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MPT

See the Value of


OCTOBER 2015

Mechanical Seal
Energy Audits
How to Save a Dying
Septic System
Modern Pumping Today

Internal Gear Pumps in


Providing Solutions for the Worldwide Pump Industry Industrial Operations

www.modernpumpingtoday.com
CONTENTS
14 28
MPT
Modern Pumping Today
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266

@ModPumpMag

JEFF FLETCHER Publisher


jeff@modernpumpingtoday.com

32 J. CAMPBELL Editor
jay@modernpumpingtoday.com

MICHELLE SEGREST Editorial Consultant

SCOTT GORDON Art Director


scott@modernpumpingtoday.com

LISA AVERY Assistant Art Director


lisa@modernpumpingtoday.com

TONYA BROWNING Associate Publisher


tonya@modernpumpingtoday.com

DAVID MARLOW Account Executive


davidm@modernpumpingtoday.com
A NOTE ON THIS ISSUE:
Very soon many of us will welcome small visitors to our INGRID BERKY Admin Assistant
doorsteps bearing the familiar greeting trick or treat, but
for process pump usersespecially those at refineries
and petrochemical plantsone trick they are on watch for For information about advertising, call
throughout the year is energy loss due to mechanical seal
performance. To that end, were proud to offer a treat in this
issue: The first installment of a four-part series by Tom Grove
205.795.0245
and Heinz Bloch on the value of mechanical seal energy audits.
With new performance regulations soon taking hold across the
industry, the need for energy efficiencyand monitoring that J. Campbell, Editor
efficiencyhas never been greater. Modern Pumping Today
Another treat: This issues Pumping Trends features
a conversation with Aaron Zahn, the president and CEO
of Florida-based NuTerra. His company has a compelling vision to transform the
wastewater and organic waste industry in response to the growing global water crisis. www.highlandspublications.com
In a relatively short time, NuTerra has been able to deliver an impressive 100 percent 312 Lorna Square | Birmingham, Alabama 35216
success rate on a lifecycle basis for its client facilities. T: 866.251.1777 | F: 205.824.9796
Finally, Id like to extend a thank you to all of the people who stopped by the MPT
booths at the recent TPS and WEFTEC shows. It was a pleasure seeing both familiar TIM GARMON RUSSELL HADDOCK
and new faces of our friends and partners in the pump industry. CEO/President COO/Publisher

CHRIS GARMON DONNA CAMPBELL


CFO VP, Editorial
EDITORIAL ADVISORY BOARD:
Terry Bell Product Manager, Baldor Electric Company
No part of this publication may be reproduced or transmitted in any form or by any
Heinz P. Bloch, P.E. Consulting Engineer, Process Machinery Consulting means, electronic or mechanical, including photocopy, recording, or any information
storage-and-retrieval system without permission in writing from the publisher. The
Robert G. Havrin Director of Technology, Centrisys Corporation views expressed by those not on the staff of Modern Pumping Today, or who are
not specifically employed by Highlands Publications, Inc., are purely their own. All
Michael Mancini Consultant and Trainer, Mancini Consulting Services Industry News material has either been submitted by the subject company or pulled
directly from their corporate website, which is assumed to be cleared for
John M. Roach Engineering Manager for New Product Development, Trebor International, release. Comments and submissions are welcome, and can be submitted to
Inc.: A Unit of IDEX jay@modernpumpingtoday.com.

Lisa Riles Business Development Manager, Wastewater Pumps, Xylem Inc.: Flygt
Frank Knowles Smith III Executive Vice President, Blacoh Surge Control
Greg Towsley Director of Regulatory and Technical Affairs, Grundfos
Trey Walters, P.E. President, Applied Flow Technology
OCTOBER 2015
INDUSTRY NEWS 6

TRADE SHOW PROFILE 12 POWER-GEN INTERNATIONAL 2015

CASE STUDIES 14 From Fresh to Frozen... Fast


16 Electrical Signature Analysis

WATER & WASTEWATER SOLUTIONS 20 North Las Vegas Wastewater Treatment


Plant Upgraded
22 Peach Lake Finds a Solution for
a Dying Septic System
Part 1 of 2

