensite with some austenite.
he combination of carbides and
martensite provide an excellent com-
bination for resistance to low- and
medium-stress abrasion. Standard
sand cast Ni-hard will have a BHN of
550 to 650. For grit service where the
maximum hardness of silica sand can
exceed the minimum hardness of stan-
dard Ni-hard, extra steps must be taken
to push the Ni-hard BHN even higher.
his is achieved by modifying standard
Ni-hard through a cryogenic process to
increase both hardness and toughness.
he freezing of the sand cast material
converts a large portion of the retained
austenite to martensite increasing the
hardness to a BHN range of 650 to 700.
hick Wet-End Components
Typically, grit ow rates fall into the 150
to 300 gallons per minute range result-
ing in a 3-inch or 4-inch pump selection.
Recommended minimum volute thick-
nesses are inch for 3-inch pumps
and inch for 4-inch pumps. Wear
plates/suction pieces for each respec-
tive design will be 1 inch or greater for
3-inch pumps and 1 inches for 4-inch
pumps. he impeller designs are dier-
ent but will have vane tip thicknesses in
the -inch to -inch range.
Sacriicial Components
As previously indicated, the position
of these components is dictated by
the hydraulic ow path through each
respective pump design. he responsibility of these compo-
nents is to eliminate the need to replace the casing in its entirety
due to wear. For a radial vane design, this comes in the form of
a peripheral wear plate allowing for a single piece casing (back
plate is separate). For the cup-type design this comes in the
form of a suction piece as well as a peripheral wear plate (when
the rim of the impeller wears su ciently ow will be directed
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to the periphery) resulting in a two-piece casing. he back plate
is separate.
Low Pump Operating Speeds
he goal is to keep the pump operating speeds as low as possible
targeting tip speeds below 5,300 feet per minute (note typically
for grit applications pumps are operating with tip speeds below
4,000 fpm). his is ultimately
dictated by the total dynamic
head (TDH) requirement upon
the pump and whether it is in
a direct-drive or V-belt-drive
conguration. Note that hard
metal slurry pumps for abrasive
mi n i n g
a p p l i -
c a t i o n s
will allow tip speed operation as high as
5,300 feet per minute for up to 30 per-
cent solids by volume so the above crite-
ria are conservative.
Mounting Congurations
Typically, grit pump installations require
that the pump be mounted in a dry
pit with a horizontal drive congura-
tion. his arrangement will provide the
most robust foundation and allow for
the easiest maintenance and operation.
Given that hard metal construction is
being used, the pumps will traditionally
incorporate a full-diameter impeller and
will meet specic hydraulic conditions
through a V-belt-drive arrangement. he
motor can either be mounted on the side
or in elevated congurations (Z-mount
or over-head, for example).
In some cases, a wet pit installation
is favored, typically due to spatial con-
straints within the plant. When this is
the case, the most common congura-
tions available are either a vertical canti-
lever or submersible pump arrangement.
For vertical cantilever pumps, the pump
setting (distance from base plate to the
casing suction ange) is most often lim-
ited to 72 inches, and a suction tailpipe
is added to position where the ow is
drawn.
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Sealing Arrangements
his is dictated by plant preference, but historically, the
dry pit pumps will either be supplied with a packed stu-
ing box or a commercially available single mechanical
seal incorporating hard faces (silicon carbide or tungsten
carbide). With both sealing options, a clean, pressurized
water ush is required. For vertical cantilever pumps, no
seals are required, and for submersible
pumps, a tandem seal arrangement with
a hard faced lower seal is used.
Conclusion
Clear guidelines for selecting an appro-
priate grit pump have long been estab-
lished, and there are proven pump
designs in the market. he greatest
concern facing clients now is with some
manufacturers sourcing substandard
wet-end material (i.e. 600 BHN or less)
o-shore. here are a multitude of North
American foundries providing suitable
650 BHN minimum hard metal materi-
als, and this must remain the standard.
Any material hardness less than this is
unacceptable for ensuring long, reliable
component life.
P&S
Graham Hicks is the vice president, Manufactured
Products, with Hayward Gordon and has been with
the company for more than 25 years holding various
marketing, sales and engineering positions within the
pump and mixer product groups. He can be reached
at graham@haywardgordon.com. his article was
completed with contributions from Steve Evans.
Stay Connected With
on
@PumpsSystemsMag
and at
www.pump-zone.com
See us at
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#5737
T
he Villa Magna, a 92-unit luxury condominium in
Highland Beach, Fla., sits between the Atlantic Ocean
and the Intracoastal Waterway. When a major main-
tenance program was due to be carried out at the 30-year-
old high-rise, the Villa Magna condominium association
approached repairs as a unique opportunity to improve the
e ciency of systems to conserve water and energy. he results
of their eorts have not only beneted their budget but also the
environment.
Problems with the Current Setup
Bresnak Services Inc., a company that specializes in pumping
systems for boosting water pressure in high-rise buildings, did
the work on a new domestic water supply system and an air con-
ditioning condensation collection system at the condo. Gary
Bresnak, managing director for Bresnak Services, says that after
investigating the existing water supply and air conditioning
systems, he concluded that the primary problem with both was
their lack of controllability.
he system for boosting the pressure of the water supply,
which is a common feature in high-rise buildings, used two
25-horsepower pump motors running at full speed for 24 hours
per day. he motors consumed 19 amps continuously, regard-
less of water demand. Pressure was controlled by mechanical
Motors, Drives Improve
High-Rise Condo
Efciency
Rick Kirkpatrick, Baldor Electric A Member of the ABB Group
Signicant energy and money savings are realized when using variable speed motors
controlled with drives.
By using drives to control the domestic water system in the high-
rise building, residents now have constant water pressure despite
usage.
By replacing xed speed pump motors with variable speed drives
and motors, Villa Magna has a more reliable system that is saving
electricity and water. These changes, along with the installation of
solar panels, heat pumps, energy-efcient lighting and appliances,
has earned Villa Magna a great deal of recognition, including the
2010 Florida Communities of Excellence Award for Energy and
Water Conservation.
regulators, an ine cient system that required regular and
expensive maintenance. Since modern domestic appliances
are considerably more water e cient, Bresnak also judged the
existing system to be far too large for what was required.
The New Conguration
For a more e cient and reliable solution, Bresnak replaced the
xed-speed, 25-horsepower motors with
10-horsepower variable speed motors
controlled by drives. he drives V/Hz
control mode enables motor speed to be
controlled by feedback from a pressure
sensor, to maintain constant water pres-
sure under dierent ow rates, explains
Bresnak. A time switch sets the duty
cycle of each pump to 12 hours, to max-
imize reliability. Each motor consumes
just 5.8 amps, which is less than a third
of the energy demanded by the previous
system.
he condominiums air condition-
ing system was equally ine cient. Water
is pumped through heat exchangers in
each of the buildings apartments and
then fed via a roof-mounted cooling
tower before being sent back into the
system. Bresnak found that the existing
pump system used two 40-horsepower
motors running at full speed from the
60-Hz supply, which consumed 80
amps. He also discovered that the ow
rate was far too high, resulting in a temperature drop of only a
few degrees in the cooling tower.
By retrotting the condenser pumps with motors and
bypass pump drives, we can now run the pumps at 50 Hz,
explains Bresnak. he result is that the current consumption
has been dropped from 80 amps to 53 amps. Plus, we have
been able to lower the ow rate to the point where there is
Ten-horsepower variable speed motors
controlled by drives were selected for the
system to maintain constant water pres-
sure under different ow rates.
Technical Features:
Okpkocn"Nkhg"E{eng"Equvu."Tgxgtukdng"Qrgtcvkqp."Ugnh"Rtkokpi."
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Applications include:
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now as much as 10 degrees of heat loss in the cooling tower,
rendering the entire buildings air conditioning system much
more e cient.
Another part of the project involved an air conditioning
condensation collection system to help conserve water, a par-
ticularly valuable commodity in Florida. Instead of losing con-
densation down the drain, it is now collected in a 400-gallon
tank and then recycled back into the tower to further aid cool-
ing. Bresnak says the goal is to introduce the cold water into the
cooling tower at a slow rate.
Again, my solution was to use another bypass pump drive
for the multistage pump, says Bresnak. By providing this very
slow speed control, we can match the usage rate with the collec-
tion rate. his kind of control allows us to slowly add the water
as the cooling tower needs it without overowing the tower and
wasting any water.
Bottom Line Results
Frank Strachan, Villa Magnas building manager, is pleased
with the results. he work carried out by Bresnak Services is
saving us approximately $2,000 a month on our water bill,
says Strachan. Over the last 12 months, we have also saved
about $24,000 on electricity. hese gures are considerably
better than those achieved by some energy-saving schemes in
other areas and say much for Bresnaks ability to apply Baldor
variable speed technology so knowledgeably.
Strachan says the savings achieved so far have more than
paid for the motors and drives. Now, with the investment paid
for, he says he is looking forward to years and years of more
savings.
Saving energy and water is the right thing to do, and
being green makes you feel good, says Strachan. But it also
feels good to save money. his has been a win-win because we
are conserving our water resources and using less electricity.
Bresnak says, I have a good relationship with the drives
engineers. [hey treat] me as their partner and understand that
I cant have any problems out in the eld. Whenever I call to
talk through issues and need help, I get it, and thats why I con-
tinue to choose [these] products.
P&S
Rick Kirkpatrick is an industry and OEM
manager for Baldor Drives, Baldor Electric
A Member of the ABB Group. He is an
electrical engineer and has his MBA. He
has worked with drives since 1987 in a
variety of positions including sales, opera-
tions and marketing. Kirkpatrick can be
reached at rakirkpatrick@baldor.com or 864-281-2239.
For more information about Baldor Electric, please visit
www.baldor.com.
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NO FLUID
P
ositive displacement pumps, specically reciprocating
and peristaltic types, create pulsating ow that results
in damaging vibration and pressure spikes. hese ow
pulses occur because the pumps liquid chamber or chambers
are repeatedly lled with liquid on the inlet stroke and then
expelled on the discharge stroke.
Typically, the discharge ow from the pump is not linear.
he ow from a piston or diaphragm pump for example, accel-
erates at the start of the pump stroke, reaches maximum veloc-
ity at midpoint and decelerates to zero ow at the end of the
stroke. While the ow is accelerating and decelerating, the uid
pressure at the pumps discharge is increasing and decreasing.
Peak ow from the pump can be as much as 3.14 times the
average or mean ow, creating an acceleration head phenom-
enon that must be considered when designing a liquid pump-
ing system.
he design and construction of a liquid pumping system
is often concentrated on ensuring that the desired pressure and
ow are achieved downstream of the pump. his is critical, of
course, but acceleration head is another important factor to
consider.
Frequently, pump inlet conditions are not given proper
consideration in system design. With positive displacement
pumps, especially reciprocating types, it is crucial to include a
complete design analysis of pump inlet conditions.
Two components of the inlet or suction side of a pump
that must be considered to achieve the required system pres-
sure and ow are net positive suction head required (NPSHR)
and net positive suction head available (NPSHA). NPSHR is
a function of the pumps design and determines the amount of
NPSHA at the pump inlet required to prevent more than a 3
percent capacity drop in stated uid ow, including consider-
ation for acceleration head.
NPSHR must be supplied by the pump manufacturer.
NPSHA is the absolute pressure above uid vapor pressure
available at the pump inlet. When dealing with positive dis-
placement pumps, NPSHA is often expressed as net positive
inlet pressure available (NPIPA) and net positive inlet pressure
required (NPIPR). hese terms reect the use of pressure units
rather than feet. Once feet of head are calculated, it is easily
converted to psi.
his article explores acceleration heada component that
is frequently forgotten or given too little thought in calculat-
ing NPSHA. So, what is this often overlooked phenomenon?
Remember, positive displacement pumps by design, especially
reciprocating types, start and stop ow with every stroke.
Depending on the number of pistons or chambers, complete
stoppage can occur or some overlap can exist from chamber to
chamber. he liquid mass in the suction line to the pump must
be started and stopped with every pump stroke. he pump
must expend energy to accelerate the liquid into the pump
during the suction stroke and then stop the inlet ow on the
discharge stroke.
his is the acceleration head component of NPSHA for
reciprocating pumps and can be calculated using the generally
accepted formula shown below. his equation is not inclusive
enough to account for uid compressibility or elasticity of com-
ponents but will serve well in most applications.
ha =
LVnC
Kg
Where:
ha = Acceleration head in feet
L = Length of suction line in feet
V = Velocity in suction line in feet per second (fps)
n = Pump speed in cycles per minute (cpm)
*C = Constant (by pump type)
*Constant Pump Type
0.200 duplex single-acting (diaphragm pump)
0.115 duplex double-acting
0.066 triplex single or double-acting
0.040 quintuplex single or double-acting
0.028 septuplex single or double-acting
0.022 nonuplex single or double-acting
*K = A factor representing the reciprocal of the fraction
of the theoretical acceleration head which must be
Solving Pump Inlet
Problems
Gary L. Cornell, BLACOH Fluid Control, Inc.
Flow and pressure downstream are important, but inlet pump conditions also require
attention during design.
provided to avoid a noticeable disturbance in the
suction line
*K Liquid
2.5 Hot oil
2.0 Most hydrocarbons
1.5 Amine, glycol, water
1.4 De-aerated water
1.0 Urea and liquids with small
amounts of entrained gases
g = Gravitation constant (32.174
ft/sec
2
)
he velocity component in the
equation can be found in readily avail-
able tables or calculated as:
V = 0.4085
Q
D
2

