pumps & systems - august 2015
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Component or CartridgeChoose the Right Seal
How Remote MonitoringEmpowers Plant Employees
Trade Show PreviewTurbomachinery &
Pump Symposia
OPTIMIZE SYSTEM
PERFORMANCE
The Leading Magazine for Pump Users Worldwide
AUGUST 2015
PUMPSANDSYSTEMS.COM
®
SYSTEMS
4 highly engineered solutions to help you get the most from your pumps
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August 2015 | Pumps & Systems
2
From the Editor
As you � ip through the pages of
this issue, the Pumps & Systems
team is gearing up for a busy season of
trade shows and travel. Next month,
we will be heading to Houston for
the 44th Turbomachinery & 31st
Pump Symposia (TPS), Sept. 14-17,
where optimizing pumping systems—
including piping, lubrication,
motors, drives, seals, couplings and
alignment—will be a core focus.
Because system optimization is
a goal for every pump user, we are
bringing you coverage of four highly
engineered solutions that will help
you get the most from your pumps.
Beginning on page 60, this month’s cover series will highlight how technological
advances are allowing end users to cost-e� ectively revamp existing equipment for
more e� cient operation. � e series continues with “10 � ings You Need to Know about
NPSH” (page 68), which outlines how thorough and accurate NPSH calculations can
provide users the information they need to enhance system performance. � e series
also discusses the bene� ts of engineered composites (page 72) and electrical inspections
(page 78) for minimizing costs, improving reliability and eliminating downtime.
You also don’t want to miss our newest column, Common Pumping Mistakes, authored
by Jim “Maddog” Elsey. Introduced in February as a bimonthly piece, the column will
now appear in every issue. A seasoned industry expert, Elsey shares lessons learned from
40 years in the � eld that will help readers further improve their equipment operation.
How do you optimize your pumping systems? Drop by our booth (#1318) at TPS to
share your thoughts, ideas and best practices. We’d love to hear from you! We’ll also be at
WEFTEC in Chicago, Sept. 26-30, so feel free to stop by our booth (#4256) there as well.
As always, we appreciate your insight and hope to see you soon!
Best regards,
EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibaldaarchibald@cahabamedia.com • 205-314-3878
SENIOR TECHNICAL EDITOR: Mike Pembertonmpemberton@cahabamedia.com205-314-8279
MANAGING EDITOR: Amelia Messamore amessamore@cahabamedia.com 205-314-8264
MANAGING EDITOR: Savanna Graysgray@cahabamedia.com • 205-278-2839
ASSOCIATE EDITOR: Amy Cashacash@cahabamedia.com • 205-278-2826
CONTRIBUTING EDITORS: Laurel Donoho, Lev Nelik, Ray Hardee, Jim Elsey
CREATIVE SERVICES
SENIOR ART DIRECTOR: Greg Ragsdale
ART DIRECTOR: Melanie Magee
WEB DEVELOPER: Greg Caudle
PRINT ADVERTISING TRAFFIC: Lisa Freemanlfreeman@cahabamedia.com • 205-212-9402
CIRCULATION
AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay lmasaoay@cahabamedia.com • 205-278-2840
ADVERTISING
NATIONAL SALES MANAGER: Derrell Moody dmoody@pump-zone.com • 205-345-0784
ACCOUNT EXECUTIVES:
Mary-Kathryn Bakermkbaker@pump-zone.com • 205-345-6036
Mark Goinsmgoins@pump-zone.com • 205-345-6414
Addison Perkinsaperkins@pump-zone.com • 205-561-2603
Garrick Stonegstone@pump-zone.com • 205-212-9406
MARKETING ASSOCIATES:
Ashley Morris amorris@cahabamedia.com • 205-561-2600
Sonya Crockerscrocker@cahabamedia.com • 205-314-8276
PUBLISHER: Walter B. Evans Jr.
VP OF SALES: Greg Meineke
CREATIVE DIRECTOR: Terri J. Gray
CONTROLLER: Brandon Whittemore
P.O. Box 530067Birmingham, AL 35253
EDITORIAL & PRODUCTION
1900 28th Avenue South, Suite 200Birmingham, AL 35209205-212-9402
ADVERTISING SALES
2126 McFarland Blvd. East, Suite ATuscaloosa, AL 35404205-345-0784
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and additional mailing offi ces. Subscriptions: Free of charge to qualifi ed industrial pump users. Publisher reserves the right to determine qualifi cations. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call 630-739-0900 inside or outside the U.S. POSTMASTER: Send changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. ©2015 Cahaba Media Group, Inc. No part of this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submis-sion, you grant Cahaba Media Group, Inc., permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 23, Issue 8.
This month, we welcome Mike Pemberton as the newest member of the Pumps & Systems team. With more than 25 years of experience in the pump industry, Pemberton will serve as the magazine’s senior technical editor, responsible for ensuring that Pumps & Systems continues to provide readers with the most respected, authoritative, relevant and timely content possible. A well-known leader in the pump industry and a long-time member of the Pumps & Systems Editorial Advisory Board, Pemberton will play a valuable role in providing the high-quality content that makes Pumps & Systems the leading magazine for pump users worldwide.
Pumps & Systems is a member of the following organizations:
Managing Editor, Amelia Messamore
amessamore@cahabamedia.com
HYDRAULIC DISC PUMPS show great advantages in the transportation
of fluid in general industry, including: oil and petrochemical,
chemical processing, municipal water/wastewater, food and
beverage, pharmaceutical manufacturing, pulp and paper, steel
manufacturing, general industrial and specialty applications.
For more information, please contact Sonia Ruiz: sales@discflo.com.
DISCFLO CORP. SANTEE, CA 619-596-3181 DISCFLO.COM
Discflo’s pumps have been solving the pumping problems of
the general industry for over 30 years. The powerful combination
of superior abrasion resistance, gas-entrained pumping ability,
and non-emulsifying laminar flow make the disc pump the ideal
choice for some of the toughest applications.
Experimental studies and field tests show that the Hydraulic
Disc Pump manufactured by Discflo Corporation is a
feasible solution for multiphase flow pumping, including gas,
liquid and solid. The pumping mechanism of our Disc Pump
is based on the effect of boundary layer and viscous drag,
resulting in lower NPSH levels.
THE POWER OF
NON-IMPINGEMENT
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4
August 2015 | Pumps & Systems
60 OPTIMIZE HIGH-ENERGY PUMPS WITH IMPROVED IMPELLER DESIGN
By Bob Jennings & Dr. Gary Dyson, Hydro, Inc.
As new design and manufacturing technologies are developed, end users can a� ordably upgrade their systems and verify better performance.
68 10 THINGS YOU NEED TO KNOW ABOUT NPSHBy Simon Bradshaw, ITT Goulds Pumps
Because cavitation is unavoidable in pump operations, understanding how to reduce it using NPSH calculations is necessary to maintain pump functionality and health.
72 ENGINEERED COMPOSITES OFFER OPPORTUNITIES FOR UPGRADING EQUIPMENTBy John A. Kozel, Sims Pump Valve Company, Inc.
� ese pumps prevent equipment from corroding, provide lower costs and increase e� ciency.
78 ELECTRICAL INSPECTIONS REDUCE COST OF OWNERSHIPBy James Jette, KSB Pumps Inc.
O� ine and online testing can improve reliability and reduce downtime.
COVERS E R I E S
2 FROM THE EDITOR
8 NEWS
82 TRADE SHOW PREVIEW
106 PRODUCTS
107 ADVERTISERS INDEX
108 PUMP USERS MARKETPLACE
112 PUMP MARKET ANALYSIS
PUMP SYSTEM OPTIMIZATION
PUMPING PRESCRIPTIONS
14 By Lev Nelik, Ph.D., P.E. Pumping Machinery, LLC
E� ciency Monitoring Saves Plants Millions
PUMP SYSTEM IMPROVEMENT
18 By Ray Hardee Engineered Software, Inc.
Piping System Controls
Last of Two Parts
COMMON PUMPING MISTAKES
22 By Jim Elsey
Rethinking NPSH
COLUMNS
Image courtesy of Hydro, Inc.
60
PRACTICE & OPERATIONS
102 CENTRIFUGAL PUMP SAVES SAND MINE MORE THAN $1.5 MILLIONBy Chris DunnCrisp Industries&
Bill Schlittler Cornell Pump Company
104 HOW REMOTE MONITORING EMPOWERS PLANT EMPLOYEESBy Jason Vick & Jack Creamer Schneider Electric
102
68
Component or CartridgeChoose the Right Seal
How Remote MonitoringEmpowers Plant Employees
Trade Show PreviewTurbomachinery & Pump Symposia
OPTIMIZE SYSTEM
PERFORMANCE
The Leading Magazine for Pump Users Worldwide
AUGUST 2015
PUMPSANDSYSTEMS.COM
®
SYSTEMS
4 highly engineered solutions to help you get the most from your pumps
This issue AUGUSTVolume 23 • Number 8
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6
August 2015 | Pumps & Systems
DEPARTMENTS
84 BUSINESS OF
THE BUSINESSPrecision Agriculture & Remote Monitoring Modernize Pump Systems
By Arun Prasath
Frost & Sullivan
86 EFFICIENCY MATTERSInternal Gear Pumps Handle Harsh Conditions
By Chrishelle Rogers
Maag Industrial Pumps
90 MAINTENANCE MINDERSOil & Gas Facilities Detect Costly Faults Early
By Cynthia Stone
GE Intelligent Platforms
92 MOTORS & DRIVESUnderstanding System E� ciency in Motor-Driven Rotating Equipment
By William Livoti
WEG Electric Corporation
95 SEALING SENSEEnergy E� ciency of Compression Packings in Rotodynamic Pump Applications
By Henri Azibert
FSA Technical Director
100 HI PUMP FAQSDynamic Analysis in the Petroleum Market & Piping Installation for Rotary Pumps
By Hydraulic Institute
SPECIALS P E C I A LS E C T I O N
BEARINGS, COUPLINGS & SEALS
26 VALIDATE SEALING SYSTEMS FOR OPTIMIZED PERFORMANCE By Larry Castleman,
Trelleborg Sealing Solutions
Investment at the start of a project can lead to improved safety, reliability and savings.
30 COMPONENT OR CARTRIDGE: HOW TO CHOOSE THE RIGHT SEALBy Eugene Vogel, EASA
� e balance between cost and ease of installation should be the major deciding factor.
34 HOW TO INTERPRET PUBLISHED SEALING DATA By Jim Drago,
Garlock Sealing Technologies, LLC
Gasket information and the tests used to generate it can help users make the best possible equipment selections.
38 WHY BEARINGS FAILBy Chris Rehmann, AESSEAL
Modern labyrinth bearing protection seals can protect precision elements from contamination.
42 HYBRID BEARINGS ENHANCE PERFORMANCE OF DRY-START VERTICAL PUMPS By Fumitaka Kikkawa & Yoshimasa
Kachu, Mikasa Corp. & Hiroshi Satoh,
Oridea Inc.
� is equipment exploits the elasticity of synthetic rubber and ensures stable bearing behavior.
48 THE BASICS OF COUPLING SELECTIONBy Robert Bramer, Fischer Process Industries
Users should consider these important factors when choosing the best equipment for their applications.
52 POLYMER SEALS PERFORM RELIABLY AFTER YEARS OF USE By Jim Hebel, Quadrant
Two sets of seals, in service for 11 and 15 years, still meet baseline standards.
58 COMPOSITE BEARINGS RESIST WEAR IN CIRCULATING WATER PUMPSBy Greg Gedney, Greene, Tweed & Co.
A thermoplastic composition in abrasive applications helped bearings meet end user speci� cations.
26
This issue
THOMAS L. ANGLE, P.E., MSC, Vice President Engineering, Hidrostal AG
ROBERT K. ASDAL, Executive Director, Hydraulic Institute
BRYAN S. BARRINGTON, Machinery Engineer, Lyondell Chemical Co.
KERRY BASKINS, VP/GM, Milton Roy Americas
WALTER BONNETT, Vice President Global Marketing, Pump Solutions Group
R. THOMAS BROWN III, President, Advanced Sealing International (ASI)
CHRIS CALDWELL, Director of Advanced Collection Technology, Business Area Wastewater Solutions, Sulzer Pumps, ABS USA
JACK CREAMER, Market Segment Manager – Pumping Equipment, Square D by Schneider Electric
BOB DOMKOWSKI, Business Development Manager – Transport Pumping and Amusement Markets/Engineering Consultant, Xylem, Inc., Water Solutions USA – Flygt
DAVID A. DOTY, North American Sales Manager, Moyno Industrial Pumps
WALT ERNDT, VP/GM, CRANE Pumps & Systems
JOE EVANS, Ph.D., Customer & Employee Education, PumpTech, Inc.
DOUG VOLDEN, Global Engineering Director, John Crane
LARRY LEWIS, President, Vanton Pump and Equipment Corp.
TODD LOUDIN, President/CEO North American Operations, Flowrox Inc.
JOHN MALINOWSKI, Sr. Product Manager, AC Motors, Baldor Electric Company, A Member of the ABB Group
WILLIAM E. NEIS, P.E., President, Northeast Industrial Sales
LEV NELIK, Ph.D., P.E., APICS, President, PumpingMachinery, LLC
HENRY PECK, President, Geiger Pump & Equipment Company
SCOTT SORENSEN, Oil & Gas Automation Consultant & Market Developer, Siemens Industry Sector
ADAM STOLBERG, Executive Director, Submersible Wastewater Pump Association (SWPA)
JERRY TURNER, Founder/Senior Advisor, Pioneer Pump
KIRK WILSON, President, Services & Solutions, Flowserve Corporation
JAMES WONG, Associate Product Manager – Bearing Isolator, Garlock Sealing Technologies
EDITORIAL ADVISORY BOARD
AUGUST
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Colfax Fluid Handling delivers what no other pump supplier can –
a single source for trusted product brands, the most complete
line of pumping technologies on the market and direct
access to global experts in locations near you –
to help your business succeed.
Discover the many ways we’re redefining what’s possible.
colfaxfluidhandling.com/redefining
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8 NEWS
August 2015 | Pumps & Systems
NEW HIRES, PROMOTIONS & RECOGNITIONS
MIKE DUPUIS, JIM SMITH &
LENWOOD IRELAND, EASA
ST. LOUIS (June 25, 2015) – The Electrical Apparatus Service Association (EASA) announces new international oficers for the 2015-2016 administrative year. The new oficers are:
• Chairman of the Board: Mike Dupuis of Morrish Electro Mechanical Company in Windsor, Ontario, Canada
• Vice-Chairman: Jim Smith of Advanced Electric Equipment in La Crosse, Wisconsin
• Secretary/Treasurer: Lenwood Ireland of Ireland Electric in Virginia Beach, Virginia
Dupuis has more than 30 years of experience in the electrical apparatus industry. He previously served as president of EASA’s Ontario Chapter and as director of Region 8. Serving on the Executive Committee with the above oficers are Immediate Past Chairman Doug Moore of Kentucky Service Company in Lexington, Kentucky; Gary Byars of Heavy Machines, Inc, in Memphis, Tennessee; and Brian Larry of Larry Electric Motor Services, Ltd., in Peterborough, Ontario, Canada. easa.com
NORMAN ZOMBOR,
NETZSCH CANADA, INCORPORATED
EXTON, Pa. (June 25, 2015) – NETZSCH Canada, Incorporated, recently expanded its sales force by hiring Norman Zombor as western regional manager for the oil and gas market. He is responsible for supporting and promoting NETZSCH products in Alberta and British Columbia. Zombor has a CET in mechanical engineering and a career of increasing levels of responsibility in the oil and gas industry. netzsch.com
SHAWN KELLY, PIONEER PUMP
CANBY, Ore. (June 25, 2015) – Pioneer Pump appointed Shawn Kelly as the regional sales manager for the South Central Region. Kelly’s responsibilities will include managing distribution and increasing the region’s sales in all markets, including industrial, municipal, oil and gas, and rental. Kelly has more than 20 years of experience in pump rental and sales and has been instrumental in managing large municipal, industrial and utility bypass projects. Kelly has also lead multiple major lood recovery efforts following events such as Hurricanes Katrina and Ivan. pioneerpump.com
THOMAS DONATO,
ROCKWELL AUTOMATION
ABU DHABI, UAE (June 24, 2015) – Thomas Donato was appointed president of Rockwell Automation’s Europe, Middle East and Africa (EMEA) region. Donato was most recently Rockwell Automation’s regional vice president in Canada. He is now responsible for driving growth in this important region. He has 18 years of automation industry experience and holds a Diplom-Ingenieur degree in automation and controls engineering from the University of Applied Sciences in Darmstadt, Germany. rockwellautomation.com
STEFAN HANTKE,
SCHAEFFLER INDUSTRIAL
SCHWEINFURT, Germany (June 22, 2015) – Stefan Hantke has assumed global management of sales and engineering of the Industrial division of Schaefler Technologies AG & Co. KG. In this new position, Hantke is a member of the Industrial Division’s Management Board and is responsible for the global sales management for rolling and plain bearing components and systems for about 60 industrial sectors. He is also responsible for the 27 Schaefler Technology Centers (STC) worldwide. Hantke has more than 20 years of sales and engineering experience in the mechanical engineering sector, particularly in the ield of bearing and linear technology. schaeffler.com
JOHN CONWAY, GRIFFCO VALVE
AMHERST, N.Y. (June 19, 2015) – Griffco Valve, Inc., announced the appointment of John Conway as its new national sales manager for North American Sales. In this role, he will be responsible for the sales and promotion of Griffco Valve chemical-feed accessories across the U.S. and Canada. Conway has an MBA from Canisius College in Buffalo, New York. griffcovalve.com
Shawn Kelly
Norman Zombor
Jim Smith
Lenwood Ireland
Mike Dupuis Thomas Donato
FCX Performance, Inc., acquired Process Control Services, Inc. June 16, 2015
Sulzer acquired Precision Gas Turbine Inc. June 4, 2015
Jason Industries acquired DRONCO GmbH. June 1, 2015
MERGERS & ACQUISITIONS
John Conway
Stefan Hantke
9
pumpsandsystems.com | August 2015
GENE KOONTZ, AWWA
ANAHEIM, Calif. (June 17, 2015) – Gene Koontz of Harrisburg, Pennsylvania, recently began his one-year term as president of the American Water Works Association (AWWA). A specialist in water quality and treatment, Koontz oversees the national water market for Gannett Fleming, a global infrastructure firm that provides planning, design, technology and construction management services for a diverse range of markets and disciplines. Koontz has been an AWWA member since 1982. awwa.org
ROBERT RICHTER, LEISTRITZ
ADVANCED TECHNOLOGIES CORP.
ALLENDALE, N.J. (June 15, 2015) – Leistritz Advanced Technologies Corp. appointed Robert Richter as chief financial officer. His responsibilities include the pump, machine tool and turbine component business units based in Allendale, New Jersey, as well as the extruder business unit based in Somerville, New Jersey. Richter is a graduate of Lehigh University in Bethlehem, Pennsylvania. leistritzcorp.com
JAYANTHI IYENGAR,
XYLEM INC.
RYE BROOK, N.Y. (June
15, 2015) – Xylem Inc. has appointed Jayanthi (Jay) Iyengar as senior vice president and chief innovation and technology officer. In this newly created position, Iyengar will lead the company’s global research and development, technology, and innovation activities. Iyengar has a bachelor’s degree in mechanical engineering and two master’s degrees in mechanical engineering. xyleminc.com
STEVE MARTINEZ, DAN ADAMS &
PAT TRENTLER, DXP
HOUSTON (June 10, 2015) – As part of its western region expansion, DXP/Quadna has promoted and assigned several leaders to new responsibilities. Steve Martinez, an area manager based in Farmington, New Mexico, and Dan Adams, an area manager based in Denver, Colorado, will jointly manage sales and operations for DXP branches located in Minot, North Dakota; Billings, Montana; Gillette and Rock Springs, Wyoming; Farmington, New Mexico; and Boise, North Dakota. Pat Trentler, an area manager, will oversee sales and operations for Casper, Wyoming; and Dickinson and Williston, North Dakota. dxpe.com
To have a news item considered, please
send the information to Amelia Messamore,
amessamore@cahabamedia.com.
Jayanthi Iyengar
5300 Business Drive, Huntington Beach, CA 92649 USA 714-893-8529 • fax: 714-894-9492 • sales@blue-white.com
www.blue-white.com
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What makes the ?DAI*LNK ® a Superior Diaphragm Metering Pump?
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10 NEWS
August 2015 | Pumps & Systems
Nidec & IBM Japan to Jointly Develop IoT Technology KYOTO, Japan (June 22, 2015) – Nidec Corporation announced that it has launched a joint development of a big data analysis technology with IBM Japan with the main purpose of “improving production ratio via early detection of problems” and “shortening downtime via better factor analysis eficiency” for various production equipment and machinery equipped with the Nidec Group’s motors.
Nidec is executing a strategy of equipping its group’s products with Internet of Things (IoT) functions to increase their added value in order to create new, large-scale businesses to achieve the group’s 10 trillion yen sales target set for the iscal year ending March 31, 2031.
This joint project aims to establish a system which, by analyzing data obtained based on correlations among various sensors, will detect problems before humans do and execute measures for such problems even before they occur. Eventually, they plan to start offering this technology to companies outside of the Nidec Group as well. nidec.com
Water Crisis Leads to Development of New Way to Connect Industry LeadersSANTA MONICA, Calif. (June 19, 2015) – The challenges of the water crisis have led to the creation of an online deal platform, watercluster.com, designed to connect technology, talent and investors that can solve urgent water problems compounded by record drought on the West Coast.
Founder Thomas Schumann was inspired to launch the online venture by the U.S. Environmental Protection Agency Water Technology Innovation Cluster Program and seeks “disruptive collaboration” through the website, which allows members to work together and match needs with solutions in a real-time environment.
The watercluster.com platform enables water industry leaders, tech companies, investors, universities, corporations, utilities, governments, NGOs and service providers to connect, communicate, collaborate and conduct business. watercluster.com
HI Publishes New Guidebook for Wastewater Treatment Plant Pumps PARSIPPANY, N.J. (June 15, 2015) – The Hydraulic Institute (HI) recently published a guide on wastewater treatment plant pumps. “Wastewater Treatment Plant Pumps: Guidelines for Selection, Application, and Operation” is intended to assist in the understanding of the general layout, components and operation of a typical wastewater treatment plant. The book also provides readers with the guidance necessary to select pump types, pump materials and auxiliary components so the pumping system performs effectively, eficiently and reliably in the various plant operations.
Topics in this guidebook include, but are not limited to:• Processes, applications, and pump
selection in an aerobic wastewater treatment plant.
• Proper pump selection for each application including information about the materials of construction.
• Proper motor and mechanical seal selection to improve overall system reliability. pumps.org
DOE Releases New Pump Energy Index Calculation Tool PARSIPPANY, N.J. (June 12, 2015) – The Hydraulic Institute (HI) and its members have worked closely with the Department of Energy (DOE) throughout the rule-making process for the Energy Conservation Standard on Commercial Industrial Pumps.
As part of that process, HI’s Pump System Performance Metric committee worked with the DOE to develop a tool to evaluate the pump energy index (PEI) of pumps. This tool will help pump manufacturers evaluate how their pump eficiencies stack up to the proposed minimum eficiency levels which will be set in the Energy Conservation Standard.
The DOE released the PEI calculation tool to the public June 12. pumps.org
Asahi/America Opens New HeadquartersLAWRENCE, Mass. (June 11, 2015) –Asahi/America, Inc. oficially opened its new headquarters in Lawrence, Massachusetts, on April 23 with a ribbon-cutting ceremony and open
house. Guests from across the U.S. and around the world gathered for the celebration.
Asahi/America’s Chief Financial Oficer Stephen Harrington emceed the opening ceremony which included remarks by Asahi/America President and CEO Daniel S. Anderson, City of Lawrence Mayor Daniel Rivera, and Koji Fujiwara, president of Asahi Organic Chemical, Asahi/America’s parent company in Japan. During his remarks, Anderson previewed what guests would see inside the renovated 200,000 square-foot facility including corporate ofices, warehousing, valve and actuation assembly shops, fabrication, skid assembly, powder-coating, a clean room, and machine shop. He also spoke about the company’s goals and intentions for the future.
“We are intensely focused on customer satisfaction. We strive to be innovative, goal driven, and trustworthy,” said Anderson said. “We will be an asset to our community, we will be a charitable company, and we will respect the environment where we conduct our business.” asahi-america.com
Clean Water Rule Protects Streams & Wetlands WASHINGTON (May 27, 2015) – In May, the U.S. Environmental Protection Agency (EPA) and the U.S. Army inalized the Clean Water Rule to protect the nation’s streams and wetlands from pollution and degradation. The rule ensures that waters protected under the Clean Water Act are more precisely deined and predictably determined, making permitting less costly, easier and faster for businesses and industry. The rule does not create any new permitting requirements for agriculture and maintains all previous exemptions and exclusions.
After receiving requests for more than a decade from members of Congress, state and local oficials, industry, agriculture, environmental groups, scientists, and the public, the EPA and the Army have taken action to provide clarity on protections under the Clean Water Act. Speciically, the Clean Water Rule does the following:
• Clearly deines and protects tributaries that impact the health of downstream waters
AROUND THE INDUSTRY
11
pumpsandsystems.com | August 2015
• Provides certainty in how far safeguards extend to nearby waters
• Protects the nation’s regional water treasures
• Focuses on streams, not ditches• Maintains the status of waters
within Municipal Separate Storm Sewer Systems (The rule does not change how those waters are treated and encourages the use of green infrastructure)
• Reduces the use of case-speciic analysis of waters
A Clean Water Act permit is only needed if a water is going to be polluted or destroyed. The Clean Water Rule only protects the types of waters that have historically been covered under the Clean Water Act. It does not regulate most ditches and does not regulate groundwater, shallow subsurface lows, or tile drains. It does not make changes to current policies on irrigation or water transfers or apply to erosion in a ield. The Clean Water Rule addresses the pollution and destruction of waterways—not land use or private property rights. epa.gov/cleanwaterrule and army.mil/asacw
ITT expands Westminster, S.C., Manufacturing OperationsWHITE PLAINS, N.Y. (May 21, 2015) – ITT Corporation announced that it is expanding its manufacturing operations in Westminster, South Carolina, by investing approximately $1 million to build a new test facility. The investment is part of a total of $2.5 million that the company expects to invest in the facility during the next ive years.