MAINTENANCE SOLUTIONS 28 Root Cause Analysis: The Justification Game


Part 2 of 2

30 Reliability Starts from the Ground Up

PUMP SOLUTIONS 32 The Benefits of Internal Gear Pumps


in Industrial Operations
Part 1 of 2

DEWATERING SOLUTIONS 36 Copper Mine Quadruples Pump Wear Life

MOTOR SOLUTIONS 38 Turning Away from Tradition

POWER GENERATION SOLUTIONS 40 Reliable Energy Is Looking Up Down Under

PROCESSING SOLUTIONS 42 Minimizing Leaks and Environmental Hazards


for Fluid Transfer

VALVES & CONTROLS SOLUTIONS 44 Managing Assets, Saving Time

SEALING SOLUTIONS 46 Mechanical Seal Energy Audits


and Their Value
Part 1 of 4

MODERN PUMPING PRODUCTS 52 Featured Product Release: GRIFFCO VALVE


Y-Strainers for Chemical-Feed Systems

PUMPING TRENDS 56 The Growth of Big Green


INDUSTRY NEWS

RELIABILITY CONCEPTS PURCHASES GES WATER BUSINESS TO ACQUIRE


ALIGNMENT SUPPLIES, INC. NETHERLANDS-BASED IMT SOLUTIONS
Michael Olszewski, president of Reliability Concepts GE announced that it has agreed to acquire IMT Solutions,
based in Michigan is pleased to announce that RC has a private Netherlands-based manufacturer of ultrafiltration
recently purchased Alignment Supplies, Inc. based in and microfiltration membranes for water treatment. With
Maumee, Ohio. Alignment Supplies has been a provider of IMTs ultrafiltration membrane technology, GE will be
machinery laser alignment and measurement equipment expanding and complementing its existing ZeeWeed
for almost thirty years. This experience in distribution, advanced ultrafiltration hollow-fiber membrane portfolio.
sales, and customer service, along with Reliability The acquisition of IMT will enhance GEs water treatment
Concept's expertise in the full spectrum of predictive product offerings and further GEs commitment to
technologies and broader product line offering will excellence in water treatment. GE will use its global reach
provide customers with a complete resource for all of their to take IMTs membrane technology, integrate it with its own
predictive, corrective, and preventive maintenance needs. and proliferate it across the world.
With this acquisition, Alignment Supplies, Inc. will now Over the past twenty years, the ZeeWeed family has
be offering the Hamar Laser Instrument Stealth Series grown and evolved to become the vast, industry leading
line of Laser Shaft Alignment systems. Stealth Series ultrafiltration membrane portfolio it is today. GE is
shaft alignment systems offer a full suite of features and committed to continued technology advancements and
capabilities to meet the most demanding of alignment growth in water reuse, wastewater, and tough-to-treat
scenarios. water technologies. The acquisition of IMT Solutions and its
Alignment Supplies, Inc. has officially become the US polyethersulphone membranes will complement our current
Master Distributor for the innovative B.A.T. Belt Alignment offerings and offers terrific opportunities for further growth,
Tool. With national reach, the collective effort of our says Heiner Markhoff, president and CEOwater and
merged resources will broadcast the proven concept of process technologies for GE Power & Water.
the fast, Dual-Cross Firing Laser technology, which slashes Our technologies have great synergy and together will
belt alignment time by 75 percent and eliminates errors be able to reach a broader market, says Nico Marsman,
inherent with single laser and puck target systems. general manager, IMT Solutions.

6 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


INDUSTRY NEWS

ALL-TEST PRO OFFERS NEW RENEWABLES WILL BOOST JAPANS INSTALLED


MOTOR DIAGNOSTICS WORKSHOP CAPACITY TO 390 GIGAWATTS BY 2025, SAYS
Online registration is now open for the electrical GLOBALDATA
machinery diagnostics workshop sponsored by All-Test Japans cumulative installed capacity will rise from
Pro, LLC. The workshop will take place November 16 317.5 Gigawatts (GW) in 2014 to an estimated 389.8
through 20 in Chicago, Illinois. Interested parties can GW by 2025, representing a moderate Compound
register at the website chicago2015.alltestpro.com. Annual Growth Rate (CAGR) of 1.9 percent, according to
Participants will learn how to diagnose all plant- research and consulting firm GlobalData.
related electric motor system issues, improve motor The companys latest report states that while thermal
performance and maintenance routines, and experience sources will contribute the majority of installed capacity,
with the latest testing equipment. The workshop focuses with an expected overall share of 54.7 percent, other
on practice with the theories, concepts, and analysis skills renewable sources (excluding hydropower) will more
needed to identify motor system faults and learn how than double by the end of the forecast period.
to correct them. The workshop offers participants the Chiradeep Chatterjee, GlobalDatas Senior Analyst
chance to earn up to 3.8 CEUs. covering Power, says, Despite the new Japanese
The course will be led by Bill Kruger, world- governments rethink on the decision to phase out
renowned for his Theory and Application of Motor nuclear power after the Fukushima disaster, there is
Diagnostics courses. Kruger has guided many Fortune still a focus on promoting renewable power, not only to
500 companies when implementing their own in-plant reduce reliance on the nuclear sector but also to tackle
PdM Programs. The course will explain electric motor the huge cost of importing natural gas and oil.
theory and operation in a straightforward, easy-to- A new feed-in tariff system introduced in July 2012
understand manner. Attendees can then truly understand will drive renewable installed capacity growth, as
how to properly test all aspects of energized and de- utility companies must purchase power from renewable
energized motors. Additionally, they will be armed with energy sources, including solar, wind, small hydro,
the expertise needed to implement a reliable predictive geothermal, and biomass, at pre-set premiums for up to
maintenance program in their facility. twenty years.

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8 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


