Pump & Systems Marc 2013

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2 March 2013 www.pump-zone.com PUMPS & SYSTEMS
From the Editor
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 110, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and
additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the right to determine qualications. Annual subscriptions: US and possessions $48, all
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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 descrip-
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is a member of the following organizations:
F
or several years, the industry has been buzzing
about pumps used in irrigation and agriculture
applications. It makes sense. Almost 60 percent
of the worlds freshwater withdrawals are used for
irrigation, according to several sources including a
recent study by the USGS Water Science School.
Consider this . . . power plants use 10 times
more water than is treated in municipal drinking
water plants. In fact, they extract and treat more
water than all other industries combined. Te only
larger use of water is for irrigation, according to a
2011 study by Te McIlvaine Company.
Efective irrigation systems use energy-ef cient
equipment and designs that also help minimize the
amount of unnecessary water use. Some common
causes of wasted energy in irrigation systems,
according to the Natural Resources Conservation
Service (NRCS), are worn or improperly sized
pumps, worn nozzles and improperly sized or
designed fttings. Irrigation equipment problems
and maintenance problems tend to go hand in
hand. Pumps, motors and engines that are badly
designed or poorly maintained reduce the irriga-
tors degree of control over water applications,
making it impossible to maintain correct soil
moisture levels. Tis leads to crop stress, reduced
yields, runof, erosion and other problems.
Agricultural irrigation is an energy intensive
operation, and modifying irrigation systems can
reduce energy usage and costs. Pressurized irri-
gation systems, especially center pivot sprinkler
installations, use a high fow rate pump and require
a large electric motor or engine. Te major causes
of increased energy use are associated with pipe-
line leaks, engine and pump ef ciency and well
maintenance. Poor uniformity of water applica-
tion can also afect energy use by increasing pump-
ing time.
As we increase our coverage of pumping systems
used in agricultural, irrigation and groundwater
applications, our cover series this month features
cutting-edge solutions to complex irrigation
installations (page 25). Te lead article describes
how todays agricultural irrigation is not just about
pumps. Variable speed drives, intelligent control
and remote management are all vital to a com-
plete energy-ef cient system. Complete pumping
systems have replaced large, isolated pumps as the
solution moving forward.
Our cover series also includes two articles that
describe the diesel versus electric debate for pow-
ering the pump (page 30 and page 34).
Pumps & Systems will continue to research and
report about pumps in agricultural irrigation. Tell
us about your experiences and share your case
studies by contacting me directly,
msegrest@pump-zone.com.
Michelle Segrest
Editor
Editorial Advisory Board
Thomas L. Angle, P.E., MSc, Vice President Engineering,
Hidrostal AG
Robert K. Asdal, Executive Director, Hydraulic Institute
Bryan S. Barrington, Machinery Engineer,
Lyondell Chemical Co.
Kerry Baskins, Vice President of Sales, Viking Pump
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
David A. Doty, North American Sales Manager,
Moyno Industrial Pumps
Walt Erndt, Director of Market Development SSB,
Environment One Corporation
Joe Evans, Customer & Employee Education, PumpTech, Inc.
Ralph P. Gabriel, Chief EngineerGlobal, John Crane
Bob Langton, Vice President, Industry Sales, Grundfos Pumps
Larry Lewis, President, Vanton Pump and Equipment Corp.
Todd Loudin, President/CEO North American Operations,
Flowrox Inc.
John Malinowski, Sr. Product Manager, AC Motors,
Baldor Electric Company, A Member of the ABB Group
William E. Neis, P.E., President, Northeast Industrial Sales
Lev Nelik, P.E., APICS, President, Pumping Machinery, LLC
Henry Peck, President, Geiger Pumps & Equipment/
Smith-Koch, Inc.
Mike Pemberton, Manager, ITT Performance Services
Adam Stolberg, Executive Director, Submersible Wastewater
Pump Association (SWPA)
Bruce Stratton, Product Manager, KLOZURE, Garlock
Sealing Technologies
Kirk Wilson, President, Services & Solutions, Flowserve
Corporation
Publisher
Walter B. Evans, Jr.
VP of Sales
George Lake
glake@pump-zone.com 205-345-0477
VP of Editorial
Michelle Segrest
msegrest@pump-zone.com 205-314-8279
Creative Director
Terri Jackson
tjackson@cahabamedia.com
EDITORIAL
Editor
Michelle Segrest
msegrest@pump-zone.com 205-314-8279
Managing Editor
Lori K. Ditoro
lditoro@cahabamedia.com 205-314-8269
Associate Editor
Amanda Perry
aperry@cahabamedia.com 205-314-8274
Contributing Editors
Laurel Donoho
Joe Evans, Ph.D.
Dr. Lev Nelik, PE, APICS
CREATIVE SERVICES
Creative Director
Terri Jackson
Senior Art Director
Greg Ragsdale
Art Director
Jaime DeArman
jdearman@cahabamedia.com
PRODUCTION
Production Manager/Trafc
Lisa Freeman
lfreeman@pump-zone.com 205-212-9402
Web Advertising Trafc
Ashley Morris
amorris@pump-zone.com 205-561-2600
CIRCULATION
Jeff Heine
jheine@cds1976.com 630-739-0900
ADVERTISING
Derrell Moody
dmoody@pump-zone.com 205-345-0784
Mary-Kathryn Baker
mkbaker@pump-zone.com 205-345-6036
Mark Goins
mgoins@pump-zone.com 205-345-6414
Addison Perkins
aperkins@pump-zone.com 205-561-2603
Vince Marino
vince@pump-zone.com 205-561-2601
P.O. Box 530067
Birmingham, AL 35253
Editorial & Production
1900 28th Avenue South, Suite 110
Birmingham, AL 35209
Phone: 205-212-9402
Advertising Sales
2126 McFarland Blvd. East,. Suite A
Tuscaloosa, AL 35404
Phone: 205-345-0477 or 205-561-2600

305.591.8935 | info@ludeca.com | www.ludeca.com
Downtime is costly. Equipment reliability
is critical to your business. LUDECA is your
reliability partner. With over 30 years of
experience and commitment to quality, we will
never let you down. Keep it running.
ALIGNMENT VIBRATION BALANCING
ROTALIGN
Ultra iS
Laser Alignment, Geometric
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VibXpert
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Table of Contents
March 2013
Volume 21 Number 3
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6 Readers Respond
8 20th Anniversary Top 20 List
By Amanda Perry
Top 20 Apps for Pump Users
12 News
15 Calendar of Events
42 Efciency Matters
By Arno Gehrer, ANDRITZ GROUP
Design Software Increases Hydraulic Efciency
45 Maintenance Minders
By Tom Davis, Maintenance Troubleshooting
Pump Rebuild Tips
48 Sealing Sense
By The Fluid Sealing Association
Gaskets for Rigorous Applications
51 HI Pump FAQs
By The Hydraulic Institute
Submersible Pump NPSH3, Trench-Type Wet
Wells & Starting Torque Requirements
65 Product Pipeline
72 Pump Market Analysis
By Jordan, Knauff & Company
SPECIAL
REPORT
20 Pump Specication, Purchase, Installation
& Application
By Amin Almasi, WorleyParsons Services Pty Ltd.
Sharing all the information about an application can help
with the selection and installation of the ideal pump.
Departments
25 Pump Systems for Todays
Agricultural Irrigation
By Vahan Bagdasarian, Grundfos
Complex irrigation applications require customized and
cutting-edge solutions.
30 Powering the Pump:
Diesel Versus Electric Motors
By Tim Albers, Nidec Motor Corporation
Make the ideal motor selection for irrigation applications.
34 Powerful Mine Dewatering
By Kristen Gurick, Godwin Pumps, a Xylem Brand
Electric and diesel centrifugal pump options
The Pump Purchase Process
Columns
16 Pump Ed 101
By Joe Evans, Ph.D.
Branch-Line Pumping and Other Options
18 Pumping Prescriptions
By Lev Nelik, P.E., Pumping Machinery, LLC
Will Impeller Velocity Triangles
Keep You Awake at Night?
2 From the Editor
41 Trade Show Coverage
68 Index of Advertisers
68 Pump Users Marketplace
COVER
SERIES
Agricultural Irrigation & Dewatering
Practice & Operations
54 Prefabricated Treatment System Solves Water Quality
Concerns
By Mark Koester, Koester Associates, Inc.
With the simultaneous construction and site preparation, the quick turnaround
required for the project was accomplished with cost-efcient results.
57 New Optimized Aeration System Reduces Energy
Consumption
By Lars Larsson, Xylem, Inc.
A wastewater treatment plant experiences a 65 percent energy savings with the
installation of improved equipment.
60 Positive Displacement Pumps in Wastewater Treatment
By Oakley Roberts, ARO Fluid Products, Ingersoll Rand
Select the right pumping technology to keep treatment processes running efciently.
62 Power Generation on Demand
By Brad Chrudimsky, Baldor Electric Company, a member of the ABB Group
The application, geography, regulations and proper size must be considered when
choosing a generator set.
READERS RESPOND
Pump System Design, February 2013
Thanks for your article Pump System Design
published in the February 2013 Pumps &
Systems. It included good items to consider for
simplifed system modifcations or upgrades.

Homework Background and Answers
For a 12-hour per day operation at 800 gallons
per minute (gpm), there will need to be storage
capacity for at least 576,000 gallons of oil. An approximate 70-foot
diameter by 21-foot deep storage tank was used in the analysis.
To keep the analysis simple, only half the 20-foot storage tank
draw-down was used to arrive at an average lift value. An average lift
of 20/2 + 50 = 60 feet was used. The recommended pump place-
ment close to the storage tank was used.
A 71-foot length of vertical discharge piping and a couple pipe
elbows were also included. Friction losses totaled about 97.7 feet
including tank entrance and process end discharge losses.
The calculated required pump head was 1.3-foot discharge
velocity head + 60 feet of lift + 97.7 feet for friction = 159 feet
(used 160 feet).
Using a 2-pole speed of 3,500 rpm, an approximate specifc
speed value of 2,200 was calculated. Based on the effciency-
versus-specifc speed graph at www.mj-scope.com/pump_tools/
pump_effciency.htm, a maximum, 81-percent pump effciency
might be expected for best-effciency-point (BEP) operation.
I did fnd a commercial refnery/API type pump with an approxi-
mate 78 percent effciency at the above design conditions. The
curve indicated an 80 percent best effciency zone.
Assuming that the BEP operating head (160 feet) is about 85
percent of the head at zero fow,
a shutoff head of 188 feet was
estimated.
Equating this shutoff head value
to V
t
^2 / 2g, where V
t
= [pi(D/12)
(N/60)] is the impeller tip speed, an
impeller diameter of 7.21 inches was
calculated.
The curve for the 78-percent eff-
cient pump indicated an approximate 7.25-inch diameter impeller
for the design conditions. The calculated minimum net positive suc-
tion head available at 6 p.m. full 20-foot draw-down was 37 feet.
This is greater than the curve net positive suction head required
value of 20 feet.
By designing to the average tank draw-down, the estimated
pump performance may vary between 825 gpm at 155 feet in the
morning to 775 gpm at 165 feet at 6 p.m. The design point, 800
gpm at 160 feet, would theoretically be seen around noon.
Good luck reflling the storage tank each day before 6 a.m.
Lee Ruiz
Oceanside, Calif.
Lev Nelik responds:
Tank you, Lee. Glad to see you got to use the Ef ciency
Estimator Program, with close correlation to an actual com-
mercial pump. I am reproducing the link you noted from
the website (see Figure 1) and compared the numbers to
a copy of a performance curve from a randomly selected
pump OEM catalogue.
Te 800 gpm and 143-foot head come out with a 6.79-
inch impeller and 81.7 percent ef ciency by the program
and about the same impeller size and 77 percent ef ciency
by a random OEM performance curve. Te diference in
ef ciency is about 4 percent. Tis is a question for Pumps &
Systems readers. Why the diference in ef ciency? (Please
feel free to share your answers to Levs question. Send these
answers to Amanda Perry, aperry@cahabamedia.com.)
Editors Note: For the Estimator Program referenced in
the February 2012 column to work, readers may need
to download a Microsof Web component from www.
microsoft.com/downloads/details.aspx?amp;display
lang=EN&familyid=982B0359-0A86-4FB2-A7EE-
F3A499515DD&displaylang=en). Readers should only
need to download the program once. P&S
To have a letter considered for Readers Respond, please send it to
Amanda Perry, aperry@cahabamedia.com.
Lee Ruiz
Figure 1. Screen shot from www.pumpingmachinery.com
Mobile
Power
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emergency power that can be
towed to a sewage lift station in a
moments notice, Baldor has the
mobile power solution for you. Built
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for long life, low maintenance and
reliable service, Baldor stocks
towables from 25 to 400 kVA for
immediate shipment.
For more information on our
complete line of mobile generators
and light towers, contact Baldor to
learn how you can have ready to
roll power.