where:
V = Velocity in feet/second
Q = Flow rate in gallons per
minute
D = Pipeline inside diameter
Acceleration head, sometimes
referred to as inertia pressure, on the
suction side of a pump can be positive,
negative or both, but it must always be
considered in several dierent ways.
Steady State Flow
As stated previously, positive displace-
ment pumps have a maximum ow per
stroke of more than three times the mean
ow due to the nature of their pump-
ing action. One of the biggest single
mistakes made by system designers is to
start NPSHA calculations by referring
to standard pipe pressure loss tables and
using mean ow numbers determined
by system design requirements. hese
tables show pressure loss based on steady
state ow. However, momentary peak
ow rates will be higher on every stroke,
and this higher rate should be used for
friction loss determination.
he dierence in loss on the dis-
charge side of a pump can usually be
overcome by added pump energy, but
small dierences on the inlet side can
be critical to the limitations of NPSHA.
Larger pipe diameter, elevated supply
source or shorter suction piping may be
required. his is a simple and common mistake that can have
serious consequences to anticipated ow projections.
Cavitation
Because liquid in the inlet piping has been stopped during
the discharge stroke of the pump, it must be accelerated by
the pump on the inlet stroke. To do this, especially under low
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NPSHA conditions, a low pressure area at the pump inlet is
created. If the acceleration pressure required lowers the inlet
pressure below the vapor pressure of the liquid, then vaporiza-
tion and subsequent cavitation can occur. NPSHA calculations
must be made, including acceleration loss, because inlet sys-
tems have positive pressure under steady state conditions that
can go negative at the start of the pumps inlet stroke.
Suction Lift
One of the advantages of positive displacement pumps is their
ability to self-prime under suction lift conditions. Air-operated
diaphragm and peristaltic pumps, for example, can self-prime
up to as much as 20 feet of lift, while controlled volume meter-
ing pumps are usually limited to 3 to 5 feet. Acceleration head
loss under these conditions must be calculated carefully and
may be the dierence between being able to self-prime at all
and requiring some sort of assistancesuch as check or foot
valves in the inlet piping. he size and interior surface nish of
the inlet piping can also inuence suction lift.
Multiple Chamber Pumps
Pumps with multiple pumping chambers, such as duplex and
triplex pumps, typically have lower acceleration head losses
primarily because, once liquid is in motion, at least theoreti-
cally, a small amount of continuous ow overlap exists as one
chambers inlet valve closes and the next chambers inlet valve
opens. Pump rpm and valve closure timing can have an impact
on this. Lack of complete pump chamber ll can occur as liquid
is rst accelerated to one chamber and then must be redirected
to the next chamber. If su cient time is not available for the
stroke rate to allow each chamber to ll completely, pump
damage can occur. An accumulator-type inlet stabilizer can
usually minimize this condition by accumulating a quantity of
liquid available at the pumps inlet.
Positive Inlet Pressure
While acceleration head on the inlet or suction side is generally
a negative and subtracts from NPSHA, it can be positive. In
fact, it can be too positive. Depending on pipe prole, supply
tank elevations, pump speed and valve closure sequence, too
much positive pressure can result.
Under most conditions of application, the pumps inlet
valve(s) are quick closing valves. When a valve closes quickly
against a owing liquid, rapid velocity change occurs and a
pressure spike, often referred to as water hammer can occur.
he magnitude of the pressure spike is a function of the liquids
mass, ow rate velocity and the rate of the change in velocity. If
the water hammer or pressure spike is of su cient magnitude,
it can damage system inlet components such as plastic pipe,
gauges, seals and other components.
In duplex pumps, especially air-operated double-dia-
phragm pumps, this pressure spike can be particularly danger-
ous for the pumps diaphragms. As liquid ow is stopped by
the closing of one inlet valve, the opposite chambers inlet valve
is opening. he pressure spike carried by the ow of diverted
liquid rushes into the chamber being lled and slams into the
diaphragm, stretching and weakening it until premature failure
occurs. To minimize this pressure spike, the ow rate of the
liquid must be held below a critical velocity for the system. To
prevent the pressure spike from occurring in the rst place, an
inlet accumulator can be installed at the pump inlet to capture
liquid during valve closure.
Minimize Acceleration Head
Other factors beyond this discussion should be considered
when designing any pumps inlet conguration, but clearly,
when positive displacement reciprocating pumps are involved,
acceleration head is a critical factor that must be addressed.
Minimizing the negative eects of acceleration head on the
suction side of the pump can be accomplished in many ways.
Some are discussed in this section.
Pumps and Piping
he following changes and additions to pumps and piping may
inuence acceleration head:
Increase pipe diameter to reduce friction loss and liquid
velocity.
Make sure there is straight pipe for at least 10 to 15 pipe
diameters at the pump inlet to minimize turbulence.
Move the pump as close as possible to the source of supply
to reduce mass that must be reaccelerated on every stroke
and to reduce friction loss.
Eliminate as many turns and elbows in the suction line as
possible. Use sweeping elbows rather than 90-degree elbows.
Use a larger pump to allow for slower stroke speed. (his
can be an expensive solution.)
Use suction piping 1.5 to 2 times the size of the pumps
inlet port to reduce friction loss and help ensure an ade-
quate supply of liquid into the pump chamber(s). Caution:
Larger suction piping can adversely aect suction lift.
Use pumps with multiple chambers to reduce acceleration
head loss. his is an expensive x, and multiple chamber
pumps may raise cavitation concerns.
Standpipes
Standpipes can be used to help control acceleration head by
providing an area of accumulation and release of pumped
liquid as the pumps inlet valve alternately opens and closes.
he standpipe needs to be at least 1.5 times the diameter of the
pipe it is mounted on and, generally, as tall as the supply tank to
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the pump. It must be mounted within 25 pipe diameters from
the pumps inlet (preferably within 10 pipe diameters).
It must also be capped and typically vented to the supply
tank. Standpipes can never be used in a suction lift application
because air could be sucked into the supply piping.
he other disadvantage of standpipes is that they can
become waterlogged and rendered ineective when trapped air
at the top becomes entrained in the liquid accumulated in the
standpipe.
Inlet Stabilizers
Essentially a pulsation dampener, an inlet stabilizer has a ex-
ible internal diaphragm or bladder to prevent mixing of the
system liquid with the stabilizers gas charge. Properly sized and
installed in a tee within 10 pipe diam-
eters of the pump inlet, it can usually
reduce acceleration pressure loss to less
than 3 or 4 psi. It does this by accumu-
lating liquid during the pumps discharge
stroke and releasing the liquid back into
the suction line during the pumps inlet
stroke.
In eect, the inlet stabilizer uses
the stored energy of the compressed gas
to reaccelerate the liquid back into the
suction line. It will only have an eect
on the liquid between it and the pumps
inlet so proper location is critical.
An inlet stabilizer essentially oper-
ates for free because the energy expended
by the pump to stop ow by closing the
inlet valve on the discharge stroke is
returned when that same energy stored
in the stabilizers compressed gas pushes
accumulated liquid back into the suc-
tion line as the inlet valve of the pump
opens. his, of course, minimizes the
pumps job of reaccelerating the liquid in
the suction line. Pulsation and pressure
uctuations are minimized, and a near
constant ow of liquid is available at the
pump inlet.
Traditionally, both standpipes and
inlet stabilizers have required positive
pressure available to the pump, but nei-
ther was particularly eective in suction
lift applications. However, inlet stabilizer
models are now available that can be
used in both positive pressure and suc-
tion lift applications. hese models have
a venturi control arrangement that can
either direct pressure into the inlet stabi-
lizer for positive pressure applications or
create a partial vacuum to assist in suc-
tion lift applications.
In suction lift applications, liquid
can move away from the pump inlet as
the inlet valve closes. he vacuum on the
gas side of the stabilizer will pull product
into the unit and momentarily hold it
until the inlet valve opens on the pumps
suction stroke.
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The more you know
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Knowledge is power.
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Again, the
idea is to accu-
mulate liquid
close to the
pump inlet so
that the entire column of liquid does
not have to be accelerated. his type
of inlet stabilizer will not assist in
initial pump priming but will
reduce pump energy once
the pump is primed.
As a general rule, a
pulsation dampener at the
pump discharge must
be at least 15 times
the volume of the
pumps liquid cham-
ber, depending on the
number of pumping cham-
bers. An inlet stabilizer
must be at least the same size
and preferably 1.5 times the
size of the pulsation dampener.
he inlet, or nozzle, on the stabilizer must be at least the same
size as the pipe on which it is mounted. he gas charge on the
inlet stabilizer will be determined by the specic application
according to guidelines provided by the manufacturer.
Conclusion
his article is meant to be a general guideline to make the
reader aware of factors that must be considered when design-
ing the layout of inlet piping for positive displacement pump
systems, particularly those applications using reciprocating and
peristaltic pumps. Acceleration head, often overlooked and
misunderstood, was emphasized.
While no attempt was made to give specic engineering
guidelines for designing inlet systems, the goal was to provide
useful information on design criteria for e cient and eective
liquid handling systems. P&S
Gary Cornell is chairman/CEO of
BLACOH Fluid Control, Inc., based in
Riverside, Calif. Cornell, a member of
the Hydraulic Institute and the American
Society of Mechanical Engineers, has
worked in the reciprocating pump indus-
try for more than 35 years and has writ-
ten several articles on uid energy stabilization. For more
information, contact BLACOH at 951-342-3100 or 800-
603-7867, or visit www.blacoh.com.
An inlet stabilizer can
reduce acceleration
pressure loss.
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At Global Pump, we ofer a wide
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fuel eicient pumps on the market.
D
aily challenges abound for collection system operators
and administrators as they work to support the proper
operation of their pipes, pumps, controls and related
auxiliary system equipment. Continual system stress due to a
recent tightening of maintenance and operational budgets has
caused the ever-increasing challenge of handling the modern
trash found in todays new wastewater.
What Is Modern Trash?
A huge component to the headaches of todays modern trash
are plastics and the synthetic sheet goodsthe non-woven
material used by manufacturers to act as a carrier for cleaning
agents; fabric softeners; and on the softer side, personal care
and baby wipes. hese thin sheets have become the bane of the
collection system.
Of great concern is the impact that these materials have
had on collection system pumping operations. hese products
have been found to partially and fully clog (soft clogging) tra-
ditionally designed solids-handling pumps, most of which can
attribute their hydraulic designs to work originally conducted
by A. Baldwin Wood from about 1917. Woods work centered
on designing a trash handling, multichannel impeller by using
impeller vanes with blunt vertical leading edges and a three-
inch vane throughlet.
Flushability
Front and center to the pump soft clogging issue is the
ushability of modern trash. Flushability is the term that
refers to passage quality of disposable, single-use products often
marketed as ushable.
hese ushable items may include such products as baby
wipes, personal hygiene wipes, single-use oor mop pads,
dental oss, single-use toilet cleaning pads, protective under-
garments, anti-bacterial surface cleaning wipes and other simi-
lar products. In reality, the wastewater industry has found that
many of these products are not readily degradable in sewer and
septic systems and should not be considered ushable.
INDA, the U.S.-based Association of Nonwoven Fabrics
The New Wastewater
Robert Domkowski, ITT WWW USA Flygt
Modern trash causes big issues for wastewater collection systems.
A pump covered with modern trash
A soft clog mass
Industry, and ENDA, the European counterpart, have taken
the initiative to produce ushability guidelines. his initiative
commenced because no consistent or widely accepted deni-
tion of what constitutes a ushable nonwoven consumer prod-
uct existed. he initial report from INDA
1
that was three years
in the making was released in 2008. INDA describes ushabil-
ity as the quality that the individual modern trash component
possesses that must:
Pass through the domestic toilet and drainage-line system
Be transported in a wastewater conveying system
Be compatible with wastewater treatment systems
The Complications of Modern Trash
he resulting problems with modern trash range from signi-
cant damage to equipment, losses in system e ciency, increased
operational costs, additional costs for labor/overtime, creating
potentially dangerous situations for employees, environmental
impacts and time diverted from other needed system main-
tenance. In most cases, the increased costs associated with
addressing the system impacts from these personal convenience
products are unbudgeted expenses that divert precious, limited
funds from other system needs.
Todays modern trash signicantly challenges proper oper-
ation of the hydraulics of traditional solids-handling pumps.
Laboratory testing continues to support eld ndings that the
plastics, non-woven and synthetic sheet
materials readily become impinged upon
the vertical leading edges of the rotating
pump impeller disturbing the hydrody-
namic shape of the impeller and lower-
ing its hydraulic e ciency. As additional
materials continue to agglomerate with
the initial trash, clogging of the pump
impeller continues resulting in reduced
pump output and ultimately near-complete clogging of the
pump impeller.
Concern was rst raised in 1993 in a technical paper
Flushability, Transportation and Decomposition of Nonwoven
Products
2
when the authors related that ushable nonwoven
products may not be ushable in the future. Federal legisla-
tion reduced the ush volume for residential plumbing xtures
to 1.6 gallons, eective January 1, 1994. he paper described
that laboratory and eld studies predicted di culty in develop-
ing consumer products to meet both regulation and the users
needs.
In 2010, a survey developed by the Maine Waste Water
Collection Association (MWWCA)
3
was sent to its member-
ship to assess the impact of ushable products upon their
collection system operations. Selected data from that survey
includes:
87.5 percent report that they have experienced problems
due to ushable products.
61.4 percent report that they have experienced >10 inci-
dents due to ushable items
84.4 percent report clogging problems with small lift/
pump stations due to ushables
51.1 percent report clogging problems with large lift/pump
stations due to ushables
59.6 percent report that typical corrective costs due to
A pump draped with modern trash
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ushables is up to $1,000 per
incident
12.8 percent report that typical
corrective costs due to ushables of
$1,001 to $2,000 per incident
88.9 percent of respondents report
that their problems with ushables
are increasing
Case Study: Moraga
Pumping Station
In November, 2010 a report was issued
describing the results of a study con-
ducted in June 2010 at the Moraga
pumping station located in Moraga in
Contra Costa County California. In 2009, the original Moraga
pumping station inlet bar screen, with a three-inch bar spacing,
was changed to a bar screen having 1.5-inch bar spacing. his
resulted in some reduction in pump clogging with an increase
in bar-screen cleaning. Pump blockages continued at the rate
of once every one to two weeks, which required work stoppage
and disassembly of the aected pump to clear the blockage.
Identication of Materials Entering the Moraga Pumping
Station
4
executive summary reported that the quantity of
materials found at the Moraga pumping station yielded two
distinct categories:
1. Bar screen samples were dominated by paper with signi-
cant amounts of household cleaning and personal hygiene
products. As these material came into contact with the bar
screen and overlapped onto one another, forming pancake
structures. hese formations hindered the rate of ow into
the pumps, demanding daily removal procedures.
Paper hand towels comprised 54 percent of the trash
caught by the bar screen while 17 percent of the captured
waste was made up of personal hygienic products and 13
percent household cleaning wipes.
2. he pump clog sample consisted of
stronger nonwoven materials. hese
long brous products, typical of per-
sonal hygiene and household cleaning
wipes, were twisted and torn into long,
knotted rope-like systems. hese types
of materials were part of the contribut-
ing factors leading to the formation
of blockages that periodically disabled
the pumps at the Moraga pumping
station.
Personal hygiene products, wipes
and cleaning wipes combined to
constitute 89 percent of the pump
clogging materials.
Legislation & Testing
On the legislative front, in June 2010,
California Assemblyman Jared
Human brought forth draft Assembly
Bill 2256, which would use INDAs
guidelines to place into law a con-
sistent denition of ushability and
regulation concentrating on packag-
ing for products sold in California. In
February 2011, Maine Representative
Melissa Walsh Innes (D-Yarmouth)
submitted a bill to the Maine legisla-
ture (LR 1564) on behalf of the Maine
Waste Water Control Association
(MWWCA) to address the rapidly
growing concern of impacts caused by
products advertised as ushable that are
not dispersing properly in the wastewater systems.
In summary, the bill would prohibit the packaging or
labeling of consumer products for distribution or sale in the
State if the package or label states that the product is ushable
or safe for sewer and septic systems unless the product meets
ushability standards. he bill directs the Maine Department
of Environmental Protection (DEP) to adopt ushability stan-
dards. Maine DEP would be responsible for the review of
acceptable criteria for ushability as published by INDA.
he National Sanitary Foundation (NSF) has begun to
market an independent validation service to test consumer
products as to their ushability and issue a certication for the
particular product. he NSF Certication oers validity of the
product for use with septic systems and/or for sewer systems.
NSF relates that to claim that a product is ushable, the prod-
uct must generally undergo a toilet bowl and drain-line test,
a dispersability test, a column settling test and aerobic and
anaerobic disintegration tests. hese tests encompass the dif-
ferent U.S.- and European-size pathways that a product may
follow in the wastewater system.
A Pumping Solution
Recognizing and understanding the
increased challenges being experienced by
collection system professionals, a new sol-
ids-handling pump design was developed.
he pump was specically designed to
handle the growing challenges of the new
wastewater. A departure from the earlier
work of Mr. Wood, this semi-open, back-
swept impeller employs horizontally posi-
tioned vane leading edges that pass across
a groove located in the volute suction
cover that promotes trash passage, wiping
the impeller leading edge clean. his
design has proven to handle the modern
trash found in the new wastewater, all the
while sustaining high hydraulic e ciency
and saving energy.
Wet-well debris from a Brewer, Maine, wastewater
treatment facility
The hydraulics of the new solids-handling
pump
Case Study: Andalusia, Ala.
A recent successful retrot project in
Andalusia, Ala., using the new solids-han-
dling pump was completed. At the Central
lift station, three 85-horsepower pumps
and two 45-horsepower pumps were
replaced. At Riverside wastewater treat-
ment plants (WWTP) inuent pump sta-
tion, three 45-horsepower pumps replaced.
he project was funded by a block grant
from the U.S. Department of Energy and
administrated by the Alabama Department
of Economics and Community Aairs.
he project specication required that
a minimum 25 percent energy savings be
achieved due to the pump retrot. he
documented results revealed energy savings of 56.1 percent at the Riverside WWTP
inuent pump station, and 48.1 percent was achieved at the Central lift station.
5

