june 2015
DESCRIPTION
June 2015.pdfTRANSCRIPT
-
SYSTEMSThe Leading Magazine for Pump Users Worldwide
SYSTEMS
JUNE 2015
PUMPSANDSYSTEMS.COM
Trade Show
Preview
ACHEMA & EASA
2 Simple Steps to
Choosing the Right Motor
PLUS: Prevent System Failures In CHEMICAL PUMPING Applications
-
""""
""""""""""""""""
Gzgewvkxg"uwooct{"Gpgti{"equvu"jcxg"dgeqog"cp"kpetgcukpi"eqpvtkdwvqt"vq"rworkpi"u{uvgou"Vqvcn"Equv"qh"Qypgtujkr"*VEQ+0"Kp"hcev."gpgti{"equv"tgrtgugpvu"62'"qh"vjg"VEQ"qh"c"v{rkecn"rwor0"Kv"ku"rquukdng"vq"tgfweg"vjg"gngevtkecn"eqpuworvkqp"d{"cv"ngcuv"52'"wvknkkpi"Xctkcdng"Urggf"Ftkxgu"yjkng"fgetgcukpi"ockpvgpcpeg"equvu"cuuqekcvgf"ykvj"vjg"ogejcpkecn"ftkxgp"u{uvgo0"Vjku"rcrgt"gzrnckpu"jqy"vq"tgfweg"VEQ"ykvj"c"nkokvgf"kpxguvogpv"hqewugf"qp"vjtgg"mg{"ctgcu
-
Circle 111 on card or visit psfreeinfo.com.
-
June 2015 | Pumps & Systems
2
From the EditorAs you know, Pumps & Systems is the only trade publication that covers motors and drives in every issue. is
month, we head to San Antonio for the
largest motor-related trade show of the
year, the Electrical Apparatus Service
Association (EASA) Convention &
Exposition.
We recently reported (March 2015)
about how to prepare for the new
Department of Energy Electric Motor
Effi ciency Rule, which takes eff ect in
June 2016. is will certainly be a topic
of conversation at this years EASA event.
Drop by Booth 262 at EASA to visit the Pumps & Systems team.
Original equipment manufacturers and end users should contact their motor suppliers
and prepare a plan to convert their motors to premium effi cient designs if they are not
already being used. e performance of more effi cient motors may be slightly diff erent
because they have less slip and operate at a higher speed. Impeller designs may need
trimming to prevent overloading the motor from increased fl ow. We will continue to
bring you information, and you can also access it quickly at pumpsandsystems.com.
Be sure and see our cover series on motors and drives in this issue, beginning on page
54, which features two simple steps to choosing the right motor.
is month, Pumps & Systems also attends the largest chemical trade show in the
world. ACHEMA is the premier world forum for chemical engineering and processing
and takes place every three years in Frankfurt, Germany. More than 160,000 visitors
from 111 countries attended the show in 2012, and 3,800 exhibitors are expected to
showcase their products and services this year. We hope to see you there!
e challenge for manufacturers and users of many dangerous chemicals is to
construct, handle and transfer them in a way that eliminates any chance for their release
into the atmosphere. Some of the solutions are addressed in this months Effi ciency
Matters (page 84). You can also read about how sealless pumps with magnetic couplings
are helping to solve chemical processing challenges (page 88).
Best regards,
EDITORIAL
EDITOR-IN-CHIEF: Michelle [email protected] 205-314-8279
MANAGING EDITOR: Savanna [email protected] 205-278-2839
MANAGING EDITOR: Amelia Messamore [email protected] 205-314-8264
MANAGING EDITOR: Michael Lambert [email protected] 205-314-8274
ASSOCIATE EDITOR: Amy [email protected] 205-278-2826
SENIOR EDITOR, PUMPS DIVISION: Alecia [email protected] 205-314-3878
CONTRIBUTING EDITORS: Laurel Donoho, Lev Nelik, Ray Hardee, Jim Elsey
CREATIVE SERVICES
SENIOR ART DIRECTOR: Greg Ragsdale
ART DIRECTORS: Jaime DeArman, Melanie Magee
WEB DEVELOPER: Greg Caudle
PRINT ADVERTISING TRAFFIC: Lisa [email protected] 205-212-9402
CIRCULATION
AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay [email protected] 205-278-2840
ADVERTISING
NATIONAL SALES MANAGER: Derrell Moody [email protected] 205-345-0784
ACCOUNT EXECUTIVES:
Mary-Kathryn [email protected] 205-345-6036
Mark [email protected] 205-345-6414
Addison [email protected] 205-561-2603
Garrick [email protected] 205-212-9406
EUROPE-MIDDLE EAST: Maik [email protected] +1 205-567-1547+49 170 58299 59
MARKETING ASSOCIATES:
Ashley Morris [email protected] 205-561-2600
Sonya [email protected] 205-314-8276
PUBLISHER: Walter B. Evans Jr.VP OF SALES: Greg Meineke
VP, EDITOR-IN-CHIEF PUMPS DIVISION: Michelle Segrest
CREATIVE DIRECTOR: Terri J. Gray
CONTROLLER: Brandon Whittmore
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 5.
The Pumps & Systems and Upstream Pumping teams visiting the team from Accudyne at OTC in Houston
Pumps & Systems is a member of the following organizations:
Editor, Michelle Segrest
-
Vaughans Rotamix System sets the standard for hydraulic mixing, providing the customer with
lower operating and maintenance costs, more efficient breakdown of solids and Vaughans
UNMATCHED RELIABILITY. Its perfect for digesters, sludge storage tanks, equalization basins
and other process or suspension type mixing applications.
- Over 1000 installations worldwide
- Optimizes solids contact with its unique dual rotational zone mixing pattern
- 10 Year Nozzle warranty
See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP
Circle 110 on card or visit psfreeinfo.com.
-
4
June 2015 | Pumps & Systems
This issue 54 2 SIMPLE STEPS TO CHOOSING THE
RIGHT MOTOR By Mike Stockman, Franklin Electric
Consider more than the e ciency rating to select the most cost-e ective system for the pumping application.
58 HOW TO PREVENT THE MOST FREQUENT CAUSES OF MOTOR FAILURE Last of Two Parts By Rob Amstutz, GE Power Conversion
Protecting these two components can lead to longer equipment life.
62 STAINLESS STEEL IDEAL FOR EQUIPMENT IN SANITARY ENVIRONMENTSBy David Steen, Baldor Electric Company
is motor material provides an improved total cost of ownership for the food and beverage industry.
64 BEARING PROTECTION FOR VFD-DRIVEN, EXPLOSION-PROOF
MOTORS IMPROVES RELIABILITYBy Rick Munz & Adam Willwerth,
Marathon Electric Motors
In plants that process combustible materials, these motors avoid electrical bearing damage often caused by energy-saving inverters.
68 DOC ENGINE TECHNOLOGY PROVIDES COST-EFFECTIVE TIER 4 COMPLIANCE By Anne Chalmers, Pioneer Pump
Pumping packages that use a diesel oxidation catalyst can minimize cost, maintenance and equipment downtime.
70 ENERGY-EFFICIENT MOTORS CURB ENVIRONMENTAL CRISISBy Zi Ning Chong, Frost & Sullivan
e Chinese government is promoting greater automation and optimization of processes to improve the energy utilization rate.
JUNEVolume 23 Number 6
COVERS E R I E S
PUMPING PRESCRIPTIONS
14 By Lev Nelik, Ph.D., P.E. Pumping Machinery, LLC
Handling Power Plant Transients
PUMP SYSTEM IMPROVEMENT
18 By Ray Hardee Engineered Software, Inc.
Understand How Valves & Fittings A ect Head Loss
Last of Two Parts
COMMON PUMPING MISTAKES
22 By Jim Elsey Summit Pump Company, Inc.
What You Need to Know About Bearing Oil
Last of Two Parts
GUEST COLUMN
32 By Heinz P. Bloch, P.E.
How Oil Viscosity & Temperature In uence Bearing Function
First of Two Parts
2 FROM THE EDITOR
8 NEWS
91 PRODUCTS
92 PUMP USERS MARKETPLACE
96 PUMP MARKET ANALYSIS
MOTORS & DRIVES
SPECIALS P E C I A LS E C T I O N
CHEMICAL PUMPS & EQUIPMENT
84 SOLID-BODY AODD PUMPS WITHSTAND & CONTAIN DANGEROUS CHEMICALS EFFICIENCY MATTERS
By Peter Schten, Almatec
is equipment avoids the risk of leaks and pipe damage associated with injection mold pumps.
88 STOP SEAL FAILURES IN CHEMICAL APPLICATIONS By James Gross, Dickow Pump Company
Sealless pumps improve reliability and safety when pumping hazardous uids.
54
64
88
COLUMNS
73 TRADE SHOW ELECTRICAL APPARATUS SERVICE ASSOCIATION CONVENTION
90 TRADE SHOW ACHEMA
-
VR Series vertical multi-stage pumps are now available in 3, 5, 9, 15, 20, 30, 45, 65,
and 95 m3/h options with all 316 stainless steel hydraulics for superior durability,
eciency, and performance. The rugged components ensure long operating life in
the toughest applications: water supply and pressure boosting; heating, ventilation
and air conditioning; light industry; water treatment; irrigation and agriculture.