baldor.com 479-646-4711
2011 Baldor Electric Company
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Top 20 Apps for Pump Users
Mobile applications assist pump users in the feld and on the go.
First of Two Parts
By Amanda Perry
YEARS
1 9 9 3 - 2 0 1 3
A
s we continue to celebrate 20 years as the leading magazine for pump users worldwide, we bring you a favorite Top 20
list compiled from reader surveys and editorial research in each issue. See Part Two of Top 20 Apps for Pump Users in
the April issue.
Flatness App for ALiSENSOR LEVEL Alignment Supplies, Inc.
Te Flatness App for ALiSENSOR Level makes geometric measurement cost-efective, more accessible
and easier to perform. Te app allows users to measure the fatness of surfaces of a wide range of shapes and
sizes to be calibrated to user-made fxtures of all sizes. Users can perform precise fatness measurements and
customize the number of measurement points for specifc applications. Te measurements are performed
quickly, and the user is guided in every step by a live 3D model of the measurement. Upon completing
their measuring, users can create an instant PDF report with all the data, including an adjustable-scale
schematic drawing of the fatness results. Tis app requires separately purchased hardware.
Free / iPad, iPhone, iPod Touch
KoolApp: KoolCode, Refrigerant Slider,
CoolGame, Fitters App, Compass Danfoss
Danfoss designed the new KoolCode app for service technicians, refrigeration engineers and in-store
technicians to easily look up alarm, error, status and parameter codes for a range of Danfoss refrigeration
controllers with a three-digit display. KoolCode joins Refrigerant Slider, CoolGame, Fitters App and
Compass in Danfoss app library.
Users can look up KoolCode display codes by:
Quick code translation without knowing the controller
Hierarchical controller selection among Danfoss refrigeration controllers
Automatic controller identication using a QR-code scan
Free / Android, iPad, iPhone, iPod Touch
Toolbox Technician Emerson Industrial Automation
Power Transmission Solutions
Power Transmission Solutions designed the award-winning Toolbox Technician app for HVACR
technicians. Named an Honorable Mention winner of the 2013 AHR Expo Innovation Award, it
combines the Browning Bearing & Belt Drive Pocket Reference Guide with an energy-ef cient calculator.
Toolbox Technician enables users to easily search the reference guide and quickly calculate information
on ef ciency savings. Te material can be continually updated as new products are developed, so users will
have the most current information. Te upgraded app also provides improved navigation, a belt identifca-
tion wizard and GPS functionality.
PUMPS & SYSTEMS www.pump-zone.com March 2013 9
20
READERS CHOICE
Grundfos GO Remote Grundfos Pumps Corporation
Grundfos GO Remote is an app that works as a mobile tool box. GO Remote provides handheld pump
control that can save users time on control, reporting and data collection. Tis app works with all of
Grundfos e-pumps and communicates with radio and infrared technology. Users have full access to
all the Grundfos Online tools with this app. Features include product dashboard, status data, alarms
and warnings, confguration/commissioning, create installation report, and read/write profles. Special
hardware from Grundfos is required to communicate with the pumps.
Laser Align LUDECA Inc.
Te Laser Align app is a reference tool for the shaf alignment of rotating equipment. Users can access
important reference material and learn about key laser shaf alignment concepts. Laser Align features
several tools with useful reference guides, including Short Flex Tolerance Table, Spacer Shaf Tolerance
Table, Termal Growth Calculator and Sof Foot Assistant.
Laser Align also provides interactive links for additional information on Prufechnik laser shaf align-
ment products and condition monitoring products.
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Amanda Perry is associate editor of Pumps & Systems.
Send information about your favorite mobile
app to her at aperry@cahabamedia.com.
seepex Pumps, SCT seepex, Inc.
Te seepex Pumps, SCT app provides users with information on seepexs Smart Conveying Technology
(SCT) for progressive cavity pumps. In addition to providing valuable information, the seepex app also
has a comparison calculator, which directly shows the potential cost savings that can be made with SCT
compared to an equivalent conventional seepex progressive cavity pump over a period of up to 10 years.
Versa-Matic and Sandpiper Mobile Apps Warren Rupp, Inc.
Te Versa-Matic and Sandpiper mobile apps are designed to help pump owners quickly and easily fnd the
tools to support pumps installed in the feld and pumps being built and shipped. Users can locate specifc
pump information with quick bar scanning or manual entry. Both apps allow users to review the Chemical
Compatibility Guide using the interactive guide, access the latest full line catalogs, and watch service and
repair training videos. Although not yet available for Android or Blackberry, users with these devices can
use the web version, which allows access to many of the mobile apps tools.
Pump Energy Savings Calculator Rockwell Automation, Inc.
Rockwell Automation addresses rising energy costs with Te Pump Energy Savings Calculator app.
Tis app compares conventional fow control methods with PowerFlex drives and shows the diferential
power consumption of each. It calculates the potential energy savings of using variable frequency drives to
power pumps and fans. Users can calculate energy consumption by entering the minimum pump or ow
percentages, annual operating hours, cost per kilowatt and other information about their facility or by
using the built-in sample data provided by Rockwell Automation.
Free / Android, iPad, iPhone, Blackberry
20
W
i kl
W
READERS CHOICE
Xylect Mobile Xylem Inc.
Xylect Mobile is designed to give users quick and easy access to detailed product information from any
location. Since users ofen work on site, the ability to access this information is important. Te app allows
users to input specifc requirements and search for the ideal product to meet their needs. It gives users the
ability to search by application or product type, input required fow and pump head specifcations, and
identify all available spare parts for a product by inputting the products serial number. It also allows users
to search products from a defned duty point (fow and head) and from a product denomination.
Free / Android, iPhone, iPad
TDH Pump Calculator Rain for Rent
Te TDH Pump Calculator provides users with a tool to estimate hydraulic conditions required for pump
systems. Te app is designed for engineers, feld operators and technicians. It is based on Hazen-Williams
equations, and users can enter the hydraulic parameters of the pumping system. Te app will return the
total dynamic head (TDH). It is useful in the feld or of ce. Intuitive controls allow users to simulate any
combination of pre-loaded valves and fttings.
20
iled product info
READERS CHOICE
NEWS
NEW HIRES, PROMOTIONS & RECOGNITIONS
TIM CALLANDER, SJE-Rhombus
DETROIT LAKES, Minn. (Feb. 6, 2013)
SJE-Rhombus announces the addition of Tim
Callander as regional sales manager for their
wholesale controls product line. He will sup-
port customers in the central region of North
America from Texas to Canada. SJE-Rhombus
is a control solutions provider for the water and wastewater
industry. www.sjerhombus.com
GREG DUNCAN & CHRIS DISTASO, Pump
Solutions Group
OAKBROOK TERRACE, Ill. (Feb. 1, 2013)
Pump Solutions Group (PSG) named Greg
Duncan senior director of business develop-
ment and Chris Distaso director of engineer-
ing. Duncan will be responsible for leading the
organizations growth and proftability eforts.
Distaso will be responsible for the overall
supervision and management of the Research
and Development function. PSG is a business
unit within Dover Corporation and manufac-
tures positive displacement pumps and related
technologies. www.psgdover.com
STUART CAMPTON, Precision Polymer
Engineering Ltd
BLACKBURN, England ( Jan. 28, 2013)
Precision Polymer Engineering (PPE)
appointed Stuart Campton as new distribu-
tion manager for its EMEA (Europe, Middle
East and Africa) sales territories. Tis is a
new role to enhance the support that PPE gives to exist-
ing dealers and distributors and to identify new partners in
new geographies. PPE provides o-rings, technical moldings
and sealing solutions to a diverse range of industries. www.
prepol.com
MICHAEL JAMMAL, RACO Manufacturing and
Engineering Company Inc.
EMERYVILLE, Calif. ( Jan. 29, 2013) RACO Manu-
facturing and Engineering Company Inc. announced the
addition of a new director of engineering and manufactur-
ing. Michael Jammal, former program manager at Rockwell
Automation, joins the RACO team and will oversee
engineering, engineering-related departments, and new
business growth and development. RACO Manufacturing
and Engineering Co. provides municipalities, industry and
government with remote communications systems and
RTUs for data logging, alarm auto dialing, remote monitor-
ing, reporting and control. www.racoman.com
ERIC FORD, Graphite Metallizing Corporation
YONKERS, N.Y. ( Jan. 28, 2013) Graphite Metallizing
Corporation named Eric Ford vice president of sales and
marketing. Ford joined Graphite Metallizing in 2007
as director of sales. Graphite Metallizing manufactures
GRAPHALLOY, a graphite/metal alloy that is a unique
self-lubricating bearing material used in machinery and pro-
cess equipment. www.graphalloy.com
AROUND THE INDUSTRY
BIO-MICROBICS and HELD & ASSOCIATES Meet with
Nigerian Delegation
SHAWNEE, Kan. ( Jan. 30, 2013) Bio-Microbics, Inc.
and Held & Associates, Inc., hosted an event welcoming the
visiting delegation of the U.S. Ambassador to Nigeria. Te
purpose of the visit was for the Delegation to participate in
AG CONNECT, an international trade show for the agri-
culture industry. Bio-Microbics is a manufacturer of decen-
tralized wastewater. www.biomicrobics.com
NATIONAL PUMP & COMPRESSOR Opens New Branches
BEAUMONT, Texas ( Jan. 24, 2012) National Pump &
Compressor (NPC) starts 2013 with the opening of three
new locations in Williston, N.D.; Fort Collins, Colo.; and
Wilmington, Del. In addition, NPC announced the grand
opening of the branch in Bakersfeld Calif. NPC produces
industrial pumps, industrial compressors, industrial dryers,
and related equipment for the industrial, petrochemical,
refnery, construction, marine, oilfeld, municipal, environ-
mental and mining industries. www.npcrents.com
MCILVAINE COMPANY Revises Growth Forecast
CHICAGO ( Jan. 22,
2013) McIlvaine Com-
pany has revised its forecast
for growth in the industrial
valve industry over the
next fve years. Te current
forecast is for 5 percent
Tim Callander
Stuart
Campton
Greg Duncan
Chris Distaso
Continent 2013 ($ Millions)
Africa 2,913
America 15,483
Asia 23,956
Europe 13,340
Total 55,692
growth. Tis is being revised to 5.5 percent CAGR for the
2013 to 2017 period. Te basis is the increased anticipated
revenues from the sales of smart valves. Tis is the latest
forecast in Industrial Valves: World Markets published by
the McIlvaine Company. McIlvaine Company is a market
research company. www.mcilvainecompany.com
FLUKE CORPORATION Recalls Digital Clamp Meters
EVERETT, Wash. ( Jan. 21, 2013) Fluke Corporation is
recalling certain digital clamp meters that were manufac-
tured between Sept. 1, 2010, and Oct. 31, 2012. Certain
Fluke 373, 374, 375 and 376 Digital Clamp Meters are
afected by the recall. If you own one of these clamp meters,
please stop using it immediately, and send it back to Fluke
for repair. Te printed circuit assembly in these units may
not be properly fastened to the test lead input jack. Tis
may result in inaccurate voltage readings, including a low or
no voltage reading on a circuit energized with a hazardous
voltage, presenting a shock, electrocution or thermal burn
hazard. Fluke Corporation is a manufacturer of compact,
professional electronic test tools. www.fuke.com
HYDRAULIC INSTITUTE Publishes New Standards
PARSIPPANY, N.J. ( Jan. 18, 2013) The Hydraulic
Institute (HI) has published ANSI/HI 9.6.12012
Rotodynamic Pumps Guideline for NPSH Margin.
MERGERS & ACQUISITIONS
NSF INTERNATIONAL
acquires INASSA Group LLC Jan. 29, 2013
BILFINGER
acquires Johnson Screens Jan. 22, 2013
DANFOSS
acquires ownership of Danfoss Turbocor Jan. 21, 2013
AES ENGINEERING LTD GROUP
acquires AVT Jan. 16, 2013
SKF GROUP
to acquire Blohm + Voss Industries Gmbh Jan. 9, 2013
SULZER METCO
acquires Protective Coatings LLC Dec. 19, 2012
For details about industry M&A activity subscribe to
Pump Industry Insider and visit www.pump-zone.com.
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NEWS
HI also updated the 1998 edition of the ANSI/HI stan-
dard on pump intake design and published ANSI/HI 9.8
2012 Rotodynamic Pumps for Pump Intake Design.
In addition, membership in HI has been opened to pump
and supplier companies that manufacture wholly outside
North America but who sell into the North American
market. Tis change signifcantly expands HI membership
opportunities globally.
Te Hydraulic Institutes mission is to be a value-adding
resource to member companies, engineering consulting
frms and pump users worldwide. www.pumps.org
XYLEM Expands into the Middle East
ABU DHABI, UAE ( Jan. 16, 2013) Xylem Inc. will
expand its presence in the Middle East region with the open-
ing of a new of ce in Saudi Arabia in
the coming months, as well as up to
three additional of ces in other key
regional markets later this year. Xylem
is a global water technology provider.
www.xyleminc.com
KIRLOSKAR BROTHERS LIMITED
Inaugurates New Delhi Facility
NEW DELHI, India ( Jan. 11, 2013)
Kirloskar Brothers Limited (KBL)
inaugurated its second Authorised
Refurbishment Centre (ARC). Te
facility will ofer services such as
overhauling pumps, impeller bal-
ancing, hydro testing, corrocoating,
performance enhancement, testing,
shot blasting and painting. Kirloskar
Brothers Limited is a global fuid
management company. www.kirlos-
karpumps.com
Clean Water Groups Collaborate to
Shape the Utility of the Future
WASHINGTON ( Jan. 13, 2013)
The National Association of Clean
Water Agencies, the Water Envi-
ronment Research Foundation and
the Water Environment Federation
have jointly released a document that
defnes the evolving environmental,
economic and social roles that clean
water utilities are playing in their
communities.
Tis new Water Resources Utility
of the Future will transform the way
traditional wastewater utilities view
themselves and manage their opera-
tions. Te document explores how
traditional, publicly-owned treat-
ment works have mastered their core
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APRIL
WQA AQUATECH USA
April 2 5, 2013
Indianapolis Convention Center
Indianapolis, Ind.
630-505-0160 / www.wqa.org
ENDRESS+HAUSER APRIL TRAINING
SCHOOLS
April 8 10, Flow School-Introductory
Memphis, Tenn.
April 23 24, Pressure & Temperature School
Matthews, N.C.
317-535-7138 / www.us.endress.com
SWPA PUMPING SYSTEMS AND
CONTROLS TRAINING SEMINAR
April 17 18
Hotel InterContinental OHare
Chicago, Ill.
847-681-1868 / www.SWPA.org
CALENDAR
wastewater treatment function and
are now redefning themselves as
resource recovery agencies and vital
community enterprises.
ITT GOULDS PUMPS Heart of
Industry Award, Pulse of Industry
Honor Roll Nominations
SENECA FALLS, N.Y. ( Jan. 10,
2013) ITT Goulds Pumps is now
accepting nominations for the Heart
of Industry Award and the Pulse of
Industry Honor Roll. Te Heart of
Industry Award recognizes industrial
operations for excellence in using
pump technology to improve plant
processing, satisfy customers and
enhance our modern way of life. Te
deadline is March 1, 2013.
ITT Goulds Pumps is a manu-
facturer of pumps for a wide range
of industrial markets. www.gould-
spumps.com
HYOSUNG GOODSPRINGS
Announces Supplier Agreement
with Siemens
PITTSBURGH (Nov. 20, 2012)
Hyosung GoodSprings announced
that Siemens selected the company as
the supplier for condensate extraction
pumps (vertical can) and conden-
sate recirculation pumps (API 610)
for fve combined cycle plants being
constructed in Texas and Argentina.
Hyosung GoodSprings also delivered
its frst circulating water pumps in the
U.S. to a geothermal power plant in
northern Nevada.
Hyosung GoodSprings manufac-
tures pumps.
www.hsgoodsprings.com
P&S
To have an item considered for News, please
send the information to Amanda Perry,
aperry@cahabamedia.com
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PUMP ED 101
By Joe Evans, Ph.D.,
PumpTech, Inc.
P&S Editorial Advisory Board
Branch-Line Pumping and Other Options
Last of Two Parts
L
ast month, this column reviewed several examples of
open fow, branch-line pumping applications. We used
the Branch Line Pumping Calculator (available at www.
PumpEd101.com) to compare a branch-line system with
two diferent discharge elevations to a multi-line system
that used two individual pumps. Based on the input data,
the multi-line system was more ef cient, and its breakeven
point was barely more than 2 years.
ALTERNATIVE SYSTEMS
In addition to multi-line, multi-pump systems, a system
designer has several other alternatives to open-ended,
branch-line systems with multiple elevations. One of the
most common is the tank-based system. In this type appli-
cation, a storage tank is installed at or above the upper most
elevation. A lower fow pump is used to keep the tank flled,
and gravity supplies water, under pressure, to the lower ele-
vation discharge points.
One of the more common examples is a municipal water
supply system. Elevated tanks or those located on hillsides
use gravity to supply pressure to the surrounding areas.
Another example is high-rise buildings. Many older build-
ings use roof-mounted tanks to supply pressurized water to
the upper foors. One more option is to use a single-service
line with two or more pumps operating in series. Figure 1
compares this design to an open-branch system.
SYSTEM COMPARISON
Te upper pipeline shown in Figure 1 is the same open-fow,
branch-line design illustrated in Part 1. Te pump at Point
A produces 600 gallons per minute (gpm) at a total dynamic
head (TDH) of 200 feet and supplies outfows of 400 gpm
and 200 gpm at branch Points B and C. Te power required
to meet the two branch fows is 43.2 horsepower. Te high
horsepower is required because the total head seen by the
pump is directly proportional to the elevation at Point C.
Te pumping system in the lower portion of Figure 1 is
diferent. Te pump at Point A still provides 600 gpm, but
since it is pumping to Point B only, its discharge head is
reduced to 100 feet. A second pump, located at Point B and
operating in series, moves the remaining water to Point C.
Tis design reduces the total power required by 33 percent.
Tis results in a smaller pump at Point A that requires 21.6
horsepower and an even smaller one at Point B requiring
just 7.2 horsepower. Figure 2 is the calculator portion and
compares the variables involved in these two alternatives.
As in the confgurations in Part 1, the required data are
entered into the yellow cells, and the column to the lef is
the open-fow, branch-line system. Te two columns in the
middle represent the series system from Points A to B and B
to C. Te initial cost of the branch-line system is $44,000.
When converting to a series system the cost is reduced by
$8,000 because of the smaller pump required at Point A.
Te additional pump and controls
required at Point B adds an addi-
tional $11,000 to the cost of the series
system. Terefore, the total additional
cost for the series system is $3,000.
Based on an annual electrical savings
of about $3,300, the payback is less
than one year.
For this example, the series system
is more ef cient than the single pump
system. It also trumps the two pipe-
line design shown in Part 1 of this
series. Te horsepower required for
the series system and the two pipeline
design are exactly the same, but the
lower piping cost of the series system
makes it a more cost-efective system.
Figure 1. Comparison of a single service line with two or more pumps operating in series to an
open-branch system
As I stated in Part 1, my branch-line pumping calculator
is not a design tool. Instead, it is an evaluation tool that
allows you to compare traditional branch-line systems with
several alternatives. Once a choice is made, any number
of sofware systems can assist with the design phase. Te
Branch Line Pumping Calculator can be downloaded from
the Pump Evaluation, Selection
& Testing Tools page at www.
PumpEd101.com. P&S
Note: Part 1 (February 2013) of
this series contained an error. When
describing Figure 2, I said that Point
A was at an elevation of 100 feet and
Point B is 100 feet higher. Point A
should have been Point B and Point
B should have been Point C.
Joe Evans is responsible for customer and
employee education at PumpTech, Inc., a
pump and packaged systems manufacturer
and distributor with branches throughout
the Pacifc Northwest. He can be reached
via his website www.PumpEd101.com.
If there are topics that you would like to
see discussed in future columns, drop him
an email.
Figure 2. The Branch Line Pumping Calculator computations of the systems
PUMPING PRESCRIPTIONS
By Dr. Lev Nelik, P.E., Pumping Machinery, LLC
P&S Editorial Advisory Board
Will Impeller Velocity Triangles
Keep You Awake at Night?
Last of Two Parts
A
pparently, impeller velocity triangles do keep some folks
awake at night.
Part 2 contains information that is similar to what was
discussed in Part 1, but it includes more detail regarding
the vectors for each vane outlet at the same location for the
three types of impellers. Tis detail will hopefully make the
interpretation of the triangle more realistic.
We have shown only three positions on each type to pro-
vide the best possible illustration without sacrifcing clarity.
Tis also helps show, more clearly,
the velocity vectors on Figures 1
and 2 from Part 1.
As shown in Figures 1 and 3,
the locations for the backward
and forward vane inlets are dif-
ferent, assuming that the same
inlet vane angle is maintained.
Note that the impeller curvature
(inlet and outlet) is set by a cir-
cumference used to fx the rela-
tive inlet and outlet velocities.
A tangent is drawn to the inlet
and outlet from the center of the
circumference. Inlet and outlet
peripheral velocities are drawn
using tangents from the center of
the impeller.
In the case of the radial impel-
ler (see Figure 2), the vanes are
straight to the center of the cir-
cumference. Any vane curvature
is ignored for simplicity.
Note that for the turbopump
(see Figure 4), the fow vectors
for its turbine wheel, which has
the fow direction reversed compared to the pump impel-
ler, are shown as infows rather than outfows like the other
examples. In particular, note the match between the vectors
at the inlet of the pump and the outlet of the turbine wheel.
We also assumed, for simplicity, that the tangential veloc-
ity components at the pump impeller outlet can be consid-
ered equal to the turbine inlet and the turbine outlet equal
to the pump inlet.
u
2
2
W
2
u
2
W
2
v
2
2
v
2
v
2
Figure 1. Backward-bladed centrifugal impeller ( < 90 degrees)
Editors Note: Lev Nelik received many comments on this subject after Part 1 (Pumps & Systems,
January 2012). Alberto Delgado, a former process engineer with Brown & Root, provided interesting
feedback and detailed gures that resulted in several exchanges of ideas between the two. Tis infor-
mation is presented as a follow up on this advanced and specialized subject of pump hydraulic design
and is coauthored by Delgado.
Te following legend applies to Figures 1 through 4,
which are used to illustrate the velocity triangles:
U = rotational, peripheral, tip velocity vector
v = absolute resultant velocity
W = relative velocity to blade tip
= absolute vector angle
= blade vane angle
= angular, rotating velocity
P&S
Dr. Nelik (aka Dr. Pump) is president of Pumping Machinery, LLC, an Atlanta-
based frm specializing in pump consulting, training, equipment troubleshoot-
ing and pump repairs. Dr. Nelik has 30 years of experience in pumps and pump-
ing equipment. He can be contacted at www.pump-magazine.com.
Alberto Delgado is a retired process engineer who formerly worked at Brown
& Root.
v
2
u
2
2
W
2
v
3
u
3
3
W
3
W2 v2
u2
3
W3
u3
v3
2
v
2
v
W4
u4
v4
1
W1
v1
u1
v
4
1
v
u
2
2
W
2
W
2
u
2
2
v
2
v
2
v
2
W
2
u
2
u
2
2
2
v
2
W
2
v
2
v
2
Figure 4. A pressure recovery hydraulic turbine, backward bladed (left) and a turbopump, forward bladed (right)
Figure 3. Forward-bladed centrifugal impeller ( < 90 degrees) Figure 2. Radial-bladed centrifugal impeller ( < 90 degrees)
SPECIAL REPORT
M
ore than 90 percent of all pumps in many diferent
industries are centrifugal pumps. Variable-speed, large
centrifugal pumps are well-known for critical and large
pumping services. Centrifugal pumps exhibit a suitable
operating curve compared to other pumps (for example,
axial pumps and positive displacement pumps ofer relatively
steep curves). Te curve characteristics can be matched with
the system requirements. A more backward angle could
make a higher reaction (from the pump impeller) and a
relatively steeper curve.
As pump stages are put together, the overall fow range
of the combined stages could be less than the smallest fow
range of the individual stages. Because of the compound-
ing efect, as the fow is changed, the combined curve of
a multistage pump could have a smaller operating range.
When developing a pump system and before specifying and
purchasing a pump, many factors should be considered
including the application, installation, lubrication system,
pump operation and pump noise generation. Tese consid-
erations are discussed in the frst part of this article. Part 2
will be in the April 2013 issue of Pumps & Systems.
PUMP SPECIFICATION AND PURCHASE
Te pump operation conditions should be divided into a set
of normal conditions and a set of abnormal conditions. Te
entire anticipated range of operating conditions should be
defned either by range limits or alternative operating con-
ditions. Unusual operating conditions, even insignifcant
ones, should be indicated when developing a list. All avail-
able details should be shared with the pump manufacturer.
Above: An example of different pump sizes/models in a pump family. These are sealless magnet drive ANSI pumps. Six models
are in this family.
Pump Specifcation, Purchase,
Installation & Application
Sharing all the information about an application can help with the selection and installation
of the ideal pump.
First of Two Parts
By Amin Almasi, WorleyParsons Services Pty Ltd.
In many cases, insignifcant system or environmental condi-
tions can cause considerable problems. Examples could be
corrosive traces in the liquid, even if they are in the parts-
per-million level.
Te purchaser should know as much as possible about
the system in which the pump will be installed and the fuid
that the pump/system will move and then inform the manu-
facturer. Particularly, the purchaser should be aware of any
unusual conditions and potential upsets that could afect
the pump. An example is the liquid temperature runaway
potential in some hot liquid units. Te pump specifcation
should note all expected maximum temperature values, and
the pump vendor should be asked about the maximum tem-
perature that the pump can handle.
Another example is the potential of the sudden dead-
heading of a centrifugal pump when switching operations
during some batch-type processes. Te pump manufac-
turer should also be informed of any fouling potential. Te
potential pump conditions should be carefully explored and
any fouling potential should be noted. By correctly includ-
ing the fouling potentials in the description of the system
conditions, the pump vendor may be able to include a solu-
tionsuch as additional head marginswhen selecting/
manufacturing the best pump for the application.
Te pump requisition should include a complete list of
the scope of supply and service (preferably in a table format).
Te pump nozzle orientation is important as well. Ideally,
the nozzle orientation details should be agreed upon with
the pump manufacturer from the beginning.
Do not assume that the pump vendor is completely knowl-
edgeable about the material requirements for the system/
process. Stating the minimum material of construction
requirement can help the pump vendor during the pump
design/selection phase and avoid future problems. Te
vendors focus is to provide a pump that is compatible with
the specifcations and reliable enough to cover the vendors
guarantee period at the minimum possible cost. With the
proper wording of the pump specifcations, the minimum
material requirements can be noted. It can also invite com-
ments that may reveal the vendors experience with pump
material selection.
A large number of unscheduled shutdowns are traced
back to the vendor design; the vendor material selection;
or the component selectionsuch as seal problems, bear-
ing issues, excessive fouling, high degradation, corrosion,
erosion and other factors. However, these problems actually
refect a lack of application knowledge, which could have
been prevented if the purchaser communicated improper
specifcations. A good example is the use of austenitic stain-
less steels, which are normally considered premium materi-
als. However, they cannot be used if chlorides are present in
the pumped liquid because of intergranular corrosion and
subsequent cracking problems.
Te orientation of the inlet piping and its infuence on
pump performance is important. Tere should be neither
pre-rotation nor anti-rotation. Te fow should be free from
random distortion. Based on the design, the liquid veloci-
ties and the system/process conditions, a minimum length
of straight pipe may be required before the pump inlet.
BID EVALUATION FOR PUMPS
A bid evaluation should be made that factors the energy
cost, frst cost and reliability issues using an established eco-
nomic equation. If the data are available, the total cost of
ownership can be estimated, which is the best available mea-
sure for the bid evaluation of a pump. It is absolutely nec-
essary to fx all items and clarify all issues before the pump
purchase order placement. Until the vendor is sure he has an
order, he will stay in a trading posture.
Te successful bidder becomes the vendor when a con-
tract is written and accepted. Tis is important because the
clock has started at this time, and all future dates will be ref-
erenced back to this date. Tis also is the date from which
the pump delivery is counted.
Figure 1. An example of different pump sizes in a pump family
SPECIAL REPORT
PUMP LUBRICATION SYSTEM
Based on some reports, considerable reductions in the
oil fow of the manufactured lubrication oil system can
occur compared to the initially-proposed system that was
included at the biding stage. Te purchaser and vendor have
many discussions and debates regarding this issue.
In some cases, the lubrication systems capacity can be
reduced by 20 to 30 percent, occasionally by as much as
40 percent for some large and critical pumps. Te proposal
technical data (the bid technical details) are not fnal and
some modifcations could be expected.
However, an oil fow reduction of more than 25 per-
cent, compared to the purchase order, should not usually
occur. Any reduction in excess of 30 percent would require
a detailed justifcation. Te vendor should supply the data
and the basis for any oil fow reductions that occur, particu-
larly any signifcant reduction in the oil fow of the hydrody-
namic bearings. Suf cient oil supply to the hydrodynamic
bearing(s) and the gear units is always a concern.
PUMP INSTALLATION
How and where the pump/pump system will be installed
must also be considered. Te prime function of the pump
foundation is to hold the pump train in alignment during
all operating modes. To perform this function, the foun-
dation should be rigid. Establishing and maintaining the
alignment between pump train componentsparticularly
for large pump trains delivered in several skidsis dif cult
if the foundation is prone to excessive defections.
Te foundation should be large enough to prevent exces-
sive diferential defections and dynamic vibrations, which
can have considerable efects on long-term operation.
Another aspect is the foundations natural frequency. Te
foundation should be tuned in such a way that any founda-
tion natural frequency is not in coincidence with any of the
pump train excitation frequency. It is desirable to have all
the foundations natural frequencies well above any pump
excitation speed, as far above as practical.
Ideally, the pump can be placed on the foundation, aligned
and grouted, and piping can be connected according to the
pump installation procedure. Lags ofen occur between dif-
ferent steps. Carelessness can delay start-up and could result
in an unsuccessful pump installation. More details on instal-
lation will be covered in Part 2 in the April 2013 issue.
PUMP OPERATION
In many cases, the main contributors to centrifugal pump
problems are related to the seal, the bearing and rotor
dynamics. Long slender rotors can cause problems in cen-
trifugal pumps. Some high-speed pump rotors are subjected
to critical speeds, which are encountered during startup
(particularly in high-pressure pumps).
Sensitivity to unbalance can also cause operational prob-
lems. During operation, as time passes, pumps experience
degradation, which usually manifests in ever-increasing
levels of unbalance. Te more sensitive the rotor, the shorter
the runtime.
In many cases, the decision to replace or redesign a pump
train component was incorrect. An incorrect diagnosis or
wrong interpretation of the reason for a pump failure some-
times results in a solution that appears to fx the problem.
However, if it is incorrect, the solution could possibly
lead to worse problems in the future because an incorrect
symptom-cause relationship is established. Careful problem
solving should accurately determine the real cause of a prob-
lem and prevent complications.
Te cleanliness of the liquid stream is a key factor, as well,
for smooth pump operation and reliability. Te corrosive
substances and traces require a special material selection
and operation considerations. Fouling because of contami-
nation or liquid reaction can cause rapid degradation.
PUMP NOISE
Te overall sound pressure level is generally based on 1
meter from the pump skids edge. Tis means that the sound
pressure level of each component at 1 meter from the skids
edge could be diferent, usually lower for the large pump
packages, than the indicated noise value for each compo-
nent, which is the noise at 1 meter from that component.
Te pump package noise is not simply the sum of the noises
of diferent package components.
Figure 2. An example of a belt-driven ANSI pumpthe ANSI pump
design can sometimes help overcome issues, such as space
restrictions or low NPSH.
Te gear unit, if used in a pump package, is the major
source of noise. For the noise emission of a gear unit, the
design of the gear unit has more infuence than the trans-
mitted power. A gear unit may generate the same noise or
sometimes a slightly higher noise during part-load opera-
tion compared to full-load operation. As another example,
a 1-megawatt gear unit and a 1.5-megawatt gear unit using
the same design principles may generate practically the same
noise level.
Te pump vendors sound calculation programs usually
do not simulate any sound boundary condition near the
pump package. For example, the boundary conditions (such
as a wall close to the pump skid) can infuence the noise
measured in the plant. Terefore, an allowance is needed
to accommodate for this efect. Based on experience, an
increase of around 3 to 5 decibels of the expected sound
level for a pump package is observed at some unfavorable
boundary conditions.
CONCLUSION
When the pump user and the pump vendor work together
as a team and if all the engineers involved give suf cient
attention to details, changes and requirements, reliable and
high performance pumps can be expected. Te keys to suc-
cess are up-to-date knowledge, correct specifying, proper
review of pump vendor documents, correct inspection of
vendor activities, and modern operation and maintenance
policies. Te true proftability and cost savings in a pump
installation can only be achieved by combining perfor-
mance, reliability, safety, availability and maintainability.
See the April 2013 issue of Pumps & Systems for more infor-
mation on installation and alignment. P&S
Amin Almasi is lead rotating equipment engineer at
WorleyParsons Services Pty Ltd., Brisbane, Australia. He pre-
viously worked at Technicas Reunidas (Madrid, Spain) and
Fluor (various offces). He holds a chartered professional
engineer license from Engineers Australia (MIEAust CPEng
Mechanical) and a chartered engineer certifcate from
IMechE (CEng MIMechE), RPEQ (Registered Professional
Engineer in Queensland). He specializes in rotating machines including cen-
trifugal, screw and reciprocating compressors, gas and steam turbines, pumps,
condition monitoring and reliability. Almasi is an active member of Engineers
Australia, IMechE, ASME, Vibration Institute, SPE, IEEE, and IDGTE. He has
authored more than 60 papers and articles dealing with rotating machines.
Almasi can be reached at amin.almasi@ymail.com or +61 (0)7 3319 3902.
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is a registered trademark of seepex GmbH +Co KG.