hese savings were directly due to the new pumps ability to sustain a clean impeller
leading edge and prevent their fouling by modern trash. Recently, this pump was
chosen by the Water Environment Association to receive its prestigious Collection
System Innovative Technology Award for 2011.
The Importance of Education & Labeling
he best solution to minimizing this problem is educating the public regarding the
proper use/disposal of these collection system challenges. his requires a combina-
tion of the eorts of the product manufacturers to properly label the product pack-
ages, INDA and municipalities to inform and instruct end users with regard to the
proper disposal of these challenging materials as well as the possible development of
carrier sheet materials that can break-down after use within the collection system.
P&S
Reference:
1. Guidance Document for Assessing the Flushability of Nonwoven Consumer Products First Edition
June 2008, INDA.
2. Flushability, Transportation and Decomposition of Nonwoven Products - T. Konen and C.
Christodoulatos - Environment 1993 Conference.
3. 2010 MWWCA Survey courtesy of he MWWCA Flushables Working Group: Michelle
Clements (Portland Water District), Paul Rodriguez (Woodard & Curran Engineers, MWWCA
president), Tom Connolly (Yarmouth, ME WWTF), Gilles St. Pierre (Presque Isle, ME WWTF),
Aubrey Strause (Tata & Howard Engineers).
4. Identication of Materials Entering the Moraga Pumping Station November, 2010 R. Casey.
5. Project Report City of Andalusia, Ala., Wastewater Pumping System Energy E ciency Upgrade.
GMC No.: A10003, June, 2011, R. Domkowski (ITT Flygt).
Robert Domkowski, graduate of Faireld University, School of
Engineering, is the business development manager municipal
/ engineering consultant for ITT Water & Wastewater USA
Flygt located in Shelton, Conn., and has more than 28 years
experience with applying solids-handling pumps to collection sys-
tems and wastewater treatment systems. He is currently a member
of the WEF Collection Systems Committee, NEWEA Collection
Systems Committee and is past president and executive board member of the
Submersible Wastewater Pump Association (SWPA) and a member of the Waste
Water Equipment Manufacturers Association (WWEMA). Mr. Domkowski
can be reached at: bob.domkowski@itt.com.
Education and proper labeling is the best
solution to the modern trash problem.
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N
estled within the Berkshire
Hills in Western Massachusetts,
Pittseld is noted for its blend of
New England tranquility and charm and
its embrace of modern progress. Once
frequented by writers such as Herman
Melville, Henry Wadsworth Longfellow
and Nathaniel Hawthorne, the city of
roughly 46,000 people is also known
as the plastics technology center of the
nation because of its many locally-based
plastics companies.
Now, thanks to a project that will
implement energy and environmental
reform, Pittseld is about to earn another
notable distinction: a city at the vanguard
of the green movement. Pittseld is in
the process of constructing an upgrade
to its wastewater treatment facility, which
will feature a combined heat and power
(CHP) system, using three 65-kilowatt rated microturbines for
a total rating of 195 kilowatts. he microturbines will be fueled
by the treatment facilitys digester gas, which is a methane-
based byproduct derived from its wastewater sludge treatment
process. he digester gas is a biofuel and a renewable energy
source.
he Pittseld CHP project is not only good for Mother
Earth, but for the wallet as well. Along with a reduced envi-
ronmental impact, the city will benet from a reduced util-
ity bill because the digester gas will be used to generate both
electricity and heat for on-site use. In addition, the plant will
generate approximately $45,000 per year in revenue through
the Renewable Energy Credit market.
Pittseld is more than just a center
of culture and industry. It is also a worthy
example of how individual municipalities
can be both economically savvy and envi-
ronmental stewards at the same time.
The Design
he design for the upgrade to Pittselds
wastewater treatment facility has a
number of features, including a brick-
and-block building to house the entire
CHP system, space provisions to allow
for a fourth microturbine should the city
decide to expand and the furnishing and
installing of electrical systems for inter-
connection of the CHP generated power
for use within the entire treatment facility.
Furthermore, there are plans to
replace the existing shell and tube sludge
heat exchanger with a single 1.2 MMBTU
per hour spiral heat exchanger and furnish and install three pro-
posed double-disc digested sludge transfer pumps to replace the
existing pumps. Also, the design calls for:
Installing instrumentation to monitor sludge and hot water
temperatures
Installing instrumentation to automate sludge mixing
through use of programmable timers and interlocking
mixing operations with sludge pumping
How the CHP System Works
he sludge, or biosolids, processing infrastructure at the waste-
water treatment facility includes primary and waste-activated
sludge pumping, gravity belt thickeners, thickened waste
Wastewater Treatment
Facility Upgrade
Features CHP System
Alan Wells, P.E., Kleinfelder
Pittseld, Mass., wastewater treatment facility saves money and shrinks
environmental footprint.
activated sludge pumps, secondary and primary anaerobic
sludge digesters, belt lter presses and dewatered sludge pumps.
he purpose of this infrastructure is to reduce the overall mass
and volume of the sludge for disposal.
Anaerobic digestion at the facility is a two-stage process.
he rst stage uses active heating and mixing to facilitate the
destruction of volatile solids. Mixing is accomplished by recir-
culating compressed digester gas from the headspace of the
primary digester to the bottom of the vessel through lances.
Heating of the primary digester is accomplished by recirculat-
ing sludge from the primary digester through a heat exchanger
located within the digester building. he second stage allows
for solids-liquid separation through quiescent settling of the
sludge.
A byproduct of the anaerobic sludge digestion process is
digester gas (primarily composed of methaneapproximately
62 percent by volumeand carbon dioxide), which is then
used as a fuel for boilers located in the plants pump and power
building. he boilers are used to heat a water loop, which then
heats the sludge in the digesters, maintaining it at the optimal
temperature for anaerobic digestion. Excess digester gas is used
to heat the pump and power building in the winter or is ared
through a waste gas burner located on the top of the digester
building.
Under the proposed CHP system, the digester gas will
be sent through a fuel gas conditioning system that removes
contaminants from the digester gas and boosts the gass pres-
sure to the microturbines. he target contaminants of the fuel
gas conditioning system include water vapor, hydrogen sulde
and siloxanessilicone-based compounds contained in many
health and beauty care products.
he conditioned digester gas will then be used to fuel the
microturbines, which will generate heat and electricity to meet
the plants base-load demands. he waste heat in the exhaust
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Tel: +1 618 654 2341
info@basler.com
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franceinfo@basler.com
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S
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#8605
of the CHP system will be used in a heat exchanger to pro-
duce hot water. his hot waters purpose is to heat the sludge in
the primary digester and serve as building heat in the digester
building.
It is anticipated that the heat generated will not be enough
to meet the peak sludge heating requirements under design
winter conditionsmaking use of the existing boilers in the
pump and power building for sludge heating and building
heat a possible necessity. However, the microturbine system
is expected to reduce the operating time of these boilers and,
therefore, the volume of required diesel fuel for the operation
of the existing boilers, as well as minimize signicantly the
amount of digester gas diverted to the are-gas burner.
Economically and Environmentally
Conscious
hanks to these proposed upgrades, the Pittseld wastewa-
ter treatment facility is expected to reduce the aring of the
digester gas and consumption of diesel fuel, provide an esti-
mated 30 percent reduction in the plants electric billsaving
taxpayers over $200,000 per year.
So this small Western Massachusetts city, long known for
its persons of letters and as a pioneer in plastics technology, is
now leading the way in the green revolution, setting the exam-
ple as an environmental steward with its wastewater treatment
facility and combined heat and power project.
P&S
Alan Wells, P.E., is a program manager
with Kleinfelder/SEA, an employee-owned
science, architecture and engineering con-
sulting rm. He can be reached at 860-
563-7775 or al.wells@seacon.com. For
more information, visit www.kleinfeler.
com or www.seacon.com.
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t0QFSBUJPOBM'MFYJCJMJUZ
SEE HOW
At www.wildenpump.com/seemoregreen
With
Best in Class AODDP
T
he topic of waterits use, short-
age, valueis currently pervasive.
Developing countries face the
brunt of this water scarcity as not even a
well-known hero like James Bond could
prevent the villainous seizing of control of
the drinking water supply system in these
areas. his serves to highlight the current
situation involving the global water supply
and how 21st century popular and political
theater can shape the discussion.
Demand for Fresh Water
A glass of chilled water is fast becoming a
hot commodity. Worldwide, water usage
is increasing while the availability of fresh
water sources is shrinking. Much of the
Earths freshwater is either locked up as
ground water or as glaciers, with only a
small percentage of per capita water eco-
nomically available. his is most apparent in the Middle East
where the per capita water consumption is almost equal to the
per capita water availability. Asia Pacic and Africa also suer
from water scarcity.
his issue is compounded by the rapid industrialization
and high population growth in these regions. While most
European countries witnessed a negative population growth
rate and a negative or low economic growth rate in 2010, all
the countries in the Middle East witnessed around a 2 percent
population growth rate and around a 5 to 15 percent economic
growth rate. he increased standards of living and rapid indus-
trialization require better access to clean drinking water and
better wastewater and sewage collection and treatment facili-
ties. In the next few decades, increasing population and global
warming will put additional burdens on strained water sources.
Sensing the need for better water and wastewater infra-
structure, various governments have been focusing on improv-
ing their water policy to ensure the availability of clean drink-
ing water for their country, including desalination eorts.
China
he Outline of the National Planning for Development of
Ocean Economy targets to achieve a desalination capacity of
20 million tons per year, with a seawater utilization of 50.00
billion m
3
per year by 2010. he aims are to meet this target
with several integrated seawater utilization demonstration
bases in water decient northern cities and build up several
demonstrations in coastal cities for large-scale seawater
utilization.
Saudi Arabia
Saudi Arabia produces almost 8 billion gallons of water
per day from desalination, about half the worlds total, and
continues to invest in various desalination projects across
the country.
India
he Indian government has allocated $12 billion for urban
water supply under the eleventh ve year plan that will sup-
port more desalination plants in India.
he water scarcity problem is not isolated to emerging
economies. Parts of developed countries face acute water short-
age. For example, the 2011 summer in Texas has seen one of the
worst droughts in decades. he Canary Islands and the coast
along the Mediterranean in Spain face heavy water shortages.
As a result, across the world, there is a need for better, reliable
and cost-eective water treatment technology.
Desalination
Among the water treatment technologies, desalination is one of
the most technologically promising. As oceans cover more than
Liquid Gold
Anand Mugundhu Gnanamoorthy & Laurel Donoho, Frost & Sullivan
Pumps in the growing global desalination market
B
USINESS
OF THE
BUSINESS
Figure 1. World water availability and consumption
B
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ITT is a global provider of water handling and treatment solutions for municipal and industrial customers in more than 140 countries.
Flygt | Godwin | Leopold | Sanitaire | WEDECO
Experience a new level of reliable and efcient pumping
Inspired by you. Engineered by us.
The Flygt heritage of groundbreaking innovations continues, as yet again
our application expertise and engineering excellence lead the way. From the
development of the worlds rst submersible pump which revolutionized the
worlds municipal wastewater infrastructure, to sustaining high efciency with
our innovative N-hydraulics. Time and again, we listen to you to understand
your daily operations. This, together with our pioneering spirit, inspires us
to achieve the extraordinary.
Now its time for the leaders to move forward once again
70 percent of the Earths surface,
regions focusing on extracting
fresh water from seawater is a
logical step. Vaporization and
distillation of seawater to obtain
fresh water was one of the rst
desalination technologies. hese
technologies need huge energy
inputs to heat the water. As the
oil boom spread in the water
starved Middle East region, this
area embraced the vaporization
and distillation technique and
quickly became the leader in the desali-
nation market. Because of the challenges
of large quantities of heat and space
required for vaporization and distilla-
tion, researchers developed the reverse
osmosis (RO) process. RO forces water,
at high pressure, to separate from salt
using a semi-permeable membrane.
his new technology required much less
energy and space and was increasingly
adopted across the world.
RO currently accounts for around
60 percent of the entire installed desali-
nation base. hough RO technology is
more e cient than multi-eect distilla-
tion (MED) or multistage ash (MSF),
separating salt from water is still a very
energy intensive process. See Figure 2.
To increase the e ciency, recovery sys-
tems were developed to use the high
pressure of the waste brine left after the
RO process, leading to reduced operat-
ing cost. An estimated 18 billion gallons
of water per day are treated using desali-
nation across the world, and this market
is expected to grow around 7 percent
every year for the next ve years. About
80 percent of the water being treated is
seawater and brackish water.
Pumps, Piping and Valves
in Desalination
he global desalination equipment
market is expected to generate revenue
of around $6.78 billion in 2011. Of this
$6.78 billion, 17.8 percent is being spent
on pumps, piping, valves and control
systems, and a majority of this money
is spent on pumps. Pumps play a key
role in the desalination process and are a
critical process component. See Figure 3.
However, the use of pumps varies
Figure 2. Summary of three popular types of desalination processes
Figure 3. Desalination equipment market
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according to the desalination process. RO systems use pumps
as the key equipment to purify water while other techniques
such as MED or MSD use pumps to transfer water and brine.
To achieve optimal system performance and e ciency,
four key factors must be considered:
1. Pump ei ciencyAs energy is one of the major operating
costs, cost of desalination per liter of water depends on the
optimal use of energy. Pump e ciency is a key criterion
in keeping energy costs down. Positive displacement (PD)
pumps operate with 80 to 95 percent e ciency, while cen-
trifugal pumps operate at 40 to 65 percent e ciency. PD
pumps are preferred for small- and medium-sized desalina-
tion plants while centrifugal pumps are preferred in large
desalination plants. Increasing pump e ciency brings
down the cost of desalination and increases the return on
investment (ROI).
2. Material of the pumpGlobal warming has resulted in
an increase in the salinity and temperature of sea water,
which is highly corrosive. his impacts the pumps perfor-
mance and operating life. It also increases the maintenance
cost. herefore, optimal selection of material is a key factor
to reduce operating cost and increase the pumps life cycle.
Pump material selection directly inuences the ROI.
3. Uninterrupted lowhe pump system has to be
designed to ensure uninterrupted water circulation while
keeping the energy consumption
low. To ensure that there is always
a positive ow of water, second-
ary systems may be used but these
additional pumps increase the initial
investment and the operating costs,
and reduce the ROI. Designing the
system for optimal water circulation
is critical.
4. Pumping system accessories
Accessories used in pumping are as
important as the main pump. he
pressure monitoring system and
pressure relief valve ensure that the
RO system does not rupture the
membrane due to sudden blockage
of water circulation. Components
such as pulsation dampeners ensure
that the pulsation created by the
high pressure water pump do not
damage the delicate membranes.
Failure of these accessories can result
in pump damage.
Conclusion
Water is a vital resource for human health
and well-being, industry production and
agriculture, and its demand will increase
in the coming decades. Emerging
nations with rapid industrialization and
population growth are the most vulnerable. Desalination of
seawater and brackish water is one of the best available alterna-
tive sources to fulll growing water demand.
As pumps and other accessories form an integral part
of desalination systems, growth in the desalination market is
expected to spur the growth for demand of these products.
However, to achieve higher e ciency, desalination equipment
manufactures and pump manufacturers need to consider key
factors that aect the e ciency and performance of desalina-
tion equipment.
P&S
Laurel Donoho is the research manager,
Industrial Automation & Process Control,
for Frost & Sullivan. She has 19 years of
strategy, analysis and consulting expertise
in the industrial space. She can be reached
at laurel.donoho@frost.com.
Anand Mugundhu Gnanamoorthy is a
senior analyst, Industrial Automation &
Process Control, for Frost & Sullivan. He
has experience in market research and
consulting in a broad range of sectors.
Gnanamoorthy can be reached at anandg@
frost.com.
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piet explitas pe ium quam reiuntia di blandelicia nimini
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blaborrunt verio qui remporepel molo eumque rem susciam
alis aliquod itaecus, commoluptat.
T
his years WEFTEC in sunny L.A. promises to be another
successful conference with a large turnout. Expecting about
18,000 attendees from more than 70 countries, this conference
will consist of 114 technical sessions divided into 12 tracks of
continuous education covering the water quality eld.
WEFTEC 2011 will also have 27 workshops and eight facil-
ity tours, as well as more than 800 presentations and posters. he
exhibit hall will feature more than 900 exhibitors throughout the
three exhibit days.
WEFTEC Tracks
Emerging Research and Innovation
Industrial Issues and Treatment Technology
Municipal Wastewater Treatment Process and Design
Facility Operations
Residuals and Biosolids Management
Collection Systems
Stormwater Management
Watershed Resources Management and Sustainability
Utility Management
Water Reclamation and Reuse
Future Insights, Global Issues, and Sustainability
Government Aairs/ Exhibitor Forum
Exhibit Hours
Monday, October 17 9 a.m. 5 p.m.
Tuesday, October 18 9 a.m. 5 p.m.
Wednesday, October 19 9 a.m. 5 p.m.
WEFTEC 2010 by the Numbers
More than 17,000 attendees
984 companies that covered more than
290,000 square feet of exhibit space
112 technical sessions
35 work shops
9 facility tours
T
o most people, sodium hypochlorite is simply known
as liquid bleach. To the people charged with produc-
ing, transporting and metering sodium hypochlorite
in a wide range of industrial applications, there is nothing
simple about it. Sodium hypochlorite was rst produced in
1789 when Frenchman Claude Berthollet passed chlorine
gas through a solution of sodium carbonate. Today, sodium
hypochlorite is formed when chlorine gas is bubbled into a
cold and diluted sodium hydroxide solution.
Finished sodium hypochlorite is a clear,
slightly yellowish solution with a characteristic
odor. In its commonly used liquid-bleach form,
it has 5 percent sodium hypochlorite with a pH
of around 11, which makes it irritating to the
skin.
However, in more concentrated doses, such as 10 to 15
percent sodium hypochlorite, its pH level rises to 13, which
means it will burn and be corrosive to many substances.
hat is why anyone working with high levels of sodium
hypochlorite must take precautions to protect themselves
and the environment.
hese precautions are being taken daily at industrial
facilities around the globe because sodium hypochlorite is a
key component in thousands of production or disinfection
processes in industries as diverse as agriculture, chemical,
paint, lime, food, glass, paper, pharmaceutical, synthetics
and water treatment.
he powerful disinfection and oxidation properties of
sodium hypochlorite allow it to be used in such operations
as bleaching in the paper and textile industries, disinfection
of drinking water, preventing the growth of algae and shell-
sh in industrial or HVAC cooling towers and disinfection
and odor control in wastewater facilities.
Efciency Matters
Bleach Use in
Wastewater Treatment
Tom ODonnell, Neptune Chemical Pump Company
Mechanically actuated metering pumps improve operational efciencies
and eliminate concerns associated with off-gassing in sodium hypochlorite
applications.
An electronic metering pump
The Challenge
his article focuses on the use of sodium hypochlorite as a disinfectant and odor
controller in wastewater treatment plants. In wastewater treatment applications,
sodium hypochlorite is introduced to the system via metering pumps. In addition
to the need to handle sodium hypochlorite with care because of its elevated pH
levels, a critical concern when pumping and metering the liquid is its propensity
to o gas. When this happens, the consequences to metering pump operation
include air binding and loss of prime, which adversely aect the operational e -
ciency of the metering pump, leading to compromised metering operations.
To combat o-gassing in metering pumps during sodium-hypochlorite-han-
dling operations, facility managers can follow a number of simple steps to mini-
mize concerns:
When selecting a pump style for use in sodium hypochlorite metering, always
use a high-stroking model with a short stroke length. his type of pump is less
likely to allow the accumulation of gas in the pump head.
In pumps that are turned o for a length of time, the gas can accumulate in the
suction line or pump head. For applications that require the pump to sit idle
for any period of time, including a bypass line with an automated valve that
can recirculate the sodium hypochlorite when not feeding is recommended.
Mechanical diaphragm metering pump
WASTEWATER
& WATER
S OL U T I ONS
S P E C I A L I Z E D
295 DeKalb Pike North Wales, PA 19454
1.888.3NEPTUNE
www.neptune1.com
Visit us at: booth #2719
84th Annual Water Environment Federation
Technical Exhibition and Conference
Los Angeles Convention Center| Los Angeles, CA, USA
Conference > October 1519 | Exhibition > Oct. 1719
weftec

2011
the water quality event
Fluid Technologies:
Metering: Hydraulic, Mechanical &
Electric Diaphragm
Mixing/Blending: Polymaster, Agitators
Applications:
%PTJOHt.FUFSJOHt$IFNJDBM*OKFDUJPO
Transfer of Sludge
Highland Oaks I,
1100 W 31st Street, Suite 120
Downers Grove, IL 60515
Tel: 909-512-1257
Fax: 909-512-1209
Info@pumpsg.com
pumpsg.com
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Efciency Matters
Provide a short, ooded suction-pipe
arrangement for the metering pump
with the suction piping sloping
down from the storage tank to the
pump. his setup will allow any gas
bubbles to travel back to the storage
tank, rather than to the head of the
metering pump. his also means
that the metering pump that is
used in sodium hypochlorite service
should not be top-mounted, unless
the concentration is very low.
Ensure that the sodium hypochlo-
rites feed tank is not located in
direct sunlight. Direct sunlight and
higher temperatures will increase
sodium hypochlorite o-gassing.
Use a sodium hypochlorite solution
with the lowest concentration pos-
sible for the application, and use the
largest capacity metering pump pos-
sible. his combination will result in
less o-gassing.
If possible, use an air vent or purge
valve in the head of the metering
pump. his will aid in evacuating
any trapped sodium hypochlorite gas
that may reach the metering pump.
The Solution
he type of pump that can meet all
requirements for handling sodium hypo-
chlorite in wastewater applications
especially in combating the deleterious
eects of o-gassing while providing
accurate meteringare mechanically
actuated diaphragm pumps (electronic
or motor driven). he piston in a
mechanically actuated diaphragm pump
is attached to the diaphragm and is nor-
mally compressing a spring in the for-
ward (positive) movement of the piston
ensuring positive diaphragm return and,
therefore, assisting suction.
More specically, a mechanically
actuated diaphragm pump that has a
The pumps that can meet all requirements for handling
sodium hypochlorite in wastewater applications are
mechanically actuated diaphragm pumps.
high stroking speed and short stroke
length should be used to minimize gas
accumulation in the pump head. In
addition, the pump can be provided
with an automatic vent valve to allow
any trapped gas to be purged from the
pump head. Some of these pumps are
oered with manual control, automatic
control or fully programmable control
features.
Another feature is a straight
through ow path pump head, which
does not allow any areas within the
pump head for the gas to lodge. Also,
look for pumps that are self-priming.
Two materials that are most suitable for
sodium hypochlorite applications are
PVC and Kynar.
Conclusion
Sodium hypochlorite is one of the most
versatile cleaning and disinfecting uids
available. From completing basic house-
hold chores to disinfecting hospitals,
from being fed as a biocide to inhibit
biological growth to removing odors
from wastewater, sodium hypochlorite
plays an ever-present role in a wide
array of day-to-day operations around
the world.
However, it must be handled with
care, especially in its higher concentra-
tions. It also has a few quirky character-
istics that, if not addressed, can ham-
string an industrial application. Facility
managers familiar with these character-
istics know that they need to select, use
and rely upon the best metering-pump
technology when metering sodium
hypochlorite. Finding the right pump
technology is especially crucial when
considering the negative aects that o-
gassing can have on sodium hypochlo-
rite metering operations.
hats why managers of wastewater
treatment facilities who want to opti-
mize production while simultaneously
reducing maintenance costs, downtime
and product loss choose mechanically
actuated diaphragm metering pumps
for their sodium hypochlorite-handling
responsibilities.
P&S
Tom ODonnell is a product manager for Neptune Chemical Pump Co., North Wales,
Pa. You can contact him directly at tom.odonnell@neptune1.com or 215-699-8700.
Neptune is an operating company within Pump Solutions Group (PSG), Downers
Grove, Ill. PSG is comprised of seven leading pump brandsAlmatec, Blackmer,
EnviroGear, Griswold, Mouvex, Neptune and Wilden. For more information on
Neptune Chemical Pump, please go to www.neptune1.com.
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T
oday, tremendous eort is
made to reduce energy con-
sumption. he Department
of Energy (DOE) and the Hydraulic
Institute (HI) work together to
reduce the energy consumption of
pumps, motors and pump systems.
his is where composites can be of
great benet. hey can signicantly
reduce energy consumptionin
some cases by 20 percent or more.
Corrosion, Cavitation &
Erosion Resistant
Corrosion, erosion, cavitation, rotor imbalance and leakage
between the wear rings, casing rings and inter-stage bush-
ings are major contributors to the loss of pump e ciency.
Damage from corrosion, erosion, and cavitation quickly
destroys the metallic pump and pump parts, which makes
the pump ine cient and increases energy consumption.
As seen in Figure 2, energy costs dwarf any other
expenses. Here, the acquisition cost is only 9 percent of the
total life cycle cost of one pump.
his is why the DOE, Europump, and the HI have
focused on pump life cycle costs.
Composite Wear Components and
Surface Finish
Wear between the rings and bushings create
large clearances, which result in substantial
decreases in pump e ciency as well as huge
increases in the energy consumed to operate the
pump.
Historically, most pump companies and
repair facilities have used metallic parts for wear
rings, casing rings, sleeves, bushings, and guide
bearings. hese metallic parts have the potential
to gall and seize and, therefore, require larger
clearances between the parts. Compounding
the issue is that these metallic parts do not have
self-lubricating qualities as many composites
do. Also, metallic parts are subject to corrosion,
which further increases clearances and energy
consumption.
Structural Composite
Parts
John Kozel, Sims Pump Company
Composites signicantly reduce energy consumption, maintenance costs and
repair costs.
Maintenance Minders
Figure 1. A corroded impeller on the left and a composite impeller on the right
Figure 2. Life cycle costs for a 60-horsepower, vertical, in-line metallic pump
in salt water for ve years
hermoplastic and thermoset engineered composites
have been used successfully to replace these metallic parts. In
a structural composite the bers are not chopped, cut or mac-
erated. hermoset structural composites have the mechanical
strength of metal and have self-lubricating qualities embedded
in the composite eliminating the risk for seizing and galling.
Furthermore, these engineered composites have extremely
smooth surfaces with an excellent surface nish and a low coef-
cient of friction on all surfaces. his low coe cient of fric-
tion increases e ciency and reduces
energy consumption. Because they will
not seize or gall like metallic rings, they
run with tighter clearances, which adds
to the increased e ciency and decreased
energy consumption.
Low Coefcient of Friction
As shown in Figure 3, most composites
have a lower coe cient of friction than
metallic materialssuch as bronze or
stainless steelthat have been tradition-
ally used in pumps. Structural graphite
composites and engineered composites
have the lowest coe cient of friction,
lubricated or non-lubricated. he low
coe cient of friction reduces the fric-
tion losses of the liquid being pumped,
which allows for an increase in e ciency
and a reduction in energy consumption.
Composite coatings have been used
to coat pump casings, which not only
protects the casings against corrosion
and erosion but also smooths the rough
surfaces, reducing friction and increasing
e ciency. Some studies have shown that
e ciency can be improved by as much
as 2 to 3 percent by using composite
rings, guide bearings and coatings.
Savings Potential
Since many composites are impervious to dierent corrosive
environments, they will not corrode, or erode. Although com-
posite wear components will reduce energy consumption for all
pumps, including all fresh water services, the greatest savings
occur in corrosive environments such as salt water, wastewater,
chlorinated water and chemical processing because the com-
posites, in many cases, will not corrode at all.
When metallic pump parts begin to wear from corrosion,
pump e ciency drops drastically. he life cycle of the pump is
often reduced to months instead of years.