Experience Innovation. Experience Franklin.
franklinwater.com
EXPANDING YOURPUMPINGCAPABILITIES
Circle 108 on card or visit psfreeinfo.com.
-
6
June 2015 | Pumps & Systems
SPECIALS P E C I A LS E C T I O N
JUNEThis 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
MIKE PEMBERTON, Manager, ITT Performance Services
SCOTT SORENSEN, Oil & Gas Automation Consultant & Market Developer, Siemens Industry Sector
ADAM STOLBERG, Executive Director, Submersible Wastewater Pump Association (SWPA)
JERRY TURNER, Founder/Senior Advisor, Pioneer Pump
KIRK WILSON, President, Services & Solutions, Flowserve Corporation
JAMES WONG, Associate Product Manager Bearing Isolator, Garlock Sealing Technologies
EDITORIAL ADVISORY BOARD
INSTRUMENTATION, CONTROLS & MONITORING
DEPARTMENTS
74 MAINTENANCE MINDERSMonitoring Software Enables Scheduled Maintenance at Oil & Gas Facilities
By Cynthia Stone
GE Intelligent Platforms
76 MOTORS & DRIVESMotor Automation Can Help Solve Industry Labor Shortage
By William C. Livioti
WEG
78 SEALING SENSENew FSA/ESA Gasket Handbook O ers Guidance for Equipment Usage & Troubleshooting
By Mike Shorts
FSA Member
82 HI PUMP FAQSCorrosion Prevention, Rotodynamic Pump Speed & How Harmonics A ect VFDs
By Hydraulic Institute
42 PROTECT PUMPS WITH ONE ESSENTIAL TOOL
By Craig McIntyre, Endress+Hauser
Pump sensors can improve system operation and detect dangerous faults.
47 ELIMINATE CABLING COSTS THROUGH PROPRIETARY WIRELESS NETWORKING
By Dave Eifert & Benjamin Fiene, Phoenix Contact
A German municipal water utility optimized pressure booster stations with automated modules.
36 NEW HI DOCUMENT PROVIDES GUIDANCE ON DYNAMIC ANALYSIS OF ROTODYNAMIC PUMPS
By J. Claxton, P.E., Patterson Pump Company, a Gorman-Rupp company
is 10-year project concluded with the recent publication of recommended guidelines for pump professionals.
INDUSTRY UPDATESPECIAL REPORT
-
Circle 109 on card or visit psfreeinfo.com.
-
8 NEWS
June 2015 | Pumps & Systems
NEW HIRES, PROMOTIONS & RECOGNITIONSTONY SWENDSRUD, PSG
OAKBROOK TERRACE, Ill. (April 23, 2015) PSG, a Dover company, announced that Tony Swendsrud has joined the company as its new chief financial officer. In this role, Swendsrud will be responsible for all facets of PSGs financial functions and will report directly to PSG President Karl Buscher. Swendsrud joins PSG from the Honeywell Corporation, where he held the position of CFO Analytics Americas. Swendsrud holds a bachelors degree in accounting from St. Cloud State University in St. Cloud, Minnesota. He is also a certified public accountant. He will be based in PSGs headquarters office in Oakbrook Terrace, Illinois. psgdover.com
HASAN AVCI, GRUNDFOS
SINGAPORE (April 23, 2015) Pump manufacturer Grundfos has recently appointed Hasan Avci to head its Strategy, Commercial Excellence and Marketing functions in the Asia Pacific region. Avci has been with Grundfos since 2003. Before his posting to Grundfos Asia Pacific headquarters in Singapore, Avci was the director of sales and marketing for Turkey and the Middle East region. In his new role, Avcis main responsibility will be to formulate organizational strategies for performance improvements across the region. He will also implement commercial processes, undertake strategic corporate planning, evaluate new business opportunities and spearhead initiatives to promote business growth. grundfos.com
MICHAEL RICHART, ESE, INC.
MARSHFIELD, Wis. (April 21, 2015) ESE, Inc., has named Michael Richart as the companys director of business operations. Richart brings more than 20 years of experience as a versatile strategic executive. Richart will lead the sales and business operations areas of ESE. Throughout his career, Richart has helped companies succeed by optimizing the intersection of data, people, process and technology. Richart received his Bachelor of Sciences degree in industrial engineering from Purdue University and his MBA from the University of Wisconsin Oshkosh. ese1.com
PAUL COOKE, BOSCH REXROTH
CORPORATION U.S.
CHARLOTTE, N.C. (April 20, 2015) Effective July 1, Paul Cooke has been appointed regional president Americas and president & CEO of Bosch Rexroth Corporation U.S. Cooke will continue as senior vice president sales within the Business Unit Industrial Applications at the headquarters in Lohr, Germany, until the end of June 2015. Cooke has more than 30 years of experience in both industrial technology and general management. He received his
Bachelor with Honors Degree in mechanical engineering from The University of Newcastle in Tyne, England. Berend Bracht, current regional president Americas and president & CEO of Bosch Rexroth Corporation U.S., is resigning from the organization for personal reasons.
JIM LAURIA, MAZZEI INJECTOR
COMPANY, LLC
BAKERSFIELD, Calif. (April 9, 2015) Mazzei Injector Company, LLC, has appointed Jim Lauria as vice president of sales and marketing. Lauria has been a leader in water and wastewater for more than 15 years and has had articles published in prominent water industry publications worldwide. Lauria holds a Bachelor of Chemical Engineering degree from Manhattan College. Lauria will be replacing Paul Overbeck who is retiring. mazzei.net
PHIL CARLIN & MICHAEL SAVIGNAC, OPW
HAMILTON, Ohio, & HODGKINS, Ill. (April 2, 2015) OPW, a Dover company, announced that, as part of its growth strategy and One OPW initiative, it has consolidated its OPW KPS, OPW Fibrelite and OPW Fluid Transfer Group Europe management teams to create a single business unit, named OPW EMEA. Phil Carlin has been appointed managing director of the new business unit and will report directly to OPW President David Crouse. Carlin joined OPW in 2000 and has held multiple positions with the company, including several senior executive positions. He will be based out of OPW EMEA headquarters in Kungsr, Sweden. In addition, Michael Savignac joined OPW as vice president and general manager for the OPW Electronic Systems business unit, succeeding Carlin. Savignac will provide leadership and overall management of the Electronic Systems business unit, which OPW formed in April 2014. Savignac will be based at the OPW facility in Hodgkins, Illinois, and will report to Crouse.
To have a news item considered, please send the information to Amelia
Messamore, [email protected].
Hasan Avci
Michael Richart
Jim Lauria
ACOEM Group acquired VibrAlign, Inc. April 30, 2015 ERIKS Seals and Plastics acquired Seals and Packings, Inc. April 21, 2015 Lewis-Goetz acquired Action Industrial Group April 9, 2015
MERGERS & ACQUISITIONS
Paul Cooke
Michael Savignac
-
9pumpsandsystems.com | June 2015Circle 118 on card or visit psfreeinfo.com.
-
10 NEWS
June 2015 | Pumps & Systems
Danfoss Recognized for Impact on Technology, Jobs & Local Partnerships NORDBORG, Denmark (April 24, 2015) During a press conference on April 22, The Economic Development Council of Tallahassee/Leon County announced Danfoss as its featured business for the month of April as part of its Made in Tallahassee: Produced Regionally, Sold Globally initiative. The program is planned as a public awareness campaign that focuses on the important role that the research and development, manufacturing, software development and technology industries play in the success of the local economy. danfoss.com
WERF & WEF Launch Projects to Further Water Sector Innovation ALEXANDRIA, Va. (April 22, 2015) The Water Environment Research Foundation (WERF) and the Water Environment Federation (WEF) are launching three new projects under the Leaders Innovation Forum for Technology (LIFT) program, a joint WERF/WEF initiative designed to promote innovation in the water sector.
The first project, Genifuel Hydrothermal Processing Bench Scale Technology Evaluation (LIFT6T14), will evaluate a new biosolids to energy technology. The project is funded by WERF, the U.S. Environmental Protection Agency (EPA) and approximately 10 utilities participating in the LIFT program. The U.S. Department of Energy is also providing in-kind support.
The next project, Creating the Space to Innovate (LIFT8C14), is co-funded by WERF and WEF to promote the adoption of innovative technologies and practices.
WERF has also awarded The Canton Group with a contract to develop a LIFT Database (LIFT2R14), which is designed to support new water technology innovation, collaboration and implementation for the water sector. The platform will help deliver information on water technologies, facilitate collaboration for speeding innovation into practice, provide data from demonstrations and more. The development of the platform is supported in part with funding from the U.S. EPA. werf.org/lift
Truckee Meadows Water Authority Wins National AwardRENO, Nev. (April 17, 2015) Truckee Meadows Water Authority (TMWA) has received the Presidents Award from the Partnership for Safe Water (PSW). With this award, TMWAs Chalk Bluff Water Treatment Plant ranks among the highest performing water treatment plants in the country for individual filter performance. Only 18 utilities across the country have achieved this award.