Tit SX i t di t ib t f t f

COVER
SERIES
COVER
SERIES
Agricultural
Irrigation
& Dewatering
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M
odern agricultural irrigation is a complex interplay
of sustainable energy consumption, water use,
market conditions, and the application of experience
and knowledge to ensure the best design for irrigation
applications. Understanding past practices, current water
and energy issues, and developments in pump technology
contributes to building pumping systems that best service
the needs of modern agriculture. Te agricultural market is
changing rapidly, and farmers cannot rely on the technology
and practices of the past.
To keep productivity high and stay competitive in the
market, farmers need to focus on proftability, which
includes energy optimization and better
use of water resources. Pumping systems
play a vital role in providing optimized
solutions for energy and water use.
WHAT IS IRRIGATION?
Irrigation is an artifcial application of
water to plant roots with the purpose of
assisting the growth of agricultural crops.
Fertilizer and chemicals can be added to
an irrigation system. Irrigation can also
play a role in frost protection.
Successful agriculture depends on
farmers having suf cient access to water.
In the middle of the last century, the
common perception was that water was
an infnite resource. Today, we know that
water is a resource that must be man-
aged. Tis is not only a question of more
mouths to feedpeople consume more
calories and eat more meat. Tis requires
more water to produce food.
Farmers must consider energy con-
sumption. Energy for irrigation pumps
is one of the highest single cost drivers
for farmers. However, many are unaware
of the potential savings from more efective and ef cient
energy use.
Modern agriculture requires irrigation solutions that
optimize uniformity, reduce energy costs, safeguard the
water resource and keep productivity at its best. Te agri-
cultural market changes require greater focus on applying
knowledge, experience and total irrigation solutions inte-
grating all components.
WHAT TO CONSIDER WHEN GETTING WATER TO THE CROP
Irrigation starts with sourcing water for the crop from
groundwater or surface water from a channel or storage
Pump Systems for Todays
Agricultural Irrigation
Complex irrigation applications require customized and cutting-edge solutions.
By Vahan Bagdasarian, Grundfos
A pump system for todays irrigation is not only about the pumps. Variable speed drives,
intelligent control and remote management all necessitate the integration of components
in an irrigation system.
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SERIES
pond. Next is water treatment, if necessary, and perhaps the
addition of fertilizer or chemicals. Finally, water is delivered
to the crop using diferent techniquessuch as fooding,
sprinkler irrigation or drip/micro-spray applications.
Mechanized sprinkler systems, such as pivot irrigation, are
efective for covering large areas. Tese systems are typically
attached to a pump that can supply the necessary amount
of water, pressure and signifcantly more, as a precaution. A
valve handles the excess fow and pressure.
Drip and micro-spray irrigation are used for low-pressure
applications in which reducing as much potential evapora-
tion and run-of as possible is a requirement. Keeping the
pressure constant is vital to ensure
uniform application throughout
each zone in the system. Tis can be
the most energy-ef cient method
of irrigation, if managed properly.
Achieving this requires that the
system be able to compensate for vari-
ations in fow to ensure constant pres-
sure as zones cut in and out.
TRADITIONAL APPROACHES AND
PUMPING SOLUTIONS
Groundwater withdrawal has typi-
cally involved submersible or vertical
turbine pumps that bring water to
the surface. For surface water intake,
centrifugal pumps in diferent con-
fgurations, split case pumps and end
suction pumps have been traditional
solutions.
Tese pumps are required to meet
changing conditions above and below
ground, which have an efect on the
pressure and fow required from day
to day and from season to season. A
pumping system must deliver the
right amount of pressure and fow
at the nozzle. Te simple solution is
to oversize the pump, so the pump is
able to handle a worst case scenario.
However, as a result, the pump will
almost never operate at its optimal
duty point. It will produce too much
pressure and consume too much
energy, which is not used produc-
tively in any way.
Traditionally, water has been dis-
tributed from the water source
either groundwater or surface
waterat low or constant pressure
from pumps operating at single speed.
Delivery to the crop has been from
nozzles, where the focus has been on
surface coverage, without much atten-
tion placed on run-of, canopy evapo-
ration and wind drif. Soil moisture
monitoring to ensure an even spread
over the irrigated area is a relatively
new discipline.
In contrast, pressure management
has long been an issue. Trough the
years, pressure reduction valves have
been used to reduce pressure in the
system. However, valves are costly to
install and require frequent service
and replacement, and their operation
consumes a lot of energy.
If end users think of an agricul-
tural irrigation system as a car and the
pump as the motor, would it make
sense to drive the car at constant
full throttle and control the speed
with the brakes? Tis is a common
approach for irrigation pumps.
MEETING THE CHALLENGES OF
MODERN AGRICULTURE
Complete pumping systems instead
of large, isolated pumps are the solu-
tion going forward. For example, the
costly and time-consuming use of
pressure reduction valves to maintain
constant pressure can be eliminated
by investing in pump controllers for
efective pressure management. Tis
saves costs in the long term, reduces
the need for service and minimizes
energy consumption.
Te same can be said of using valves
in sprinkler irrigation. Using a vari-
able speed pump and a pressure sensor
on the pivot, which would automati-
cally adjust the pump performance to
match the requirements for the pivot,
is a much better approach. Tis would
ensure higher irrigation uniformity
and keep energy costs down. A
pump controller ofers the additional
advantage of protecting the pump
from dry-running or power supply
To keep productivity high and stay competitive in
the market, farmers need to focus on proftability,
which includes energy optimization and better use
of water resources.
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Supported around the globe.
COVER
SERIES
irregularities, which will extend the lifetime of the pump.
Te rises and falls in water level, below ground and for
surface water, essentially change the specifcations for a
pumping system because these variations change the head.
A single speed pump dimensioned to lif from the lowest
water level will burn energy dollars when the level is high.
On the other hand, a variable speed pump adjusts its head
and fow to compensate for water level changes, reducing
energy costs.
DESIGNING AN IRRIGATION SYSTEM FOR
TODAYS APPLICATIONS
Farmers and pump system providers need to think through
the specifc irrigation applications in new ways, and in par-
ticular they need to think about irrigation system design in
the application. Te pumps must be much more integrated
with the rest of the irrigation system. Tis means the pump
must be designed to match the irrigation equipment or the
irrigation equipment must be designed to match the pump.
Te current approach of simply installing a pump capable
of always delivering more than enough water ends up wast-
ing money and energy. Returning to the aforementioned
metaphor, which compares the system to a car and the
pump to its motor: Purchasing an over-sized motor to place
in a car will end up a costly afair and ofers no guarantee of
a comfortable or fuel-ef cient ride.
Tink about this in an irrigation system, in which the
pump must do more than simply deliver water to the pipes
to be efective. For example, adding variable speed drives
improves the ef ciency of groundwater withdrawal when
pumping directly into an irrigation system. Surface water
intake and distribution can be improved by using multi-
pump pressure boosting systems. Across the board, moni-
toring and control systems further safeguard the reliable
fow of water by protecting the pump from dry-running,
motor breakdown or power supply irregularities.
All these elements must be fully integrated into the design
to provide the benefts that a modern irrigation pump
system can ofer the farmer. Maintaining correct pressure
and fow in the pipes and at the nozzle means more water
per kilowatt hour and savings on energy, which is one of the
highest cost items in farming.
Earlier, the importance of maintaining a constant pressure
in a pivot irrigation system was explained. Tis becomes rel-
evant if the pivot is equipped with an end gun and maybe
even a corner section. As soon as the end gun or corner
section comes on, the pressure in the pivots main line will
drop. Tis will impact the irrigation uniformity.
The range of pump applications in agricultural irrigation is many and varied. The
key to success is intelligent pump controls that are designed specically for
each application.
Figure 1. If a pump is specied to run continuously at
the highest levelfor example when the corner section
comes onenergy is wasted. The different requirements
for optimal energy use on a pivot application can be met
by using a variable speed pump. This offers substantial
energy savings while maintaining pressure requirements.
Te solution is to replace the pivots main pump with a
variable speed pump, which will immediately react to a pres-
sure drop when an end gun or corner section cuts in. In such
a confguration, it is possible to maintain the same pressure
on all the sprinklers and, therefore, deliver high uniformity
(see Figure 1).
THE FUTURE: TOTAL SOLUTIONS,
TAILORED TO THE APPLICATION
Te development in irrigation sys-
tems described in this article reveals
a need for careful consideration of
the entire irrigation system and each
components integration, tailored to
the application.
Tis requires experience and knowl-
edge. Te ability to follow water from
the source to the cropfrom water
intake, water treatment and distribu-
tion to the irrigation application
and carefully monitor it along the
way is critical for an irrigation pump
system.
Modern agriculture requires a
broader understanding of component
integration, and the system must ensure
that the farmer is able to respond to
issues of energy consumption and water
supply, specifcally by isolating areas in
which savings can be made, generating
increased proft per acre.
Tis is not an exercise that can be
carried out in isolation. All relevant
local conditions must be added to the
equationsuch as soil conditions,
the crop, topography and weather
patterns. Pump control, including
monitoring and intelligent manage-
ment, is then the way forward.
Energy savings are there to be made
and are substantial. Te added ben-
eft for the farmer is, in addition to
the lower operating costs, that water
is delivered with greater precision to
the crop. Tis results in a better har-
vest, increased proftability and better
water management, ensuring sustain-
able agriculture in the future. P&S
Vahan Bagdasarian is innovation manager, Irrigation, for
Grundfos. He can be reached at vbagdasarian@grundfos.
com. With an annual production of more than 16 million
pumps, Grundfos is a provider of pump solutions and special-
izes in circulator pumps for heating and air conditioning and
centrifugal pumps for industrial applications, water supply,
sewage and dosing. www.grundfos.us
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COVER
SERIES
O
f the 6.3 million farms in the U.S. in January 1925, only
205,000 received centralized electric services. Private
utility companies that supplied electric power to most of
the nations consumers argued that it was too expensive to
string electric lines to isolated rural areas, and most farmers
were probably too poor to aford it.
To rectify that situation, the Rural Electrifcation
Administration (REA) was created by executive order and
was charged with administering loan programs for electri-
fcation and telephone service in rural areas. Between 1935
and 1939the frst 4 years afer REAs establishment
the farms using electric services more than doubled.
Even though farmers were gaining access to the power
grid, they were still using diesel engines to power their
pumps. One reason for this is that they had already invested
in diesel. Also, in most cases there simply was not enough
juice to power the farmhouse and the pump house.
By the early 1970s, about 98 percent of all U.S. farms had
access to afordable electric service. Many farmers, though,
were still using engines to power their pumps and would
continue to do so. Most would argue that despite some price
spikes, diesel fuel was still cheaper than electricity. Afer all,
those diesel engines still worked. Why switch to electric?
Te trend toward switching from diesel to electric began
gaining steam within the last 15 years. Environmental con-
trols and regulations on the operation of diesel engines and
the rising cost of diesel fuel have accelerated the conversion.
Changing from diesel to electric makes sense from several
diferent standpoints.
COST
Operating and maintenance cost advantages are available
when switching from diesel to electric. On the operational
front, end users must consider the cost of diesel fuel. It is
expensive, and likely to remain so as global demand rises.
Figure 1 illustrates that running an engine on electricity is
less expensive than running one on diesel. Tat was not the
case in 1992, but times have changed. Te economics of irri-
gation pumping favor electric motors.
Figure 2 details the operating hour scenarios and cost
points for diesel and electricity. It shows estimates of the
total costs of operation for an irrigation pumping system.
Te costs include estimates for energy, repairs, fxed cost
depreciation, maintenance and service. Because each pump-
ing station will be unique, the costs are an estimate, but they
clearly show the economics of today.
1