The addition provides a new specialized testing facility for natural gas vehicle (NGV) components, which are part of the company’s Conolow brand of products. These NGV components consist of compressed natural gas pressure regulators and liquid natural gas regulators for heavy vehicles. itt.com
SEPCO Awarded for Excellence in International TradeMONTGOMERY, Ala. (March 25, 2015) – SEPCO (Sealing and Equipment Products Co., Inc.) was recently awarded the Governor’s Trade Excellence Award by Alabama Governor Bentley. SEPCO’s accomplishments, which include
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August 2015 | Pumps & Systems
NEWS
EVENTSALL-TEST Pro, LLC, Electrical Reliability Training SeminarAug. 10-14, 2015Holiday Inn OrlandoLake Buena Vista, Fla.860-399-4222 / alltestpro.com
5th Annual Pumps Hands-on Training: Maintenance, Energy and Reliability Conference (PumpTec-Israel)Aug. 18 – 19, 2015Tel Aviv, Israel770-310-0866pumpingmachinery.com/pump_school/pump_school.htm
IDA World CongressAug. 30 – Sept. 4, 2015San Diego Convention CenterSan Diego, Calif.wc.idadesal.org
TPS 2015Sept. 14 – 17, 2015George R. Brown Convention CenterHouston, Texas979-845-7417 / tps.tamu.edu
Pumps & Systems Webinar Presented by BaldorSept. 24, 2015pumpsandsystems.com/webinars
WEFTECSept. 26 – 30, 2015McCormick PlaceChicago, Ill.240-439-2554 / weftec.org
Pack Expo (PMMI)Sept. 28 – 30, 2015Las Vegas Convention CenterLas Vegas, Nev.703-205-0480 / packexpolasvegas.com
Centrifugal And Positive Displacement Pumps (Basics) Oct. 28 – 29, 2015Pumping Machinery Training CenterNorcross, Ga. / 770-310-0866pumpingmachinery.com/pump_school/pump_school.htm
exporting Alabama-made mechanical seals and compression packing to customers around the world, reflect the state’s economic growth strategy and have contributed to state job creation. Award winners are selected based on a wide range of criteria such as their level of export sales as a proportion of total sales, sustainable growth in export sales, quality of export marketing strategy, senior management commitment to export development, and exporting innovations. Established in 2005, The Governor’s Trade Excellence Awards Program recognizes Alabama manufacturers and service companies for excelling in international trade. SEPCO was one of eight companies awarded in 2015. sepco.com
Circle 141 on card or visit psfreeinfo.com.
13
pumpsandsystems.com | August 2015Circle 114 on card or visit psfreeinfo.com.
Effi ciency Monitoring Saves Plants Millions
Part 2
Editor’s Note: While running a pump at its best e� ciency point saves money, reduces downtime and improves performance, many plant managers
are unaware of how their equipment is actually performing. � is series, which began in the July 2015 issue of Pumps & Systems, depicts a real-
world scenario that is intended to illustrate the importance of monitoring pump e� ciency.
Despite the municipal
water plant’s tight budget,
maintenance manager Jim
decided to speak with his boss
about improving the facility’s pump
e� ciency. Charlie began working at
the Blue Creek water plant about a
year ago and was not aware of the
plant’s history or the details about
its pumps.
“What you got, Jim? Make it
quick. I have a corporate meeting
to be at after lunch. � ey want
to talk about the in� uent screen
problems at the Willow Wastewater
Processing Plant and asked all
watershed plant managers to go.”
“OK, boss. I just wanted to let
you know that Bob from the Duck
Pump Company did some energy
e� ciency testing of our main water
booster pumps and found they
need some � xing. He says their
e� ciency is low.”
“Really? I had a similar issues
back at my old company. We had a
ton of old light bulbs installed all
over the facility, and this guy came
and did some e� ciency testing
and suggested that we switch to
some sort of energy-e� cient light
� xtures. Tons of money involved,
but apparently we still saved some
money overall. How much savings
are you talking about?”
“Well, he � gured we burn nearly
$125,000 extra in wasted energy,
and with just one repair, we could
recoup the cost in about a year.”
“So it’s about a $125,000
repair job? � at’s a lot of money.
I don’t think we have it in this
year’s budget.”
“� at’s what I told him, too.
Anyway, Charlie, just wanted you
to know.”
“� anks. Let’s talk more about
this tomorrow.”
� e next day, Jim and Charlie
got together to look over a fresh
quote from Bob on the pump repair
and upgrade. It was $143,600,
which was higher than the original
budgetary estimate. Bob explained
in his quote, however, that the
extra money was justi� ed by
switching from a single to double
mechanical seal, which would
save water and improve the
unit’s reliability.
“So, how long will it take them to
do the upgrade, Jim?” Charlie was
examining the numbers. “It says
eight to 10 weeks—will it really
take that long?
“Yeah, that’s not bad though. � e
last time they did this, it took them
about the same. � ey do a pretty
good job. We did the last pump
about four years ago, and that is
usually how they take care of us.”
“We need a major overhaul
every four years? Isn’t that a bit
too often?”
“� at’s right. Duck Pump gives
us a full one-year warranty, and
if the pump stays idle most of the
time, they extend the warranty to
two years. � at way, the less we
run the pumps, the more money
we save.”
“You know, Jim, let’s go to the
store room. I want to see one of
these pumps. Do you have a spare?”
“I sure do. Actually, I have two
spare units and four installed ones.
We usually only run one pump at a
time. During peak hours, we � re up
the second pump to get more water
to folks if the other plant is down
and we need to cover for them.”
Charlie and Jim, joined by
Rusty the mechanic, walked to
the shop to examine the pumps.
Store manager Grady Cricket put a
newspaper aside and got up to
meet them.
Charlie glanced around the shop.
“� is is the pump, Jim? Doesn’t
look like a $100,000 job to me!”
Image 1. Spare parts allow for fl exibility when repairs are necessary. (Courtesy of the author)
14 PUMPING PRESCRIPTIONS
August 2015 | Pumps & Systems
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
Troubleshooting & repair challenges
“Well, I meant we have a couple
of spare rotors, not a complete
pump. Usually, when they do a
repair, they keep the casing in
place, pop the top o� and just
remove the shaft with the impeller
and bearings with their housing.”
“OK, I see. So, in his quote, Bob
mentioned changing wear rings
to restore clearance. How big are
those clearances originally, and
how much do they open up as a
result of wear?”
“It’s all in the pump manual,
Charlie. I don’t remember the
exact number; the manuals are at
engineering downtown, and I don’t
get out there often. But I think
these are roughly 0.020-inch or so,
and they get bigger as they wear.”
“But how do they wear? Does
the impeller ring touch the casing
ring? I’m not an engineer, but I’d
imagine that Duck Pump Company
would design the shaft big and sti�
enough so it doesn’t de� ect very
much to touch.”
“I would think so. If they touch,
something is wrong—either the
design is bad or the bearings are
gone. � e main reason for wear is
probably the pumpage.”
“Pumpage? But we pump clean
drinking water! How abrasive can
it be?”
“Yeah, you’re right. I don’t know
either. � is pump is a bit above
my pay grade. We can ask Sandy
from the corporate engineering
department. I saw her a few times
when she came to see the plant a
couple of years ago. She would have
all the manuals and data. Rusty, is
this stainless?”
“Let’s see.” Rusty picked up a
dial indicator base and popped
the magnet over the shaft surface.
“Doesn’t stick. Must be stainless.”
Jim raised his eyebrows. “No
wonder it’s expensive. What about
the impeller and the ring?”
Rusty moved the magnet over
the impeller and determined that
it, too, was stainless. However,
when he moved it over the ring, the
magnet stuck.
“� e wear ring’s not stainless!”
Jim was perplexed. “What’s going
on here? Is this why it’s wearing
out? Maybe it just rusts away (no
15
pumpsandsystems.com | August 2015
Circle 147 on card or visit psfreeinfo.com.
pun intended, Rusty!). You know something—
we better get Sandy to come to the plant, and we
might as well set up a meeting with Bob to go
over his quote.”
Charlie was pleased with what he was
learning, but what he discovered left more
questions than answers. “Let me know when
you set up the meeting. Let’s do it some time
next month.”
In Part 3 of this series, Sandy visits the plant
and discusses the pump repairs and e� ciency with
Bob from Duck Pump Company. Will the non-
magnetic ring Charlie and Jim discovered cause
rusting and wear?
References
1. Nelik, L., “Pump Repair and Upgrade Standards”, pages
16-17, Pumps & System, May 2012
2. Kale R.D., and Sreedhar B.K., “A � eoretical Relationship
Between NPSH and Erosion Rate for a centrifugal Pump”,
ASME 1994, FED-Vol. 190, Cavitation and Gas-Liquid
Flow in Fluid Machinery”
3. Nelik L., “How Much Energy is Wasted When Wear Rings
are Worn to Double � eir Initial Value?”, March 2007
The pump performance and geometry
was hidden in the conversations
among Jim, Bob and Charlie in the
July and August issues. Can you
uncover the real versus expected pump
performance curves and geometry
data? Send your reconstructed curves
and a pump cross-sectional sketch to
pumpeditors@cahabamedia.com. The
correct answer will win admission to
the next Pump School session.
Dr. Nelik (aka “Dr. Pump”) is president of
Pumping Machinery, LLC, an Atlanta-based
fi rm specializing in pump consulting, training,
equipment troubleshooting and pump repairs.
Dr. Nelik has 30 years of experience in pumps
and pumping equipment. He may be reached
at pump-magazine.com. For more information,
visit pumpingmachinery.com/pump_school/
pump_school.htm.
16 PUMPING PRESCRIPTIONS
August 2015 | Pumps & Systems
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pumpsandsystems.com | August 2015
GORMAN-RUPP PUMPS l P.O. BOX 1217 l MANSFIELD, OHIO 44901-1217 l USA l 419.755.1011 l GRSALES@GORMANRUPP.COM l GRPUMPS.COM538 © Copyright, The Gorman-Rupp Company, 2015 Gorman-Rupp Pumps USA is an ISO 9001:2008 and an ISO 14001:2004 Registered Company
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That’s why your plant needs a dependable solution for handling solid waste. Gorman-Rupp
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Trust Gorman-Rupp pumps to keep your operation running smoothly month after month, year after year.
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Circle 107 on card or visit psfreeinfo.com.
This series discusses the
control elements of a piping
system, which improve
the quality of the product. Part
1 (Pumps & Systems, July 2015)
covered passive controls, such as
over� ow and bypass controls, on/
o� controls, and manual controls.
Active Control Operation
Active controls maintain a set
value of a process variable under
changing system operating
conditions. � ey are often referred
to as a control loop (see Figure 3).
� e level in the destination tank is
measured by the level transmitter
that sends the measured value
(MV) to the level controller. � e
desired tank level set point (SP)
is entered into the controller. � e
controller compares the MV to the
SP, and a controller output (CO) is
sent to the � nal control element—a
control valve in this case. � e � ow
rate into the tank (Qin) is adjusted
to maintain the desired tank level.
� e destination tank level can
vary for several reasons, such as
changes in:
• pump � ow rate, caused by
changes in the static head
• pump � ow rate, caused by
mechanical wear
• the � ow rate out of the tank
caused by a change in the
system � ow demand
• the tank level set point caused
by the operator
Level control loop operation
can be examined by looking
at a low-level condition in the
destination tank. � e set point
for the destination tank level is
� ve feet above the tank bottom.
Because of a change in system
� ow demand (Qout), the tank
level drops to 4.9 feet. � e level
transmitter senses the measured
value of 4.9 feet and sends the
information to the level controller.
Because the level controller SP is
5 feet, the controller compares the
measured value of 4.9 feet to the
set point of 5 feet.
� e error between the measured
value and the set point causes the
control to send an open signal
to the control valve. � e valve
positioner causes the valve to
open. � is results in less head
loss across the control valve,
causing an increase in the � ow
rate. If the resulting
� ow rate through the
control valve is greater
than the system � ow
demand, the level
of the destination
tank increases. Over
time, the level in
the destination tank
reaches a steady state
condition.
Level Control with a
Control Valve
� e pump curve in
Figure 2, Part 1 of this
series (Pumps & Systems,
July 2015) shows that
the pump produces
125 feet of head at 400
gallons per minute (gpm). � e sum
of the static and dynamic head
for 400 gpm through the system
is 76 feet. At 400 gpm, the pump
produces 125 feet of head, but the
system only needs 76 feet of head.
As a result, the control valve must
absorb 49 feet of head to limit the
� ow rate to the set value.
� e advantage of level control
with a control valve is the ability
to minimize process variability
by maintaining a more consistent
tank level. � e disadvantage is
the added cost of the control loop,
the need to tune and maintain
the control loop, and the added
head loss across the control valve
necessary to maintain control.
� e annual operating cost of a
control valve appears in Table 3
(see page 20).
A better understanding of complete system operation
Figure 3. An example of an active control loop maintaining tank level by adjusting the fl ow rate into the tank (Graphics courtesy of the author)
Piping System Controls
Last of Two Parts
18 PUMP SYSTEM IMPROVEMENT
August 2015 | Pumps & Systems
By Ray Hardee
Engineered Software, Inc.
19
pumpsandsystems.com | August 2015
It’s time you get more thanyou paid for in a PLC.
Introducing the
NEW
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• 5 built-in communications ports right on the CPU – All the communication you need is builtright in! Modbus TCP/IP, EtherNet/IP, andserial devices are supported with no additionalmodules required!
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CPU and I/OComparison
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Total System Price with USB, Ethernet and Serial
8 Analog InputChannels (mA)
16 24VDC Inputs
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$69.00P2-04B
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Level Control with a
Variable Speed Drive
Figure 2 in Part 1 of this series
shows that for the pump with
the 10.5-inch impeller diameter
running at 1,780 rpm, the
maximum possible � ow rate is
616 gpm. � is is where the energy
supplied by the pump equals the
energy required by the process
elements. Under this condition, no
di� erential pressure is required
across a control.
If we were able to adjust the
pump performance so it only
produces the head required by the
process elements at the desired
� ow rate, the control valve could
be eliminated. � at is the function
of a variable speed drive. By
adjusting the pump’s rotational
speed, the head can be maintained
to be equal to the head required to
meet the � ow rate.
Adjusting the rotation speed of
the impeller changes the pump
performance curve. Figure 4 shows
the pump performance for a range
of speeds. When the pump is
running at 1,424 rpm, it produces
76 feet of head, which is equal to
the head required by the process
elements at 400 gpm. � e pump
e� ciency lines are superimposed
on the system curve as well.
� e advantage of level control
with a variable speed drive is to
minimize process variability by
maintaining a more consistent
tank level and eliminate the
excess head required across the
control valve.
� e disadvantage is the added
capital cost of the control loop and
variable speed drive. In addition,
the losses across the variable speed
drive need to be taken into account
in power requirement.
Conclusion
Passive controls have simple
designs and low installation costs,
but they can have greater process
variability and operating costs.
Active controls can maintain a set
point with minimal changes in the
process variable. � ese systems
have tighter control that comes
at a higher original cost, but the
operating cost can be much lower.
Ray Hardee is a principal founder
of Engineered Software, creators of
PIPE-FLO and PUMP-FLO software.
At Engineered Software, he helped
develop two training courses
and teaches these courses in the
U.S. and internationally. He is a
member of the ASME ES-2 Energy
Assessment for Pumping Systems
standards committee and the ISO
Technical Committee 115/Working
Group 07 “Pumping System
Energy Assessment.” Hardee was
a contributing member of the HI/
Europump Pump Life Cycle Cost
and HI/PSM Optimizing Piping
System publications. He may be
reached at ray.hardee@eng-
software.com.
Table 3. The annual operating costs for using a control valve to control the fl ow. This is the same operating cost calculation for the manual control.
Annual Operating Cost Mode: Control Valve
Flow rate (gpm) 400
Pump head (feet) 125
Pump effi ciency (%) 0.69
Motor effi ciency (%) 0.93
Fluid density (lb/ft3) 62
Annual operation (hr) 8000
Power cost ($/kWh) 0.08
Annual pumping cost $9,337
Figure 4. A pump system curve showing the pump operating at various speeds. The pump operating at 1,424 rpm provides 76 feet of head, equal to the process requirements at 400 gpm.
20 PUMP SYSTEM IMPROVEMENT
August 2015 | Pumps & Systems
21
pumpsandsystems.com | August 2015
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COMMON PUMPING MISTAKES
Net positive suction head
(NPSH) and its two
main components—
NPSHR and NPSHA—are an often
misunderstood mystery to a
large percentage of people in the
pump industry. I have studied and
catalogued more than 150 technical
articles on NPSH in the last 40
years, and most have begun with
comments about the complexity
of the topic. A common statement
in the pump industry is that 80
percent of all pump problems are
on the suction side of the pump. I
would state that, with the exception
of operating the pump away from
the best e� ciency point (BEP), the
percentage is much higher.
Rethinking the Concept
� e responsibility and purpose of
the centrifugal pump is to receive
the liquid that the suction system
delivers and move it downstream.
� e suction-side system, if properly
designed and operated, delivers the
� uid to the pump. � e pump does
not reach upstream and retrieve the
� uid, nor is it capable of doing so.
� e common misconception
is that the pump will “suck” the
� uid from the suction system into
the pump.
Perhaps if liquids had tensile
strength characteristics, that could
be remotely possible (I acquiesce
that the impeller does create a
small di� erential pressure at the
eye), but the suction-side system
must have adequate energy to
deliver the � uid to the pump. Using
the analogy of a cellphone, if the
suction-side system does not have
enough “signal strength” (bars
of energy), then the “call” will be
dropped or be of poor quality—in
other words, the pump will cavitate.
Suction Pressure
One of the most common errors
I witness is confusing suction
pressure with net positive suction
head available (NPSHA). Even
people with decades of pump
experience and education seem
to make this mistake. A common
comment is, “I do not need to
calculate NPSHA because I have
135 psig of suction pressure.”
What they fail to understand is
that the temperature of the � uid in
this case is 350 degrees F. (Please
assume water as the � uid for all
examples in this article.)
� e formula for NPSHA indicates
that 100 percent of the negative
head caused by the vapor pressure
of the 350 degree � uid negates
the positive head contributed by
the pressure of 135 psig. After
accounting for the losses that
result from friction head, the only
positive head available to make
up the remaining energy (bars of
signal strength) is the static head.
Static head is the energy (bars)
contributed by the elevation of
the � uid over the centerline of
the impeller. (Note: � is article
does not account for velocity
head because of the fractional
contribution and, in this case,
� ooded suction.)
Pump users must also remember
that NPSH is not pressure. Pressure
is a force, but head is an energy
level, and the suction pressure is
only one of numerous components
in the total makeup of NPSH.
By Jim Elsey
Summit Pump, Inc.
Rethinking NPSH
Understanding this complex topic can help end users avoid common pitfalls.
The formula for calculating NPSHA is:
NPSHA = h abs.prs – h vpr.prs. – h static – h fric
(For a suction lift)
NPSHA = h abs.prs – h vpr.prs. + h static – h fric
(For a fl ooded suction)
Where:
h abs.prs = head due to absolute pressure
converted to feet
h vpr.prs. = head loss due to the vapor pressure
of the fl uid
h static = head due to static pressure; can be
negative or positive
h fric = head loss due to fl uid friction in the
pipe and all components
1 I suggest you convert all factors to feet (meters) and work in absolute values.
2 I have not included the fi fth factor of velocity head (hVel.) because it is typically so small. If present, it would be a positive factor.
3 Vapor pressure and friction never work in your favor.
4 Static head will be negative and works against you in a lift situation.
5 Static head will be positive and works for you in a fl ooded situation.
6 If you have NPSHA problems, use the formula as a road map to look for solutions.
7 Using a pump of lower speed, dual suction or different impeller geometry can also resolve NPSH issues.
7 TIPS FOR CALCULATING NPSHA
August 2015 | Pumps & Systems
22
Another comment I often hear
in the � eld is, “I do not need to
calculate the NPSHA because I
have a � ooded suction.” Again,
these individuals are not taking
the negative factors of friction and
vapor pressure into account.
Submergence
Submergence is the vertical
distance from the top surface of
the � uid to the centerline of the
pump intake line. Submergence is
applicable to both � ooded and lift
situations. If the submergence is
not positively su� cient, then the
velocity of the � uid in the suction
line will create a vortex. � e
captured air will be ingested into
the pump. Centrifugal pumps are
not designed to pump (or compress)
air, and the average centrifugal
pump will drop performance
quickly even with small amounts
of entrained air. While certain
designs, such as recessed impeller
pumps, can handle up to 24 percent
entrainment, just 12 percent
will stall most pumps. � is is
vital because many people in the
� eld confuse cavitation with air
binding/entrainment.
Every pump suction-side
installation has a minimum
submergence below which air
will be ingested. � e � ow rate for
a pipe of a given size, geometry
and material makeup has a
corresponding � uid velocity. � e
resultant velocity corresponds
with an amount of required
submergence (distance) to prevent
the formation of a vortex. Keep in
mind that just because you cannot
see the vortex with the naked
eye does not mean the vortex
phenomenon is absent.
Vacuum
At the bottom section of most
steam condensers is a collection
area, usually a tank-shaped
reservoir for the condensate
commonly known as the hot
well. In these applications, end
users commonly make errors
determining the correct absolute
pressure when making the NPSHA
calculations. Pumps are subject
to vacuum on the suction side in
many other instances as well.
� e error is in the assumption
that the vacuum level is equal to
the absolute pressure. Consider
a condenser with a vacuum level
of 28 inches of mercury (Hg).
pumpsandsystems.com | August 2015
23
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COMMON PUMPING MISTAKES
Inexperienced users might incorrectly
assume that they need to convert the
vacuum level to a corresponding head,
which they determine is the absolute
value (see Equation 1). In reality, the
actual absolute pressure is the di� erence
between the existing vacuum and what
would be the perfect vacuum or zero
absolute pressure. � ink about it as how
much pressure remains if the vacuum
is at some level, X, (as in this case of 28
inches Hg). A perfect vacuum would be
14.69 (atmospheric pressure at sea level)
x 2.31 (the conversion factor) = 33.933
(rounded to 34 feet).
At sea level, the atmospheric pressure
typically supports a mercury column not
more than 29.92 inches high. � erefore,
the standard for atmospheric pressure
at sea level is 29.92 inches Hg, which
translates to an absolute pressure of
14.69 psia, which is usually rounded to
14.7 psia.
So the true absolute pressure (to
be converted to head) is really the
di� erence between the two (see
Equation 2). � e correct absolute
pressure converted to head is 2.22 feet
not 31.78 feet.
At some point, you will be required to
calculate the value for NPSH available.
Why not be ready to do it the right way
and avoid the unnecessary drama and
expensive corrections?
Jim Elsey is a mechanical engineer
who has focused on rotating
equipment design and applications for
the military and several large original
equipment manufacturers for 43 years
in most industrial markets around the
world. Elsey is an active member of
the American Society of Mechanical
Engineers, the National Association
of Corrosion Engineers and the
American Society for Metals. He is the
general manager for Summit Pump,
Inc., and the principal of MaDDog
Pump Consultants LLC. Elsey may be
reached at jim@summitpump.com.
Equation 1 (Incorrect approach)
28 in/Hg vacuum x 1.135 conversion, in/Hg to feet of water = 31.78 feet
Equation 2 (Correct approach)
34 - 31.78 = 2.22 feet
(Note: I have rounded off and assumed sea level for the example)
24
August 2015 | Pumps & Systems
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800-966-5240 | 623-979-3560
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Proud Member of the
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September 15-17Booth #1136
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August 2015 | Pumps & Systems
SPECIAL SECTION
BEARINGS, COUPLINGS & SEALS
26
S ealing systems can play a vital role in equipment
performance and are considered critical
components in the validation process of a design.
Engineers should closely examine the sealing
systems used in their equipment, because they do
everything from preventing seal leakage and extending
hydraulic cylinder life to lowering dynamic friction and
controlling hydraulic motor position.
Component designers must contend with extreme
wear conditions and harsh chemicals. In addition, they
must meet tight tolerances and factor in signifi cant
vibration and high pressures. Many variables
can aff ect sealing capabilities,
and their impact can vary greatly depending on
the sealing application. Manufacturers and users
are often challenged to balance resources properly
when addressing what could be substantial sealing
issues. Issues with the sealing system can aff ect
performance signifi cantly and may lead to decisions
in the validation process that produce erroneous or
misleading results or consume excessive resources.
So, what are the right methods to properly address
the validation of sealing systems?
Validate Sealing Systems for Optimized PerformanceInvestment at the start of a project can lead to improved safety, reliability and savings.
BY LARRY CASTLEMANTRELLEBORG SEALING SOLUTIONS
Image 1. Seals play an important role in overall equipment functionality, and validating seals is part of a successful system. (Images courtesy of Trelleborg Sealing Solutions)
pumpsandsystems.com | August 2015
27
Seal System Verifi cation
Verifi cation and validation of a system design process are
independent procedures that are used to ensure that a
system meets the intended specifi cations, requirements
and objectives. � ey provide assurances that reliability
and performance will be maintained over the life of the
process. Equipment manufacturers want to minimize the
cost of validation without jeopardizing any requirements.
� e validation process delivers a comprehensive
understanding of the risks or liability associated with the
process and gives insight into many of the infl uences on
the system’s performance.
Systems validation requires considerable planning.
Any mistakes in planning can lead to falsely validating
systems. � e product could then have to be redeveloped,
or it could be launched with poorly understood behavior.
For instance, seal leakage can aff ect cylinder or actuator
life, which can be a vital part of operations, controlling
valves in every area, and managing the fl ows of water, gas
or chemicals. Another example is sealing system friction,
which can aff ect position control. Since sealing system
performance and process performance are directly linked,
the validation of sealing system performance plays a
crucial role in process validation procedures.