The Presidents Award recognizes achieving Phase IVs stringent individual filter performance goals for turbidity. awwa.org
POWER-GEN Europe Launches the Confidence Index to Build Industry ExpertiseLONDON (April 14, 2015) POWER-GEN Europe and its co-located event Renewable Energy World Europe has announced the launch of the POWER-GEN Confidence Indexa pan- European study of the regions power market which will allow power generation industry practitioners from across Europe to have their say on the industry. The results will be launched in September 2015, and they will allow industry decision makers across Europe to make well-informed choices as they navigate the next critical stages of the energy transition.
The report will evaluate the industrys attitude toward new initiatives and give companies insight into how these changes are viewed by the industry.
The survey that feeds into the Index will be carried out on an annual basis and allow the industry to track year-on-year trend analysis and comparison. powergeneurope.com
Xylem Participates in U.S. Presidential Trade Mission to the Peoples Republic of ChinaRYE BROOK, N.Y. (April 13, 2015) Xylem Inc. participated in the U.S. Presidential Trade Mission to the Peoples Republic of China, April 12-17. U.S. Secretary of Commerce Penny Pritzker and Deputy Secretary of Energy Elizabeth Sherwood-Randall led this Smart Cities Smart Growth Business Development Mission, accompanied by representatives from 25 companies.
The trade mission was intended to help U.S. companies launch or increase their business operations in China for sustainable products and services.
Chris McIntire, Xylem senior vice president and president, analytics and treatment, and Shuping Lu, president of Xylem China, represented Xylem on this mission. xyleminc.com
PTDA Welcomes Three New Distributor MembersCHICAGO (April 13, 2015) The Power Transmission Distributors Association (PTDA), an association for the industrial power transmission/motion control (PT/MC) distribution channel, welcomed three new distributor member companies: BK Industrial Solutions, LLC (Beaumont, Texas), SAECOWilson Limited (Auckland, New Zealand) and Warrior Industrial, LLC (McKinney, Texas). ptda.org
SFPUC Completes New Seismic Upgrades to Drinking Water Treatment Plant SAN FRANCISCO (April 10, 2015) The San Francisco Public Utilities Commission (SFPUC) together with San Mateo Board of Supervisors Dave Pine and Peninsula water agencies stood on top of a new 11 million gallon treated water reservoir to celebrate the completion of a $278 million project improving the seismic and operational reliability of the Harry Tracy Water Treatment Plant located in San Bruno. The 43-year-old treatment plant is responsible for treating the drinking water for more than 1 million customers in San Mateo and San Francisco Counties.
The project is part of the SFPUCs $4.8 billion Water System Improvement Program, which consists of 83 projects across seven counties designed to improve seismic and water supply reliability for 2.6 million people in the Bay Area. sfwater.org
ABB Opens New Automation & Power Service Office in Louisiana SULPHUR, La. (April 8, 2015) ABB has opened a new local service office near Lake Charles, Louisiana. The office will provide services and support for ABBs automation and power
AROUND THE INDUSTRY
-
11
pumpsandsystems.com | June 2015
Those shiny new bearings you just installed
could look like this in
just 3 months!
1-866-738-1857 | sales @ est-aegis.com
BEARING PROTECTION RINGS
Protect bearings from shaft voltage damage
For more information aboutAEGIS Bearing Protection Ringsor for an informative guide toMotor Bearing Protection, visit:
www.est-aegis.com/handbook
EASA Show: Booth 630
Visit us at
Circle 107 on card or visit psfreeinfo.com.
-
12
June 2015 | Pumps & Systems
NEWS
portfolio including control systems, instrumentation, analytical products, low-voltage drives, and power systems and products. The new office will offer scheduled in-
center training, as well as customized training courses. ABB has also announed several new investments in the area. abb.com
Xylem Contributions Recognized at HIs 2015 Annual MeetingRYE BROOK, N.Y. (April 2, 2015) Five employees from the Applied Water Systems (AWS) business unit of Xylem were recognized by the Hydraulic Institute (HI) for their longtime service to and involvement in HI. Awards and the team members they
were presented to are as follows: Mark Handzel, Vice President
Product Regulatory Affairs and Director, HVAC Commercial Buildings, Americas Industry Leadership Award for U.S. Department of Energy pump efficiency regulations
Mark Heiser, Test & Validation Manager Industry Leadership Award for development of HI Standard 40.7 and recognition for completion of standard development for DOE pump efficiency regulations
Paul Ruzicka, Chief Mechanical Engineer Industry Leadership Award for development of HI Standard 40.6 and recognition for completion of standard development for DOE pump efficiency regulations
Chris Johnson, Global Engineering Manager, Centrifugal Pumps Recognition for contributions to HI standards development
Jim Roberts, Associate Principal Mechanical Engineer Recognition for 20 years of service to the development of HI standards
xyleminc.com
Powdersville Water District Receives National AwardDENVER (March 30, 2015) Powdersville Water is the first utility in South Carolina to achieve the Directors Award in the Partnership
for Safe Waters Distribution System Optimization Program and one of only 11 nationwide. Powdersville Water received this award for successfully completing a comprehensive self-assessment of distribution system operations. Powdersville Water will be one of a
select group of utilities recognized at the annual conference and exposition of the American Water Works Association in June. awwa.org
AEP Ohio Offers New Energy Efficiency ProgramRALEIGH, N.C. (March 26, 2015) AEP Ohio, a unit of American Electric Power, in partnership with Advanced Energy, has launched the Emotor Rewind Pilot Program to promote energy efficient rewinds in the industrial/manufacturing sector and provide incentives to users and motor service centers. The program covers 300- to 5,000-HP, three-phase induction motors and is expected to achieve annual energy savings of 5,900 to 116,000 kWh, depending on the motor size. AEP Ohio customers located in Ohio will receive $2 per HP, and certified motor service centers will receive $1 per HP. aepohio.com
ITTs Conoflow Brand Names Enertech Exclusive Global Nuclear Industry RepresentativeWESTMINSTER, S.C. (April 20,
2015) ITTs Conoflow brand has appointed Enertech, a business unit of Curtiss-Wright Nuclear Division, as the exclusive nuclear industry representative for its valve and regulator products globally. ITTs Conoflow manufactures natural gas vehicle (NGV), low-pressure and high-pressure regulators along with filter and specialty regulators. Enertech has served the nuclear power industry for more than 40 years. In this partnership, Enertech will be the point of contact for technical inquiries, quotations and order entry/status, while Conoflow will retain its nuclear quality assurance program, along with certifications and documentation. conoflow.com
EVENTSPump School Training: Centrifugal & Positive Displacement Pumps June 2-3, 2015One Midtown Plaza Atlanta, Ga. 770-310-0866pumpingmachinery.com/pump_school/pump_school.htm
American Water Works Association Annual Conference & Exposition (AWWA-ACE) June 7-10, 2015 Anaheim Convention Center Anaheim, Calif. 800-926-7337 awwa.org
EASAs 2015 Convention & Exhibition June 14-16, 2015 Grand Hyatt San Antonio & Henry B. Gonzalez Convention Center San Antonio, Texas easa.com/convention
ACHEMAJune 1519, 2015Messe FrankfurtFrankfurt am Main, Germanyachema.de/en.html
National Fire Protection Association (NFPA) Conference & ExpoJune 2225, 2015McCormick PlaceChicago, Ill.800-344-3555nfpa.org/training/conference
5th Annual Pumps Hands-on Training: Maintenance, Energy and Reliability Conference (PumpTec-Israel)July 7, 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/
-
13
pumpsandsystems.com | June 2015
Demand ReliabilityBecause downtime is never on the schedule.
www.alltestpro.comwww.bjmpumps.com
The ideal instrumentsfor troubleshooting,quality control andtrending of electric
motors, transformersand generators
Complete Stator and
Rotor Analysis Detect early
faults in AC & DC motors,
transformers and generators.
Driven Load Analysis Evaluate
and trend the condition of geared,
belted and bladed equipment.
Route-Based Testing and
Trending Ideal for predictive
maintenance.
Comprehensive Reporting
Includes bad connections, winding & turn faults, air gap,
broken bar, contamination, ground faults and more.
ALL-TEST Pro instruments providecomplete electric motor system
health analysis in minutes!
Electric SubmersiblePumps for DifficultWastewater Solids
Patent Pending RAD-AX
Dual Shredding Technology Radial and axial
shredding elements. System efficiency alleviates
potentially high surge load to the motor.
High Efficiency Motor High-torque,
4-pole motor - 2, 3 and 5HP.
Impeller Design High solids passage impeller
design expedites flow and hydraulic performance,
preventing clogs.
Robust Construction Chrome iron impeller
and suction cover. All shredding elements
are hardened 440C SS with a Rockwell hardness
of 55C+.
Superior Motor Insulation and SS Motor
Housing Class F insulation and SS motor
housing for superior corrosion resistance
and longer life.
Double Mechanical Seals
Oil-lubricated (SIC x 2), with separate
lip seal.
Oversized Bearings and Shaft
Handle extra torque and loads.
Motor Overload Protection
Defense against thermal and amperage
overloads. Available in 208v, 230v,
460v and 575v.
33 Ft. Heavy-
Duty SOOW
Power and Seal
Minder Cable
For early warning
moisture detection.
