Pumps & Systems Oct2010

The Magazine for Pump Users Worldwide October 2010
pump-zone.com
circle 100 on card or go to psfreeinfo.com
PUBLISHER
Walter B. Evans, Jr.
Letter from the Editor
ASSOCIATE PUBLISHER
VP-SALES
O
George Lake ne of civilization’s earliest inventions, ITT and other companies are working to
glake@pump-zone.com
205-345-0477 pump technology has not changed change that, as illustrated in this month’s cover
EDITOR much through the years. Since 200 series Smart Pumps (page 18). “Our process
VP-EDITORIAL B.C., pumps have moved water and other vis- pumps ship with onboard digital sensors—the
Michelle Segrest
msegrest@pump-zone.com cous materials from Point A to Point B. No pumping equivalent of a “check engine” light
205-314-8279 matter the consistency of the liquid—whether to warn of temperature or vibration issues,” says
MANAGING EDITOR it’s peanut butter or oil—a pump can suck, Kernan.
Lori K. Ditoro
lditoro@cahabamedia.com push or lift it to its destination. he PumpSmart® drives on this month’s
205-314-8269 However, the pump industry continues to cover are the digital version of an automatic
MANAGING EDITOR— be innovative and intelligent in the advance- transmission, adjusting pump speed to process
ELECTRONIC MEDIA
Julie Smith ments of technology. Because of constant conditions. ProSmart™ condition monitoring is
jsmith@cahabamedia.com developments, Pumps & Systems covers instru- similar to auto safety systems, such as OnStar®,
205-314-8265
mentation, monitoring and controls in every that assess conditions remotely and use wireless
CONTRIBUTING EDITORS
Laurel Donoho issue (coverage this month begins on page 28). communications to provide help when needed.
Joe Evans, PhD As manufacturers continue to see the value in Intelligent pumping systems continue to
Dr. Lev Nelik, PE, APICS
pump system optimization, “Smart Pumping” improve performance and reduce energy con-
SENIOR ART DIRECTOR is revolutionizing the industry. sumption by combining a pump and a variable
Greg Ragsdale
“From the cell phones we carry to the frequency drive with digital control capabilities
PRODUCTION MANAGER
Lisa Freeman cars we drive, technology advancements have (page 19). Learn how intelligent pumping sys-
lfreeman@pump-zone.com transformed the way we live,” explains Dan tems have become a driving force in the pump
205-212-9402
Kernan, manager of monitoring, controls at market (page 22) and how single phase pump-
CIRCULATION
Tom Cory
ITT Industrial Process. “On-board intelligence ing can be made safer and smarter (page 25).
TomCory@cirtecinc.com and digital communications make the machines
630-482-3050
we use every day more efficient.
ACCOUNT EXECUTIVES
“But if you work with industrial machines, Best Regards,
Charli K. Matthews
cmatthews@pump-zone.com walking onto the shop floor can be a step back
205-345-2992
in time. Some pumps being sold today have
Derrell Moody barely changed in 50 years. hat’s because too
dmoody@pump-zone.com
205-345-0784 many pump manufacturers have been slow to Michelle Segrest
Mary-Kathryn Baker integrate digital and interactive technologies Editor
mkbaker@pump-zone.com msegrest@pump-zone.com
205-345-6036
with their products.”
Mark Goins
mgoins@pump-zone.com Editorial Advisory Board
205-345-6414
William V. Adams, Director, New Business John Carter, President, Warren Rupp, Inc.
ADMINISTRATIVE ASSISTANT Development/Corp. Mktg., Flowserve
Ashley Morris David A. Doty, North American Sales Manager,
Corporation
amorris@pump-zone.com Moyno Industrial Pumps
205-561-2600 Thomas L. Angle, PE, Vice President, Product
Ralph P. Gabriel, Director of Product Development,
Engineering, Weir Specialty Pumps
John Crane
Robert K. Asdal, Executive Director, Hydraulic
A Publication of Institute William E. Neis, PE, President, NorthEast Industrial
Sales
Bryan S. Barrington, Machinery Engineer, Lyondell
Chemical Co. Dr. Lev Nelik, PE, Apics, President, Pumping
P.O. Box 530067 Machinery, LLC
Birmingham, AL 35253 Kerry Baskins, Vice President, Grundfos Pumps
Corporation Henry Peck, President, Geiger Pumps & Equipment/
Editorial & Production
1900 28th Avenue South, Suite 110 Smith-Koch, Inc.
R. Thomas Brown III, President, Advanced Sealing
Birmingham, AL 35209 Mike Pemberton, Manager, ITT Performance
Phone: 205-212-9402 International (ASI)
Services
Advertising Sales Chris Caldwell, Director of Advanced Collection
Technology, ABS, & President, SWPA Earl Rogalski, Sr. Product Manager, KLOZURE®,
2126 McFarland Blvd. East,. Suite A
Garlock Sealing Technologies
Tuscaloosa, AL 35404
Phone: 205-345-0477 or 205-561-2600
is a member of the following organizations:

PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Pumps & Systems, a member of the Cahaba Media Group, 1900 28th Avenue So., Suite 110, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the right to determine qualifications. Annual sub-
scriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call (630) 482-3050 inside or
outside the U.S. POSTMASTER: send change of address to Pumps & Systems, PO BOX 9, Batavia, IL 60510-0009. ©2010 Cahaba Media Group, Inc. No part of this publication may be reproduced
without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, articles or descriptions herein, nor does
the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily
represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained
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republish your submission. Submissions will not be returned.
2 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

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Table of Contents
Cover photo: ITT Industrial Process. Engineers monitor

The Magazine for Pump Users Worldwide October 2010
pump-zone.com
pumping system with PumpSmart.

October 2010
Volume 18 • Number 10
COVER SERIES: SMART PUMPS
p
19
Optimization Solutions
Jack Creamer, Dan McGinn and Jim Morgan,
Schneider Electric
Improvements in performance and energy reduction can be achieved.
39TH ANNUAL TURBOMACHINERY
p
22
Intelligent Pumping Market
Ram Ravi and Douglas Weltman, Frost & Sullivan
SYMPOSIUM AND EXHIBIT SHOW
Current analysis and future outlook
p
65
Show Preview
p
25
Safer and Smarter Single Phase Pumps
Aaron Wolfe, P.E., & Bill Chandler, Jr., CSI Controls
New motor starting controller provides one solution.
SPECIAL SECTION: INSTRUMENTATION, DEPARTMENTS

CONTROLS & MONITORING Readers Respond . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
p Reliable and Efficient Remote Lift
29 Stations
Paul S. Twaddell, Eaton Corporation
P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control panel products enhance smooth operations. Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Joe Evans, Ph.D.
p Mass-Based Propane Odorant Injection System

32 Wesley Sund, Brooks Instrument, LLC
Details of a mass-based chemical injection system
Variable Frequency Parallel Pump Analyzer
Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 16
Dr. Lev Nelik, P.E., APICS, President, Pumping Machinery, LLC
p
36 Improving SCADA Operations Using Wireless
Pumps
Hany Fouda, Control Microsystems
Eben Walker, Graphalloy Company
Specialty Materials Help Improve Pump Reliability and Save Energy
Many reasons for wireless conversion reluctance are resolved with new Maintenance Minders. . . . . . . . . . . . . . . . . . . . . . . . . 40
technology. Mark D. Hinckley, SKF USA Inc.
The Attraction of Magnetic Bearings
Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PRACTICE & OPERATIONS Wallace Wittkoff
p Flexible Impeller Pumps in the Food Industry

54 David Farrer, Depco Pumps
One of the best kept secrets in pumping technology
Efficiency Through Indirect Measures
FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 50

What Is the Sealing System Energy Footprint for Removing Diluents
from the Process Stream?
p
57 Pump Castings
Alfred ‘Fritz’ Hall, Benton Foundry
The most misunderstood, most overlooked and possibly most important pump HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Bearings used in high-temperature applications, suction
component.
recirculation in pumps and Newtonian and non-Newtonian fluids
p
58 Not All ANSI Pumps Are Created Equal
Patrick Prayne, ITT Goulds
OEM pumps and parts outperform replicated products and can save
Product Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . 67
thousands per year in operating costs.
Bulletin Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
p
63 Data Loggers and Flow Meters
Evan Lubofsky, Onset Computer Corporation
Low-cost additions help bottle maker manage compressed air use and energy
Pump Users Marketplace. . . . . . . . . . . . . . . . . . . . . . 69
P&S Stats and Interesting Facts . . . . . . . . . . . . . . . . 72

costs on a shoestring.

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Readers Respond
Grouting: Pumps and Telephone Poles,

July 2010 Lev Nelik responds:
No part of the anchor bolt should contact the grout. It hank you for your kind words. here are several specs
should be sleeved through the grout so the tension is trans- which touch on the base plating and grouting, such as API-
mitted to the foundation. I have sleeved and also used several 610 for pumps, ANSI and also articles by the folks involved in
wraps of duct tape where a sleeve is not practical. he grout this business. However, there is no formal specification for this
will not stick to the duct tape. subject, as I know, which is unfortunate, as the subject is very
Duct tape also makes a great non-stick surface when important.
applied to the forms. It works better than wax to keep epoxy I have raised the need for such specifications in several of
grout from sticking. my publications and have added references to this in various
Roy Lightle articles in Pumps & Systems and elsewhere.
PTA Maintenance Superintendent If there is sufficient interest on this further, I would be
glad to lead a team effort to help develop such much needed
Lev Nelik responds: standards.
Excellent point—thanks, Roy. As promised, you get the Perhaps a starting point would be to compile the articles
free admission to our Pump School! If interested, we have room into a set to which we can add more, and then a committee
for our class in August (19 – 20) in Atlanta: would form to expand and develop them into a formal speci-
www.pumpingmachinery.com/pump_school/pump_school. fication. I will also raise this issue with the PumpTec-2010
htm. Advisory Committee in Atlanta this month,
www.pumpingmachinery.com/pump_school/pump_school.
Enjoyed your latest article, “Grouting: Pumps and htm, and we will plan to add such a session to the next PumpTec
Telephone Poles”, in the July Pumps & Systems magazine. Conference in 2011.
Good info.
In response to the “parting quiz,” no part of a bolt should
be in contact with the non-shrink grout. However, “J”-type Sealing Sense, October 2007
and sleeve-type anchors, are commonly embedded into the Water quality is an important consideration. Can you
concrete below the grout. Figure 3, in the article, illustrates please give me the minimum required flush water quality?
the grout above the concrete. If the bottom Jay Wen
nut, below the baseplate in this illustration,
was removed the anchor should be able to FSA Responds:
stretch, from tensioning, approximately from he following are suggested water quality specifications:
the top nut to the concrete surface. Particle Size: 50 micron max.
Lee Ruiz Solids Content: 10 milligram/liter max.
Oceanside, Calif. Percent iron: 1 milligram/liter max.
Lee Ruiz
Water should be free of clay and humus
Lev Nelik responds: Permanganate Number: max. 30
Your note echoes the one just sent to me by another engi- Total Hardness: Max. 10 degrees dH
neer at BP, with both of you essentially echoing the same good
point. Right on! I will ask the P&S Editors to publish your
input in Readers Respond. What Is a Safe NPSH Margin for a
As promised, you get the free admission to our Pump Centrifugal Pump? Can You Provide Too
School! If interested, we have room for our class in August (19
– 20) in Atlanta.
Much NPSH? June, 2009
I have a question on NPSH margin. he typical industry
standard (i.g. PIP) would use a 3-foot margin from minimum
Great articles in the Pumps & Systems magazine…I look
stable flow to 110 percent of the rated operating point. I’m
forward to reading each month.
not sure if HI 9.6.1 1998 is still applicable (ratio of NPSHA/
Your article in July that discussed grouting and base plates
NPSHR = 1.1). Would it be appropriate to use HI in this case
was very good. Is there an accepted technical standard for base
as well? his is for the power generation industry.
plate design? I have looked at the HSI standard for centrifugal
William Nguyen
pump design and application, but it is mostly qualitative. It
Mechanical Engineer
does not provide much in the way of specifics. If you know of
a better more specific base plate standard, please let me know.
Terry Henshaw responds:
And keep up the good work in your articles; it helps.
I addressed the complex and controversial subject of
Bob Pritchard

NPSH margin for centrifugal pumps in the June 2009 issue of Most so called cavitation problems are not NPSH related but
Pumps & Systems, as well as in my article in the September 2001 are the result of a poor suction line design. Valves, poor designed
issue (which I think resulted in HI withdrawing their margin reducers and pipe bends are disturbing the flow towards a pump
recommendations). I hope these will answer your question. If causing lots of collision losses and collision noise, and the client
the product is water, keep the 3-percent-head-drop suction spe- blames the pump for having a poor NPSH value...I have also
cific speed, at bep, when tested at 1,800 rpm, at or below 8,500 experienced poorly designed (cheap and locally made) pumps
(in U.S. units). Please see my articles in the September, October running with cavitation, although the NPSHa is far above the
and November 2009 issues. NPSHr. he most common solution is to redesign the suction
line. I have had lots of pump problems solved after suction line
modifications. Pump efficiency was increased by 5 to10 per-
Net Positive Suction Head: NPSHR and cent, and the pump efficiency came back to test-bed measured
NPSHA, May 2008 (These comments values.
For reciprocating pumps with a constant speed, a dynamic
are part of this article’s discussion on flow computer analysis may determine a certain pipe length
LinkedIn.) and diameter to use for the dynamic behavior to increase the
NPSH calculations for positive displacement reciprocat- pump’s suction action.
ing plunger type pumps—I am requesting software and calcu- Huub Janssen
lations that apply. For anyone who has good information avail- Apeldoorn, Netherlands
able, I would like to include it on my website.
Bruce Schuetz he key to determining NPSHA is working in terms of
Chicago, Ill. absolute pressure. It is always best to think in terms of the
margin of NPSHA over NPSHR. Also, keep in mind that the
NPSH required is performed at the pump manufacturer. NSPHR that value your pump vendor provides is based on a
NPSH available is depending on the design and static head. certain percentage of head loss based on cavitation present at
he last one can be easily calculated via a spreadsheet program. that NSPH value. So if your system is operating with NSPHA
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PUMPS & SYSTEMS www.pump-zone.com OCTOBER 2010 7
Readers Respond
= NPSHR, then you will have cavitaiton. the fluid (PSIA ) equals NPSHA at that location. Convert that
If you measure the suction pressure of your incoming fluid (PSIA) number into feet of fluid (PSIA x 2.31 / specific gravity
relatively close to the inlet of the pump, then you have a pretty = feet of fluid).
good idea of your suction pressure. Based on the temperature Add any elevation corrects (feet of elevation) to get to your
and pressure of the fluid coming in you can estimate the vapor pump centerline, and add any velocity head corrections (feet
pressure of the fluid as it enters the pump. of head).
Suction pressure in (PSIA) minus the vapor pressure of Note that if you’re close to the pump, and in the center of
a straight section of pipe, your estima-
tions will be much more accurate. he
farther away from the pump you get the
less accurate your calculations. As high-
lighted by Huub, the more twisted your
piping gets, the more piping losses you
have, and more errors in your pressure
measurements will increase due to the
uneven flow distribution in the pipe. I
work with centrifugal pumps, but the
measurements should be identical
Paul Wegner
Portland, Ore.
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P&S News
PEOPLE ized water reactors at both the Sanmen and Haiyang nuclear
power plants in China. Emerson’s Fisher® air-operated con-
PLIDCO (WESTLAKE, OHIO)—the Pipe trol valves will serve several functions related to operational
Line Development Company—recently safety in the nuclear containment area. As part of the safety-
promoted Pete Haburt to general sales related system, the valves are engineered to comply with
manager. In his role, Haburt will oversee all government requirements, including ASME Section III
export and domestic sales staff. Haburt has standards for components of nuclear facilities, and undergo
35 years of experience with PLIDCO. rigorous qualification testing at the new Emerson Innovation
PLIDCO has been helping companies Pete Haburt Center in Marshalltown, Iowa.
avoid shutdowns with pipeline repairs for Emerson Process Management, an Emerson business,
more than 60 years. he company is a designer and builder of helps businesses automate their production, processing and
standard and custom engineered products for pipeline repair distribution in the chemical, oil and gas, refining, pulp and
and maintenance. www.plidco.com paper, power, water and wastewater treatment, mining and
metals, food and beverage, life sciences and other industries.
www.emersonprocess.com
AROUND THE INDUSTRY
SEPCO (ALABASTER, ALA.) held its 2010 Distributor’s INPRO/SEAL (ROCK ISLAND, ILL.) announced the launch
Conference on August 26 – 27. Distributor’s from across of its new website on September 1, 2010. he site addresses
the globe—including Argentina, Mexico, Australia and Can- each of Inpro/Seal’s engineered system and bearing protec-
ada—attended the two-day event. On August 26, attendees tion technologies. Visitors to the site can check the ROI of
toured SEPCO headquarters and were briefly introduced to their Inpro/Seal Bearing Isolator; submit an electronic RFQ
new products. On August 27, they learned the details about form; run new, informative product animations; and view
new product offerings for 2011. www.sepcousa.com the new Inpro/Seal video.
Inpro/Seal has been delivering sealing solutions for
DICKOW PUMPEN KG (WALDKRAIBURG, GERMANY) cel- more than 30 years and is now part of Waukesha Bearings
ebrated 100 years of manufacturing on September 10, 2010. and Dover Corporation. www.inpro-seal.com
Founded by Karl Dickow in 1910, the firm began as a man-
ufacturer of heating plants and water pipes. After WWII, TORCUP (EASTON, PENN.) announced
Dickow was relocated to its present location. Since then, the its sponsorship of the FAZZT race team
company has grown from producing water pumps to fuel and driver Alex Tagliani in his Honda
transfer pumps and pumps for the chemical industry. Powered #77 IndyCar for the balance of
Dickow is represented in North America by Dickow the 2010 IZOD IndyCar Series.
Pump Company of Marietta, Ga., and is best known for TorcUP designs bolting tools.
its line of sealless, magnetically coupled centrifugal pumps. www.torcup.com
www.dickow.com
LEE MATHEWS EQUIPMENT (KANSAS CITY, MO.)—now
COLFAX CORPORATION (RICHMOND, VA.) announced that known as Cogent—has been identified in the most recent
its Allweiler AG business unit will deliver a €5 million fuel- edition of Inc. magazine as one of the 5,000 fastest-growing
injection skid order through Siemens AG for use in gas tur- private companies in America, receiving this honor for the
bines in Iraq. he skids will be used for power plant expan- fourth year. Honorees were noted for their proven success in
sions in Kirkuk as well as new plants being built in Baiji and the face of a national financial meltdown, serious recession
Baghdad. he first two skids will be completed in early 2011. and continuing economic turmoil. Lee Mathews (Cogent)
he Iraqi Ministry of Electricity has ordered an additional has demonstrated a three-year growth rate of 64 percent
five and has options to purchase three more. since 2008.
Colfax Corporation is a manufacturer of fluid-handling In the second
products and technologies. Colfax manufactures positive dis- quarter of this year, Lee
placement industrial pumps and valves used in the oil & gas, Mathews Equipment,
power generation, commercial marine, defense and general along with Vandevanter Engineering and BRI launched opera-
industrial markets. www.colfaxcorp.com tions under the new flagship brand, Cogent. However, the
management teams, operations, locations and customer rela-
EMERSON PROCESS MANAGEMENT (MARSHALLTOWN, tionships of the partner companies have remained unchanged.
IOWA) has been awarded two multimillion dollar purchase Cogent has offices in five states and is a distributor of
orders from Westinghouse Electric Company for critical con- fluid pumping, water treatment/processing and rental equip-
trol valves to be used in the first of two AP1000™ pressur- ment in the Midwest. www.cogentcompanies.com