Te cost for electricity can vary depending on when and
where it is consumed. Avoiding peak power demand times
can lower the costs of electricity even further. In some parts
of the U.S., irrigating at of-peak hours is a good economic
idea and ofen mandated.
From a maintenance standpoint, electric motors win
this battle, too. Maintenance on a diesel motor requires
more time and attention than electric motors. Depending
on the application, a pump engine may be required to run
for extended periods if that pump drives multiple systems
during the irrigation season. If so, the diesel engine will con-
stantly need to be refueled and the oil levels and flters will
require monitoring.
Electric motors do not have to be refueled. Tey also do
not have engine oil and flters that must be checked and
replaced. Tey only require lubrication once every season.
Powering the Pump:
Diesel Versus Electric Motors
Make the ideal motor selection for irrigation applications.
By Tim Albers, Nidec Motor Corporation
Figure 1. Total annual costs in thousands to operate a 75-horsepower
irrigation pump 1,500 hours per year using an electric motor or
diesel engine.
Source: Curley, Robert G. & Gerald D. Knutson,Cost Comparison: engines vs.
electric motors for irrigation pumping, California Agriculture, Vol. 48, Num. 5
ENVIRONMENTAL IMPACT
Perhaps the overriding motivation to change to electric, par-
ticularly in the past few years, is the concern with environ-
mental issues. An electric motor runs cleaner than a diesel-
powered engine. Electric power plants continue to create
power in cleaner ways. Also, the addition to the grid of alter-
nate energy sources, such as wind and
solar, provide electricity with virtually
zero carbon emissions.
An electric motor allows for the use
of much lower carbon emission power
versus a comparable diesel engine.
Te harmful environmental efects
from internal combustion engines
outnumber those from electricity.
PUMP CONTROL
In addition, installing pump controls
and variable speed controls is easier on
an electric motor than it is for a diesel
engine. While these types of con-
trols can be added to diesel engines,
they are costly, and more important,
they can reduce the ef ciency of the
engine.
Tis is not the case when adding
controls and variable speed features to
electric motors, which when applied
correctly, greatly increase the ef -
ciency and durability of the motor,
improve control in pipelines and
canals and reduce energy use. Electric
motors can be automated and con-
trolled remotely. Variable speed drives
and sof starters in electric motors
are components that help mitigate
power surges. Te technology exists
and is growing quickly based on ever
decreasing costs to monitor and con-
trol an electric-driven irrigation pump
system remotely.
THE DECISION
Diesel engines remain in use today and
for good reason. In some areas of the
world, electricity is unavailable. Also,
the diesel engines installed years ago
continue to work today. Operators
do not want to scrap something that
works to spend more money on new motors, even if those
new motors will eventually pay for themselves in reduced
operating costs and improved ef ciency and have less impact
on the environment.
Te question becomes when to make the switch. Te
answer is easy if and when that diesel engine fails. However,
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COVER
SERIES
if end users engines are operating well, they should
consider having a plan in place to switch to electric
motors at some point in the future. Hopefully, they
can make that switch when they want to instead of
being forced to repair a broken diesel engine to com-
plete the irrigation season.
Te bottom line is thisin 2013, for many irriga-
tion applications, operators choose electric motors, if
electricity is available, to power their pumps. P&S
Figure 2. Operating scenarios and costs for diesel fuel and electricity.
Reference
1. Curley, Robert G. & Gerald D. Knutson,Cost Comparison: engines vs.
electric motors for irrigation pumping, California Agriculture, Vol. 48,
Num. 5.
Timothy Albers is the director of product management and OEM marketing for the
Industrial Motor Division of Nidec Motor Corporation and is responsible for product
management, marketing and quotation support. During the past 16 years, Albers has
held different positions in marketing for Nidec Motor Corporation and Emerson Motor
Company, including product-line manager for NEMA motors. Before joining Emerson, he
was employed by General Electric Company in the marketing and sales of electric motors
and drives. Albers career includes a stint in the U.S. Navy as an operating engineering
offcer. He is a senior member of IEEE.
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COVER
SERIES
M
ining applications are as diverse as construction or water
and wastewater applications. Each jobsite has specifc
requirements and needs. Underground and open pit mines
have several layout and design obstacles. Regardless of the
mine and its setup, water is a mines biggest enemy.
Getting water outand keeping it outis the primary
focus of any mine plan. Te deeper the mine, the more
water that will be encountered and need to be removed.
Once dewatering begins, mine planners can get back to
what they do best.
MINE DEWATERING
A pump company or dewatering solutions provider can
partner with mine planners and engineers in the design
and planning stages. A system analysis should be performed
frst. Ten pump selection can begin. Factors to consider in
mine planning include portability, easy maintenance and
solids-handling.
Another consideration is pH. Pumps can be customized
with durable materials of construction specifcally designed
for low pH and other corrosive liquids.
Pump systems are completely customizable, and the right
one can only be selected afer the operator or mine engineer
understands the mine plan. Pump and piping design and
pump control can be tailored to the mine plan. In addition
to length of fow, elevation and discharge, consider layout
drawings, hydraulic grade lines and pipe wall thickness.
Perform friction loss calculations.
Powerful Mine Dewatering
Electric and diesel centrifugal pump options
By Kristen Gurick, Godwin Pumps, a Xylem Brand
A centrifugal pump with a fuel cube
Also, consider present and future requirements.
A mines design can change based on weather
conditions, landscape vulnerability and market
demands. A dewatering pump company can help
design the mine plan, so mine operators and engi-
neers can focus on mining. A reliable dewatering
system allows them to continue working.
Te power source is another component to
consider for mine dewatering pump selection.
When selecting a centrifugal pump to ft their
needs, many mine operators select diesel-driven
centrifugal pumps. As with any other application,
operators have options. Te initial setup costs
should be measured against the lifetime costs of
pumping for the project. For a temporary job in
a mine or quarry, diesel-driven pumps will typi-
cally be the most logical choice. Setup costs are
virtually zero. Te pumps run on diesel fuel for
the short duration of the project. If available near
the mine, natural gas is also an option.
Hydraulic submersible pumps are another
option for mine planning. Tese pumps feature a
A diesel-driven centrifugal pump
GE Works to boost mine efciencies.
In the mining industry, GEs SPS pumping systems
work to increase efciency, reduce environmental
impact and provide versatile pumping solutions.
For example, our multi-stage centrifugal SPS pumps
are used in a wide range of mining and mineral
processing applications including water supply
and transfer, water disposal, cavern leaching
operations, dewatering, dust suppression, mine
drainage, chemical processing, boiler feed and in
water processing plants. Our SPS systems provide
enhanced pumping efciencies by lowering noise
and vibration levels, decreasing construction lead
times and delivering improved reliability and
extended runtimes. With GE, you have a worldwide
support system ready to provide engineering, eld
service or sales support.
Take a look at our results, and see how
GE can work for you.
Call +1 713 260 6731 or e-mail sps.inquiry@ge.com
www.geoilandgas.com/sps
power pack ftted to a submerged pump. Te pump ends
usually sit at varying levels of submergence, and their power
packs sit above ground. Tey are ideal for abrasive fne sand,
high specifc gravity (such as that found in slurries) and can
ofer a total dynamic head up to 600 feet. Tese hydraulic
submersible pumps can be diesel driven or electric, depend-
ing on system requirements.
ELECTRIC-DRIVEN PUMPS
If a project is more long-running, con-
sider electric-driven pumps. Electric
submersible pumps have a solid history
in mining applications. Tese pumps
can handle moderately large fows (up
to 2,500 gallons per minute) or extreme
high heads (up to 750 feet).
In addition to these submersible
pumps, electric-driven centrifugal
pumps are ideal for both prolonged tem-
porary pumping and permanent installa-
tions. Designed for long-lasting durabil-
ity, these pumps were initially used in
industrial and municipal applications.
However, their benefts span many more
applications. A permanently installed
A diesel-driven hydraulic power pack in the foreground (pumps in the background are diesel-
driven booster pumps)
W
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Contact your authorized Wilden distributor:
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Series air-operated double-diaphragm (AODD) pumps are the most advanced, versatile,
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COVER
SERIES
electric-driven centrifugal pump will provide reliable, con-
tinuous pumping and reduced operating and maintenance
costs.
While not frequently used in mining applications, elec-
tric-driven centrifugal pumps are a viable option for a perma-
nent installation or lengthy temporary pumping job. If the
site location is not extremely remote, an electricity source
can be found and power lines run to the jobsite. Accessing
electricity can outweigh the lifetime costs of a diesel-driven
pumping system if the timeframe is long enough. Costs for
running electric-driven pumps will eventually be the more
economical choice, even factoring in initial setup costs.
For temporary jobs in which refu-
eling is dif cult, an electric pump is
the ideal solution. Once power lines
are established, pump accessibility is
almost a nonissue. Lines can be run
into underground mines and bolted
to the ceiling. Mine planners may
not consider this option, but once
designed and implemented, electric-
driven pumps require less access.
Tey do not need refueling, and their
motors require less servicing. Tese
centrifugal pumps also reduce the
carbon footprint of any job.
Case Study: Electric-Driven Pumps
A gold mine had an environmental
restriction that would no longer allow
diesel-driven pumps, which had been
operating at their site, provided by a
rental company. Te mine requested
a solution for a portable pumping
system that could use the voltage that
was available at the tailings dam. Te
pumps needed to supply 7,500 gal-
lons per minute (gpm) to the roaster
facility (the location used to heat the
ore and extract the gold) and 4,000
gpm to the autoclave system (similar
to the roaster facility, but using pres-
sure along with heat) at the mine.
A pump provider designed a system
that used the electricity available
onsite. Te electro centerthe house
containing the switch gear, variable
frequency drive (VFD) and all the
pump controlswas on a portable,
structural skid and housed within an
enclosure. Tis unit was placed on the
crest of the tailings dam. Using this
solution, the company provided three
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pumps, each capable of heads up to
390 feet and solids-handling capabili-
ties up to three inches. Tese pumps
provided the necessary fow rates and
allowed the system to be moved up-
gradient as the tailings levels rose.
DIESEL-DRIVEN PUMPS
Considering all the benefts of elec-
tric-driven pumps, diesel is still the
right ft for many mining applica-
tions. If no on-site power can be
made available, a permanent diesel-
or natural gas-driven pump is a great
option. Diesel-powered centrifugal
pumps come equipped with a diesel
engine for stand-alone operation.
Tese pumps will work on any site, no
matter how remote. Engines should
meet the latest emissions regulations
and tier compliance standards.
Standard models of centrifugal
pumps are ofen used for high-volume
fow (which can reach 15,000 gpm or
more), average total dynamic heads
and solids-handling capabilities.
Advanced lines of centrifugal pumps
are better suited to applications with
high or extreme high heads, or those
that are used as jetting pumps.
Te total dynamic head of these
pumps, single staged, can reach or
exceed 600 feet. Tis means that, in a
mining application, one of these high-
head pumps can be suf cient to meet
the pumping needs, or great heights
can be achieved with just a few pumps
staged together.
Safety should always be a consid-
eration. When running diesel-driven
centrifugal pumps in an underground
mine, air should be vented in to bal-
ance the diesel exhaust. Tis safety
condition is eliminated with electric-
driven pumps.
Getting water outand keeping it outis the
primary focus of any mine plan. The deeper the
mine, the more water that will be encountered and
need to be removed.
1971 Plymouth Duster
Creating Value.
Carver Pump Company
2415 Park Avenue
Muscatine, IA 52761
563.263.3410
Fax: 563.262.0510
www.carverpump.com
Low NPSHa on your vacuum receiver got
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Carver 855 Series are designed for use on
vacuum receivers operating with up to 26 Hg
vacuum. Flange mounted directly to the vacuum
receiver tank eliminates suction piping/NPSH
problems. Whether operating at a trickle or full flow,
specially designed impellers allow pumping to resume even
after periods of interrupted flow.
Capacities range to 600 GPM depending on discharge head
and speed of operation. Available in 6 sizes ranging from 1- 4,
standard materials of construction include All Iron, CD4MCu and
Rubber Lined. The 855 Series features an overhead v-belt drive
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Packing is standard in the stuffing box with
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TYPICAL
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COVER
SERIES
Case Study: Diesel-Driven Pumps
A coal mine needed to dewater its mine foor afer a 100-year rain event.
All mine operations were stalled. Te mine operators needed to get the
process back online as quickly as possible. Given the amount of water, the
pumps needed to supply 1,100 gpm with 760 feet of total dynamic head.
A solution was designed that required a six-man crew; 15,000 feet of
high density polyethylene (HDPE) pipe; two diesel-driven, eight-inch
high-head centrifugal pumps; and onsite fusion machines. All equipment
was onsite within 10 days of the food event. Te pipe was fused on loca-
tion, and the mine was quickly operational again.
CONCLUSION
When water creeps into a mine, it becomes the most important aspect
of mine planning. It needs to be dewatered as quickly as possible, but a
design also needs to be developed that makes the most sense for the mine.
Operators must consider available power sources for the most economi-
cal mine plan and reliable mine dewatering system. P&S
Kristen Gurick is a marketing communications specialist for Godwin, a Xylem
brand. She can be reached at kristen.gurick@xyleminc.com or 856-467-3636.
www.godwinpumps.com.
A centrifugal pump equipped with a Tier-4 diesel engine
Our progressive cavity pumps handle highly viscous, non-
flowable products with ease.
A seepex engineered panel controls, dry running protection
sensors, load cell sensors, pressure gauge and boundary layer
injection. Low capital, operating and maintenance costs,
along with simple integration with dewatering and drying
equipment is why seepex helps take the load off.
Contact your seepex expert today to learn more about the
Cake Pump System.
seepex Inc.
511 Speedway Drive sales@seepex.net
Enon, Ohio 45323 www.seepex.com
Award Winner.
Complete Cake Pump System Solution
T
he WQA Aquatech USA conference brings multiple
water industry groups together in one event for
education, training, networking and business opportunities.
Te conference attracts diferent water industry groups
including process; drinking water; and ultrapure for
residential, commercial and industrial users. Attendees can
develop relationships and learn about equipment, devices
and innovative technology at this annual event through
exhibits, hands-on training, roundtable discussions and
networking events.
WQA Aquatech USA represents residential, commercial
and industrial segments of the water treatment and supply
market with emphasis on custom water applications from
drinking, process and wastewater. It also showcases tech-
nologiessuch as RO; membranes; media; and supporting
elements, including pumps, tanks, valves, pipes, tubing, and
other key products and services.
Te comprehensive water quality forum provides the
latest information, tools, resources and strategies for build-
ing business. Attendees have the opportunity to connect
with manufacturers, suppliers and service providers. It also
provides business and
technical educational
sessions and opportuni-
ties to network with col-
leagues and experts.
All vendors at WQA
Aquatech USA can be
visited in one location,
enabling attendees to
gain valuable industry
data and discover new
products and services in one place. Tousands of water
industry professionalssuch as water treatment dealers,
engineers and end userswill attend to learn about trends
infuencing the industry. For more information, visit http://
s36.a2zinc.net/clients/wqa/wqa13.
Exhibition Hours
Wednesday, April 3 11 a.m. 5 p.m.
Thursday, April 4 10 a.m. 5 p.m.
TRADE SHOW COVERAGE
EFFICIENCY MATTERS
A
n international technology group supplies equipment and services for hydropower
stations, the pulp and paper industry, solid/liquid separation in the municipal and
industrial sectors, the steel industry and the production of animal feed and biomass
pellets. Te company, headquartered in Graz, Austria, operates more than 180
production sites and service and sales companies worldwide.
Te pump division develops and manufactures customized large pumps and standard
centrifugal pumps for a wide range of applications and industries, such as:
Water transport and irrigation
Energy sector (cooling water and ue gas desulfurization pumps)
Pulp and paper, sugar and bioethanol industries
Many years of experience in hydraulic machinery construction and comprehensive
process knowledge form a solid footing for the performance standards met by these
pumps. Te company is a single-source supplierincluding development, model tests,
design, manufacture, project management, and afer-sales service and training.
DESIGN PROCEDURE
Te pump manufacturer has developed a modern design system that consists of com-
puter-aided-design-based geometry defnition, hydraulic optimization by means of
numerical fow simulation and analysis of mechanical behavior.
For an initial impeller or guide vane design, TURBOdesign1 (design sofware) is
extensively used within the company. Te sofware provides good solutions in a short
time period, especially when starting from scratch.
Te hydraulic behavior is then evaluated by solving the full 3D-Navier-Stokes equa-
tions in combination with a robust turbulence model. Based on the initial design sof-
ware solution, the blade profle is further optimized by experienced designers and inter-
action with the stationary components, such as the casing, must be tuned. Finally, the
progress in hydraulic design is verifed by model test results.
APPLICATION OF THE SOFTWARE TO PUMP DESIGN
Two years ago, the sofware was introduced to the pump manufacturer for hydraulic
development of a new vertical line shaf pump (see Figure 1). Tis pump type is typi-
cally used for irrigation and cooling water supply to thermal power plants.
Because of changing requirements, the pumps operating range had to be shifed to
higher fow rates and higher heads. Terefore, the company needed to develop new
runner blades and new guide vanes. Te hydraulic designs were verifed by computa-
tional fuid dynamics (CFD), including all fow-relevant components (see Figure 2).
Design Software Increases
Hydraulic Effciency
Pump manufacturer streamlines the design and production process.
By Arno Gehrer, ANDRITZ GROUP
Figure 1. Pump assembly model of a
vertical line shaft pump with adjust-
able impeller blades
RESULTS
An extensive series of measurements was carried out in the
pump companys in-house hydraulic laboratory on a fully
homologous model. Tese experiments provided:
Performance data (ow rate, head, power and
e ciency)
Cavitation observations
Hydraulic forces (axial thrust, radial force and
momentum)
Stability limits (for example, pressure pulsations)
Compact Design
Compared to the old reference pump, the new design was
smaller and had signifcantly higher blade loading and pro-
vided greater head and fow rate (see Figure 3). Te ef -
ciency at the design point (OP1) could be improved.
Figure 2. CFD pump model
Figure 3. Model test resulthead and efciency comparison with
reference design
EFFICIENCY MATTERS
Enhancement of Cavitation Limits
Regarding cavitation, the net positive suction head required
(NPSH
required
) curve of the reference design had to be shifed
to higher fow rates to avoid pressure-side cavitation in the
start-up condition, OP2 (see Figures 4 and 5).
Finally, the new design fulflled the fundamental condi-
tion NPSH
plant
NPSH
required
for the whole operating range
(see Figure 5), and the measurements were completed with
a successful acceptance test, witnessed by the manufacturers
customers. In conclusion, the sofware considerably sup-
ported the pump manufacturer in accelerating the hydraulic
design process. P&S
Arno Gehrer has been a research engineer at ANDRITZ
GROUP since 2001. He obtained his Ph.D. in mechanical
engineering from the University of Graz in Austria. At present,
his main focus is the hydraulic design of turbines and pumps,
both with CFD and model testing. He is leading the group for
hydraulic development & CFD.
Figure 4. CFD result, reference design (old) at OP2pressure eld
and ISO surface of cavitation on the impeller blade surface
Figure 5. Model test resultNPSH comparison with reference design
For 50 years DP Pumps has been the preferred silent
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MAINTENANCE MINDERS
A
few years ago, I took a class to learn to be a
horologista person who repairs antique mechanical
clocks. My instructor said that some of the students may
learn to be good clock repair people, but time will tell.
Tat expression started with clock repair.
If a horologist does a quality job repairing a wall clock, it
can be wound and will run for eight days before a rewind
is needed. If the horologist repaired the clock poorly, the
clock might quit afer only four days and keep bad time. Te
device can be rebuilt, but the quality of the time it keeps
refects on the horologist. Do a bad job, and time tells on
you.
In a tighter economy, plants and facilities rebuild their
own pumps to cut costs. Some plant managers believe that
using plant personnel instead sending it out for repair is less
expensive. Time will tell with pumps rebuilds, too.
I have participated in the supervision of many electrical
and mechanical repairs. If an electrical mistake is made, it is
known quickly. Te lights go out; sparks fy; or even worse,
something melts.
However, mechanical repair mistakes are less obvious.
Miss a critical step in alignment, ignore the bearing ft or
allow the shaf to wobble, and the pump continues to run. It
pumps, but time will tell how long it will last. Te unit might
only last two years when it should have lasted 10 years. Afer
two years, supervisors may forget who previously serviced
the pump, and two years may become the normal expecta-
tion. If it stopped working afer a week, management may
pay more attention. Rebuilding a pump to last requires skill
and a focus on detail. Tis article provides steps to follow
when rebuilding a pump to lengthen the time interval
between repairs.
CHECK FOR PIPING STRAIN
A simple check can be made to avoid piping misalignment
and the strain that it puts on critical pump components,
such as bearings and mechanical seals. When the pump has
been properly shut down with safety locks in place, separate
the coupling between the pump and the driver.
Place two dial indicators on the pump coupling half or
the pump shaf if it is accessible. A good way to hold them
in place is with a magnet base. One indicator is placed on
the side of the coupling half to detect horizontal movement.
Te other is placed at the top to detect vertical movement.
Depress the indicators and set them at zero. Ten release
the bolts on the suction and discharge fanges. Tey do
not have to be removed, just backed of to be fnger tight.
If either indicator moves 0.001 inch or more, piping strain
exists and must be corrected before re-installing the pump
afer the rebuild.
Tis step is ofen skipped. Chances are the new or rebuilt
pump put in the same location with the same piping will
have a short life because of the twist and stress induced
when the piping is secured.
INSPECT BEARING FITS
Installation of anti-friction bearings involves some mea-
surement steps. Te bearing is round when it is removed
from the box. It has certain prescribed internal clearances
that allow for smooth movement. If the shaf is oversized
or slightly tapered in the bearing seat or if the housing bore
is belled out, the bearing will not remain round during
operation. Roundness in a bearing means long life.
Check the housing bores and shaf seats with a microme-
ter capable of reading to ten-thousandth of an inch (0.0001
Pump Rebuild Tips
Avoid common mistakes to get the longest life from a rebuilt pump.
By Tom Davis, Maintenance Troubleshooting
Trimming the impeller diameter to give a better performance, even if
completed on a lathe, removes unequal amounts of metal from the
cast surfaces resulting in dynamic unbalance.
MAINTENANCE MINDERS
inch) to ensure proper ft. Tis step must be completed. If an
end user does not know the proper dimensions, they should
ask the pump vendor for a critical dimension checking
print, or look up the proper ft using Machinery Handbook
or a similar industrial reference.
Unfortunately, if a machinist fails to make a shaf cor-
rectly, he/she will ofen leave it slightly oversize and the
housing bore a bit undersize. Metal is easier to remove than
to add back, so they shoot high on the shaf and low on
the bore (always leaving metal that can be removed). Tey
sometimes leave more than desired. Te pump bearing will
install, but it will be pinched on the outside diameter (OD)
or expanded too much on the inside diameter (ID) and will
fail quickly. Remember, the pump bearing might last a year
in this condition, but it should have lasted 10 or more if the
dimensions were correct.
ENSURE PUMP SHAFT STRAIGHTNESS
Pump shafs are subjected to unbalanced impellers, worn
bearing fts, impeller rubs and other mechanical strains
that can cause them to bow. With the pump shaf removed
from the pump during the rebuild and all other components
removed, end users should take the opportunity to check
the shaf for straightness.
A pool player takes the cue, lays it on the pool table and
rolls it back and forth. If it bumps as it rolls, it is not straight.
A similar check on a shaf can be completed on a shop bench
with a dial indicator and two V-blocks.
Place the shaf bearing seats on the V-blocks and position
the indicator at the center of the shaf. Turn the shaf slowly
while watching the indicator hand. On a 24-inch pump
shaf (or smaller), the indicator should not defect more
than 0.002 inch. In the 24-inch to 60-inch range, 0.003
inch is the limit. For 60-inch to 120-inch pump shafs, the
defection can be to 0.006 inch at the
midpoint. If a shaf is bowed in places,
an unnecessary push on the bearings
and seal faces occurs with each revo-
lution. Seal life is reduced to months
instead of years.
CAREFULLY HEAT THE BEARING
FOR SHAFT INSTALLATION
Almost all pump bearings have an
interference ft between the ID of the
bearing (the bore of the inner race)
and the shaf seat (the place where the
bearing sits on the shaf). Te bearing
bore is smaller than the pump shaf and must be pressed on
or heated to expand the bore before assembly. An anti-fric-
tion bearing is a great example of metallurgy. Te bearing
companies use excellent quality control to produce a bear-
ing that is hard, but not too hard, to provide a long service
life. If the bearing is overheated, it becomes annealed and
will not last for its intended life.
Modern shops use induction heaters or cone heaters to
rapidly heat the inner race to allow shaf assembly. However,
the temperature-sensing mechanism on the heater can
ofen be out of calibration or non-existent. In that case, the
mechanic must use an infrared thermometer or temperature
sensitive crayon that melts at the correct temperature value
to make sure that the bearing is not overheated.
Te magic number to avoid is more than 250 F. Most
good pump shops never heat them to more than 230 F to
avoid the possibility that they will overheat the bearings.
Overheating a bearing during assembly removes years from
its life, and plant management may never know the true
reason for the shortened life cycle.
SQUARE THE BEARING TO THE SHAFT SHOULDER
Improper squareness causes frequent problems. All pump
shafs have a shoulder that determines the stopping point
for a bearing on the shaf. Te face of the inner race of a
bearing should meet this shoulder all around the shaf
it makes the bearing square to the shaf (at a perfect right
angle).
Pump manuals caution, Make sure the bearing is square.
However, many do not indicate how. Te check is an easy
one. A feeler gauge of 0.001 inch to 0.002 inch is used to see
if any gap exists between the face of the inner race and the
shaf shoulder at the 12, 3, 6 and 9 oclock positions.
When using a press to install a bearing, a gap is usually not
present, or less chance exists of one. If
thermal means are used to expand the
inner race (no more than 230 F), the
bearing must be held against the shaf
shoulder so it does not shrink away as
it cools. Most mechanics may think
that holding the bearing in place for
a minute or two will be enough to
avoid a gap. Tis line of thinking is
incorrect. Te bearing should be held
in position for 3 to 5 minutes. Tis
simple step, if not performed, leads
to cocked bearings and rapid bearing
wear following installation.
If the bearing is not square to the shaft shoulder,
bearing misalignment occurs. Checking square-
ness is vital to ensure that a pump spins freely.
REBALANCE A TRIMMED IMPELLER
With emphasis on energy savings and a desire to operate
a pump closer to its best ef ciency point (BEP), the
impellers diameter is ofen trimmed to ensure that the
pump more closely fts the systems requirements. Te
af nity laws are used to calculate that, for instance, a
10-inch diameter impeller should
be machined down to 9 inches
to better marry the pump curve to
the piping. If an end user orders a
9-inch diameter impeller from the
factory, it is dynamically balanced.
However, if a machine shop trims
the impeller in a lathe, the impel-
ler is unbalanced. It is a casting. Te
removal of as little as inch from the
diameter can result in massive unbal-
ance when the pump spins at 1,750
rpm or worse at 3,550 rpm.
Asking the machine shop to send
the impeller out for dynamic bal-
ancing is no trouble and costs little,
certainly less than the failed bearings
and unplanned downtime that can
occur as the pump vibrates because of
unbalance. When the pump is assem-
bled, that is not the time to think
about balance.
Balancing must take place during
disassembly. Te components can be
placed on a balancing machine and
corrected before reassembly. In some
cases, the shaf and impeller should
be assembled together and balanced
as a unit to ensure against excessive
vibration forces. P&S
Thomas B. Davis (Tom) is a graduate mechanical engineer
who owns Maintenance Troubleshooting, a consulting frm
specializing in assistance for corrective repair of rotating
equipment. He can be reached at mechanicalengineer@
pobox.com or 302-690-0871.
REBUILD CHECKLIST
Check for piping strain
Inspect and verify bearing ts
Ensure shaft straightness
Use care when heating the
bearing for shaft insertion
Square the bearing to the
shaft shoulder
Rebalance an impeller
after trimming
SEALING SENSE
G
rooved metal gaskets with covering faces, ofen called
kammprofle gaskets, consist of a metal core with
grooves or serrations in each face. Tey can be supplied with
or without a guide ring.
Sof materialsuch as polytetrafuoroethylene (PTFE),
fexible graphite or other high temperature facingis
applied to both sides of the concentric serrated sealing core.
It is a problem solver for heat exchangers and large vessels
since it provides one of the tightest seals combined with
superior load bearing characteristics.
PREFERRED IN RIGOROUS APPLICATIONS
Kammprofle gaskets are a preferred design when improved
performance at low seating stresses is required. Teir M
values, Y stresses and other gasket constants are lower than
those of grooved metal gaskets without any facings, other
reasons for their preference. Metal to metal contact seals
require a higher degree of loading.
While the facing materials are typically sof and easy to
seal, the deep grooves keep the facing from extruding under
high compressive loads or internal pressures. Kammprofle
gaskets have the ability to seal at low compressive stresses,
but they also handle higher compressive loads and high
internal pressures, making them unique problem solvers.
DIMENSIONAL FLEXIBILITY
Another important use of kammprofle gaskets is when the
exact contact dimensions of a fange are unknown prior to
opening the joint.
It may be known that an existing fange has a raised face
(RF), but its exact outside diameter (OD) may not be avail-
able until the old gasket is removed. A spiral wound gasket
must be sized so that the windings start and end on the
fange.
If the inside diameter (ID) of the windings is smaller than
the fange contact area or the OD of the windings is beyond
the OD of the RF, the windings may buckle. Tis is not a
concern for a kammprofle gasket. It can hang over the RFs
OD without damaging the gasket.
TYPICAL KAMMPROFILE GASKET DESIGNS
Tree typical designs are availablea gasket without a guide
ring, with a guide ring and with a loose-ft guide ring. A
kammprofle gasket without a guide ring can be applied in
recessed fange applicationssuch as tongue-and-groove
connections or a heat exchanger applicationto replace
double-jacketed gaskets as an upgrade design (see Figure 1).
Note that when a nubbin is present in the sealing area, it is
strongly recommended that it be removed when upgrad-
ing from a double-jacketed design. Tis type kammprofle
gasket is acceptable in standard pipe fanges as long as the
gasket is sized to center itself on the bolts.
Kammprofle gaskets with a guide ring are manufactured
with an integral guide ring for centering (see Figure 2). Tese
are recommended for application in RF, ASME B16.5 pipe
fanges and also can be sized to EN 12560-6 specifcations.
Kammprofle gaskets with a loose-ft guide ring are
applied to nominal pipe size and pressure class fanges and
Gaskets for Rigorous Applications
What are grooved metal gaskets, and where are they applied?
By FSA members Darine Aghnim & Dave Burgess
Figure 2. Design with guide rings
Figure 3. Design with a loose-t guide ring
Figure 1. Design without a guide ring
used when thermal cycling expansions and contractions are
present (see Figure 3). Te gasket is designed to comply with
either ASME B16.5 fange or EN 12560-6 specifcations.
OTHER GASKET DESIGNS
Te kammprofle grooves or serrations can be applied as
an upgrade to a typical fat metal washer, which can be dif-
fcult to seal. Flat washers might be used on a plug type
threaded application, where the head of the plug will turn
down against the washer. Solid metal washers can be tough
to seal, of course. Tese plugs are common on air cooler or
fn fan heat exchangers. Typical heat exchanger plugs with
this type washer are shown in Image 1.
Kammprofle gaskets can also be designed as a dual seal
solution with leak detection device incorporated into
fanged assemblies. Tese might be used in critical applica-
tions such as phosgene service. Tey have a primary inner
sealing area with a relief section and holes on the outer por-
tion of the sealing. Past these relief holes is a secondary seal-
ing area that maintains the integrity of the bolted joint.
Te kammprofle design
with sof facing material
can also be applied on the
sealing area of ring joint
gaskets.
Tis is an ideal solution
for applications in which
cracking or embrittlement
has occurred in ring joint
fange grooves (see Figure
4). Kammprofle gaskets
can be manufactured in
Image 1. Typical heat exchanger plugs with solid metal washers
Greyline PTFM Portable 1.0
Transit Time Flowmeter
Accurately measure water, chemicals and clean
fluids. Use it for pump tests, troubleshooting,
calibrations and balancing flow. Works with
clamp-on ultrasonic sensors on the outside of
metal and plastic pipes.
Portable F M low eter
www.greyline.com
888-473-9546
info@greyline.com
SEALING SENSE
diferent metal materials, shapes (circular and non-circu-
lar) and custom-engineered designs to ft diferent appli-
cations. Te recommended fanges sealing surface fnish is
125 to 250 microns per inch.
CONCLUSION
Grooved metal gaskets can efectively seal a wide range of
applications because of their unique characteristics, design
fexibility and facing material options. End users should
consult their gasket manufacturer for recommendations for
their specifc applications. P&S
NEXT MONTH:
What are the important considerations for the proper
torque of a valve packing gland?
We invite your suggestions for article
topics as well as questions on seal-
ing issues so we can better respond
to the needs of the industry. Please
direct your suggestions and questions
to sealingsensequestions@fuidseal-
ing.com.
Figure 4. Ring joint gasket
Image 2. Design with integrated leak detection
HI PUMP FAQs
A. NPSH3 is the net positive suction head required,
in meters (feet) that will cause the total head (or frst-stage
head of multistage pumps) to be reduced by 3 percent.
Four typical arrangements are available for determining
the NPSH3 characteristics of rotodynamic submersible
pumps. For all arrangements, the fow toward the pump
must be uniform and free of undue disturbances. A pump
tested with suction piping may require a fow-straightening
device before entering the pump. Arrangements for cooling
or heating the liquid in the loop may be needed to maintain
the required temperature.
In one arrangement (see Figure 11.6.7.2c), the pump is
supplied from a closed tank in which the level is held con-
stant. Te net positive suction head available (NPSHA) is
adjusted by varying the air or gas pressure over the liquid,
varying the temperature of the liquid, or both. Tis arrange-
ment tends to strip the liquid of dissolved air or gas. Testing
with a closed loop without the closed tank on the suction
side is also acceptable.
In another arrangement (see Figure 11.6.7.2d), the entire
pump is mounted in an enclosed tank to allow the NPSH
testing to be done without the suction piping connection.
Te testing for this arrangement is normally performed at
a constant fow rate while varying the NPSHA by adjusting
the air pressure over the liquid in the suction tank.
In each arrangement, water must be used as the test liquid.
Taking the following precautions will minimize aeration:
No cascading return ow outlets
Reservoir sized for long retention time to allow air to