KSB ANNOUNCES NEW FOUNDRY worked as an intern for Cashco, after growing up in nearby
AT GIW INDUSTRIES INC. Brookville, Kansas.
GIW Industries Inc., the leader in the design, manufacture, Darrin has proven to be able to adapt to change quickly
and application of heavy-duty centrifugal slurry pumps, and incorporate process improvements to both improve
announces its foundry grand opening. The foundry is part the quality of our products and provide his group with the
of a large expansion that includes a new distribution center, proper tools to do the tasks easier and more efficiently,
additional heat-treat and casting cleaning facilities, CNC says Clint Rogers, president of Cashco, Inc. With this
machines, and an assembly center. new position, all of manufacturing will now operate under
This expansion is one of the largest in the companys Darrins direction, while Quality Control will continue to
history and is the biggest project ever undertaken by GIW, report directly to me in order to provide the checks and
a fully owned subsidiary of KSB. The foundry construction balances ISO requires.
and related expansion projects are just the first phase in a Since returning to the area a decade ago, Vanderbilt has
path of continuous investment for the company. Phase one since built a home for his family near his own boyhood
included the new foundry, which features 72-foot ceilings home in Brookville, where he and his wife, along with two
and is about the size of a football field. These new facilities sons, manage to keep busy with school activities and sports.
will more than triple GIWs current manufacturing capability.
Long term, this expansion will give GIW and KSB a DANFOSS
significant advantage in the mining market. The investment PARTICIPATES
will allow for better handling of the sizeable castings IN SECOND
needed by GIWs customers; some produced by GIW WHITE HOUSE
can weigh well over 40,000 pounds and are bigger than a INDUSTRY LEADER
cement truck. This expansion will allow GIW to keep up with ROUNDTABLE
current market demand and to be able to quickly adapt to Danfoss participated
support future growth. in an industry leader
roundtable hosted by
SMITH STEPS DOWN FROM VAL-MATIC the White House to
Val-Matic announces the retirement of Vice President of reduce greenhouse
Sales and Marketing Carl W. Smith. After a thirty-two-year gas emissions from
career with Val-Matic Valve and Manufacturing Corp., Carl hydrofluorocarbons
W. Smith will retire form the company on March 31, 2016. (HFCs).
Over his tenure, Mr. Smith opened new markets for Danfoss North
Val-Matic across the globe in international sales and later America President John Galyen provided an update on
became National Sales Manager. As Vice President of the companys ongoing commitment to a Codes and
Sales and Marketing he helped launch several new valve Standards Task Force, which is helping address major
products and built a successful representative network in barriers in broad adoption of mildly flammable, low-GWP
the water and wastewater industry. He also represented refrigerants. Galyen noted what the Task Force has already
Val-Matic for many years as a member and board member accomplished and what it hopes to accomplish over the
of several industry organizations including Water and Sewer next twelve months.
Distributors of America (WASDA), Water and Wastewater Additionally, Danfoss announced a multi-million dollar
Equipment Manufacturers Association (WWEMA) and the investment in a new Application and Development Testing
American Water Works Association (AWWA). Center to increase the amount of available laboratory
President and CEO, Ted Makowan says, Throughout capacity to help air conditioning and refrigeration
his career, Carl Smith has demonstrated an enduring equipment manufacturers prepare to meet both energy
commitment to our Company and its mission to provide efficiency and refrigerant regulations, as part of the
quality products and service to our customers. His service companys commitment to the adoption of low-GWP
has been important to the success of Val-Matic. refrigerants.
Other participants included leading executives
CASHCO NAMES NEW VICE PRESIDENT from refrigeration and air conditioning equipment and
OF OPERATIONS component manufacturers, refrigerant producers and
As part of its plan for growth and future succession, Cashco, industry associations in a roundtable briefing of senior
Inc. recently promoted Darrin Vanderbilt to the position White House officials, including Department of Energy
of Vice President of Operations. Although Vanderbilt most Secretary Ernest Moniz and Environmental Protection
recently served as Engineering Services Manager, he has Agency Administrator Gina McCarthy. The event was
assumed a number of responsibilities since joining Cashco moderated by Assistant to the President and Senior Advisor
fulltime in 2005 as engineering lab manager. Ironically, his Brian Deese, who oversees climate, conservation, and
history with the company goes back even further to when he energy policy.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 9


INDUSTRY NEWS

XYLEMS GOULDS WATER TECHNOLOGY ENDRESS+HAUSER INTRODUCES CA80AM


FACTORY SCHOOL RELEASES Q4 AMMONIA ANALYZER
TRAINING SCHEDULE Endress+Hauser introduces the Liquiline System CA8AM
Goulds Water Technology announces its 2015 fourth quarter ammonium analyzer for monitoring critical control points
Factory School schedule for in-person and online training. in water and resource reclamation facilities. The CA80AM
Live in-person training sessions are available at the analyzer and its sample preparation systems provide an
educational facility in Seneca Falls, New York. Classes automated approach to process control and regulatory
provide hands-on training in water systems, variable compliance.
frequency drives, wastewater and commercial applications. To keep discharges at permitted levels and to avoid
This training is designed to provide attendees with penalties, managers of water treatment and other
extensive, firsthand experience in the Campbell Education resource recovery facilities need accurate and reliable
Center laboratory. measurements in their nutrient monitoring systems. The
The Commercial/Industrial Pump Product and Application Liquiline CA80AM colorimetric analyzer provides these
seminar will take place October 26 through 29, and the measurements by using the standard indophenol blue
Advanced Pumps and Drives Operations course will occur method, which is compliant to ISO 7150-1, DIN 38406-
November 9 through 12. Note that the latter course requires 5 and GB 7481-87 standards. The CA80AM analyzer
participants to possess a minimum five years experience also provides data storage and retrieval using on-
with pumps and drives. board logbooks to allow continuous documentation for
Online training is also available. These seminars provide reporting to regulatory agencies.
users with up-to-date product information, troubleshooting Multiple communications methodsincluding
support and industry knowledge. Training can be accessed EtherNet/IP, Modbus, Ethernet and an integrated web
from anywhere with an Internet connection, and courses serverallow the analyzer to be integrated into any
are offered once per quarter to ensure availability for each control system. The integrated web server allows a user
topic. to remotely analyze process disturbances and decide
For a complete list of online courses, or to register for in- on required measures quickly, all through any web
person training, visit goulds.com/factory-school. browser.