Process Validation
More than a series of tests, validation is a process. It
begins with identifying areas of concern, continues
with testing, and is completed with an analysis and
verifi cation of results. However, during design validation
or development, market forces and conditions do not
always allow for all the possible paths to be considered.
� e balance of risk, such as risk of failure mode or system
functionality loss and associated liability, is crucial to
the decision-making process. In scenarios where time
and cost associated with validation are limited, it is
prudent to take into account the right seal functionality
considerations in the equipment.
Image 2. An engineer completes a compression test to ensure performance.
August 2015 | Pumps & Systems
28 BEARINGS, COUPLINGS & SEALS
Process Workfl ow
� e process fl ow during a validation exercise
incorporates all signifi cant factors for consideration.
Even though the amount of crucial elements to consider
for a sealing system may seem overwhelming, many
of these factors provide a practical approach and fl ow.
Incorporating these important factors can reduce
common mistakes and duplicate common successes.
For starters, eff ective communication between the
sealing supplier and the end user as well as subsequent
thoughtful and planned action is benefi cial. While this
approach requires more eff ort up front, the reward is a
signifi cantly reduced chance of a negative outcome later.
Taking the critical elements of seals and bearings
into account before the testing phase of the validation
process will optimize the return on investment. � e end
result is better overall performance of the process.
Eff ective Use of Validation Flow
Knowledge of the elements of the sealing system, such
as seals, bearings and wipers, is critical to success.
Engineers should fi rst determine how to validate each
component, then determine the criteria for success or
failure. Finally, they should create a list of activities and
criteria to meet these standards.
A Learning Process
To avoid a faulty product launch or a redevelopment,
clear communication between the end user and supplier
is critical. � e results often save labor, machine time
and development costs.
Creative Sealing Solutions
Through Innovative
Engineering.
PPC Ultraseal
780/789 Dual Cartridge Seal
PPC 1200S Split Single Seal
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Made in USACir
cle
13
6 o
n c
ard
or
vis
it p
sfre
ein
fo.c
om
.
Larry Castleman is the technical
director of product development at
Trelleborg Sealing Solutions. For more
information, visit tss.trelleborg.com.
Taking the critical elements of
seals and bearings into account
before the testing phase of the
validation process will optimize
the return on investment.
pumpsandsystems.com | August 2015
29
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August 2015 | Pumps & Systems
30 BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
M echanical seals consist of a rotating element
and a stationary element, each with a
lapped, precision-smooth mating face (see
Figure 1). Seal performance is determined
primarily by the condition of the faces and the pressure
applied to them. Other key factors are vibration, heat and
pumpage characteristics. Depending on the application
and user’s needs, diff erent seal types may be appropriate.
For many larger centrifugal pumps, users have the
option of installing either component or cartridge
mechanical seals. Understanding the advantages and
limitations of each can help determine the best solution
for a particular application.
Component Mechanical Seals
Standard mechanical seals are typically component
seals. When users order a replacement, they typically
receive a box containing seal faces, holding brackets,
O-rings, boots and other parts that require the skills of
an experienced pump technician to install and adjust
properly (see Image 1).
Incorrect installation and adjustment are common
causes of component seal failure. For example, if the seal
faces are not properly seated on the shaft or in the seal
housing, they will be misaligned. Sliding O-rings and
elastomers over shaft shoulders, keyways or sharp edges
of the seal housing can also cause damage to these parts
and result in incorrect seal tension.
� e seal housing often provides limited access, so
successful adjustments require precision and accuracy.
While an experienced pump technician can successfully
install and adjust any component seal, this process
provides opportunity for error.
Cartridge Mechanical Seals
Cartridge mechanical seals and component seals use
similar components, but the stationary components
of cartridge seals are preassembled in a housing, and
the rotating components are preassembled on a shaft-
mounted sleeve that is sealed with an O-ring. � e
cartridge seal housing typically replaces the gland cover
plate and seals to the pump housing with a gasket, an
O-ring or other elastomer. Since cartridge mechanical seal
components are preassembled onto the sleeve and into the
cartridge housing, errors in parts installation are unlikely.
Component or Cartridge: How to Choose the Right Seal The balance between cost and ease of installation should be the major deciding factor.
BY EUGENE VOGELEASA
Liquid Pumpage Vaporized Liquid
Rotating Shaft
Rotating Seal Face Stationary Seal Face
Figure 1. Common mechanical seal (Images and graphics courtesy of EASA)
pumpsandsystems.com | August 2015
31
� e amount of spring tension applied to the seal
faces is an important factor that aff ects successful seal
installation. On component seals, technicians can set
this tension manually by adjusting the length of the
installed seal spring. With cartridge mechanical seals,
the spring tension is preset. To ensure the proper tension,
a retaining device holds the rotating and stationary
elements in alignment until after the seal is mounted.
While the details of whether a cartridge mechanical
seal can be fi tted to an application are complex, one
Image 1. Component (left) and cartridge (right) mechanical seals
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August 2015 | Pumps & Systems
32 BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
criterion is whether the seal installs from the wet side
or dry side of the seal chamber. Pumps with a seal that
installs from the wet side, behind the impeller, are
generally not candidates for cartridge mechanical seals.
In addition, submersible pumps, which are usually
fi tted with dual component seals, cannot be converted to
cartridge mechanical seals because the seals install from
the wet side of the pump.
Component vs. Cartridge
For end users deciding between a component and
cartridge seal, the primary considerations are cost and
ease of installation. If a competent pump technician
services the pump during overhaul under good working
conditions, ease of installation may seem like a minor
issue. However, the concern will be for subsequent seal
replacement during an emergency outage.
Cartridge mechanical seals may cost two to three times
component seals, so unless otherwise stated, competitive
repair bids are typically for component seals. Despite
the higher initial investment, however, a cartridge seal
can be a more cost-eff ective, long-term solution, given
the expectation that pump maintenance may require
in-service seal replacement. Potential savings accrue
from lower labor costs and
less production downtime
when subsequent seal
replacement is needed.
Projected savings
also include the
elimination of seal
failures resulting from
improper installation of
component seals.
Dual Seals
Dual seals are eff ective
solutions for many pumping environments and
applications that are tough on seals, including high
temperatures, high pressures and foul pumpage laden
with abrasives. Dual seals have a chamber between the
seals into which barrier fl uid can be pumped to provide
cooling, lubrication and protection from abrasives in
the pumpage. While redesigning a single-seal pump to
accept dual component seals would be challenging, the
precision components of a cartridge mechanical seal can
be designed as a dual seal that can easily fi t in the same
space as a single component seal (see Image 2).
Image 2. A cartridge dual mechanical seal
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Dcnn"("Tqnngt"Dgctkpiu
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dgctkpiuBpc
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Circle 133 on card or visit psfreeinfo.com.
pumpsandsystems.com | August 2015
33
Impeller Adjustment
Some pumps, particularly those with semi-open
impellers, require periodic adjustment of the impeller
face clearance. Users can make this adjustment by moving
the pump shaft axially, which can change the tension on
the seal. On a component seal, resetting the seal tension
requires signifi cant disassembly of the pump. Most
cartridge mechanical seals have retaining devices that
can be reinstalled to align the stationary and rotating
elements. � is makes it easy to reset the seal tension after
the impeller face clearance has been adjusted.
Split Cartridge Mechanical Seals
Replacing a mechanical pump seal, component or
cartridge usually requires pump disassembly. One way
to avoid this is to use a split seal. � e faces and other
circumferential components are split in half so they can
be installed without disassembling the pump. Since each
circumferential component must be properly fi tted and
joined together, installation of split component seals can
be problematic and requires a high degree of technical
ability. If any mistakes are made, the seal won’t work.
Recent developments in seal technology have led to
the production of split cartridge mechanical seals, which
greatly simplify the installation of split seals. Whether
a split cartridge mechanical seal is the best option
depends on ease of installation versus cost. � e additional
cost may be justifi ed if, historically, the application
has required in-service seal replacement and if pump
disassembly is diffi cult.
Making the Right Choice
If users are aiming to fi nd the most cost-eff ective, long-
term solution to pump maintenance and they anticipate
in-service seal replacement, a cartridge mechanical seal
will likely be a good choice. Incorporating a cartridge
mechanical seal also allows the conversion from a
packing seal to a mechanical seal. When low initial cost
is important, component seals—and a well-trained pump
technician—are the best option.
Eugene Vogel is a pump and vibration
specialist at the Electrical Apparatus
Service Association, Inc. (EASA) based in
St. Louis, Missouri. Vogel may be reached
at 314-993-2220. For more information,
visit easa.com.
T F S E A L S U S A . C O M
We Deliver!
sales@tfsealsusa.com
Phone: 1.713.568.5547
Fax: 1.713.758.0388
10620 Stebbins Cir, Suite E
Houston, TX 77043
Serving Manufacturers and Distributors Over 30 Years!
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August 2015 | Pumps & Systems
34 BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
E very industry has its own terminology. For
example, depending on the frame of reference,
the acronym “API” can mean American Petroleum
Institute, active pharmaceutical ingredient or
application programming interfaces. To know what is
meant, one needs to know the context. In the case of
industrial sealing products, the context is often a catalog
published by the manufacturer, which to the uninitiated,
may raise as many questions as it answers. Yet, accurately
deciphering the information is vital to making informed
decisions in the selection of the optimal seal for a
particular application (see Table 1).
When considering gasket information, note that the
service temperature, pressure and pressure X temperature
(P X T) values of the intended application do not exceed
the published ratings of the product.
Temperature limits are sometimes expressed in what
appears to be a dual rating—maximum and continuous
maximum. Maximum temperature is the temperature the
material could survive for an extremely short duration.
� e continuous maximum temperature is the working or
allowable temperature a product can withstand for the
duration of its service life. Analogous to these limits is
the published tensile strength of a structural material,
where the maximum temperature would be expressed as
ultimate or yield stress, and the continuous maximum
temperature would correlate to maximum allowable
stress. � is stress is typically the ultimate stress divided
by a safety factor.
Chemical compatibility of the material with the
media is another important consideration. Gasket
manufacturers publish tables ranking acceptability with
hundreds of common media.
Users should also consult the sealability numbers and
consider the nature of the media being sealed. Lower
values indicate the ability to seal more tightly than higher
How to Interpret Published Sealing DataGasket information and the tests used to generate it can help users make the best possible equipment selections.
BY JIM DRAGOGARLOCK SEALING TECHNOLOGIES, LLC
Image 1. A technician tests a gasket for leak tightness using DIN-3535 method and equipment. (Images and graphics courtesy of Garlock Sealing Technologies, LLC)
pumpsandsystems.com | August 2015
35
ones. When comparing gasket materials, the unit of
measure should be noted. Sealability data is expressed in
milliliters per hour (ml/hr), milliliters per minute (ml/
min) or cubic centimeters per minute (cc/min).
If the application thermally cycles, consider gasket
materials with the lowest creep values, indicating they
will not become as thin under compressive load as
materials with higher values. � e more a gasket creeps,
the more load will be lost from the fl ange bolts. � is
loosening can result in shorter service life, leaks or blow-
out. Note that thinner gaskets tend to creep less than
thicker ones.
In the case of non-metallic, worn or damaged fl anges,
materials with higher compressibility should be
chosen. � e higher the compressibility of a gasket, the
more conformable it will be to the fl ange surface. � e
manufacturer should always be consulted with regard to
the choice of product and selection logic.
Gasket Sheet Properties, Test Methods
& Signifi cance
� e following information describes in more detail the
types of tests conducted and the meaning of the results.
P X T – Pressure X Temperature Value
Test equipment includes a fl anged joint, heat source
and pressure source. In this destructive test, the gasket
is taken to a point of failure. � e pressure and
temperature at failure are noted, the product of which
is the ultimate level to which a safety factor is applied
for the published value.
ASTM F37B & DIN 3535-4
ASTM F37B “Standard Test Methods for Sealability
of Gasket Materials” and DIN 3535-4 “Seals in gas
supply; seals of It-Plates for gas valves, gas appliances
and gas pipelines” gauge how well the material seals.
Table 1. Typical catalog information for gaskets
Seal Composition Filled Restructured Polytetrafl uoroethylene (PTFE)
Compressed Aramid Fiber
Compressed Inorganic Fiber
TemperatureMinimumMaximumContinuous maximum
-450 F (-268 C)
---500 F (260 C)
-100 F (-75 C) 700 F (370 C)400 F (205 C)
-100 F (-75 C)800 F (425 C)
550 F (290 C)
Pressure 1,200 pounds per square inch (psi) (83 bar)
1,000 psi (70 bar) 1,200 psi (83 bar)
P x TMaximum for 1/32 inch, 1/16 inch (0.8 millimeters, 1.6 millimeters)
For 1/8 inch (3.2 millimeters)
350,000 pounds per square inch gauge (psig) x F (12,000 bar x C)
250,000 psig x F(8,600 bar x C)
350,000 psig x F (12,000 bar x C)
250,000 psig x F (8,600 bar x C)
400,000 psig x F (14,000 bar x C)
275,000 psig x F(9,600 bar x C)
Sealability – American Society for Testing and Materials (ASTM) F37BNitrogenASTM Fuel A
---0.22 ml/hr
0.2 ml/hr0.6 ml/hr
0.2 ml/hr1.0 ml/hr
Gas permeability – Deutsches Institut fur Normung (DIN) 3535 Part 4
<0.015 cc/min 0.05 cc/min 0.05 cc/min
Creep relaxation – ASTM F38 18% 21% 15%
Compressibility – ASTM F36 7-12% 7-17% 7-17%
Recovery – ASTM F36 >10% 50% >50%
Tensile strength – ASTM D1708 2,000 psi(14 Newtons per square millimeter
(N/mm2))
2,250 psi(15 N/mm2)
1,500 psi(10 N/mm2)
August 2015 | Pumps & Systems
36 BEARINGS, COUPLINGS & SEALS
F37 and DIN 3535-4 give seal tightness at standardized
pressures and ambient temperatures. Custom tests can
introduce elevated temperatures and thermal cycling. F37
covers both gas and liquid at relatively low pressures and
compressive loads on the gasket. DIN 353-4 compressive
loads on the gasket are at levels that might be found in
a Class 150 raised-face fl ange. Gas is at a pressure of
580 psig.
ASTM F38 & DIN 52913
ASTM F38 “Standard Test Methods for Creep Relaxation
of Gasket Material” and DIN 52913 “Testing of static
gaskets for fl ange connections - Compression creep testing
of gaskets made from sheets” indicate joint longevity.
Standard temperature, compressive load and duration
rank the ability of a material to maintain its thickness,
which indicates how well a fl anged joint will maintain its
tightness. � e F38 tests are conducted at 100 C (212 F)
for 22 hours and DIN 52913 at 300 C (572 F) for 16 or
100 hours.
ASTM F36
� e “Standard Test Methods for Compressibility and
Recovery of Gasket Material” are ambient temperature
tests that indicate the ability of a material to compress
and conform under load. � e recovery portion of the test
reveals the material’s resilience. � e test results have little
meaning after a material has been exposed to elevated
temperatures. � e greater the compressibility, the more apt
the material is to conform to fl ange surface irregularities.
ASTM F152
� e “Standard Test Methods for Tension Testing of
Nonmetallic Gasket Materials” look at material strength.
Gaskets are cut into standard tensile test “dog bone”
coupons. � e results indicate that the material has been
manufactured properly and is strong enough to be cut
and handled.
Conclusion
Understanding published gasket information and the
tests used to generate it provide confi dence in the process
of selecting application-appropriate materials. � ese
selections, in turn, can be confi rmed by the manufacturer’s
applications engineers resulting in well-informed choices.
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Jim Drago is principal applications engineer
at Garlock Sealing Technologies, LLC. He has a
B.S. in mechanical engineering from Clarkson
University. He may be reached at
jim.drago@garlock.com or 800-448-6688.
pumpsandsystems.com | August 2015
37
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August 2015 | Pumps & Systems
38 BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
B earings are precision components that require
clean lubrication in adequate amounts to ensure
a long, trouble-free life. Even small amounts of
contamination or slightly elevated temperatures
can lead to bearing failure.
A study of equipment reliability conducted at a major
refi nery concluded that 40 percent of rotating equipment
failures (pumps, mixers, etc.) were attributable to
bearing failure. It further estimated that 48 percent of
bearing failures were due to particle contamination and
4 percent were due to corrosion (caused by liquid in the
oil). In fact, bearing oil contamination accounts for 52
percent of bearing problems and 21 percent of rotating
equipment failures.1 If water, dust or other process fl uids
enter a bearing, it is headed for trouble. Modern labyrinth
bearing protection seals can help prevent these issues.
Dust Contamination
Dust in the production environment is a major problem
for bearings. Heavy dust is made of particles as small as
50 microns that can become airborne.
Because they fall at about 200 millimeters per
second, these particles are unlikely to move beyond the
production area. Heavy dust is readily seen as a cloud with
the naked eye.
Light dust, which is smaller than 50 microns in size,
may stay in the air for more than 30 minutes. � is type
of dust can travel well beyond the manufacturing site,
although it is commonly seen as a fi ne coating when it
settles on machinery, bearing housings and other surfaces.
Why Bearings FailModern labyrinth bearing protection seals can protect precision elements from contamination.
BY CHRIS REHMANNAESSEAL
Figure 1. While the shaft is rotating, a micro-gap opens, allowing the thermal expansion in the bearing housing. While the shaft is not rotating, the micro-gap is closed, forming a perfect vapor seal (Images and graphics courtesy of AESSEAL)
Image 1. Three months after running, the air purge still keeps dust away from the stator to rotor interface.
Outboard Air Purge
Inboard Air Purge
pumpsandsystems.com | August 2015
39
Both types of dust are a concern because even light
dust will fi nd its way into a bearing. Although the
housing off ers some protection, ingress still happens.
One signifi cant factor in bearing oil contamination is the
breathing process that occurs with all rotating equipment.
When equipment rotates, the bearing housing heats up,
and the oil and air mixture inside expands and is forced
through the seal. � e problem arises when equipment
cools, because the oil and air mixture also cools and
contracts, sucking air laden with dust from the external
atmosphere through seals back into the housing. Over
time, dust builds up inside the bearing and eventually leads
to oil contamination, abrasion to components and bearing
failure. Bearing seals must facilitate this breathing cycle to
extend bearing life, while preventing dust contamination.
Some modern labyrinth seals with an air purge
design are suitable for use in extreme environments and
applications where contamination may completely cover
the seal or equipment (see Image 1). � ese use a positive
air purge to enhance the performance of the labyrinth
in combination with mechanical seal pressure balancing
technology to maximize the performance of the seal and
minimize air consumption.
Figure 2. When equipment rotates, the bearing housing heats up, and the oil and air mixture inside heats up forcing air through the seal. As equipment cools the oil and air mixture contracts, it sucks air from the atmosphere.
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August 2015 | Pumps & Systems
40 BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
Humidity & Moisture Contamination
Moisture can enter bearing housings through old-style
labyrinth seals or lip seals as airborne water vapor or as
a stream of water from hose-down operations. It can also
enter through other ways, such as the breather vent or
from the widely used non-pressure balanced constant
level lubricators or abraded oil ring material.
Water vapor present in the atmosphere is also a cause of
many contamination problems. Even though the air in a
production plant may appear to be dry, moisture is always
present. Warm air can hold more water vapor, so the hot air
around machinery will have a higher relative humidity.
� e pathway for water vapor entering the bearing starts
when the bearing house begins to breathe. As the machine
cools, this warm, moisture-laden air (along with airborne
dust) is sucked back into the housing. As the equipment
continues to cool and reaches dew point, minute water
droplets form inside the bearing. � is moisture builds up,
causing corrosion and eventually failure.
Moisture and humidity alone contribute to damage
within mechanical components, however when
coupled with noxious elements from the air around the
production process, it can create an even more corrosive
combination for bearings.
To reduce the risk of humidity and moisture
contamination, the bearing housing would need to be kept
above dew point to prevent condensation from forming.
However, since this is not practical, the best way to reduce
the risk is use of modern labyrinth bearing protection.
When the shaft stops rotating, the bearing protection
creates a perfect vapor seal against both moisture and
dust. � ese labyrinth designs also protect against other
sources of moisture contamination such as powerful
waterjets. Some labyrinth seals can operate in completely
fl ooded or submerged environments, providing the
bearing with complete protection.
Overheating is another common cause of bearing
failure. To prevent overheating, users should get the
bearing running at optimum temperature, which requires
adequate, but not excessive, lubrication. Discoloration of
the rings, balls and cages, ranging from shades of blue to
brown, is a sure sign of bearing overheating. Unless the
bearing is made of special alloys, temperatures in excess
of 200 C (292 F) can anneal the ring and ball materials,
resulting in loss of hardness and, in extreme cases,
deformation of the bearing elements. � e most common
cause of overheating is excessive speed, inadequate heat
dissipation/insuffi cient cooling and lubricant failure.
Overheating is a major problem, because even slightly
elevated temperatures can cause oil or grease to degrade
or bleed, reducing effi ciency of the lubricant. Under even
higher temperatures, oxidation causes loss of lubricating
elements and the formation of carbon, which may clog
the bearing. � e most eff ective way to extend the life
of the lubricant and ensure that it remains in optimum
condition is to use a modern labyrinth bearing protector.
� ese devices have been proven to protect against
contamination ingress and lubricant egress.
Lubrication Issues
Improper lubrication accounts for about one-third of
all bearing failures. Poor lubricant viscosity, prolonged
service or infrequent changes, excessive temperature,
using the wrong type of lubrication or over-lubrication
are common problems. External contamination is another
major cause of compromised performance of the lubricant.
Creating optimum lubrication conditions is a
balancing act between over-lubrication and under-
lubrication. Both create a problem as do contamination
or the use of a lubricant not suited to the equipment.
Consistency, viscosity, oxidation resistance and anti-
wear characteristics all play a role in the selection of
a lubricant. Usually, the application will dictate the
amount, type and frequency of lubrication needed.
Figure 3. While the shaft is rotating, a micro-gap opens, allowing the thermal expansion in the bearing housing. While the shaft is not rotating, the micro-gap is closed, forming a perfect vapor seal.
pumpsandsystems.com | August 2015
41
Extending Bearing Life
Manufacturers have developed more advanced labyrinth
bearing protection seals that can off er protection against
all types of contamination. For example, one seal that
is non-contacting in operation to avoid shaft wear
incorporates patented dynamic lift technology to protect
against the breathing issues that contribute to 52 percent
of all bearing failures centered around contamination.
� is dynamic lift technology uses the centrifugal force
of rotating equipment to open a temporary micro-gap,
allowing expansion of the oil and air mixture in the
bearing housing, which allows the equipment to breathe.
When the equipment stops rotating, the micro-gap
immediately closes, forming a perfect seal. � is prevents
dust and moisture from being sucked back into the housing
and therefore prevents contamination (see Figure 3).
Rated to IP66 of the ingress protection code, this seal
can reduce water contamination of the bearing oil from
as high as 83 percent to just 0.0003 percent compared to
lip-seals, even when exposed to high-pressure water jets.
� e range is Atmosphères Explosives (ATEX) certifi ed for
use in explosive environments. Special designs make it
suitable for a wide range of applications.
It is also designed with a thinner cross-section and
seal length than competing devices, which means that it
can be retrofi tted on more equipment without having to
carry out modifi cations. Furthermore, the design enables
it to be positioned diff erently on the shaft than lip seals,
which means that damaged shafts can be retrofi tted
without costly replacement.
Conclusion
When all of the issues that cause bearing failure are
addressed, bearings should have a long, trouble-free
life. Taking steps to address these problems before they
happen can result in signifi cant cost savings. Bearings
are precision elements and require an ongoing supply of
clean lubricant in the appropriate amount to ensure long
equipment life and low maintenance. Modern labyrinth
bearing protectors have been shown to prevent the entry
of contaminants, as well as the loss of lubricant.
References:
1. Bloch, Heinz; “Pump Users Handbook: Life Extension” 2011
Chris Rehmann is business development manager for
AESSEAL in Knoxville, Tennessee. Prior to joining
AESSEAL in 2002, he earned his engineering
degree from Notre Dame and worked for 15
years in various management positions with an
oilfi eld engineering services company. For more
information, visit labtecta.com.
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August 2015 | Pumps & Systems
42 BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
A fter 30 years of research, an engineering
team in Japan has developed a hybrid-type
submersible bearing that prevents burnouts
during vertical pump dry-starts, exploits the
elasticity of the synthetic rubber to level the pressure
during typical operation, and ensures stable bearing
behavior by conferring vibration control while supporting
the rotating shafts.
Using polytetrafl uoroethylene (PTFE) strips as slide
members and synthetic soft rubber for cushioning
between the slide elements and metal shell (or the base
plates), the hybrid bearing can be used for dry-start
operation of vertical pumps without applying lubricating
water from the outside prior to pump operation.
Advantages of Adopting a Dry-Start Bearing
A wet-start vertical pump system requires that water
be injected from outside the pump into shaft protection
tubes at the top of the column pipes before operation. In
most cases, the water is pumped up automatically after
a fi xed time to avoid wasting the feed water pump power
or the water from the tap, which is usually called self-
feed water. A dry-start pump does not require lubrication
and is less prone to environmental damage from crevice
corrosion in joint parts where seawater remains. Because
the stainless steel shafts are exposed directly to the pump
main fl ow, pitting corrosion—prone to occur in low-fl ow-
velocity or stagnant regions—is reduced.
Structure of Hybrid Bearings
� ree molds have been developed to produce three types
of bearings, each suitable for a diff erent range and scale
of application. � ese include full-molded, segmental and
barrel type bearings.
Bearings are basically composed of four layers: PTFE
strips as slide elements, synthetic rubber for cushioning,
base plates as the backing-plates and a metal shell that
serves as the holder. � e full-molded bearing is used
almost exclusively for vertical pumps, making a simple,
three-layered structure as shown in Figure 1.