P&S News
DREISILKER ELECTRIC MOTORS (GLEN ELLYN, ILL.) celebrated its 55th anniver-
sary at its headquarters.
Dreisilker provides complete electric motor solutions to commercial, industrial
and municipal customers. www.dreisilker.com
CSI CONTROLS (ASHLAND, OHIO) named Gilbert Pump & Mechanical, Inc., (Ft.
Dreisilker employees during 55th anniversary Walton Beach, Fla.) as its authorized engineered distributor. Gilbert Pump will serve
municipal and industrial water and waste-
water customers in the Florida Panhandle
and Alabama and supply them with cus-
tom engineered control panel solutions.
A “DESIGNATED DRIVER” CSI Controls® manufactures con-
FOR YOUR ROTATING EQUIPMENT trol panels, pump controllers, septic
tank alarms and accessories for water and
wastewater. www.csicontrols.com
VALVE AND FILTER (ARVADA, COLO.)

announced that Valve and Filter and
Olson Irrigation jointly won the IA Award
for best New Golf Product at the Irriga-
tion Association Show for a water saving
flushing system for automatic filters.
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eqortguuqtu»vq"pcog"lwuv"c" Valve and Filter produces industrial
hgy"crrnkecvkqpu0""Pqy"cxckncdng" water filters and self-cleaning automatic
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UPCOMING EVENTS POWER-GEN EVERYTHINGABOUTWATER
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October 5 – 7
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Pump Ed 101
Joe Evans, Ph.D.
Variable Frequency Parallel

Pump Analyzer
T
here are several ways to control two iden-
tical, parallel pumps operating under
variable frequency control in pump-
ing applications. One method is to size a single
drive to handle both pumps and vary the speed
of both synchronously. A more efficient method
uses two drives to control the pumps. Once one
pump reaches its maximum speed, the second
pump is brought online and both are operated at
synchronous speeds (as in the previous example).
Yet another two-drive method keeps one pump at
maximum speed and varies the speed of the other.
his example can also be achieved with a single
drive and a transfer switch. When the drive reaches
full speed, the switch causes a contactor to operate
that pump across the line, and the drive is trans-
ferred to the second pump. he downside to this Figure 1. VFPPA Data Input Tab
control scheme is that there is no back up drive.
he first example can work if the normal tabs that are generated. he “One Pump” tab shows the H/Q
flow is always greater than the maximum flow of one pump. curves and hydraulic efficiencies of a single pump at speeds
Otherwise, it can be inefficient. Examples two and three of 45 to 60 Hz. he “Two Pumps” tab shows the same infor-
are better alternatives, but which is best? It depends upon mation for two pumps running at synchronous speeds. he
the breadth of a pump’s hydraulic efficiency and the system other tabs show both single and two-pump operations at dif-
conditions in which it is operating. Comparing these two ferent speeds and are used if a more detailed view is required.
control schemes to see which can provide the best operating he Average Efficiency Calculator and the Energy Savings
conditions is valuable. he beta version of variable frequency Calculator normally seen online at the right of the screen are
parallel pump analyzer (VFPPA) allows for the comparison shown in Figure 4 and will be discussed later.
of the hydraulic efficiencies of identical, parallel pumps oper-
ating under synchronous or independent speed control.
Synchronous Speed Control
Figure 1 is a screen shot of the data input tab of VFPPA
he example included with the analyzer is vertical multistage
Excel sheet. It shows the required data (yellow cells) and the
with a BEP flow of 350 gallons per minute (gpm) and a BEP
efficiency of 78 percent. he rather flat H/Q curve
is typical of this design. he system curve shows a
required static pressure of 206 feet.
Figure 2 is the plot produced in the “Two
Pumps” tab and shows the H/Q curves produced
from 45 to 60 Hz under synchronous speed con-
trol. he data labels show the average hydraulic
efficiency. As shown, when both pumps run at full
speed (60 Hz), they produce a flow of 700 gpm
at 206 feet TDH and operate at BEP efficiency
(78 percent). he black angled line is the operat-
ing point of both pumps at single pump maxi-
mum flow (350 gpm). he speed is approximately
54 Hz and the efficiency drops to slightly below
Figure 2. Plot produced by two pumps running at synchronous speeds 60 percent. As flow (speed) increases, so does the

still have a one point advantage. As flow increases to
600 gpm, the two efficiencies get closer, but individual
control is still higher by about 0.3 percentage points.
his trend continues until flow reaches 700 gpm, and
both control techniques operate at 78 percent.
For this particular pump, individual speed con-
trol is the best control choice. For others, synchronous
control may work equally as well, or even better. It
will depend upon the application and the efficiency
range. When three or more pumps operate in paral-
lel, individual speed control should still be compared.
However, it will have less of an impact as more pumps
are brought online. For example, when the second
pump is brought online and operated synchronously,
Figure 3. Plot produced by one pump running at 60 Hz each pump will initially operate at 50 percent of its
BEP flow. When a third pump is added, each will
average efficiency of the two pumps. he red angled line crosses begin at 66.6 percent, and if a fourth pump is added,
the system curve at 450 gpm at a speed of approximately 56 each will begin at 75 percent of BEP flow. hese increased min-
Hz, and efficiency is increased to about 67 percent. Let’s take a imum flows will also result in an increase in average efficiency.
look at individual speed control and compare the two operating Now, you may wonder if a savings of $0.24 per
efficiencies at 450 gpm. hour is worth the
trouble. I think
Individual Speed Control that it is. If the
Figure 3 is the plot produced in the “One Pump” tab. As shown, system operates
a single pump operating at 60 Hz will produce a maximum just above one
flow of 350 gpm at 78 percent hydraulic efficiency. Under this pump flow for
control scheme, when the pump reaches maximum flow, it is extended periods,
maintained at full speed and the second pump is brought online even this small
at some reduced speed. he red angled line crosses the system savings will add up
curve at 100 gpm at a speed of about 52 Hz. his is the flow that over several years
must be provided by the second pump to match the 450 gpm of operation. Also,
flow produced by two pumps running at synchronous speeds. the savings can
he hydraulic efficiency at this flow point is about 50 percent. be much larger as
application BHP
Determining the Most Efficient Option increases. Finally,
To compare the efficiencies of these two control techniques, it costs nothing
the information above is entered into the Average Efficiency because both
Calculator, which is used to determine which control technique schemes require
is best for a particular pump and application. the same com- Figure 4. Average Efficiency and Energy
he calculator, seen in Figure 4, requires the flow and effi- ponents. hink Savings Calculators
ciency of the pump running at full speed and the flow and effi- of it as one small
ciency of the pump running at a reduced speed. Upon entry, it step that, when included with others, allows the best possible
calculates the percent of total flow contributed by each pump and increase in overall efficiency.
the average hydraulic efficiency of the two pumps. he calculator he beta version of VFPPA is available for download
shows an average efficiency of 71.8 percent, which is about 5 per- from the “Pump Sizing & Selection Tools” section of www.
cent higher than the 67 percent produced at synchronous speed. pumped101.com. he final version will support the generation
he Energy Savings Calculator (also in Figure 4) requires of a system curve that is composed of both static and friction
the efficiency of the pumps operating at synchronous speed, head. It should be available early next year. P&S
the motor efficiency and the cost per kW of power. It calculates
Joe Evans is responsible for customer and employee educa-
the total BHP and cost per hour of operation for each control
tion at PumpTech, Inc., a pumps and packaged systems
scheme. As shown, synchronous operation requires an addi-
manufacturer and distributor with branches throughout the
tional 2.9 BHP, and the cost per hour is increased by 24 cents.
Pacific Northwest. He can be reached via his website, www.
When the efficiencies of the two control techniques at 400
pumped101.com. If there are topics that you would like to see
gpm are compared, individual control trumps synchronous
discussed in future columns, drop him an email.
control by about six percentage points, and at 500 gpm, it will

Pumping Prescriptions
Dr. Lev Nelik, P.E., APICS, President, Pumping Machinery, LLC
Eben Walker, Graphalloy Company
Specialty Materials Help Improve

Pump Reliability and Save Energy
E
fficiency degradation in
pumps can be related to
three areas. Worn clear-
ances between the wear rings
of the impeller and the casing
can increase leakage and drop
the volumetric efficiency of the
pump. Rough, rusty and dam-
aged internals increase friction,
reducing hydraulic efficiency.
Finally, rubs, galling, friction in
the mechanical seals and bear-
ings, can result in the reduction
of mechanical efficiency.
Together, these three
pumping problems reduce the
Figure 1. Product flow through the pump
available flow, lower pressure
and/or require more power con-
with their clearance separating internal regions of pressure
sumption. hese three issues also make a pump less reliable.
from each others.
Pump efficiency and reliability are often intertwined.
Four main types of clearances are:
• hroat bushing, which separates the suction (inlet) pres-
Centrifugal Pump Reliability Problems sure (50 psig) from the mechanical seal cavity (to the
Consider, for example, a case of reliability problems in a right of the illustration, not shown in Figure 1). Since the
multistage, horizontally-split centrifugal pump in service at seal area is immediately adjacent to the suction area, it is
a pipeline booster station. his pump had been de-staged under the same pressure as suction.
from the original, four-stage opposite impeller design, to a • Center bushing, which separates the intermediate-pressure
three-stage modification. Originally, the pump service was from the high-pressure zones. his pressure differential
for lower flow and pressure. To match a new set of operat- has increased due to the de-staging, making this a more
ing conditions (3,100 barrels of gasoline per hour, at 690-psi important leakage path.
pump developed pressure) the first stage of this pump was • hrottle bushing, which separates the intermediate pres-
replaced with a blank pass-through spool. sure from the suction pressure (the area to the left of the
In the case described above, the pump rotor seized, on illustration, past the throttle bushing, is connected to the
average, nearly once per year, resulting in poor reliability, suction area via a balance line).
increased repair costs and lost production. Upon inspection, • Impeller-to-case wear rings. Typically, there is one stage
a low suction pressure zone was found, which resulted in pressure across these rings.
periodic flashing of the product, causing cavitation, which • Hub wear rings. Typically a minimum flow area with
affected the side of the bushing adjacent to this low pressure little differential pressure. his pump has only one such
zone, as evidenced by the pitting that was found on the rotor clearance between stages 3 and 4.
and bushing area. Flashing of product in that area resulted
in a loss of the needed lubricating film of liquid within the In trying to solve the reliability problem, the designer
clearance of the bushing. his lack of lubrication liquid also or engineer needs to balance the conflicting requirements
contributed to the rotor seizure at the bushing area. of efficiency and reliability. With a power level nearly 2,000
Figure 1 illustrates the flow of product through the hp, each percentage point of efficiency savings translates to
pump, indicating pressure increase from one stage to another, approximately $13,000 per year, assuming non-stop opera-
as well as showing the orientation of the internal bushings tion, at 10 cents energy cost of each kilowatt-hour. Efficiency

is a key criteria for these large high energy pumps. Dr. Nelik (aka “Dr. Pump”) is president of Pumping
We try to solve the reliability while keeping the clearances Machinery, LLC, an Atlanta-based firm specializing in
as close as possible to reduce leakage (effect on volumetric effi- pump consulting, training, equipment troubleshooting and
ciency), but not so tight that contact occurs the the high speed pump repairs. Dr. Nelik has 30 years of experience in pumps
(3,600 rpm): rotating parts would gall and seize to the station- and pumping equipment. He can be contacted at www.
ary parts (the casing and impeller wear rings). PumpingMachinery.com.
The Solution
he answer to the problem was apply-
ing a graphite/metal alloy, to allow the
reduction of clearances (this material is
non-galling). As a non-galling material
clearances can be cut to half the normal
API clearances for metal fitted pumps.
his change improved reliability as well
as saving energy. Initially, only the throt-
tle bushing, the most critical part, was
made from Graphalloy to replace the
originally supplied metal part. he clear-
ance was reduced from 0.014 inches to
0.008 inches, which resulted in effi-
ciency improvements of approximately
2.2 percent. his improvement resulted
in nearly $30,000 in yearly energy sav-
ings. At the same time—due to the non-
galling qualities of the new material, an
occasional rotor contact was not a prob-
lem, and rotor seizures were eliminated,
making this pump much more reliable,
and production uptime was improved2.
P&S
References and Bibliography
1. Nelik, L., “How Much Energy is Wasted
When Wear Rings Are Worn to Double heir
Initial Value?,” Pumps & Systems, March 2007,
page 18.
2. Knoch, H., Kracker, J., and Long., W.,
“Sintered Alpha Silicon Carbide Pump
Bearings – Tribological Materials Optimization
to Improve Reliability,” Texas A&M Pump
Symposium, October 1993, Houston, Texas.
3. Komin, Robert P., “Improving Pump
Reliability in light Hydrocarbon and
Condensate Service With Graphite/Metal
Alloy Wear Parts” Texas A&M Pump
Symposium, 1990, Houston, Texas.
4. Walker, Eben T., “Bearings Take the Heat,”
Machine Design, May 2004.
5. Komin, Robert P., “Improving Boiler
Feedwater Pump Reliability With Graphite/
Metal Alloy Wear Parts,” Pump Engineer, May
2004.
6. “GRAPHALLOY Pump Application Guide,”
Graphite Metallizing Corp., USA copyright
2008.

Cover Series: Smart Pumps
Cover Series
Photo courtesy of Alejandro

Oscar de la Fuente, Schneider
Electric, oil and gas solutions
business manager.

Optimization Solutions
Jack Creamer, Dan McGinn and Jim Morgan, Schneider Electric
Improvements in performance and energy reduction can be achieved.
I
ntelligent pumping is simply defined by ARC Advisory Group
as the combination of a pump and a VFD with digital control
capability. While this defined the beginnings of the intelligent
pump trends, we now see numerous specific drivers around topics
such as energy management, application specific algorithms and
pump OEM-specific application programs.
he term intelligent pumps is broadening to include the sen-
sors that collect data and transmit pumping system performance.
Some key attributes involved with intelligent pump systems include
variable speed and multiple pump control.
Intelligent Pumps and Energy Savings

While the building automation industry has embraced the intel- Table 1. Intelligent pump capabilities
ligent pumps trend strongly, accounting for almost 50 percent of all
intelligent pumping revenues, many other industries are leading the
way—such as water/wastewater, mining and minerals, pulp and paper
and oil and gas.
Figure 1 shows the areas in which industries can take action to
reduce energy consumption. While many companies focus on areas
such as HVAC systems and motor retrofits, it is clear that pump system
upgrades provide the largest energy savings potential. Figure 2 provides
insight into the key industry segments that have the most to gain from
energy-savings initiatives. he potential in energy savings with intel-
ligent pumping can add as much as 20 percent to the bottom line,
according to the U.S. Department of Energy.
In addition to energy, other key drivers include OEM initiatives, Figure 1. Areas with potential for energy savings
such as OEM personalization. OEMs can customize software to either
match pumping systems to application needs and/or pre-load pump
data to greatly simplify start up and commissioning requirements.
Intelligent Pumps in the Oil & Gas Industry

here is excitement about intelligent pumping solutions in the oil and
gas industry, specifically in the opportunities to improve the output of
mature oil fields.
Most mature, onshore oil wells are not big producers, with many
producing less than 10 barrels of oil per day. Pumpjack systems, pro-
gressive cavity pumps (PCP) and electrical submersible pumps (ESP)
work hard to bring oil to the surface, and more operators are deploying
carbon dioxide injection and other enhanced recovery techniques to
boost production rates and extend field life.
Many operators deploy conventional time-on/time-off pump con-
trols to prevent a pumped off condition from occurring. hese con-
trollers stop the pump jack for a predetermined period to ensure fluid Figure 2. Industry segments that can most benefit from
is available before restarting the lift. Although simple to operate and energy-saving initiatives

adjust, they do not ensure maximum production recovery is improved by using information about the condition of the well
achieved and only work as a safety mechanism to prevent dam- to optimize the pump speed. he ultimate, intelligent pump-
ages caused by pumping a dry well. ing solution is one that takes advantage of this information in
Process efficiency is most improved with an intelligent real-time and constantly optimizes the pump speed. In some
pumping solution that employs a variable frequency drive to more shallow wells, this can be done by using the motor load
provide pump off control by varying the speed of the well and information in the drive as the primary data point. Deeper
maintaining an effective fill level. Efficiency can be further wells should take advantage of load profile information directly
from the rod and, ideally, the calculated
or “down-hole” load profile information.
A typical productivity improvement for
fully-optimized systems might be 5 per-
cent. he results vary substantially up or
slightly down based on the natural per-
formance of the well in its previous, un-
Never ask for less – optimized state.
Pumpjack optimization can include
® scalable options for an operator:
New LEWA • Torque only. his solution uses
pump motor load information to
Protect your process understand well conditions and
determine optimum speed. It is the
with LEWA’s Double- least costly solution for wells with
Diaphragm design depths of up to 500 meters.
• Surface card. his solution uses feed-
back from a rod-mounted load cell
(dynamometer card) to analyze well
conditions. It can optimize speed
and fill rate for deeper wells.
Extreme
• Down-hole card. his solution uses
operational safety
an advanced algorithm to compute
the rod load at the bottom of the
well. his represents the ultimate
API 675 Compliance solution with the greatest optimiza-
tion and return on investment.
Simple installation
Highest he elements of such a system
and start-up
metering precision include a variable frequency drive to
control the pump motor speed, instru-
mentation to detect well conditions and
an embedded controller to operate the
well, read the instrumentation, calculate
an optimized speed command for the
drive and provide host communication.
A fully optimized pumpjack is not
Compact design Double Diaphragm with
monitoring system
only more productive but also has a
higher availability and longer equipment
life. Most of the wear and maintenance
issues associated with pumpjack opera-
Suction pressure
down to 1 psi a tion are reduced as the optimized system
automatically reduces operating condi-
tions that cause undo wear (i.e., fluid
LEWA, Inc. · 132 Hopping Brook Road
Holliston, MA 01746 · Phone +1 508 429-7403 www.lewa-inc.com pound, gas compression). Optimized
wells also require much less human inter-
vention because the optimization adapts
to changing conditions in the well automatically. Maintenance- It is important to keep wells consistently pumping at an
related downtime for a pumpjack system can be reduced by as optimum level rather than just creating new wells. In addition
much as 80 percent. to injection methods, intelligent pumping solutions can repre-
Beyond individual pumpjack systems, the oil field as a sent a more scalable investment to maintain and improve oil
whole can be further optimized by making an enterprise of the field production.
entire field. A “digital oil field” is based on a suite of interac- P&S
tive and complementary technologies that allow operators to
gather and analyze information from
wells to more strategically manage a
lease. It employs a scalable, modular and
collaborative architecture that leverages
intelligent pumping solutions and the
capabilities of modern information tech-
nology to deliver actionable information
directly from a well to the field’s central
control station.
Implementing the digital oil field
starts with extending remote com-
munication to the oil field assets. his
includes the pumpjack systems as well
as other pump system types (PCP, ESP,
Injection, etc.) and ancillary equipment
It’s not just an ECO-TRIP. . .
such as tank level and flow monitor-
ing applications. Radio and cellular
telemetry options are a must for intel-
ligent pumping applications in oil fields. IIt’t’s the
the wworld’
orld’s
Telemetry can provide remote monitor-
ing and secure control of oil field assets. first eenergy
first nergy
In the form of remote individual opera-
tors or more sophisticated central, con- conscious
conscious
trol station operating rooms connected
to intelligent pumping systems. air-operated
air-operated
Jack Creamer is the market segment double-diaphragm
double-diaphragm
manager for pumping equipment
at Schneider Electric, Square D, pump ((AODDP)
pump AODDP)
8001 Knightdale Blvd., Knightdale,
NC 7545. He can be reached at
1-919-217-6464,
jack.creamer@us.schneider-electric.
com, www.schneider-electric.us.
Dan McGinn is the director of engi-
neering and projects for Schneider
Electric’s Industrial Solutions Center.
He has over twenty years experience
in industrial control systems.
Jim Morgan is the business develop-
ment manager, oil and gas sector, for
Schneider Electric’s North American
Operating Division. Based in New ฀ ฀ ฀ ฀฀ TERRACE, CA 92313-5607
Orleans, Jim has more than 20 ฀ ฀฀ ฀ ฀
years of experience in the oil and gas w i l d e n p u m p . c o m
industry. www.pumpsg.com