The new SKG Series from BJM isdesigned to obliterate flushablewipes and other difficult solids inwastewater applications.
Innovative features include:
Test All Electric Motors, Regardlessof Location
MotorTesters
De-energizedtesting
Predictive MaintenanceTroubleshooting
Route-Based TestingTrending
Quality Control
Energized testing
Circle 103 on card or visit psfreeinfo.com.
-
Letter from a Reader
e following comments relate to
scenarios described in Parts 1 and
2 of Can Deaerators Create Pump
Trips? (Pumps & Systems, March
and April 2015), which discuss
handling power plant transients.
Steady fl ows to and from the
deaerator (DA) and gradual
isentropic thermodynamic changes
from the high to low temperature/
pressure conditions are assumed.
A gradual power plant cool down
period after a shutdown event may
mitigate general or local fl ashing.
From Part 1 at Point A:
DA total tank volume V =
20,000 gallons = 2,674 cubic
feet (ft3).
Tank liquid (water) volume
(Vliq) = 10,000 gallons =
1,337 ft3.
Mass of tank liquid (mliq) =
Vliq
vf= 76,564 lbm.
Mass of tank vapor (mvap) = 0
lbm (all mass is saturated
liquid at vf).
Total mass of tank contents (M)
= mliq + mvap = 76,564 lbm.
Using the above values, the
calculated specifi c volume
(v) should agree with the
temperature-specifi c volume
(T-v) diagram at Point A.
However, calculated v =
V
M= 0.03492 ft3/lbm.
is value is greater than vf
= 0.01746 ft3/lbm from the
diagram. Since the vapor
volume Vvap = mvap x vg =
0 ft3, the analysis might be
conducted by assuming that
the total tank volume revV =
Vliq + Vvap = 1,337 ft3. In other
words, assume the total DA
tank volume is 10,000 gallons
and completely full of liquid
(water) at Point A. en, at
Point A on the diagram, v =
revV
M= 0.01746 ft3/lbm = vf.
Using revV and v for
calculations at Point B, X = 0.003%,
vapor mass mvap = X x M = 2.3
lbm, vapor volume Vvap = mvap
x vg = 24.5 ft3, liquid mass mliq
= (1-X) x M = 76,562 lbm, liquid
volume Vliq = mliq x vf = 1,312.3
ft3. erefore, the total volume and
mass of the tank contents remain
the same. However, the vapor
volume has increased by the same
amount that the liquid volume has
decreased. e less dense vapor
must occupy a larger space than
the reduction in liquid volume.
Because there is no additional tank
space to occupy, some liquid may
be expelled from the 10,000-gallon
DA or excess vapor pressure might
activate a relief valve.
Expelled tank liquid may imply
that the total mass of the DA tank
contents decreases at Point B:
Specifi c volume at Point B is greater
than at Point A. Using vb = 0.018
ft3/lbm at Point B, the calculated
vapor volume is now about 66 ft3
at Point B compared with 24.5 ft3
if v = 0.01746 ft3/lbm. Since the
new liquid volume is now 1,312 ft3,
about 41 ft3 must be expelled from
the tank at Point B: 66 + 1,312 41
ft3 = 1,337 ft3 = the tank volume.
However, I would not expect
a DA tank to be either half full
of liquid without any vapor or
completely full of liquid. A more
likely location for Point A might be
to the right of the saturated liquid
state where a two-phase liquid and
vapor state existsPoint A1.
e originally calculated specifi c
volume, v = 0.03492 ft3/lbm,
represents a liquid and vapor
state at 302 F. If this value is
chosen, a new set of values can be
determined at Point A1 and Point
B1: X = 0.17% at B1, Vvap = +23
ft3, and Vliq = -23 ft3. In this case,
the vapor has enough room for
expansion going from a calculated
1,341 ft3 at A1 to 1,363 ft3 at B1.
However, while the calculated
liquid volume has decreased at B1,
the corresponding liquid mass has
increased. is seems unlikely.
After some trials, it was
determined that reasonable
changes in volume and mass occur
if the specifi c volume is greater
than about 0.29 ft3/lbm for the
given data in this article. If another
specifi c volume such as v = 0.5
ft3/lbm is chosen, another set of
liquid and vapor state values can
be determined at Points A2 and B2:
X = 4.52% at B2, Vvap = -1.33 ft3,
and Vliq = +1.33 ft3. In this case,
the vapor volume has contracted
going from a calculated 2,587 ft3
at A2 to 2,586 ft3 at B2. Now, the
calculated liquid volume and mass
have both increased at B2, while
the calculated vapor volume and
mass have decreased at B2. Vapor
condensation, from state A2 to B2,
Handling Power Plant Transients
14 PUMPING PRESCRIPTIONS
June 2015 | Pumps & Systems
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC,
P&S Editorial Advisory Board
Troubleshooting & repair challenges
-
is now the result. is seems to
be a realistic outcome after slowly
cooling. Although it should be
noted that, with v = 0.5 ft3/lbm,
there is a substantial diff erence in
liquid and vapor mass and volume
values when compared with the
original calculations from above.
After an emergency trip
situation, there may be ongoing
automatic and/or manual
adjustments as various plant
elements (DAs, pumps, etc.) react
to changing system conditions. If
the liquid+vapor mass (M) within a
fi xed-volume DA tank can decrease
or increase in response to some of
these changes, maybe the specifi c
volume is not necessarily constant
at diff erent thermodynamic states.
Besides the dynamics occurring
inside the DA tank, I would expect
that any major net positive suction
head (NPSH) problem at the pump
suction might be attributed to
entrained air, not water vapor,
being transferred from the DA
liquid to the boiler feed pump.
Before being shut down, the
injected pegging steam might have
removed most of this air.
In Part 2, I would not expect
a signifi cant problem at Pump 2
from an interaction at the junction
of its header and the hotter liquid
in Header 1. If the liquid in Header
2 is gradually cooling and fl owing
past the junction, the temperature
diff erence at a junction may be too
gradual for a fl ashing reaction.
However, for Pump 1, if it is again
started with its header full of 302
F liquid and only 39 psia available
at the junction, there might be an
insuffi cient NPSH condition as
pointed out in the article. Perhaps
Pump 1 would be able to pass
the 50-ft header full of hotter
liquid quick enough to avoid any
signifi cant damage or pump trip.
Of course, the above analysis
is based on simplifi ed ideal
conditions with gradual
thermodynamic changes. Feedback
from readers with experience in
power plants and the eff ects of
transients on pumps would be
insightful.
Lee Ruiz
Oceanside, California
Neliks Response
ank you for your comments.
ese are very diligent and
methodical calculations. I have a
few notes to your comments.
Your assumption of the process
being gradual and isentropic
cannot be assumed, because it
is highly transient. is is one
of the reasons it is not easy to
calculate. Several thermodynamic
sub-processes that are highly
time dependent are taking place:
convection from hotter liquid
to colder, phase transformation
and cooling of the vapor that is
evolving back into liquid phase as
it tries to rise through the colder
liquid layer. Perhaps the only safe
assumption for the process is
that it is adiabatic, assuming no
heat loss through the pipe to the
surroundings occurs as a result of
thick insulation.
My assumption that Point A is
liquid that occupies half of the
tank space with zero vapor above it
is problematic. While the pressure
is signifi cant, a complete absence
of vapor in the space above the
liquid is impossible, as it would
p1 = 69 psi
266 F
302 F
subcooled
saturated
subcooled
?
1 FT3
1 FT3
p2 = 50 psiA
266 F
302 F
Figure 1. Visualization of vaporization and re-condensation (Courtesy of the author)
15
pumpsandsystems.com | June 2015
-
imply full vacuum. Because the
fl uid in the DA is at the saturation
curve or in the subcooled region,
something must be present above
the liquid to maintain pressure.
To explain what keeps the void
above the liquid at pressure in this
case, we would need to understand
more precisely the specifi cs of the
DA design.
Your note is well-placed; if we
instead make a slight adjustment to
starting Point A to be slightly into
a two-phase region, this diffi culty
immediately disappears. e entire
space above the liquid would be
vapor, the combined volume in the
tank could be treated as the entire
tank (20,000 gallons) instead of
half of it (10,000 gallons), and the
total combined specifi c volume
would be total tank volume divided
by total mass (which at Point A is
mostly liquid). at would make
the total combined volume double
that if we used only half the tank.
It does not aff ect Point A but makes
things easier when going to point
B, as we now have a total volume
of the entire 20,000 gallons fi lled
with a mixturesome liquid and
some vapor. From there, vapor
mass fraction x and volume can
be calculated.
My assumption that the entire
system is a constant volume is
valid, because otherwise, it is
impossible to make any other
reasonable assumptions. For
example, we cannot assume
constant pressure at Point B (As an
example, imagine that the tank had
a free heavy lid that would apply
constant pressure and that the
expanding volume of vapor would
move the lid up).
e tank described in these
articles does not have moveable
boundaries. e only openings
are to the condensate piping and
through the running pumps, but
those are essentially closed (by
running water).
As explained in Part 2, vapor
wants to expand according to a new
pressure to which the surface of the
DA is now suddenly at (Point B).