escape
Inlet line properly located to prevent vortexing
Reservoir ba es to isolate inlet from the return line
Tight pipe joints to guard against air leakage into the
system
For more information about NPSH tests for rotody-
namic submersible pumps, see ANSI/HI 11.6 Rotodynamic
Submersible Pumps for Hydraulic Performance, Hydrostatic
Pressure, Mechanical, and Electrical Acceptance Tests. P&S
Figure 11.6.7.2d. The entire pump is mounted in an enclosed tank
to allow the NPSH testing to be completed without the suction
piping connection.
Figure 11.6.7.2c. A pump is supplied from a closed tank with a constant
level.
Q. How do I determine the NPSH3 for a rotodynamic submersible pump?
Q. How should I design trench-type wet wells for the intake of rotodynamic pumps, and how are
these different from rectangular intake structures?
A. Trench-type wet wells difer from rectangular intake
structures by the geometry used to form a transition between
the dimensions of the infuent conduit or channel and the
wet well itself (see Figure 1). An abrupt transition is used to
create a confned trench for the location of the pump inlets.
While limited physical modeling work has been con-
ducted on trench-type wet wells, successful applications
with individual pump capacities as great as 75,000 gallons
per minute (gpm) or 4,730 liters per second (L/s) and
Submersible Pump NPSH3, Trench-Type Wet
Wells & Starting Torque Requirements
By The Hydraulic Institute
HI PUMP FAQs
installation capacities of 225,000 gpm (14,200 L/s) have been constructed for
centrifugal pumps. Axial and mixed fow applications include individual pump
capacities of 46,000 gpm (2,900 L/s) and total installation capacities of up to
190,000 gpm (12,000 L/s).
Most applications of
the trench-type design
have been with the
incoming fow directed
along the wet wells long
axis (coaxial). Physical
model studies shall
be conducted for any
installation with individual pump capacities exceeding 40,000 gpm (2,520
L/s) or stations with capacities greater than 100,000 gpm (6,310 L/s). P&S
Figure 1. Trench-type well
Q. What information is available regarding starting torque
requirements for reciprocating power pumps with liquid bypass?
A. Using reciprocating power pumps requires carefully considering their
starting and running torque demands. Tese afect the selection of driver
motors, motor starters, engines, gear reducers, belts or chain drives, couplings,
and universal joints. Tese loads efects on an electrical distribution system
require thought, especially for a large pump.
For starting the pump with a liquid bypass, the operator manually opens
a bypass valve or a power-actuated dump valve opens automatically. Tis
bypasses the liquid during
starting and stopping. A
check valve in the dis-
charge line remains shut
if the bypass (dump) valve
remains fully or partially
open (see Figure 6.47).
Te liquid pressure
exerted on the plung-
ers (or pistons) is largely
caused by liquid mass and
friction. When correctly
sized, the bypass valve and
piping cause low back-
pressure. Relatively small
torque is required while
bypassing the liquid to a
tank. With liquid bypass,
the total starting torque
requirement is mainly
related to the mechani-
cal inertia of the pump,
couplings, gears and
Figure 6.47. Schematics of liquid bypass systems
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motor rotor. Tese components are
heavy and require substantial starting
torque. Te liquid in the pump suc-
tion line and in the bypass line must
be accelerated from standstill to full
liquid velocities.
Te torque needed to accelerate
the entire mechanical hydraulic iner-
tia system depends on the inertia of
all the moving partsincluding the
liquid, the rate of acceleration and the
total system friction. Te rate of accel-
eration is important, and the starting
torque is directly proportional to it.
Peak torque is inversely proportional
to the time duration of acceleration.
A few pumps are provided with
mechanical suction valve unloader
devices. Tey reduce the total start-
ing torque required to accelerate the
mechanical itemsthe pump crank-
shaf, gears, couplings, etc. Tey stop
liquid pumping action by mechani-
cally holding open the pumps suction
valves, allowing the liquid inducted
into each liquid cylinder to be deliv-
ered back into the pump suction.
Because no liquid pumping occurs,
the driving machinery does not need
to apply torque to accelerate the
liquid. Only the torque to overcome
mechanical inertia and friction is
needed during the start.
Afer the pump and driver have
reached full speed, the suction valve
unloading devices are retracted, and
normal pumping action commences.
At this point, the driver must supply
additional torque to accelerate the
liquid system and meet the total run-
ning torque requirement caused by
discharge pressure. P&S
Pump FAQs is produced by the Hydraulic Institute
(HI) as a service to pump users, contractors, dis-
tributors, reps and OEMs. Visit visit www.pumps.
org for more information.
PRACTICE & OPERATIONS
I
nnovation comes in many forms. Afer many years of
struggling with water quality and dependability, the
residents of the Pheasant Hill Subdivision formed their own
Pheasant Hill Water Corporation. Tey worked with their
consultant, Clark Patterson, to perform a needs assessment
and applied for a Drinking Water State Revolving Fund
(DWSRF) grant. Tey were successful and received a
$2-million grant and an additional $600,000 in low-interest
fnancing.
DESIGN
Clark Patterson designed the new water treatment system,
which included two wells, No. 4 and No. 6; a chlorination
system; a pumping system; and a new 30,000 gallon storage
tank (see Image 1). Since this systems source was a well, it
has fltration avoidance, and chlorination is the only treat-
ment. Space for a new cartridge
fltration system was designed
within the water treatment
plant, in case the wells are
reclassifed in the future.
CONSTRUCTION
Once funding was in place, the
design, construction and start-
up of the new water treatment
plant and storage tank was on
a fast-track schedule. Clark
Patterson evaluated the cost of
building the water treatment
plant in-place. Te design
frm also examined an inno-
vative approach of working
with a pump station manufac-
turer to design a prefabricated
water treatment and pumping
system. Te evaluation showed
that the prefabricated concept
was more expedient and more cost-ef cient.
Te installing contractor awarded the pumping system
contract to Dakota Pump Inc. Te 14-foot wide by 51-foot
long by 13-foot high, prefabricated water treatment build-
ing is a multi-room water treatment plant that includes:
A stand-by generator room
Space for future ltration equipment
A chlorination room
A separate room for pumps and controls
Te stand-by generator with automatic transfer switch
comes on when a loss of power occurs (see Image 2). Tis
allows the plant to continue operation. Te variable-fre-
quency-driven booster pumps maintain adequate pressure
in the distribution water main, and the chemical feed equip-
ment provides proper disinfection. Controls were also a key
Prefabricated Treatment System Solves
Water Quality Concerns
With the simultaneous construction and site preparation, the quick turnaround required for the
project was accomplished with cost-effcient results.
By Mark Koester, Koester Associates, Inc.
Image 1. The water treatment plant included pressure-maintaining
booster pumping and metering capabilities.
factor for the station. When the tank level lowers to
a pre-determined point, the controls call for the well
pumps to start. Te components were incorporated
into a pre-manufactured and prefabricated water treat-
ment plant.
APPEARANCE
Te appearance of the treatment plant was another
consideration. Since the project was located in a resi-
dential setting, the designers wanted the building to
have an appropriate residential look. Dakota Pump
Inc worked with the Pheasant Hill Water Corporation
and Clark Patterson to incorporate standard 2-inch by
6-inch construction on a prefabricated steel base plate,
reinforced to accommodate the structural needs of the
water equipment and the building.
Te structural base, walls and ceiling received a high
R-value coating of spray foam insulation, and the exte-
rior of the building was covered with architectural
horizontal siding. With the help of the consultant, the
owner was able to choose the style and color for the
siding, the type of sof t and fascia, and the color for
the laminated asphalt roof shingles.
Te result was a treatment building
that looks professional and blends
with the foliage of the Pheasant Hill
subdivision.
INSTALLATION
Prefabricating the water treatment
plant building allowed the construc-
tion of the treatment plant at the
factory to coincide with the general
contractors site preparation. Tis pro-
vided a shorter construction window.
Once the construction site was fully
prepped and the prefabricated water
treatment plant was constructed and
factory tested, the treatment plant
was transported via a specialized
tractor-trailer from Mitchell, S.D., to
Minisink, N.Y. (see Image 3).
Afer the station arrived at the site,
it was lifed into place onto the con-
crete foundation. Te inlet and outlet
connections were made, and the elec-
trical hook-up was completed.
Image 2. A natural gas-red generator with automatic transfer
switch provided emergency power service.
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Te station was ready for start-up and commissioning.
With this treatment plant, the Pheasant Hill residents
have reliable and safe drinking water at consistent pressures
and suf cient storage for all conditions. Te prefabricated
approach saved the residents money and allowed the project
to be completed on schedule. P&S
Mark Koester has been active in the water and wastewater
industry in upstate New York for 30 years. He has a degree in
sanitary engineering and retains leadership positions in the
New York Water Environment Association and New York Rural
Water Association. Koester is also active in the American
Water Works Association and local water works affliates. He
can be reached at (315)697-3800 or email mark@koesteras-
sociates.com.
Image 3. The oversized treatment system and building was transported via specialized hauler from Mitchell, S.D., to Minisink, N.Y.
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B
iological-secondary treatment is the most energy-
intensive phase in the wastewater treatment process
with aeration consuming between 25 and 60 percent of
the total energy used in a municipal
plant.
1
According to a report by the
Environmental Protection Agency (EPA)
in the U.S., these costs are increasing
because of rising energy prices and
more stringent requirements for ef uent
quality.
2
An increase in environmental
awareness and the rising cost of electricity
have motivated operators to reduce
the energy consumption of biological-
secondary treatment in wastewater
treatment systems.
TESTS AT SWEDISH WASTEWATER
TREATMENT PLANT
Full scale trials by a global water solution
company show that the energy consump-
tion of a wastewater treatment plants
aeration system was successfully reduced
by a signifcant 65 percent when more
energy ef cient equipment was installed.
Te tests were conducted at the Stern
Municipal Wastewater Treatment Plant
in southern Sweden.
Built in 1997, the Stern plant was
designed to cater to a population of
26,000 calculated on biological oxygen
demand (BOD) 7 load 70 g (pe day)-1.
Aeration consumed 44 percent of the
plants total energy usage.
Te plant consisted of two parallel bio-
logical treatment lines that performed
the pre-denitrifcation of the wastewater.
During the study, one of the treatment
lines was used as a test line with the new
aeration and control equipment installed.
Te other line with aeration equipmentconsisting of tube
difusers, lobe blowers and a simple dissolved oxygen (DO)
controlwas lef unchanged and kept as a reference line.
New Optimized Aeration System
Reduces Energy Consumption
A wastewater treatment plant experiences a 65 percent energy savings
with the installation of improved equipment.
By Lars Larsson, Xylem, Inc.
New aeration equipment.
Te new aeration equipment installed into the test line
was a screw blower; fne bubble, low-pressure difusers; and
measurement equipment.
THE RESULTS
Te results of the full scale trials showed that the new screw
blower reduced the energy consumption of the test line by
35 percent.
Te low-pressure difusers reduced the energy consump-
tion by another 21 percent. By fne tuning the controllers,
the oxygen concentrations and the air pressure, the energy
consumption of the test line was reduced an additional 9
percent. Te fnal energy savings of the test line were 65
2 percent.
Each aeration equipment upgrade increased the energy
savings with:
Blower, 35 percent
Diusers, 32 percent
Oxygen control with decreased DO concentrations
and air pressure, 21 percent
EVALUATION PERIODS
Te new installations were performed in stages. Te efect
of each new installation was evaluated separately, and the
results were:
Phase 1 involved the installation of a new screw
blower and a non-tuned DO cascade control system.
During Phase 1, the majority of the energy savings
was related to the increased e ciency of the blower.
Aeration grids were installed during Phase 2. An addi-
tional 23 percent of the total energy savings gained
during Phase 2 was acquired by the high standard
oxygen transfer e ciency (SOTE) and low system
head loss of the new aeration system.
During Phase 3, a process control system was
installed, which increased the energy reduction by
an additional 9 percent through a combination of
a further decreased system head loss from the most
open valve logic and the implementation of DO
cascade control and an energy optimized DO prole.
Te DO prole was energy optimized by changing
the DO set points from 1.7/0.7 milligrams per liter
circle 141 on card or go to psfreeinfo.com circle 140 on card or go to psfreeinfo.com
to 0.7/1.0 milligrams per liter,
which distributed the load more
evenly throughout the length of
the basin.
AIRFLOW & AERATION EFFICIENCY
With the new system, aeration ef -
ciency was almost three times as
high in the test line compared to the
reference line. Te required airfow
was reduced by 30 percent, and the
system pressure was reduced by 15
percent. Tese savings were gained by
a combination of:
A more e cient blower
A higher SOTE
Lower head loss
Energy-optimized DO control
and DO prole
More than 40 years of expertise
in wastewater treatment system
optimization
PAYBACK PERIOD
Te payback period for implement-
ing the aeration system was calcu-
lated at four years. If both lines were
upgraded, the payback period would
decrease to just three years since some
of the equipment could be shared
between the lines. Tese full-scale
tests were performed throughout
a 6-month period. Te annual sav-
ings for the test plant was more than
$28,000 if both of the plants treat-
ment lines were upgraded. P&S
References
1. WEF, 2009. MOP No. 32: Energy
Conservation in Water and Wastewater
Facilities.
2. EPA, 2010. Evaluation of Energy
Conservation Measures for Wastewater
Treatment Facilities. EPA 832-R10-005.
Lars Larsson is the global prod-
uct manager, biological treat-
ment for Xylem, Inc. He can be
reached at +46 8 475 63 60 or
lars.larsson@xyleminc.com.
The nal energy savings of the test line were 65 2 percent.
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M
any manufacturers are committed to sustainable
practices to improve their environmental, economic
and social performances. Companies that use or produce
fuids in manufacturing processes face the challenge
of properly disposing of the byproducts. For example,
chemical manufacturers, food and beverage processors and
metal fnishers generate fuids that have to be treated in
accordance with local government regulations before waste
fuid is discharged into sewer systems.
Te manufacturing sustainability trend is driven by cus-
tomers; shareholders; government regulations; and the
increasing costs of process inputs, such as water. As the cost
of water increases, the industry is investing heavily in treat-
ment processes using recycled water.
Industrial pumps are at the core of wastewater treatment
systems, and diferent pumps are used in the treatment
process. Positive displacement
pumps are used to transfer liq-
uids from tank to tank because
they are durable enough to
handle a wide range of fuids
and solid particles.
Metering pumps play a vital
role in the treatment process
as well. Tis type pump has the
technology required to accu-
rately dose and meter chemicals
at low fow rates and is one of
the smallest positive displace-
ment pumps on the market.
Air operated diaphragm
pumps (AODP) are the work-
horse of the wastewater treat-
ment system. Tis type of
positive displacement pump is
durable enough to withstand
submersion and continuous
fow rates inherent in waste-
water applications. AODPs are
ideal for low- to mid-range fow ratesup to 350 gallons
per minuteand produce enough back pressure, up to 250
psi, to move high viscosity fuids and sediment.
THE PUMPS ROLE
Positive displacement pumps have three main applications
in the wastewater treatment process:
Transferring uids from the sump to
the reactor
Dosing chemicals into the reactor and
neutralizer tanks
Drawing slurry o the clarier tank to feed the
lter press
A typical wastewater treatment process begins as fuid
builds in a sump tank. A positive displacement pump is
Positive Displacement Pumps in
Wastewater Treatment
Select the right pumping technology to keep treatment processes running effciently.
By Oakley Roberts, ARO Fluid Products, Ingersoll Rand
AODPs are used in multi-step, batch waste treatment systems to remove metal precipitation. One AODP
moves the solution from the collection tank to the treatment tank. Others move the treated waste from
the treatment tank to the drain.
used to move the fuid to a second tank where the rinse
water fow is equalized and pushed into a reactor tank. Te
composition and temperature of the fuid running through
the system must be considered when specifying this pump
because the fuids can be corrosive and abrasive. AODPs
can be confgured to meet the chemical compatibility of the
fuids, making them a low-risk solution.
Once the waste fuid is transferred from the sump to the
reactor, concentrated chemicals are introduced to neutralize
the pH balance. An electromagnetic or mechanically actu-
ated simplex diaphragm pump, a highly controllable type
of metering pump, doses treatment chemicals at a low fow
rate. Tis level of accuracy ensures that the fuids are treated,
neutralized and clarifed to adhere to local regulations.
Finally, the neutralized liquid fows into the focculator
where a chemical is added that adheres to particulates, caus-
ing them to coagulate on the bottom of the clarifer tank.
AODPs are used to draw the slurry from the bottom of the
tank and prime the flter press.
AODPs can handle this abrasive and corrosive mixture
and produce enough back pressure to force the fuid into
the flter, leaving only solid waste behind. Te clean fuid
returns to the treatment process before being discharged
to the sewer or reused. Te cake is removed from the flter
press and disposed as solid waste.
SELECTING THE RIGHT AODP
Pumps are critical to manufacturing processes. If one fails,
it may force the entire plant to stop production until opera-
tors can fnd a way to restore it. Specifying the right pump
for the application to increase reliability and prevent unex-
pected downtime is critical.
Pumps must be compatible with the fuids they transfer
to prevent abrasive and corrosive materials from reacting
with the composition material of the pump. Plant manag-
ers can ask a pump manufacturer to specify the best com-
position material for the application.
Polymer fuid chambers made from nonreactive mate-
rials, such as polypropylene or polyvinylidene fuoride
(PVDF), are commonly used with elastomeric ball checks
and diaphragms to prevent corrosion and increase a
pumps longevity.
Pump manufacturers can consult with plant managers to
determine if continuous-duty pumps should be installed
to meet the heavy-duty cycle required in wastewater treat-
ment. Continuous-duty pumps prevent icing and stalling,
and pulsation dampeners can be added to help equalize the
pressure fow and keep the system running reliably.
AODPs ofer several unique advantages over other posi-
tive displacement pumps:
Tey are powered by compressed air and do not
require electrical hookups at the installation sites,
which dramatically reduces installation costs.
Some AODPs can be submerged in uids, making
them a convenient option for sumps and pits.
Tese pumps can be integrated with electric interface
control devices, such as solenoids and tank ll, to
control the pumps operation.
AODPs are not damaged by downstream blockages in
the system.
Tey are more compact than other pumps.
Tese pumps have reduced purchase prices because
they do not require electric motors or gear boxes.
AODPs do not have mechanical seals that could leak
or need replacement.
Tey are portable and have plug-and-play capability
for easy installation.
TOTAL COST OF OWNERSHIP
When evaluating if an AODP is right for a facility, plant
managers should note the initial purchase price and then
include the total cost of ownership. Tese factors will help
plant managers determine if an AODP is the most econom-
ical pump for the application:
Compare the time required for maintenance on the
AODP and how that aects productivity.
Calculate the downtime costs of the plant and
whether it is cost eective to keep an extra AODP in
stock so it can be replaced quickly.
Determine whether the AODP pump shares common
parts with other units in the plant and manage inven-
tory accordingly.
Select a modular pump design that allows mainte-
nance teams to repair one piece of the AODP without
disabling the entire unit.
Consider the installation costs and energy consump-
tion required to get the pump up and running.
If specifed correctly, AODPs can be an efective and reli-
able solution to a facilitys wastewater treatment process.
Plant managers should contact an authorized pump manu-
facturer to determine if an AODP is the right
choice for their application. P&S
Oakley Roberts is the product management director for ARO
Fluid Products, Ingersoll Rand. He can be reached at oakley_
roberts@irco.com or 419-633-6935. For more information,
visit www.ingersollrandproducts.com.
G
enerator sets are available in a wide range of power
ratingsfrom small, portable sets to mobile power
systems or large stationary generator sets supplying power
in the demanding scenarios worldwide. To determine
if a generator set installation is required, the intended
application, geographical rules and regulations and proper
sizing of the generator set must be considered.
APPLICATION
Generator sets are used in many applications. Te frst con-
sideration is to determine the generators intended use. Will
it be transported from jobsite to jobsite, provide relief in the
event of a catastrophic event, or will it be used to provide
power during peak demands? Te intended application
must be reviewed to ensure that the correct equipment is
specifed and installed. When deciding if mobile power,
emergency power, or a continuous or peak shaving power
system is needed, several factors must be addressed.
Diesel mobile and continuous or peak shaving power
systems (stationary nonemergency) must comply with the
latest Environmental Protection Agency (EPA) engine
emission regulations. Tese have become one of the most
discussed topics in the power generation industry. Tey
must be driven by an EPA-compliant certifed interim
Tier 4 or a Tier-4-capable engine. By 2015, products in a
mobile, continuous or peak shaving application will need to
meet the stringent emission regulations of Tier 4 unless the
manufacturer uses the Transition Provisions for Equipment
Manufacturers Program. Tis program gives the manufac-
turer fexibility to design products in a timely manner to
meet emission regulations.
Emergency power systems have several diferent require-
ments. Te three classifcations for power systems are
emergency systems, legally required standby systems and
optional standby systems
Articles 700, 701 and 702 from the National Electric
Code (NEC) explain each classifcation. Article 700 details
emergency systems, which are required to automatically
supply illumination, power or both to designated areas
essential to human safety if the normal power supply fails. In
Article 701, legally required standby systems are intended
to automatically supply power (other than those classifed
as emergency systems) to designated areas if power fails and
could result in safety hazards and hamper rescue eforts.
Optional standby systems, highlighted in article 702, are
installed to supply power to public or private facilities
where human safety does not depend on the performance of
the system and can supply power automatically or manually.
Power Generation on Demand
The application, geography, regulations and proper size must be considered
when choosing a generator set.
By Brad Chrudimsky, Baldor Electric Company, a member of the ABB Group
Mobile generator sets provide temporary relief.
FUEL
When choosing a fuel source, diesel, natural gas and liquid
propane have advantages and disadvantages. For example,
diesel is portable, easy to store and readily available. Diesels
disadvantage is its limited shelf life (10 to 12 months). Also,
the overall cost of a diesel-driven power system is typically
higher because of fuel storage requirements and the need to
refll the fuel as it is consumed.
Another option and a cleaner burning fuel is liquid pro-
pane. Liquid propane is portable and easy to store. It also
has a longer shelf life than diesel.
Te third option for fuel is natural gas. It burns cleaner
than diesel and is the easiest of the three to obtain. Because
of a surplus as a result of the shale gas boom in North
America, there is a practically unlimited supply. With the
advantages of natural gas comes the hazard of leaky or burst-
ing pipes. Because of these hazards, it cannot be used in life
safety applications. Also, much more natural gas is needed
to produce the same amount of power when compared to
other fuels. When making this crucial decision, federal,
municipal, state and local codes can help defne which fuel
source should be used.
AGENCY APPROVALS
Minimum requirements may need
to be met when installing a genera-
tor set in certain geographical loca-
tions. Tird-party safety certifcation
standardssuch as Underwriters
Laboratories UL2200 health and
safety of use standards, National
Fire Protection Association (NFPA)
110 fre protection standards and/or
NFPA 20 installation of stationary
fre pumps for fre protection stan-
dardscan ensure that the power
system is appropriate for the applica-
tion. Contacting the local authority
having jurisdiction (AHJ) can pro-
vide clarity of federal, state, municipal
and local rules and regulations. Te
AHJ has the fnal say in the generator
set installation and commissioning.
If UL2200 or NFPA 110 is specifed
at the time of order, several require-
ments need to be met to ensure that
the complete system is a safe and reli-
able piece of equipment. For instance,
UL2200 requires additional testing and documentation if
the generator is wrapped in an enclosure or any modifca-
tions are made to the generator set afer it leaves the original
manufacturers production site. To carry the UL listing, all
system components must meet the UL standards.
Diesel fuel tanks can be installed as a sub-base for generator sets.
WHEN QUALITY AND
DELIVERY MATTER
WHEN QUALITY AND
DELIVERY MATTER
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NFPA 110 sites the importance of the power system to
human safety, the amount of time it takes the set to be at
full power, and the runtime before the power system must
be refueled or recharged. If using the generator set to supply
power to a fre pump motor, NFPA 20 standards and NEC
Article 695 standards must be met. Te standards make cer-
tain that the fre pump motor runs when needed. Correctly
calculating the required loads helps properly size the set.
SIZING
Properly sizing the generator set for operating speeds of
motors and fre pump motors is crucial. More importantly,
sizing the generator set to start a motor versus a fre pump
motor is the more dif cult task. Typical motor starting kilo-
volt amperes (kVA) allows a 30 percent voltage dip, while
NEC 695-7 permits a voltage drop of only 15 percent at the
controller line terminals when starting a fre pump motor.
To meet this requirement, the generator set must be upsized
by as much as three times.
Te generator set can carry a UL2200 listing if the circuit
breaker does not exceed the standards 125-percent thresh-
old. If not sized properly, the third-party certifcations may
not apply. Te generator sets fuel supply shall be suf cient
to provide eight hours of fre pump operation at 100 percent
of the rated pump capacity and supply required for other
demands according to NFPA 20. Contacting federal, state,
municipal and local resources can help specify the proper
unit. P&S
Brad Chrudimsky is the product marketing specialist for
Baldor Generators and is based at the companys gen-
erator manufacturing facility in Oshkosh, Wisc. He can be
reached at brad.chrudimsky@baldor.abb.com. Baldor Electric
Company is a member of the ABB Group.
To carry a UL2200 listing, the generator set components need to safely
operate as a complete system.
SHARK GRINDERS
Zoeller Engineered Products ofers
a line of grinder pumps with models
available from 1 to 7 horsepower.
Cool run design technology efec-
tively disperses heat, promoting
longer service life. Te units are
available with multiple discharge
confgurations and wet end designs.
Some models feature reversing cutter
design, which prevents cutter jams.
Models are available with standard or
explosion proof motors.
Circle 221 on card or go to psfreeinfo.com
CIRCULATOR PUMPS
Grundfos introduces
its energy-ef cient
circulator pump.
MAGNA3 is an
energy-optimized, vari-
able-speed wet rotor
circulator that features
a permanent magnet
motor design that will
cut power consumption up to 85 percent. Te circulator
uses a variable-speed electronically commutated motor
(ECM) that uses an integrated logic algorithm, enabling
the sofware to automatically determine the lowest pos-
sible operating-ef ciency point demand.
DATA LOGGER
Omega introduces its
new series of precision
resistance temperature
detector (RTD) data
loggers. Te OM-CP-
RTDTEMP101A
accepts 2-, 3- or 4-wire
100 platinum RTD input and features a battery life of
10 years, multiple start/stop function, ultra high speed
download, 670,000 reading storage capacity, memory
wrap and programmable high and low alarms. Te data
logger is ideal for chemical, water and food industries and
for lab, HVAC and R&D applications.
BALL VALVE SEAT
Metallized Carbon
Corporation introduces
its carbon-graphite ball
valve seats for use in
valves designed to handle
hot liquids or hot gases.
Te ball valve seats are
available in more than
150 grades of Metcars carbon/graphite material. Te
seats are ideal for use in temperatures from approximately
350 F to 800 F in oxidizing environments. Tey are also
ideal for fre safe petroleum industry ball valves.
DISINFECTION SYSTEM
Xylem Inc. has engi-
neered enhancements
to its most cost-efective
solution for ultra-
violet (UV) wastewater
treatment with the
WEDECO TAK 55 Smart UV light disinfection system,
which is ideal for small- to medium-sized municipalities.
Te solution ofers a full menu of options to help custom-
ers design their systems to meet ef uent qualitiessuch
as combined sewer overfows, primary or secondary
wastewater sources, lagoons, or tertiary wastewater recla-
mation and reuse.
d f b l f f
PROGRESSING CAVITY PUMPS
Moyno, Inc.,
ofers the L-Frame
Progressing Cavity
Pump for depend-
able performance
and maximum
operating ef ciency.
Tese pumps are
ideal for handling
clean, thin, shear-sensitive products to viscous, corrosive,
abrasive slurries and sludges. All these pumps are available
with a variety of drive options, sealing confgurations,
motors and controls.
PRODUCT PIPELINE
PRODUCT PIPELINE
TESTING PEN
Dwyer Instruments, Inc., introduces its WPH2 Waterproof pH Testing Pen, which accurately monitors pH
and temperature levels in many applications. Te pocket-sized tester is ideal for pH level measurements in the
lab, industrial plants or on-the-go in the feld. It features an easy-to-replace electrode option and a one-touch,
three-point auto-calibration. Temperature and pH appear on the large dual display.
FUSE HOLDERS
WAGO Corporations 811
Series Class CC and Midget-
Style (10 x 38 mm) Fuse Holders
provide machine- and panel-
builders with a new approach
to branch and supplemental
protection. Te holders feature
a DIN-rail mount clip for easy
installation and removal. Circuit identifcation/marking
options are provided by WAGOs WMB multi-marking
strip and exclusive continuous marking strip adapters.
CABLE GLAND
RST introduces its cable gland section
of AlphaX, GammaX and DeltaX prod-
ucts, recently approved by the new ATEX
standard for explosion-proof products. All
armored cables can be mounted with just
one gland. Te DeltaX and GammaX series
can be dismounted easily and in a controlled
manner. Te design of the grounding and
sealing inserts ensures that the spare parts
cannot be lost during installation.
UNMATCHAB L E E XP E RI E NCE
I N P RI VATE COMPANY
TRANS ACTI ONS
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
ltration industries (Flow Control).
Our lines of business include: selling companies,
raising debt and equity capital, and assistance
on acquisitions.
To learn more about Jordan, Knauff & Company,
contact any member of our Flow Control
team. Access our Flow Control research at
www.jordanknauff.com/owcontrol.
G. Cook Jordan, Jr.
Managing Principal
cj@jordanknauff.com
312.254.5901
David A. Kakareka
Associate
dkakareka@jordanknauff.com
312.254.5907
ANSI/HI Pump Standards on CD
Version 3.1 Now Available
ANSI/HI Standards on CD contains all the
current Pump Standards including:
Controlled-Volume Metering Pumps for Test (ANSI/HI 7.6)
Intake Design for Rotodynamic Pumps (ANSI/HI 9.8)
Rotodynamic Pumps Guideline for NPSH Margin (ANSI/HI
9.6.1)
Rotodynamic (Centrifugal & Vertical) PumpsGuideline for
Allowable Operating Region (ANSI/HI 9.6.3)
Rotodynamic Submersible Pumps for Hydraulic
Performance, Hydrostatic Pressure, Mechanical, and
Electrical Acceptance Tests (ANSI/HI 11.6)
Order the newly-published
CD Version 3.1 now at the HI
eStore at eStore.Pumps.org
VARIABLE SPEED DRIVES
Zero-Max variable speed
drives meter and dispense
seed and fertilizer guided by
global positioning systems.
Te drives provide accurate
and repeatable settings to
optimize the seeding and
fertilizing process. Te drives
can be used as a prime mover connected to a motor, or as
a secondary drive connected to a shaf in the machines
driveline.
REDUNDANCY MODULES
Phoenix Contacts Quint
ORing active redundancy
modules use new auto current
balancing (ACB) technology
for precise load sharing. Te
ACB technology, coupled
with load current monitoring,
remote diagnostics and visual
indications, ensures maximum reliability in redundant
power systems. Te module, available in two 24-volt DC
versions, can also monitor load current.
To have a product considered for Product Pipeline, please send the information to Amanda Perry, aperry@cahabamedia.com.
COUPLINGS
Staford Manufacturing Corp. introduces a full line of rigid shaf couplings in a broad range
of types, sizes and materials for joining unsupported shafs in applications ranging from delicate
instruments to large mixers and pumps. Te couplings are ofered in one-, two- and three-piece
designs, with or without keyways. Te couplings are machined from stainless steel, steel and
aluminum.
AWEA
Solutions for Success
www.WINDPOWERexpo.org
Registration
Now Open!
WINDPOWER
is the Source
to Find Your
Business Solutions
PUMP USERS MARKETPLACE
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
Comprehensive
Industry Coverage
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.
Visit us at www.frost.com
For more information, contact Britni Myers
at 210-477-8481 or britni.myers@frost.com
INDEX OF ADVERTISERS
ABZ, Inc. 70 146
Advanced Engineered Pump, Inc. 70 145
AWEA 67 110
Baldor Electric Company 7 100
Bartlett Bearing Company 70 147
BaseTek, LLC 59 139
Benshaw Incorporated 27 112
Blacoh Fluid Control, Inc. 13 114
Blue-White Industries 29 115
Burns Dewatering Service 71 148
Carver Pump Company 39 113
Cascade MVS 52 132
Dakota Pump 47 111
Dan Bolen & Associates, LLC 69 149
Discfo 14 131
Flowrox Inc. 43 116
Frost & Sullivan 68 142
GE Oil & Gas, Surface Pumping Systems 36 101
General Pump 35 117
GIW Industries, Inc. 31 118
Global Pump Company IFC 109
Godwin, a Xylem brand 15 119
GPM, Inc. 44 120
Greyline Instruments Inc. 49 170
Griffco 26 121
Grundfos BC 102
Houston Dynamic Service, Inc. 70 151
Hydraulic Institute 66 144
Jordan, Knauff & Company 66 143
Junty International, LLC 69 152
Load Controls, Inc. 9 122
LobePro 69 150
LUDECA, Inc. 3 103
Magnatex Pumps, Inc. 69 153
Meltric Corporation 71 154
National Pump & Compressor 41 123
NETZSCH Group 32 125
Pioneer Pump 17 124
Proco Products, Inc. 50 133
PumpWorks 610 63 138
Reason Technology Co. Ltd. 53 134
Ruthman Companies 53 135
Scenic Precise Element Inc. 70 155
seepex, Inc. 40 126
SEPCO 38 127
SEPCO 69 156
SERO Pump Systems 71 157
Sims Pump Company 33 108
Sims Pump Company 69 158
Singer Valve 58 141
SJE-Rhombus 56 136
Smith & Loveless IBC 104
Summit Pump, Inc. 71 159
SWPA 64 130
Tarby, Inc. 23 128
Topog-E Gasket 71 160
Trachte, USA 71 161
Tuf-Lok International 71 162
UniqueFlo 68 163
Varisco USA Inc. 68 164
Vaughan 5 105
Vertifo Pump Company 58 140
Vertifo Pump Company 71 166
Vesco 70 165
Vogelsang USA 55 137
Wilden 37 129
Xylem USA 1 106
Zoeller Company 11 107
* Ad index is furnished as a courtesy and no responsibility is
assumed for incorrect information.
Advertiser Name Page RS#
Serving the Pump & Rotating
Equipment, Valve, and Industrial
Equipment Industry since 1969
Domestic & International
Specializing in placing:
General Management
Engineering
Sales & Marketing
Manufacturing
DAN BOLEN JASON SWANSON
CHRIS OSBORN DAN MARSHALL
9741 North 90
th
Place, Suite 200
Scottsdale, Arizona 85258-5065
(480) 767-9000 Fax (480) 767-0100
Email: danbolen@mindspring.com
www.danbolenassoc.com
EXECUTIVE SEARCH/RECRUITING
ROTARY LOBE SLUDGE PUMPS
FOR SLUDGES/SLURRIES/CORROSIVES
912-466-0304 www.LOBEPRO.com Made in USA
SeIf Priming to 25'.
ReversibIe operation.
SIow running. Non-contacting
Iobes permit dry running and
pumping of abrasives.
Wear pIates and housing
segments are customized
for abrasive, corrosive, and
generaI appIications.
EMPLOYMENT
PUMP USERS MARKETPLACE
800-523-3382
www.bartlettbearing.com
Solve
dry start
problems with
Vesconite Hilube
bushings
G Increase MTBR
G No swell
G Low friction = reduced
electricity costs
G Quick supply.
No quantity too small
Tollfree 1-866-635-7596
vesconite
@
vesconite.com
www.vesconite.com
Rotating Equipment Repair Specialists
Rotating/Centrifugal Pumps | Turbines | Compressors
Fan & Blowers | Gears/Gear Boxes | Centrifuges
P 713.928.6200 | F 713.928.9203 | 8150 Lawndale, Houston, TX 77021
www.houstondynamic.com
800.433.7642 meltric.com
OFF
Button
Protects from electrical hazards
Simplifies NFPA 70E compliance
Qualified technicians can quickly
disconnect and connect power
up to 200A, 60hp, 600V.
FREE Samples Available
Easy
Lockout
Dead
Front
OFF
Button
Your Best Value in
Self Priming Pumps
Model SN
Green Bay, WI
www.SUMMITPUMP.com
PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch
By Jordan, Knauff & Company
T
he Jordan, Knauf & Company ( JKC) Valve Stock
Index was up 10.4 percent over the last 12 months,
below the broader S&P 500 Index, up 13.1 percent. Te
JKC Pump Stock Index was up 6.7 percent for the same
time period.
1