10 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


T R A D E S H OW P R O F I L E

POWER-GEN
INTERNATIONAL 2015
The industry comes together to charge into the future

P
ower-Gen THE PLACE TO BE
International is With a record-setting
the world's largest POWER-GEN 2015 AT A GLANCE expected attendance of
power generation event Where: Las Vegas Convention Center, more than 22,000 power
focusing on the industry's Las Vegas, Nevada professionals from more
latest innovations, than ninety countries and
When: December 810, 2015
technical trends, and a show floor comprised of
business strategies. Website: www.power-gen.com more than 1,400 exhibiting
Presenting a broad companies, there's no other
range of qualified power place to be for education,
professionals with the power to purchase, Power-Gen networking, and new business development that the 2015
International is the place not only to assess the direction meeting of Power-Gen International. Attendees will hear
of the industrys future but also to get business done from more than 200 of the industrys top speakers and
today! Throughout its history, Power-Gen International have access to more than fifty educational conference
has provided a global meeting space for the innovations, sessions.
ideas, and solutions that shape the industry now and in Events at Power-Gen International 2015 will also include
the future. multiple Competitive Power College courses, networking

12 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


events, technical tours, as well as
online conference proceedings.
Power-Gens wide array of
offerings draws professionals from
myriad specialty fields, including
electric utilities, fuel suppliers,
independent power producers,
architects and engineers, original
equipment manufacturers, power
industry consultants, power plant
designers, equipment inspection
and repair specialists, construction
contractors, maintenance service
providers, and many, many more.

WOMEN IN POWER
LUNCHEON
A luncheon hosted by the Women
in Power committee that features
the 2015 Woman of the Year and
finalists. The Power-Gen Women
in Power committee selects a
Woman of the Year each year to
serve as a role model to inspire
young women to pursue careers in
energy. Luncheon attendees will
have the opportunity to network
with women in the power industry
and learn about the career paths
of some of the most successful
women in the industry. The winner
of the Power-Gen 2015 Woman of
the Year Award will be announced
during the Awards Gala on
Monday, December 7 at 6:30 pm.

AN INDUSTRY UNITED:
POWER GENERATION WEEK
Covering every aspect of the
power generation industry, Power-
Gen International, Nuclear Power
International, Renewable Energy
World Conference and Expo
North America, Coal-Gen, and
GenForum converge in 2015 to
form Power Generation Week.
Benefit from five days packed
with pre-conference workshops,
technical tours, more than seventy
conference sessions, panel
discussions, three exhibition days
,and multiple networking events.
This unique collaboration provides
attendees with the chance to
access nearly every facet of the
marketall under one roof.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 13


CASE STUDIES

From Fresh to
Frozen Fast
Hidrostals F pump passes peas for Pinguin
By Lucy Ogden, Hidrostal Ltd.

P
inguin Foods is a leading, international processor of MOVING FROM FIELD TO FORK
harvest fresh vegetables priding itself on delivering At Pinguins site in Boston Lincolnshire, the company
fresh to frozen produce that are tasty, healthy, and utilizes a field to fork approach that encompasses the
of the highest quality. Pinguin is an independent division washing, de-stoning, separation, blanching, and freezing
of the major European Food Group, Greenyard Foods, of raw vegetables. Hidrostals F type pumps, ideally
which processes over 440,000 tons of product annually suited for food processing, are employed to transfer the
over eleven production field harvested peas
sites. However, moving directly with the use
food from fresh to frozen Hidrostals pumps have proved of recycled mains
requires solids handling water as the motive
that is reliable, efficient, extremely reliable with minimal media.
and fast. Hidrostal Ltd., Pea season
the UK distributor for maintenance required. They typically runs from
the major Swiss pump
manufacturer, has need to be reliable otherwise June until August
where the produce
provided an international
processor of fresh to
production stops. is being transferred
at a rate of up to
frozen vegetables with 11 tons per hour
the perfect pump for
Barry Cooper, per line during this
passing peas. Pinguin engineering stores manager period. The process

Pinguins food processing involves washing, de-stoning, separation, blanching, and Pea processing at Pinguin
freezing of raw vegetables.

14 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


involves peas picked fresh from the
fields which are then put through
an ongoing process to remove, silt,
stones, soil, and loose pods and
skins before entering the blanching
and freezing process.

KEEP IT MOVING, KEEP IT CLEAN


This solution allows the vegetable
produce to be pumped and piped
to its destination in favor of an
open belt conveyor system, which
under these open environment
circumstances would be susceptible
to contamination, debris, and product
loss. In addition it has the added
benefit of allowing Pinguin to retain
the main road through its premises
and not affect the traffic and transport
of product across its yard.
The Hidrostal pumped option was
selected due to its proven ability
to handle and transfer delicate
product with zero damage due to its
low velocity and low shear design
hydraulics while retaining optimum
efficiency and maximum energy
saving.

MORE THAN JUST PEAS


After pea season the same pumps
are then used to transfer cauliflower
and broccoli florets with the same
level of output and accuracy. These
pumps are critical to the successful
continuation of the entire production
cycle.
Both the client and the manufacturer
are delighted that their pumps
have functioned so well for Pinguin
and ensured the safe and speedy
processing of peas from production to
our plates.