Intelligent Pumping
Market
Ram Ravi and Douglas Weltman, Frost & Sullivan
Current analysis and future outlook
T
he advantages of adopting intelligent pumping
systems has been well-documented, including the
adaptability to process conditions, lower operating
costs and contribution to decreased plant downtime. hese
advantages resonate in mature markets in which reduced
maintenance staffs drive companies to improve process
efficiency to maintain cost-competitiveness. Although
demand is increasing, intelligent pumps have not yet
enjoyed the wider adoption that their operational benefits
would imply due to several restraining factors.
Market Overview
As a result of environmental regulations and incentives
in North America and Europe, end users are searching
for alternative ways to save energy. Intelligent pumping
systems can facilitate energy efficient processes. Another
driver is the cost of unplanned plant downtime, primarily
due to rotating equipment failure. hese expenditures can
have a significant impact on a company’s profit margin.
he possibility of equipment failure also requires
companies to retain a large in-house maintenance staff
to monitor and make repairs in an efficient manner. costs versus standard pumping equipment, which challenges
Intelligent pumping solutions can help mitigate maintenance solution providers to prove the cost-value ratio of their prod-
labor challenges through facilitating equipment monitoring ucts to end users.
and reducing equipment wear.
Sales of intelligent pumping systems are affected by the
excess production capacity that currently exists in key end- Value Chain—Challenges and Solutions
user verticals. Without higher levels of industrial capacity use, Original equipment manufacturers (OEMs) of pumps can offer
expenditures on capital equipment are limited. his might only the broadest array of intelligent pumping solutions. Many have
be a minor issue for the solution providers of intelligent pump- made strategic investments in adjacent technologies that can
ing modules that are designed to control installed equipment. accommodate the necessary instrumentation. his has allowed
However, it can be a daunting challenge for solution providers them to bundle various products to provide turnkey solutions
of the more expensive, bundled intelligent pumping solutions. to end users. In addition to new systems, OEMs have also
Another important limiting factor in the market is the begun offering intelligent pumping modules that can be used
shifting of industrial production toward countries with a low- to control existing pumps. Most of these modules are compat-
cost labor force. he move toward overseas production reduces ible only with the OEM’s installed base of equipment, limiting
the demand for new pumping equipment in mature economies their use. However, some firms have introduced vendor-agnos-
that benefit most from intelligent pumping solutions. In addi- tic modules that can control different OEMs’ equipment. As
tion, intelligent pumping solutions have higher acquisition manufacturers penetrate their captive equipment markets, the

Focus on what you
can control. Everything.
Think about ITT.
Introducing the Flygt Station Control Panel.

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The new Flygt Station Control Panel System delivers:

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t$PNQBUJCJMJUZXJUI'MZHUT"RVB7JFX4$"%"4ZTUFN 8&#BDDFTTPSFYJTUJOHDFOUSBMJ[FETZTUFNT
To find your local Flygt distributer, visit www.flygtus.com
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trend toward vendor-agnostic intelligent pumping modules is asset management business with their end users while more
expected to strengthen, altering the competitive dynamics in tightly integrating their customers’ businesses with their own.
this market. Intelligent pumping aftermarket services allow distributors to
One of the most significant growth challenges for the expand their menu of pre-market services and product value
intelligent pump market for distributors is the need to develop enhancements.
the necessary instrumentation and electronics background to here are several challenges impeding the widespread
sell and support intelligent pumping systems. Although most adoption of intelligent pumping systems in today’s mature
large distributors can develop adequate expertise in-house, these markets. To overcome them and increase market penetration,
investments in human capital can be prohibitively expensive for solution providers must understand the needs of their custom-
products that still need to demonstrate commercial potential. ers and prove the product’s value. Intelligent pumping solu-
Another significant constraint includes the need for a tions must be able to seamlessly integrate into a plant’s existing
strong local presence and the ability to configure new intelli- infrastructure, reduce unplanned plant downtime and lower
gent pumping systems. hese factors are critical to distributors operating costs.
who want to facilitate a broader adoption of this technology. P&S
Ram Ravi, an industry analyst with Frost & Sullivan, has

Aftermarket Benefits
expertise in growth consulting and research projects within
Major OEMs can use intelligent pumping solutions to win
the industrial process control and automation practice. He
asset management agreements. Intelligent pumping systems
analyzes emerging trends, technologies and market dynam-
allow end users to address shrinking headcounts. One attractive
ics for pumps, valves and compressor. Douglas Weltman, a
feature of asset management agreements is that they enable an
research analyst with Frost & Sullivan, works on research
ongoing engagement with the end users. Intelligent pumps sys-
and consulting projects in process control equipment, after-
tems’ reliance on instrumentation and data analysis tools offer
market services and welding technology. He examines end-
improved outsourced service opportunities for OEMs.
user behaviors, disruptive technologies and industry best
Distributors benefit in a similar way to OEMs. Intelligent
practices. For further information, visit www.frost.com.
pumping solutions give them a natural way to enter the
• Membranes
• Desalinization
• Water Treatment
• Water Purification
Self-Cleaning Filtration
• No Electric Motors, No Pistons
• 10 to 1500 Micron Filtration
• 316L Stainless Standard
• High Pressure Ratings Optional
• ASME “U” Stamp Available
• Seawater Compatible Using
Duplex Stainless ...Wherever Water Flows.
www.ValveAndFilter.com
303-425-4242
Filtration Systems TM 5270 Marshall Street • Arvada, CO 80002 • USA

Safer and Smarter
Single Phase Pumps
Aaron Wolfe, P.E., & Bill Chandler, Jr., CSI Controls
New motor starting controller provides one solution.
P
ump systems come in all sizes, from
large municipal plants to small resi-
dential systems using single phase
pumps that are 3 horsepower or smaller. All
systems require reliability, but because of the
large volume of smaller systems, the consis-
tent dependability of these stations is impor-
tant. One of the largest problems facing
service personnel in servicing these pumps
and controls is the traditional start circuit.
Without any real protection on the start
winding and start circuit, the start capacitor
commonly fails. his often means the capac-
itor explodes, sending hot oil and capacitor
debris into a control panel—or worse and
more dangerous, onto a service technician. Failed start capacitor
most instances, this is because the capacitor is expected to be

The External Start Process in the circuit for a short period of time, and a capacitor that is
All single phase pumps with external start components use a
rated for the full voltage would cost more money and require
start relay along with a start capacitor and a run capacitor to
more space. If the start capacitor does not get removed from
start and run the pump. A run capacitor stays in the motor
the circuit, the capacitor will fail because of the lower voltage
circuit continually, while the start capacitor is designed to
rating. Often, this results in the top exploding off the capacitor
be removed from the circuit once the pump motor is up to
spraying hot oil (300 degrees F and hotter) and projectiles and
speed. he purpose of the start capacitor is to cause the voltage
exposing dangerous electrical voltages. Several situations may
applied to the start winding to be out of phase with the voltage
cause the start circuit not to open. One of the most common is
coming from the power source. his phase change gives the
a locked rotor on the pump. In this case, the pump is plugged
motor increased torque when starting. he start relay’s job is
or jammed from debris, and the motor cannot rotate. If the
to remove the start capacitor from the circuit when the motor
pump cannot rotate, it will not build up the voltage on the
gets up to speed. Traditionally, this is accomplished by using
start winding needed to drop out the start capacitor, which
a potential relay as the start relay. As the motor increases in
will create the conditions that allow the capacitor to fail.
speed, the voltage potential across the start winding increases.
Once the voltage potential reaches a predetermined value,
the start relay will energize, opening the circuit to the start Motor Module Replaces Starter,
capacitor. Under normal operation, the start capacitor will be Start Relay
removed from the circuit less than a second after power has A motor power module (MPM) will soon be available to
been applied to the motor. replace the motor starter (contactor and overload) and the
he start capacitor has a lower voltage rating than the start relay, all in one compact unit. One of the most significant
voltage that will be applied to it from the start winding. In features of the MPM is that it protects the start capacitor by

monitoring its usage. If its usage is excessive, the MPM will disable the capacitor for a
period of time, allowing for cool-down time, typically a few minutes.
In applications using single phase grinder pumps, the MPM improves the pump
performance in another way. During normal operation, the pump often sucks debris
through the cutters of the pump, introducing an added load to the pump motor.
Depending on the type of debris and the condition of the cutters on the pump, this load
can be significant and slow the pump. A traditional start circuit with a potential relay
Motor power module
1967 Nova Pro Street allows the pump speed and flow to drop
below 40 percent of its normal operat-
ing speed/flow before pulling in the
start circuit to provide the added torque
needed to prevent the pump from stall-
Process Maxum
ing during the grind. his reduction
Do you have flows up in speed compounds the problem of
to 9,900 GPM (2,000 grinding and expelling the debris as the
m3/hr), heads up to 720 Ft water flow through the pump is greatly
(220 M), speeds up to 3,500 RPM, and
reduced. he MPM begins “boosting”
temperatures up to 500°F (260°C)? Then you
the pump by pulling in the start circuit
need Carver Pump Process Maxum Series muscle!
when the pump speed and flow reach 85
With an extended range of hydraulic coverage and
percent of normal. he MPM controls
rugged construction, the Process Maxum Series is ideal
for Industrial Process applications. Manufactured in just how much boost is given to the start
35 sizes, standard materials include WCB, WCB/316SS, circuit, providing only the amount of
316SS and CD4MCu, with others available upon request. boost needed to maintain speed, maxi-
A variety of options include various types of mechanical mizing the amount of usage available for
seals and bearing lubrication/cooling arrangements, the start capacitor.
auxiliary protection devices and certified performance
Another advantage of using the
testing. Whatever your requirements, let us
build the muscle you need!
MPM is that it reduces the complexity
of matching proper start components
with motors. With traditional systems,
every pump motor on the market has
its own combination of start relay, start
Creating Value. capacitor and run capacitor. Applying
Carver Pump Company the wrong component combination
2415 Park Avenue can cause start capacitor failure. he
Muscatine, IA 52761 MPM monitors the characteristics of
563.263.3410
Fax: 563.262.0510 the motor as it starts and removes the
www.carverpump.com start capacitor at the proper time based
on those characteristics. One MPM
can be used for any pump within the
MPM’s rated current range. Even if Aaron Wolfe is the R&D electronic lead engineer for CSI Controls. Aaron has over
the wrong start capacitor is chosen, the ten years of experience with controls in the waste water industry. He can be reached at
MPM is designed to protect against fail- aaron.wolfe@csicontrols.com.
ure. he motor torque will be affected
by the wrong capacitance, but relatively Bill Chandler, Jr., founded CSI Controls in 1993 and is currently the director of prod-
normal pump operation may still be uct development for CSI Controls. Bill holds several patents for water treatment and
possible depending on the pump motor pump controls. He can be reached at bill.chandler@csicontrols.com.
and the value of the capacitance.
All in One
he MPM combines the functions of
the motor contactor, overload relay and
start relay in one compact unit, which is
approximately the size of a comparable
standard motor contactor. his com-
bined unit saves at least 60 percent of
the panel space taken up by a traditional
start circuit.
NEW!
One of the ways the MPM is able
to provide this kind of space reduction
is by using patented zero-cross technol-
ogy, which controls the exact timing of non-clogs that don’t clog
the opening and closing of the contacts
that supply the power to the motor.
Without zero-cross technology, the con-
tacts would open randomly compared to
the AC voltage waveform, often causing
arcing across the contacts. his normally
requires larger contacts, and a larger
contactor to handle the motor power.
With zero-cross technology, the arcing
is almost eliminated, which increases
the life and reliability of the relay, while ‹ New 4SH series with three different styles
allowing the use of a smaller contactor to of impellers offers superior clog resistance
control the pump. and efficiency.
In addition to zero-cross technol-
ogy, the MPM includes advanced motor › Plug-and-play cable system for the Frame 21
protection and monitoring, and imple- sizes will result in significant reduction in
ments a Class 10 electronic overload maintenance costs and inventory.
while monitoring for under-current to
protect the pump from a “run dry” situ- fi X-Pruf® ratings with FM and CSA certifications
ation. he MPM monitors incoming design with industry-leading lead time.
voltage and can be set to protect against
a low-voltage situation either from the
power line, or because too small a wire
gauge was used to supply the power to www.cranepumps.com
the pump (causing too much voltage
drop in the source feed wires).
his approach, using new tech-
nology in pump controls, will con-
tinue to enhance safety, reliability and
serviceability.
P&S
Special Section: Instrumentation, Controls & Monitoring
A Special Section of
October 2010
Operator diagnoses
station fault remotely
and takes a pump off line.
Photo credit: ITT Water &
28 OCTOBER 2010 Wastewater USA Inc.
www.pump-zone.com PUMPS & SYSTEMS
Reliable and Efficient
Remote Lift Stations
Paul S. Twaddell, Eaton Corporation
Control panel products enhance smooth operations.
O
perating reliable, efficient lift stations can be chal-
lenging. Increasingly lean staffs maintain hundreds
of remote stations in a wastewater system, which are
often located in difficult-to-access or hazardous areas making
maintenance and troubleshooting time intensive.
Maintenance is critical when control panels and compo-
nents are subjected to extreme weather conditions and caustic
liquids and gases. Downtime can be caused by many issues:
pump ragging and overheating, broken impellers and malfunc-
tioning level sensors. Environmental hazards and hefty fines
can result.
Advanced Overload Relays

By monitoring energy and power factor, facilities can avoid
peak demand charges, shed non-vital loads, identify and correct Facilities can monitor volts, amps, thermal capacity, frequency,
power, power factor and easily translate this data to motor or
increased consumption, spot the discrepancies between equal
pump conditions.
loads and see power factor line items.
Advanced overload relays can monitor current and voltage and failing the pump.
in each phase and identify conditions that can lead to motor Without an overload relay that detects low power, the
or pump failure with greater speed, reliability and repeatabil- pump would continue to run. he water level would not
ity than traditional failure detection devices. With remote, increase and the float switch would not drop. A second pump
real-time data monitoring, facilities are able to protect assets, may be turned on to compensate, and two pumps would be
prevent energy waste and manage costs—all while maintaining running and doing the work of a single pump. he protective-
system integrity and uptime. fault, low-power feature of today’s overload relays can help
Overload relays identify unusual and inefficient operations avoid needless run-time hours and component wear would be
in real time. hey can monitor energy use to avoid peak demand reduced.
charges, shed non-vital loads and detect increased energy con-
sumption, discrepancies between equal loads and power factor
VFDs and Soft Starters
line items. With industry standard communication protocols
Today’s sophisticated variable frequency drives (VFDs) are
and central supervisory control and data acquisition (SCADA)
better able to fine-tune motor speed to regulate and control
systems, customers can identify and correct situations to pre-
flow, resulting in energy savings from 10 to 50 percent. Soft
vent downtime before incurring energy costs. hrough fieldbus
start controllers reduce motor demands during startup, result-
commands and online via the operator interface (OI), custom-
ing in reduced energy and increased mechanical system life.
ers can remotely monitor and control their systems and shut-
he latest VFDs are more accurate and energy efficient.
down nonessential assets. Energy use between similarly-sized
Enhancements in capacitors, direct current (DC) link reac-
pumps can be compared and spot checks can be eliminated.
tors, insulated gate bipolar transistors (IGBTs), heat manage-
When maintenance is necessary, remote lift station operators
ment, processing power and measuring technology, and new
can dispatch personnel. Neglected conditions can be remedied
algorithms that improve drives’ efficiency to greater than 97
as they occur. Without the ability to detect and fault when low-
percent.
power conditions occur, pumps can heat up, damaging the seal,
Shaft
Alignment Soft start controllers provide smooth acceleration and deceleration of the load,
minimizing shock to mechanical components, extending the life of the system,
& Geometric increasing reliability, reducing downtime and lowering costs. Soft starters reduce slip-
Measurement page, squealing and the stretching of belts. With special pump control algorithms,
the soft starter can control motor deceleration, reducing the water hammer effect. A
compact soft starter provides the same benefits of soft starting without the need for
a change in enclosure sizes or additional assemblies. High performance soft starters
have extensive monitoring and protection functionality, improving troubleshooting.
Using a drive with a bypass-built-in soft starter provides enhanced control, flex-
ibility and protection. Adding a soft starter allows the motor to be ramped up to full
speed when in the bypass, reducing mechanical and electrical stress.
Sophisticated Controls, Interfaces and Pushbuttons