Life Cycle Costs
According to the DOE, many centrifugal pumps may be less
than 50 percent e cient but have the potential to improve by
20 to 30 percent through upgrades and system changes. Pump
upgrades can improve performance, maintenance and repair
issues and improve e ciency, pump life and reliability. Pump
upgrades prevent expensive products from deteriorating. hey
can prevent pump leaks that can result in costly cleanups and
nes from regulatory agencies. In most cases, reduced down-
time outweighs all other benets.
In di cult times, allocating the funds for the upgrades may
be hard, but the payback is quick. he resulting savings frees up
funds that otherwise would have been wasted on energy, and
Figure 3. Coefcients of friction
Maintenance Minders
more expensive repairs at a later date.
he incremental costs of upgrades
are minimal when compared to the
expense of downtime and repairs.
Plant outages, ship overhauls,
building new vessels, building new
manufacturing plants, plant expan-
sions and new system installations are
good opportunities to specify pumps
with upgraded e ciency and reliabil-
ity features such as structural graphite
composite pump components (impel-
lers, casing rings, sleeves, bushings, bearings and mechanical
seals).
Lower Costs & Increased Performance
Because of the self-lubricating characteristics of many engi-
neered composites and because composites do not wear or cor-
rode, the performance curve will actually increase over time. A
1,000-hour performance test was made by Warren Pumps on
a U.S. Navy standard re pump manufactured from titanium
used an engineered structural composite impeller and casing
rings. he results clearly showed a substantial increase in the
head-capacity (H-Q) Curve 2.5 percent with the compos-
ite impeller and rings at the end of the 1,000-hour endurance
test. he new alternative composite solutions for impellers and
rings are excellent for new pumps, repairs or retrot applica-
tions. hey are lightweight and virtually indestructible. Wear
of other pump parts, including the pump casing, is greatly
reduced, because of the impellers perfect balance; lightweight;
self-lubrication; sealing; and corrosion, erosion, and cavitation
resistance.
Optimization
It is a common problema pump is purchased for one spe-
cic performance and when it is put into service, the pump
operates at another point completely dierent from the original
design point (best e ciency point BEP) because of the system
requirements. When a pump is operated away from the BEP,
it causes problems, including excessive
noise and vibration; shaft oscillation;
cavitation; premature wear; and fail-
ure of the mechanical seals, bearings,
rings, sleeves and impellers. In extreme
cases, the pump shaft will break. hese
problems can be resolved by installing
alternative solution impellers and rings
which have been re-engineered for the
system requirements.
Impellers
he impeller is the heart of any centrifu-
gal pump. Like a human heart, a pump
impeller is the most loaded pump com-
ponent, constantly stressed by hydrody-
namic forces, fatigue, corrosion, erosion
abrasion, chemical attack and cavitation.
Engineered structural composite impel-
lers oer potential to reduce energy con-
sumption. Because of their corrosion,
erosion and cavitation resistance, light
weight, smooth vane passageway sur-
faces, anti-galling and anti-seizing char-
acteristics, composite impellers are able
to operate at signicantly higher e cien-
cies than metallic impellers.
Composite impellers are machined
as opposed to cast or molded which
enables the composite impeller to be
Figure 4. Corrosion resistance chart: As seen in this chart, composites do not corrode in salt
water or wastewater and are excellent with chemicals that are compatible with the composite.
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Maintenance Minders
optimized hydraulically for the service in which
the pump runs. Machining allows for perfect bal-
ance, both mechanically and hydraulically, because
of the accuracy of the vane passages. hese impel-
lers may not go into imbalance even after years of
service. his reduction in vibration translates into
higher e ciency, a reduction in energy consump-
tion and reduced maintenance.
he overall e ciency of a centrifugal pump is
in direct correlation to the e ciency of the impel-
ler. he impellers hydraulic design must corre-
spond to the hydraulic design of the pump casing
and to the operating conditions of the pump in
service (in the plant) to maximize e ciency. Any
centrifugal pump tted with a structural compos-
ite impeller will save money for the pump owner and operator in
repair and maintenance costs as well as in energy consumption.
Designed for Superior Hydraulic Performance
Because structural composite impellers are computer engi-
neered, designed and precision machined, the impeller vane
geometry can be engineered using CFD (computerized uid
dynamics) techniques and programs to maximize e ciency and
performance. Problems such as recirculation, radial thrust and
cavitation can be minimized or eliminated by using structural
composite impellers instead of the traditional metallic ones.
Impeller vane shapes can easily be modied to provide the best
shape for the specic application and performance requests.
Composite Versus Bronze Impeller
Figure 5 shows that changing a bronze impeller to a structural
composite impeller increased e ciency 15.8 percent. he
e ciency on this 20 kilowatt pump (26.8 horsepower) went
from 57 percent with a metallic impeller to 66 percent with
a structural composite impelleran increase of 9 points. At
0.11 cents per kilowatt hour this translates into a savings of
$2,218.00 per year, per pump.
After only one year of service in a
corrosive salt water environment, the
bronze impeller began to corrode, fur-
ther reducing e ciency. Depending on
the service, the temperature of the salt
water and how the pump was operating,
the e ciency will be reduced by as much
as 5 to 7 percent or more, resulting in
additional energy costs.
Upgrading to a structural composite
impeller will not only increase e ciency
15.5 percent from the start but will also
prevent the losses in e ciency as a result
of corrosion resulting in a total saving to
the customer of more than 20 percent,
which results in a savings of $4,155.00
per year per pump.
P&S
John Kozel is the president of Sims
Pump Company, the manufacturer
of Simsite, a patented family of struc-
tural engineered composite pumps
and pump parts approved by the U.S.
Navy, for Navy, marine, chemical,
industrial and wastewater applica-
tions. He can be reached at simsite1@
aol.com.
Figure 5. Composite impeller versus bronze impeller
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W
ater is the most abundant liquid on the Earths
surface and is vital to many aspects of our daily
lives. For these reasons, a wide variety of uid
handling applications involve transporting and/or pressur-
izing water in its liquid form. As a liquid, water is generally
a neutral uid that is easily handled without special consid-
erations. However, water does present some unique sealing
challenges that should be considered.
With the focus of this issue on pumps in water handling
systems, this article highlights four potential challenges to
successfully applying mechanical seals in these pumps.
Freezing
Flashing
Scaling
Ultra-Purity
Freezing
Water is one of the few substances that expands when it
transforms from a liquid to solid state. his expansion, which
is about 9 percent, can cause damage to seal components,
especially elastomeric secondary sealing elements. Icing in
and around the exibly mounted components of a pusher
seal can also restrict axial movement, causing the dynamic
secondary seal to hang-up, resulting in the separation of the
mating faces. In addition, seal chamber piping plans that
provide a water ush can become restricted or completely
blocked with ice, especially for applications that are not oper-
ated continuously.
To minimize the damage risk, alternative secondary seal
optionssuch as exible graphiteshould be considered.
he dynamic secondary seal can be eliminated by selecting
a welded metal bellows seal design. he seal operating envi-
ronment can be protected from the eects of low tempera-
ture water or ice by introducing a heating spool between the
back plate of the pump and the seal chamber. Electric heat-
ing cables can also be applied to the piping plans to provide
heat tracing, preventing freezing in the piping of the auxil-
iary systems.
Flashing
Many applications employ water that is at or near its atmo-
spheric boiling point of 100 degrees C (212 degrees F) and
require consideration of the characteristics of water in its
gas phase. Even at temperatures as low as 70 degrees C (160
degrees F), the viscosity of water is reduced to less than 0.4
centipoise (82.64 x 10
-4
pounds/feet-second). In this condi-
tion, water cannot provide the lubricity necessary for suc-
cessful operation of typical hard face material combinations.
Although water may remain in a liquid phase at the pro-
cess pressure, it may transition to a gas phase as the water
passes across the seal interface and drops to atmospheric
pressure.
he addition of heat from friction between the mating
seal faces also contributes to a reduction in the vapor pressure
margin which further increases the instability of the uid
across the seal face.
In its gas form, water behaves much like a ashing
hydrocarbon with respect to load support and lubrication at
the seal faces. As a result, special considerations for the seal
face design are required for these applications. In addition to
lubrication property concerns of hot water, many common
elastomers do not perform well in high temperature water.
Special consideration must be given to secondary seal selec-
tion. Fluoroelastomer (FKM) o-rings, which are widely
used in many chemical and petrochemical applications, can
undergo severe degradation in a steam environment, result-
ing in leakage and secondary seal hang-up. In general, uo-
roelastomers are not recommended for water applications
above 70 degrees C (160 degrees F).
To mitigate the poor lubricity of hot water, hydropads
and specially designed hydrodynamic surface topography
may be applied to the seal faces. hese features ensure that
a liquid lm exists across the majority of the seal face area
and minimize or eliminate seal face contact forces. Hard face
material combinations should be avoided in hot water appli-
cations and, whenever possible, carbon-graphite should be
used as one of the mating seal faces to provide the needed
tribological properties.
What are the challenges with sealing water applications?
This months Sealing Sense was prepared by FSA Member Rob Phillips
From the voice of the uid sealing industry
SEALING SENSE
When abrasive solids or high pressures make carbon-
graphite seal faces undesirable, hard face material combinations
should only be applied as a part of an engineered sealing solu-
tion that addresses the risks of hard-versus-hard-face contact in
a poor lubrication environment.
he uid pressure in the seal chamber can also be increased
using throat restrictions and auxiliary piping to increase the
vapor pressure margin in the region
of the seal faces. API Piping Plans 21
(recirculation from the pump discharge
through an orice and heat exchanger
into the seal chamber) and 23 (recircu-
lation via a circulating device through
a heat exchanger and back into the seal
chamber) can also be applied to reduce
the temperature and increase the vapor
pressure margin in the region of the seal
faces. EPDM elastomers are generally
recommended for secondary seals in
steam applications.
Scaling
Because of its polarity, water is often
referred to as the universal solvent
and un-softened or hard water typically
carries high levels of dissolved minerals,
such as calcium. hese dissolved miner-
als can impact the reliability of mechani-
cal seals. As noted previously, water will
often transform from a liquid to a gas as
it passes through the sealing gap between
the mating faces.
During this transformation, dis-
solved minerals may precipitate from
the solution and cause three-body abra-
sive wear across the seal faces. hese
deposits can also build up at the atmo-
spheric side of the mechanical seal, lead-
ing to secondary seal hang-up and other
problems.
Scaling can also have an indi-
rect impact on mechanical seals by
diminishing the eectiveness of the cooling systems. Hard
water can deposit minerals on the walls of the coils in the heat
exchangers used in several standard API piping plans. his min-
eral build-up causes fouling of the heat exchangers, result-
ing in reduced heat transfer e ciency. Fouling becomes more
common when cooling water ow rates through the coils are
below 0.9 meters/second (3 feet/second). his can result in the
Figure 1. Calcium carbonate build up at the
atmospheric side of a seal face
sealing system being unable to main-
tain the intended operating environ-
ment for the seal, resulting in reduced
seal reliability.
Water treatment can reduce the
mineral content or soften the water and
prevent the accumulation of mineral
deposits. A regular maintenance pro-
gram can also be implemented to clean
accumulated fouling from the heat
exchanger coils. Many heat exchangers
are designed specically to facilitate a
regular cleaning process. Heat exchang-
ers should also be operated with cool-
ing water ow rates greater than 0.9 meters/second (3 feet/
second). In addition, an API Piping Plan 62 (external quench
on the atmospheric side of the seal) can be implemented with a
steam quench to prevent the build-up of mineral solids.
Ultra-Pure Water
he scaling concerns addressed in the previous section are a
particular concern in industrial boiler and cooling tower sys-
tems. To address this issue, improve reliability and reduce boiler
system maintenance costs, many fossil fuel and nuclear power
plants have incorporated increasingly sophisticated feed water
treatment systems. A recent trend in these treatment systems
has included the use of ultra-pure water.
he combination of ultra-pure, deionized water with
increased duty parameters of feed water pumps has resulted in
a phenomenon known as electro-corrosion. Electro-corrosion
can attack the rotating equipmentincluding the mechani-
cal seal components. Electrical potential between dissimilar
seal face materials is created in boiler feed pumps from friction
at the seal interface and is normally safely discharged by con-
ductive water around the seal. When electrical conductivity of
high purity feed water falls below 2 Siemens/centimeter, it no
longer acts as a conductor and instead allows electrical potential
to build on the surface of the silicon carbide seal face.
Electro-corrosion occurs when this static charge builds on
the silicon carbide face that is acting as a super capacitor. When
the charge becomes large enough, it discharges to the mating
face or even to a dierent point on the same silicon carbide
surface. he extremely high temperatures from the arc created
by this discharge can result in the localized ablation of material
at the point of impact.
Sealing system designs to address electro-corrosion are
currently under continued development. Some general, basic
design approaches have been accepted for applications in which
electro-corrosion is likely to occur. Mechanical seal manufac-
turers can address the root cause by selecting seal face materials
with similar electrical conductivities. As noted in the ashing
discussion, it is desirable to apply a carbon-graphite material
mated with a hard face material (typically silicon carbide) in
high temperature water applications. In the past when the ideal
combination of seal face properties could not be found, eorts
to mitigate the eect of electro-cor-
rosion focused on the symptoms and
approaches such as ammonia dosing
and grounding brushes, which have
met with mixed success.
By applying surface treatments or
special coatings to silicon carbide seal
faces, the electrical conductivity of the
hard face can be matched quite closely
to that of the carbon-graphite seal face.
his approach addresses the root cause
of electro-corrosion while permitting
the use of the preferred seal face mate-
rial combination, which includes a
carbon-graphite seal ring.
Conclusion
hese four issues are just some of the operating parameters
that must be considered when selecting the most reliable
mechanical seal system design for a water handling application.
Working with your mechanical seal supplier will help ensure
that all pertinent operating conditions are identied so a sealing
system with maximum reliability can be selected for any water
application.
Next Month: What are the key steps to cutting packing for
optimum performance?
We invite your questions on sealing issues and will provide best
eort answers based on FSA publications. Please direct your ques-
tions to: sealingsensequestions@uidsealing.com.
P&S
he following members of the Mechanical Seal Division
sponsored this Sealing Sense:
Advanced Sealing International (ASI)
Ashbridge & Roseburgh Inc.
A.W. Chesterton Co.
Daikin America, Inc.
EagleBurgmann Mechanical Seals
Flex-A-Seal, Inc.
Flowserve, Flow Solutions Group
Garlock Sealing Technologies
Industrias Vago de Mexico SA de CV
John Crane
Latty International S.A.
Metallized Carbon Corp.
Morgan AM&T
Nippon Pillar Corp. of America
Scenic Precise Element Inc.
SEPCO - Sealing Equipment Products Co.
SGL Technic Polycarbon Division
H.C. Starck Ceramics GmbH & Co. KG
Figure 2. Silicon carbide mechanical seal face
damaged by electro-corrosion
FSA Sealing Sense
Q. What symptoms are typical indicators of an ine cient
pumping system?
A. Many pumping system components are not dynamic. hat
is, these components allow uid or heat transfer but, aside from
thermal expansion or structural vibration, do not move and do
not have dynamic surfaces that wear out. he most common
types of problems in these components are leakage, fouling,
valve failure and cracks in pipe supports.
For many industrial facilities, the energy consumed in
pumping uids comprises a large fraction of the facilitys over-
all electricity usage. Operators of pumping systems often are
not aware of how eectively the energy required to pump the
uids is being used. If they are unable to meet their functional
requirements, a large part of the plant, even the entire facility,
may be aected.
A few symptoms in pumping systems often indicate if
improper sizing, selection, operation or other issues aect the
systems performance. hey are:
Systems in which valves are throttled to regulate ow rate,
level, pressure, etc.
Systems that employ bypass (recirculation) ow regulation
Systems that involve a batch-type process, but one or more
pumps operate continuously
Frequent on/o cycling of a pump in a continuous process
Presence of cavitation noise either at the pump or elsewhere
in the system
An equipment procurement policy based solely on lowest
bid price
A multiple, parallel pump system in which the same
number of pumps are always in operation
A pumping system that has undergone a change in func-
tion (for example, a system that formerly provided cooling
water to eight plant heat exchangers, two of which are no
longer in service), but with no change in pump equipment
or operation
A pumping system with no ow, pressure or power indica-
tion (akin to driving a car with no speedometer, gas gauge
or other critical indicators)
he existence of any one of these symptoms does not guar-
antee signicant savings potential, but it indicates a greater
likelihood of achieving savings. he more symptoms present,
the greater the likelihood of potential energy savings.
Q. Are there any computer tools available to help analyze
pumping e ciency in systems?
A. Optimizing Pumping Systems: A Guide for Improved Energy
E ciency, Reliability, & Performance, the book referenced in the
rst question, has a list of 26 tools. Some provide a free down-
load, and others are commercially available. Two that you may
freely download include:
Pumping System Assessment Tool, which is available
from:
Department of Energy
Industrial Technologies Program (ITP)
Room 5F-065, MS EE-2F
1000 Independence Ave, SW
Washington, DC 20585
800.342.5363
www1.eere.energy.gov/industry/bestpractices/software.html
he Pumping System Assessment Tool (PSAT) helps
industrial users assess the e ciency of pumping system opera-
tions. PSAT and its accompanying valve tool support data mea-
surements in either English or metric units. PSAT uses achiev-
able pump performance data from HI standards and motor
performance data from the MotorMaster+ database to calcu-
late potential energy and associated cost savings. he tool also
enables users to save and retrieve log les, default values and
system curves for sharing analyses with other users. It is avail-
able for free download after registering on HIs Free Stu Page.
Pump System Improvement Modeling Tool (PSIM),
which is available from:
Hydraulic Institute
Pump Systems Matter
6 Campus Drive
1st Floor North
Parsippany, NJ 07054
973-267-9700
http://www.pumps.org/content_detail.aspx?id=5022
(Education/tools)
PUMP
FAQs