For more than thirty years, Hidrostal


Ltd. has been at the forefront of
designing and delivering innovative
pump solutions that deliver real
benefits to business. For more
information, contact Lucy Ogden
at Hidrostal Ltd. via email at lucy.
ogden@hidrostal.co.uk or visit
www.hidrostal.co.uk.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 15


CASE STUDIES

Electrical Signature
Analysis
As performed on vertical turbine pump
motors in municipal application
By William Kruger, All-Test Pro, LLC,
and Alex Panattoni, City of Henderson Dept. of Utility Services Electrical Section

O
riginally put into operation in 1999, Pump
Station P-19A supplies drinking water to
the City of Henderson, which is the second
largest city in Nevada. Serving a population well
over 270,000 people, P-19A is one of the most
critical potable pump stations operated by the city.
The pump station originally utilized three pumps
when its operation began, but in 2006, two more
vertical pumps were installed in the pump station
(Pumps 1 and 5).

CAUSE FOR CONCERN


In 2006, the pump size was increased, but the motor
horsepower remained the same. The motors have a
service factor of 1.15 and often exceed 105 percent
of nameplate full-load amperage (FLA). Although
this is within the capabilities of the motors, they
operate at near maximum output.
In November 2014, vibration analysis was
performed as part of the plants Predictive
Maintenance Program. While those test results
suggested the possibility of early bearing
degradation in Motor 5, the rotor bar passing
frequency was within range
The vibration summary concluded that systems
were operating within acceptable limits and that
no maintenance actions needed to be taken at
that time.
Two months later, in January 2015, Motor
5 exhibited signs of overheating; reaching
temperatures that exceeded 320 degrees Fahrenheit
(160 degrees Celsius). Although the other pumps
did not show any symptoms similar to that of Motor
5, the maintenance team took action and initiated an
The All-Test Pro 31 troubleshoots start-up and quality control
in-house investigation of all five pump motors using
of AC/DC electrical motors, generators, or transformers. their predictive maintenance equipment.

16 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


Vertical Turbine Pump Info

GPM 7400

# of Stages 5

Size 20x20 GHC-5

Suction Size 20-inches

RPM 1200
All-Test Pro 31 for initial tests Rotor Tested at 5-degree Intervals All-Test IV Pro for initial test

COMPREHENSIVE TESTING at different individual rotor positions. During the test, the
TO PREVENT MOTOR FAILURE rotor is positioned at exact intervals, as seen in the picture
The in-house maintenance team utilized their hand-held to the right.
All-Test Pro 31 and All-Test IV Pro. These high-tech The City of Henderson performed an extensive rotor
instruments, which are used for de-energized testing, are testtaking readings every 5 degrees of shaft rotation
designed to detect potential winding faults and provide using the All-Test IV Proonly then did indications show
indications of rotor problems. an issue with both Pump 1 and Pump 5.
First, they used both the All-Test Pro 31 and All-Test While the tests indicated the possibility of a rotor
IV Pro to perform winding tests and confirm that the problem, the results didnt show the problem definitively.
windings were in good condition. Technicians knew the current was modulating and put a
Then they used this equipment to conduct insulation time trace on it, but needed to do more extensive testing.
to ground tests to prove the insulation was not grounded. At the maintenance teams request, a third-party
Next, they performed a rotor inductance test, which specialist went to the pump station to perform vibration
measures the inductance of all three phases of a motor analysis. When the vibration analysis did not indicate

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 17


CASE STUDIES

ESA Data from ATPOL II


Pump 1 Pump 5

Pump Speed: 1183 RPM 1175 RPM

Demand Power: 738.98 HP 726.96 HP

Load: 100.7% 99.1%

Output Load: 507.95 KW 495 KW

Severity Rating: 6 out of 7 7 out of 7 ALL-TEST PRO On-Line II Rotor bar breaks all occurred in the middle three rows
of laminations.

any electrical faults (pole pass very small change in motor load.
frequency sidebanding) in the The rotor was running considerably
associated vibration FFT signatures below name plate; after running
the decision was made to bring in about thirty minutes, the rotor
technical support from ALL-TEST speed was 1171 rpm. This was
Pro to perform additional testing. also confirmed by an independent
An All-Test Pro technician tach system provided by the third-
went to the pump station party who performed the vibration
in January to perform analysis. While the results of the
an Electrical Signature vibration analysis did not show any
Analysis. Electrical indications of rotor problems, the
Signature Analysis is a speed and the ESA data taken with
diagnostic technology the ATPOL II indicated that several
that uses the motors rotor bars were broken.
supply voltage and Rotor bars are solid continuous
operating current to bars that run through the rotors
identify existing and steel laminations, which are
developing faults in the spaced to allow air flow to cool
entire motor system. To the rotor. Once the maintenance
perform the Electrical team received the report from the
Signature Analysis, he Electrical Signature Analysis, which
brought with him the All- showed severe indications of rotor
Test Pro On-Line II. The bar issues (Pump 1 had a severity
ATPOL II is an energized rating of 6 out of 7 and Pump 5 had
motor testing tool which, a severity rating of 7 out of 7), they
when in ESA mode, pulled Motor 5 and found that 30
evaluates the condition of percent of the rotor bars were in fact
incoming power, the control broken.
circuit, the motor itself,
and the driven load. Kruger REBUILDING THE ROTOR WITH
requested that MVA data be DIFFERENT METALLURGY
taken simultaneously while the After discussing the issues with
Electrical Signature Analysis was the motor manufacturer and a third
being performed. party motor repair company, the
maintenance team chose to have
ELECTRICAL SIGNATURE both Motor 1 and Motor 5 rebuilt
ANALYSIS REVEALS BROKEN with copper rotor bars. Pumps 2,
ROTOR BARS 3, and 4 had copper rotor bars and
During the energized motor tests, did not have the same issues as
data was taken at different times; Pumps 1 and 5. The original rotor
first shortly after start-up, then bars in Pump 1 and Pump 5 had
again after the pump had been been made of aluminum. This was
running. Of significance was the believed to be the root cause of the
large change in rotor speed with a problem.