Today’s innovative and small programmable logical controllers (PLCs) moni-
tor diverse parameters in remote lift stations to reduce maintenance and improve
efficiency. OIs help operators visualize equipment activities, monitor and control
equipment, provide real-time and historical trending, alarms, database interface and
the ability to run soft logic and make decisions. PLCs monitor the moisture level
and temperature and the operation of the pump helping optimize maintenance and
Rotalign® ULTRA prevent downtime. Rugged OIs and human machine interfaces (HMIs) help moni-
tor processes and keep them running.
Vibration PLCs are also able to share remote information with operators of an unexpected
event. In larger systems, they can help facilitate load sharing so that the operational
hours can be balanced between pumps to extend equipment life. Sophisticated OIs
Analysis offer lift station operators connectivity with ruggedized electronics for increased
reliability in harsh environments. High performance interfaces feature increased
& Balancing memory to run larger applications, store event histories and record operational
trends. hey also have enhanced display brightness and resolution and faster appli-
cation performance and allow operators to move easily among machines and pro-
vide time-saving access to PLCs and other devices. Some interfaces can combine the
functionality and flexibility of Microsoft® products with the reliability of solid-state
hardware design.
Global suppliers provide customers with comprehensive 22.5 millimeter and
30.5 millimeter pushbuttons to meet diverse needs. Remote lift station controls
include flush and extended pushbuttons, along with selector switches, pilot lights
and emergency stops (E-stops).
E-stops are red operator buttons used in the case of emergency to protect per-
sonnel and equipment. hese need to meet EN 418 IEC 609475-5, which does not
allow for “teasing” the contact block but requires trigger action.
h VIBXPERT® II
WatcOS Molded Case Circuit Breakers
IDE
V ine Molded case circuit breakers (MCCB), sometimes up to 99.99 percent reliable, are
Onl
designed to provide circuit protection for low-voltage distribution systems and pro-
tection against overloads in conductors and short circuits in connected equipment.
Easy-to-use Panel boards use either fuses or breakers, which offer enhanced safety, improved
solutions for your reliability and energy savings. Compared to fuses, circuit breakers save energy with
maintenance needs! less watt loss for similar ratings. Circuit breakers can be remotely reset after tripping,
while fuses must be replaced.
Sales • Rentals • Services In a remote lift station, a walking beam solution can be useful. It prevents the
main and emergency from being “on” at the same time.
P&S
Paul Twaddell is the industry segment manager for pumps and compressors at
Eaton Corporation. He can be reached at paulstwaddell@eaton.com. For more
305-591-8935 • www.ludeca.com information, go to www.eaton.com.

Mass-Based Propane
Odorant Injection System
Wesley Sund, Brooks Instrument, LLC
Details of a mass-based chemical injection system
I
n 1937, a natural gas leak at a horizontal cylinders. he delivery
school in Texas killed 237 stu- window to withdraw from the pipe-
dents. he gas leak in the school line is fixed, and it is critical that all
was not detected even though it had delivery equipment be in good oper-
been leaking for a long time. To solve ating condition to take the delivery.
the problem of detecting odorless, Any equipment failure can interrupt
hydrocarbon, gaseous fuels, laws or stop delivery. Lost propane deliv-
were passed that required natural eries equal lost sales . . . resulting in
gas and propane to be odorized, so lost profits for the terminal operator.
they can be detected by the average Propane is odorized as the pro-
human nose at 1/5 the lower explo- pane is withdrawn from the pipe-
sive limit in air. Ethyl mercaptan must be added to propane to meet line. Odorant injection equipment
Propane is primarily sourced as a DOT requirements for safe transportation and usage. operating perfectly is critical to the
byproduct of the production of natu- terminal operation’s financial health.
ral gas. To maintain the heating value of natural gas within his is the primary reason why a propane terminal operator in
a narrow range, heavier components (natural gas liquids) are the upper Midwest invested in a more accurate, reliable and
removed from the natural gas near the production well. he consistent propane odorization system.
liquids are sent to an additional plant where these liquids are Positive displacement dosing pumps have been the tradi-
separated for higher value uses. Propane is sold as a fuel and tional method for metering odorant into propane. A flowmeter
is distributed throughout the country via pipeline or rail car. measures the propane delivered to the terminal, and a control
Mercaptans are sulfur-containing analogs of alcohols system commands the metering pump to periodically inject a
(oxygen replaced by sulfur), and the human nose is sensitive to known quantity of mercaptan in the propane at a frequency to
these chemicals. A skunk’s smell, for instance, is a mixture of meet the desired dosing rate. he stroke detector on the pump
methyl and butyl mercaptans. For propane, the most common sends a signal back to the control system as confirmation that
mercaptan used for odorization is ethyl mercaptan, which odorant is being injected.
matches the vapor pressure of propane but is also resistant to If after a number of commands to stroke the pump there
decomposition. Ethyl mercaptan must be added to propane is no signal indicating stroking, the terminal control system
to meet Department of Transportation (DOT) standards for will stop delivery of propane. Problems with the injection
over-the-road shipment at a minimum of 1 pound per 10,000 pump might put the delivery of propane in jeopardy.
gallons of propane. Metering pump system seals must be replaced on a peri-
odic basis. Pump-based systems are typically set to overdose to
Propane Odorization compensate for any inaccuracies, with the result being higher
To efficiently handle the distribution of propane from a single operating costs to purchase odorant.
pipeline across a wide geographical area, pipeline storage A better solution was sought that would provide the fol-
terminals are built along the pipeline. At periodic intervals, lowing benefits:
propane is withdrawn from the pipeline and stored in large • Higher accuracy to minimize odorant consumption

• No moving parts for reliable operation, minimal metering device to determine fluid mass flow rate. A vibrat-
maintenance ing tube acts as the sensor. he momentum of the fluid flow-
• Documentation of actual odorant dosing rates ing through the tube will change the shape of the tube as it
vibrates. Detectors are used to measure the change in shape
Mass-Based Odorant Injection and, when calibrated, a linear relationship exists between the
A liquid mass flow controller based on Coriolis technology degree of tube twist and the fluid’s mass flow rate.
was selected to provide these desired benefits. he operat- Coriolis devices accurately measure fluid mass flow
ing concept of a mass flow controller-
based odorization system is simple. he
odorant injection control system takes
a reading from the propane delivery
meter and calculates the flow set point
required to meet the odorant mass/
propane volume ratio specification. he
flow controller is sized to meet a wide
variation in propane delivery rates expe-
rienced from summer to winter.
he key technology in the liquid
mass flow controller is the Coriolis
sensor tube. Coriolis sensor technology
has been used in process flow metering
since the 1970s but only recently has
the technology been reduced in size to
meet the lower flow requirements for
injection of chemicals like odorants.
Coriolis mass flow measurement
technology is simply a momentum
See us
TurboM at
achin
Show, B ery
ooth
#930
Mass flow injector designed to be mounted

in a hazardous environment associated
with propane terminal operations.
Propane Odorant Injection Injection

Delivery Propane Flow
Control System Report Printer
Flow Ethyl
Meter Mercaptan
Injection Tank
Setpoint
Propane Delivery Line 90-160 psig
PID Control Loop
Tescom
Coriolis
Pressure Wanner
Control Mass Recirculation
Reducing 3 Stage
Valve Flow 568 liters/hr
Tracking Diaphragm
Sensor
Regulator Pump
Quantim Closed Loop
Flow Control
Propane Pressure 225 psig

Tescom
Backpressure
Regulator
Process schematic for an injection system illustrating the use of a mass flow controller with pump
pressurization system to inject odorant into propane in proportion to flow rate.
independent of fluid properties such as viscosity and density. measurement accuracy is better than 0.5 percent of rate, and
Water is used as the calibrating fluid at the factory, and there calibration can be NIST traceable. he controller system con-
is no change in accuracy when measuring mercaptans. he tains an integrated control valve, which is sized to control the
Don’t Forget
to Enter Your
Product
Submit your Product at

www.pump-zone.com
And look for the winners in

the December issue.
flow of odorant over the range of delivery rates from summer delivery. he new system with the flow sensor is capable of pro-
to winter, 0.25 to 25 pounds of odorant/hour. viding a printed report of actual odorant injection mass versus
To drive the fluid through the injector system, the mer- propane delivered volume. An integrated printer generates a
captan must be pressurized to at least 60 psig above line pres- report detailing the delivery specifics.
sure. Nitrogen gas pressurization is not acceptable due to the
volume of gas required and the difficulty of disposing the mer- Conclusion
captan saturated gas during odorant tank refilling. he business results for the new system are positive. here have
he solution design uses a positive displacement pump in been no propane delivery stoppages due to odorization equip-
a recirculation loop with a back pressure regulator as a source ment failures since installation. he injection rate of odorant
of pressurized liquid to drive the liquid through the control- has been reduced from 1.5 to 1.2 pounds per 10,000 gallons
ler and into the propane. A three stage diaphragm pump was due to the higher accuracy of the system. his has resulted in
selected for this application. Mercaptan is a non-lubricating chemical savings. he system provides a high level of docu-
fluid, and this particular pump design uses an elastomeric seal mentation that can be used to prove propane was odorized
to isolate the pumping pistons from the mercaptan. to meet DOT minimum standards. Finally, the pump pres-
A critical device that maintains a constant differential pressurization system has saved the purchase cost and handling of
sure across the flow controller from summer to winter opera- nitrogen cylinders.
tion is a dome-loaded differential pressure tracking regulator. he basic design of this mass-based chemical injection
he dome of a regulator is connected to the propane pressure, system could be applied to any application that requires criti-
and the regulator will maintain a constant downstream pres- cal dosing of a trace chemical into a continuous flowing fluid.
sure as the propane pressure varies with ambient temperature.
Documenting that the correct amount of mercaptan has P&S
been injected in the propane was an important consideration in
designing the new system. he previous injector-based system Wesley Sund is a marketing manager for Brooks Instrument,
could not provide a positive confirmation of actual odorant LLC. Contact him at wesley.sund@brooksinstrument.com.

Improving SCADA
Operations Using
Wireless Pumps
Hany Fouda, Control Microsystems
Many reasons for wireless conversion reluctance are resolved with new technology.
D
uring the last 10 years, dramatic change has occurred Reliability
in radio technology and, more important, in how In industrial applications, reliability is a major concern. Wireless
control engineers use it. Radio modules prices have pumps must be as reliable as conventional, wired units. Even
plummeted recently, and this has made integrating them into in simple applications, such as remote monitoring, users come
pumps for monitoring, diagnostics, data acquisition and even to expect a certain level of reliability and network availability.
control easier for industrial vendors. Radio signals are subject to reflection as a result of structure,
Pumps are an ideal device for wireless connections. hey trees, bodies of water and buildings. Other wireless interfer-
are often located in remote pumping stations or installed in ence adds more challenges. Radio frequency (RF) design is
areas of the plant that are difficult to access by maintenance becoming more effective in addressing many of these issues.
personnel. But many plants remain reluctant to install wireless By designing sensitive radio receivers and using transmit power
control because of perceived problems with reliability and con- efficiently and high gain antennas, engineers can establish reli-
nection to the SCADA system. Modern wireless devices solve able RF point-to-multipoint links.
these problems.
Adaptability
Why Wireless? Wireless instrumentation networks are required to adapt to
he business case behind deploying the existing environment. Finding
wireless pumps is a compelling one. a location for an access point or
By eliminating cabling and trench- base radio that provides reliable
ing, the cost of deployment can be communication with the wire-
dramatically reduced—sometimes less instruments can be difficult.
by as much as 70 percent. Since Relocating the access point or base
wireless instrumentation is battery radio to improve the RF link with
powered, it is much easier to deploy one sensor could result in degrad-
in the field relative to its conven- ing the links with other sensors in
tional counterparts. Wired systems the same network.
can take days or weeks to be prop-
erly installed. Wireless instruments Integration
require only the installation of the Managing and debugging dis-
sensor in the process, saving hours persed wireless networks presents
or days and valuable resources. a new level of complexity to field
If the business case is that operators that could deter them
strong and the return on invest- from adopting wireless instrumen-
ment is solid, why are some still tation, despite the exceptional sav-
reluctant to deploy wireless pumps Figure 1. Bridgeport, Calif., replaced phone lines with a ings. he wireless network integra-
in their facilities? 900 MHz wireless system. tion dilemma is more apparent in

SCADA systems. Since wireless instrumentation networks are wireless LAN (WLAN). he WLAN allows operators and staff
designed to tie into the same SCADA infrastructure available at to access any pump site over a wireless connection from por-
the site to relay valuable operating data to the SCADA host, the table laptops.
ability to manage the complete infrastructure as one network Older wireless installations can be updated easily. In 2000,
becomes essential. a GPRS cellular system was installed in Sofia, Bulgaria, to
Despite the abundance of tools that are available to cap- help control its water and wastewater system. Unfortunately,
ture, process and analyze data, ensuring data integration is still the unintelligent GPRS modems were difficult to use and
a major problem. Some SCADA systems
even have a separate historian module
that must be purchased as an add-on
to handle the data from wireless instru-
mentation networks.
Wireless Challenges
A new generation of base station radios
or gateways integrates both a wire-
less instrumentation base radio and a
long range industrial radio in the same
device.
Adaptability can be addressed by
using lower frequency bands, such as
the license-free 900 MHz, which tend
to provide better coverage, longer range
and better propagation characteris-
tics, allowing the signal to penetrate
obstacles.
he City of Bridgeport, Calif., was
using dedicated telephone lines to con-
nect its well pump stations to the cen-
tral control system, but the system was
unreliable. It failed periodically without SENTRY Pulsation Dampeners & Surge
warning, resulting in inconsistent pump
Suppressors remove hydraulic shock and
control. Other problems included inac-
curate tank-level readings and nonexis- vibration, enhancing all-around performance
tent system alarms, which required fre- and reliability of fluid flow applications.
quent operator visits.
Bridgeport installed 900 MHz SENTINEL Diaphragm Seals protect and
spread-spectrum radios (Figure 1) and isolate all forms of system instrumentation
SCADAPak controllers at each well and from hazardous and corrosive process fluids.
tank site. Pump control is now handled
at each site, and the SCADAPak con- More than just leak detection! The patented
trollers send level, flow and other data SPILLSTOP Leak Containment System
to the main control room via wireless. prevents costly and hazardous spills caused
A similar situation existed at a by pump diaphragm failure.
wastewater treatment plant in Ottawa,
Ontario, Canada. he City of Ottawa
serves a huge area of 2,758 km2, and
the pump sites communicated mostly
via dial-up phone lines. he system was
unreliable and expensive.
Ottawa installed 900MHz wireless Don’t Pump Without Us
modems at each pump station and local
SCADAPak controllers, which commu-
800.603.7867 ■ 951.342.3100 ■ www.BLACOH.com ■ Sales@Blacoh.com
nicate to the main control system via a
consumed high rates of electrical power at solar-powered Modern Solutions

remote pump locations. he solution was simple. Modern Other solutions to wireless problems include high-gain, external
SCADAPak controller installations at each site solved the com- antennas that can be mounted as high as possible on a structure.
munications problem. he SCADAPak manages the reporting Improved receive sensitivity of radio modules also plays a crucial
of events to the SCADA system, saving bandwidth and reduc- role in ensuring network adaptability in industrial environments.
ing network traffic. he SCADAPak saves power with its “sleep A modern, long-range remote radio is configured as a
mode” and reduced power mode capabilities. remote device for relaying information to a master radio at the
main SCADA center. he serial ports
on the radio are configured to tunnel
Modbus® polling and diagnostic data
VFD-Induced simultaneously to the wireless instru-
mentation base radio. his allows opera-
Bearing Currents tors to manage and diagnose the wireless
instrumentation network through the
Kill Motors! existing long-range SCADA infrastruc-

ture. Live data and status information
for all field units are displayed in a sepa-
rate view or integrated in the SCADA
host.
On the data integration front,
modern SCADA host software offers
a fully integrated environment that
includes an integrated and scalable his-
torian to handle additional data without
going through expensive and some-
times lengthy upgrades. Developing
the SCADA screens based on templates
allow engineers to add data points easily
and rapidly to their systems.
Save energy with a VFD, Save your motor with
Conclusion
As the adoption of wireless instrumen-
SGR tation networks increases, users will be
BEARING PROTECTION RING faced with a number of challenges to
ensure successful integration within their
Proven in hundreds of thousands of existing infrastructure. New RF and
installations, the AEGIS™ SGR protects antenna designs help address reliabil-
motor bearings from damaging VFD-
induced currents and extends motor life. ity and adaptability challenges. Hybrid
It also dramatically reduces downtime gateways, allow users to view, manage
and improves the reliability of motor- and diagnose their dispersed wireless
driven equipment and systems. systems from a single point. Similarly,
Conductive epoxy mounting
U Safely channels harmful currents away simplifies field installation
advanced SCADA host software, with
from bearings to ground an integrated historian and rapid devel-
U Patented time-tested design opment environment using templates,
®
can facilitate the integration of new data
U Maintenance-free, easy to install, lasts points generated by a growing network
for life of motor
of wireless sensors.
U Standard sizes for any motor P&S
To download a free technical paper on bearing

protection technologies, visit our website:
Hany Fouda is the VP of marketing
at Control Microsystems. He can be
1-866-738-1857 | sales @ est-aegis.com reached at
www.est-aegis.com/ps1 hfouda@controlmicrosystems.com.