Pump System Improvement Modeling Tool (PSIM) is a
free educational tool focused on helping end users better under-
stand the hydraulic behavior of pumping systems. With the
challenges of todays marketplace, uid handling systems must
be both cost eective and energy e cient. It is essential that
users evaluate the total pump system in their designs. PSIM
models systems with up to 12 pipe runs. It is available for free
download, after registering on HIs Free Stu Page.
Q. Where can I obtain detailed information on improving
the e ciency and reliability of pumping systems?
A. Pump Systems Matter and the Hydraulic Institute (HI)
have published a book on this subject titled Optimizing Pump-
ing Systems: A Guide for Improved Energy E ciency, Reliability,
& Performance, available from www.Pumps.org.
Pumping systems are used throughout the world to trans-
port water and other uids and in the operation of most indus-
trial processes. Commercial and residential buildings also rely
on pumps for heating and cooling, re protection and other
functions. Pumping systems account for nearly 25 percent
of the energy consumed by electric motors and for 20 to 60
percent of the total electrical energy usage in many industrial,
water and wastewater treatment facilities. Fortunately, eco-
nomically feasible opportunities exist to
make industrial pumping systems more
e cient, allowing for reduced energy
costs, lower operating and maintenance
expenses and enhanced protability.
he initial purchase and installa-
tion cost of a new pumping system is
typically a small part of the total cost to
operate a system over its life, which can
be more than 15 to 20 years, depending
on the application. It is the routine oper-
ating costs of energy, maintenance and
other recurring expenses that are the pri-
mary components of the total lifetime
cost. herefore, optimum e ciency in
designing and operating pumping sys-
tems is in the best interest of all facilities.
However, the importance of pump-
ing systems in the daily operation of
facilities promotes the practice of over-
sizing pumps to ensure that the needs of
the system will be met under all condi-
tions. his practice, unfortunately, often
leads to ine cient operation, resulting
in unnecessarily high energy and main-
tenance costs.
P&S
Pump FAQs is produced by the Hydraulic Institute as a ser-
vice to pump users, contractors, distributors, reps and OEMs
as a means of ensuring a healthy dialogue on subjects of
common technical concern.
HI standards are adopted in the public interest and are
designed to help eliminate misunderstandings between the
manufacturer, the purchaser and/or the user and to assist the
purchaser in selecting and obtaining the proper product for
a particular need.
As an ANSI approved standards developing organiza-
tion, the Hydraulic Institute, process of developing new stan-
dards or updating current standards requires balanced input
from all members of the pump community.
We invite questions and will endeavor to pro-
vide answers based on existing HI standards and
technical guidelines. Please direct your inquiries to:
pumpquestions@pumps.org.
For more information about HI, its publications,
Pump LCC Guide, Energy Saving Video-based educa-
tion program and standards, please visit: www.pumps.
org. Also, visit the new e-learning portal with a compre-
hensive course on Centrifugal Pumps: Fundamentals,
Design and Applications, which can be found at:
www.pumplearning.org.
Practice & Operations
W
hen a pump is started and run across the line, it
will provide maximum ow at optimal e ciency.
However, a pump motor operated continuously
at full rated speed is ine cient during periods when maxi-
mum ow is not required, and the pump and motor will
wear out faster than if the pump speed were regulated.
he a nity lawswhich express the relationship
between a pumps shaft speed, volumetric ow rate and
powerstate that running a pump at rated speed generates
rated ow at rated power. However, a pump motor powered
directly from the line will still be running near full power
during periods of reduced demand. Operating in this way
is ine cient, especially if the pump is oversized to accom-
modate future demand. One method of designing a better
pumping system is to use lead-lag control.
Lead-lag control is nothing new in the pumping indus-
try, and a common lead-lag design features a duplex booster
pump system to maintain building water pressure. In these
designs, lead-lag control is used so that a system that requires
multiple pumps to maintain water pressure at peak demand
will not have to use all the pumps when the demand is
reduced or nonexistent.
Preferably, some of the pumps can be shut down when
demand is low, and the system can be designed so that the
water pressure can be maintained by a single pump during
periods of low demand. Properly designed lead-lag systems
will improve the e ciency, performance and longevity of the
pumping system.
VFDs Beat Mechanical Control
A lead-lag system requires that the pump controls switch the
pump motors on and o based on demand. he simplest way
to switch the motors on and o is with an across-the-line
starter in the form of a contactor. However, starting a motor
directly across the line at full power presents issues. Powering
a motor directly across the line will result in high starting
currents. he current draw from a line started motor can be
in excess of six to seven times the motors full load amper-
age rating. his not only stresses the motor, but can result in
excess demand charges from the electric utility.
Across-the-line starters can be used in combination with
other mechanical devices to regulate the pumps output
including balancing valves, ball valves and buttery valves.
Some of these devices will require manual adjustments, while
others are designed to automatically control pressure. hese
mechanical devices can reduce pressure to desired levels but
do not solve the across-the-line starting issue nor signicantly
contribute to energy savings.
A better approach for maintaining the desired water
pressure is to regulate the speed of the pump motor with a
variable frequency drive (VFD). VFDs control the speed of
AC induction motors by controlling the frequency and volt-
age supplied to the motor. While mechanical devices can be
installed at a pumps output to adjust ow, a VFD regulates
ow by adjusting the motor/pump speed. his approach is
much better for a number of reasons:
Uses a minimum amount of energy
Reduces motor starting current
Provides a degree of motor protection
Cuts the wear and tear on the motor
Simplies the design of the ow control system
Provides extensive diagnostics
Reduces the required maintenance
When a VFD is used, the controlled motors e ciency
is optimized and runs at maximum e ciency regardless of
the required ow and corresponding motor/pump speed.
he VFD input current rises linearly with respect to output
power because the VFD can slowly ramp the pump up to
speed. As a result, the typical six to seven times motor rated
current seen with an across-the-line started motor is nonex-
istent with a VFD.
As a result, the negative impact of frequent start/stop
cycles is greatly reduced because the VFD limits the motors
inrush current, which and prevents the motors thermal rises
that are inherent with across-the-line starting.
Basic VFDs provide phase loss detection and motor
thermal overload protection. Advanced pump-specic VFDs
oer features such as loss of prime detection, detection of a
pump in a no-ow (deadhead) condition, low/high-pressure
VFDs Improve Motor &
Pump Control
Christopher Jaszczolt, Yaskawa
VFDs replace mechanical devices and PLCs for lead-lag pump control.
level detection, broken pipe protection and pump over cycle protection. hese
factors make VFDs superior to mechanical devices for regulating pump ow, and
other features of VFDs allow direct implementation in complex pump control
applications.
Integrated PID Control Is Better Than External PLCs
(Moved later in the paragraph) Many VFDs have a built-in proportional-integral-
derivative (PID) loop controller, which makes external PID controls unnecessary.
hese External controls are typically implemented with a programmable logic control-
ler (PLC) or a stand-alone proportional-integral-derivative (PID) controller. In either
case, an extra component must may need to be purchased, programmed, installed
and interfaced to the VFD. However, many VFDs have a built-in proportional-inte-
gral-derivative (PID) loop controller, which makes external PID controls unneces-
sary. Performing PID and other control functions internal to the VFD saves money,
reduces complexity and cuts installation eort. he advantages of this setup are:
Costs less
Simpler to congure
Reduces integration among control components
Requires less space
Requires less maintenance
In pump control applications, the VFDs built-in PID feature is used to con-
tinuously monitor a feedback signal to maintain an output set point by adjusting
motor/pump speed. In the case of a system used to maintain water pressure in a
building, the VFD automatically increases the motors speed and the pumps output
as the feedback signal shows a drop in pressure.
Conversely, the VFD reduces motor/pump speed and eventually shuts the
system down based on pump ow requirements as determined by the feedback
from the pressure sensor. As a result, the VFD controls the motor/pump to gener-
ate the required ow to maintain the demanded pressure, all without the need for
additional external automation components.
Using VFDs to Implement a Lead-Lag System
A single VFD can be used in a basic lead-lag system to regulate pressure by directly
controlling the lead pump motors speed, while turning the lag booster pumps on
and o through each pumps across-the-line starter (See Figure 1). his scheme uses
the VFDs discrete outputs (dry output relays) to control each booster pumps motor
contactor.
Typically, the VFD activates the lag pumps one at a time when the demanded
pressure can no longer be maintained by the active system. Eventually, the VFD-
controlled lead pump and the lag pumps all run simultaneously to provide full ow
to meet the systems peak demand requirements.
he VFD regulates water pressure as demand uctuates, and the input power
required by the pumping system is minimized. Simply put, the VFD will moni-
tor the pressure and draw just enough power to ensure that the system maintains
demand. In addition, the VFD will reduce the speed of the lead motor as each
lag pump motor is activated, reducing stress imposed on the system due to water
hammer and further increasing e ciency.
Inversely, the VFD will shut o each lag sequentially as the system requires less
ow to maintain demand. As each backup pump shuts o, the VFD will adjust the
speed of the lead motor to maintain the demanded ow. his will occur until the
lead motor/pump is solely responsible for meeting demand. Ultimately the demand
may diminish enough so that the pump will barely be creating ow. At this point,
the VFD can be programmed to shut the motor/pump o, essentially putting the
system to sleep until demand increases.
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Multiplexing VFDs
Multiplexing allows multiple VFDs to operate as a coordi-
nated system, and it requires a high level of automation. If this
automation is to be implemented via VFDs alone as opposed
to VFD/PLC combos, advanced pump-specic VFDs are
required. All the VFDs must be able to communicate over a
digital network, and each VFD must be able to provide the
required pump logic and PID control.
In the example shown in Figure 2, the multiplex pump
system uses a transducer to sense line pressure. his transducer
sends an analog 4-20mA signal proportional to pressure to one
of the VFDs. Communications among the VFDs is via a simple
Modbus RS-485 digital network in this example, although
many networks are available to accomplish the required com-
munications including Ethernet-based networks such as
Ethernet/IP.
Required control and sequencing is congured through the
VFDs, with communications among the VFDs via the digital
network. he single pressure feedback signal is re-transmitted
among the VFDs over the network, so only one feedback device
is required no matter how many VFD/pump combinations are
used.
However, multiplex systems typically use at least two
feedback sensors congured in a redundant mode in case one
sensor fails. Upon losing the primary feedback signal, the VFD
will automatically switch to the other feedback signal, while
simultaneously alerting the operator of the primary feedback
signals failure. As a result, the pump system will experience no
interruptions.
Another level of redundancy is built into each of these
pump-specic VFDs. If a VFD is currently running a pump
and loses power or shuts o, the other idle VFDs will automati-
cally come online as required to maintain system demand.
Figure 1. VFD with across-the-line lag motors and pumps
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RS-485 Network
Twisted Pair Wire
M M M M
Pump 1 Pump 2 Pump 3 Pump 4
Suction
Discharge
Transducer
Feedback
Optional:
Flow Sensor
Feedback
SCADA
Software
Used for remote
control and monitoring
of system
Optional:
Suction Transducer
Feedback
Systems can be configured for use with multiple feedback transducers for redundant backup.
A minimum of one feedback transducer is required for system operation.
Figure 2. Four VFD multiplex pump system
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Advanced pump specic VFDs can be congured to oper-
ate in dierent ways in a multiplex system. In the Figure 2
example, when the lead VFD cannot maintain the demand of
the system, it activates the lag units through the digital net-
work. When this occurs, the most recently activated VFD
becomes the lead and regulates its output frequency based on
the feedback signal, while the former lead unit becomes a lag
unit running at a xed preset speed.
An alternate conguration would allow all the VFDs to
regulate motor/pump speed based on the pressure feedback
signal, ensuring that the pumps share the load equally. In typi-
cal operating conditions, this would result in all the motor/
pumps running at the same speed. his would balance pump,
motor and VFD wear and tear.
With this alternate conguration, as the demand decreases
the running pumps will shut down one by one until a single
pump is left running. If demand continues to reduce, the nal
pump can be congured to shut o.
Some advanced pump-specic VFDs have the capabil-
ity of alternating which unit starts as the lead VFD based on
lowest total run time, ensuring that each VFD/motor/pump
will accumulate a roughly equivalent run time. Some pump-
specic VFDs can also be congured to accommodate systems
where a jockey or pressure maintenance is used to maintain
the desired pressure in low demand conditions. More complex
pump control capabilities available in some VFDs include
pressure control using a secondary feedback for water level
monitoring and regulation, suction level monitoring and/or
regulation water level or suction pressure control and ow level
monitoring.
Like a PLCadvanced VFDs can be programmed, moni-
tored and maintained with PC-based software. Unlike a PLC,
this software is generally provided free by the VFD supplier.
VFD programming and monitoring software is also easier to
use than similar software for PLCs because the software is for a
single application specic rather than general purpose.
VFDs have been used to control pumps for many years.
However, advanced pump-specic VFDs now allow users to
improve motor/pump control and protection without the need
for ine cient mechanical devices or costly PLCs.
P&S
Christopher Jaszczolt is an application
engineer with the Drives and Motion
Division of Yaskawa America, Inc., in
Waukegan, Ill. He has a BSEE from
Northern Illinois University and ve years
experience applying variable frequency
drives in industrial applications. He can
be reached at chris_jaszczolt@yaskawa.com.
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I
ndustrial producers typically invest millions in their
infrastructure. Despite such investments, many produc-
tion facilities lack critical motor performance monitoring
and reporting capabilities to help maximize e ciency and
energy use and better manage overall operating costs.
Without the kind of data provided by integrated
automation, producers are similar to a race car driver in a
200-mile-per-hour race who is just using a common auto-
mobile dashboards fuel, speed and temperature gauges.
Limited visibility into the performance of their production
processesand therefore how to optimize themis only
part of the challenge that producers face. If a process breaks
down and production stops, costs of lost output and standby
labor can mount by the hour.
Motors Are the Muscle
Electric motors are the muscle that keeps materials and
work in progress in industrial processes. When a motor fault
occurs, production can come to a halt until the cause is diag-
nosed and repaired and the motor restarted. hese outcomes
can put production at riskranging from reasonable (restart
within seconds) to costly (restart taking hours or days).
Risk Insurance
Overload relays were invented to protect industrial motors
from damages caused by overload conditions. hey are spe-
cialized devices that can sense an overload or other adverse
circuit condition, open a circuit and then provide control or
some operational indicator. In eect, the motor protective
function of a conventional overload relay can place process
productivity at risk by protecting its connected motor.
Dierent overload relay types are available, ranging
from simple thermal sensing units to more complex, solid-
state relays. hese may include a wide range of programmed
intelligence and reporting capabilities, which is called smart
motor management (SMM). An important feature of this
type of SMM device is the capability of assuming local con-
trol of the process if communication is lost. While overload
relays are designed to protect the motor only, SMM can help
protect the motor and the process it drives.
Weak Link in Complex Processes
In the past few decades, industrial processes have become
increasingly complex. Fast-changing market demands,
including customer expectations of more diverse prod-
ucts (and mass customization of those products), require
tremendous production exibility from manufacturers.
Competition among manufacturers drive them to respond.
Given this complexity and the demands for manufac-
turing exibility and responsiveness, industrial engineers face
the challenge to keep up. No matter how sophisticated their
process and control designs, simple or catastrophic motor
failure anywhere along the line can stop feeder, production
or collateral processes with many possible consequences.
Smart Motor Management
Traditional motor starters, controlled by a PLC or DCS, pro-
vide little status and diagnostic data into the connected con-
trol system. For years, a single, contactor-operated auxiliary
contact (ON status) and an overload-relay-operated auxiliary
contact (FAULT status) wired to PLC or DCS inputs pro-
vided acceptable levels of status and diagnostic data.
A cost is associated with each input status and output
control in a conventional PLC or DCS control system. In
addition, a cost and complexity to wire is associated with the
conventional two inputs and one output of the traditional
motor starters.
In fact, the total cost of wiring 25 motor starters to their
PLC or DCS alone (guring an average of 100 feet of wire
for each connection) can be up to $15,000, not counting
conduit, cable tray or I/O cabinet space. Nor does it account
for the di culty in troubleshooting about 2.5 miles of wire if
something goes wrong.
Clearly, another approach is needed. smart motor man-
agement. With an SMM device in place, all this information
can be brought into the PLC or DCS without additional
Smart Motor
Management
John Burns & Jeff Woolfolk, Siemens Industry, Inc.
Data-driven visibility helps protect industrial processes and motors.
traditional I/O or interconnecting wiring,
saving thousands.
Simply dened, this SMM model uses the
latest in compact, solid-state technology cong-
ured with modular, pre-congured intelligence
to provide a wide range of real-time operational
data that can be used for early warning and
post-fault diagnostics.
he congurable nature of SMM devices
allows the user to select the device response to
conditions that would cause other motor over-
load relays to trip.
Network or Local Control
If network communications fail, the intelligent
overload relay can immediately take over local
control of the motor until the network comes
back up, keeping the process motors moving.
When network operation returns, the local
operating data updates the central control unit,
so its operating prole stays current. In addition to predened
motor control applications, user dened logic elements, such as
truth tables, timers, counters, etc. are included to allow the user
to customize the predened motor control applications to meet
their individual needs.
Using PROFIBUS communications, these intelligent
overload relays can provide much more operational data and
information, such as:
Load status (on, o, warning, trip)
Warning and trip indicators (jam, loss of load, vibration and
more)
Figure 1. Optional measurements are also available with SMM.
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Progressing Cavity Pumps