But it is not a steady state process,
and things are very transient. As
vapor tries to form and fl oat up,
it encounters a colder layer above
it and condenses back to liquid
almost instantaneouslyat many
orders of magnitude faster than it
takes for vapor to travel through
the suction header of the running
(colder) pump to reach its entrance.
Instead, what likely is happening is
convective cooling of the hotter leg
by the colder leg via this attempted
vaporization and re-condensation
(see Figure 1, page 15).
Imagine that you have two layers
of fl uid of equal volume, separated
by a very thin membrane. Initially,
69 psi is enough to keep both
liquids subcooled (the lower layer
is subcooled but not as subcooled
as the upper layer). Suddenly,
pressure at the surface drops to
50 psi, at which the top layer is
still subcooled, but the bottom
layer enters the vapor phase. Will
it immediately fl ash out to many
times more vapor volume? If so,
where will it go?
Assume that the membrane is
thin and raptures as vapor forms.
e bubbles trying to form at the
lower layer would have to meet
the colder layer and return to
liquid form. is would go on for
some time and eventually both
fl uids would mix at the average
temperature (266+302)/2. If 50 psi
is in a vapor region, the fl uids will
turn to vapor and fi ll the entire
can. If the can is very tall, there
will be more space for vapor to
form (if it corresponds to vapor
condition). Initially, however, all
was in two liquid layers. After the
drop of pressure (and if the new
condition is vapor phase), however,
the vapor will expand to take up
the complete volume.
Part 2 shows that, for the
conditions used in the example
and at the resultant average
temperature, no two-phase
situationand thus no vapor
exists. is means the system
experiences no cavitation or NPSH
problem. However, in reality, no
vapor would reach the running
pump because the colder column
is not static and mixing with the
hotter liquid. Instead, while vapor
wants to form and transmit its
energy to heat up cooler liquid,
that liquid is actually in motion,
taking a heated chunk and moving
it toward the pump.
By the time the chunk fl ows
through the entire length of pipe,
the resultant rise in temperature
of the fl owing liquid is minuscule.
As a result, it is not even close to
heating the cooler leg substantially.
In other words, it is the DA
temperature that would dictate the
temperature of fl uid reaching the
running pump.
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
June 2015 | Pumps & Systems
-
17
pumpsandsystems.com | June 2015Circle 113 on card or visit psfreeinfo.com.
-
This series discusses valves and fi ttings and evaluates how these devices aff ect the
operation of piping systems. Part 1(Pumps & Systems, May 2015) covered head loss, K value and L/D coeffi cient.
CV Coeffi cient
e CV value is an indication of the capacity of a valve or fi tting and is often used to describe the performance of control valves. e CV coeffi cient is often used to describe the hydraulic characteristics of elements in a pipeline. e defi nition of CV is the number of U.S. gallons per minute (gpm) of 60 F water fl owing through a valve or fi tting results in a 1 pound per square inch (psi) pressure drop across the device. For example, if a device has a
CV value of 200, then when 200 gpm fl ows through the device, a 1 psi pressure drop would occur. Equation 6 describes the CV value.
CV = Q
Pin - PoutSG
Equation 6
WhereCV = Flow coeffi cient (unitless)Q = Flow rate (gpm)P = Pressure (psi)SG = Specifi c gravity of the fl uid
(unitless)
e equation can be rearranged to allow for the solution of the fl ow
rate for a given pressure drop and the pressure drop for a given fl ow rate.
Q = CV dPSGEquation 6 gives the result of using C
V in diff erential pressure instead
of head. If a manufacturer provides information in C
V, users must
convert it to diff erential pressure, then convert the results to head loss. Equation 7 can be used to eliminate the need to convert from pressure to head. It allows for the conversion of a C
V value to a
K value.
K = 890.3 x
d4
(CV)2
Equation 7
WhereK = Resistance coeffi cient
(unitless)CV = Flow coeffi cient (unitless)d = internal diameter (inches)
Calculating the Head Loss
Using K Value
Regardless of the method used to arrive at a K value for a valve or fi tting, Equation 8 is used to calculate the head loss resulting from valves and fi ttings.
hL = 0.00259
KQ2
d4 Equation 8
When multiple valves and fi ttings in a pipeline have the same diameter, the K values for each valve or fi tting can be added. e sum of the K values can be used to calculate the head loss for all the valves and fi ttings.To demonstrate, calculate
the head loss for the valves and fi ttings in a pipeline when 600 gpm of water is fl owing through the following valves and fi ttings: a sharp-edged transition from a tank to pipeline, a full-seated globe valve and a strainer with a CV value of 450. ese full-seated devices are in a 6-inch pipe with a turbulent friction factor of 0.015 inches. e K values are listed in Table 1. e resulting head loss with 600 gpm going through the pipeline is shown in Equation 9.
Cross Section of Valves &
Fittings
Reference 1 has cross sections of types of valves and fi ttings and the corresponding K values or L/D coeffi cients. ere are too many types of valves and fi ttings to present in this article, but some attributes can be generalized. For example, a full-seat ball valve
A better understanding of complete system operation
Understand How Valves & Fittings Affect Head Loss
Last of Two Parts
hL = 0.00259
KQ2
d4 = 0.00259
11.55 x 6002
6.0654 = 7.95 ft of fl uid
Equation 9
dP = Q2 x SG(CV)2
18 PUMP SYSTEM IMPROVEMENT
June 2015 | Pumps & Systems
By Ray Hardee
Engineered Software, Inc.
-
with its straight-through design has a much lower
L/D value than a globe valve through which the
fl uid must make four changes of direction and
fl ow around the valve disk within the fl ow path.
e type of valve employed is based on many
factors. Leak tightness is an important factor,
but when two types of valves meet the same
requirements, it is recommended to use the one
with the lower head loss.
Another example of fi ttings with varied loss
coeffi cients are elbows. A short radius 90-degree
elbow has an L/D coeffi cient of 20, but a long radius
90-degree elbow has a L/D coeffi cient of 14. is
may not seem like a signifi cant loss, but it adds up.
So do the associated costs. e pump must supply
the energy that is lost across the valves and fi tting.
Cost of Pipeline Operation
To demonstrate the pumping cost associated with
valves and fi ttings, calculate the operating costs for
diff erent types of valves and fi ttings. Equation 10
can determine the pumping cost.
Item Method Coeffi cient Value K value
Sharp-edged transition
K 0.5 0.5
Globe valve fT L/D 0.015 x 340 5.1
Strainer Cv 450 5.95
Total K for pipeline 11.55
Table 1. Calculation of K value for different methods describing valves and fi ttings (Graphics courtesy of the author)
Valve / Fitting Type K value
Head Loss (ft)
Annual Operating Cost ($)
Elbow short radius 0.33 0.5 $53
Elbow long radius 0.23 0.35 $37
Entrance inward 0.78 1.23 $128
Entrance sharp edge 0.50 0.79 $82
Entrance rounded 0.04 0.06 $7
Ball 0.05 0.08 $8
Gate 0.13 0.20 $21
Plug 0.29 0.45 $47
Butterfl y 0.73 1.14 $118
Globe 5.54 8.58 $893
Table 2. The relationship between K values, head loss and annual operating cost for valves and fi ttings. The example is for 4-inch valves and fi ttings passing 400 gpm.
19
pumpsandsystems.com | June 2015
AROzone.com/ACHEMA
Automate Your ProcessesWith the ARO Controller and
EXP Series Electronic Interface Pump
Watch it!
Learn about it!
Experience it!
Visit us at booth #E18 Hall 9 for a demonstration
E i it!
Cir
cle
12
5 o
n c
ard
or
vis
it p
sfre
ein
fo.c
om
.
-
OC = .746 Q H 247,000 M
OH x $/kWh
Equation 10 WhereOC = Operating cost ($/time)Q = Flow rate (gpm)
H = Head (feet of fl uid) = Density (lb/ft3) = Effi ciency, M motor, P pump,
V variable speed drive (VSD) (percent)
O = Operating hours in evaluation (hours)
$/kWh = Electrical power cost ($/kWh)
In this example, the pump effi ciency is 70 percent, and the motor effi ciency is 90 percent. No VSD is installed, the evaluation period is 8,000 hours, and the cost of power is $0.10/kilowatt-hour (kWh). is example evaluates 4-inch valves and fi ttings with a fl ow rate of 400 gpm. e results are presented in Table 2 (page 19).
Every item placed in a piping system has an operating cost. is should be considered every time a user specifi es a valve time or adds elbows.
Conclusion e often overlooked performance of the multitude of valves and fi ttings adds up. ey have a compounded eff ect on performance in a fl uid operation and need to be taken into consideration for effi ciency planning and optimization.
Next months column will investigate how the control elements operate and the role that these devices play in piping systems and their associated cost.
References1. Flow of uids through valves, ttings, and pipe.
(1957). Chicago: Crane2. Flow of Fluids through Valves, Fittings and
Pipe Technical Paper 410. 2013 Crane Co. Stamford CT 06902.
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 [email protected].