Manufacturing began 2013 on a positive note.
In January, the Institute for Supply Managements
Purchasing Managers Index (PMI) increased 2.9 percent
over December to reach 53.1 percent, the highest level
since April 2012. All fve PMI component indexesnew
orders, production, employment, supplier deliveries and
inventoriesregistered growth in January. Most important,
the index for new orders moved from contraction at 49.7
percent in December to slight growth at 53.3 percent.
Te Commerce Department reported that shipments
of manufactured durable goods increased $2.6 billion (1.1
percent) to $230.1 billion in December. Tis followed a 1.8
percent November increase.
Total, nonfarm payroll employment increased by 157,000
jobs in January according to the U.S. Bureau of Labor
Statistics. Employment numbers for November were revised
from 161,000 to 247,000 jobs, while the numbers for
December were revised from 155,000 to 196,000 additional
jobs. Including these revisions, nonfarm payrolls rose 2.2
million in 2012, roughly 180,000 per month. Manufacturing
employment was essentially unchanged in January and has
changed little since July. Job gains in January occurred in
retail trade, construction, health care, and wholesale trade.
Due to ongoing activity in onshore basins, the U.S. Energy
Information Administration (EIA) expects U.S. crude oil
production to continue its growth during the next two years.
Increasing from an average of 6.4 million barrels per day
(bpd) in 2012, the EIA predicts that crude oil production
will average 7.3 million bpd in 2013 and 7.9 million bpd in
2014. Drilling in tight oil plays in the Williston, Western
Gulf and Permian Basins will account for most of the fore-
casted growth, with the Western Gulf Basin accounting for
more than half the onshore domestic liquid production
growth. Te Williston Basins Bakken formation (North
Dakota and Montana) and the Western Gulf Basins Eagle
Ford formation (Texas) currently produce about two-thirds
of the tight oil in the U.S.
On Wall Street, Te Dow Jones Industrial Average had
its largest January increase since 1994. Better-than-expected
earnings for the fourth quarter combined with a brighter
employment scenario and encouraging numbers from
the housing sector boosted the markets. Te Dow Jones
Industrial Average increased 5.8 percent, the S&P 500 Index
gained 5.1 percent and the NASDAQ Composite rose 4.1
percent in January. P&S
Reference
1
Te S&P Return fgures are provided by Capital IQ.
Jordan, Knauff & Co. is an investment bank based in Chicago, Ill., that provides
merger and acquisition advisory services to the pump, valve and fltration indus-
tries. Please visit www.jordanknauff.com for further information on the frm.
Jordan Knauff & Co. is a member of FINRA.
Figure 2. U.S. Energy Consumption and Rig Counts
Figure 3. U.S. PMI Index and Manufacturing Shipments
Source: U.S. Energy Information Administration and Baker Hughes Inc.
Source: Institute for Supply Management Manufacturing Report on Business and
U.S. Census Bureau.
Figure 1. Stock Indices from Feb. 1, 2012, to Jan. 31, 2013
Source: Capital IQ and JKC research. Local currency converted to USD using historical
spot rates. Te 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.
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CALL S&L AFTER MARKET 800.922.9048