Friction Coeffi cients
Creating submersible bearings with materials that
have low friction coeffi cients has been a top priority
for submersible bearing manufacturers. Figure 2 shows
friction coeffi cients in tap water of diff erent bearing
materials (PTFE, polyether ether ketone [PEEK] and
polyurethane in hybrid structure with rubber) used in
dry-start vertical pumps and rubber bearings used in wet-
start pumps. Friction coeffi cients were obtained using
identically structured bearings to match test conditions.
� e graph plots one of the outcomes obtained by
changing the bearing loads from 0.25 to 1.0 mega-Pascals
Hybrid Bearings Enhance Performance of Dry-Start Vertical PumpsThis equipment exploits the elasticity of synthetic rubber and ensures stable bearing behavior.
BY FUMITAKA KIKKAWA & YOSHIMASA KACHU, MIKASA CORP.
& HIROSHI SATOH, ORIDEA INC.
Figure 1. PTFE/rubber hybrid bearings for pumps (Images and graphics courtesy of the authors)
pumpsandsystems.com | August 2015
43
(MPa) at four stages. Results show that all bearing
materials have excellent friction coeffi cients.
Eff ects of Synthetic Rubber
Friction coeffi cients obtained using the two test bearings
during wear resistance testing indicate that the test
bearing with the persistently soft rubber layer (72 Shore A
hardness) has a lower friction coeffi cient than the bearing
with the rubber layer turned into ebonite (80 Shore D
hardness). � is suggests that the rubber layer may prevent
sharp rises in the local pressure on the bearing conferred
by the shaft defl ection. � e rubber seems to keep pressure
low overall and limit the solid contact friction areas.
� e free surfaces of the rubber made by or among the
PTFE strips may improve the elastic eff ect compared with
the bearings without free surfaces facing the shaft, as with
a the bearing with a monolithic ring-like structure of metal
and resin.1 � e balance between the number of grooves and
the size of the area in which the water fi lm formed to lower
the friction coeffi cients is important. If the number of
grooves is increased to enhance the elasticity of the rubber,
the size of the water fi lm area will decrease and invite the
larger friction coeffi cients and vice versa.
Because the pump shafts of the vertical pumps are
suspended on the center of the column pipes, the bearing
load by the shaft weight is comparatively small, which is
typical with vertical pumps. � is reduces the importance
of self-alignment, but another problem may emerge.
Adhesive & Abrasive Wear Resistance
Wear resistance related to adhesive wear and the abrasive
wear of the slide members is an important factor for
submerged bearings from the viewpoint of tribology.
Figure 3 shows the results of an adhesive wear test on
two pieces of same-sized bearings. One was the PTFE
and rubber hybrid bearing, while the other contained
abundant sulfur and was vulcanized to harden the rubber
into ebonite with the hardness of 80 Shore D.
Figure 3 plots the coordinating friction data
according to the wear amount after confi rming the
friction coeffi cients through a series of tests performed
concurrently for the pure wear test and the measurement
of the friction coeffi cients. � e wear amount of the PTFE/
ebonite hybrid bearing is displayed as a ratio, while the
wear amount of the PTFE/rubber hybrid is assumed to
be 1.0. � e graph indicates that the wear of the original
bearing with the soft rubber layer is about one-half
of the wear amount of the bearing with a rubber layer
transformed into ebonite.
Absorptivity of Shaft Vibration
In addition to the eff ect on friction coeffi cients, the
rubber layer also aff ects shaft vibration control. A
viscoelastic material like rubber suppresses the self-
excited or sub-synchronous vibration that is caused by
the strong nonlinearity of the bearing characteristics
Figure 2. Friction coeffi cients in tap water
Figure 3. Test results of PTFE/rubber hybrid bearing Figure 4. Vibration amplitude when using three types of bearings
August 2015 | Pumps & Systems
44 BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
and tends to appear when loads are small, as in the case
of the shafts of vertical pumps.
Figure 4 (page 43) shows the peak-to-peak amplitude
measured on a bearing spider fi xed on the middle part
between the column pipes of the test pump in operation.
� e inside radiating spokes holding the bearing in the
shaft center were replaced with rods extruded from the
load cells to measure the bearing load. � is pump was
6 meters long under the fl oor. A 200-millimeter bored
vertical pseudo-pump with three bearings (upper, middle
and lower) was fi xed in the bearing spiders. � e impeller
of this pseudo-pump was replaced by a rotating disk with
the same rotating inertia to cease its pumping action.
� e amplitude curves shown in Figure 4 compare
the three kinds of bearings (PTFE/
rubber hybrid, nitrile rubber [NBR] and
cylindrical silicon carbide [SiC] bearing).
Rotation speed was continuously altered
throughout the test, and the loads on each
bearing, as well as the vibration amplitude,
were traced.
Only the cylindrical SiC bearings
generated a self-excited vibration
accompanied by the hysteresis
phenomena. � e PTFE/rubber hybrid
bearings ran quietly through the full
range of rotational speeds. Once excessive
vibration is generated with the use of
SiC bearings, an abnormal noise occurs,
and the loads on both upper and middle
bearings can increase by as much as
tenfold.2 � ese phenomena were often
observed in real pumps in factory tests and
in the fi eld.
Based on these fi ndings, the rubber
layer improves the damping performance
of the pump system and weakens the
nonlinearity of the bearing spring
constant because of the viscoelastic nature
of the rubber. � e actions diff er markedly
from the actions of the monolithically
structured metal/resin without rubber
lining eff ects. Once a vibration like sub-
synchronous resonance is generated, pump
parts such as the shaft might fracture.
Even if the consequences are not severe,
the abnormally raised bearing loads will
result in extreme wear of the bearings.2
Acceptability of Dry Runs
Figure 5 shows the threshold of the
possible dry-start continuing time
relative to the bearing pressure in an
experimental run at a progressively higher
shaft speed. � e plot shows a nearly
inverse relationship between the dry-run
continuing time and bearing pressure. As
expected, the bearing pressure remains
low on the vertical pumps as long as their
assemblies and alignments stay normal.
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45
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August 2015 | Pumps & Systems
46 BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
� e dry run can presumably be extended to a few minutes.
Under the ordinary usage requirements for vertical
pumps, the period of in-the-air operations using the dry-
start bearings at the point of pump startup is 10 seconds
or less. � erefore, Figure 5 shows that almost all of the
vertical pumps are capable of dry start.3
Acceptability of a Lack of Lubrication Water
A lack of lubrication water arises when some force or
phenomenon intercepts the fl ow of replacement water to
or from the bearing surroundings.
Assuming a cutoff of the passage of lubricating water
to and from the bearing, the test bearing was sealed in
Figure 5. Dry-run continuing time at different bearing pressure and shaft speeds
Figure 6. Temperature change when preventing feed water exchange to the bearings
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pumpsandsystems.com | August 2015
47
an experiment using the oil seals at both ends after
immersion in water. � e bearing temperature was
measured in the vicinity of the bearing surface.
Figure 6 shows the temperature change of the test
bearings during the experiment. Points A, B and C in
the fi gure are temperature measurement points. Point
B is at the middle of the longitudinal location of the
bearings, and points A and C are at the two ends. When
the infl ow and outfl ow of lubrication water is blocked,
the rubber bearings are at high risk of seizure. For
hybrid bearings, the risk exists only when the bearing
surfaces get wet.4
References
1. Satoh H., Okada K., Furukawa S., 1994a, ‘Infl uence of Grooves of
Compound-Structured Submerged Bearings for Vertical Pumps,’
Transactions of the Japan Society of Mechanical Engineers, Vol.60,
No.571, pp.1033-1038.
2. Satoh H., Takeda H., 1989, ‘Dry-Start Bearings for Vertical Pumps,’
Proceedings of 6th International Pump Users Symposium, pp. 75-82.
3. Kikkawa F., Ogawa R., Satoh H., 2010b, ‘PTFE submersible dry-start
bearings,’ World Pumps, No.531, pp.31-34.
4. Kikkawa F., Ogawa R., Satoh H., 2010a, ‘PTFE submersible dry-start
bearings,’ World Pumps, No.530, pp. 30-33.
Satoh H., Takeda H., Kikkawa F., 1988, ‘Dry-Start Bearings for
Vertical Pumps,’ Journal of Turbomachinery Society of Japan,
Vol.16, No.7, pp. 382-390.
Satoh H., Sugiya T., Okada K., Yamada S. 1994b, ‘Infl uence of
Submerged Bearings for Vertical Pumps on Vibration Characteristics,’
Transactions of the Japan Society of Mechanical Engineers, Vol.60,
No.578, pp.3233-3237.
Dr. Fumitaka Kikkawa is a director of Mikasa Corp.
and oversees the industrial products division.
Dr. Kikkawa earned a Ph.D. in engineering from
Nagasaki University with a focus on submersible
bearings for pumps and ships. He may be reached
at kikkawa@mikasasports.co.jp.
Yoshimasa Kachu is a graduate of the chemical
engineering program at Fukuoka University. He is
one of the chief engineers in the industrial products
division at Mikasa Corp. He may be reached at
kachu@mikasasports.co.jp.
Dr. Hiroshi Satoh has been engaged for the last
seven years as a consultant in mechanical
engineering at several companies, including
Mikasa. He received a Ph.D. in engineering from
Yamanashi University. He may be reached at
oridea-satoh@ab.thn.ne.jp.
Represented by Global Pump Marketing
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August 2015 | Pumps & Systems
48
A coupling transmits power from a driver to a
driven piece of equipment. � e driver can be
anything from an electric motor to a steam
turbine, and the driven equipment can be
a gearbox, fan or pump. While the coupling is often
viewed as the weak link in the pump assembly, replacing
a coupling element is still much easier than replacing a
sheared shaft.
For the purposes of this article, the driver will be an
alternating current (AC) electric motor, and elastomeric
couplings will be the focus. Typically, these couplings
consist of three to six components, excluding fastener
hardware. � ey have two hubs with bores to match the
drive shaft and driver shaft and an elastomeric element
between them. Some couplings, especially spacer types,
have more components. A spacer coupling assembly, for
example, can have two shaft hubs, two fl anges and one
elastomeric element. � e assembly bolts together in such
a way that the two fl anges and element drop out of the
center section.
Based on the calculation for horsepower (HP) indicated
in Equation 1, the proper sizing of couplings is highly
dependent on HP, torque and shaft speed. In addition to
these variables, other elements such as service factor and
misalignment capabilities can aff ect coupling operation
and application. For this reason, many users rely only on
the manufacturer’s methods for proper sizing. Reading a
few coupling manuals will indicate that a vast selection of
couplings can meet a user’s power criteria. Still, selecting
the best coupling for the job depends on the environment
and the operators just as much as the mathematics
behind the sizing. When selecting a coupling for a pump
application, end users should consider the following factors.
HP = T(n)
63025 Equation 1
Where
HP = horsepower
T = torque (inch-pounds)
n = shaft speed
Service Factor
Service factor is an application- and coupling-dependent
multiplier that should be factored into sizing data. It is a
buff er between the torque capacity used to size a coupling
and what happens in the real world.
For example, if a pump requires 500 inch-pounds (in-lb)
of torque and the coupling manual recommends a 1.2
service factor, the coupling would be sized for 600 in-lb
(500 in-lb x 1.2 = 600 in-lb). � is is to help compensate for
application details such as shock loads, type of driver and
The Basics of Coupling Selection Users should consider these important factors when choosing the best equipment for their applications.
BY ROBERT BRAMERFISCHER PROCESS INDUSTRIES
Image 1. Spacer couplings are engineered to have a drop-out center section to allow for easy removal of the pump rotating assembly without having to unbolt the motor. (Images and graphics courtesy of Fischer Process Industries)
BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
pumpsandsystems.com | August 2015
49
type of driven equipment. Each type of equipment has its own
load characteristics and can generally be found in the sizing
section of a coupling manual; if not, consult the manufacturer.
Always use the service factor recommended for the particular
coupling to be used, and resist the urge to oversize the
coupling. � e coupling is meant to be the weak link.
Fail Safe
A fail-safe coupling will transmit power even after the
element fails, because part of both hubs operates in the
same plane. A jaw coupling is an example of a fail-safe
coupling. Alternatively, couplings that are not fail-safe
are also available. When the element fails, these couplings
will no longer transmit power, because no part of the hubs
operates in the same plane.
Load Characteristics
Users should always know the load characteristics for
their pumps. Are uniform or non-uniform loads expected?
Is this a variable-torque (centrifugal pump) or constant-
torque (positive displacement) application?
Starting torque is particularly important. Progressing
cavity pump applications are a prime example of an
application where starting torque is much greater than
the running torque. � is possibility must be taken into
consideration during coupling sizing. � e number of starts
and stops per hour also plays a role in selection.
Back Pull-Out Design
When specifying a coupling for a pump that uses a
back pull-out design, a spacer coupling is an ideal choice.
Spacer couplings are prominent in the pump industry
and are available in a wide variety of designs. � ey are
Image 2. Radially split elements can typically be replaced with less effort and without the need to unbolt fl anges from hubs.
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August 2015 | Pumps & Systems
50 BEARINGS, COUPLINGS & SEALS
engineered to have a drop-out center section to allow
for easy removal of the pump rotating assembly without
having to unbolt the motor (see Image 1, page 48).
� e distance between shaft ends (DBSE) must
be large enough to allow the rotating assembly to
be removed without having to unbolt the motor. A
coupling with a DBSE that is too small can lead to a
fl awed buildup and require the maintenance personnel
working on the pump to move the motor in order
to remove the rotating assembly, which defeats the
purpose of a back pull-out design.
With the exception of American Petroleum Institute
(API) applications, which are beyond the scope of this
article, using an elastomeric coupling with a radially
split element is a solid choice for a general-purpose
spacer coupling. Radially split elements can typically
be replaced with less eff ort and without the need to
unbolt fl anges from hubs (see Image 2, page 49).
5 COMMON COUPLING MISTAKES
1. Failing to check maximum bore capacity: Sometimes
the shaft size of the driver or the driven piece of
equipment exceeds the maximum bore capacity of the
coupling hub. In this case, the shaft sizes dictate the
coupling size. Avoid coupling bores that use shallow
keyways because these hubs use different size keys. As
Murphy’s law would have it, the key you will need during
a breakdown will not be included in the box.
2. Using the one-size-fi ts-all approach: The coupling is the
weak link, so size it accordingly. Making all the couplings
the same size may seem like a good idea, but it is not. An
oversized or undersized coupling will lead to destroyed
pumps and failed couplings.
3. Ignoring multiple duty points: Size the coupling for
the highest torque duty point, but pay attention to
the service factor of the duty with the lower torque
requirement. Keep in mind the torque limit of the shaft.
Consult a coupling manual for help with these types
of applications.
4. Ignoring heat and chemical compatibility: Make
sure the coupling elastomer is compatible with the
environment where it will be used. In other words, is what
you’re pumping compatible with the elastomer? A seal
failure can expose the element to the pumped fl uid. Is
the temperature limit of the element acceptable for the
environment where it will be used?
5. Overlooking space restrictions: Make sure your
coupling can fi t where you want to put it. A high-torque
application, gearbox to pump for example, often requires
a coupling with a large outside diameter. Consider using
an element with a higher torque rating, or look into
different designs that have a higher-torque density.
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51
In addition, the entire coupling assembly often has
fewer components. � e fewer components, the less
users have to keep track of.
Misalignment
Shaft misalignment includes parallel off set,
angular off set and a mixture of the two (see Figure
1). Coupling manufactures often talk about the
misalignment their coupling can tolerate. Just
because the coupling can handle the misalignment
does not mean that the pump can. For example,
a popular model elastomeric coupling used in the
pump industry can handle more than 0.060 inches of
parallel off set. However, the installation, operation
and maintenance (IOM) manual for the pump to
which the coupling is being mounted indicates that
the manufacturer only recommends 0.005 inches
of parallel off set. � e coupling can tolerate more
than 12 times the parallel off set that the pump is
recommended to handle. Improper alignment will lead
to bearing and seal issues down the road. Taking the
necessary time to align their pump assemblies before
putting them into service will help save plants money
in the long run.
Robert Bramer is a mechanical engineer with
Fischer Process Industries. He may be reached at
robertb@fpv.com or 513-583-4800.
Figure 1. Shaft misalignment includes parallel offset, angular offset and a mixture of the two.
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August 2015 | Pumps & Systems
52 BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
A dvanced thermoplastic materials off er
several advantages over aluminum and other
metals for turbo-compressor labyrinth seals.
Polymer seals eliminate the risk of metal tooth
deformation and mating shaft damage during shaft
rubs. � is enables end users to tighten initial clearances
and reduce clearance loss over time. Overall compressor
effi ciency improves greatly over the life of the seals.
� is article provides mechanical property data from
two diff erent sets of seals. � e integrity of the seals after
11 and 15 years in service was compared with new, off -
the-shelf seals of the same material.
� e fi rst set of seals, including fi ve diff erent seals
for evaluation, was installed in 1996 and remained in
service for 11 years in a natural gas compressor. Visually,
the seals were in good condition, with the exception of
damage suff ered during the removal process. � ey each
exhibited damage ranging from a few gouges to being
completely broken.
Upon removal, the in-service seals showed little signs
of wear and the teeth were well-defi ned and in good
condition. � e seals did incur some damage during the
removal process: Some had just a few gouges, and others
were completely broken.
Polymer Seals Perform Reliably After Years of UseTwo sets of seals, in service for 11 and 15 years, still meet baseline standards.
BY JIM HEBELQUADRANT
Image 1. The fi rst set of seals were removed from a natural gas compressor after 11 years in service. (Images and graphics courtesy of Quadrant)
Image 2. The second seal was removed from a different compressor, which had been in service for 15 years.
pumpsandsystems.com | August 2015
53
Another seal was evaluated from
a diff erent compressor, which had
been in service for 15 years. � is
seal also showed some gouges from
removal and handling during the
compressor’s rebuild.
Evaluating the Seals
To evaluate the integrity of the
seals, the mechanical properties of
the returned seals were compared
with those of standard seals.
Only one seal—from the initial
set, B-case, 2nd wheel—was large
enough to allow full-sized tensile
test bars to be machined.
Tensile properties are the
fi ngerprint of a material’s
integrity. Full-sized tensile
bars are needed to yield a full
complement of tensile properties,
including strength, modulus and
elongation values.
In addition, other mechanical
properties were evaluated,
including compressive strength
Table 1. The two sets of seals used in the evaluation and their descriptions
Summary of received seals
Seal Set 1 - 1 Years in Service Seal Set 2 - 15 Years in Service
B-Case (2) C-Case C-Case C-Case C-Case 8th Stage
2nd Wheel 5th Wheel 4th Wheel 5th Wheel(possibly)
7th Wheel 2nd Wheel
TCE PartNumber
C-029-126-002 D-029-164-005 D-029-100-029 D-029-100-029
D-029-100-029
D-029-126-002
Nova SerialNumber
120201187 120201103 Not identifi ed 120201090 Not identifi ed
120201187
Marking onPart
Not identifi ed 14388 K201C #5
lower
14387 K201C #4
lower
14386 K201C 14389 K201C #7
Not identifi ed
Size 15.242" OD x 12.6"
ID x 2.226”
18.057" OD x 16.4" IDx 1.180”
11.623" OD x 10.0"
ID x 1.562”
11.623" OD x 10.0"
ID x 1.562”
11.623" OD x 10.0"
ID x 1.562”
15.242” OD x 12.6” ID x 2.226”
Seal Confi g 2-segment shaftseal
2-segment impeller
seal
2-segment shaftseal
2-segment shaftseal
2-segment shaftseal
2-segment shaftseal
Material Torlon 4540 Torlon 4540 Torlon 4540 Torlon 4540 Torlon 4540 Torlon 4540
Temp Exposure
47 to 60 C 49 to 64 C 44 to 57 C 49 to 64 C 61 to 77 C 31 to 45 C
Time in Service
11 yr 11 yr 11 yr 11 yr 11 yr 15 yr
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Houston, Texas
August 2015 | Pumps & Systems
54 SPECIAL SECTION BEARINGS, COUPLINGS & SEALS
Table 2. The results of the mechanical property testing for both the 11-year-old and 15-year-old polymer labyrinth seals
Summary of received seals
Seal Set 1 11 Years in Service
Seal Set 2 15 Years in Service
Test Method
Duratron T4540Baseline (1)
B-Case(2) C-Case C-Case C-Case C-Case 8th Stage
RecentProduction
2nd Wheel
5th Wheel
4th Wheel
5th Wheel
7th Wheel
2nd Wheel
Specifi c gravity ASTMD792
1.47 1.47 NA NA NA NA 1.47
Tensile strength, psi
ASTMD638
10,516 9,416 NA NA NA NA 10,323
Elongation at yield, %
ASTMD638
3.40 2.23 NA NA NA NA 3.34
Elongation at break, %
ASTMD638
3.40 2.23 NA NA NA NA 3.34
Tensile modulus, psi
ASTMD638
608,843 634,536 NA NA NA NA NA
Flex strength, psi
ASTMD790
11,864 13,217 NA NA NA NA 9,160
Flex modulus, psi
ASTMD790
546,492 608,581 NA NA NA NA 687,283
Compressive strength, psi
ASTMD695
23,606 21,140 21,475 21,136 20,345 21,860 22,132
Compressive modulus,psi
ASTMD695
346,670 433,450 437,000 450,000 454,160 456,440 376,060
DSC Tg, oC ASTMD3418
281 280 NA NA NA NA 272
Moisture content at time of testing, %
ASTMD570
Dry 0.47 NA NA NA NA 0.58
(1) Quadrant production sample data based on averages between 18” x 11” x 6” and 12” x 3.5” x 6” tubular bars
(2) B-Case, 2nd wheel was the only component large enough to allow for a full-sized machined tensile bar, which allowed for tensile strength, elongation and modulus data. As a result, only compressive data was generated on the other samples.
The property values of both the 11-year-old and 15-year-old
compressor seals revealed consistent performance compared
with standard data for the product.
pumpsandsystems.com | August 2015
55
and modulus. For the initial set of seals,
only compressive test samples could
be machined and tested because of the
limited sample size of the other, smaller
cross-section seals.
� e single, 15-year seal underwent a
full complement of testing, except for
tensile modulus testing. Without
enough material to yield a full-sized
tensile bar, the modulus value could not
be determined.
� e property values from the
in-service seals were then compared to
a baseline set of data. To determine the
baseline values, compression-molded
tubular bars were used to replicate
the same production process as the
returned, older samples. Two tubes were
pulled from production, test plaques
were machined and tested, and the
results were documented.
Results
� e property values of both the 11-year-
old and 15-year-old compressor seals
revealed consistent performance
compared with standard data for
the product.
For the 11-year-old seals, the tensile
strength and elongation properties of
the B-case sample were a little lower
than baseline, but the tensile modulus
was higher. � e lower properties
were due to slight embrittlement
during service.
� e fl exural and compressive
properties were higher than current
production, which can also be attributed
to embrittlement. � e glass-transition
temperature (Tg) of the 11-year-old
material remained steady at 280 degrees
C, at which no major degradation of
the polymeric structure occurred. � e
compressive strength and modulus
values were also tightly packed and
within a 7 percent spread, showing good
data integrity among the returned seals.
For the 15-year-old seal, both tensile
and compressive data matched closely to
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Circle 154 on card or visit psfreeinfo.com.
IQV"UNWTT[A
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Circle 152 on card or visit psfreeinfo.com.
August 2015 | Pumps & Systems
56 BEARINGS, COUPLINGS & SEALS
James Hebel is application development and technical
service manager at Quadrant EPP, where he has been for
14 years. He holds a B.S. in mechanical engineering from
Virginia Polytechnic Institute and State University and
an M.S. in mechanical engineering from
The Catholic University of America. His
prior work experience includes the U.S.
Department of Defense and U.S. Gypsum
Company. He may be reached at james.
hebel@qplas.com or 610-320-6730.
Image 3. For seals from the B-case sample, tensile strength was lower than baseline, but tensile modulus was higher.
baseline values, including the tensile elongation. Flexural
strength was less than baseline, while fl exural modulus
was above baseline. However, the data was within
acceptable variation considering the age of the polymer.
After 11 and 15 years of service in a natural gas
compressor, the integrity of seals appears to be similar to
current production.
Overall compressor effi ciency
improves greatly over the
life of the seals.
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57
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Circle 116 on card or visit psfreeinfo.com.
August 2015 | Pumps & Systems
58 BEARINGS, COUPLINGS & SEALSSPECIAL SECTION
O ne of the largest electric power generation
companies in the U.S. conducted an upgrade
project of their water pumps at their nuclear
plant facility. � e pump original equipment
manufacturer (OEM) was contracted to produce a series
of vertical circulating water pumps. � e vertical pump
model is designed to pump high volumes of seawater
and has an external fl ush provided to each of the four
composite bearing locations. � e bearings are composed
of a proprietary thermoplastic material, which is designed
specifi cally for use as bushings, bearings and wear rings
in pumps handling abrasive media up to 250 F (120
C). Its properties make it a more reliable material than
traditional rubber, ceramic or bronze.
� e Challenge
� e nuclear plant engineering team requested that the
pump manufacturer add a low-fl ow/fl ush alarm to the
upgraded pumps. � e alarm would trigger when the
fl ush drops below 5 gallons per minute (GPM) of fl ow to
the bearings. � e bearings in the pump must survive 15
minutes of low-fl ow/fl ush conditions to give the operators
adequate time to respond.
Although the pump OEM was confi dent the bearings
would survive for 15 minutes under low-fl ow/fl ush
conditions, suffi cient data was not available to confi rm
the composite bearings’ performance.
Composite Bearings Resist Wear in Circulating Water PumpsA thermoplastic composition in abrasive applications helped bearings meet end user specifi cations.
BY GREG GEDNEYGREENE, TWEED & CO.
Image 1. A bearing made of the proprietary thermoplastic material and a stainless steel shaft (Images and graphics courtesy of Greene, Tweed & Co.)
Figure 1. The test matrix shows the results of using the testing rig.
pumpsandsystems.com | August 2015
59
� e Solution
A test program was developed to confi rm the bearing’s
ability to survive in the end user’s condition. � e
program’s objective was to verify that the running
clearance would remain within an acceptable limit (less
than two times the original clearance) after a 15-minute
dry run, using the same operating conditions as the
vertical pump.