One is right for your application
Learn more. NETZSCH Pumps North America, LLC
Tel: 610-363-8010
email: PUMPS@netzsch.com
www.netzschusa.com
NETZSCH, the world market leader with 60 years of
experience and over 500,000 progressing cavity pump
installations worldwide. With sales, production and service
on 6 continents ensuring customer support to provide
NETZSCH Pumps & Systems Solutions you can trust
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Statistical data (starts, trips, operating hours)
Measured values (current, voltage, power
factor, KW, temperature and more)
PROFIBUS DP can also save the cost and
hassle of conventional wiring: up to 124 devices
can be connected to a single two-wire network
connection. hese savings can add up fast and
help oset, if not pay for, a plants conversion to
SMM. At the very least, the savings can accelerate
the plants ability to break even on its investment.
Power measurements such as the ones listed
in Figure 1 can help plant management monitor
site power consumption much more precisely and
shed loads down to a single motor, which can help
reduce peak usage charges. his information can
also help them compare measured energy usage
with utility billings to check for possible over-
charges and get reimbursed. In eect, all the addi-
tional data that can be used to open a window of visibility
for optimizing a plants motor infrastructure becomes available.
Applications
SMM, has many uses in industrial processes, whether the pro-
cesses feed production, make up production or dispose of pro-
duction wastes.
Pumps & Mixers
Fluids can be part of industrial production as work-in-progress
gets washed, cooled, coated, rinsed or any combination, with
excess uids re-circulated or disposed. In some cases, uids
themselves are the work-in-progress, whether producing harsh
chemicals or baby formula.
Of course, mixers are used to combine inputs while pumps
keep the material moving unless a motor faults or perhaps a
pump rotor bearing fails. Either way, production can stop, or
if upstream ows do not stop, pressure buildup can damage
piping, seals or create unsafe conditions.
If a rotary bearing fails due to increased friction, two con-
ditions occur: motor current or variant temperature. SMM
devices can measure the increased motor current. Add a tem-
perature input, and they can monitor the temperature increase.
In this situation, the SMM device senses the condition(s) and
alerts plant management so that a technician can be dispatched
to x the problem before the process fails.
Cooling Towers
Many plants require cooling towers with industrial fans to
release the heat generated by production. Exhaust fans are also
used to draw o fumes that a petrochemical plant may produce
or the dust that a milling operation can generate.
When fans get out of balance, their vibrations can begin to
degrade their motors performance. With an analog sensor con-
nected to the SMM device, vibrations outside set parameters
can signal that a fan needs maintenance before the motor faults,
which can prevent a fan failure that would force a production
shutdown and possibly invoke OSHA, EPA and other regula-
tory nes.
Valves
Industrial plants can have many hundreds, if not thousands,
of PLC-controlled, motor-driven valves that open and close
at specic production points. Timing of the valves operation
often requires exacting precision to allow just the right amount
of uid ingredients into the process or e uent waste out.
When a valve gets stuck, a process can be slowed or possi-
bly even awed as incorrect amounts of inputs enter the produc-
tion ow or waste isnt appropriately discharged. SMM devices
can signal the problem because the valves motor current will
increase. Plant management can immediately send a technician
to x the valve prior to failure.
Circuit Breakers
For non-communicating breakers, SMM can measure the cur-
rent, voltage and power usage at the breaker level and trans-
fer those measurements back to the PLC and DCS. his is a
cost eective solution for intermediate energy consumption
measurement.
Conguration, Not Programming
Advanced intelligent overload relays have sophisticated yet
easy-to-use conguration software that eliminates costly and
time-consuming programming. A graphical user interface (see
Figure 2) enables users to select applications easily. No pro-
gramming or complicated conguring is needed. For example,
conguring the SMM device illustrated in Figure 2 to sense and
report over-current conditions requires just two mouse-clicks.
Clyde Bergemann Case Study
Atlanta-based Clyde Bergemann Inc., an OEM supplier of
state-of-the-art boiler cleaning systems, wanted to oer custom-
ers e cient and future-proof solutions for the modernization of
Early knowledge of valve motor current problems can help avoid failure.
its boiler systems. Its process engineers chose an SMM for its distributed design.
hey found its features provided many more useful functions which help make the
engineers work much easier and reduce costs.
As a exible and modular system, it can be easily connected to PROFIBUS,
oers a standardized interface and provides detailed operational, service and diag-
nostics data. It can be easily parameterized and guarantees a reliable cleaning opera-
tion even under harsh ambient conditions.
Paulaner Brewery Case Study
Operating for 24 hours per day every day of the year, Munichs Paulaner brewery
produces approximately 66 million gallons of beer per year. To maintain this output
and make the plant t for the future, management decided to deploy a modular and
expandable SMM platform when modernizing the ltration system control tech-
nology. Especially appealing was the high functionality of SMM device that went
far beyond just measuring current.
hanks to the increased number of signal connections realized with the addi-
tion of digital modules, all ltration and cooling process steps can be centrally
monitored and controlled. Process data are directly transferred to the control center.
he high plant transparency assures a precise detection and fast correction of motor
faults as well as the easy conguration of standardized diagnostic routines.
Conclusion
E cient and cost-eective industrial process and control designs are more critical
than ever to the vitality, protability and future of manufacturing and processing
industries. hat is because market demands and competitor pressures require ex-
ibility, adaptability and responsiveness, while optimal performance helps ensure
cost-competitiveness. To gain these benets, plant management should investi-
gate SMM and its applications. his can deliver the motor data needed for greater
Samples of one SMMs pre-programmed functional applications include:
Protective Functions
Overload protection
(Class 5 - 40)
Thermistor motor protection
Phase failure monitoring
Unbalance protection
Stall protection
Earth-fault monitoring
Monitoring of current limit values
Monitoring of operating hours
Monitoring of motor stop times
Number-of-starts monitoring
Control Functions
Direct online starter
Reversing starter
Star-delta starter
Star-delta starter with reversal of rota-
tional direction
Two speeds, motors with separate wind-
ings (pole changeover switch), also with
reversal of rotational direction
Two speeds, motors with separate
Dahlander windings, also with reversal
of rotational direction
Solenoid valve actuation
Positioner actuation
Soft starter actuation
Soft starter actuation with reversal of
rotational direction
Expanded Monitoring Functions
Temperature monitoring Pt100,
Pt1000, KTY83, KTY84
Voltage monitoring
Power monitoring
Cos-phi monitoring
Phase sequence detection
Input, output and monitoring
0/4-20 mA signal
Measuring curves reporting
Additionally
Logic modules (truth tables, counters,
timers, edge evaluation, limit monitoring
and more)
Standard functions (power failure moni-
toring, emergency start, external faults
and more)
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operational visibility, energy sav-
ings and motor life. It can also
eectively enable processes to
become situation-aware to help
prevent shutdown due to a motor
failure. his alone can more than
pay for the capital costs and help
lower the life cycle costs.
P&S
Figure 2. A graphical user interface allows for easy con-
guration of system parameters.
John Burns has been with Siemens Industry Inc. for 14 years and is product manager for
the Control Components and System Engineering division. He is responsible for the life cycle
management and promotion of Siemens communication capable control products for the U.S.
market. Burns can be reached at john.burns@siemens.com or 770-625-5726.
Je Woolfolk is target market consultant for the Low Voltage Motor Control Centers at Siemens
Industry Inc.s Industrial Automation Division and is based in Norcross, Ga. In this role, he is
responsible for promoting motor control centers and related products to specifying engineers and
end users. Woolfolk joined Siemens in 1982 as an application engineer in West Chicago, Ill.
A New Revolution in Hose Pump Technology

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he groundbreaking oil-less vacuum technology
(OVT) priming system oers multiple improve-
ments to traditional vacuum priming systems.
While both allow for a basic pump to prime automatically,
the OVT does this more e ciently with lower maintenance
and higher air handling for faster priming. In addition,
the OVT systems non-contacting rotors eliminate internal
wear, which increases longevity and provides the reliability
of no decrease in performance over time.
he OVT system oers lower maintenance and oper-
ating expenses because the system is dry runningno re-
circulating oil is needed. Eliminating the oil, in turn, elimi-
nates any possible pollution that traditional priming systems
may experienceoering a much-improved, eco-friendly
alternative to prior technology. Traditional vacuum prim-
ing systems require service every 5,000 hours. he OVT
priming unit only requires service every 20,000
hours, which is four times less maintenance.
Not only does the OVT system have high
vacuum capability with deeper suction lifts of
28.4 inches of mercury, but it also maintains a
high vacuum at lower speeds. his air-cooled
priming system has no water levels to check
and no cooling system to maintain unlike
traditional vacuum priming systems. hese
capabilities allow the OVT priming system to
perform in a variety of applications from sewer
bypassing to wellpoint dewatering.
Most interestingly, the OVT priming
system is tolerant of accidental liquid carryover.
Prior vacuum priming systems would be dam-
aged if liquid carried over. In turn, this makes
the OVT priming system the most rugged
priming system on the portable pump market
today.
Oil-less Vacuum
Technology
Kirsten Petersen Stroud, Thompson Pump
Increased efciency, higher air handling and fast, automatic priming are provided
with new technology.
The OVT priming system
Two OVT pumps on the sewer bypass application
Proven Technology
Research and development of the OVT priming system began
in late 2006. Designing, building and testing prototypes began
immediately following a full feasibility study. housands of
hours in durability and eld testing lead to the validation of
the ideal technology to release for consumer availability.
Recently, the manufacturer provided three OVT pumps
for a sewer bypass project near Highway 49 South in Richland,
Miss. he customer, Hemphill Construction, has had several
highly successful sewer bypass projects with the manufacturer
in the past. Initial priming times were a concern for this proj-
ect. herefore pumps with OVT were recommended since
they provide high CFM (air ow) which allows for fast initial
priming and re-priming times.
When we delivered one of the OVT pumps, we tested
the unit with a 20 suction lift, says Jim Templeton, the
manufacturers sales representative. From totally dry, the unit
primed with the engine idling, in just less than a minute.
Since the line to tap into the initial bypass was 38 feet
deep, the contractor excavated a pit to lower the pumps to an
elevation with a manageable suction lift. he OVT pumps not
only t the anticipated duty point very well, they minimized
the number of pumps that would need to be placed in the
excavated pit.
he four month project used the three 18-inch OVT
pumps to bypass a peak ow of 30 MGD (million gallons per
day) while the 48-inch West Rankin Sewer District gravity
pipeline was being slip-line repaired, where a smaller pipe is
placed within the larger, deteriorated pipe. Each hompson
Pump provided was capable of 11,000 gallons per minute
(GPM), 160 feet of head and solids-handling up to 4 inches.
he pumped sewage was rerouted using two 1,500-foot
lines of 18-inch high-density polyethylene (HDPE) pipe that
connected into the force main line that lead directly to the
treatment plant. Once these HDPE pipes delivered the sewage
into the force main line, the hompson OVT pumps contin-
ued to push the sewage down the line almost 6 miles to the
Savanna Street Water and Wastewater Treatment Plant in the
neighboring city of Jackson.
he OVT pumps performed to a T, said Templeton.
In Summary
he OVT priming system provides:
Dry runningno sealing or lubricating oil is needed in the
vacuum compression chamber.
Ultra low maintenancethe unit only requires servicing at
20,000 hour intervals.
Extremely high air handlingfaster priming times (97
cfm).
High vacuum capabilitydeeper suction lifts (28.4 inches
of mercury).
E ciencylow horsepower for high cfm.
Longevitylow life cycle costs, non-contacting rotors
eliminate internal wear.
Air coolingno water levels to check and no oil system to
maintain.
Ruggedtolerable to liquids, dust, and modest solids.
Reliabilityno decrease in performance over time.
Performancemaintains high vacuum at lower speeds.
Versatilitycan be used in a variety of applications from
sewer bypassing to wellpoint dewatering.
Economicaloperating costs are low because of the main-
tenance-free design and the reduced energy requirement,
made possible by the high-volumetric e ciency along with
a zero friction chamber.
Eco-friendlyno sealing or lubricating oil provides for no
oil pollution or smoke.
Guaranteed performance.
he OVT priming system can be added to certain cen-
trifugal pumps.
P&S
Kirsten Petersen Stroud is the market-
ing manager for hompson Pumpa
provider of heavy-duty lines of portable
pumps ranging in size from 2 inches to 18
inches for use in applications in the areas of
public works, municipalities, construction,
agriculture, dewatering, mining, sewer/
lift stations and water/waste water. She can be reached at
kpetersen@thompsonpump.com.
Curve of pump with oil-less system (September 2010)
T
he volute serves a simple purpose in
radial machinery: to transfer ow from
an annular cross section to an exit pipe.
Of course, there are many variations on the
theme. he process is reversed for turbines,
where more than one exit or inlet to the volute
may exist, and many other arrangements are
possible.
Despite its simplicity of purpose, the
volute can be a complex component to design
and analyze. he curved, three-dimensional
shapes can be di cult to layout in a computer-
aided design (CAD) system. he process often
requires many iterations across departments
until a rational, three-dimensional shape is
obtained that satises even the basic aero or
hydrodynamic requirements.
Volute Geometry
Volutes are broken into two basic families. he overhung
or asymmetric style of volute is typical of designs used in
the compressor industry. he chief advantage of this type
of design is the ability to control the centroid of the cross-
sectional area, thereby controlling the angular momentum
of the volute.
he other broad family of volute designs is the sym-
metrical style commonly used in pumps. hese designs often
use a parameterized layout. Also, complicated variations are
more common in this family, such as dual exit volutes and
splitters to control radial thrust. A special type of volute with
a splitter oriented in a vertical direction is used to handle
the dual engine exhaust that is channeled into turbocharger
turbines.
here are two approaches to laying out a volutes geom-
etry. he rst method is a volumetric intersection method
and is typically accomplished with solid modeling techniques
using CAD. he scroll and exit pipe sections are formed and
blended together, and the intersecting volume of the two
shapes is cut away. For designs that use this method, the
tongue is simply the edge that results where the scroll inter-
sects with the pipe section of the volute.
hese designs allow little control of the resulting edge,
although a llet may give some aerodynamic control. hese
designs are generally considered easier to manufacture, par-
ticularly for asymmetric designs.
he other volute design method uses a technique of
building up cross sections that ride up over a dened tongue.
his allows the shape and angle of the tongue to be explicitly
controlled. he volute tongue is a leading edge and can show
a signicant sensitivity to the ow direction, similar to the
leading edge of an impeller or diuser.
Figure 1 illustrates two virtually identical volutes with a
huge dierence in the ow elds that result from a modest
change to the tongue region. he design on the left shows a
massive separation that starts at the tongue and grows out
to the exit plane. he design on the right shows a much
Gain Efciency with
Volute Design
Concepts NREC
Simplifying the design and analysis of this complex component
Figure 1. Even a modest design change to the tongue region of a volute means
signicant ow eld differences.
smoother ow eld after the tongue angle was aligned better
with the incoming ow direction.
Laying out a volute can be a tedious process in CAD. A
parameterized method of dening the volute using computa-
tional uid dynamics (CFD) can make the process much easier
and save a lot of time and eort. hese methods allow for spe-
cic control of key uid dynamic considerationssuch as area
of the scroll for a specied level of diusion.
Other issues such as centroid locations and
geometry constraints can be accommodated much
more easily than working directly in a CAD system.
Figure 2 shows a parameterized volute allowing for
explicit control of the cross-sectional shape, tongue
region, area distribution and pipe direction.