VISIT SelectIt.SmithandLoveless.com
S&| Nor-0|og Pap w|re-to-water ef|o|ero |s a t||rg of beaat. Ar4
oar pab||s|e4 pap oares s|ow oa t|e pat| to sa|rg or ererg oosts.
Bat |t's w|at |s |rs|4e t|at ooarts, ||ke t|e water |r4astr's ost 4arab|e
s|aft & sea| oorstraot|or, oasto-tr|e4 |pe||ers t|at ooraer to4a's
o|ogs, ar4 speo|a||-4es|gre4, pre|a ef|o|ert otors. |aotor-teste4 at
4es|gr oor4|t|ors before s||pert, oa oar see w| S&| Nor-0|og Paps
4e||er beaat|fa|, power-sa|rg perforaroe. !ake pr|4e |r oar Paps.
Ask as aboat ererg-sa|rg S&| Pap retro|ts!
VISIT SELECT TTTIT ITT IT.SMITH THAN ANDLOVELES SS.CO OM
FOORR CURV RVVES, SPECCCCS, & CCOM OMPLETE DE ESSIGN N TTOOLS
Technology & Innovation:
Its what drives us
As a recognized global leader in pump technology and solutions,
Grundfos is constantly developing new and improved ways to meet
water and energy challenges.
ALPHA
MAGNA3
PROVIDING
TOMORROWS
TECHNOLOGY
TODAY
GO REMOTE
f.com/GrundfosPumpUSA
twitter.com/GrundfosUSA
youtube.com/GrundfosUSA
www.grundfos.us