� e Results
Four bearings were tested on a horizontal testing rig.
Multiple tests were run on the four bearings, each for a
specifi ed amount of time (15, 30 and 60 minutes). � e
bearings demonstrated outstanding wear resistance
throughout the test program, shown by the minimal
change in measured internal diameters (ID) in Table 1.
� e results show a greater than 4x safety factor. � e
bearings showed no problems when tested for up to 60
minutes. � e pump manufacturer integrated the alarm,
and the power generation company specifi ed bearings
made from the proprietary thermoplastic material for all
circulating water pumps supplied to their nuclear facility.
Before Test Test 1 (15 min) Test 2 (30 min) Test 3 (60 min)
Test Results: 5 psi load Inner Diameter Inner Diameter Inner Diameter Inner Diameter
Bearing 1 2.705” (68.72 mm) 2.706” (68.73 mm) 2.705” (68.72 mm) 2.706” (68.73 mm)
Bearing 2 2.705” (68.72 mm) 2.705” (68.72 mm) 2.705” (68.72 mm) 2.705” (68.72 mm)
Test Results: 10 psi load
Bearing 3 2.705” (68.71 mm) 2.705” (68.71 mm) 2.705” (68.70 mm) 2.705” (68.70 mm)
Bearing 4 2.706” (68.74 mm) 2.706” (68.73 mm) 2.706” (68.73 mm) 2.706” (68.74 mm)
Table 1. The inner diameter of the bearings measured in inches (”) and millimeters (mm) before and after testing
Greg Gedney is the equipment segment
manager at Greene, Tweed & Co. He may be
reached at ggedney@gtweed.com or 281-765-
4550. Visit gtweed.com for more information.
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60
August 2015 | Pumps & Systems
T he rising cost of electrical power has caused
many industrial plants to shift their focus to
energy consumption. Plants often run pumping
equipment continuously, and much research has
pointed to opportunities for cost savings by optimizing
pumping equipment.
When evaluating the potential for energy savings, end
users cannot consider a pump in isolation. � e suitability
of the pump for the system within which it operates
is vital. Even the best designed and most effi cient
equipment off ers power-saving potential if it is run off
its best effi ciency point (BEP) in a system for which it
is ill-applied.
Many plants have been in operation for more than 40
years, and their operating philosophies have changed
over time. Plant improvements have enabled higher
throughput, often increasing production by as much as
125-150 percent. Unfortunately, little is done to improve
or increase the performance of the support-service
pumping equipment, such as cooling water pumps.
As system fl ow demands increase, the duty point of the
pumps is forced to shift far to the right of the BEP, well
outside the acceptable operating range (AOR). � is causes
effi ciency and pump reliability to decrease dramatically.
Casting tolerances, surface fi nishes, and impeller/
volute or impeller/diff user geometry have all dramatically
improved during the last 40 years. But because
many pumps were installed when the plants were
commissioned, the existing pumps were manufactured
using techniques that would be considered obsolete today.
� e result is higher energy costs and reduced reliability
and availability, which often cause production delays.
� e Starting Point
Pumps react to changing system conditions. System
demand (or system resistance) determines the fl ow and
pressure at which a pump will operate. As system fl ow
demand increases, the fl ow throughput of a pump also
increases, causing it to operate further on the right-hand
part of the performance curve.
� e system demand is graphically represented by
plotting the system resistance curve as a function of fl ow.
� is curve enables the end user to quickly determine
system fl ow for a given pump since the pressure and
fl ow are determined by the intersection of the pump
performance curve (red) with the system head curve
(green). A process design engineer would ideally select a
pump with an operating point that would have coincided
Optimize High-Energy Pumps With Improved Impeller DesignAs new design and manufacturing technologies are developed, end users can aff ordably upgrade their systems and verify better performance.
BY BOB JENNINGS & DR. GARY DYSONHYDRO, INC.
PUMP SYSTEM OPTIMIZATION
61
pumpsandsystems.com | August 2015
with the BEP. � is could yield a pump
effi ciency of 80 percent, as shown in Figure 1.
However, many support pumping systems
have exceeded their original design and have
much higher fl ows to support the higher plant
production. � is is particularly common in
cooling water applications, condenser water
pumps, descale pumps or any application
where water usage is proportional to
production.
While the original design may have
called for two-pump operation, present-day
requirements may require 2 1/2 pumps online,
with two pumps being insuffi cient and three pumps too
many. As fl ows increase, the result is usually that system
requirements have exceeded the AOR of the pumps (see
Figure 2, page 62).
Original Duty Point
� e original system design for one processing plant’s
service water pumps was to have three pumps operating
in parallel with an installed spare as a standby. � e total
system requirement was 105,000 U.S. gallons per minute
(GPM) (23,864 cubic meters per hour) at a pressure of 190
feet (57.9 meters) total dynamic head (TDH). Each pump
was rated for 35,000 GPM (7,955 cubic meters per hour)
at 190 feet (57.9 meters) TDH.
As production increased, more service water was
required, causing the existing pumps to operate
further out to the right of the performance curve. � is
caused the net positive suction head required (NPSHR)
to exceed the NPSH available (NPSHA), leading to severe
cavitation issues. To reduce cavitation problems, the
plant ran four pumps in parallel and throttled each
pump to keep the individual pump fl ows low enough
to prevent cavitation.
Image 1. Much research has pointed to opportunities for cost savings by optimizing pumping equipment. (Images and graphics courtesy of Hydro, Inc.)
Figure 1. Pump and system curve interaction
62 PUMP SYSTEM OPTIMIZATIONCOVER S E R I E S
August 2015 | Pumps & Systems
Over time, the design of the impellers also drifted
away from optimal because no testing or verifi cation of
the performance took place. Cavitation and insuffi cient
service water continued until the pumping station
could not keep up with plant demand. As Figure 3 (page
63) shows, fi eld pump assessments and subsequent
individual performance tests conducted on the
poorly replicated impellers showed that the pump
performance had been dramatically compromised.
New Impeller Design
� e technological advances made in recent years
with reverse engineering, laser digitizing equipment,
computation fl uid dynamics (CFD) software and the
ability to print 3-D foundry molds from computer-
aided design/computer-aided modeling (CAD/CAM)
software has revolutionized the aftermarket industry.
Solutions that were cost-prohibitive fi ve years ago
are now within the realm of fi nancial feasibility. � e
solution helped manufacturers and end users solve
their energy optimization diffi culties in three ways:
1. Capture system resistance data and operating
conditions. � e plant’s pumps operated at diff erent
fl ow conditions. Understanding how these fl ow
requirements matched the system’s resistance enabled
an optimized design fl ow to be derived that would
Circle 131 on card or visit psfreeinfo.com.
Figure 2. Pump Performance curve interaction based on different system requirements
Acceptable Operating Range
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pumpsandsystems.com | August 2015
ensure that head was not generated by the pump to
be dissipated over a control valve, so the number of
pumps running was optimized for the demand.
2. Capture the geometry of the existing impeller
using advanced laser-scanning equipment and
build a CFD model of this impeller. � is
allows design scenarios to be evaluated
to get the optimized design for the newly
established fl ow conditions.
3. Use additive manufacturing in the
form of 3-D foundry sand printers
and casting simulation software
to drastically reduce lead-time and
overhead normally associated with
pattern/core box sand casting processes.
� e 3-D printing process directly from
the design data ensures that the integrity
of the design is completely captured. � e
high accuracy of sand printing means that
vane-to-vane symmetry and vane shape is
identical. Sand printing also off ers improved
casting surface fi nish. � ese manufacturing measures
alone can lead to a 3 percent effi ciency increase.
Tables 1-3 show the before and after energy usage,
based on the projected energy audits (see page 64).
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Figure 3. Pump performance test data illustrating performance degradation
64 PUMP SYSTEM OPTIMIZATION
Table 2. Newly designed system
Measurement Per Pump Per System
GPM 48,333* 144,999*
TDH 160 160
Effi ciency 0.89 0.89
Brake horsepower 2,194 6,582
kW 1,637 4,911
Hours per year 8,400 8,400
kW rate $0.07 $0.07
Total energy cost per year $962,556.00 $2,887,668.00
* Note: Three redesigned pumps online
Table 3. Total projected energy savings for the system
Energy Costs - Original (Present) $ 4,431,168.00
Energy Costs - New Impeller Design $ 2,887,668.00
Impeller Design and Manufacturing Costs for 4 impellers
$ 390,000.00*
Total Savings $ 1,153,500.00
* Number excludes the regular repair cost(s) normally incurred for this equipment.
Table 1. Original system
Measurement Per Pump Per System
GPM 40,000* 160,000*
TDH 185 185
Effi ciency 0.74 0.74
Brake horsepower 2,525 10,101
kilowatts (kW) 1,884 7,536
Hours per year 8,400 8,400
kW rate $0.07 $0.07
Total energy cost per year $1,107,792.00 $4,431,168.00
* Note: Four pumps online throttle to prevent cavitation
August 2015 | Pumps & Systems
In addition to energy savings, improved reliability and availability
translates to extended mean time between repairs, signifi cantly reducing
maintenance costs.
Conclusion
Signifi cant energy savings opportunities exist in every manufacturing
facility worldwide, particularly with pumping systems that:
• use pumps driven by 200 horsepower and above
• are primarily providing cooling water
• include demands proportional to the plant throughput
• are used for batch operations
• have inherent delays or production slowdown
• currently use dump valves or bypass lines
• feature fl uctuating system loadingCir
cle
15
9 o
n c
ard
or
vis
it p
sfre
ein
fo.c
om
.
65
pumpsandsystems.com | August 2015
Cir
cle
11
8 o
n c
ard
or
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it p
sfre
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.
66 PUMP SYSTEM OPTIMIZATIONCOVER S E R I E S
August 2015 | Pumps & Systems
Circle 149 on card or visit psfreeinfo.com.
Dr. Gary Dyson is managing director with
Hydro Global Engineering Services. He has
a Ph.D. from Cranfi eld University and 30
years of experience in the pump
industry in senior positions
with many manufacturers.
His expertise includes pump
hydraulic performance,
design and reliability
improvement.
Bob Jennings has worked in sales, repair
and troubleshooting pumping systems for
HydroAire since 1976 and has more than
15 years of experience dedicated
to submersible pump
development and applications
in the municipal industry.
Jennings is the lead training
instructor for Hydro, Inc.
In the past, pump upgrades or rerates
tended to lie strictly with the OEM
because they were the only party with
access to cost-eff ective cast parts.
However, with the technology revolution
that is taking place in the aftermarket,
upper tier service centers with on-staff
hydraulic engineering support can often
provide cost-eff ective, newly designed
impellers or volutes with solutions
specifi cally designed for the application.
With reverse engineering, laser
digitizing equipment, CFD software and
rapid prototyping coupled with the ability
to print 3-D foundry molds directly from
CAD/CAM software, the end user is no
longer required to limp along with an
obsolete pumping system. Solutions are
readily available and well within the realm
of fi nancial feasibility.
With reverse engineering, laser digitizing equipment, CFD software
and rapid prototyping coupled with the ability to print 3-D foundry molds
directly from CAD/CAM software, the end user is no longer required to
limp along with an obsolete pumping system.
Visit us at
Booth# 1928 at
the 2015 Pump/
Turbo Symposia
67
pumpsandsystems.com | August 2015
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P O W E R G E N E R AT I O N F O O D P R O C E S S I N G B U I L D I N G S E R V I C E S C H E M I C A L
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EXPERTS
U nderstanding net positive suction head (NPSH)
and cavitation is essential for plant managers,
pump manufacturers and operators. Proper
NPSH calculations are vital for preventing
cavitation and ensuring proper pump functionality.
� e following 10 facts about NPSH can help end users
improve system operation and effi ciency.
1. Analyzing NPSH margins can help
reduce cavitation.
Cavitation is defi ned as the partial evaporation of a liquid
in a system. Vapor forms when the static pressure in a
liquid’s fl ow drops below the vapor pressure of that liquid.
A two-phase fl ow occurs when a vapor bubble appears and
fl uid evaporates. When these bubbles enter a region where
static pressure exceeds vapor pressure, they will implode,
causing cavitation. � ese bubbles can cause cavities that
impair the head and effi ciency of the pump, creating
excessive noise and vibration. Cavitation erosion can be
detrimental to the pump’s head and effi ciency. Damage to
ancillary components, such as bearings and seals, from
higher vibration is also likely. � e region of the lowest
pressure generally occurs around the leading edge of the
vane, and this is where cavitation will most likely occur.
10 Things You Need to Know about NPSHBecause cavitation is unavoidable in pump operations, understanding how to reduce it using NPSH calculations is necessary to maintain pump functionality and health.
BY SIMON BRADSHAWITT GOULDS PUMPS
Figure 1. Cavitation visualization
(Images and graphics courtesy of ITT Goulds Pumps)Figure 2. Analyzing NPSH margins can
help reduce cavitation.
68 PUMP SYSTEM OPTIMIZATIONCOVER S E R I E S
August 2015 | Pumps & Systems
Although cavitation cannot be completely
suppressed in a pump, measuring the required
NPSH (NPSHR) and analyzing NPSH margins
are key to reducing cavitation and keeping the
pump running smoothly.
2. NPSH has two main components.
NPSH distinguishes between the pressure
available to give to the pump (NPSHA) and
the pressure required by the pump (NPSHR)
to limit the reduction of pump head to an
acceptable level.
3. NPSHA requires an in-depth calculation.
NPSHA is caused by atmospheric pressure, tank elevation
or pressure inside a tank. � is measurement must be
calculated by the user. At sea level, the atmospheric
pressure provided is 14.77 pounds per square inch
(psi), or 1 bar, which fl uctuates depending on elevation.
Additionally, the fl uid vapor pressure will vary with
temperature. With this calculation, the manufacturer
must convert pressure to feet or meters and consider the
fl uid temperature and elevation surrounding the pump.
4. Critical tests determine NPSHR.
NPSHR is the minimum amount of pressure required at
the pump impeller to limit the reduction in pump head
to an acceptable level. Instead of using a calculation as
with NPSHA, the manufacturer will run tests to validate
the critical quantity of NPSHR. To do this, the fl ow is kept
constant, and the NPSHA is reduced. As NPSH
A is lowered,
cavitation inside the pump will increase until it begins to
block fl uid fl ow through the pump. � ese tests must be
repeated until every fl ow point has been recorded. NPSHR
is commonly called NPSH3, because a three percent head
drop criteria is often used during a NPSHR test.
Circle 148 on card or visit psfreeinfo.com.
Image 1. Calculating NPSHA
69
pumpsandsystems.com | August 2015
5. � ere are other forms of NPSH.
Many diff erent forms of and acronyms for NPSH exist.
Similar to NPSH3, NPSH
1 or NPSH
0 results when the pump
head is only reduced by 1 or 0 percent, respectively. NPSHi,
where the “i” stands for inception, is where cavitation
fi rst occurs.
NPSH40K
is the NPSH at which the impeller will have a
40,000-hour life. NPSH40K
usually can be determined only
by the pump supplier, as in-depth knowledge of the impeller
geometry and material is necessary. NPSH40K
typically is
used for boiler feed pumps, large critical pumps and for plant
owner/operators who want confi dence that the impeller will
not fail between major overhauls.
6. � ree methods can be used to
determine NPSH40K
.
Pump suppliers can determine NPSH40K
using three methods. � e fi rst method
involves building a full-size or a scale-
factor test rig of the impeller and recording
subsequent damage after a test run. � is
process can be costly and time-consuming.
Another is Vlamming, an empirical
method used for stainless steel impellers
in water. Using certain parameters
associated with the impeller within the
equation, suppliers determine a value.
Gülich is the third method and is based on
the size of the cavitation bubble, which is
usually determined by computational fl uid
dynamics (CFD) and impeller material.
7. Proper material selection can
reduce NPSH margin.
� e new Hydraulic Institute (HI) Standard
9.6.1, released in 2012, provides guidelines
and recommendations for NPSH margins,
how much NPSHA is needed for a given
pump service and what features are needed
in a pump based on the NPSHA.
Proper material selection in a pump
can reduce NPSH margin requirements
and, as a result, life cycle cost. During the
process of selecting materials, end users
should consider materials less susceptible
to cavitation damage, which could impact
overall system cost.
8. All pumps have cavitation
regardless of NPSH.
Frequently, pump users infer that as
long as NPSHA is above the NPSH
R, no
cavitation will occur. � is is a common
misconception. For example, in order to
completely suppress cavitation in a pump
where the NPSH3 occurs at 19 feet, the
NPSH1 occurs at 25 feet, the NPSH
0 occurs
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70 PUMP SYSTEM OPTIMIZATIONCOVER S E R I E S
August 2015 | Pumps & Systems
at 63 feet and the NPSHi at 107 feet, the NPSH
A must be
about 5.5 times the NPSHR. Few, if any, pumps operate with
this margin, revealing that all pumps have cavitation. � e
only question is whether it is damaging cavitation.
9. Specifi c materials can help prevent cavitation.
Because cavitation is present in every
pump, users must fi nd the right materials
to minimize damage. � e leading material
chosen for cavitation resistance is
Martensitic stainless steel, also known
as CA6NM, chrome steel or 13-4. More
resistant materials are available, but they
are less common and more expensive,
making Martensitic stainless steel an ideal
option in freshwater applications.
10. � e thermodynamic eff ect can
aff ect NPSH.
If a fl uid has a high vapor pressure or
temperature, more energy must be
exchanged across the vapor-fl uid boundary
and the vapor bubble. � is is known as the
thermodynamic eff ect, or the hydrocarbon
correction factor. Cavitation bubbles
become smaller, and NPSHR is reduced.
If in doubt, consider the critical point
of a fl uid. As you get closer to water’s
critical point—374 C or 705 F—the
thermodynamic eff ect becomes more
pronounced. At this critical point, only
a single phase is present, either a low-
density liquid or a high-density gas, and
because there is no liquid-gas mixture,
cavitation cannot occur. Guidance on this
method can be found in H.I. Standard 1.3.
Conclusion
Cavitation is unavoidable in pump
operations. Understanding how to reduce
it using NPSH calculations is necessary to
maintain pump functionality and health.
Although methods and materials are
available to reduce the eff ects of cavitation,
the truth is that cavitation will always be
present. Proper management of cavitation
to prevent damage is the end goal.
Circle 124 on card or visit psfreeinfo.com.
Simon Bradshaw is director of API product
development & technology for ITT Goulds
Pumps. Bradshaw has more than 20 years of
engineering experience in the pump industry.
Read more online at
pumpsandsystems.com/npsh.
71
pumpsandsystems.com | August 2015
E ngineered composites can be designed and used
to improve performance and effi ciency as well as
reduce maintenance and repair costs. Composite
upgrades prevent expensive products from
deteriorating, extend the life and reliability of existing
equipment, and increase pump effi ciency.
� ey can even prevent pump leaks that can
result in costly cleanups and fi nes from
regulatory agencies. In most cases, reduced
downtime resulting from introducing
structural composite pump upgrades is one
of the most important benefi ts.
� e impeller is the heart of any
centrifugal pump. Like a human heart,
a pump impeller is the most critical
pump component, constantly stressed by
hydrodynamic forces, fatigue, corrosion,
erosion abrasion, chemical attack
and cavitation. � e overall effi ciency of a
centrifugal pump is in direct correlation to
the effi ciency of the impeller. To maximize
effi ciency, the impeller’s hydraulic design
must correspond to the design of the pump
casing and to the operating conditions of
the pump in service.
Any centrifugal pump can be made
energy-effi cient by upgrading the impeller
and rings to an optimized and engineered
composite, such as one company’s
structural graphite epoxy composite. � is company off ers
impeller and ring upgrades for any centrifugal pump,
which provide higher effi ciencies and increased longevity.
� ey can also design the impeller so that the operating
point becomes the best effi ciency point (BEP).
Engineered Composites Off er Opportunities for Upgrading EquipmentThese pumps prevent equipment from corroding, provide lower costs and increase effi ciency.
BY JOHN A. KOZELSIMS PUMP VALVE COMPANY, INC.
Image 1. Structural composite upgrades can extend pump life, improve performance and increase effi ciency. (Images and graphics courtesy of SIMS Pump Valve Company, Inc.)
72 PUMP SYSTEM OPTIMIZATIONCOVER S E R I E S
August 2015 | Pumps & Systems
When companies are trying to save money, it may
seem diffi cult to justify the upgrades, but the payback
for pump upgrades is extremely quick—usually less
than one year return on investment. In most cases,
the incremental costs of upgrades are minimal when
compared with the loss in
downtime, energy and expensive
repairs. Plant outages, ship
overhauls, building new vessels,
constructing new manufacturing
plants, plant expansions and new
system installations are good
opportunities to upgrade existing
pumps to composite internals
and specify pumps with upgraded
effi ciency and reliability features.
As equipment starts to age,
pumps lose performance and
effi ciency. � ey also require
additional maintenance, repairs,
expenses and downtime. Often,
the aging or corroding equipment
cannot keep up with plant
demand. Before equipment gets to
this point, pumps can be upgraded
to structural composite to extend
the life of the pump, return the
pump to the proper performance
and increase effi ciency.
Pump Optimization
Too often, a pump is purchased
for a specifi c performance but
when put into service, it operates
at a point completely diff erent
from the original design point,
or BEP, because of the system
requirements. � e pump operating
away from the BEP also causes
problems such as excessive noise
and vibration, shaft oscillation,
cavitation, and premature wear
and failure of the mechanical
seals, bearings, rings, sleeves
and impellers.
In extreme cases, the pump
shaft will break right behind the
impeller from the excessive radial
forces that occur when a pump is
operated away from the original
design point.
Operating a pump away from the BEP has a detrimental
eff ect on pump effi ciency. � e larger the pump, the more
energy is wasted. Operating any pump away from the
BEP wastes a tremendous amount of money, because an
estimated 85 percent of the total cost of owning a pump
73
pumpsandsystems.com | August 2015
Circle 126 on card or visit psfreeinfo.com.
is the operational cost (maintenance cost plus the cost of energy).
Fortunately, these problems can be easily resolved by installing
engineered structural composite impellers and rings, which
have been re-engineered for the system’s requirements.
� e reliability and longevity of the complete pump is also
substantially improved.
Image 2 shows two severely deteriorated impellers in a two-
stage horizontally split-case cooling pump in a power plant. � ey
were underperforming and were terribly ineffi cient. A 75-kilowatt
(kW) motor operating in this condition could easily lose 50
percent of the original effi ciency.
If the original effi ciency was 80 percent and now the pump is
operating at 40 percent effi ciency, there would be an approximate
loss of $31,104 per year at $0.12 per kilowatt (kW) hour (see
Equation 1).
30 kW loss x 8,640 hours x $0.12/kW hour = $31.104
Equation 1
Even if the pump was operating only 10 percent away from
the BEP, the approximate loss would be $7,776 per year, plus
additional maintenance expenses (see Equation 2).
Image 2. Two severely deteriorated impellers in a two-
stage horizontally split-case cooling pump
74 PUMP SYSTEM OPTIMIZATIONCOVER S E R I E S
August 2015 | Pumps & Systems
Circle 145 on card or visit psfreeinfo.com.
7.5 kW loss x 8,640 hours x $0.12 kW hour = $7,776.00
Equation 2
� e composite pump in Image 4 was re-engineered
into a two-stage structural composite pump with single-
suction impellers (see page 76). It is approximately 11
percent more effi cient than the original metallic pump
(before corroding), and this new composite pump will
never corrode. All wetted parts are manufactured
with structural composite, and the bearing frames are
machined from type 316 stainless steel.
Improved Effi ciency
In 2015, tremendous eff ort has been put forth to reduce
energy consumption. � e Department of Energy (DOE)
and the Hydraulic Institute have been working together
to reduce the energy consumption of pumps, motors and
pump systems. Engineered composites can contribute to
this eff ort. By re-engineering the pump/impeller design,
they can signifi cantly reduce energy consumption—in
some cases by 20 percent.
Equipment Longevity
In addition to improved effi ciency, engineered composite
impellers off er many advantages over traditional products
cast from metal. � ey do not corrode, are lightweight,
can run with tighter clearances, are designed for high
effi ciency, and are not subject to casting defects or
Image 3. Damage from corrosion, erosion and cavitation can quickly destroy metallic pumps and pump parts.
75
pumpsandsystems.com | August 2015
Circle 137 on card or visit psfreeinfo.com.
imperfections. Many of these impellers and
casing rings have been used successfully
since 1955 in the Marine, Navy, wastewater,
industrial and chemical markets. Structural
composite impellers have often outlasted
and outperformed products manufactured
from bronze, stainless steel, duplex steel,
monel and even titanium.
Reduced Wear
� e new alternative composite solutions
for impellers and rings are ideal for new,
repair or retrofi t applications. Engineered
impellers and rings are lightweight and do
not corrode.
Wear of other pump parts—including
the pump casing—is greatly reduced
because of the engineered impeller’s
balance, light weight, self-lubrication,
sealing, and resistance to corrosion, erosion
and cavitation. � is means far less expense
for replacement of parts and downtime.
Reducing or eliminating corrosion, erosion
and cavitation can increase effi ciency and
reduce costs substantially.
Maximized Performance
Because of new technologies, structural
composite impellers are computer-
engineered and precision-machined. � e
impeller vane geometry can be engineered
using computational fl uid dynamics (CFD)
techniques and programmed to maximize
effi 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 modifi ed to provide the best
vane shape for specifi c applications and
performance requests.
Corrosion, erosion, cavitation, rotor
imbalance and leakage between the wear
rings, casing rings and interstage bushings
are major contributors to the loss of
pump effi ciency. Damage from corrosion,
erosion and cavitation quickly destroys
the metallic pump parts. Because of the
self-lubricating characteristics of many
Image 4. This composite pump was re-engineered into a two-stage structural composite pump with single-suction impellers. It is approximately 11 percent more effi cient than the original metallic pump (before corroding).