20 PUMP SYSTEM IMPROVEMENT
June 2015 | Pumps & Systems pumpsandsystems.com | June 2015
the #1 value in automation2UGHU7RGD\6KLSV7RGD\
* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
Research, price, and buy at: www.automationdirect.com/ eldIO
eXactly where you need it! 7KHH;DFW,2\RXQHHG
$63.00(PX-248: 8-point DC
Output)
$36.00(PX-172-1: 2-point
AC Input)
$24.00(PX-970: AC Power
Feed Terminal)
$277.00(PX-334-K:
Thermocouple)
$384.00(PX-TCP2: 2-port
Modbus TCP Coupler)
5DFNOHVVGHVLJQIRUHDV\LQVWDOODWLRQLQDUHDVZLWKOLPLWHGVSDFH
v %XV&RXSOHUVDYDLODEOHLQERWK0RGEXV578$6&,,DQG
0RGEXV7&3SURWRFROVWRLQWHJUDWHZLWKDZLGHYDULHW\
RIFRQWUROOHUVDQG6&$'$+0,SDFNDJHV
v 'LVFUHWHWHUPLQDOVDYDLODEOHLQ$&DQG'&ZLWKDYDULHW\
RISRLQWFRQoJXUDWLRQVLQFOXGLQJRUSRLQWV
v DQGFKDQQHODQDORJWHUPLQDOVZLWKP$
9'&DQG9'&FDSDELOLWLHVDVZHOODV57'
DQG7KHUPRFRXSOHRSWLRQV
v )XOO\H[SDQGDEOHXSWR,2WHUPLQDOV
v )5((GRZQORDGDEOHHDV\WRXVHFRQoJXUDWLRQ
VRIWZDUHWRRO
v $YDULHW\RISRZHUVXSSO\DQGSRZHUGLVWULEXWLRQ
RSWLRQVJLYH\RXDGGHGYHUVDWLOLW\
Xpansion I/O has never been so practicalBuilt to be versatile in the eld, the new Protos X Field I/O system has a slim design with numerous I/O point con gurations. The small footprint lets you install Protos X I/O assemblies exactly where you need them, even in tight locations. No need for excess eld wiring, no need for unused I/O points and with the already low price, youll save money again and again with Protos X.
TM
Distributing I/O for your process saves space, wiring and
money!
1970 Dodge Super Bee
Creating Value.Carver Pump Company2415 Park AvenueMuscatine, IA 52761563.263.3410Fax: 563.262.0510www.carverpump.com
Do you have flows up to9,900 GPM (2,000 m3/hr), heads up to 720 Ft (220 M), speeds up to 3,500 RPM, and temperatures up to 500F (260C)? Then you need Carver Pump Process Maxum Series muscle!With an extended range of hydraulic coverage andrugged construction, the Process Maxum Series isideal for Industrial Process applications.Manufactured in 35 sizes, standard materialsinclude WCB, WCB/316SS, 316SS and CD4MCu,with others available upon request. A variety ofoptions include various types of mechanical sealsand bearing lubrication/cooling arrangements,auxiliary protection devices and certifiedperformance testing. Whatever your requirements, let us build the muscle you need!
Process Maxum
Circle 123 on card or visit psfreeinfo.com.
-
21
pumpsandsystems.com | June 2015
the #1 value in automation
Qtfgt"Vqfc{."Ujkru"Vqfc{#* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved. 3/:22/855/2627
Research, price, and buy at: www.automationdirect.com/ eldIO
eXactly where you need it! Vjg"gZcev"K1Q"{qw"pggf
$63.00(PX-248: 8-point DC
Output)
$36.00(PX-172-1: 2-point
AC Input)
$24.00(PX-970: AC Power
Feed Terminal)
$277.00(PX-334-K:
Thermocouple)
$384.00(PX-TCP2: 2-port
Modbus TCP Coupler)
Tcemnguu"fgukip"hqt"gcu{"kpuvcnncvkqp"kp"ctgcu"ykvj"nkokvgf"urceg
" "Dwu"Eqwrngtu"cxckncdng"kp"dqvj"Oqfdwu"TVW1CUEKK"cpf"Oqfdwu"VER"rtqvqeqnu"vq"kpvgitcvg"ykvj"c"ykfg"xctkgv{"qh"eqpvtqnngtu"cpf"UECFC1JOK"rcemcigu
" "Fkuetgvg"vgtokpcnu"cxckncdng"kp"CE"cpf"FE"ykvj"c"xctkgv{"qh"rqkpv"eqp"iwtcvkqpu"kpenwfkpi
-
COMMON PUMPING MISTAKES
Most pump bearings fail
long before their design
life span. e American
Petroleum Institute (API) typically
requires a minimum bearing life
(L10) of 25,000 hours, and ANSI
B73.1 specifi cation for horizontal
ANSI pumps specifi es a minimum
L10 bearing life of 17,000 hours at
maximum load and rated speed.
Prudent end users frequently
request bearings with more
than 40,000 hours L10, but most
bearings do not reach that many
hours of operation before failure.
More than half of pump bearings
fail as a result of contamination,
excess heat or both. Preventing
this introduction of contaminates
is easier and less expensive than
removing them. Some studies
suggest removing contaminates
can be eight to 10 times more
expensive than prevention.
Oil Contamination
is premature failure rate
is typically the result of
contamination of the oil not a
fault of the bearing or pump
manufacturer. Dirt, wear particles
and other foreign debris as well
as improper bearing installation
procedures can contribute to
contamination that leads to
reduced bearing life.
Other forms of contamination
include heat and air in the form
of air entrainment and aeration.
Increased levels of heat and air lead
to increased oxidation rates.
One of the most common sources
of contamination, however, is
water, which is often introduced
because of improper storage and
handling. During pump operation,
water can leak into the bearing
housing from external sources
such as area wash down, spray
from failed mechanical seals (or
packing) or leaks from equipment
near or above the pump. Another
common method of water
introduction is condensation
through machine aspiration
(moisture laden air is drawn in due
to pressure diff erentials).
For example, a pump running
steady state at a given temperature
above ambient for fi ve days is shut
down on Friday at 4 p.m. As the
What You Need to Know About Bearing Oil
Last of Two Parts
By Jim Elsey
Summit Pump, Inc.
Figure 1. Oil level on bottom ball of the bearing (Graphics courtesy of the author)
June 2015 | Pumps & Systems
22
-
pump cools, the ambient air is drawn into the
bearing housing where it cools and the moisture
condenses, releasing the entrained water into the
housing where it mixes with the oil.
According to sources at the SKF Bearing
Company, 250 parts per million (PPM) water in
the lube oil will reduce bearing life by a factor
of four, and another source states that 0.002
percent water in the oil will reduce the bearing
life by 48 percent. According to other sources, the
reduction of oil contamination levels from the
ISO 21/18 to the ISO 14/11 will increase bearing
life by a factor of 7.
Because water in the oil is invisible at low
levels, a lab should test the oil using the Karl
Fisher method or the end user should conduct
a simple sizzle test in which the oil is quickly
subjected to a hot surface temperature of 250 to
300 degrees F. A hot plate is commonly used, but
a metal spoon or aluminum foil with a butane
lighter can also be used. If more than 800 to
1,000 PPM water is present in the oil, a sizzle
sound can be heard when the oil temperature
exceeds 212 to 220 F. If the oil sizzles, too much
water is present in the oil. Because the sizzle
test can have dangerous side eff ects, always
check with plant safety procedures before
conducting the test.
Companies that strive for longer mean time
between failures (MTBF), mean time between
repairs (MTBR) and improved plant reliability
select their oil or grease based on equipment
requirements and properly match them with the
oil properties. ey also store and allocate the oil
using controlled and clean methods.
I have seen end users store oil drums upright,
outside and unprotected with an open bung. I
have also seen mechanics draw oil from drums
into used paper coff ee cups or soft-drink cans.
When confronted, they reply, at is the way we
have always done it, and we are not having any
bearing or oil problems, or I washed out the
container fi rst.
If a pumps bearings are not lasting three to
eight years, the plants equipment lubrication
practices should be questioned. Check with your
oil supplier, or consult articles, books and other
publications that discuss these subjects. e
October 2006 issue of Pumps & Systems magazine
explores this topic, and I highly recommend any
pumpsandsystems.com | June 2015
23
Cir
cle
12
2 o
n c
ard
or
vis
it p
sfre
ein
fo.c
om
.
-
COMMON PUMPING MISTAKES
books and technical papers on this
subject by Heinz Bloch (see page
30), Alan Budris or Rojean omas.
Bearing Lubrication Methods
Selection of a bearing design
for a specifi c service will, to a
large degree, determine how it is
lubricated. Depending on the pump
speed, type of service, horsepower
(HP) range and size, diff erent types
of bearings are available.
A properly selected oil-lubricated
ball or roller bearing will work
for most applications less than
200 HP, 400 F (fl uid temperature)
and 3,600 revolutions per minute
(rpm). For some smaller and lower
temperature applications (less than
320 F), grease-lubricated bearings
may also work well. Larger pumps
at higher speeds and system
temperatures will require line,
sleeve or plain journal bearings
for radial support (hydrodynamic
journal bearings) and tilted shoe
(pad) designs for thrust bearings.
Methods and designs that are
acceptable for ANSI specifi cation
pumps may not be acceptable for
API, process, marine and power
generation applications where HP
can often exceed 70,000 brake
horsepower (BHP) with speeds in
excess of 6,000 rpm.