18 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


Because the motors at P-19A
normally run 100 percent to 110
percent of load, there is a high Alex Panattoni is the control systems technician leading the Electrical Section of
current flowing through the rotor. the City of Henderson's Department of Utility Services. William Kruger is technical
This produces heat that causes and training manager for All-Test Pro, LLC, which for three decades has provided a
wide range of industries with the most advanced predictive maintenance testing and
expansion and contraction. Over a
troubleshooting tools for AC and DC motors, coils, windings, transformers, generators,
period of time, the aluminum rotor and more. For more information, visit www.alltestpro.com.
bar breaks under tension, then
the arcing occurs at the spot of the
break. The currents are then forced
through the remaining bars, putting
more loads on them and causing
more broken bars, weakening the
strength of the entire rotor.
This issue would have eventually
shorted out the stator winding by
the increased operating temperature
or arcing metal from the rotor, and
would have caused the need for a
rewind or possible scrapping of the
entire motor, in addition to the repair
or replacement of the rotor. Having
the motors rebuilt with copper rotor
bars enabled the maintenance team
to avoid catastrophic failure of their
vertical turbine pump motors.
Motor 5 was rebuilt and installed
in May of 2015. Another round of
MVA and ESA testing was performed
immediately after installation to
ensure proper operation. The
electrical signatures taken in May
reported excellent rotor condition.
It also showed that rotor speed
increased, while overall current
dropped.
The newly rebuilt Motor 1 is
being installed in September 2015
and a third round of testing will be
scheduled before the end of the year.

LESSONS LEARNED
Having a Predictive Maintenance
and proper diagnostic tools program
is important. It is essential to equip
your maintenance team with state-
of-the-art equipment to increase
the effectiveness of your Preventive
Maintenance program. Tools like
the ATPOL II exist so you can
perform higher level testing, such as
Electrical Signature Analysis, which
is proving to be a very effective
technology for detecting faults
before they lead to catastrophic
failure.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 19


WATER & WASTEWATER SOLUTIONS

North Las Vegas


Wastewater Treatment
Plant Upgraded
GEs LEAPmbr technology provides
reduced energy and maintenance costs
By GE Power & Water

L
ocated within the greater Las Vegas metropolitan area, wastewater. Historically, the city of North Las Vegas relied on
North Las Vegas, Nevada, also sits in the majestic the city of Las Vegas to treat its wastewater, but in 2012, North
Mojave Desert, which means that how the city treats Las Vegas built its own plant using GE ZeeWeed membranes
and manages its water supply is of premium concern. The and MBR technology. The city then upgraded the facility with
upgraded water reclamation MBR facility, one of the largest LEAPmbr technology three years later to provide the same
in the United States, treats the municipal wastewater for more treatment capacity and highly treated water quality while
than 300,000 of North Las Vegass residents and processes up reducing energy and maintenance costs and increasing
to 25 million gallons of wastewater per day. productivity.

MAKING THE LEAP SAVING GREEN BY GOING GREEN


Earlier this year, GE provided the city with its high- Environmental and economic concerns led us to upgrade our
performance LEAPmbr membrane bioreactor (MBR) wastewater treatment plant with GEs LEAPmbr technology,
technology for an upgrade to the citys wastewater treatment which provided us with a more energy-efficient and cost-
plant. By using GEs LEAPmbr system, the city will reduce effective way to operate our facility, says Dave Commons,
its energy and maintenance costs including an estimated 29 water reclamation facility administrator for North Las Vegas.
percent reduction in membrane scour energy costs. The retrofit will give us a 29 percent energy reduction on
With GEs LEAPmbr and ZeeWeed 500 membranes, the membrane aeration and will save more than $100,000 per year
newly upgraded facility can more efficiently treat the citys in energy and maintenance costs.

Increased Surface Area


ZeeWeed Module
Simplified Aeration Piping
No Air Cycling Valves

Optimized
Tank Design Increased
ZeeWeed
Productivity Lower Energy LEAPmbr
Aeration Technology
Reduced Blower Size

20 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


LEAPmbr Technology energy-efficient method of aeration. bacteria and viruses from water or
Additionally, LEAPmbr improves water wastewater. GEs ZeeWeed ultrafiltration
enables the City of quality, increases water treatment membranes offer an unmatched
North Las Vegas to capacity and offers the lowest life combination of performance, energy
cycle costs available from any MBR efficiency, durability, ease of operation
operate the plant technology, says Yuvbir Singh, general and reliability. More than 1,000 plants
more efficiently, manager, engineered systems worldwide use this technology to
water and process technologies for produce superior quality water.
while increasing GE Power & Water.
productivity.
RETROFIT KITS PROTECT INITIAL
INVESTMENTS GE Power & Water provides customers
GEs LEAPmbr aeration technology Specifically for the project, GE with a broad array of power generation,
provides optimal energy usage by retrofitted the existing membrane energy delivery and water process
reducing membrane air scour costs cassettes by supplying LEAPmbr retrofit technologies to solve their challenges
along with essentially eliminating kits. This allowed the plant to take locally. Power & Water works in all
areas of the energy industry including
cyclic valve maintenance. In addition, advantage of the lower air and energy
renewable resources such as wind
the plants advanced SCADA system requirements while continuing to get and solar; biogas and alternative
allows the city of North Las Vegas to the full lifecycle operation out of the fuels; and coal, oil, natural gas and
have minimal staffing at the plant and originally installed membranes. nuclear energy. The business also
the wastewater treatment facility can be LEAPmbr builds on tweny-five years develops advanced technologies to
help solve the worlds most complex
controlled remotely. of experience to deliver the most challenges related to water availability
LEAPmbr is our latest innovation advanced MBR solution to date. At the and quality. Follow GE Power & Water
in membrane technology and core of LEAPmbr is GEs ZeeWeed 500 and GEs water business on Twitter
upgrading to it gives the city of North membrane, an advanced ultrafiltration @GE_PowerWater and @GE_Water.
Las Vegas a more cost-effective and technology that separates solids,