76 PUMP SYSTEM OPTIMIZATIONCOVER S E R I E S
August 2015 | Pumps & Systems
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engineered composites and because
composites do not wear or corrode,
the performance curve will actually
increase over a period of time. A 1,000-
hour performance test was completed
on a U.S. Navy Standard Fire Pump
manufactured from titanium with
one company’s engineered structural
composite impeller and casing rings.
� e result showed a 2.5 percent
increase in the head-capacity (H-Q) at
the end of the test.
One of the many advantages of using
composite pumps is that the casing
volute geometries and the impeller
geometries can be designed and
engineered specifi cally for the required
operating point in the plant or vessel.
With premium effi ciency engineered
structural composite pumps, strength
can be added and removed based
on need.
Premium effi ciency composite
pumps are designed and engineered to
keep their overall sizes at a minimum
so that they can easily fi t into confi ned
spaces. � ese types of pumps are
also engineered to minimize piping
modifi cations while maintaining or
exceeding pump performance. � ese
engineered composite equipment
upgrades help pump users increase
the effi ciency and longevity of their
pumping systems.
John A. Kozel is president and CEO of SIMS Pump Valve Company, Inc.
He may be reached at 201-792-0600 or at
simsite1@aol.com. For more information, visit simsite.com.
Image 5. This vertical in-line structural graphite composite pump replaced the type 316 stainless steel pumps onboard the Navy Military Sea Lift Command Vessel.
Because of the self-lubricating characteristics
of many engineered composites and because
composites do not wear or corrode, the
performance curve will actually increase over a
period of time.
77
pumpsandsystems.com | August 2015
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W hy should electrical inspections be an
integral part of a pump maintenance
routine? � e answer is simple: Performing
electrical inspections on pumps and their
systems helps locate faults before they become failures.
� is allows the maintenance technician to order parts or
replacement pumps and schedule system maintenance in
advance to avoid costly downtime and emergency repairs.
Electrical inspections can provide a great deal of
information about the overall condition of the pumping
system. � is is especially true for submersible pumps in
which the motor and the pump are packaged as a single
unit. Most of these pumps are equipped with internal
sensors for winding temperature, bearing temperature
and the presence of moisture. During the last fi ve years,
vibration sensors have become standard equipment in
larger pumps. � e information these sensors provide
can mean the diff erence between a simple rebuild or
stator rewind and rotor replacement. Regular electrical
inspections can help reduce each pump’s total cost of
ownership (TCO).
Offl ine Testing
During a motor inspection, several tests are performed
on the stator windings. A multimeter can be used to test
the resistance of the coils and compare them to each
other. For single-phase motors, the resistance readings
can be compared to an ohms chart provided by the
manufacturer. In three-phase motors the resistance
(ohms) on each phase should be within 2 percent. Shorts
to ground can only be found with a multimeter if there
is a direct short. Other conditions, such as moisture,
dirt or carbonization, may not be detectable. When
electrical arcing occurs between the windings and
ground or between coils, the insulation of the windings
becomes carbonized, basically turning the material into
a semiconductor. A semiconductor acts like an insulator
until a barrier potential voltage is reached. � en, it shorts
and behaves like a conductor.
In the case of carbonized winding insulation, a
multimeter cannot detect the ground fault because the
test voltage of the meter (9-10 volts [V] direct current
[DC]) is too low to reach the barrier potential of the
carbonized insulation. In the past, a hipot test was
used to fi nd ground shorts. During a hipot test, a high
voltage potential (2,000 V) is placed across the windings,
and leakage through the insulation is measured to
determine the condition of the insulation (see Image 2,
page 80). Unfortunately, these testers can damage the
windings over time. If moisture or dirt is present, the
Electrical Inspections Reduce Cost of Ownership Offl ine and online testing can improve reliability and reduce downtime.
BY JAMES JETTE KSB PUMPS INC.
Image 1. A Megger test in action
(Images courtesy of KSB)
78 PUMP SYSTEM OPTIMIZATIONCOVER S E R I E S
August 2015 | Pumps & Systems
hipot may cause an arc to
fl ash, instantly ruining
the windings. Hipot tests
are used at factories to
determine the dielectric
breakdown voltage of new
windings. A hipot test is
also required for explosion-
proof certifi cation.
In 2015, a Megger (a
registered trademark of
the Megger Corporation)
is used to test for shorts to
ground. Megger tests work
by sending a low-amperage
(0.001 amps) pulse of DC
voltage between the coil
leads and the stator ground
at two times the motor’s
operating voltage (250-
1,000 V).
� e Megger displays the
results in megaohms (see Image 1). Readings from the
Megger can determine whether there is a direct short
to ground or an insulation fault in the windings, such
as moisture or dirt. In the case of moisture or dirt, the
stator can be washed, dried and re-dipped in varnish to
save the owner from an expensive rewind.
For coil-to-coil and turn-to-turn shorts, multimeters
and Meggers can only detect a major short. For minor
shorts, a coil and winding tester is needed. When
a small turn-to-turn fault occurs, there is typically only
a tiny change to the DC resistance. With larger motors
this change can be too small to detect with an
ordinary multimeter.
To fi nd the short, the end user must look at the
diff erence between the alternating current (AC)
resistance (inductance) and the DC resistance. While
the DC resistance may change slightly because of a
minor short, the AC resistance will vary greatly with
frequency. Minor shorts can be easily detected by
comparing the three windings while testing a range of
frequencies. Two types of coil and winding testers are
available. Both types input a low voltage AC signal and
read the output. A surge tester—the most common
style of coil tester—has a screen that displays the
waveform as the tester steps through the frequencies.
Other types calculate the diff erential internally and
display the results on a screen.
79
pumpsandsystems.com | August 2015
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This new guide provides the guidance necessary to select pump types, pump materials, and auxiliary components so the wastewater pumping system performs effectively, efficiently, and reliably in various plant operations. Find out what’s inside by visiting the link below.
NEW: Hydraulic Institute’s Wastewater Treatment Plant Pumps Guidebook
Attention Pumps & Systems Readers: Take 15% off your purchase of this guide by applying coupon code WWPS15GB during checkout in the HI eStore at eStore.Pumps.org/Wastewater
Online Testing
� e most exciting new development in the world of pump
electrical maintenance is the development of online
testing. � is new breed of instruments can be attached
to a pumping system to monitor the pump and motor
while they are running. � e temperature, vibration, fl ow,
pressure, power and electrical waveforms can be analyzed
using online testing.
On the motor side, users can detect problems with
incoming power, bearings, stator shorts, and dirty or
wet windings. On the pump side, the intake pressure,
discharge pressure, fl uid temperature, fl ow rate, bearing
condition and vibration can be measured.
Another feature of online testing—known as data
logging—is the ability to collect measurements over a
period of time. � e majority of pump system problems
happen when an operator is not present—the “ghost”
failures that occur in the late hours of the night. Data
logging can monitor multiple channels of information
for long periods of time to capture these events as they
happen. Examining data logger records collected over
extended periods can also reveal trends that point to
gradual deterioration of pump or motor conditions before
they become critical.
A data logger can also show the operating parameters
of the pump system and help end users evaluate the exact
duty point and duty cycles of the system. Comparing
this information with the
manufacturer’s pump curves,
end users can determine with
high accuracy where the pump is
operating on the curve, measure
the system curve and determine
where the motor is running on the
power curve.
� is information shows the
eff ects of pump wear, pipe
restrictions and suction issues.
� is information can also be used
to accurately calculate the pump
system effi ciency, which allows the
engineer to off er solutions that
can improve effi ciency, reduce wear
and decrease downtime.
James Jette is a senior service sales
expert at KSB Canada. Jette has a degree in
electronics and computer science from the
New England Technical Institute.
His credentials include a Red
Seal certifi cate as an industrial
millwright from Toronto-based
Humber College.
Image 2. Hipot testing performed on a submersible pump stator
80 PUMP SYSTEM OPTIMIZATIONCOVER S E R I E S
August 2015 | Pumps & Systems
The Power of Knowledge Engineering
Monitor them.Got VFDs on your motors?
SKF’s EXP4000 and NetEP dynamic motor monitoring solutions reveal adverse impacts variable-frequency drives have on motors, and they can help you optimize performance of those VFDs.
To learn more, call 970-282-1200, or visit www.skf.com/emcm.
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FOR MORE INFORMATIONEMAIL: info@turbo-lab.tamu.edu
OR VISIT: TPS.TAMU.EDU
44TH TURBOMACHINERY & 31ST PUMP SYMPOSIA
HOUSTON, TEXAS | SEPTEMBER 14 - 17 2015 | GEORGE R. BROWN CONVENTION CENTER
REGISTER44TH TURBOMACHINERY & 31ST PUMP SYMPOSIA
The premier conference for turbomachinery and pump professionals.
DEVELOPED FOR THE INDUSTRY, BY THE INDUSTRY.
TPS.TAMU.EDU
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August 2015 | Pumps & Systems
82 TRADE SHOW PREVIEW
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Comprehensive Industry Coverage
• Positive Displacement Pumps• Centrifugal Pumps• Specialty & Other Pumps• Industrial Valves• Pneumatic & Hydraulic Valves• Industrial Automation & Process Control• Electric Motors & Drives• Actuators• Compressors• Custom Research• White Papers
Frost & Sullivan evaluates and implements
effective growth strategies. We employ 50
years of experience in partnering with Global
1000 companies, emerging businesses and
the investment community from more than
40 offices on six continents.
For more information, contact Liz Clark
at 210.477.8483 or liz.clark@frost.com
Visit us at www.frost.com
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Engineered Wood, Food & Beverage,
Chemicals, Pharmaceuticals,
Waste Water, and more!
678-324-4481
4364 Winfred Dr
Marietta, Ga 30066
“It’s all about reliability”www.enviropumpandseal.com
“It’s all about reliability”www.enviropumpandseal.com
l b l
MADE IN
USA
C""Uvglcfc"Eqorcp{
The annual Turbomachinery & Pump Symposia (TPS 2015) feature a
technical program and international exhibition, complete with full-
size equipment and hundreds of companies. he Turbomachinery
Symposium is the only meeting organized by users for users. he members of
the Advisory Committee are recognized leaders in the rotating equipment and
power generation community. he event promotes professional development,
technology transfer, peer networking and information exchange.
he symposia cover topics including maintenance, troubleshooting,
operation and purchase of pumps. More than 6,000 rotating equipment and
power generation professionals attend the event. he Texas A&M Engineering
Experiment Station and the Texas A&M University System organize the event,
which represents industries such as oil and gas, chemical and petrochemical, power, manufacturing, mining
and metals, and water.
With 17 short courses and 88 technical sessions, professionals have the opportunity to grow their
knowledge of pumps and turbomachinery. he technical sessions include lectures, tutorials, discussion groups
and case studies. Executives, managers, engineers, sales directors and technicians are represented. More than
300 companies take part in the exhibition. For more information, visit tps.tamu.edu.
44TH Turbomachinery & 31ST Pump SymposiaSept. 14-17, 2014George R. Brown Convention CenterHouston, Texas
Exhibition Hours
Tuesday, Sept. 14 Noon – 2 p.m.
Tuesday, Sept. 14 2:30 p.m. – 7 p.m.
Wednesday, Sept. 15 Noon – 2 p.m.
Wednesday, Sept. 15 2:30 p.m. – 6:30 p.m.
Thursday, Sept. 16 9:30 a.m. – Noon
Visit us at Booth 1318
pumpsandsystems.com | August 2015
83
STAY COMPETITIVE
AND RELEVANT
WEFTEC offers the
highest-quality, most
comprehensive
educational sessions
available today.
DISCOVER
THE NEWEST
INNOVATION AND
SOLUTIONS
WEFTEC features the
largest water quality
exhibition in the world
with more than 1,000
exhibiting companies.
ACCESS GLOBAL
BUSINESS
OPPORTUNITIES
WEFTEC is your gate-
way to global water,
wastewater & resource
recovery — and the
only water show
selected to be a part
of the U.S. Commercial
Service International
Buyer Program.
EXPERIENCE
SPECIALIZED
PAVILIONS
See the latest equip-
ment, services and pre-
sentations in focused
areas on the exhibit
floor, including: the
Stormwater Pavilion,
Innovation Pavilion and
more than 10 Country
Pavilions.
MAKE VALUABLE
CONNECTIONS
WEFTEC hosts more
than 22,000 attend-
ees from around the
world and all sectors
of water quality.
WEFTEC 2015 is the event for water professionals, industry experts, and the most innovative
companies from around the world to gather together for the advancement of water.
COUNTLESS OPPORTUNITIES.
88th Annual Water Environment Federation Technical Exhibition and Conference
September 26 – 30, 2015 McCormick Place, Chicago, Illinois USA
Register Today!www.WEFTEC.org
ONE WORLD.ONE WATER.ONE EVENT.
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August 2015 | Pumps & Systems
84 BUSINESS OF THE BUSINESS
The agriculture industry has
historically been a slow
adapter of new technology.
With more than 7 billion people
currently on the planet, the
need for precision farming has
caused a rapid evolution in the
industry. Precision agriculture
is thought by many to be the
biggest technological change in
agriculture since the introduction
of hydraulics in the 1940s.
Food Security
One of the key challenges the
world faces today is population
growth, particularly in developing
countries. According to a recently
released report from the United
Nations, the world’s 7.2 billion
people will increase to 8.1 billion
by 2025 and 9.6 billion by 2050.
Most of that growth will occur
in developing regions, which are
projected to increase from
5.9 billion in 2013 to 8.2 billion
in 2050. � e current food
production rate, however, falls
signi� cantly short of meeting this
increased need.
� is de� cit is pushing farmers
to adopt better technologies that
will meet the increasing demand
and to optimize resources with
minimum waste. Adoption of
precision agriculture, particularly
in developing regions, can play
a signi� cant role in feeding the
burgeoning global population.
A few key challenges will
contribute to food insecurity in the
21st century:
• Growing urbanization,
which will lead to decreases
in green space resulting
from the extension of cities
and movement of rural
communities to urban areas
• Declining agricultural
productivity resulting from
lack of healthy soil, water and
habitat
• Increasing water scarcity, which
will be the key challenge for
crop cultivation
Precision Agriculture
Built on location-based
technologies such as global
positioning systems (GPS) and
geographic information systems
(GIS), precision agriculture has
transformed the way farming is
conducted. It enables farmers to
monitor � eets remotely, conduct
soil analysis, monitor yield or
create customized maps to target
each area of a � eld uniquely. It
ensures better crop yield and
output e� ciency, enabling high
pro� tability with optimum use of
available resources.
Emerging countries are
expected to invest heavily in
precision agriculture. In developed
countries, investment is expected
to be in the more highly e� cient
precision farming systems
and procedures.
As food production needs
increase, precision agriculture
will be one of the key technologies
farmers rely on to increase
productivity by maximizing the
use of available land.
Implementation of precision
agriculture technology can lower
costs for seed, fertilizer, fuel and
labor and increase a � eld’s yield.
Often, payback periods can be
one to � ve years depending on the
technologies used.
Established agriculture and
technology companies and a
host of startups are providing
innovative products and services
that are focused on helping
farmers improve operational
e� ciency. Precision agriculture is
considered to be a huge advantage
for geospatial companies. Many
smaller companies will be bought
as they gain momentum and
provide unique products and
services. Trimble’s extensive
Connected Farm o� erings,
for example, include precision
agriculture products and services
that could drive the increased
e� ciency and yield needed to
develop the industry.
Precision Agriculture & Remote Monitoring Modernize Pump Systems
As food production needs increase, this technology allows end users to conserve
water and increase effi ciency.
By Arun Prasath
Frost & Sullivan
pumpsandsystems.com | August 2015
85
Remote Monitoring
New technologies will enable
multiple innovative applications
that change the way we live,
communicate and conduct
business. In 2015, the number of
connected devices is around 8.5
billion, and the installed base of
connected devices and machines
is expected to grow to 50 billion
units by 2020.
Remote monitoring is crucial
and intensive in agriculture.
In farming, water levels, soil
conditions and temperature
require continuous examination.
On the plant side, yield
monitoring and weed monitoring
are closely related key metrics.
Conserving water is a vital part
of farming. Water monitoring
and management are critical to
ensure this resource is allocated
e� ectively and used e� ciently.
Farmers spend approximately
one-third of their time traveling
to inaccessible or distant places to
ensure pumps are working well.
� e demand for pump monitoring
has increased as farmers look
to reduce costs. Some farming
operations, however, expend a
signi� cant amount of time and
labor to monitor the operation
of the irrigation pumps on their
farms. With the adoption of
Internet of � ings (IoT), end users
can monitor and control pump
systems from their smartphones
or tablets.
A pump monitoring system
is composed of a sensor and
a transmitter. � e sensor is
positioned in the water � ow of
the discharge from the irrigation
pump and senses whether or not
water is present. In this system,
each pump being monitored
is given a descriptive name or
number that is indicated in
the message so the producer
knows exactly which pump is
not operating. Once the pump
is operating again, the system
sends a signal indicating the water
� ow has been reestablished. It is
also possible to use the monitor
system to turn o� power units
remotely from a computer through
a website.
Several companies o� er wireless
technology for agriculture
professionals. Net Irrigate,
a manufacturer of wireless
irrigation monitoring technology
for the agriculture industry,
designed PumpProxy, which allows
farmers to remotely monitor and
shut down irrigation pumps by
website or mobile app and receive
text, voice or email noti� cations
about issues including thermal
overloads or power failures.
Conclusion
� e modern agriculture
industry provides a wide range
of opportunities for remote
monitoring and control. Water
conservation is a major challenge
for farmers, and because of
new regulations in water usage,
farmers are looking for better
ways to use available resources.
� e growing awareness—coupled
with technology savvy farmers—
will increase the rate of growth of
precision agriculture at automated
farm processes.
Arun Prasath is an industrial
automation and process control
industry analyst for Frost &
Sullivan, North America and India.
Prasath has an MBA in marketing
and operations from BIM, Trichy,
India, and a bachelor’s
degree in mechanical
engineering
from AAMEC,
Tanjore, India.
Adapt:
Conservation
agriculture
Utilize: Better water
management systems
Improve: Agricultural productivity
Develop: Sustainable agricultural practices
g
Food Security
Figure 1. Tackling food insecurity (Courtesy of Frost & Sullivan)
August 2015 | Pumps & Systems
86 EFFICIENCY MATTERS
Pumps make industrial
manufacturing possible.
Every day, thousands of
industries around the world rely
on various pumping technologies
to move raw materials and end
products through the production
process. Whether handling lube
oils, paints and coatings, or
working in applications from
heat transfer to chemical
processing, pumps must reliably,
e� ciently and safely transfer an
array of � uids, all of which have
unique—and often challenging—
handling characteristics.
If a pump is the weak link in
the production process, the entire
operation will be compromised,
with the downtime required for
repair or replacement eating away
at production quotas and the
bottom line.
Industrial manufacturers can
choose from a wide range of pump
options when out� tting their
facilities. A number of factors
also go into choosing pumping
technology. Operational reliability
and the ability to meet speci� c
� uid-handling requirements
are among the most important.
With manufacturing operations
governed by operating budgets and
expenses, equipment acquisition
costs and subsequent maintenance
are also primary concerns.
While all pumping technologies
can have positive points in
Image 1. In order to fashion a handling and transfer operation that optimizes reliability, effi ciency and safety, many chemical processors are making the decision to install internal gear pumps. (Images courtesy of PSG)
Internal Gear Pumps Handle Harsh Conditions
These pumps offer effi ciency and reliability in complex industrial operations.
By Chrishelle Rogers
Maag Industrial Pumps
pumpsandsystems.com | August 2015
87
industrial manufacturing
operations, positive displacement
internal gear pumps can o� er
precise and consistent transfer of
demanding � uids.
Chemical processing and
manufacturing is one of the most
complex industrial operations. � e
chemical manufacturing process
is so intricate that it is comprised
of several unit operations,
from cracking, distillation and
evaporation, to gas absorption,
scrubbing and solvent extraction.
Within that family of unit
operations, � uid transfer
touches every stage of the
manufacturing process and is vital
for overall process success. Often
oversimpli� ed as “transporting
� uid from one point to another,”
� uid transfer in chemical
manufacturing is much more.
Fluid transfer includes a
spectrum of applications, with
responsibilities all along the
chemical production chain. For
example, thin or viscous raw
materials can be transferred to
storage tanks or blending and
mixing tanks. Final formulations
can be transferred to holding
tanks, and � nished products can
be loaded into intermediate bulk
containers (IBCs) for delivery or
consumer packaging.
In many cases, chemical
manufacturing processes require
the use of dangerous substances,
such as strong acids, caustics,
solvents, resins and polymers.
Despite their inherent danger, these
are necessary for the manufacture
of thousands of consumer goods
or to facilitate other industrial
processes. � e challenge when using
dangerous chemicals is to construct,
handle and transfer them in a safe
and reliable way.
Fortunately for chemical
processors, positive displacement
Image 2. No acid, polymer, resin or caustic has the same handling characteristics, which makes pump versatility a primary concern for chemical processors. These internal gear pumps overcome many handling concerns by featuring a method of operation that can successfully and safely transfer fl uids of differing viscosities and chemical makeups.
For more information, please go to:
psgpumps.com/ps815mip
EnviroGear® and G Series Internal Gear Pumps o er you highly reliable and versatile pumping solutions for a wide range of applications, from thin to viscous � uids. With � eld-proven technology that’s safer, greener and interchangeable with competitive technologies, the G Series and EnviroGear line of pumps are the workhorses you’ve been looking for!
PSG 22069 Van Buren Street
Grand Terrace, CA 92313-5651P: +1 (909) 422-1731
psgdover.com
VersatilityReliabilityand
Improve
EnviroGear
• Lowest overall cost of ownership
• 50% reduction in maintenance costs
• Single fluid chamber design eliminates leaks
• Patented between-the-bearing support greatly improves reliability
G-Series
• Best-in-class delivery
• Interchangeable with competitive models
• Flexible design for easy installation
• Multiple seal options available
• Available in cast iron and stainless steel
Where
Innovatio
n Flows
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August 2015 | Pumps & Systems
88 EFFICIENCY MATTERS
internal gear pumps have continually
o� ered the reliability and cost-
e� ectiveness required for handling
raw materials and � nished products.
One manufacturer has created an
internal gear pump with a simple
design that includes only two
moving parts, a pair of coinciding
gears called the rotor and idler, for
precise and consistent transfer of
demanding � uids.
� is design creates a four-step
operating process:
1. � e rotor and idler gears
un-mesh at the suction port to
create an atmospheric vacuum
that draws � uid into the pump.
As the rotor turns, the � uid is
forced between the rotor teeth
and idler teeth.
2. Continual rotation of the rotor
forces the � uid through a
crescent-shaped area within the
wetted path. � e crescent-shaped
area divides the � uid and acts as
a barrier between the inlet and
discharge ports.
3. As the rotor continues rotation,
the � uid is forced past the crescent-
shaped area and moves toward the
discharge port.
4. As the rotor completes its
rotation, the rotor and idler teeth
engage, forcing the � uid through
the discharge port of the pump.
� is method allows the pumps
to operate equally well in either
direction, resulting in a positive,
non-pulsating � ow of the pumped
� uid. Other design features
include a rotatable pump casing
that allows for multiple inlet and
outlet port positions and single-
point end-clearance adjustment. It
also features an enlarged bearing
housing at the rear of the pump
that allows easy drive-end access
to the shaft seal.
Image 3. Internal gear pumps feature a unique design that features only two moving parts, a rotor and idler gear, which allows them to operate equally well in either direction and deliver positive, non-pulsating fl ow of the liquid being handled.
DISCOVER BETTER DESIGNS.
FASTER.FOR OPTIMAL PUMP PERFORMANCE
AUTOMATE YOUR DESIGN SPACE EXPLORATION WITH CFD
www.cd-adapco.com
info@cd-adapco.com
VISIT US AT PUMP & TURBOMACHINERY SYMPOSIA AT BOOTH 1529/1531
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pumpsandsystems.com | August 2015
89
Chemical processors must deal daily
with � uids that are di� cult to transfer.
� eir task is to create a handling and
transfer regimen that includes pumping
equipment compatible with many di� erent
types of dangerous chemicals while also
o� ering reliable operation and cost-
e� ectiveness with regard to maintenance,
repair and downtime.
Chrishelle Rogers is the global gear pump product manager for Maag
Industrial Pumps, Grand Terrace, California, and PSG, Oakbrook Terrace,
Illinois. Rogers can be reached at 909-222-1309 or chrishelle.rogers@
psgdover.com. For more information, visit psgdover.com.
Image 5. Fluid transfer touches every stage of the manufacturing process and is vital for overall process success.
Image 4. Internal gear pumps feature a unique design that have only two moving parts, a rotor and idler gear, which allows them to operate equally well in either direction and deliver positive, non-pulsating fl ow of the liquid being handled.
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August 2015 | Pumps & Systems
90 MAINTENANCE MINDERS
Every oil and gas facility
is comprised of critical
equipment and processes
that must operate reliably for
successful production. One
loose bolt or faulty thermostat
can result in equipment failure
and downtime. To prevent these
catastrophic events, many
facilities are turning to modern
software solutions that allow them
to remotely monitor equipment
conditions and detect faults before
they result in costly damage.
� e two examples below show
how early fault detection using
remote monitoring software can
save oil and gas facilities valuable
time and money.
Broken Valve Bolt
On March 13, a remote monitoring
software solution identi� ed a
sudden and sustained rise in the
number of impacts over time on a
reciprocating compressor.
Values for this sensor were
expected to stay near 0 for
sustained periods of time. � e
software provider’s reliability
center noti� ed the end user of this
issue during their scheduled
weekly call.
When the operators
investigated the issue, they found
that valve center bolts had broken
on three separate valves. Parts of
one of the bolts had fallen into the
cylinder head and were damaging
the piston.
� e debris from the broken
bolts could have caused a
catastrophic failure of this
compressor and could have
resulted in the compressor
requiring a complete overhaul.
Because the issue was detected
early, the user was able to replace
the piston and valves and return
the machine to service.
Faulty � ermostat &
Low Oil Level
In early July, this same software
solution detected a drop in lube
oil pressure on a reciprocating
compressor at another oil and gas
facility well before the pressure
reached the shutdown limit.