Flow Behavior and Modeling
A common misconception in volute analysis is
that angular momentum is constant in the scroll
In fact the walls of the volute can exert an uneven
pressure force on the ow that changes the angular
momentum
However, a more uniform velocity and pressure
distribution can be achieved if the ow is maintained
at a constant angular momentum by controlling the
cross-sectional centroid. his can be achieved in
practice by ensuring that the cross-sectional area of the scroll
divided by the centroid radius varies as a linear function of the
circumference of the scroll.
Meanline models for volutes have been around for many
years. A common technique used to model the scroll loss is
to break down the incoming ow into tangential and radial
components. he radial portion of the kinetic energy is consid-
ered to be lost (or at least some signicant fraction of it), and
Figure 2: Using a parameterized method to dene volutes saves time and effort.
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Learn more. NETZSCH Pumps North America, LLC
Tel: 610-363-8010
email: SLUDGECAKE@netzsch.com
www.netzschusa.com
NETZSCH, the world market leader with 60 years of
experience and over 500,000 progressing cavity pump
installations worldwide. With sales, production and service
on 6 continents ensuring customer support to provide
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the tangential component undergoes an area expansion loss if
there is net diusion. Other embellishments such as friction
loss and a diuser-like loss for the pipe section can round out
the calculation.
Figure 3 shows the results of volute performance calcu-
lated in a meanline model. Note the signicant variation in
performance across the ow range. CFD generally provides the
most denitive results for volute performance. he
ow eld can be complex. Grid generation can be
tricky for the complicated shapes, but several meth-
ods have been developed to build structured grids
for the volute shapes. Unstructured grid generation
is often used, as well.
Impact of the Volute
he performance of the volute has a signicant
impact on the overall stage performance. For simple
stages with an impeller and volute combination, the
volute can represent the dominant portion of lost
e ciency, particularly at o-design conditions or if
the volute is not sized correctly. Leaving the volutes
design as an afterthought can have a detrimental
impact on the overall design. Many design, layout
and analysis options are now available for improving
the process.
P&S
Concepts NREC is an organization that provides turboma-
chinery design, engineering, manufacturing and CAE/
CAM software. For more information, email info@con-
ceptsnrec.com, or visit www.ConceptsNREC.com.
Figure 3. Results of volute performance calculated in a meanline model show-
ing signicant variation across a ow range.
UNMATCHA8 L L L XP L R| L NCL
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ralslng oebt ano equlty capltal, ano asslstance
on acqulsltlons.
To learn more about [oroan, Knautt & Company,
contact any member ot our Flow Control
team. Access our Flow Control researcb at
www.joroanknautt.com/Nowcontrol.
G. Cook [oroan, [r.
Managlng Prlnclpal
cj@joroanknautt.com
312.254.5901
[ack C. Gonoer
vlce Presloent
jgonoer@joroanknautt.com
312.254.5918
Davlo A. Kakareka
Assoclate
okakareka@joroanknautt.com
312.254.5907
O
n Friday, January 7, 2011, a processing unit was
shut down due to a sequence of events that led to
the loss of main fractionation tower bottoms circu-
lation at a renery. he east bottoms circulation train, which
consisted of a turbine, gearbox and pump, was already out of
service for a pump bearing repair. he west bottoms circula-
tion train had been in service for several days prior to the
event.
Lubrication Issues
he day of the event, the lubricating oil in the west turbine
was reported to be dark and the bearing housing temperature
was externally measured to be approximately 350 degrees F.
he unit was safely shutdown and the equipment prepared
for maintenance. he pump and turbine are equipped with
oil rings that provide lubrication to the bearings. See Figure
1 for a cut-a-way of the oil ring design for turbine.
he Basic Operator Training course for the renery
instructs new operators to check the lubricating oil for mois-
ture, particles and breakdown by draining a sample from the
bearing bracket so that the condition can be visually assessed.
his technique, however, does not take into consideration
the size of the bearing bracket reservoir or the design of the
bearing.
In this particular situation, the turbine is equipped with
a journal bearing with only a small lubricating oil reservoir.
Turbine Bearing Failure
Keith Schindler & Terry Auger, Toledo Rening
Oil quality assessment causes lubrication issues at a renery.
Oil
Level
Typically
1/4 - 3/8
spider or
setting tabs
inside oil cup
Journal Bearing
Oil Fill Bulb
Bearing Housing
Normal Operating Scenario: Static Oil Systems
Sleeve (journal) bearing with oil- ring lubrication; consists of a metal ring that rides on top of the shaft
Oil level height is set so the oil ring is submerged about inch into the oil
Oil level in the bearing housing is controlled by the setting of the spider or setting tabs inside the oil ill bulb
housing
Figure 1. Oil ring lubrication for a sleeve bearing application
As a sample of oil is removed from the bearing housing, the oil
level in the reservoir drops below the oil ring (See Figure 2).
he lubrication to the journal bearing is, therefore, tem-
porarily interrupted. he oil level in the bearing housing subse-
quently drops below the oil level setting in the side oiler and the
oiler starts to replenish the oil in the reservoir, but the ll rate
can be slow depending on outside temperature conditions. he
bearings had failed because the oil replenishment took too long
after the samples were taken. he bearing ran without adequate
lubrication. he oil lm was depleted and the shaft rubbed the
babbet bearing.
Conrmation of the Failures Cause
To conrm the cause of the failure, a test was performed in
a controlled shop environment (the shop temperature was
approximately 68 degrees F) with the same type of turbine, bear-
ing bracket and lubricating oil. Proper oil level was established
in the bearing bracket and then all the oil was drained to get a
measure of the total volume (See Figure 3).
he oil removed was replenished to the bearing bracket,
and a second sample was pulled. he second sample removed
only enough oil from the bearing bracket to drop the oil level
below the oil ring as illustrated in Figure 3. his amount of oil
in the sample jar was determined to be very close to the total
amount of oil in the bearing bracket.
Also during this test, the replenish rate from the side oiler
was timed to see how long reestablishing the reservoir to the
proper level for satisfactory oil ring operation would take. It
took seven minutes for ISO grade oil at 68 degrees F to replen-
ish the level in the bearing bracket through the -inch NPT
connection for the side oiler. Note that the ll rate will be
slower for the colder outside temperatures experienced with the
application. he investigation followed a Latent Cause Analysis
methodology to determine the root cause of the eventas
Oil Fill Bulb
Journal Bearing
Bearing Housing
Oil
Could drop below
oil ring
Level
Oiler is not able to
respond quickly
enough to replenish
the oil in the bearing
bracket
Drain
Wrong way to check the bearing housing for water or drain water
Drain the oil/water out of the bearing housing drain; typically the drain connection is a larger pipe diameter than the
oiler side connection.
Drain rate is faster than the oiler ill rate; the oil level will drop below the oil level.
Oil ring runs dry, momentary loss of lubrication to the sleeve/journal bearing.
Lack of lubrication to the shaft. Metal to metal contact occurs.
Oiler slowly replenish the bearing housing with oil.
Note: Outside weather conditions will affect the oiler ill rate; the viscosity increases as the temperature drops.
Figure 3. Draining, ushing or sampling scenario
samples are taken to test the oil, the reservoir was not replenish-
ing the oil quickly enough.
Conclusions
Because the west pump was out of service for repair, the east
pump/turbine was critical to the units availability. To ensure
reliable service, the unit operators increased the monitoring
rounds on the main fractionation bottoms circulation train.
he lubricating oil was sampled frequently from the pump
and turbine to check for moisture, particles and oil breakdown
(darkening).
he New Operator Training program only briey covers
the generic steps to check for moisture or breakdown in equip-
ment with wet sump lubrication, and it did not provide ade-
quate steps to prevent this type of failure. he program should
be expanded to cover the generic oil check steps and expanded
to include specic designs so the unit operators can provide
proper monitoring techniques. he expanded program will
provide new operators with the foundation to expand with
experience to prevent this type of failure from reoccurring.
P&S
Keith Schindler is a reliability engineer for Toledo Rening
Company, LLC a subsidiary of PBF Energy. Keith has
more than 20 years of renery experience. He holds a BS
degree in mechanical engineering. He can be reached at
keith.schindler@pbfenergy.com.
Terry Auger is the lead machinist trainer for Toledo
Rening Company, LLC a subsidiary of PBF Energy. Terry
has more than 30 years of renery experience and is respon-
sible for the machinist training and development program
for the Toledo Rening Company. He can be reached at
terry.auger@pbfenergy.com.
Figure 2. The difference in the oil level when the bearing housing
is full and when the slinger ring is not submerged adequately is
small.
Our Pumps Do
What Others Cant
Maag gear pumps are engineered for some of the
most demanding conditions to which a pump can be
subjected:
pressures to 5,075 psi
temperatures to 600 F
viscosities to 4,000,000 cP
Clearances in four different pump areas are chosen
for the particular application. Available stand-alone or
as a system with motor, drive, etc. Call to learn more.
Maag Automatik Inc.
Charlotte, NC
MaagAmericas@maag.com
704-716-9000
a brand of maag group
ShanIey Pump & Equipment, Inc.
2525 South Clearbrook Drive
Arlington Heights, Illinois 60005
Phone: 847-439-9200 Fax: 847-439-9388
Visit our Website at www.shanleypump.com
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T
he Department of Energy (DOE) has adopted new
energy conservation standards for electric motors.
he DOE has determined these standards will result
in a signicant reduction of energy usage. Higher motor e -
ciency will result in lower billed power cost to the consumer,
but may actually increase the energy use.
Motor Comparison
Take the case of these two 125-horsepower, 4-pole motors:
Motor W: nameplated NEMA nominal
eficiency of 94.5% at 1,780 rpm, 3 Phase, 60
Hertz, 460 Volts.
Motor U: nameplated NEMA nominal
eficiency of 95.4% at 1,785 rpm, 3 Phase, 60
Hertz, 460 Volts.
Which one will result in a signicant conservation of
total energy use?
Motor W: 109.950 kW energy usage:
nameplated 94.5% eficiency
Motor U: 117.121 kW energy usage:
nameplated 95.4% eficiency
Why does the motor with the lower e ciency use less
energy?
Efciency Denition
he dierence in energy use between the two motors comes
from the basic denition of e ciency. E ciency is real
input power divided by (total) output power. E ciency is
a measure to determine the cost of operating the motor.
Surprisingly, we do not pay for the total power input, only
the real component of power.
he total power of the AC induction (reactive) motor
can be represented as a rotating vector summation of real
power and reactive power (Figure 1).
Total Efciency
Another term is needed: total e ciency, which is the total
electrical input power divided by the total mechanical output
power. For three-phase, AC induction motors:
Total electrical input power for three phase,
AC induction motors = line to line voltage
line current 3
For the example motors:
Total mechanical input power (converted to
kilowatts) = HPout 0.746 = 125 0.746 =
93.250 kW
To calculate the total electrical power input, additional
nameplate information is needed to calculate KVA:
The Case of Action/
Reaction
Dennis Rimmel, Sloan Electric
Energy efciency may not always mean total efciency.
KVAR
Reactive
Power
KW (Real)
Resistive Power
Rotation
KVA
Total
Power
Figure 1. Vector representation of total power and the power