Larox Flowsys has been providing
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www.larox.us circle 107 on card or go to psfreeinfo.com

Maintenance Minders
The Attraction of
Magnetic Bearings
Mark D. Hinckley, SKF USA Inc.
Minimal vibration, the elimination of lubrication and improved control

make magnetic bearings an appealing alternative.
M
agnetic bearing systems represent a dif-
ferent approach from rolling bearings to
support rotating machinery, and in recent
years, their benefits have attracted attention for more
applications.
As a non-contacting technology, magnetic bear-
ings will exhibit negligible friction loss and no wear.
hey can attain high speeds with undetectable vibra-
tion and are valued for their energy-efficient per-
formance and savings in applications ranging from
vacuum pumps to gas and air compressors.
For example, a 12,000 rpm, 12 MW centrifu-
gal compressor at a natural gas pipeline facility in
upstate New York was fitted with magnetic bearings
instead of traditional, hydrodynamic bearings. his
switch to a system that consumes a fraction of the
energy (because it rotates without contact) yielded
documented annual energy savings of 700,000
kWh and an overall 88 percent energy saving for
the compressor system (encompassing compressor Centrifugal compressor fitted with magnetic bearings
and motor). In addition, an auxiliary oil lubrication
become irrelevant.
system, cooling system, gearbox (variable, high-speed motor
• Programmable characteristics. Depending on the appli-
directly coupled to the compressor), and condition monitor-
cation or process variables, the physical response of the
ing equipment were eliminated, which reduced the footprint
bearing can be adjusted “on the fly.” In some cases, this
of the machinery and the number of potential failure points.
means that a shaft can safely pass through critical vibra-
While, depending on the application, the advantages
tion speeds and operate at speeds that were previously
of magnetic bearing technology compared with the oil film
unattainable.
technology it replaces will vary in importance, the following
features and benefits will often be cited:
For all the advantages, the technology is not without
• Reduced wear. In normal operation, the rotating por-
some limitations. Magnetic bearings tend to be physically
tion of the machinery is not in contact with any parts.
larger than similarly specified bearing systems. Also, by
Reduced wear decreases maintenance requirements and
necessity, magnetic bearings require electric power to drive
operating costs.
the control systems, sensors and electromagnets.
• Increased efficiency. Virtually no shaft energy is con-
sumed by bearing friction. More power goes directly into
the process and enhanced efficiency follows. Incorporating Distinct Technologies
• “Green” operation. Without lubrication oil, concerns An active magnetic bearing system consists of several dis-
about potential leakage, accidental loss and disposal tinct technologies: electromagnet bearing actuators, position
40 OCTOBET 2010 www.pump-zone.com PUMPS & SYSTEMS

sensors, control system
and power amplifiers.
he bearing actuators
and sensors will be
located in the machine,
and the control system
and amplifiers usu-
ally will be located
remotely.
Magnetic bearings
provide attractive elec-
ITT.
tromagnetic suspen-
sion between the rotor
for a total savings of 20 to 60 percent. For more information, call 1-800-734-7867, or visit ittpps.com. Think about
and stator by applying
electric current to fer- Radial Bearing
romagnetic materials
We’ll assess your system, perform upgrades, and cut your energy costs while improving reliability—
used in the stationary parts (the stator) of the magnetic bearing. his creates a flux
path through both components and levitates the rotor, creating the air gap separat-
ing them. (he air gap between the stator and the rotor will usually be 0.5 mm to 2
mm and makes the non-contact operation possible.)
To straighten out unnecessarily complex pump systems, call Energy Performance Services from ITT.
As the air gap between these two parts decreases, the attractive forces from the
magnets increase. Since electromagnets are, in this way, inherently unstable, a con-
trol system is necessary to constantly adjust the strength of the magnets by changing
the current and provide stability of the position of the rotor.
he control process begins by measuring the rotor position with a position sensor.
he signal from this device is received by the control electronics, which compares it
to the desired position established during machine start-up. Any difference between
these two signals results in a calculation of the force necessary to pull the rotor back
to the desired position. his is translated into a command to the power amplifier con-
nected to the magnetic bearing stator. he current is increased, causing an increase in
magnetic flux, an increase in the forces between the rotating and stationary compo-
Inefficient pump system?

nents, and movement of the rotor toward the stator along the axis of control.
he entire process is repeated thousands of times per second, enabling pre-
cise control of machinery rotating with peripheral speeds of up to 200 meters per
second. A closer look at each of the system components follows.
Radial and hrust Bearings

A typical system incorporates two radial bearings and a thrust (or axial) bearing.
Each radial bearing has a stator and sensor system mounted over a ferromagnetic
rotor installed on the shaft. he rotor consists of a stack of lamination rings mounted
on a sleeve that fits onto the shaft. (Laminations are designed to reduce eddy current circle 137 on card or go to psfreeinfo.com
losses and improve the response of the bearing.) he stator includes a stack of lami-
nation rings with poles on the internal diameter. Coils are wound around each pole
to divide the bearing into four quadrants. he coils in each quadrant are wound in
series to make each quadrant function as one electromagnet. Typically on horizontal
machines, the quadrants are aligned 45 degrees from vertical. Opposing quadrants
constitute an axis (each radial bearing, then, can be described by two axes). A set
of sensors to measure shaft position is mounted as close to the bearing as possible.
he thrust (or axial) bearing typically consists of two stators, one on either side
of a rotor disk as well as a position sensor to indicate the rotors axial position. he
stators are made either of solid steel or solid steel wedges with radial slots between
the wedges filled with laminations to improve the response of the bearing. he
thrust stators also have one or two circumferential slots machined into the face and
filled with coils. With a stator mounted on each side of the rotor, the thrust bearing
can counteract axial forces in both directions.

Maintenance Minders
Control System he controller receives the voltage signal from the position
he control system utilizes the signals from the position sensor sensors, processes the information and sends current requests
to determine the position of the shaft. his signal is compared to the amplifiers. he controller consists of anti-aliasing filters,
to a reference to determine the error in the position. After analog-to-digital (A/D) converters, a digital signal processor
appropriate conditioning, this signal is sent to power amplifiers (DSP) and pulse-width modulation (PWM) generators.
that control the current sent to the bearings. he voltage from the position sensors is passed through the
In simple terms, the control system reduces the upper anti-aliasing filters to eliminate high-frequency noise from the
bearing current when the shaft is above the center position signal. (his noise can cause the signal to inaccurately represent
and increases the current when the shaft is below the center the position of the shaft.) After the high-frequency content is
position. removed, the position signal is sampled by the A/D converter.
Magnetic bearing control normally will be performed in a his converts the voltage signal to a form that can be processed
single input/single output (SISO) manner. his means that the by the DSP and the digital information is passed through a
position information from one sensor causes only the control digital filter by the DSP. his produces an output proportional
current in the corresponding axis to be varied. (Control systems to the amount of current required to correct the position error
can also be multi-input and multi-output, or MIMO. MIMO in the shaft.
is used when higher levels of control are required or when sig- he requested current is compared to the actual current in
nificant cross-coupling between axes is expected.) the bearing, which is also sensed, filtered and sampled with an
he components of the control system include position A/D converter. he error between the actual and requested cur-
sensors and electronics, controller, and amplifiers. Sensors relay rent is used to characterize the PWM signal that is sent to the
information about the position of the shaft to the controller amplifiers. his information is forwarded to the PWM genera-
in the form of an electrical voltage. Normally, the sensors are tors, which create the PWM wave form sent to the amplifiers.
calibrated so that when the shaft is in the desired position, the Each bearing axis has a pair of amplifiers to provide cur-
sensor produces a null voltage. When the shaft is moved above rent to the bearing coils and provide an attractive force to cor-
this desired position, a positive voltage is produced, and when rect the position of the rotor along that specific axis. he ampli-
it is moved below, a negative voltage results. fiers are high-voltage switches that are turned on and off at a

Clean Environments
A magnetic bearing system will not contaminate a clean process
with oil, grease or solid particles.
High-Speed Applications
Because a rotor in a magnetic bearing system spins in space
without making contact with the stator, drag on the rotor is
minimal. his allows the bearing to run at exceptionally high
speeds. he only limitation to speed will be the yield strength
of the rotor material. he positive outcome is that no other
type of bearing can match magnetic bearings for sheer speed.
Magnetic bearings have been designed with surface speeds up
to 250 m/s. To achieve a fraction of this speed, conventional
bearings would require a complex lubrication system.
Centrifugal compressor fitted with magnetic bearings Position and Vibration Control
Since magnetic bearings use advanced control algorithms
high frequency, as commanded by the PWM signal from the to influence the motion of the shaft, they precisely control
controller. the position of the shaft within microns and eliminate most
vibration.
When to Consider the Technology
Magnetic bearings can both complement and contribute to Extreme Conditions
applications in which particular conditions will be experienced A magnetic bearing system can operate over a wide tempera-
or where specific performance requirements must be met. Some ture range—as low as -256 degrees C and as high as 220
appropriate applications follow. degrees C—temperatures at which traditional bearings cannot
PROTECT PUMPS
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Maintenance Minders
function. Systems can additionally operate in corrosive envi- stimulus/response diagnostics and static clearance checking.
ronments, are not sensitive to pressure, can be submerged in he hardware integrated into the bearing system (instead of
process fluid under pressure without requiring seals and can expensive add-on equipment) can continuously monitor, while
operate in a vacuum. online, changes in machine vibration against predetermined
limits as an indication of machine or process anomalies.
Machine Diagnostics In cases of excessive load, the system can signal process
his capability can take three forms: online machine analysis, control equipment to stop the machine instantaneously before
serious damage can occur. Besides con-
trolling and minimizing vibration in a
shaft, an active magnetic bearing system
Made in the USA
GRIFFCO VALVE can perform diagnostics by exciting the
shaft with controlled wave forms and
frequencies, either while the machine is
idle or running.
G-SERIES BACK During operation with conven-
PRESSURE VALVES
tional bearings, process errors may over-
load the bearing system, which forces an
operator to restart a potentially damaged
machine or take the machine off-line
for inspection. (his usually involves
dismantling a portion of the machine,
accruing associated maintenance costs,
and losing productivity.) A magnetic
M-SERIES bearing system can mitigate these issues
PRESSURE
RELIEF VALVES with the capability to move the shaft
within its clearance limits and indicate
any changes caused by effects such as
Innovation, technology and reliability. thermal distortion or metal deformation.
Vjtgg"tgcuqpu"yj{"gpikpggtu."rtqlgev"
ocpcigtu"cpf"rncpv"qrgtcvqtu"tgswguv" Conclusion
Itkhheq"Xcnxgu"hqt"vjgkt"ejgokecn"hggf" he evolution of sophisticated software
u{uvgou0"Qwt"pgy"I"cpf"O"ugtkgu" control systems and the unique inher-
xcnxgu"ykvj"vjgkt"kplgevkqp"oqnfgf" ent characteristics of magnetic bearings
Pqt{n"vqru"kortqxg"vgorgtcvwtg"cpf" have advanced the technology as a prac-
rtguuwtg"tcvkpiu"yjkng"eqpvkpwkpi"vq" tical solution for an increasing number
fgnkxgt"cp"gzvtgogn{"tgnkcdng."equv" of applications. In fact, failure modes of
ghhgevkxg"yc{"vq"cejkgxg"eqpukuvgpv." magnetic bearings tend to be limited to
wugt"cflwuvcdng"tcvgu"qh"àqy"cpf"uchgv{" the control electronics, power electron-
ics and electrical windings, and even in
tgnkgh"kp"ejgokecn"hggf"crrnkecvkqpu0"
these modes, magnetic bearings provide
performance and reliability levels that
make magnetic bearings an attractive
choice for many critical applications.
Your source for high quality P&S

chemical feed accessories
฀ ฀ Mark D. Hinckley is director,
฀ Mechatronics, for SKF USA Inc.
Contact him at 267-436-6510 or
via email at mark.d.hinckley@SKF.
www.griffcovalve.com 6010 North Bailey Ave, Suite 1B
Amherst, NY 14226 com. For more information, visit
Email sales@griffcovalve.com www.skfusa.com.

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Efficiency Matters
Efficiency Through
Indirect Measures
Wallace Wittkoff
Indirect factors can directly impact the true efficiency of the

product-transfer process.
F
or months, the focus of the Pumps & Systems “Efficiency
Matters” column has been on pump design, installa-
tion and operation, factors that directly affect the energy
consumption of the pump itself. For example, the April and
May 2010 articles on pump performance bands discussed how
normally, when a positive displacement pump has less slip, it
will more efficiently pump the fluids. he amount of product
pumped per unit of energy used would be considered a direct
measure of efficiency.
However, the decision-maker who is tasked with opti-
mizing energy use and reducing costs must also consider
indirect costs. he global energy impact decisions must also Figure 1. Transfer line from sweetener storage
be made. his article explores how pump design can affect experts in the industry note that we typically see 10 times the
three indirect efficiency areas: amount of water used for seal flush than what is necessary.
• Use of seal coolant (water) with associated cost and water
treatment
• Pump design that affects efficiency of product recovery Benefits of Eccentric Disc Design
• Pump design that reduces loss and waste treatment Negating the use of seal water altogether can help to avoid
energy usage and costs this cost (and possible creep). he solution is to use pumps
that have totally sealed pumping chambers and do not
hese indirect factors often result in energy creep. his is require seal flush. Diaphragm and magnetic-drive pumps
when indirect efficiency issues are not monitored and unin- may be familiar options. However, new to the field are eccen-
tended waste occurs. tric movement pumps that better fit some applications that
are not suitable for the former pump styles.
Most processors realize that water is becoming a valuable
Energy Efficiency of Mechanical Seals (and increasingly expensive) natural resource. Water is a vis-
While seal cooling or flush only applies to a subset of pump ible expense as the county, city or other sources that provide
applications, it serves as a good example of an indirect effi- it are passing onto the processor the costs to supply and then
ciency issue for those analyzing the total energy footprint of treat it. If the processor treats the water, he can determine the
pump selection. Frequent applications can be found in the energy usage and costs for this. As an example, a processor
food, beverage and pharmaceutical industries where trans- who handles sweeteners in the confectionary industry calcu-
ferring sweeteners that tend to crystallize on seal faces can lated that his plant’s total cost for water used in flushing seals
cause premature seal failure. (See Figure 1.) Traditionally, was more than $10,000 per year/per pump.
the common solution has been to use advanced seals (most In another case, a processor that makes sauces in the
of which are not permitted or adaptable for hygienic applica- Southeastern U.S. was faced with a permit cost of more than
tions) or using mechanical seals with water or other fluid flush. $400,000 if additional water was to be used in the plant.
However, seal water usage on pumps is a classic case in his hurt growth. In addition, if water is used over and above
which energy creep can occur. It is typical over time that the limit, the county must expand its water-treatment capacity.
volume of seal water is increased to be safe. In fact, some Whether it is a per-pump water use cost or permit cost, new

Eccentric Disc, Sliding Vane & Peristaltic Pumps
ZI Plaine des Isles, rue des Caillottes
Auxerre, France 89000
33-3-86-49-86-30
mouvex.com
Figure 2. Eccentric disc design pump cutaway
options to negate the use of water means less energy used to supply and treat the
water, as well as other costs that may be incurred.
he eccentric movement or eccentric disc design for sealing pumps is an alter-
native to the magnetic drive or diaphragm, no-flush options. he eccentric move-
ment sealed pumps do not use mechanical seals and, therefore, seal flushing is not
applicable or needed. Compared to magnetic drives, the eccentric movement can
be implemented so that it is sanitary/hygienic and also withstands semi-abrasives
better. Finally, the eccentric movement does not produce heat buildup.
his pump also offers efficiency because of low slip (a direct efficiency param-
eter). With this pump, the example of indirect cost through water consumption is
eliminated, and the global efficiency of the pumping solution within the application
is realized.
he eccentric movement pump negates the use of dynamic seals. In most cases,
this pump is driven by standard rotating drives. his drives the shaft within the
pump with a coupling. However, unlike most pumps, the shaft is machined on
different planes so that the drive end of the shaft is on a different plane than the tip
that is driving the pumping mechanism (See Figure 2.).
Attached to the shaft are bearings and both are enclosed by a hermetically
sealed metal bellow or rubber boot. he shaft rotates, the metal bellows or rubber
boot does not rotate thanks to the bearings. Instead, it flexes in an eccentric motion.
his flexing is minor and within the elastic range of the stainless steel so that preven-
tive maintenance inspection is recommended at 150 million duty cycles.

he actual pumping mechanism is similar to the peristaltic effect of hose
Highland Oaks I,
1100 W 31st Street, Suite 120
Downers Grove, IL 60515
Tel: 909-512-1257
Fax: 909-512-1209
Info@pumpsg.com
pumpsg.com
Figure 3. Eccentric disc design pump components

Efficiency Matters
pumps, but this pump does not use hoses, so it does not fall on clearances for operation and, in fact, takes up clearance that
victim to any of the possible issues associated with them. he could be generated by wear, the pump has negligible slip. he
disc of the pump is driven by the eccentric movement of the result of this was illustrated in the “Efficiency Matters” columns
shaft, which produces a peristaltic effect on a channeled cyl- published in Pumps & Systems April and May 2010. With no
inder. Product flows in an inner and outer pumping chamber, mechanical seal, there are no surfaces on which products, such
producing fully complementary flows. he pump, therefore, as corn syrup, liquid sugar, glucose or any number of difficult-
does not produce pulsation. Since this pump does not depend to-seal fluids can crystallize. herefore, the need for flush water
to remove these products is eliminated.
Why Discard What You

Already Pumped?
THE FLARE he eccentric movement pump concept
goes beyond resolving global efficiency
KNOCK-OUT issues from a water or seal-flush use per-
PUMP THAT spective. During the production cycle of
a traditional pumping system, startup
ENTRAINED and shutdown are highly inefficient
GASES CAN’T because:
• he pumping system is not stabi-
KNOCK OUT lized, so the product being pumped
is not to specification and must be
re-worked or treated.
• For most pumps, once the inlet tank
is empty and the pump loses prime,
the discharge line remains full of
product and also becomes a loss.
It is clear that pumping a product

and then not using it is an inefficient
use of resources. Disposing or treating
this unsuitable fluid further adds to this
inefficiency.
Leistritz’ twin-screw flare knock-out pumps are perfect
for corrosive, abrasive, or flammable liquids and operate Efficiencies When Starting a Process
trouble-free, even when confronting entrained gases. Since it has essentially no slip, the eccen-
tric movement technology is able to pro-
Results: duce a stabilized and usable product flow
s Reliable across a broad range of viscosities, much earlier in the startup process. his
s Excellent NPSH capabilities, compares with pump styles that have slip
and require a control system to adjust
s Low pulsation, and compensate. As a field application
s No risk of vapor lock. example, companies that use spray-dry-
ing processes find this to be the case in
Replaceable liners, integral shafts, external bearings and their operations.
double mechanical seals simplify service, keeping downtime Typically, processes of this nature
to a minimum, even after years of operation. begin on water for calibration and sta-
bilization. he water is replaced with
actual product. However, a process upset
occurs when this change occurs. he
degree to which a pump has no slip and
Leistritz Corporation, 165 Chestnut St., Allendale, NJ 07401 (201) 934-8262
can maintain constant flow during the
Call us, or visit www.leistritzcorp.com/pumps transition is related to how the process
retains stability and product losses are
See us at Turbomachinery Symposium Booth #1013
minimized during transition. In the case
circle 122 on card or go to psfreeinfo.com of spray driers, much like shower heads,

if flow changes the spray pattern changes, rendering differences in the Wallace Wittkoff is the Hygienic Director for Dover
product and possible rejection. Corporation’s Pump Solutions Group (PSG™). He can be
reached at 502-905-9169 or wallace.wittkoff@pumps-
Efficiencies When Ending a Pumping Process gcom. PSG is comprised of six leading pump companies—
On termination of a process, the residual product left in the pump Wilden®, Blackmer®, Griswold™, Neptune™, Almatec® and
discharge line also represents an opportunity for added costs, as well Mouvex®. You can find more information on Mouvex at
as waste-treatment costs. www.mouvex.com and PSG at www.pumpsg.com.
In another field application exam-
ple, a company that produces coffee
extract was able to recover an additional
400 pounds of product at the end of
each run because, even after the feed
tank was empty, the pump continued
to effectively pump air, thus helping
purge the line. Pumps that are able to
run dry and perform this way can pro-
duce a compressor effect following the
product. Pumps that employ the eccen-
tric movement principle produce such
an effect. When considering the effect
of efficiency, recovering 400 pounds per
run meant:
• Resources did not need to be used in
treating it as waste
• All the resources to produce it were
not lost
• Resources would not be used to
reproduce the lost coffee extract
he additional, indirect efficiency

issue was that coffee extract was aggres-
sive on mechanical seals and required
advanced seals or water flush. Eccentric
movement technology, with its sealless
design, also helped in this application
because resources were not expended
for seal water, product was not lost, and
treatment to remove the lost product
was not needed.
Putting It All Together