Given the operating conditions,
lube oil pressure values were
expected to operate between 55
and 60 pounds per square inch
gauge (PSIG) (4.8 and 5.2 bar). � e
software provider immediately
sent a noti� cation to the user
when the lube oil pressure
dropped to 48 PSIG (4.3 bar) and
discussed the issue on the next
weekly call. Actual values for lube
oil pressure continued to drop
as low as 33 PSIG (3.3 bar). � e
Oil & Gas Facilities Detect Costly Faults Early
A software solution alerted two end users of problems with their reciprocating
compressors, saving time and money.
By Cynthia Stone
pumpsandsystems.com | August 2015
91
shutdown limit for the asset was
at 30 PSIG (3.1 bar).
When the facility investigated
this issue, they discovered a
thermostat that was getting
stuck and causing the lube oil to
not be properly controlled. � e
user replaced the thermostat and
reported this maintenance action
on the next weekly call.
However, the software
provider’s reliability center
was not able to verify that the
facility’s maintenance action
was fully successful because
actual values had not returned
to expected values. A follow-up
maintenance action, performed
by the user, identi� ed a second
issue—the lube oil tank level
was low. � e user re� lled the lube
oil tank.
Loss of proper lube oil could
cause catastrophic damage to
the reciprocating compressor,
leading to a loss of production.
In this case, the facility received
several days of warning, which
allowed them to investigate
and correct the issue before any
damage occurred to the machine
or the drop in oil pressure reached
the low-pressure shutdown
limits. � e user was also able
to receive veri� cation that
both maintenance actions were
e� ective at correcting this issue
by seeing the actual values return
to expected values.
Cynthia Stone is a product
marketing manager for Industrial
Data Intelligence at GE. She has
nearly a decade of experience
working in predictive analytics
for power, oil and gas,
mining and aviation.
Stone may be
reached at cynthia.
stone@ge.com.
The debris from the broken bolts could have caused a catastrophic
failure of this compressor and could have resulted in the
compressor requiring a complete overhaul.
Check out past Maintenance Minders
articles to read about the following topics:
• How monitoring software enables
scheduled mainteance
• How remote monitoring prevents valve
failure at combined-cycle power plants
• How turbine error identifi cation stops
costly power plant outage
• How system component malfunctions
lead to higher pump speeds with
stagnant fl ow rates
Next month’s Maintenance Minders will
discuss how remote monitoring software
detected a wiped bearing on a feedwater
pump as well as an operational issue
on a lube oil pump at combined-cycle
power plants.
READ MORE ONLINE AT
pumpsandsystems.com/mmgeip
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August 2015 | Pumps & Systems
92 MOTORS & DRIVES
Energy e� ciency has become
a major focus for the U.S.
government, municipalities,
power utilities and the industrial
sector, with much of the attention
falling on components such as
motors and pumps. For end users,
understanding the di� erence
between component e� ciency
and system e� ciency as applied to
motor-driven equipment is critical
for evaluating a total system and
making appropriate upgrades. � e
Energy Independence and Security
Act (EISA) is one standard that
users must understand and comply
with to successfully improve
system e� ciency.
E� ciency Standards as
De� ned by EISA
For each general-purpose
rating (Subtype 1) from 1 to
200 horsepower (HP) that was
previously covered by EPAct, the
law speci� es a nominal full-
load e� ciency level based on
National Electrical Manufacturers
Association (NEMA) premium
e� ciency as shown in NEMA MG
1, Table 12-12. All 230- or 460-volt
(and 575-volt for Canada) motors
currently under EPAct that were
manufactured after December 19,
2010, must meet or exceed this
e� ciency level.
General-purpose electric
motors (Subtype II) not previously
covered by EPAct will be required
to comply with energy e� ciencies
as de� ned by NEMA MG 1, Table
12-11. � e term general-purpose
electric motor (Subtype II) refers to
motors that incorporate the design
elements of a general-purpose
electric motor (Subtype I) that are
con� gured as one of the following:
• U-frame motor
• Design C motor
• Close-coupled pump motor
• Footless motor vertical solid
shaft normal thrust motor (as
in a horizontal con� guration)
• An 8-pole motor (900 rpm)
• A poly-phase motor with
voltage of not more than
600 volts (other than 230 or
460 volts)
Motors that are 201 to 500
HP that were not previously
covered by EPAct will be required
to comply with energy e� cient
e� ciencies as de� ned by NEMA
MG I, Table 12-11.
� is information and the Tables
referenced above are readily
available on the Department of
Energy (DOE) website.
So, what does the new EISA
Standard have to do with system
e� ciency? Many end users
believe that any system e� ciency
improvement is the result of
an increase in motor e� ciency;
however, that is not always the
case. For example, consider a
centrifugal pump system operating
at a � xed speed. � e system
requires variable � ow and is
controlled by a motor-operated
valve. One might believe that
replacing the standard-e� ciency
motor with the new EISA premium-
e� cient motor would lead to an
incremental gain in e� ciency and
a lower operating cost. � is seems
reasonable, but more factors must
be considered.
In order to meet the EISA
standard, motor original
equipment manufacturers (OEMs)
had to redesign their equipment
to achieve the increased e� ciency
as mandated by government
regulations. To understand what
is meant by “increased e� ciency,”
users must know the de� nition of
a premium-e� ciency motor and
what a� ects that e� ciency.
Motor Losses
Losses in a motor include stray
losses, rotors, stators, core losses
and fan design (windage).
To make a motor more e� cient,
a manufacturer must add more or
better material. � ese additions
and adjustments could include
more active material such as
copper in the winding, a longer
stator, rotor cores and improved
electrical steel (silicon steel is
used for the stator and rotor). A
Understanding System Effi ciency in Motor-Driven Rotating Equipment
Users should consider system changes to comply with the new EISA standard.
By William Livoti
pumpsandsystems.com | August 2015
93
low-loss fan design could also be
used to reduce friction and windage
losses. To reduce the stray load
losses, manufacturing processes
are assured through International
Organization for Standardization
(ISO) 9001 procedures.
Some advantages of energy
e� cient motors are:
• Maximum E� ciency – Energy-
e� cient motors operate at
maximum e� ciency even when
they are lightly loaded because of
better design.
• Longer Life – Energy-e� cient
motors dissipate less heat
compared with standard motors.
Use of energy-e� cient fans
keeps the motor at a lower
temperature, which increases
the life of the insulation and
windings as well as the overall
life of the motor.
• Lower Operating Cost – � e
total energy cost of energy-
e� cient motors during its
life cycle is much lower when
compared with conventional
motors.
• Other Bene� ts – Energy-
e� cient motors have better
tolerance to thermal and
electrical stresses, the ability to
operate at higher temperatures,
and the ability to withstand
abnormal operating conditions
such as low voltage, high voltage
or phase imbalance.
System E� ciency
Energy-e� cient motors can also
improve system e� ciency, but
end users must consider the
following factors:
• Motors meeting higher
e� ciencies tend to run faster
than their less e� cient
counterparts.
• Matching speeds to application
need (such as pump � ow) is
important to consider.
• Drives may be required, which
o� ers the opportunity to
increase system e� ciency in
applications with variable output
requirements. Variable frequency
drives (VFDs) require further
considerations for optimum
reliability and e� ciency.
• In some cases, mounting
dimensions for motor into
machinery may be slightly
di� erent.
Case Study
� e following case study graphically
illustrates the impact of a premium-
e� cient motor in a centrifugal
pumping application.
Figure 1 (page 92) provides four
separate scenarios for reducing
energy consumption in a cooling
tower pumping system. � e
portrayed system is a typical closed
loop con� guration where the
discharge is being throttled over a
range of operation. � e system in
this example operates 24/7, 365
days per year. At this particular
load point, that means it operates
70 percent of the time—or 6,250
hours per year.
Columns 1 and 2 in Figure 1
indicate the various components
factored into the system e� ciency
calculation. Column A is the
base condition where the system
operates 50 percent of the time.
� e component e� ciencies for the
VFD and gearbox are at 100 percent
because they were not used.
Under the base condition,
the total power required is
approximately 1,777 HP; almost
356 HP is being lost (wasted) across
a control valve. In addition, the
pump is operating back on the curve
at 65 percent e� ciency. Under
these conditions, the total system
e� ciency is 49 percent.
Column B provides the new
operating conditions with the
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August 2015 | Pumps & Systems
94 MOTORS & DRIVES
addition of a VFD. � e head required
has been reduced to 150 feet because
the loss across the valve has been
eliminated by reducing the speed of
the pump to meet required system
demand. Motor e� ciency remains the
same, and a 2 percent loss has been
added as a result of heat generated
across the drive. Note the dramatic
improvement in the overall system
e� ciency (81 percent) and the
total operating cost reduction from
$414,306 to $187,360. � e total cost
savings is $226,946 per year.
Column C addresses the impact on
the system by improving the e� ciency
of the pump. Nothing else in the
system was changed.
� e minimal improvement of the
overall system e� ciency (53 percent)
results from increasing the pump
e� ciency by 5 percent. � e 50 feet
of head loss across the control valve
remains, so the total power required
is 1,650 HP. � is scenario does not
present huge savings based on the cost
of a new pump and installation and
potential piping changes. Factor in the
ongoing reliability issues, such as the
pump operating back on the curve, and
$29,593 would be di� cult to justify.
Column D identi� es potential
savings when motor e� ciency is
improved by 2 percent. Again, nothing
has changed in the system with the
exception of an additional 5 feet of
friction loss across the valve as a
result of the reduced slip in the
premium-e� cient motor (head
increases to the square of the
speed). In this case, the system
e� ciency remains the same at
49 percent. Note that the power
required for the additional friction
has increased to 330 HP. � e total
power required was reduced to
1,650.2 HP (a reduction of 127
HP) with a total savings of $518
per year.
References
1. EISA Standards Department of Energy
2. WEG Electric
William Livoti is the power
generation business development
manager for
WEG Electric
Corporation. Livoti
may be reached at
wlivoti@weg.net.
Figure 1. Four separate scenarios for reducing energy consumption in a cooling tower pumping system (Courtesy of WEG)
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pumpsandsystems.com | August 2015
95
Compression packings have
su� ered from a reputation
of being an old-fashioned
technology unsuited to modern
industrial processes. In the case of
rotating equipment, they are largely
superseded by mechanical seals. In
particular, many believe packings are
ine� cient because of high frictional
losses. Much of this perception
is based on outdated products
and not on modern types that
use sophisticated synthetic yarns
combined with complex lubricants.
� is article describes the
development of a straightforward
test procedure for compression
packings used in rotary applications.
� e procedure was used to study the
frictional characteristics of several
packing types in comparison with
various mechanical seals using a
test rig speci� cally designed for
the purpose. � e results from the
friction testing on a number of
packing types and mechanical seals
will also be discussed. � ese results
call into question the theoretical
methods currently used to calculate
packing friction.
Test Procedure Development
As early as 2004, the European
Sealing Association (ESA) along
with its U.S. counterpart, the Fluid
Sealing Association (FSA), formed a
joint task force to develop a realistic,
performance-based test method for
compression packings used in rotary
applications. � e driving force for this
project was to enable manufacturers
to publish true comparative data on
packing performance and allow end
users to better di� erentiate between
products when making selections for
their applications.
� e speci� cation was developed
through a number of iterations. At
each stage, the validity, accuracy
and repeatability were tested using
“round-robin” tests. Each member
company tested the same product
from a single source, and the results
were compared. Any deviations
from consistency were discussed
and the speci� cation re� ned for the
next validation round. To maintain
impartiality, all of the test results
were submitted to an independent
body for analysis—French research
organization Centre Technique des
Industries Mécaniques (CETIM),
who also carried out their own tests
in each round. Figure 1 shows a
typical test setup.
� e � rst drafts of the speci� cation
allowed test conditions that re� ected
those commonly encountered in
� eld applications but with water
as the test medium. � e following
parameters were to be measured and
recorded at speci� ed intervals during
each test run after the break-in
period and at the end of the test:
• Total leakage (milliliters)
• Leak rate (milliliters per hour)
• Gland temperature (degrees
Celsius)
• Number of gland adjustments
• Amount of each adjustment
(millimeters)
• Normalized power consumption
(watts per millimeter squared)
Energy Effi ciency of Compression Packings in Rotodynamic Pump ApplicationsBy Henri Azibert
FSA Technical Director
Figure 1. Typical test arrangement (Images and graphics courtesy of FSA)
SEALING SENSE
August 2015 | Pumps & Systems
96 SEALING SENSE
Leakage from the static outer side
(gland) and the dynamic inner side
(shaft) was recorded separately.
For the � rst series of tests,
the packing selected was one of
known good performance and of
material and construction typically
used by all of the participating
manufacturers. A graphite/
expanded polytetra� uoroethylene
(ePTFE) cross-plaited packing was
selected, and test packings were
manufactured by one manufacturer
from the same batch of yarn to suit
each of the participants test rigs.
� e general trends from these
early tests provided composite
results for 12 tests at six test
facilities under the same conditions
of 6 bar pressure for 100 hours at
di� erent speeds. While consistency
within each individual laboratory
was satisfactory, the variation
between them was substantial.
� e speci� cation was, therefore,
re� ned to better control the test
conditions and procedures, and the
importance of the initial � tting of
the packing and the break-in period
was emphasized.
� ree leakage classes were
introduced to allow for di� ering
target leakage levels depending
on the criticality of the intended
application area of the packing.
• L1 = less than or equal to 5
milliliters per minute (ml/min)
• L2 = less than or equal to 15
ml/min
• L3 = less than or equal to 30
ml/min
Gradually, other packings were
tested and eventually a � nal
speci� cation was reached. Figure
2 shows results from testing a
graphite/ePTFE packing under the
� nal speci� cation conditions, with
good repeatability of results.
� e � nal speci� cation was
issued and is freely available to
download from the FSA website. � e
speci� cation was also put forward
to CEN Technical Committee TC
197 – ‘Pumps’ to be adopted as a
full European Standard. � is was
approved, and TC 197/WG 3 has
prepared a Final Draft EN 16752
Centrifugal pumps- Test procedure
for seal packings, which is currently
going through the standardization
approval process and should see
� nal publication in 2015.
Power Consumption
While the � nal test procedure
produced good correlation of
results in terms of packing leakage,
temperature and post-test packing
condition, the one performance
aspect that continued to cause
debate was frictional level and
power consumption. � roughout
the round-robin test program
the results reported for frictional
torque or absorbed power showed
signi� cant variability, partly
because of the di� erent methods
used to measure it.
� is uncertainty about packing
friction is concerning, because the
generally accepted wisdom is that
packings are ine� cient in terms
of power consumption. But little
research has been conducted on
the more sophisticated products
currently available that use
exfoliated graphite, ePTFE, aramid
and other synthetic yarns and
modern lubricant systems.
To obtain de� nitive information
on packing friction, the joint
ESA/FSA Technical Task Force
commissioned CETIM to carry
out a follow-up project. It consists
of the design and manufacture of
a dedicated test rig to carry out
testing in accordance with the
procedure, including highly accurate
systems to directly measure the
frictional force of the packing alone.
Test Rig
� e test rig is designed to test
both compression packings
and mechanical seals so direct
comparison can be made under
the same conditions (see Image
1, page 98). A torque meter is
used to record the mechanical
seal or packing friction on the
shaft. Measurements of torque,
temperature and leakage levels are
Figure 2. Results from round-robin 5
pumpsandsystems.com | August 2015
97
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August 2015 | Pumps & Systems
98 SEALING SENSE
recorded, and the instrumentation
permits continuous monitoring of
all parameters throughout the test.
Initial Testing
After initial trials to validate
the equipment functionality and
accuracy of the monitoring devices,
the � rst tests were carried out on
the same graphite/ePTFE packing
that had been widely used during
the earlier test program.
Testing was conducted at
di� erent rotational speeds and
pressures, with varying target
leak rates. For direct comparison,
a typical unitized, single-spring
elastomer bellows mechanical seal
was also tested under a range of
conditions. It is an unbalanced
mechanical seal with carbon
graphite versus chromium oxide
seal faces.
� e measured torque is plotted
for di� erent water pressures, in
the case of the packing with the
associated shaft leak. During these
tests, the gland leak rate was of the
same order of magnitude as that of
the shaft.
� ese results were unexpected. � e
� gures for packing were much lower
than predicted and were of the same
order of magnitude as, and generally
lower than, the mechanical seal.
Of course, a degree of leakage must
be tolerated when using packings,
and the lubrication a� orded by
the leaking � uid will reduce the
friction. But even when the leak
rate is extremely low, as in the case
at 6 bar and 1500 rpm, the friction
recorded was the same as that for the
mechanical seal at a lower pressure.
Rigorous checks were carried out
to ensure the accuracy of the results.
In particular, the measurement
range of the torque meter was
revised to ensure accuracy at these
much lower torque levels, and it
was veri� ed that the torque levels
measured for mechanical seals
were generally in line with the
manufacturer’s published data.
Further Tests
A further series of tests was carried
out on two other packing types and
four mechanical seal variants. � e
packings were a lubricated natural
ramie � ber, which would normally
be used where higher leakage would
be acceptable, and a synthetic
aramid yarn packing.
� e mechanical seals were one
unbalanced and two balanced
component seals and a cartridge
balanced seal. � ey were chosen
to represent a cross section of
commonly used designs. � ese
featured carbon graphite versus
silicon carbide seal faces. � is face
combination is typically chosen for
its low coe� cient of friction. � e
designs had di� erent balance ratios,
and two had a composite narrow
seal face and the other two had a
monolithic narrow seal face.
All tests in this sequence were
carried out at 6 bar pressure. � e
comparative results are shown in
Figure 3.
Some of the results for the
mechanical seals were unexpected.
� e unbalanced mechanical seal
showed lower torque than the
balanced O-ring pusher seal.
� e di� erence can most likely
be explained by the fact that the
face pro� les are di� erent for the
composite seal face of the balanced
seal than the monolithic design of
the unbalanced seal.
Typical thermal de� ections are
di� erent for these variations in
design. � e composite faces tend to
have a divergent pro� le with outside
contact, while the monolithic
face tends to have a convergent
pro� le with good � uid penetration
between the faces. � e pressure
drop between the seal faces is
di� erent, leading to higher e� ective
hydraulic closing forces for the
outside contact than for the inside
contact. Di� erent spring loads for
the designs, which are di� cult to
set accurately in component seals,
would also have a signi� cant impact
on contact pressure.
� is illustrates two major
points. First, speci� c designs have
speci� c characteristics, and broad
classi� cations are not su� cient to
evaluate the power consumption
of one type of design. Second, the
pressure drop between the sealing
interface is critical in determining
the actual power consumption
of the sealing device. � is should
be considered with packing and
mechanical seals.
� e packing friction compares
favorably with all of the mechanical
seal variants. � ese unexpected
results have led to a reconsideration
of the traditional methods for
calculating packing friction.
Image 1. Friction test rig
pumpsandsystems.com | August 2015
99
� eoretical Considerations
� e formula that has long been used
to calculate power consumption
from compression packing systems is
as follows:
P= Pp x RPM x D x µ x Ap x F
Where
P = Power (HP or kilowatts,
depending on units used)
Pp = sealed pressure
RPM = rotational speed
D = shaft diameter
µ = coe� cient of friction
between the packing and
the shaft
Ap = packing contact area
F = factor, depending on
units used
� is formula is similar to the
one used for mechanical seals,
which has been shown to give
a good approximation to power
consumption levels.
Recognized approximations in
the packing formula are that it
does not take account of lubricant
levels, actual packing compression,
type of liquid sealed, viscosity or
temperature. But it can provide a
� gure for the amount of energy
consumed by the packing. It tends
to give power consumption levels
that are approximately 10 times
that of a balanced mechanical seal
used under the same conditions.
Test results show that the
approximations in the formula
are not su� cient to explain the
deviations from the calculated
values.
� e di� erences in calculated
results from the test measurements
reported here vary by factors from
25 to 100 times.
While more work is planned, the
conventional wisdom contained
assumptions that are not veri� ed
through the experiments. � us, the
use of sealed pressure as the contact
pressure for the packing along its
entire axial length must be revised.
A pressure drop coe� cient of 0.2
gives much better correlation of
calculated to testing results.
� e coe� cient of friction must
also be re-evaluated when current
advanced synthetic � ber materials
are used.
For example, a coe� cient of
friction value of 0.03 for ePTFE/
Graphite packing is more in
agreement with testing results than
the traditional value of 0.17. Other
variables must also be considered,
such as shaft speed and size as well
as leakage levels because they have a
direct impact on power consumption.
Further Work
Some further test work is planned
on other packing types. � e major
thrust of this work is to develop
a mathematical model that will
provide an accurate tool for the
calculation of packing power
consumption. A revised formula
will be � nalized once testing is
completed.
� e unquestioned switch from
compression packing to mechanical
seals to save energy in sealing
systems must be reconsidered.
Users must take many factors into
account when using one technology
versus the other, including periodic
maintenance, the availability of
trained maintenance personnel
and permissible leakage levels.
But frictional energy saving is not
as important as conventionally
viewed. � e choice of which
technology to use must encompass
all aspects of performance based on
real results rather than perception.
Acknowledgements
� e author would like to express his
appreciation to all of the ESA and
FSA member companies involved
in this project, in particular the
members of the joint ESA/FSA
Packings Technical Task Force and
David Edwin-Scott of the European
Sealing Association (UK), and Didier
Fribourg of the Technical Center
for Mechanical Industries – CETIM
(France).
Next Month: How to Achieve
Zero Emissions with Mechanical
Seals
We invite your suggestions for article topics as
well as questions on sealing issues so we can
better respond to the needs of the industry.
Please direct your suggestions and questions to
sealingsensequestions@� uidsealing.com.
Figure 3. Tests at 6 bar
August 2015 | Pumps & Systems
100 HI PUMP FAQS
What dynamic analysis
considerations are
recommended for the
petroleum market?
End users should evaluate
their need for dynamic analysis by
considering the level of proven
� eld experience available for
any given con� guration. � e
vendor and user should agree on
which types of analysis should be
performed at any level. Lateral,
torsional and structural analyses
are three identi� able and normally
separable deliverables.
In all cases, it is the user’s
prerogative to specify additional
tests, validations and/or analyses
to further mitigate risk.
Historically, dynamic analysis
trends have developed within
the various pump application
markets because of the types
and characteristics of equipment
typically used and as a result
of past experiences. In the oil
and gas industry, single-stage
overhung horizontal pumps and
between-bearings, one- and two-
stage pumps must be designed
to be classically rigid, which can
eliminate the need for lateral
dynamic analysis.
Multistage pumps identical to
pumps proven in-� eld are also
not subject to lateral analysis.
Vertically suspended pumps are
required to be designed with
established limits on bearing
spacing to ensure suitable lateral
rotodynamic performance.
Drive system con� guration and
power levels determine the need
for torsional dynamic analysis.
High-energy, high-speed,
critical-service and unspared
machines are subject to high
levels of customer intervention
and scrutiny, with the user having
varying de� nitions of these terms.
For more information on
dynamic analysis, refer to
ANSI/ HI 9.6.8: Rotodynamic
Pumps Guideline for Dynamics of
Pumping Machinery.
What piping installation
recommendations are
important to consider for
rotary pumps?
Because rotary pumps are
designed with close running
clearances, clean piping is a must.
Dirt, grit, weld bead or scale, later
� ushed from an unclean piping
system, will damage and may
seize the pump. Figure 3.4.3.11
illustrates pipe-to-pump
alignment considerations.
Piping should be installed on
supports independent of the
pump. Supports must be capable
of carrying the mass of the pipe,
insulation and the pumped � uid.
Supports may be hangers, which
carry the mass from above, or
stands, which carry the mass
from below.
Clamps or brackets may
be used to secure piping to existing
columns. Supports must allow free
movement of the piping caused by
thermal expansion or contraction.
Dynamic Analysis in the Petroleum Market & Piping Installation for Rotary Pumps By Hydraulic Institute
Figure 3.4.3.11. Pipe-to-pump alignment (Courtesy of Hydraulic Institute)
pumpsandsystems.com | August 2015
101
Supports should be installed at intervals that
uniformly and amply support the piping load,
precluding contact with piping and equipment.
Pipe strains or stresses transmitted to the pump
by improper piping support systems may cause
distortion, wear or binding of the rotary members
and excessive power requirements.
Piping systems that contain expansion joints must
be designed so the expansion joint is not exposed
to more motion than accounted for in its design.
Expansion joints or � exible connectors should not be
used to compensate for misaligned piping.
� readed joints should be coated with compounds
compatible with, but not soluble in, the pumped
liquid. End users working with Te� on-taped joints
should be careful to prevent shredded pieces of
Te� on from entering the piping system. Piping
should start at the pump and work toward the
source of supply and the point of discharge. Shuto�
valves and unions are recommended to facilitate
future inspection and repair. Reducers are preferred
to bushings when a change in pipe size is necessary.
Avoid unnecessary restrictions in the pipeline, such
as elbows, sharp bends, globe or angle valves, and
restricted-type plug valves.
Users should predetermine pipe size by taking
into account the required � ow rate; minimum
or maximum velocities; the � uid viscosity at the
lowest pumping temperature; the length of the
piping system, including valves, strainers and other
restrictions; and the elevation of the pump with
reference to supply and discharge points.
HI Pump FAQs® is produced by the Hydraulic Institute as a service to pump users, contractors, distributors, reps and OEMs. For more information, visit pumps.org.
Find more HI Pump FAQs online at
pumpsandsystems.com/
tags/hi-pump-faqs.
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U N M AT C H A B L E E X P E R I E N C EI N F L O W C O N T RO L
T R A N S A C T I O N S
MEMBER FINRA, SIPC
Jordan, Knauff & Company is a knowledgeable and experienced provider of a comprehensive line of investment banking services to the pump, valve and
Our lines of business include: selling companies, raising debt and equity capital, and assistance
To learn more about Jordan, Knauff & Company, contact any member of our Flow Control
Managing Principal Senior Associate
102 PRACTICE & OPERATIONS
For more than 100 years,
Wisconsin sand has been
prized for industrial
applications—including metal
casting, construction and
consumer products such as
iPods. Now, the sand has found
new applications in hydraulic
fracturing, or fracking. During
fracking, pumps open up deep rock
formations using a high-pressure
mixture of solutions such as sand
and water. � e sand opens the
rock, releasing oil and gas deposits
for extraction.