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Pump & Systems Marc 2013

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TM

We Know Bypass Pumping.

200 and I.M.S

1000 media retainers from Leopold

is a registered trademark of seepex GmbH +Co KG.

circle 128 on card or go to psfreeinfo.com

T2 Rotary Lobe Pump

CAN SAVE YOU MORE THAN OUR PRODUCTS COST.

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

Industrial, municipal, commercial and

Agriculture, irrigation and dewatering

Variable Frequency Drives (VFDs)

Man-Machine Interface (MMI)

Programmable Logic Control (PLC)

Communications, data logging

200+ pump bases ready for immediate delivery

Rapid turnaround of custom hole patterns

Guaranteed atness of 0.002/ft.

Signicant vibration reduction

Superior corrosion resistance

You might also like

Pump &amp; Systems Marc 2013

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Pump &amp; Systems Marc 2013

Uploaded by

Copyright:

Available Formats

TM

We Know Bypass Pumping.

200 and I.M.S

1000 media retainers from Leopold

is a registered trademark of seepex GmbH +Co KG.

circle 128 on card or go to psfreeinfo.com

T2 Rotary Lobe Pump

CAN SAVE YOU MORE THAN OUR PRODUCTS COST.

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

Industrial, municipal, commercial and

Agriculture, irrigation and dewatering

Variable Frequency Drives (VFDs)

Man-Machine Interface (MMI)

Programmable Logic Control (PLC)

Communications, data logging

200+ pump bases ready for immediate delivery

Rapid turnaround of custom hole patterns

Guaranteed atness of 0.002/ft.

Signicant vibration reduction

Superior corrosion resistance

You might also like

Pump & Systems Marc 2013

Pump & Systems Marc 2013