components
Where,
KW = kilowatts
KVAR = kilo Volt amps reactive
= power factor angle
KVA = kilo Volt Amps
Motor W = 138 amps full load current: Total
Power in = 460 138 3 / 1,000 109.950 kW
Motor U = 147 amps full load current: Total
Power in = 460 147 3 / 1,000 117.121 kW
Presuming that both motors are operating at full, rated
load, the total e ciency is:
Motor W total eficiency = 93.250/109.950 =
84.8%; but nameplated 94.5%
Motor U total eficiency = 93.250/117.121 =
79.6%; but nameplated 95.4%
Increasing the real e ciency actually increases the total
energy use in this example. Ignoring the one time increase in
energy to produce the additional materials required to increase
e ciency, there is another probable increase in energy usage
factor. Generally, extra high e ciency motors have less slip so
the rated load is at a higher speed. For centrifugal type loads,
the majority of AC motor applications, the driven equipment
will draw more power, usually negating the higher e ciency.
he premium e ciency AC motor is a recommended
purchase even with a premium price. A properly selected,
installed and maintained motor will last for the lifetime of
most applications. E ciency stills determines the cost of opera-
tion, and the long life of the AC motor will, in all cases, shortly
return the cost of investment and provide continued energy
cost savings.
In addition, premium e ciency requires premium manu-
facturing process control. Premium manufacturing process
control equates directly with increased application reliability.
For additional reference, see Regulation by Free Market
Forces or Bureaucracy. Energy Independence and Security Act
of 2007 (EISA).
P&S
Dennis L. Rimmel retired from Emerson
Electric, US Electrical Motors division
where he worked for 35 years in various
job functions in engineering, eld service
and sales. For the nal nine years he was
chief engineer and project manager respon-
sible for the design and development of
special AC electric motors including vertical hollow shaft,
submersible, single phase, cryogenic and special, built-to-
customer specications motors. He is currently semi-retired,
providing consultant services. He can be reached at acmo-
torconsultant@gmail.com.
It is
illeg
al to
duplicate this CD. Copyright 1997-2010 Hydraulic Institute, Inc. 0
0
6
0
1
1
0
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0
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Pump Standards p
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P
rior to 1850, the only way to
measure pressure was with a verti-
cal tube (usually glass) with some
liquid inside. he liquid was generally
either water or mercury. he investiga-
tor would apply the unknown pressure
to the bottom of the tube and observe
how tall a column of liquid the pressure
would support.
Using a liquid-lled instrument to
measure pressure is simple and direct,
but awkward for eld measurements.
For example, in 1647 Balise Pascals
brother-in-law Perier, measured atmo-
spheric pressure at two dierent eleva-
tions: At the base and at the summit
of the Puy de Dome. Can you imagine
carrying a 30-inch tall mercury lled
barometer 3,000 feet up a moun-
tain? Pascal writes, hus between the
heights of the quicksilver in these two
experiments there was a dierence of
three inches and one and a half lines,
which ravished us all with admiration
and astonishment. It did not take a lot
to get people excited in those days. He
actually invented the altimeter.
A liquid-lled tube can be a simple,
robust device for pressure measurement and, through some
methods, can be amazingly precise. High precision measure-
ments with liquid-lled manometers take into account ther-
mal expansion of the measuring scale, thermal eects on the
density of the ll uid, and shifts in the gravitational force
due to altitude and longitude. However, these devices quickly
become impractically tall as the pressure range increases, and
liquid-lled glass tubing does not travel particularly well.
Coiled Tube Versus Liquid
In one of those historical moments of genius, in the 1840s
Eugene Bourdon was witnessing a pressure test of a spiral
wound heat exchanger. He noticed that as internal pressure
in the helical wound tubing increased, the coil twisted and
expanded. When the pressure was relieved, the coil con-
stricted back to its original shape and diameter. He had the
mental preparation and insight to realize that the rotational
transit of the coil end was directly proportional to the pres-
sure inside the tube.
He carried the concept to its logical conclusion, design-
ing a practical instrument with a coiled tube coupled to a
gear set to amplify the tip deection. A pointer and scale
completed the system, comprising the modern mechanical
pressure Bourdon tube pressure gauge.
his device provides a simple, inexpensive and robust
way to measure pressure in countless practical applications.
Bourdon Variations
Countless variations on the design of the Bourdon tube
gauge are available, but these can be roughly divided in to
two categories:
Mechanical Pressure
Measurement
David Gardellin, P.E. Onyx Valve Company
Pressure gauges are a versatile way to monitor pump operation.
Figure 1. Fortin
mercury-lled
barometer
Figure 2. Mechanical elements of the Bourdon tube pressure
gauge
1. Open-front, drawn-case gauge. his types principle char-
acteristic is economy. hese gauges generally range from a
1-inch to 4-diameter dial, have a drawn steel or stainless
steel case, and are ANSI Grade-B accuracy (2 percent in
the middle third). Since they are an open-front design,
if they are over pressurized, the Bourdon tube can rupture
violently, and the lens and internal components will be
blown forward towards the observer.
2. Solid-front / blow-out back turret-case gauge. Generally,
these are more expensive than an open-front gauge. hey
are molded from phenolic plastic and feature a thick
barrier between the Bourdon tube and the dial with just
a small hole for the pointer axel through the wall. As a
result, if they are over pressurized and the Bourdon tube
ruptures, the fragments are blown out the back away from
the observer. hey are most frequently provided with a
4-inch diameter dial, although 6-inch dials are avail-
able. Accuracy is generally ANSI Grade-2A ( percent
throughout the range).
Adaptations of this design have evolved through the years.
For example, to operate at lower pressure levels, a bellows
or accordion assembly can be substituted for the C-shaped
Bourdon tube, but the geared travel amplication remains
intact. hese instruments generally operate at pressures well
below 1 Atmosphere.
Alternate Applications
he beauty of the Bourdon tube or bellows pressure instru-
ments is that they can be used to measure other process vari-
ables by inference.
A pressure gauge can be used as a barometer. As a general
rule, the pressure being measured is applied to the inside of
the Bourdon tube or bellows. he outside of the tube or bel-
lows is subject to atmospheric pressure. However, this can be
ipped around. If the entrance to the measuring element is
plugged, a xed volume of air is trapped inside. Atmospheric
pressure exerts a force against the outside of the measuring
capsule where slight variations in atmospheric pressure are
amplied by the gear set and registered by the pointer. his
provides an indication of the local barometric pressure.
A pressure gauge can also function as an altimeter. he
same arrangement as was used for the mechanical barometer
can, with a slight modication, function as an altimeter as
well. Atmospheric pressure decreases with increases in altitude.
A pressure gauge can be used as a thermometer. By
connecting a bulb with a specic volume of gas to the
measuring element, a Bourdon tube gauge will function as a
thermometer.
A pressure gauge can be a Flow Meter! he ow rate
through any pump can be determined. For this to work, a
pressure gauge must be placed on the suction and discharge
of the pump. he end user will also need a copy of the pump
performance curve.
Step 1 is to subtract the suction gauge reading from the
discharge gauge
reading. his pro-
vides the P across
the pump.
Step 2 is to look
at the pump perfor-
mance curve, trace
across from the P
on the y-axis to the
pump Q/H curve
and drop down to the
x-axis. Read the ow.
Ignore e ciency and
brake horsepower
curves at this stage.
In this exam-
ple, if the dierence
between the dis-
charge gauge and the suction gauge is 80 feet of head, then the
ow through the pump is 4,500 gallons per minute.
No Pressure Gauge?
Many pump installations do not have a pressure gauge on the
discharge. his leaves the plant operators blind and makes
pump problems di cult or impossible to diagnose. A frequent
justication for leaving a pressure gauge o a pump installa-
tion is that the small passages into the Bourdon tube frequently
clog, especially when handling uids such as sewage, sludge,
mining slurries, pigments or aggressive chemicals.
he solution for clogging is to provide an assembly consist-
ing of an isolator ring and gauge. he isolator ring is installed
between standard ANSI pipe anges. It consists of a steel ring
with a rubber inner tube inside. he internal diameter of the
inner tube matches the ID of the adjacent pipe, providing a
smooth transition in and out of the device. he rubber inner
tube is lled with a benign uid such as silicone instrument oil,
which communicates the process pressure to the gauge. he iso-
lator ring can be tted with a gauge, pressure switch, or pressure
transmitter, or any combination of the three.
When the gauge is combined with a switch or transmitter,
it provides a simple, robust sentinel that will monitor pump
performance and provide an early warning of any impending
performance issues.
P&S
David Gardellin, P. E. is the president of
Onyx Valve Company, which manufac-
tures pinch valves, valve actuators, controls
and pressure isolators. He holds a BS degree
in engineering from Drexel University and
is a registered professional engineer in
Maryland and New Jersey. Gardellin holds
several patents and authored numerous technical articles
related to valves and controls. He can be reached at david@
onyxvalve.com or 609-829-2888.
Figure 3. Determining the ow through a
pump with a pressure gauge
I
nstallation and setup of a pump and motor can be easy
for small systems. Both can be lifted with relatively
small equipment and do not require the use of rented
cranes, which can cost thousands per day due to the load
requirement.
Of the numerous installation steps, alignment is cru-
cial. Poor alignment can cause excessive vibration, bearing
wear, coupling fatigue or complete coupling or shaft fail-
ure. All add to maintenance costs and increase the risk of an
unplanned outage. How can a motor be aligned if the rotor
cannot be turned?
Recently, a large utility company in the northwest
contacted a motor manufacturer requesting help with this
dilemma. he vertically-mounted motor driving a circulation
water pump was rated at approximately 5,000 horsepower
and had a hydrodynamic upper thrust bearing that would
not allow them to freely turn it by hand (typical minimum
speed for a hydrodynamic bearing to develop an oil lm is
about 100 rpm). he motor rotor weighed 22,000 pounds.
he motor rotor/pump coupled together weighed 47,000
pounds. he customer had the overhead crane capacity to lift
the entire motor (20 tons) that could be used, if necessary.
he customer had been using the chain fall method
with limited success, achieving approximately 0.005 inch of
run out, which was causing vibration and bearing wear in
the pump shaft guide bearings. A custom alignment device
was developed, allowing the user to alleviate di culties with
rotating the motor shaft and obtain proper alignment with
relative ease.
Alignment Difculties
During alignment, the motor rotor must be spun by hand
since it must turn slowly enough to obtain accurate run
out readings. Alignment typically must be less than 0.001
inch from motor to pump couplings. On large pump/motor
combinations greater than 2,500 horsepower, the process
becomes compounded since access to the shaft can be limited
due to pump stand design and cramped working space.
Most rotors in this horsepower range are too large to
freely rotate by hand unless the upper bearing is an antifric-
tion type roller bearing. Once the motor is in place, there is
not enough space to access the bottom shaft extension to be
able to use a jack or other method to lift the rotor. Most sites
do not have the overhead crane capacity to lift the rotors,
which can exceed 20,000 pounds for the motor rotor and
40,000 pounds for the motor and pump train together.
Some sites are able to use the chain fall method to align
the motor and pump, as the user originally did in this case.
If a capable bridge crane is present, it can lift the rotor using
a chain fall to the top of the shaft, relieving enough weight
from the upper bearing to allow the rotor to be turned with a
breaker bar through the chain or upper rigging. his method,
depending on the style of upper bearing, can allow up to
0.015 inch radial movement of the rotor making it di cult
Proper Alignment of
Large Motors & Pumps
Reed Hamm, TECO-Westinghouse
A large utility company confronts alignment of a 5,000-horsepower motor.
Figure 1. Motor shaft extension viewed through a pump stand
opening. Dial indicators used to measure run out can be seen.
to keep the run out between the pump and motor under 0.001
inch. he lower bearing in most cases has more clearance than
the upper, generally around 0.030 to 0.040 inch, allowing for
more movement of the shaft.
If this movement is not controlled and the shaft is not kept
centered in both the upper and lower bearings, then the care-
fully planned and executed alignment can be ruined once the
motor is energized. he motor will attempt to center itself due
to the hydrodynamic forces.
Another hazard with using an overhead crane, especially
if vertical travel is not easily controlled, is damaging the upper
thrust faces or the shaft itself by lifting the rotor too much. his
is a di cult process to perform when the operator is using a
radio controlled crane and is standing at the bearing, much less
if the crane operator is 30 feet away.
Requirements in an Ideal Scenario
How can a rotor be turned by hand while keeping the shaft cen-
tered since alignment must be performed every time the motor
or pump is removed and serviced?
his question was posed by a customer who had the over-
head crane capacity but was not achieving the desired run out
between the rotor and pump, which was aecting the operation
of both pieces of equipment. Concerned with the issue, the
customer required the following:
he rotor must rotate freely with hand power although a
breaker bar could still be used.
A method must be present to center the shaft and hold it in
place in both the upper and lower bearings.
he lift of the rotor must be controlled.
Most important, the method must achieve desired run out.
Using a device on the shaft extension and lifting the rotor
from the bottom proved prohibitive due to the reasons outlined
above. he device would need to lift the rotor from the top.
Figure 2. Typical setups for measuring angular and offset
misalignment
24 al 26 de enero de 2012 | GEORGIA WORLD CONGRESS CENTER, ATLANTA, GEORGIA EUA www.ipeweek12.org www.ife12.org |
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The 2012 International Poultry Expo and International Feed
Expo will be held January 24 26, 2012, and the week of the
Expo has been oicially designated as IPE Week with an
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Solution
It became apparent that the xture would need to be capable of
lifting the pump and motor coupled together to perform nal
alignment checks. his doubled the capacity requirement from
25,000 to 50,000 pounds. he device would need to be sti
enough to limit vertical movement to prevent the rotor from
binding when turning and bulky enough not to slip or deect
once the rotor was lifted.
he simplest solution proved to be the best. he nal
design used a table to directly lift the rotor from above and
support the weight on a heavy roller bearing. his allowed the
user to slowly turn the rotor with a large socket wrench (as
designed). Portable hydraulic power was used to transfer the
weight from the motor upper thrust bearing to the lifting table.
he table also included jacking provisions to center the
shaft in the upper bearing, since the rotor would attempt to
center itself under running conditions. To center the shaft in
the lower bearing and restrain it while turning, smaller jacking
blocks with Micarta bumpers were bolted to the bottom bear-
ing bracket and then adjusted until contact was made with the
shaft.
he full process was as follows:
A lifting cap was installed on the top of the shaft to enable
jacking without damaging the shaft.
he lifting table was lowered over the upper bearing assem-
bly (extra care was taken during this step as the entire upper
bearing was exposed).
An all thread bolt was inserted through the table and
secured in the lifting cap.
he hydraulic power unit was placed over the all thread bolt
and supported on a roller bearing, then secured with a nut.
Lower bearing blocks were installed and both the upper and
lower bearings were checked for center. If not centered, the
shaft was jacked into place.
he hydraulic power unit was pumped to shift some of
the load to the roller bearing and lock the rotor in place,
preventing subsequent radial movement.
he shaft center was rechecked to ensure that no movement
occurred due to the roller bearing settling.
While applying torque to the shaft with either a strap or
socket wrench, the hydraulic power unit was pumped until
the shaft rotated easily. A dial indicator was used to measure
the vertical travel of the shaft, ensuring that damage did not
occur to the upper thrust faces from excessive lift.
he rotor was then ready for run out checks and slow roll
operation.
he rotor was able to be turned using hand power on the
lower shaft extension.
In Actual Operation
he device worked better than the designed expectations for
the utility company because the user was able to forgo the large
socket wrench and turn the motor rotor by hand using the shaft
extension on the bottom. his allowed the operator to turn the
rotor at the speed necessary to get the required run out read-
ings. Final alignment between the pump and motor was less
than 0.001 inch.
P&S
Reed Hamm graduated with from
Texas A&M University with a degree in
Mechanical Engineering and has experi-
ence in the large rotating equipment indus-
try for the past ve years. He has worked as
a service engineer for TECO-Westinghouse
Motor Company for the past three years
assisting customers with troubleshooting site issues as well
as motor rebuilds and upgrades.. Hamm can be reached at
512-255-4141.
Figure 3. Graphic of the lifting table resting on the upper bearing
bracket, and the upper shaft extension can be seen directly under
the table.
Figure 4. The custom alignment device was designed to allevi-
ate difculties with rotating the motor shaft and obtaining proper
alignment.
Vortex Pumps
Zoeller Engineered Products introduces
its broad selection of 1- to 15-horsepower
submersible solids handling pumps with vortex
impellers. Vortex pumps, recognized for their
solids handling capabilities, are being applied
in the most challenging wastewater pump-
ing applications. Zoeller oers these pumps
in either 2.5-inch or 3-inch solids handling capacity.
Discharge sizes are 3 inches, 4 inches and 6 inches with
standard or explosion proof motors.
Circle 218 or go to psfreeinfo.com
Piping System
Asahi/America, Inc.,
introduces Chem
Proline, a new crack
resistant polyethylene
piping system designed for the harshest liquid chemical
applications. A complete system that includes pipe, ttings,
valves, leak detection, injection quills and chemical feed
skids, it is made from the latest generation of PE resin
(PE100-RC), and the pipe and ttings possess the greatest
resistance to slow crack growth. Chem Proline is a lower
cost alternative to metal, berglass reinforced plastic pipe
and lined steel pipe.
ANSI Pump Flow Addition
Ruhrpumpen added the new centrifugal pump model
CPP-L to its standard product line. he CPP-L is the low-
ow version of the CPP-21 (ANSI End Suction pump
line). his model has been designed to ll the gap on the
low-ow side of the CPP-21 range. It complies with the
ANSI B73.1 Standard, and this pump can be used to replace
existing equipment without problems and with no need for
piping or base changes.
Ultrasonic Level Transmitter
he new ECHO Air Transducer is
a smart and simple solution for
noncontact level measurement
and duplex pump control. It uses
the latest ultrasonic technology
and microprocessor chip for accurate
and reliable level measurement, within
+/- 1 millimeter. he PVDF transducer and
3-degree Eective Beam Angle provide a non-
contact level solution in tough applications. he 3-meter
and 10-meter range versions come standard with two SPDT
Relays, RS485 Modbus, 4-20mA output and 9-36VDC
Power Supply.
Level Probe Converter
M.P. Electronics introduces the
LPC420 Level Probe Converter,
powered by 24VDC. It senses liquid
level to provide a 4 to 20mA analog
output for use by a pump controller
or PLC for liquid level control. he
unit monitors the ten electrodes on
the probe and provides an analog signal that is proportional
to the level. he sensitivity of the unit is set for the type
of liquid being detected. he analog output delay setting
controls how fast the analog output transitions from one
level value to another.
Peristaltic Pump Hose
Salem-Republic Rubber
Company builds peristaltic
pump hoses that are compatible
with all major positive displace-
ment pump manufacturers
and oers custom built hoses
to accommodate your specic
requirements. Our No-Crush poly carcass is constructed
using multiple plies of high tensile cord reinforcements,
and the smooth precision ground concentric cover insures
optimum performance and consistent ows.
Pipe & Duct Connection Material
Multifab is announces its
DNT SERIES M-FLEX 600
pipe and duct connection
material. M-Flex 600 uses a
new style PTFE that is capable
of continuous operation to
600 degrees F while remaining
strong. It can be used in wet or dry applications while main-
taining a zero porosity rating. he product features extreme
exibility, 6 to 1 compression ratio and demonstrates excel-
lent non-ammability properties. M-Flex 600 is a versatile
plastic exible ducting.
Pressure Transmitter
Winters Instruments is pleased to announce
the LLP Series Pressure Transmitter, designed
specically for use in applications that pro-
duce low pressures, up to 25 psi. Featuring
a 304 SS housing and 316L SS exible
diaphragm for pressure sensing, the LLP
Transmitter is ideal for general industry use
as well as for OEM customers who require a
high-quality, high-accuracy pressure transmitter.
Product Pipeline
Product Pipeline
Air Diaphragm Pumps
JDA Global LLC in conjunction
with JDA Global Pumps (Shanghai)
Co., Ltd. announces the release of
the TRANS-FLO air diaphragm
pumps assembled and manufactured
from its Shanghai facility. he four
sizes of aluminum pumps, which
can be outtted with a wide range of elastomers, will handle
most utilitarian liquid transfer needs worldwide.
Grinder System
Moynos Max-Flow Annihilator Grinder
System is a custom-engineered, headworks,
debris-handling system that protects down-
stream pumps, valves and process equip-
ment in water treatment plants and their lift
stations. he cost-eective, low-maintenance
system can be used in place of bar rakes
and screens as well as drum screen grind-
ers for enhanced performance. he Max-
Flow system contains two or more grinders
mounted side-by-side in a stainless steel retrieval frame in the
headworks of a waste water treatment system.
New Servo Technology
he Drives & Motion Division of
Yaskawa America, Inc., introduces
the Junma AC Servo, a new servo
technology providing a superior
alternative to traditional stepper tech-
nology at a comparable price. his
totally new plug and play design concept requires no param-
eter settings or gain adjustments. Simply connect and go, and
the motor is ready to run, providing high torque output at
speeds up to 4,500 rpm. Attain optimum servo performance
without time-consuming setup.
Velocity Sensor
Meggitt, a supplier of protection and condition
monitoring systems for power generation and
industrial applications, has boosted its Vibro-
Meter product line with a velocity sensor that
works with all condition and health monitoring
systems including Meggitts own VibroSight.
Meggitts system now includes the PV 102, a
piezoelectric velocity sensor for vibration moni-
toring of turbomachinery and other rotating
equipment.
P&S
BULLETIN BOARD
MONITOR PUMP PERFORMANCE
UNIVERSAL
POWER CELL
One Size AdjusLs for
All MoLors, lron Snall
up Lo 150HP
Works on variable lrequency
Drives, 3 Phase, DC and
Single Phase
10 Lines nore sensiLive
Lhan jusL sensing anps
4-20 Millianp, 0-10 volL
FLOW RAT
PUMP CONDITION
DRY RUNNINC
CAVITATION
BARINC FAILUR
CALL NOW FOR YOUR
FR 30-DAY TRIAL
888-600-3247
WWW.LOADCON1kOLS.COM
Pump Tec 2011
EVERYTHING YOU EVER WANTED TO KNOW ABOUT PUMPS!
8th Pump Tec
Pumps Hands-On Maintenance
and Reliability Conference
Atlanta, GA USA
September 21-22, 2011
For more information go to
www.pumpconference.com
770-310-0866
A. W. Chesterton Company 122 44
ABS USA 102 3
ABZ, Inc. 301 107
Advanced Engineered
Pump, Inc. 177 108
Advanced Sealing
International (ASI) 148 68
American Marsh 103 89
Amtech Drives 121 65
ARGO 160 82
Basler Electric 123 53
BJM Pumps 180 110
BJM Pumps 181 110
Blacoh Fluid Control, Inc. 124 34
Blue-White Industries 125 9
Boerger, LLC 126 37
Cashco, Inc. 127 25
Check-All Valve Mfg.Co 128 22
Concepts NREC 161 80
Dan Bolen &
Associates, LLC 178 110
Danfoss Drives 149 87
EagleBurgmann 150 59
Eaton 104 45
Eccentric Pumps, LLC 162 88
The EX ONE Company 151 70
Frost & Sullivan 163 99
Fuji Electric 199 111
The Fullo Specialties Co. 152 77
Global Pump 112 47
Godwin Pumps 105 23
Graco, Inc. 153 49
Graphite Metallizing Corp. 164 82
Griffco 130 35
Grundfos 106 7
Hayward Flow Control 107 5
Heinrichs USA LLC 165 85
Hydraulic Institute 166 99
Hyundai 108 17
ITT Water &
Wastewater USA, Inc. 101 56-57
John Crane 110 39
Jordan, Knauff & Company 167 94
Junty Industries, Ltd. 182 108
Larox Flowsys Inc. 131 26
Load Controls, Inc. 132 38
Load Controls, Inc. 302 107
LobePro 179 110
LUDECA Inc. 154 51
Lutz-JESCO 111 BC
Maag Pump Systems 168 97
Magnatex Pumps, Inc. 184 109
Meltric Corporation 185 108
Mission
Communications, LLC 133 16
Motor Protection
Electronics 169 93
Moyno 113 IBC
MSE of Canada Ltd. 183 108
Neptune Chemical
Company 134 10
NETZSCH 170 85
NETZSCH 171 93
ONYX VALVE 135 28
Orival 155 81
PCB Piezotronics Inc. 172 80
Pfannenberg 173 94
Poultry Expo 136 103
Pump Pros 129 64
Pumping Machinery 303 107
Pumps Solutions Group 156 63
Rockwell Automation 100 IFC
Ruhrpumpen 138 19
Scenic Precise Element Inc. 186 109
seepex, Inc. 139 42
SEPCO 141 33
SEPCO 187 111
SERO Pump Systems 189 109
Shanley Pump & Equipment 174 97
ShinMaywa (America) Ltd. 142 43
Siemens Industry, Inc. 114 13
Sims Pump Co. 115 75
Sims Pump Co. 115 109
Singer Valve 190 108
SJE-Rhombus 157 67
Sulzer 116 27
Summit Pump, Inc. 191 109
Swaby LOBELINE 140 73
Tamer Industries 192 111
Tarby,Inc. 158 58
TECO-Westinghouse 117 71
Trachte, USA 193 108
Trask-Decrow 194 110
Tuf-Lok International 195 109
Vanton 143 41
Varisco 188 110
Vaughan 118 21
Verder International 144 46
VERTIFLO 196 109
Vesco 197 108
VibrAlign 159 79
W.L. Gore & Associates, Inc. 119 11
Watson-Marlow
Pumps Group 146 15
WEG 176 88
Wilden 145 54
Yaskawa America, Inc. 120 69
Zoeller Company 147 31
Zoeller Company 198 111
* Ad index is furnished as a courtesy and no respon-
sibility is assumed for incorrect information.
Advertiser Name R.S. # Page Advertiser Name R.S. # Page Advertiser Name R.S. # Page Advertiser Name R.S. # Page
INDEX OF ADVERTISERS
YOUR AD COULD
BE HERE!
For More Information, Contact:
Addison Perkins
205-561-2603
e-mail: aperkins@pump-zone.com
PUMP USE RS MARKETPL ACE PUMP USE RS MARKETPL ACE
Vesconite Hilube
Pump Bearings
G Can run dry
G Increase MTBR
G Avoid shaft
seizures
Tollfree 1 866 635 7596
vesconite@vesconite.com
www.vesconite.com
PUMP USE RS MARKETPL ACE
Your Best Value in
Self Priming Pumps
Model SN
Green Bay, WI
www.SUMMITPUMP.com
circle 191 on card or go to psfreeinfo.com circle 115 on card or go to psfreeinfo.com circle 184 on card or go to psfreeinfo.com
ROTARY LOBE SLUDGE PUMPS
FOR SLUDGES/SLURRIES/CORROSIVES
912-466-0304 www.LOBEPRO.com Made in USA
Shutdown protection
avaiIabIe for
contaminants and over
pressure conditions.
SeIf Priming to 25'.
ReversibIe operation.
In PIace wear part repIacement
at 1/3 the cost and time for
equivaIent PC pump.
INDUSTRY LEADER
OVER 35 YEARS
INDUSTRY LEADER
OVER 35 YEARS
SALES SERVICE PARTS
Non-Clog dry pit
pump
Flows to 7,100 GPM
Max head 370'
Solids handling up
to 4 "
www.trask-decrow.com
1-800-287-1538
The Power Behind Your Process
Serving the Pump & Rotating
Equipment, Valve, and Industrial
Equipment Industry since 1969
Domestic & International
Specializing in placing:
General Management
Engineering
Sales & Marketing
Manufacturing
DAN BOLEN JASON SWANSON
CHRIS OSBORN DAN MARSHALL
9741 North 90
th
Place, Suite 200
Scottsdale, Arizona 85258-5065
(480) 767-9000 Fax (480) 767-0100
Email: danbolen@mindspring.com
www.danbolenassoc.com
EXECUTIVE SEARCH/RECRUITING
Employment
zoellerengprod.com
1-800-928-7867
DONT FIND
YOURSELF
IN A JAM.
Unique reversing cutter
action allows pump to
clear jams and hangups.
Doubles life by allowing
both sides of the cutter
to work.
YO YO
IN IN
Uniqu Uniqu
action action
clear clear
Doubl Doubl
both s both s
to wo to wo
Your Peace of Mind
is Our Top Priority
P&S Market
P&S Market
T
he Jordan, Knau & Company (JKC) Valve
Stock Index was up 7.9 percent over the last
12 months, below the broader S&P 500 Index
which was up 12.8 percent. he JKC Pump Stock
Index continued its upward trend, ahead 30.9 percent
for the same time period.
Manufacturing activity has slowed signicantly
in recent months. he Purchasing Managers Index fell
to 50.6 in August, slightly above the threshold of 50
which signies growth in the sector. In April, the PMI
was indicating strong growth at 60.4. he report noted,
he overall sentiment is one of concern and caution
over the domestic and international economic environment.
Of the 18 industries surveyed, 10 reported growth, including:
wood products; petroleum and coal products; miscellaneous
manufacturing; food, beverage and tobacco products; fabricated
metal products; paper products; transportation equipment;
chemical products; computer and electronic products; and
machinery.
he Bureau of Labor Statistics reported no change in net
employment between July and August. he unemployment rate
remains at 9.1 percent. he private sector generated 17,000 new
jobs, which were oset by a loss of 17,000 government workers.
he manufacturing sector lost 3,000 workers, the rst decline
since October 2010.
he Conference Board Consumer Research Center reported
that consumer condence, which had improved slightly in July,
deteriorated sharply in August. At 44.5, the index is at its lowest
level in more than two years. A contributing factor may have
been the debt ceiling discussions since the decline was well
underway before the U.S. debt downgrade. he U.S. Energy
Information Administration (EIA) lowered its projected pace
of global oil demand due to less optimistic assumptions about
global economic growth, relieving some of the potential oil
market tightness projected in its previous forecasts. However,
the EIA expects world crude oil and liquid fuels consumption
will continue growing from record high levels in 2010. In the
U.S, total consumption of liquid fuels grew 2.2 percent in
2010, the highest rate of growth since 2004. In contrast, U.S.
consumption is projected to fall 0.9 percent in 2011 and then
increase 0.4 percent, to 19.1 million barrels per day, in 2012.
he number of oil and gas rigs in operation worldwide
increased in August to 3,613, slightly above peak levels from
September 2008 and 15 percent higher than August 2010. In
the U.S., rig counts increased by 19 percent over August 2010
levels to 1,957. West Texas Intermediate crude oil spot prices
fell from an average of $97 per barrel in July to $86 per barrel
in August.
P&S
Wall Street Pump and
Valve Industry Watch
Jordan, Knauff & Company
Jordan, Knau & Company is an investment bank in
Chicago, Ill., that provides merger and acquisition advi-
sory services to the pump, valve and ltration industries.
Contact Jack Gonder at jgonder@jordanknau.com, or
visit www.jordanknau.com for more information.
Figure 2. U.S. Energy Consumption and Rig Counts
Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates. he
JKC Pump and Valve Stock Indices include a select list of publicly-traded companies involved in the pump
and valve industries weighted by market capitalization.
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.
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.
Figure 1. Stock Indices from September 2010 to August 2011
Moves a higher percentage
of solids longer distances
than any other PC pump
Lower Your Capital Investment and minimize maintenance costs
Twin Screw Feeder (TSF) most efficient feed system, self-cleaning,
no extended augers needed
VFD Control for both pump and TSF fewer energy losses, lower
horsepower needed, lower noise
Closed Piping System controls odor
G4 Pump with Ultra-Drive
non-pulsating flow equals lower

operating pressures, shortest dewatered sludge handling PC pump
on the market
(Optional) Slip Injection System further reduces discharge
pressure by 3 or 4 times
Just
1
/2 the Cost of hydraulically driven piston pump systems!
Moyno
2000 HS System
1-877-4UMOYNO
www.moyno.com
Visit Us at
WEFTEC, Booth
#2211

Pump & System - October 2011

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The Magazine for Pump Users Worldwide October 2011

, the quality ow control products we promise

range of pumps delivers unrivalled

Peristaltic Metering Pumps

Style 400 High-Resilience Tubing.

Style 400 maintains a consistent ow rate

Style 400 High-Resilience Tubing lasts almost

Style 400 High-Resilience Tubing, please visit

CAN SAVE YOU MORE THAN OUR PRODUCTS COST.

is a registered trademark oI W. L. Gore and Associates.

has more than 30 years

process for patternless production

PUMPS & SYSTEMS www.pump-zone.com OCTOBER 2011 77

wear parts survive upsets.

A New Revolution in Hose Pump Technology

Figure 1. Vector representation of total power and the power

non-pulsating flow equals lower

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