White Wisconsin sand works
well in hydraulic fracturing
applications. � e large grains
and round shape better open
� ssures, allowing more successful
extraction of fossil fuels.
In 2015, energy companies will
use more than 2.6 million tons of
sand in exploration & production
(E&P) activities. Demand for sand
has increased more than 40 percent
since 2011.
Challenges
A remote Wisconsin sand mine
experienced pump deterioration
from the abrasive sand. Because
of the harsh Midwest winters,
the mine only operates from
April 1 to � anksgiving. During
operating season, the plant is
scheduled to run 24 hours per day
to maximize production.
Initially, the plant used vertical
turbines on the wet side of the
process, where the sand was
washed, scrubbed of impurities
and sized. � e wash removes
metals and small particles of silica.
Afterward, the sand moves to the
dry side, where it dehydrates in
speci� c storage areas based on its
composition. � e sand is inspected
and tested after drying. Rail cars
transport the sand to frac sites for
mixing and injection.
� e process water is recycled,
reducing the plant’s costs and water
needs. While the process removes
the large particles for sale, the
� ne particles remain suspended
in the recycled water. Over time,
this microscopic slurry attacks
the bronze-� tted vertical turbine.
Particle accumulation around
the seal leads to failures, and the
residue eventually reduces pump
� ow. � e grit forces openings in the
rubber bushings, allowing water
to escape. Eventually, the turbine
shuts down, ceasing all operations.
Because of constant operation,
the turbines failed frequently
as � ne particles accumulated
quickly. � e sand mine incurred
major expenses from repairs and
lost productivity.
Patented Solutions
A pump distributor working
with the plant operator o� ered a
centrifugal pump with a specialized
mechanical sealing system, slurry-
resistant construction material and
superior solids-handling capability.
Unlike the seals in the vertical
turbine, the pump’s mechanical
sealing system uses vanes cast
into the impeller to wash away
� ne particles behind the impeller.
Specially angled de� ector vanes
on the dished backplate create
a cyclonic action, which pulls in
the particles. � e mechanical seal
system provides greater reliability
without the need for � ush water or
additional gauging systems.
� e pump has 10-inch suction
and 8-inch discharge and features a
Centrifugal Pump Saves Sand Mine More than $1.5 Million
The mechanical seal system, among other features, reduced downtime at the Wisconsin plant.
By Chris Dunn, Crisp Industries,
& Bill Schlittler, Cornell Pump Company
Image 1. This remote Wisconsin sand mine experienced pump deterioration from the abrasive sand. (Images courtesy of Cornell Pump Company)
August 2015 | Pumps & Systems
103
cast-iron impeller and volute. More
resilient than the bronze � ttings
on the turbine, the cast iron
helps the pump better withstand
the silica slurry. � e pumps also
include a 416 stainless shaft and
sleeve as well as deep groove
bearings rated for at least 50,000
hours. � e unit can handle heads
up to 360 feet, � ow rates up to
8,000 gallons per minute and solids
up to 3.38 inches in diameter.
Additional Features
� e pump also features a dry-
priming system with a vacuum
assist. If the pump loses prime,
the system engages the assisting
vacuum pump to draw sand into
the volute. When normal operation
resumes, the system disengages.
Unlike a venturi system, this
dry-priming method does not
materially a� ect e� ciency.
An oil reservoir can lubricate the
pump’s seal faces if it loses prime.
With the dry-priming vacuum,
the system protects the seal faces
from heat and cracking that could
occur without pumpage to lubricate
it. When the system reprimes,
the gland disengages. � e system
is self-contained and does not
spill over into the pump stream.
� e pump can run dry for hours
without damaging the seal faces.
� e new centrifugal pump was
more e� cient than the vertical
turbine—hitting the same design
and � ow speci� cations while
requiring less energy and saving
operation costs. � e motor for
the centrifugal pump is readily
available in nearby Milwaukee or
Minneapolis, while the motor for
the turbine required a signi� cantly
longer lead time to order.
Millions Saved
Since installation in March 2014,
the plant has run continuously.
With the previous turbines, the
plant would have experienced
at least 60 hours of downtime.
Processing more than 600 tons an
hour meant the plant would have
lost the opportunity to process
more than 36,000 additional tons
of sand in a year. With high-quality
hydraulic fracturing sand selling at
more than $50 a ton, the new
pump helped save more than a
$1.5 million dollars of downtime
losses in a year.
� e plant operator plans to
open several more locations in
2015, and because of the success
of this system, each facility will
be installed with 8- or 10-inch
versions of the new pump.
Bill Schlittler, PE, is mining
market manager at Cornell Pump
Company—a Clackamas, Oregon,
manufacturer of centrifugal pumps.
Schlittler has more than 30 years
of experience as a mining engineer,
specializing in slurry
applications. He may
be reached at 503-653-
0330 or bschlittler@
cornellpump.com.
Chris Dunn is general manager of
the Pipe and Pump Division of Crisp
Industries. With more than 20 years
of experience, Dunn has serviced
many mining and fracking sites and
is active in applications
across North
America. He may be
reached at cdunn@
crispindustries.com or
940-683-4070.
Images 2 and 3. Because of harsh Midwest winters, the mine only operates from April to November, when the plant is scheduled to run 24 hours per day. The constant operation requires reliable equipment with superior solids-handling capability.
pumpsandsystems.com | August 2015
August 2015 | Pumps & Systems
104 PRACTICE & OPERATIONS
While instrumentation
and monitoring
software are widely used
in manufacturing facilities around
the world, these tools alone will not
solve every production problem.
In addition to software and other
resources, the � eld workforce
plays a major role in the overall
e� ectiveness of a plant’s reliability
strategies.
� is is especially true in the
pump industry because pumps are
frequently located in remote or
di� cult-to-access locations. For this
reason, instrumentation and remote
monitoring software must be
combined with tools that empower
the � eld workforce to manage and
maintain systems reliably and
e� ciently. � is comprehensive
strategy can help � eld workers
increase their knowledge of system
processes and procedures, analyze
important equipment information,
and make well-informed decisions.
� e Importance of
Remote Monitoring
A comprehensive reliability strategy
is vital because two primary
elements make up nearly 80 percent
of the total cost of ownership (TCO)
of pumps: energy consumption
and maintenance activities (see
Figure 1). A variety of pumping
applications demonstrate that
remote monitoring of energy
consumption is critical to energy
optimization. In addition, remote
monitoring of the pumping
equipment can result in increased
uptime because of the ability to
prevent unexpected failures.
Because pumps represent more
than 50 percent of all energy
savings potential and consume
almost 25 percent of all motor
energy, energy savings is one
of the most clearly quanti� able
bene� ts of incorporating remote
monitoring into a facility’s
predictive maintenance strategy.
� e ability to monitor and adjust
system operation
to ensure
optimal energy
consumption is a
primary bene� t.
While data
collection through
remote monitoring
cannot improve
e� ciency on its
own, it is a critical
� rst step to closing
the loop around
process variables.
While remote
monitoring alone
cannot improve
e� ciency, as
part of a comprehensive reliability
strategy, it can help enhance
operational e� ciency in the long
run. For example, over time, pumps
may wear. � is degradation can
appear in the form of impeller wear,
pipe corrosion, reduced bearing
e� ciency and decreased system
e� ciencies, which may cause pumps
to operate well away from their
best e� ciency point (BEP). Remote
monitoring technology gathers data
that can indicate such changes in
operating conditions, allowing the
operator to adjust system speeds to
maintain BEP alignment. Figure 2
shows the impact of wear rings and
cavitation.
Figure 1. Typical pump life cycle cost profi le (Courtesy of Hydraulic Institute and Pump Systems Matter)
How Remote Monitoring Empowers Plant Employees
Modern monitoring software provides plants with the data they need to improve reliability while
empowering pump operators to make well-informed decisions.
First of Two Parts
By Jason Vick & Jack Creamer
Schneider Electric
pumpsandsystems.com | August 2015
105
Studies have shown that pump
maintenance accounts for 25
percent of a typical pump’s TCO.
All too often, end users discover
too late conditions that lead to
pump or motor breakdown or a
serious catastrophe that damages
equipment, cripples operations and
impacts employee safety.
Improving Predictive
Maintenance
Predictive maintenance can be
custom-designed for a user’s
speci� c system, built from regular
observation and recordkeeping
that can reveal trends and uncover
anomalies. When equipment is
commissioned, a facility may
create a pump health log to use as
a baseline for alarms and required
maintenance triggers during the
lifetime of the system. End users
can leverage this historical data
to take future actions to optimize
their operational e� ciency.
With minimal investment using
standard features built into a
variable frequency drive (VFD) or
other smart motor control system,
users can greatly expand reliability
and reduce operational costs. For
reference, users should remember
that pump equipment purchase
prices are estimated to account
for only 10 percent of the overall
lifetime expense of the system.
Monitoring Stranded Assets
Stranded assets, or assets that
are not instrumented or only
partially instrumented, are found
in industries such as re� ning,
upstream and midstream oil and
gas, petrochemical, metals and
mining, power generation and
distribution, water and wastewater,
pulp and paper, and discrete
manufacturing. In some cases,
stranded assets can make up as
much as 40 to 60 percent of a plant’s
total asset count. Because these
assets are not constantly monitored
electronically, � eld personnel must
monitor the equipment to ensure
that it remains safe and reliable.
In addition to stranded assets, a
host of regulations require that
personnel � ll out forms that ensure
compliance with such rules.
Many companies rely on
paper-based or experience-based
monitoring of stranded assets
and compliance activities. But
others have adopted advanced
mobile decision support software
applications that allow them to
collect, report and analyze non-
instrumented data.
Every option for remote
monitoring of stranded assets has
pros and cons. For every option,
however, users must decide how to
combine remote monitoring with
human interaction. For example,
when paper and experience are
relied on as the preferred methods
for monitoring stranded assets, � eld
workers often lack the situational
awareness to make well-informed
decisions. Di� erences in experience
level, miscommunication, training
de� ciencies or employee ownership
may result in poorly made decisions
that can lead to premature
equipment failures, unit shutdowns
or even worse—personal injury.
By contrast, when companies
adopt advanced mobile decision
support applications running on
mobile computers, they are able to
achieve the following:
• Positive asset/location
identi� cation
• Remote access to standard
procedures
• Heightened situational
awareness
• Advanced scheduling
• Visibility to non-instrumented
data
Positive asset and location
identi� cation are a key aspect
of remote monitoring. By using
mobile devices equipped with
barcode readers, radio frequency
identi� cation (RFID) readers, QBR
coding or global positioning systems
(GPS), mobile users can properly
identify an asset and access the
correct set of tasks they need to
complete for that asset. � e use of
positive asset identi� cation also
provides an audit trail if needed.
Jason Vick is the mobility
technical sales consultants
manager at Schneider Electric
where he is responsible for
providing mobile workforce
enablement technical
guidance and
best practices to
customers in many
vertical markets.
Jack Creamer is the segment
manager of the pumping equipment
sector for Schneider Electric—
Square D and an active member of
the Pumps & Systems
Editorial Advisory
Board. He may be
reached at jack.
creamer@schneider-
electric.com.
Figure 2. The impact of wear rings and cavitation (Courtesy of Schneider Electric)
106 PRODUCTS
To have a product considered for our Products page, please send the information to Amy Cash, acash@cahabamedia.com.
Solids Measurement
Colonial Seal Company, a New Jersey-based specialty distributor of standard and custom sealing solutions, announces a range
of new design or replacement mechanical seals. � is includes elastomeric bellows seals, conical spring O-ring mounted seals, parallel spring diaphragms, balanced diaphragm seals, parallel spring O-ring mounted seals, wave spring type seals and water pump type seals. Circle 206 on card or visit psfreeinfo.com.
Mechanical Seals
Ashcroft Inc. announces the new G3 pressure transducer, which o� ers 316L stainless steel wetted material and absolute pressure measurement to ful� ll unique OEM sensor requirements. Available in ranges from 0/5 through 0/300 psi and vacuum, the application-friendly G3 is enhanced by a broad choice of pressure and electrical
connections and outputs. � is compact transducer is constructed to stand up to shock and vibration while providing stable pressure readings over an extended life. Circle 205 on card or visit psfreeinfo.com.
Compact Pressure Transducer
SPM Instrument, Sweden, announces the DuoTech, a multi-purpose accelerometer for vibration and shock pulse measurement. In the DuoTech accelerometer, two of the most widely used and
successful methods for monitoring mechanical condition come together: vibration and shock pulse measurement. � e combination of the patented HD enveloping and SPM HD measuring techniques provides maximum � exibility, enabling superior lubrication and bearing monitoring—covering the entire bearing deterioration process.Circle 204 on card or visit psfreeinfo.com.
Multi-Purpose Accelerometer
ClearView Filtration’s patented � lter assemblies allow visual inspection of the � uid being � ltered, the � lter element and the particles � ltered out of the � uid system. � is is done in seconds without draining, leaking or the loss of � uid and without unbolting or loosening any fasteners or � ttings—even when � ltering
non-transparent � uids. ClearView Filtration helps determine if particles are from normal use or engine or � uid system components excessively wearing. Circle 203 on card or visit psfreeinfo.com.
Oil & Fluid Filter Assemblies
Zoeller Pump Company announced the � rst 1/2 horsepower (HP) grinder pump, the Shark Model 800. � is unit targets the problematic residential 1/2 horsepower sewage ejector market, which is plagued by the infamous wipes. It uses the latest design in cutter and plate technology coupled with a powerful 3,500 rpm, oil-� lled
motor. � e success of the Model 800 prompted Zoeller Pump Company to develop the next generation of grinder pumps to cover a broader range of applications. � e 803-805-807 family of cast-iron, automatic and non-automatic grinder pumps are available in 1/2 HP (803), 3/4 HP (805), and 1 HP (807). Circle 202 on card or visit psfreeinfo.com.
Grinder Pump
SEEPEX introduces Smart Conveying Technology (SCT), the innovative technology for progressive cavity pumps.
In addition to the one-stage design for pressures up to 4 bar (60 psi), SCT is now available in a two-stage design for pressures up to 8 bar (120 psi). SCT is a customized solution that is e� cient, economical and environmentally friendly. SCT delivers enhanced pump performance with a longer component service life and easy maintenance, reducing maintenance time by up to 85 percent. Circle 201 on card or visit psfreeinfo.com.
Progressive Cavity Pumps
August 2015 | Pumps & Systems
107
Advert isersFREE PRODUCT INFORMATION Visit www.psfreeinfo.com to request more information from these advertisers.
Advanced Engineered Pump, Inc. 111 169
Advanced Technical Staing Solutions, Inc. 111 168
AIGI Environmental Inc. 31 122
Amtech Drives 65 118
Automationdirect.com 19 101
Badger Meter Inc. 21 102
Bal Seal Engineering Inc. 108 170
Basetek, LLC. 108 192
BJM Pumps 55 152
Blue White Industries 9 119
Boerger LLC 56 123
CD-Adapco 88 153
Colfax Corporation 7 103
Conhagen, Inc. 71 124
Continental Pump Company 108 171
Cornell Pump Company 11 120
Crane Pumps & Systems 45 104
Dan Bolen & Associates, LLC. 111 172
Dickow Pump Company 89 125
DiscFlo 3 105
Dura Bar 5 106
Engineered Software Inc. 73 126
EnviroPump and Seal Inc. 82 163
FLSmidth 55 154
Franklin Electric 59 127
Frost & Sullivan 82 164
GE Intelligent Platforms 90-91 128
Gorman-Rupp Company 17 107
GPM, Inc. 47 129
Graphite Metallizing Corp. 39 130
Hoosier Pattern, Inc. 46 150
Hydraulic Institute 79 165
Hydro, Inc. IFC 100
Jordan, Knauf & Company 101 166
KSB, Inc. 50 151
KTR Corporation 53 155
Load Controls, Inc. 62 131
Load Controls, Inc. 108 174
LobePro 109 173
LUDECA, Inc. 63 132
Magnatex Pumps, Inc. 77 161
Master Bond Inc. 108 175
Meltric Corporation 108 176
Milton Roy 49 121
Nachi America, Inc. 32 133
National Pump Company 24 134
NETZSCH Group 109 177
NOC 109 178
NSK 36 135
Pemo Pumps 15 147
Pinnacle-Flo, Inc. 94 156
PPC Mechanical Seals 28 136
Pump and TurboMachinery Symposia 81 108
PSG, a Dover company 87 157
Pumpworks 610 75 137
R+W America L.P. 41 138
Raven Lining Systems 16 139
Ruthman Companies 37 109
Scenic Precise Element, Inc. 109 179
Schaeler Group USA Inc. 29 110
Schenck Trebel Corp. 66 149
Schneider Electric 57 116
SEPCO 44 140
SEPCO 110 180
Siemens Industry BC 111
Sims Pump Co. 109 188
Sims Pump Co. 110 193
Sims Pump Co. 97 117
SKF 80 158
Skinner Power Systems, LLC 12 141
St. Marys Foundry 109 181
Stein Seal 76 162
Stein Seal 107 190
Summit Industrial Products 70 142
Summit Pump, Inc. 110 182
Teikoku USA, Inc. 69 148
TF Seals 33 143
Titan Flow Control, Inc. 79 191
Titan Manufacturing, Inc. 64 159
Titan Manufacturing, Inc. 110 183
Trachte, USA 111 184
Tuf-Lok International 111 185
Tuthill Transfer Systems 51 144
Vaughan IBC 112
Vertilo Pump Company 110 186
Vesco 110 187
Waukesha Bearings 74 145
WEFTEC 83 113
WEG Electric Corp. 13 114
WEG Electric Corp. 93 160
Westerberg and Associates 101 167
WPI 111 189
Yaskawa America Inc 25 115
Zoeller Pump Company 23 146
he Index of Advertisers is furnished as a courtesy, and no responsibility is assumed for incorrect information.
Advertiser Name Page RS# Advertiser Name Page RS# Advertiser Name Page RS#
pumpsandsystems.com | August 2015
Circle 190 on card or visit psfreeinfo.com.
August 2015 | Pumps & Systems
108 PUMP USERS MARKETPLACE
Less downtime.
Longer seal life.
More predictability.
The Bal Seal® spring-energized seal
for critical upstream and downstream
applications.
800.366.1006 www.balseal.com
meltric.com800.433.7642
6" Connector + Switch in 1 device
6" Maximizes Arc Flash Protection
6" Minimizes PPE Requirements
MOTOR PLUGSQUICKLY CONNECT
& DISCONNECT POWER
Safety Shutter(on receptacle)
OFF Button
ce
e)
Rated up to 200A, 75hp
S
www.masterbond.com
Hackensack, NJ 07601 USA+1.201.343.8983
main@masterbond.com
Technologically Advanced Epoxies
One and Two Component Systems Feature:
corrosion
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MONITOR PUMP PERFORMANCE
•FlowRate
•PumPCondition
•dRyRunning
•Cavitation
•BeaRingFailuRe
univeRsalPoweRCell•OneSizeAdjustsfor
AllMotors,FromSmallupto150HP
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•10timesmoresensitivethanjustsensingamps
•4-20Milliamp,0-10Volt
CallnowFoRyouRFRee30-daytRail
888-600-3247
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COMPARED TO STEEL, THEY’RE FLAT OUT THE BEST!RE FLAT OUT THE BEST!
POLYMER BASEPLATES
CALL TODAY!
877-712-BASE (2273)
WWW.BASETEK.COM
pumpsandsystems.com | August 2015
109
GO WITH THE PROS!! LOBEPRO ROTARY PUMPS
912-466-0304 www.LOBEPRO.com Made in USATo learn more or get a custom quote, email PumpSales@lobepro.com
Important Properties of
LobePro Rotary Lobe PumpsLow shearMeasured FlowSelf priming to 25’ wetDischarge pressure to 175 psi (12 bar)
Capacities 0- 2, 656 GPM (0-604 m³/hr)Low pulsationSpace-saving, compact design
Circle 181 on card or visit psfreeinfo.com.
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NEMO® Progressing Cavity Pumps
For your toughest pumping problems!
NETZSCH Pumps North America, LLC 1-610-363-8010
PUMPS@netzsch.comwww.netzsch.com
Smooth operation, low pulsation, steady flow in direct proportion to speed Low to high solids content, abrasive material, shear sensitive Pressures: To 1080 psi; special designs to 3400 psi Capacities: A few gph up to 2,200 gpm Viscosity: 1 mPas up to 3 million mPas Temperatures: 5˚ F to 570˚ F Maintenance friendly, low life-cycle cost
ask about
August 2015 | Pumps & Systems
110 PUMP USERS MARKETPLACE
Your Best Value in ANSI Centrifugal Pumps
Model 2196
Green Bay, WIwww.SUMMITPUMP.com
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Solvedry start
problems withVesconite Hilube
bushings� Increase MTBR� No swell� Low friction = reduced
electricity costs� Quick supply.
No quantity too small
Tollfree 1-866-635-7596vesconite@vesconite.com
www.vesconite.com
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pumpsandsystems.com | August 2015
111
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“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
9741 North 90th Place, Suite 200
Scottsdale, Arizona 85258-5065
(480) 767-9000 • Fax (480) 767-0100
Email: dan@danbolenassoc.com
www.danbolenassoc.com
EXECUTIVE SEARCH/RECRUITING
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www.tuflok.com
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DISTS& REPS Wanted USA
Full Line Pump MFGS
Sundyne Type Drop In - ANSI 3196
API, Nuclear, VT, Cryogenic, MG, Split Case and Other Pumps lines for all Industries
Email info to
CRTTP@comcast.net713.871.1063www.deepbluepumps.com
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August 2015 | Pumps & Systems
112 PUMP MARKET ANALYSIS
By Jordan, Knauff & Company
Wall Street Pump & Valve Industry Watch
These materials were prepared for informational purposes from sources that are believed to be reliable but which could change without notice. Jordan, Knauff & Company and Pumps & Systems shall not in any way be liable for claims relating to these materials and makes no warranties, express or implied, or representations as to their accuracy or com-pleteness or for errors or omissions contained herein. This information is not intended to be construed as tax, legal or investment advice. These materials do not constitute an offer to buy or sell any financial security or participate in any investment offering or deployment of capital.
The Jordan, Knauf & Company (JKC) Valve Stock Index was down 21.5 percent
over the last 12 months, while the broader S&P 500 Index was up 4.5 percent. he JKC Pump Stock Index also decreased 22.4 percent for the same time period.1
he Institute for Supply Management’s Purchasing Managers’ Index (PMI) rose to 53.5 percent for the month of June compared with 52.8 percent in May. he Employment Index rose 3.8 percent to 55.5 percent for the month, while the New Orders Index grew to 56 percent from 55.8 percent in May. he overall PMI has averaged 52.6 percent through the irst half of the year, less than the average of 56.9 percent seen in the second half of 2014. he Production Index averaged 61.6 percent in the second half of last year while averaging only 54.8 percent during the irst quarter of this year.
he Bureau of Labor Statistics reported that nonfarm payroll employment rose by 223,000 in June, and the unemployment rate decreased to 5.3 percent. Job gains occurred in professional and business services, healthcare, retail trade, inancial activities, and transportation and warehousing. he manufacturing sector grew by 4,000 jobs, compared with
an increase of 64,000 in professional and business services. In the irst half of the year, manufacturing has added an average of just over 6,000 workers per month. Nonfarm employment increases averaged more than 250,000 per month for the past 16 months and surpassed 200,000 in 14 of the past 16 months.
he Census Bureau reported that total construction spending rose 0.8 percent in May while rising 5.9 percent during the irst ive months of the year. It is up 8.2 percent over 2014. New home sales activity was at its highest level in seven years in May. Private nonresidential construction increased 1.5 percent during the month and is up 12.7 percent year over year.
As of last year, only four countries were producing commercial volumes of either crude oil from tight formations or natural gas from shale formations according to the U.S. Energy Information Administration and Advanced Resources International Inc. Along with the U.S. and Canada, Argentina and China have recently begun production of this type. Other countries that have started to explore shale and tight oil but are still short of reaching
commercial production include Mexico, Poland, Algeria, Australia, Colombia and Russia.
On Wall Street, all indices were down for the month of June. he Dow Jones Industrial Average lost 2.2 percent, the S&P 500 Index was down 2.1 percent, and the NASDAQ Composite declined 1.6 percent. For the second quarter of the year, the Dow declined 0.2 percent and the S&P 500 lost 0.9 percent, while the NASDAQ gained 1.8 percent. Concerns about Greece’s bailout program and referendum on whether to accept terms demanded by its creditors afected investors. Despite a rise in consumer spending, upbeat housing data and encouraging retail sales, the Federal Reserve Bank indicated it will increase interest rates at a slower pace than it expected earlier this year.
Jordan, Knauf
& Company is an
investment bank
based in Chicago,
Illinois, that
provides merger and
acquisition advisory
services to the
pump, valve and
iltration industries.
Please visit
jordanknauf.com for
more information.
Jordan Knauf &
Company is a member
of FINRA.
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.
Figure 1. Stock indices from July 1, 2014, to June 30, 2015
Source: U.S. Energy Information Administration and Baker Hughes Inc. Source: Institute for Supply Management Manufacturing Report on Business® and U.S. Census Bureau
Reference
1. he S&P Return
igures are provided
by Capital IQ.
Figure 3. U.S. PMI and manufacturing shipmentsFigure 2. U.S. energy consumption and rig counts
Vaughan’s Rotamix System sets the standard for hydraulic mixing, providing the customer with
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Circle 112 on card or visit psfreeinfo.com.
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The more flexible you are, the faster
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The newest addition to the SINAMICS
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The SINAMICS GH150 drive is built to
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The control cabinet can be placed up
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The control cabinet can even be
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The SINAMICS GH150 comes with an
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Circle 111 on card or visit psfreeinfo.com.
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