While it is important to consider the
direct efficiency parameters of a pump,
such as the amount of product pumped
per unit energy consumed, consid-
erations should include the indirect
efficiency consequences of pump tech-
nology selection. he issues of periph-
ery services to the pump—such as seal
water, or consequences of the pump
design, such as the amount of product
loss and waste treatment costs—all com-
bine to create the true efficiency of the
product-transfer process.
P&S circle 119 on card or go to psfreeinfo.com
From the voice of the fluid sealing industry
SEALING SENSE
What Is the Sealing System Energy Footprint for
Removing Diluents from the Process Stream?
Third of Four Parts
This month’s “Sealing Sense” was prepared by FSA member Dave Casucci
T
his “Sealing Sense” series
provides guidance on best
practices to minimize the
size of the sealing system energy
footprint. he first article discussed
the energy losses from the interac-
tion between the faces of a mechani-
cal seal. he second discussed the
thermal energy required to maintain
the proper temperature of the inter-
facial lubricating fluid. We will now
discuss the thermal energy footprint
of removing diluents introduced by
auxiliary processes.
A flush is often added to the
stuffing box or mechanical seal
chamber. his helps to extend seal
life by displacing solids, removing Figure 1. API Piping Plan 32—energy lost through dilution and vaporization
the heat generated by packing or a
mechanical seal, and heat soak from
the seal chamber. he flush fluid
then becomes mixed with the pro-
cess fluid as a diluent that may need
to be removed from the process fluid.
Mechanical Seal System

API Plan 32 is a commonly used
system for hydrocarbon service that
introduces diluents to the process
stream. Plan 32 accounts for nearly a
quarter of all pumping system appli-
cations operating above 200 degrees
C (400 degrees F). Unfortunately, it
can also be one of the most energy
inefficient designs because the speci-
fied flush flow rate is often higher
than necessary. Figure 2. API Piping Plan 32—energy lost through dilution
When a cool flush, like the one

illustrated in Figure 1, becomes mixed
with the process fluid, energy must be
added to replace the heat lost through
cooling. Additionally, flush fluid must
be removed from the process stream.
Supplying the required heat of vaporiza-
tion to remove the flush fluid increases
the overall energy footprint significantly.
When the flush diluents can be toler-
ated in the process stream, energy require-
ments can be reduced significantly, as
illustrated in Figure 2, since the only heat
energy needed is that which restores the
process fluid to its original temperature.
Packing Systems
In packed pumps, flush fluids may be
recaptured at the stuffing box or later down
the process stream. Recapture of diluents Figure 3. Packing System—energy lost through dilution and vaporization
at the stuffing box is usually accomplished
by the use of a double lantern ring connec- the process stream to its original state. Furthermore, the diluent
tion—one connection to introduce the flush fluid and a second itself may represent energy expenditure since it usually consists
one to retrieve it. A flow restrictor may be used in the throat of of a refined fluid. he energy cost expended in synthesizing the
the stuffing box to maintain adequate stuffing box pressure. diluent as well as pumping and distributing it is a cost associ-
he example shown in Figure 3 shows a system with ated with the sealing system. his discussion demonstrates the
poor energy efficiency because of the greater amount of power importance of comparing systems rather than devices.
required to remove the water diluent.
In some cases, diluent fluids may be left unrecovered in the
process stream, acting as a tolerable contaminant even though
Conclusions
• Sealing systems found in many industrial applications (even
it ultimately reduces the purity, quality and value of the final
when functioning as intended) can be extremely wasteful of
product. A more efficient system is illustrated in Figure 4. It
energy.
minimizes the amount of diluents that is introduced into the
• Improved technology sealing systems available today can
process fluid.
eliminate the need for energy wasting systems that result
in cooling/dilution of the process and the need for down-
Overview stream separation/evaporation and/or re-heating.
In either recovery system, an energy cost is associated with the • Life-cycle costs should always be considered when designing
removal of the diluent from the process stream and restoring a sealing system.
Next Month: What is the impact of
reliability on the sealing system energy
footprint from pump shut down, repair &
re-commissioning?
We invite your questions on sealing issues and
will provide best effort answers based on FSA
publications. Please direct your questions to:
sealingsensequestions@fluidsealing.com.
P&S
his “Sealing Sense” was sponsored
by the Mechanical Seal Division
of the Fluid Sealing Association as
part of our commitment to industry
consensus technical education for
pump users, contractors, distribu-
Figure 4. Packing System—energy lost through dilution tors, OEMs and reps.

PUMPFAQs ®
Q. We are frequently replacing the ball bearings in an end at a rate of flow close to
suction pump that is pumping hot oil at 700 degrees the BEP.
F. Someone has suggested that the bearings should be Impellers that are
replaced with C3 fit bearings. What is C3 fit, and how designed for a higher
will it improve bearing life? suction specific speed
will begin to exhibit suc-
A. Ball bearings are made with different amounts of internal tion recirculation closer
clearance between the raceways and the balls. Most bearings to the BEP rate of flow
have little clearance between the raceways and the balls to accu- and sometimes even at
rately align the rotating shaft to the stationary members and the BEP. Avoid selecting
prevent any looseness or play in the shaft. However, when a pumps designed with
pump is operating using hot liquids, the shaft and inner race- high suction specific
way of the bearing will expand, closing any clearance, and can speed impellers to
impose an additional load or squeeze on the bearings. his can reduce this potential
be further aggravated if the bearing housing is cooled with a problem.
water jacket. A temporary Figure 5-12. Impeller showing
C3 fit bearings are made with greater internal clearance, approach to minimize suction recirculation
which allows for the expansion of the inner raceway and avoids the problem is to add an
the excessive load on the bearing. Bearings with even greater orifice (some times called a bulkhead ring) at the impeller inlet.
clearance designated as C4 and C5 are also available if C3 is he opening in the orifice should be sufficient to allow approxi-
not sufficient. mately 70 percent of the BEP flow, but this modification must
Check with your pump manufacturer before replacing any be coordinated with the pump manufacturer.
bearings with bearings manufactured with an internal fit differ- When suction recirculation is responsible for significantly
ent than the fit originally supplied. reduced service life, excessive downtime and lost production,
an energy efficient solution is to use an impeller appropriate for
the actual flow, based on the system requirements. If the system
requirements vary significantly, the addition of a speed control
device may be justified. For a more complete explanation, see
Q. What causes suction recirculation in pumps? How dam- Optimizing Pumping Systems: A-Guide-to-Improved-Efficiency-
aging is it, and what can be done to avoid this condition?
Reliability-and-Profitability, available at http://estore.pumps.org.
A. Suction recirculation in centrifugal pumps occurs when

the flow through the pump is lower than that for which the
impeller was designed. When this happens, a portion of the
Q. What is the difference between a Newtonian and non-
flow is forced back to the impeller inlet (suction) as shown in
Newtonian fluid?
Figure 5-12.
his recirculation of flow creates a vortex on the impel-
ler blades resulting in low-pressure regions and allows vapor A. A fluid is Newtonian when the ratio of shear stress to shear
bubbles to form and collapse causing cavitation damage to the rate is a constant for all shear rates, is independent of time,
impeller vanes. Vibration also results and leads to mechanical and zero shear rate exists only at zero shear stress. Most min-
damage to the bearings and seals. eral oils at temperatures above the cloud point (the temperature
his condition usually begins below 70 to 50 percent of at which the oil begins to appear cloudy), solvents and water
the best efficiency (BEP) rate of flow. One solution is to provide approximate this condition and are considered Newtonian
a bypass line from the discharge to the suction piping, which fluids. he viscosity of these fluids is independent of rate of
can be sized to allow sufficient flow for the pump to operate shear.

A non-Newtonian fluid will change viscosity with changes Pump FAQs® is produced by the Hydraulic Institute as
in the rate of shear applied to the fluid and/or the length of time
a service to pump users, contractors, distributors, reps and
at shear.
Several types of non-Newtonian fluids are defined below. OEMs as a means of ensuring a healthy dialogue on subjects
When the ratio of shear stress to shear rate increases as shear rate of common technical concern.
increases, reversibly and independent of time, a fluid is said to be HI standards are adopted in the public interest and are
dilatant. Highly concentrated pigment-vehicle suspensions, such designed to help eliminate misunderstandings between the
as paints, printing inks, and some starches, are dilatants fluids. manufacturer, the purchaser and/or the user and to assist the
he apparent viscosity of these fluids increases as the rate of shear purchaser in selecting and obtaining the proper product for a
increases. Some dilatant fluids solidify at high rates of shear. particular need.
Pumping such fluids requires low velocity through the pump.
As an ANSI approved standards developing organiza-
When the shear stress to shear rate ratio is constant for shear
rates above zero, it is independent of time, but when shear occurs tion, the Hydraulic Institute process of developing new stan-
only for shear stress above a fixed minimum greater than zero, a dards or updating current standards requires balanced input
fluid is termed plastic. A plastic fluid, such as putty or molding from all members of the pump community.
clay, is characterized by a yield point. his means that a definite We invite questions and will endeavor to provide answers
minimum stress or force must be applied to the fluid before any based on existing HI standards and technical guidelines.
flow takes place. Please direct your inquiries to: pumpquestions@pumps.org.
When the ratio of shear stress to shear rate decreases as shear
For more information about HI, its publications, Pump
rate increases, reversibly and independent of time, and zero shear
rate occurs only at zero shear stress, a fluid is pseudo-plastic. Many LCC Guide, Energy Saving Video-based education program
emulsions, such as water-base fluids and resinous materials, are and standards, please visit: www.pumps.org. Also visit the new
pseudo-plastic fluids. heir apparent viscosity decreases with e-learning portal with a comprehensive course on “Centrifugal
increasing shear rates but tends to stabilize at high rates of shear. Pumps: Fundamentals, Design and Applications,” which can
A fluid is thixotropic when the ratio of shear stress to shear be found at: www.pumplearning.org.
rate decreases and is time-dependent in
that this ratio increases back to its “rest”
value gradually with lapse of time at zero
shear rate and stress, and decreases to a
limit value gradually with lapse of time
Quality to the Core
at constant shear rate. Most greases,
With more than 30 years of experience,
drilling mud, gels, and quicksand are Effort is the foundry of choice for complex,
thixotropic fluids when the apparent high-integrity pump castings—impellers,
viscosity of these materials decreases for casings, channel rings, diffusers, glands,
an increasing rate of shear and for an suction heads, and more.
increasing length of time at shear.
Our ceramic core process yields cores
When the ratio of shear stress to with as-cast waterways exhibiting a C30
shear rate is constant for all shear rates at typical finish, which can improve pump
any given instant of time, but increases efficiency by 10%. The Effort Foundry
with time, a fluid is rheopectic. Some ceramic core process also allows for use
greases are intentionally manufactured of existing pattern equipment, whether it’s
made of wood, plastic, or aluminum.
to have partial rheopectic properties that
facilitate pumping in a stable condition. Effort Foundry meets your aftermarket
However, upon shearing in a bearing, requirements through our “Fast Track”
the grease builds up to a higher apparent expedited shipment program, shipping
viscosity. parts in as little as one week. What’s
more, our broad selection of alloys meets
Additional information about any pump application.
fluids and the effect of viscosity on
pump and system performance may be Learn more at www.effortfoundry.com.
found in ANSI/HI 3.1-3.5 American
National Standard for Rotary Pumps for
Nomenclature, Definitions, Application, EF Effort Foundry, Inc. ST
EM
C E R T I F I CA
TI
SY
ON
and Operation, which is available at CASTING QUALITY SINCE 1975

IS O
90
01
http://estore.pumps.org. :2 0 0 0
P&S
Practice & Operations
Flexible Impeller Pumps

in the Food Industry
David Farrer, Depco Pumps
One of the best kept secrets in pumping technology
W
hat’s a flexible impeller the impeller continues to rotate (Figure 1,
pump? In the food indus- Section 2). As the vanes reach the discharge
try, the most common port area they start to move up a ramp from
pump types are centrifugal pumps, the large diameter to the small diameter
rotary lobe pumps, rotary piston (Figure 1, Section 3). he vanes are now
pumps (often referred to as external being bent (flexed), and the cell between the
circumferential piston or ECP), air- two vanes gets squeezed and the product is
operated double diaphragm pumps discharged.
(AODD), peristaltic or hose pumps, he performance characteristics of
and many others. However, flexible the FIP take advantage of both centrifugal
impeller pumps (FIP) are a lesser- pumps and positive displacement pumps.
known pump type. hose in the dairy It has the head vs. flow characteristic of a
industry may already know that the centrifugal pump coupled with the viscosity
pump on the back of a milk collec- handling capability of a positive displace-
tion truck is a flexible impeller pump. ment pump (See Figures 2 and 3).
his article explores FIPs, including
how they work and how they are used FIPs Offer Food Processors
in the food industry. Many Features
An FIP can offer unique features and combi-
How Do FIPs Work? nations of features that other pumps cannot.
An FIP, as its name suggests, is a (Table 1).
pump with a flexible impeller, or a With these features, the FIP can perform
flexing vane. he impeller is made of many, but not all, of the duties of most other
rubber and is fitted into a concentric sanitary pump types, often less expnsively.
bore (See Figure 1). Inside the bore, In approximate terms FIPs cost about the
between the suction and discharge same as a sanitary centrifugal pump, which
ports, is a smaller diameter bore is around one-third the cost of a rotary lobe
(cam). pump.
As the impeller rotates and the
vane moves down a ramp from the FIPs Follow the “KISS”
small diameter bore to the larger
diameter bore (Figure 1, Section 1), Principle
the cell formed between two vanes We all know that one—Keep It Simple,
enlarges and consequently product Stupid. he FIP has one moving part, the
is drawn into the pump through the impeller, and has no rotors to time, no shims
suction port. his ‘trapped’ prod- and no gears. Figure 4 is an example of a ped-
uct is carried around the body as estal mounted pump.
Figure 1. FIP principle

How well
are YOU
prepared
if your
pump
system
takes
Figure 2. Viscosity vs. efficiency Figure 3. Head vs. flow a dive?
Emerson’s floating
master pump control
keeps systems up and
running.
Unlike ordinary
drives, Emerson’s
intelligent pump
Figure 4. Typical pedestal mount FIP configuration drives continuously monitor system
operation to protect the pump sys-
Applications in the Food Industry tem in the event of a problem. The
FIP food applications range from simple transfer to batching, metering, filling and result is enhanced system perfor-
dosing right through to complex process applications with flows directly linked to mance, increased uptime and reduced
process streams. Examples include: maintenance costs.
Floating Master
Dairy (Milk, Yogurt, Cheese Curd, Cottage Cheese, Cream) pump control in multi-
his truck has a 2-inch, sanitary FIP pump, bulkhead mounted in the cabinet on plex systems switches
the back of the truck. he pump is used to bring milk from the farm tank to the automatically in the
event of a problem –
Pump Performance Flexible Impeller Rotary Lobe Centrifugal Air Operated the system never goes
& ECP Double down!
Diaphragm
Pressure Low Low to High Low to Moderate Low
Temperature Moderate Low to High Low to High Moderate Go to www.emersonct.com/ps5
Flow Low to Moderate Low to High Low to Very High Moderate for more information on Control
Viscosity Low to High Low to Very High Low Moderate Techniques Pumping Solutions.
Speeds Wide Range Wide Range Limited Range N/A
Have a simplex pump?
Dry Self Priming Excellent No No Excellent
Air Entrained Liquids Yes Yes No Yes
Just plug it in! Pre-loaded,
Delicate Solids In removable memory device
Suspension Yes Yes No Yes eliminates the need for an
Hard Solids In Suspension Yes No No Yes external controller saving you
Abrasive Liquids Moderate Low Limited Yes hundreds of dollars.
Corrosive Liquids Moderate Yes Yes Yes
Dry Run Capability Up to 30 seconds Yes Yes Yes
Smooth Flow Yes Yes Yes Pulsing Flow
StarƟng Torque / HP Moderate Low Low N/A
Power ConsumpƟon Moderate Low Moderate High
Relief Valve Required Not normally Yes No No
With Periodic With Periodic
ConƟnuous Duty Maintenance Yes Yes Maintenance
Ease of Cleaning Yes Yes Yes No
Ease of Maintenance Simple Complicated Simple Complicated
Table 1. Comparison of FIPs and other common food process pumps

truck and has flows up to 165 gallons per minute. It is dry self
priming to 20 feet – primes almost instantly through 15 to On pump-zone.com . . .
20 feet of suction hose and has low shear so that it does not
damage milk globules or release free fatty acids. More information and images of these FIP
For cottage cheese transfer, a 1 ½-inch sanitary FIP is foot- food applications
mounted and coupled to a gear motor to cover the fish.
It transfers cottage cheese to the header tank on a piston
filler with flows up to 20 gallons per minute. Bakery—Cake Mix, Muffin Batter With Fruit, Coatings, Icing
& Fruit Fillings
Beverage—Water, Wine, Juice, Concentrate & Pulp To evenly spread donut glaze, a 1½-inch sanitary pump is used
In the wine industry, a 1- to 2½-inch sanitary FIP, mounted on to recirculate donut glaze to the header tank on the enrober.
a cart with a VFD, is used for wine transfer. It is used to transfer his pump can handle hard solids—such as small clumps of
from the fermentor to the press, press sump to de-stemmer, for un-dissolved sugar and pieces of donut that fall through.
must, for pump-over and to transfer the wine itself.
For fruit juice concentrate, a 1- to 2–inch sanitary pump General Food—Batter, Mayonnaise, Sauces, Dressings, Pickles,
mounted on a cart, close coupled to motor and using VFD Relishes, Salsa, Honey & Jams
speed control is used. A 2-inch sanitary pump is mounted on a cart in-line, coupled
to motor and that uses VFD speed control. his pump transfers
Meat, Fish, Poultry—Brine, Rendering, Gravy, Pet Food, corn batter into chip-forming machines and can handle hard
Meat Sauce & Meat Slurry solids, such as small clumps of un-dissolved batter.
Injecting brine into meat and poultry is accomplished by using P&S
a 1-inch sanitary pump mounted in OEM.
A 1½-inch sanitary pump, mounted in OEM equipment, David Farrer is the sanitary product manager for the Depco
supplies batter from the holding tank to the enrobing curtain. Pump Company based in Clearwater, Fla. He can be con-
Smooth flow from the pump ensures an even curtain of batter tacted at davidf@depcopump.com or 1-800-446-1656.
Peristaltic Pump Hose