Because most end users at the
high end of the HP and speed
spectrum are aware of oil types,
best practice lubrication techniques
and bearing selection, this article
will examine the middle and
lower range.
Oil splash lubrication may be the
most common method of bearing
lubrication for horizontal pumps
from 5 to 250 BHP. e oil is
contained in a sump in the housing
with the bearings. e machine is
designed so the oil level for proper
operation is at the middle of the
bottom ball in the bearings.
Oil Levels
Oil levels higher than the middle
of the lowest ball bearing will
have negative consequences and
increase oil temperature and air
entrainment. Both of these factors
accelerate the oils oxidation rate
and reduce oil and bearing life.
For splash lubrication, the oil level
should touch the very bottom of
the bottom ball in the bearing.
If the oil drops below the ball or
the outer race, the bearings could
be damaged. If the level is too
24
June 2015 | Pumps & Systems
Circle 126 on card or visit psfreeinfo.com.
WHY MONITOR POWER INSTEAD OF JUST AMPS?
NO LOAD NO LOAD
Power is Linear-Equal Sensitivity
at Both Low and High Loads
No Sensitivity
For Low Loads
FULL LOAD FULL LOAD
PO
WER
AM
PS
WWW.LOADCONTROLS.COM
CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247
PROTECT PUMPS$2925..).'s#A6)4!4)/.s"%!2).'&!),52%s/6%2,/!$MONITOR PUMP POWER
s"EST3ENSITIVITYs$IGITAL$ISPLAY
TWO ADJUSTABLE SET POINTS
s2ELAY/UTPUTSs!DJUSTABLE$ELAY4IMERS
4-20 MILLIAMP ANALOG OUTPUT
COMPACT EASY MOUNTING
/NLYXXs3TARTER$OOR s0ANELs2ACEWAY s7ALL
UNIQUE RANGE FINDER SENSOR
s7ORKSON7IDERANGEOF-OTORSs3IMPLIlES)NSTALLATION
PUMP POWER
PUMPING
VALVE CLOSING
VALVE OPENINGNO FLUID
-
low, the bearing could experience
temperature runaway, which is
when the bearing gets hot quickly
and is permanently damaged.
Variations on splash lubrication
design include fl ingers, discs, oil
rings and several other methods/
types of lubrication.
One note of caution is that
rings must be close to perfectly
concentric, and the pump shaft
must be level for the rings to work
correctly. I have rarely seen the
ring remain round, especially after
the fi rst maintenance overhaul. If
not initially leveled, the pump may
not remain level either. Problems
may also arise if the design ratio
of ring to shaft diameters is not
correct. Critical speed can also be
an issue. While the rotor may be
above the fi rst critical speed, the oil
ring speed is typically at 50 percent
of the shaft speed and may be
rotating close to critical frequency.
Other types of lubrication
include grease (with ball bearing
variations of shielded/unshielded
and sealed), oil mist, oil purge and
forced oil feed (oil is pumped to the
bearings for the larger HP pumps
and some marine applications).
Most motor bearings are grease-
lubricated, so it is important to
know if they are open, shielded,
sealed or a combination of these
options. If they are shielded on one
side, the best practice is to place
the shielded side toward the grease
fi tting. I have seen many end users
who order pumps with greased
bearings still add oil to the housing
simply because the installation,
operation and maintenance manual
(IOM) did not specifi cally say not
to. Running the pump with greased
bearings and splash oil lube at the
same time is an incorrect solution.
Oil Changes
e fi rst oil change should be
conducted at a shorter interval
than subsequent changes to
eliminate the contamination that
occurs from startup and run-in
operations. Most ANSI and some
API pump manufacturers will
state that the fi rst change should
come at 200 operating hours and
subsequent changes at 2,000 hours
or 3 months, whichever comes
fi rst. e intervals depend on
operating temperatures and how
contamination ingress is managed.
Some operations will require more
frequent oil changes, and others
Ludeca
1/2 horiz
25
pumpsandsystems.com | June 2015
305.591.8935 | www.KeepItRunning.com
Vibration hurts your equipment! Reducing vibration by just 15%
can increase bearing life in your equipment by up to 72%.
Theres no excuse to let high vibration levels cost you!
Increase machine reliability and minimize costly downtime
through proactive condition monitoring solutions.
Our equipment and support are the industry benchmark.
Keep it Running.
305.591
VibVibration hurts y
can increase be
Theres no excu
Increase machi
through proacti
Our equipment
Keep it Runnin
VibXpert II
A PRFTECHNIK product Vibration Analysis, Field Balancing and more!
Circle 127 on card or visit psfreeinfo.com.
-
COMMON PUMPING MISTAKES
can operate for several years. Oil sample analysis
and experience will aid in decisions regarding oil
change intervals.
Consider how often oil is changed in a car. If a
car was driven at 60 miles per hour for 24 hours a
day and 7 days a week for one year (8,760 hours in a
year), it would drive 525,600 miles.
You would never drive a car that many miles
without changing the oil.
Automatic Oilers
Several automatic oiler types and brands are on the
market. e question to ask is whether the oiler is
vented to atmosphere or to the housing. Old designs
vented to atmosphere, but that is how moisture
gets to the bearing housing and oil. e new best
practices are to vent the oiler to the housing and
keep the housing sealed.
e old method was to also vent the housing,
but that was a source of contamination. e
vents should be eliminated or, at the very least,
used with a desiccant breather or an equalizer
expansion chamber.
Lip Seals Versus Bearing Isolators
For more than a hundred years, lip seals have
served the industry well. While they are simple and
inexpensive, end users should consider replacing
them with the more modern and effi cient bearing
Figure 2. Cross section of bearing isolator
Tuthill
1/2 vert
26
June 2015 | Pumps & Systems
Cir
cle
13
2 o
n c
ard
or
vis
it p
sfre
ein
fo.c
om
.
-
27
pumpsandsystems.com | June 2015
Transforming energy into solutions.
2013 WEG Electric Corp.
Pump GeniusPump Process Control Software
Pump Genius is designed to reduce system operation and maintenance costs
while increasing process accuracy and protection. The software provides
multiple pump control and protection, as well as system monitoring and
protection. Pump Genius can be applied to any system that requires constant
flow or pressure.
To learn more about Pump Genius or to locate
a WEG Distributor near you, please contact
1-800-ASK-4WEG or visit www.weg.net/us
Reduce your pump system operation and maintenance cost
Increase accuracy and protection
Control up to 6 pumps dynamically alternated and controlled
Cir
cle
11
2 o
n c
ard
or
vis
it p
sfre
ein
fo.c
om
.
-
COMMON PUMPING MISTAKES
isolators. Lip seals, regardless of the
manufacturer, will, at best, only last
about 3,000 hours in service. After
approximately four months of operation,
they will fail and potentially allow
water or other contaminants to enter
the bearing housing. e advent of the
bearing isolator is what has allowed
many pump manufacturers to extend
their warranties from one to fi ve years.
e modern bearing isolator will, on
average, last eight to 10 years and, if
properly managed, even longer. During
that time, the isolator will not wear/
score a groove on the shaft and, for the
most part, will prevent the introduction
of contamination to the bearing housing
at both operating and static conditions.
Bearing isolators can be of the labyrinth
or contacting face design, and there are
numerous designs and manufacturers.
e majority of bearing isolators
are orientation specifi c; they normally
have a drain hole (expulsion port) that
should be in the 6 oclock position. If
the port is not at the correct position,
the isolator will not perform properly.
For some types of ANSI pumps, the
outboard isolator will have numerous
evenly spaced expulsion ports because
the housing it fi ts into can be rotated
when setting the impeller clearance.
e fi nal position will not be a fi xed
parameter as it is in other designs, so the
isolator incorporates numerous ports to
satisfactorily operate in any position.
Overfi lling the Bearing Housing
One of the most common problems
I see in the fi eld beyond not reading
the instructions is the overfi lling of
the bearing housings with oil. Bearing
isolators (labyrinth style) will purge any
excess oil from the housing. A common
misconception is that the isolator
The modern bearing isolator will, on average, last eight to 10 years
and, if properly managed, even longer.
MissionComm
1/2 island
28
June 2015 | Pumps & Systems
Mission managed SCADA systems aredesigned to get you up and running inhours, not days. Our packages start ataround $1,000 with a maintenance fee ofless than $1 a day. Mission strives forease in doing business. Give us a try nobureaucratic red tape, no huge commit-ment. If you like it, buy it. If not, send itback. Its that simple.
Mission flexibility allows you to expandyour system as you are ready and on yourterms. Mix and match any of our productsone at a time or all at once, the choice isyours. That is why you will find MissionSCADA in over 1,400 municipalitiesacross the United States and Canada.
Lift Station Tank and Well ControlIn Sewer Level Alarm
Advanced Monitoring Low Cost Managed SCADA
(877) 993-1911 www.123mc.com
Mission SCADA Works Right Out Of The Box, But Wont Box You InMission SCADA Works Right Out Of The Box, But Wont Box You In
Circle 128 on card or visit psfreeinfo.com.