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 21


WATER & WASTEWATER SOLUTIONS

Peach Lake Finds a


Solution for a Dying
Septic System
Part 1 of 2
By Joseph Harmes

I
t only took a few generations and Around the dawn of World War I, Memorial Day to Labor Day period
several hundred dying septic vacation homes started to occupy the was aggravated by the arrival of full-
systems to age an idyllic vacation pristine shoreline of what pioneer time residents who were upgrading
spot like Peach Lake. Dutch farmers first named Peach once simple seasonal properties
Pond; later, Peach Lake. Inevitably, in lakeside communities like North
A CLOSER LOOK water quality deteriorated as the Salem and Southeast into pleasant
AT PEACH LAKE reservoir's spring intake was abodes with additional bathrooms,
Fed for millennia by fresh flowing supplemented by wastewater flushed washing machines and dishwashers.
springswith no creeks or rivers from these summer bungalows "Most of the people are here
for drainagea basin eventually and cabins, equipped with septic year-round but we do have the 20
matured into a 1.5-mile long and half- systems that only have a normal life to 30 percent that are there in the
mile wide aquatic paradise originally expectancy of ten to forty years. summer months," says Warren Lucas,
named Pechquenakonck by the By the 1990s, the problem of supervisor of the Town of North
Kitawonks, a Mohegan group. wastewatermostly during the peak Salem. "These communities grew

Peach Lake is a quiet, private lake located in Putnam and Westchester counties in New York, about a ninety minute commute from Grand Central Terminal. Single-family homes
surround the lake, consisting of both seasonal and full-time residents.

22 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


up around the lake back in the 20s fields at many properties were sized soil conditions and shallow bedrock.
and 30s and at this point we have in to the original summer cottages and Executing the 2010 plan would be
some cases the second or third home not adequate for the additions or no easy task as it required the input,
rebuilt on these properties." newer homes; current regulations cooperation and approval of 1,000
Young families purchasing their require 5 feet between the septic tank citizens and four lake association
first houses, retirees and even work and groundwater. Significant numbers boards; the formation of sewer districts
day commuters to Grand Central failed percolation tests due to poor which included inter-municipal
Terminal about ninety minutes away
further pushed Peach Lake's fragile
ecology to the brink.

THE PUSH TO IMPROVE


WATER QUALITY
A campaign to improve the water
quality of Peach Lake began over
forty years ago and gained traction
when the Citizens Statewide Lake
Assessment Program (CSLAP),
a volunteer lake monitoring and
education program, began sampling
Peach Lake's water in 1999.
Over the next decade, the project
found the "recreational suitability
of the lake to be unfavorable" and
"'slightly' to 'substantially' impacted
for most recreational uses" like
swimming and boating as failing
septic systems had a negative impact
on water quality.
CSLAP's reports noted "High
coliform counts (resulting in
occasional beach closures), along
with algal blooms and excessive
aquatic weed growth strangled
areas near the shores. The aquatic
growth may also depress dissolved
oxygen in the lake to the point where
the fishery may also be affected"
and storm events frequently led to
fish kills.
A wastewater study showing
eutrophication (an excess of nutrients
such as nitrates and phosphates) led
to Peach Lake's inclusion on New
York State's List of Impaired Waters.
The situation was fully addressed in
2010 when a new sewage treatment
system was designed to replace the
area's 470 deteriorated septic tanks.

LOOKING FOR CAUSES


. . . AND SOLUTIONS
Engineers blamed the septic
failure on multiple origins. Scores
were situated too close to streams,
drainage ditches or the lake. Leach

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 23


WATER & WASTEWATER SOLUTIONS

Watershed to which Peach Lake


belongs.
Financing was equally complicated.
The $30 million project would be
footed by East of Hudson Funds from
Westchester and Putnam counties,
the NYDEP and federal American
Recovery and Reinvestment Act funds
created during the Great Recession
to stimulate municipal infrastructure
projects.
Residents agreed to levy
themselves $1,200 per year per
household for thirty years to form
the Peach Lake Sewer District.
Operation and maintenance costs for
a low-pressure sewer system (LPS)
incorporating grinder pump stations
were calculated at $40,000 annually.
Pressure sewer systems require only shallow trenches. The treatment plant's O&M added
another $275,000, planners said.
agreements between North Salem agencies including the New York Public outreach began at
and Southeast and their respective City Department of Environmental grassroots gatherings like pancake
counties, Westchester and Putnam, Protection (NYDEP) about 50 miles breakfasts where surveys and
which border Peach Lake; and, south which receives 10 percent of questionnaires were distributed to
a half-dozen state and municipal its drinking water from the Croton residents. As with all municipal sewer