- Smooth Precision Ground Cover
- Mul -ply High Tensile Cord Reinforcement
- Tube Compounds: Natural Rubber, EPDM, Nitrile (Buna-N), and
FDA Safe White & Tan Materials
THOUSANDS OF PUMPS - For Watson-Marlow™, Blackmer™, Verder™, Ponndorf™, Periflo™,

and Other Posi ve Displacement Pump Manufacturers
HAVE NEVER SEIZED. ID OD Length ID OD Length
Pumps fitted with GRAPHALLOY® (mm) (mm) (mm) (in) (in) (in)
10 31.0 508.0 0.39 1.22 20.0
wear parts survive upsets. 15 36.0 762.0 0.59 1.41 30.0
25 53.2 1006.4 0.98 2.09 39.6
GRAPHALLOY® bushings 32 61.0 1250.9 1.25 2.40 49.2
and case rings: 40 66.4 1489.0 1.57 2.61 58.6
• Run dry, keep on running 50 80.0 1820.8 1.96 3.14 71.6
• Run hot, cold, wet or dry 65 99.2 2336.8 2.55 3.90 92.0
• Reduce maintenance 80 122.0 2781.3 3.14 4.80 109.5
• New pumps or retrofits 100 144.0 3276.6 3.93 5.66 129.0
• Non-galling
• Self-lubricating GRAPHITE METALLIZING Non-standard or custom built peristal c hoses are also available.
• -400°F to 1,000°F CORPORATION

-240°C to 535°C+ Yonkers, NY 10703 U.S.A. Call us for a quote or visit our website for addi onal informa on.
• Corrosion resistant ISO 9001:2008 PS09a TOLL FREE: 1-800-686-4199
www.salem-republic.com
TEL. 914.968.8400 • WWW.GRAPHALLOY.COM/PS
circle 145 on card or go to psfreeinfo.com circle 149 on card or go to psfreeinfo.com

Pump Castings
Alfred ‘Fritz’ Hall, Benton Foundry
The most misunderstood, most overlooked

and possibly most important pump component
I
n the 1950s I encountered pumps for the first time while angles, radii and dimensions.
on a sales call with my father, visiting Marlow Pumps • Quotation responses should specify the part number,
in Midland Park, N.J.. Although this pump company, revision level, casting weight, piece price, quantity breaks,
as well as its product lines, has been sold numerous times minimum billing, current metal surcharge, pattern mate-
through the years, we continue to produce many castings rial, number of impressions, the number of impressions
based on the same tooling today that was used in the 1950s in the core box and the type of machine on which the
and 60s. However, the metal castings industry has drasti- part will be run.
cally evolved through the years, not only in respect to the • During the design stage of pumps, uniform metal thick-
type of machines used but also with regard to processes and ness should be maintained when possible. Isolated heavy
procedures. bosses or hubs have a tendency to create shrinkage and
Today, the biggest changes seem to be with engineer- porosity.
ing and purchasing. Although the castings that existed in the • he pump design should not include any square corners.
1950s, 60s and even 70s are still being designed and pur- To increase efficiency, sharp 90-degree transitions should
chased today, many of those in the industry have never had also be avoided within the pump casting.
the opportunity to visit a casting operation; therefore, they • Purchasing should not consider or accept quotations that
may be unaware of the industry’s advancementsand the sav- only state “one set of pattern equipment” for a specific
ings that may be available. part number.
Daily, requests are received for various pump parts, fit-
tings and bearings. Approximately five percent of these bid Currently, several pump companies design their own
requests provide the information required to generate an parts and, in some cases, build the tooling prior to seeking
accurate quotation. Based on the information supplied by quotations. It is well documented that during the lifetime of
buyers, it is not uncommon for the metal cost to represent an electric motor, the initial cost of the motor can result in
only 10 percent of the casting price. only approximately 2 to 3 percent of its lifetime cost, while
Regardless of the casting medium (iron, bronze or alu- energy accounts for 97 percent. A pump system is compa-
minum), there are guidelines to follow when designing and rable to these figures.
purchasing metal castings. A pump requiring a modest initial investment may
prove to be financially strapping over its lifetime. he effi-
Guidelines for Designing and ciency of the motor, the actual pump and fittings and the
Purchasing Metal Castings related maintenance required need to be considered to obtain
• Select a foundry that has specific experience in casting an accurate estimate of the long-term investment. Some
pumps or pressure castings. manufacturers ask the design engineer, pattern maker and
• Be thorough and accurate when developing quotation metal caster to convene to discuss maintenance efficiencies,
requests. Information such as quantities, type of metal pattern design and foundry-friendly castings.
required, casting weight and special items such as anneal-
ing or stress relieving, certifications and letters of compli- P&S
ance should be included in the formal quote request.
• Supply a legible set of blueprints or CAD files. Such files Alfred ‘Fritz’ Hall is the president of Benton Foundry. He
should include locations where brinell readings are to can be reached via phone at 570-925-6711 or via email
be taken on the castings, as well as tooling points, the at benton@epix.net. For more information about Benton
desired parting line and draft angles and the tolerance of Foundry, visit www.bentonfoundry.com.

Not All ANSI Pumps Are

Created Equal
Patrick Prayne, ITT Goulds
OEM pumps and parts outperform replicated products

and can save thousands per year in operating costs.
I
ndustrial process managers who purchase and maintain translate into wasted energy costs of at least $1,100 per
pumps are familiar with a marketing tug of war. On one year per pump, and as much as $3,700 per year on a
side are the manufacturers of well-known pump brands medium-sized pump, based on continuous operation.
who claim their products offer higher quality with a lower
cost of ownership. On the other side are replicators who Customers report that OEM pumps and parts also
make pumps and parts that cost less out of the box and claim require less maintenance and reduce downtime, which con-
to perform just as well as the OEM products. tribute to the lower operating costs for OEM pumps. his
Studies by the Hydraulic Institute show that purchase article provides details on the tests, and examples from two
price of a medium-sized ANSI pump is only 10 percent of customers who switched to using only OEM pumps and
the life-cycle cost of a pump, with energy, maintenance and parts. hey show that OEM claims to lower the total cost of
downtime costs accounting for nearly 70 percent. In many ownership are not simply marketing hype but can be verified
cases, the initial purchase price is the most heavily weighted by controlled testing.
factor in purchasing decisions.
his may be especially true for process pumps that con- Test Methodology
form to the ASME B73.1 specification, commonly known Performance tests were conducted on four sizes of ANSI
as the ANSI standard. Most ANSI pumps can look similar, pumps:
even to the eyes of a skilled engineer—and because they are • 1-inch discharge flange, 1.5-inch suction flange, 6-inch
the world’s most common process pump, with tens of thou- impeller (1x1.5-6)
sands sold each year, it may seem reasonable to assume that • 1-inch discharge flange, 1.5-inch suction flange, 8-inch
replicated ANSI pumps and parts are likely to perform as impeller (1x1.5-8)
well as those from OEMs. • 1.5-inch discharge flange, 3-inch suction flange, 13-inch
To test this, engineers at an OEM pump company impeller (1.5x3-13)
recently conducted a comparison of a popular OEM pump • 2-inch discharge flange, 3-inch suction flange, 6-inch
to pumps of identical size from non-OEM suppliers. he impeller (2x3-6)
results showed that when it comes to purchasing pumps, the
short-term gain of a lower purchase price equals long-term he testing was performed in accordance with ASME
pain in performance. In every test: B73.1 and Hydraulic Institute Standard 1.6, Level A, which
• Non-OEM pumps failed to match the OEM pump includes guidelines and uniform procedures for testing,
performance for flow, head and efficiency. recording data and acceptance criteria for centrifugal pumps.
• Non-OEM pumps performed an average of 10.25 per- Level A testing uses clean water and involves monitoring
cent lower in efficiency than the OEM counterpart. the rate of flow, system head, input power and pump speed.
• Non-OEM pumps did not perform in accordance with Level A acceptance criteria states that “no minus tolerances
their own published performance curves, and therefore or margin shall be allowed with respect to rate of flow, total
did not conform to the ASME standard. head or efficiency at the rated or specified conditions.”
• At a standard electricity cost of 7.6 cents per kilowatt Each pump was tested as-received, with only the
hour, the lower efficiency of the non-OEM pumps would

impeller clearance being set per the prod- Non-OEM 1x1.5-8 @ 3550 RPM vs. OEM
uct installation, operation and mainte- 400.0 70.0%
nance (IOM) manual.
While the size of the differential 350.0
60.0%
varied, the OEM pumps outperformed

their non-OEM counterparts in every 300.0
50.0%
measure on every test. A close-up look at
Head (ft)
40.0%
the results for two of the pump sizes tested
Eff (%)
250.0
provides a snapshot of typical findings. 30.0%
200.0
1x1.5-8 Test—OEM Pump 20.0%
Is 17 Percent More Efficient 150.0

10.0%
At 3,550 rpm, the OEM pump produced
Legend
a flow of 150 gpm, a total dynamic head 100.0
OEM
0.0 25.0 50.0 75.0 100.0 125.0 150.0 175.0
(TDH) of 271 feet, with an efficiency of Non-OEM
61.1 percent. Flow (gpm)
Flow-Head Curve
For the non-OEM pump operating Efficiency Curve
at the same speed and flow, the TDH was 1.5x3-13 Test—OEM Pump Is 8 Percent More Efficient Best Efficiency Points
only 229 feet, which is 15 percent lower.
It was operating at an efficiency of 50.7 492 feet, and an efficiency of 55.3 percent. For the non-OEM
percent, which is 17 percent lower than the OEM of the same pump operating at the same speed and flow, the TDH was only
size. 459 feet, which is 7 percent lower; and an efficiency of 51.1
he 1.5 x 3-13 pumps also were tested at a speed of 3,550 percent, which is nearly 8 percent lower.
rpm. he OEM pump produced a flow of 484 gpm, TDH of
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Small Differences Yield Big Energy the OEM pump in the test. Although these requirements fall
Savings within the published performance curve of the non-OEM
An efficiency delta of less than 10 percent may not sound like a pump, in the test, it fell short. Two costly options would be
lot, but it translates into major differences in energy costs. available. Either the transfer process would take longer, reduc-
Consider the 1.5x3-13 pump comparison, in a pumping ing productivity and process control, or the customer could
application requiring a flow of 484 gpm at 459 feet—the actual spend days or even weeks troubleshooting the underperforming
performance result of the non-OEM pump at 3,550 rpm. he pump, only to find that a larger impeller or even a larger non-
OEM pump would produce the same flow and head using a OEM pump is needed to meet the performance requirement.
smaller impeller, using 8 percent less power, saving 8.3 hp (or Energy savings were also significant involving the compar-
6.2 kW). ison with smaller non-OEM pumps in the tests. Consider an
According to the U.S. Department of Energy, in August application for the 1x1.5-8 pump that requires 150 gallons per
2008 the average price of electricity in the North American minute at 229 feet, which matches the maximum tested perfor-
industrial market was just under eight cents per kilowatt per mance of the non-OEM pump. he OEM pump would meet
hour—$0.076 on average, ranging from $0.066 in the Midwest these requirements using 2.5 horsepower (1.9 kilowatts) or 15
to $0.138 in New England. At the average price, the energy percent less power. In continuous service, the cost of wasted
costs in this application would be more than $3,700 lower per energy for the non-OEM pump would be more than $1,100
year with the OEM pump compared to the non-OEM pump. per year.
6.2 kW x $.076 kW/hr x 8,000 hours = 1.9kW x $.076kW/hr x 8,000 hours =

$3,763 per year, per non-OEM pump $1,135 per year, per pump
he lower performance of the non-OEM pump has addi- he energy savings in these examples apply to a single pump
tional cost implications. Suppose the process required a flow in continuous service. In a facility with 200 same-sized pumps
of 484 gpm at 492 feet, which matches the performance of from non-OEM vendors, the total cost of wasted energy would
range from $227,000 per year for the smaller 8-inch pumps, to
more than $700,000 for pumps with a
13-inch impeller. Engineers have repeat-
edly tested the 1x1.5-8 pump to simu-
late performance over the span of several
years, and the results showed continuous
underperformance. his proves that the
choice of one non-OEM pump could
cost a facility millions over multiple
years.
ASME B73.1 Is More

Than Just Dimensional
Interchangeability
To meet the ASME B73.1 standard, all
published performance curves, as well
as factory testing, must be compliant
with Hydraulic Institute 1.6, level “A”—
the testing procedures described in this
article.
he standard states “no minus tol-
erances or margin shall be allowed with
respect to rate of flow, total head, or
efficiency at the rated or specified condi-
tions.” In the OEM vs. non-OEM test-
ing, none of the non-OEM pumps per-
formed up to the level of its published
performance curve, meaning that none
of the non-OEM products complied
with the ANSI standard.
A high-precision manufacturing and quality control pro- that the gland continued to touch on one side, and the shaft
cess contributes to a higher purchase price out of the box com- would not turn. he OEM company’s sales engineer inspected
pared to most non-OEM products. But the tests confirm that the equipment and found that the non-OEM stuffing box cover
most OEM pumps perform as expected, consistent with their bore was undersized by 1/32- to 1/16-inch, and the gland studs
published performance curves. Full compliance with the ANSI were off-center from the bore, causing the gland, stuffing box
standard translates to lower overall operating costs throughout cover and shaft to be non-concentric. he customer ordered a
the life of the pump. new OEM stuffing box, and remarked that the non-OEM part
Dimensional interchangeability is only one aspect of the would now serve only as a boat anchor. Soon after, the pump
B73.1 standard. Many other design requirements are needed was put back into service with a new OEM stuffing box, but still
for full compliance: with the non-OEM impeller and casing.
• Flanges must comply with ASME standard B16.5 or he customer’s requirements and original OEM pump
B16.42 for pressure retaining capability, as well as leakage were designed for 900 gallons per minute at a head of 180 feet,
and safety concerns. with an efficiency of 68 percent and drawing 60 horsepower.
• Flange loading, sound, vibration, NPSH, mechanical and With the non-OEM liquid end parts, the pump was actually
performance testing must also meet or exceed HI standards. running at 954 gallons per minute with a head of only 114 feet
• Impeller balance must meet ISO 1940 standards for mini- while drawing 56 horsepower at an efficiency of 49 percent.
mal vibration and shaft deflection. he inefficiency and underperformance of the non-OEM parts
• Shaft diameter tolerance, shaft runout and surface finish generated approximately $7,600 per year in unnecessary energy
must fall within acceptable limits, which ensure proper fit costs and lost production. In addition, the pump was down for
and function of the shaft. four weeks for troubleshooting.
• Mechanical seal chambers must also meet alignment criteria
to ensure proper seal life. Field Example 2—
Paper Customer Puts Stock in OEM Parts
he lab tests demonstrate the potential cost implications A paper manufacturer in Central Canada conducted its own
in a tightly controlled environment. Two customer experiences test, by comparing the performance of OEM and non-OEM
help further confirm that manufacturing
quality at the front end yields long-term
savings.
Field Example 1—
“An Expensive Boat
Anchor”
A customer in the Southeast U.S. pur-
chased replacement parts from a non-
OEM supplier that increased operating
costs and caused a major loss in produc-
tion. he application was a typical con-
densate service, for which the customer
used a large pump, size 4x6-17. After an
extended time in service, the wet-end
components needed replacement due to
routine wear.
Against the recommendations
of the OEM company’s maintenance
team, the customer decided to use non-
OEM replacement parts to save money.
Within an hour of the new wet end’s
installation, the pump began smoking
and had to be shut down. Maintenance
engineers discovered that the problem
was in the stuffing box area, where the
newly installed gland had touched the
pump’s shaft sleeve and damaged it.
After installation of a new sleeve
from the OEM company, the team found circle 141 on card or go to psfreeinfo.com
replacement parts for a stock pump connected to a machine identical-looking pumps and parts based on OEM designs.
chest, the tank that contains thick stock pulp before it is made hough the ASME B73.1 standard is known for its dimen-
into paper. he pump’s performance levels fell drastically after sional requirements, many additional elements are needed to
replacing worn OEM parts with a non-OEM impeller and suc- ensure proper pump performance. he OEM pumps tested
tion sideplate. he facility switched back to OEM parts and were in full compliance and even surpassed the performance of
watched performance return to the published OEM curve their published pump curves. None of the non-OEM products
within an hour. met published curves, and therefore, were not in compliance
Using this example, the company’s mechanical engineer- with the standard.
ing technologist convinced executives and purchasing agents to he increased efficiency of OEM pumps can translate
switch exclusively to OEM pumps and parts. Soon after the into thousands of dollars in energy savings for each pump,
company began to switch, the maintenance and repair costs and have a huge global impact. According to the Hydraulic
dropped dramatically. Labor costs for pump maintenance Institute, pumps use roughly 20 percent of the world’s energy,
decreased, while the overall performance and reliability of the and nearly 50 percent of that energy is wasted on pump and
pumps improved significantly. system inefficiency.
In the past 10 years, the mill has increased paper produc- Along with energy savings, field experience suggests that
tion, cut its replacement parts budget in half, lowered operating OEM pumps and parts are manufactured with greater preci-
costs and decreased the manpower needed for maintenance and sion, which reduces maintenance costs and downtime. Taken
repairs. together, the findings indicate that OEM products, despite a
higher initial purchase price, have a lower total cost of owner-
Case Closed: ship over time.
All ANSI Pumps Are Not Created Equal P&S
Testing under Hydraulic Institute guidelines confirms a per- Patrick Prayne is the Global Product Manager for ANSI
formance difference between “ANSI pumps” from original Process Pumps and ITT Goulds Pumps. For more informa-
equipment manufacturers and from replicators that produce tion, visit www.gouldspumps.com.