-
DSI full page
29
pumpsandsystems.com | June 2015
Cir
cle
10
6 o
n c
ard
or
vis
it p
sfre
ein
fo.c
om
.
-
COMMON PUMPING MISTAKES
has failed, but it is just doing its
job. e oil will continue to be
expelled until the level is below the
expulsion port.
Setting the automatic oiler
level incorrectly is the next most
common mistake in the industry.
Please refer to the manufacturers
instructions for the proper
procedure. Hint: e level in the
oil bulb is not the level of the oil
in the pump housing nor is it the
centerline of the connecting pipe.
Conclusion
Centrifugal pumps are shipped
without oil in the bearing housings;
consequently, the end user must
ensure that oil is in the housing
before startup. e oil must be
of the proper viscosity. e oil
viscosity selection is based on
expected temperatures of the oil
and bearings. e oil supply source
should be clean, and the oil must
remain uncontaminated between
changes. In addition, the oil must
be at the proper level in the bearing
housing. Too much oil is just as
bad, if not worse, than too little oil.
Most bearings fail because of
contamination from water and/or
heat. Labyrinth or magnetic face
type seals (bearing isolators) can
help prevent water introduction
and contamination. Desiccant
breathers or automatic oilers that
vent to the housing in lieu of the
atmosphere can also reduce the
introduction of water.
Worldwide Electric
1/2 horiz
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 principle of MaDDog Pump
Consultants LLC. Elsey may be reached at [email protected].
Read more online
pumpsandsystems.com/
commonpumpingmistakes.
30
June 2015 | Pumps & Systems
Circle 131 on card or visit psfreeinfo.com.
-
SPX
31
pumpsandsystems.com | June 2015Circle 119 on card or visit psfreeinfo.com.
-
Some will know from their
experience with automobiles
that thicker oils, such as
Society of Automotive Engineers
(SAE) 30, are more appropriate
for warm summer months. But
thinner oils, perhaps SAE 10, can
help prepare a vehicle for winter
driving. Figure 1 illustrates where
these motor oils fi t in comparison
to the industrial oil designations
used today.
ick oils are more viscous
and may not readily fl ow into the
bearings. Users can heat the oil
or avoid oil rings and other risk-
inducing lube application methods
by using smarter means. ey can
use a jet of oil (oil spray) or convey
the oil mixed with compressed
air in the form of an oil fogalso
called oil mist. Whatever the user
chooses, he or she must guard
against using the thinnest oil
found on the market to avoid the
problem of inadequate oil fi lm
strength and thickness.
Lube Oils for Process Pumps
e MRC Engineers Handbook
states, In general, the oil
viscosity should be about 100
Saybolt Universal Seconds (SUS)
at the operating temperature.1
If for some reason a bearing was
operating at 210 degrees F, Figure
1 would call for a lubricant with
an International Organization
for Standardization (ISO)
viscosity grade (VG) somewhere
between 220 and 320. But that
is unrealistically thick for most
process pump bearings. Oil rings,
if used, would probably slow down
and malfunction in such viscous
oils. Oil overheating may be an
additional concern.
Figure 2 shows a graph from
SKF that is time-tested and widely
applicable.3, 4 It depicts the required
minimum (rated) viscosity v1 as
a function of bearing dimension
and shaft speed.3 A bearing with a
mean diameter of 390 millimeters
(mm) at a shaft speed of 500
revolutions per minute (rpm) would
require v1 = 13.2 centistokes (cSt).
For another example, if a bearing
was mounted on a 70-mm shaft
rotating at 3,600 rpm, we might
assume that the bearings outside
diameter (OD) is twice its inner
diameter (ID), or 140 mm. e
How Oil Viscosity & Temperature Infl uence Bearing Function
First of Two Parts
By Heinz P. Bloch, P.E.
Figure 1. Oil viscosity comparison chart per common industry conversion practice (Courtesy of the author)
By Heinz P. Bloch, P.E.
32 GUEST COLUMN
June 2015 | Pumps & Systems
-
bearings mean diameter would be 105 mm. To
simplify, consider it 100 mm, and travel up from
100 to a location midway between the 3,000
and 5,000 rpm lines in Figure 2. In this instance,
one could operate with a lubricant which, at the
bearing operating temperature, is somewhere
between 8 and 9 cSt.
Note that a bearings operating temperature
must be known to determine what ISO VG is
needed. e operating temperature derives its
combined thermal input from bearing load and
lube oil frictional drag. Unnecessarily viscous oils
will become hot. Figure 3 (page 32) is helpful in
this regard. Note that Figures 2 and 3 were drawn
years ago and apply to mineral oils. If users choose
premium grade synthetic oils, they will enjoy a
sizeable safety factor in lube applications.
Using lubricants with viscosities in excess of
those needed may generate excess heat and actually
work against operators. However, thicker oils have
their place, and MRC had to cover all the bases with
their 100 SUS rule-of-thumb.
Figure 2. Required minimum (rated) viscosity v1 as a function of bearing
dimension and shaft speed.3 A bearing with a mean diameter of 390 mm at a shaft speed of 500 r/min will require v
1 = 13.2 cSt. (Courtesy of SKF)
33
pumpsandsystems.com | June 2015
Dont Leave
In TheProfits
Pipeline
PSGZI la Plaine de Isles, 2 rue des Caillottes
F-89000 Auxerre, FranceTel: +33 (0) 3 86 49 86 [email protected]
psgdover.com/en/product-recovery
PSG Euro-Center 22069 Van Buren Street
Grand Terrace, CA 92313 USA Tel: +1 (909) 512-1224
Di d you know:
Manufacturers can save money by reducing energy costs, but product-recovery savings can be 110 times higher!
Food and Beverage, Pharmaceutical, Chemical and Cosmetic/Personal Care product manufacturers leave expensive fluids (and thousands of dollars) in their piping every day.
Eliminate these lost profits and recover up to 80% of your ingredients with Mouvex SLS Series Eccentric Disc Pumps.
Compression effect clears lines
Gentle handling, consistent flow
Leak-free seal-less design
Dry priming and strong negative suction lift
Scan this to learn more about
the Product Recovery benefits
of Mouvex pumps, or go to
www.youtube.com/MouvexGlobal.
For more information, please go to: psgpumps.com/ps615m
Circle 129 on card or visit psfreeinfo.com.
-
at said, a large bearing (200
decimeters) in a slow speed gearbox
(200 rpm) requires an operating v1
of 40 cSt. Figure 3 shows that ISO
VG 100 (or higher) oils would be
needed here.
Real-World Example
In a recent case history, ISO VG
100 was applied to a large pump
where ISO VG 68 mineral oil or its
equivalent ISO VG 32 would have
suffi ced. An ISO VG 32 synthetic
is the bearing life equivalent
of an ISO VG 68 mineral oil.
e synthetic ISO VG 32 runs
considerably cooler than the
mineral oil equivalent.
With ISO VG 100 mineral oil, the
oil-misted radial bearing ran a few
degrees in temperature lower than
it had with conventional sump and
oil ring lube. e user was pleased
but expressed disappointment at a
triple-row thrust bearing running
as hot as before190 F.
A premium formulation
synthetic ISO VG 32 would have
been suffi cient and would have
given the user everything a solid
reliability professional could have
asked for.
Reliability professionals would
like to see pump bearing housings
with no oil rings, no need for
constant level lubricators and
few, if any, repeat failures. ey
start with the right lubricant.
Why, with all that, is the radial
bearing cool? After all, it is also
surrounded by the thick ISO VG
100. It is cool because it has no
load. e load is in the triple-row
thrust bearing, and that creates
temperature in addition to the
frictional temperature mentioned
earlier in this article.
Part 2 of this series will examine
which temperatures are reasonable,
which are high and which are out of
allowable range for rolling element
bearing housings and pump
bearing housings.
References
1. MRC Engineers Handbook, General
Catalog 60, Copyright TRW, 1982
2. Bloch, H.P.; Improving Machinery
Reliability, Gulf Publishing Company,
Houston, TX, 1983, 1993
3. SKF America, General Catalog,
Kulpsville, PA (2000)
4. Bloch, H.P. Pump Wisdom: Problem
Solving for Operators and Specialists,
John Wiley and Sons, Hoboken, NJ, 2011
Heinz P. Bloch has been a
professional engineer for almost
50 years. He holds a BSME and an
MSME degree (cum laude) from
New Jersey Institute of Technology
and retired as Exxon Chemical
Companys regional machinery
specialist. He may be reached at
Figure 3. For a required viscosity (vertical scale), the permissible bearing operating temperatures (horizontal scale) increase as thicker oils are chosen (diagonal lines). Users enter the vertical scale near 9 cSt and move toward the right, where the line intersects with oils ranging from ISO VG 22 through ISO VG 320. If the user selects ISO VG 32, he or she might start the pump and verify that its oil temperature had leveled off at no greater than 75 C. Alternatively, the user might choose ISO VG 68 and verify that its operating temperature does not exceed 100 C (212 F). The information in this fi gure is per common rule of thumb, using average viscosity improvers. (Courtesy of the author)
Reliability professionals would like to see pump bearing
housings with no oil rings, no need for constant level lubricators and
few, if any, repeat failures. They start with the right lubricant.
34 GUEST COLUMN