Data Loggers and

Flow Meters
Evan Lubofsky, Onset Computer Corporation
Low-cost additions help bottle maker manage compressed

air use and energy costs on a shoestring.
S
aint-Gobain Containers is a building materials com- lose no more than 10 percent of air and power capacity, but
pany that produces high-performance materials and it is not unusual for systems to lose as much as 20 to 30 per-
glass containers. In North America, the company cent. Leaks are most likely to occur at joints and fittings and
employs 22,000 people in more than 350 locations. can often be averted through a simple tightening or replace-
Among its products are wine bottles and other containment of connections.
ers for the food and beverage industry. he bottle-making
process requires the use of compressed air that exists, in some Detecting Equipment Leaks
fashion, on or around every piece of production equipment With Data Loggers
in the plant. In complex or large systems, leakage monitoring and detec-
Leaks, a frequent problem in compressed air systems, tion systems can be costly and time consuming. Knowing
create inefficiencies that add to manufacturing costs. Saint- this, Greg Rhames, an energy engineer at Saint-Gobain
Gobain Containers set out to find an effective way to detect Containers Madera, Calif., plant, set out to find a low-bud-
system leaks that did not require a large capital investment in get way to find and reduce energy waste from three 1,250 hp
monitoring and management equipment. compressors that run 24/7.
he Madera, Calif., facility, which produces millions of Rhames decided to pursue what he describes as moni-
wine and champagne bottles each year, designed a low-cost toring from “an equipment-based perspective.” his runs
system using data loggers and flow meters. he company’s contrary to the more common industry method of placing
investment of less than $5,000 in monitoring equipment is large meters of different types close to the supply side of a
expected to yield tens to hundreds of thousands in annual compressed air system. Rather than monitoring the total
savings. Saint-Gobain Containers estimates that it will reduce system output, he decided to analyze the performance of
10 to 50 cubic feet per min (CFM) of compressed air from individual pieces of equipment, pinpointing problems at the
each piece of equipment placed into the monitoring system. source through measurements taken with data loggers.
“Instead of looking at this from 300,000 feet, we were
DOE Recommends Monitoring looking at it from 1,000 feet,” he says. “You can get solid
Compressed air is a vital utility that is used in a wide range of results by going to the equipment and working your way
industrial processes. However, these systems use a significant back versus monitoring at the supply side. If you monitor
amount of energy, so if they do not operate to full capacity— from the supply end, you have no resolution on issues caus-
if air leaks out—energy costs can mount. As a result, the U.S. ing the air leaks downstream.”
Department of Energy’s Office of Industrial Technologies
recommends that all facilities with compressed air systems Monitoring Systems Make Process
adopt aggressive leak detection and prevention programs
including quarterly system monitoring. More Efficient
In addition to wasting energy, leaks create other prob- Rhames devised a monitoring system that uses an energy
lems. hey can cause drops in system pressure, making tools logger, a portable data logger which includes snap-in mod-
operate less effectively, or leaks may make equipment cycle ules that convert signals from nearly any type of sensor. he
too frequently, resulting in higher maintenance costs and 15-channel data logger can measure compressed air, gauge
shortening equipment life span. pressure, kW/hr output, voltage, current, air velocity, tem-
A compressed air system in good working order should perature and a range of other parameters.

For Saint-Gobain Containers’ purposes, Rhames needed anomalies in the system became apparent.
the data loggers to measure the CFM consumption of every he individual pieces of equipment should lose no more
piece of equipment in the plant that used compressed air. To than 2 to10 CFM. If there is a loss of more than 10 CFM,
accomplish this, Rhames installed compressed air flow meters “you should really analyze the equipment and see where you’re
with remote displays, which he connected to the modules. As losing air. Find it, fix it and bring it back down to tolerance,”
the project continues, additional meters will be installed at each Rhames says.
compressed air receiver throughout the plant to allow depart- “he data so far shows we’re losing 20 to 30 CFM because
mental isolation and monitoring of system air pressure. of leaks,” he adds. “It is amazing how much waste occurs on
Rhames placed two data loggers in one of the centralized one piece of equipment. he data loggers make it immediately
equipment control panels. During installation, he performed a evident.”
10-minute logging test and gathered the results to verify that all
the components were operating correctly. He then redeployed Large Savings Achieved Quickly
the logging devices and left them to record for 24 hours. He Using the energy logging equipment, Saint-Gobain Containers
recorded the air flow measurements every two seconds. identified the worst compressed air leaks and repaired them,
Since the data loggers are portable, he was able to unplug resulting in a 10-CFM decrease in compressed air waste.
the modules, remove the loggers and bring them into his office Rhames calculates that the facility will save $2.24 for every
to download the data into a graphing and analysis software CFM of High Pressure air preserved. As a result, “the savings
package. he software provided a quick read out of the collected could be huge—possibly tens to hundreds of thousands of dol-
data, which could then be exported to Microsoft® Excel, which lars annually,” he says.
he used to manipulate the information. Using both spreadsheet By working on a small budget, Rhames avoided the delay
and graphical formats, he set a baseline measurement, studied common in most corporations when requests are made for large
the effects of various corrective actions, compared historical capital expenditures. He was able to get the project up and run-
records and established benchmarks. Most of the machinery ning in days, rather than the standard months or years. he
cycles were between 2 to 15 seconds, depending on what was data provided by the data loggers allowed for a quick reaction
occurring. By stretching the data over the course of the day, to correct the leaks. As a result, Saint-Gobain Containers was
able to start saving energy, and money,
sooner than it would have with a larger,
more costly system.
Use of the data logger will now be
standard operating procedure at the facil-
ity. Data gathered and compared, during
and after leaks are found and repaired,
will be applied to achieve a standard,
minimum, CFM-consumption bench-
mark for all similar equipment.
he data logger system proved to be
an effective way to provide real-time analy-
sis that was previously only attainable with
a larger, much more expensive system. he
project showed that a large industrial facil-
ity can institute a comprehensive, com-
pressed air monitoring system and a com-
pressed air waste reduction system, with
economical, equipment-level monitoring
and logging devices.
P&S
Evan Lubofsky is director of market-

ing for Onset. He has been writing
about sensor technologies for over 12
years and has had hundreds of articles
published in trade magazines and
newspapers around the world. For
more information, please visit http://
www.onsetcomp.com.
39th Annual Turbomachinery
Symposium and Exhibit Show
October 4 – 7
George R. Brown Convention Center, Houston, Texas
T
he 39th Annual Turbomachinery Symposium Symposium Offerings
and Exhibit Show is hosted by Texas A&M 8 Short courses 12 Lectures
University’s Turbomachinery Laboratory, a 6 Tutorials 17 Discussions
group that researches the reliability and performance 7 Case studies
of rotating machinery that removes energy from or
adds energy to fluids. Last year’s symposium was Exhibit Hours
well-attended by industries from oil and gas to paper Tuesday, October 5
and by executives, managers, engineers, sales and Noon – 2 p.m. (private for paid symposium
technicians/service representatives. This year prom- attendees and exhibit staff only)
ises to be as well-attended and to provide a wealth 3:30 – 7 p.m. (free to the public)
of programs to educate attendees of all levels and
interests. Wednesday, October 6
Noon – 2 p.m. (private for paid symposium
38th Turbomachinery Symposium Statistics attendees and exhibit staff only)
Total attendance—3,713 3:30 – 7 p.m. (free to the public)
Nations represented—31
Exhibitors—238 Thursday, October 7
Total booths—477 9:30 a.m. – noon (free to the public)
In-Stock Parts Ready To Go

FOR ALL BRANDS OF PROGRESSIVE CAVITY PUMPS
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Arlington Heights, Illinois 60005-4623
Phone: 847-640-PUMP (7867) • Fax: 847-640-7855
E-mail: info@libertyprocess.com
Web site: www.libertyprocess.com

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variable torque applications. FRENIC-Eco SEPCO intro-
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to 900 horsepower—and many advanced cartridge seal
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many communication options with a three-year standard halves. he
warranty. sealing faces
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the cartridge halves, and the springs are isolated from the
Quick Motor Change-Outs product. he XRS is designed as an internal, hydraulically-
Meltric Corporation balanced stationary design seal, mounted outside the stuff-
introduces its UL switch ing box while having the ability to handle higher speeds,
rated plugs and recepta- internal pressures and 0.065 inches TIR. he XRS split
cles. hey allow mechan- cartridge seal is fully assembled and pressure tested ensuring
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4-20 mA vibration monitoring

Continuous monitoring of critical
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4-20 mA data is a standard input

for a PLC, DCS or SCADA system
Ideal for real-time monitoring,

alarming and simplified analysis
Makes distributed condition

monitoring cost effective and scalable
Wilcoxon Research Inc

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Germantown, MD 20876
USA
Tel: 301 330 8811
Fax: 301 330 8873
"Email: wilcoxon<iaccepp.com
www.wilcoxon.com
www.meggitt.com

INDEX OF ADVERTISERS
Advertiser Name R.S. # Page Advertiser Name R.S. # Page
ABS USA 101 45 Liberty Process
Advance Diamond Equipment, Inc. 148 65
Technologies, Inc. 143 66 Liestritz Corp. 122 48
Advanced Engineered Load Controls, Inc. 123 43
Pump, Inc. 151 69 LUDECA Inc. 138 30
Advanced Sealing International 132
Alignment Supplies, Inc. 142
60
68
Meltric Corporation 156 69 Need to transfer
MSE of Canda Ltd. 157 71
All Prime Pumps 152 70 NOC 170 68 500,000 cps materials?
Amtech Drives 111 62 NSK 108 5
ATC Diversiied Electronics 112 35 Palmetto Inc. 147 65 No problem!
Aurora Motors 153 71 PPC Mechanical Seals 124 8
Benton Foundry, Inc. 102 11 Precise Castings, Inc. 158 71
Blacoh Fluid Control, Inc. 133 37 Pump Solutions Group 139 47
Blue-White Industries 114 13 Pumping Machinery 169 68 SaniForce™
Boerger, LLC 115 59 Racine Federated Inc. 125 42
Carver Pump Company 116 26 REVAK 109 9 Drum Unloaders
Crane Pumps & Systems 118 27 Salem Republic Rubber Co. 149 56
Dan Bolen & Associates, LLC 154 69 SCHENCK 126 33
Decatur Foundry, Inc. 119 49 SERO Pump Systems 159 70
Depco Pump Co. 113 64 Sims Pump Co. 127 17
EagleBurgmann 103 IBC Sims Pump Co. 127 70
EFFORT FOUNDRY, Inc. 134 53 SJE-Rhombus 140 34
Electro Static Technology 120 38 Skinner Power Systems, LLC 128 12
Emerson Industrial Automation 135 55 Summit Pump, Inc. 161 71
The Fullo Specialties Co. 141 61 Tamer Industries 162 71
Frost & Sullivan 144 69 Trachte, USA 163 71
Garlock Sealing Technologies 104 3 Trask-Decrow 164 70
Graco, Inc. 136 67 Tuf-Lok International 165 71
Graphite Metallizing Corp. 145 56 Valve & Filter Corp. 129 24
Griffco 117 44 Vaughan 110 31
Helwig Carbon Products, Inc. 172 67 VERSA-MATIC 130 7
Hydraulic Institute 146 68 VERTIFLO 166 71
Hydro, Inc. 100 IFC Vesco 167 69
Inpro/Seal 105 BC Westerberg and Associates 168 70
ITT Goulds Pumps 137 41 Wilcoxon Research, Inc. 150 66
ITT Water & Wastewater Wilden 131 21
USA, Inc. 106 23
Wood Group Surface Pumps 171 68
Junty Industries, Ltd. 155 70
Larox Flowsys Inc. 107 39 * Ad index is furnished as a courtesy and no
LEWA Inc. 121 20 responsibility is assumed for incorrect information.
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PUMP USERS MARKETPLACE
circle 151 on card or go to psfreeinfo.com circle 167 on card or go to psfreeinfo.com circle 156 on card or go to psfreeinfo.com
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Employment Comprehensive Industry Coverage:

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United States, Canada & Mexico exclusively by the All Prime
Division of Power & Pumps Inc., Jacksonville Florida. Based
on the design of Gorman-Rupp’s T SERIES® & U SERIES®,
these pumps are available as bare pumps, parts, base
mounted and assembled fiberglass lift station units.
Materials of construction available include Cast-Iron, CD4MCu,
316-SS, 304-SS, ADI, Hastelloy & High-Chrome.
T SERIES® & U SERIES® are trademarks and registered trademarks of The Gorman-Rupp Co. in the
US & other countries. All Prime is not sponsored by nor affiliated with The Gorman-Rupp Company.
“Doc’s Pump
Journal”
734 pages of “Great Pump Information”
Page after page of helpful material like
Friction loss tables for Plastic s/40,
s/80,s/160,s/200, JM*C900 & C905,
HDPE all SDR’s,PEX tubing, Steel,
Stainless, Aluminum, Copper,
Corrugated suction hose,
smooth bore hose.
Fall Special
ONLY $5995*
This is a great buy for any
pump industry professional.
Westerberg & Associates
P.O. Box 567 Liberty Lake, WA 99019
฀ ฀ ฀ ฀ ฀
email: katie@westerbergassociates.com
*Postage Rates as follows:
+$5.00 postage & handling in the USA.
+$10.00 postage & handling for Canada.
+$20.00 postage & handling in South
America, Africa and Europe. ISBN# 978-0-9778312-2-1
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Your Best Value in
ANSI Centrifugal Pumps
Model 2196
Green Bay, WI
www.SUMMITPUMP.com

P&S Stats and Interesting Facts
Plant Capacity Utilization by Industry
90.00%
85.00%
80.00%
75.00%
Chemical
70.00% Mining
Paper
Food, Beverage and Tobacco
Petroleum and Coal Products
65.00%
Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10
Source: Federal Reserve Statistical Release
Month-to-Month Percentage Price Change

in Pumps and Compressors
0.60%
Pump and Pumping Equipment Manufacturing
0.50% Air and Gas Compresor Manufacturing
Pump and Compressor Manufacturing
0.40%
0.30%
0.20%
0.10%
0.00%
-0.10%
-0.20%
-0.30%
Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10
By comparing run time to flow data a
technician determines that a pump needs he Producer Price Index program of the U.S. Department of Labor measures the average change
to be pulled for maintenance, thus avoiding over time in the selling prices received by domestic producers for their output. hese charts detail
excessive energy consumption. Photo
the month-to-month percentage change in selling prices. Source: U.S. Department of Labor
credit: ITT Water & Wastewater USA Inc.
Rig Count (U.S.): Jan. 7 – Sept. 10, 2010 Average Fuel Prices (U.S.)
1800 $3.30
$3.10
1700
$2.90
Number of Rigs Running
1600
$2.70
1500
$2.50
1400 $2.30
$2.10
1300
$1.90
1200 Average Price of Gasoline

$1.70
Average Price of Diesel Fuel
1100 $1.50
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10
Source: Baker-Hughes Inc.

Week Source: Energy Information Administration

Bigger doesn’t necessarily mean better. You may think we’re small, but EagleBurgmann
has been producing products of uncompromising quality, durability and reliability for more than
120 years. We’ve got the engineering expertise and the know-how to meet your toughest sealing
challenge, no matter what the size. Our 5,200 employees worldwide remain strong in their
customer commitment to ensure you can always rely on EagleBurgmann for your seal and service
needs. To find out more, visit www.EagleBurgmannSeals.com or 1-800-303-7735.
THE ORIGINAL
BEARING ISOLATOR
STRONGER THAN EVER
As part of Waukesha Bearings and Dover Corporation, Inpro/Seal is

stronger than ever…with the horsepower to deliver our high-performing solutions
and superior customer service around the globe. Industry-leading bearing protection,
unmatched experience and same-day shipments – only with Inpro/Seal.
So don’t lay awake at night…trust Inpro/Seal to design and deliver your custom-engineered
bearing isolator, right when you need it; our installed base of over 4,000,000 speaks for itself.
Trust Inpro/Seal, the clear leader in bearing isolators.
www.inpro-seal.com

Pumps &amp; Systems Oct2010

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Pumps &amp; Systems Oct2010

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The Magazine for Pump Users Worldwide October 2010

is a member of the following organizations:

2 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

Check on garlock.com later in the year for exciting new technologies!

MICRO-TEC® II ISO-GARD® GUARDIAN®

www.splitisolator.com | www.klozure.com | www.microtec2.com

Cover photo: ITT Industrial Process. Engineers monitor

pumping system with PumpSmart.

SPECIAL SECTION: INSTRUMENTATION, DEPARTMENTS

Control panel products enhance smooth operations. Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

p Mass-Based Propane Odorant Injection System

p Flexible Impeller Pumps in the Food Industry

FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 50

P&S Stats and Interesting Facts . . . . . . . . . . . . . . . . 72

4 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

BALL BEARINGS | ROLLER BEARINGS | LINEAR MOTION PRODUCTS | TECHNICAL SERVICES

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Grouting: Pumps and Telephone Poles,

6 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

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Join the Pumps & Systems and

Stay Connected With

10 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

VALVE AND FILTER (ARVADA, COLO.)

Choose a Skinner steam turbine to do

FSA FALL MEETING

CERTIFIED OPC PROFESSIONAL

Presented by the Packaging Manufacturers Beneﬁ ts Include:

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Variable Frequency Parallel

14 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

PUMPS & SYSTEMS www.pump-zone.com OCTOBER 2010 15

Specialty Materials Help Improve

16 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

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Photo courtesy of Alejandro

18 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

Improvements in performance and energy reduction can be achieved.

Intelligent Pumps and Energy Savings

Intelligent Pumps in the Oil & Gas Industry

PUMPS & SYSTEMS www.pump-zone.com OCTOBER 2010 19

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Current analysis and future outlook

22 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

Introducing the Flygt Station Control Panel.

The new Flygt Station Control Panel System delivers:

To find your local Flygt distributer, visit www.flygtus.com

Ram Ravi, an industry analyst with Frost & Sullivan, has

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New motor starting controller provides one solution.

most instances, this is because the capacitor is expected to be

PUMPS & SYSTEMS www.pump-zone.com OCTOBER 2010 25

Motor power module

Control panel products enhance smooth operations.

Advanced Overload Relays

Sophisticated Controls, Interfaces and Pushbuttons

30 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

Details of a mass-based chemical injection system

32 OCTOBER 2010 www.pump-zone.com PUMPS & SYSTEMS

Mass flow injector designed to be mounted

Propane Odorant Injection Injection

PID Control Loop

Propane Pressure 225 psig

Pumps & Systems Oct2010

Pumps & Systems Oct2010