24 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


projects, planners needed to win close coordination and
cooperation from homeowners for property visits, maps,
surveys, deed preparation, easement negotiations/
acquisitions and construction observation on private
property.
Seemingly the biggest concern of residents was that
an adequate sewer system might increase the density of
homes or create condo development. It was agreed that
only existing land surveys would be acknowledged with
the caveat each home could be expanded or replaced
with one new structure.
North Salem and Southeast were divided into two
separate State Environmental Quality Reviews for
efficiency and less complication given the size and
impact of the project.
"I have 74 percent of the homes (360)," says North
Salem's Lucas. "Southeast has 26 percent (120)."
The sewage treatment facility is owned in a 74-26
partnership between the two towns.
In order to pamper local sentiment, the head works
and micro-filtration facilities of the Peach Lake Sewer
Treatment Plant (a small, mostly-automated facility
designed to process 170,000 gallons per day) are
housed in red and white buildings camouflaged to
mimic the ubiquitous horse barns synonymous with the Alarm panels are located on the outside of the home to alert the homeowner or service
pastoral landscape. person about a problem.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 25


WATER & WASTEWATER SOLUTIONS

A LOOK AHEAD
Two sewer proposals were considered:
A gravity/low-pressure hybrid with
eight pump stations and a low-pressure
sewer system employing grinder
pumps at each home (or, where
housing is dense, a duplex pump
serving multiple dwellings). Next
month, well conclude this case study
by exploring Peach Lakes decision
and the benefits they discovered.

With corporate headquarters in


New York and regional offices
and distribution throughout the
industrialized world, Environment
One Corporation (E/One) is a
manufacturer and provider of
products and services for the disposal
of residential sanitary waste and
utility systems for the protection and
performance optimization of electric
utility assets. For more information,
visit www.eone.com.
E/One grinder pump stations (shown) can be buried on small lots. Only a few inches of green lid are visible to the
homeowner.

26 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


MAINTENANCE SOLUTIONS

Root Cause Analysis:


The Justification
Game
See Part 1 on
Part 2 of 2 modernpumpingtoday.com

By Robert J. Latino, Reliability Center, Inc.

I
n last months introductory article, a true RCA is viewed as luxury not a our response time and accept that
we discussed some of the barriers necessity. Think about the objections the fires are a cost of doing business.
to selling not only the concept of we hear when we offer the idea of How much money is being accepted
Root Cause Analysis (RCA) but also gathering RCA teams. What follows as the cost of doing business? Hint,
the recommendations generated is a list of common objections to RCA how much is your maintenance
as a result of these analyses. We accompanied by rational justifications budget worth?
also laid the framework for making that any manager can employ.
better predictions by generating OBJECTION: WE DO NOT HAVE
and accessing better datanamely OBJECTION: WE DO NOT HAVE THE MONEY TO BACK A RCA
predicting our Mean Time between TIME TO DO RCA EFFORT
Failure (MTBF) and Mean Time to We do not have time to do RCA Maintenance budgets are primarily
Restore (MTTR) earlier and, therefore, because we are so busy firefighting developed to respond to failures that
implementing a fix faster. that we do not have time to analyze are expected to occur. Man-hours
Given this background, lets why the fires are occurring in the and materials are assigned and
explore how we can now justify first place or how to prevent their budgeted. Therefore, if it is in the
conducting a RCA and implementing recurrence. If this paradigm is budget, it is not a failure because we
the recommendations as a result of permitted to exist, then the conclusion have compensated for it. It is a cost
the analysis. By and far, conducting is that the best we can do is sharpen of doing business. This does not have

28 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


to be the case. Just as with safety, we THE VALUE OF THE INTANGIBLES the returns from the tangibles alone
should have a zero tolerance policy In the world of RCA, we must learn are self-justifying, imagine if we were
with failure. We should question the value of the intangibles and their able to focus the creativity of the
why the things in the budget are effect on the tangible world. This all workforce towards the betterment
acceptable and look at how to revolves around the dollar and all of the organization. Remember, we
eliminate failure. aspects of the organizational system cannot do what we cannot imagine!
Secondly, when failures occur that are interdependent to optimize profits.
are compensated for in the budget, Here is a list of such intangibles:
they oftentimes affect production
hours in terms of downtime. The cost Lost profit opportunitiesthe
Robert J. Latino is CEO of Reliability
of a failure should be measured by the cost of a lost downtime hour on
Center, Inc. Mr. Latino is a practitioner
man-hour dollars + material dollars the spot market at that time. of root cause analysis in the field with
+ the lost production dollars. This is his clientele as well as an educator.
a true measure of how much is lost, World class analytical skills Mr. Latino is an author of RCI's Root
and subsequently, how much is to be investing in our peoples skills Cause Analysis Methods training and
co-author of Basic Failure Analysis
gained. Just because a $50 bearing makes them better decision Methods workshop. Mr. Latino
fails, does not mean that it did not makers and problem solvers. This has been published in numerous
cause $50,000 in lost production. allows them to do things once trade magazines on the topic of root
and do them right. How much cause analysis as well as a frequent
OBJECTION: WE DO NOT HAVE does it cost to replicate the same speaker on the topic at trade shows
and conferences. His most recent
THE RESOURCES TO CONDUCT activity over and over again? publication is titled "Root Cause
RCA AnalysisImproving Performance
However, it does seem that we Teamworkwhen people for Bottom Line Results." He can
always have the resources to fix the work on RCA teams, they gain be contacted at 804.458.0645 or
problems that occur daily. If we were an appreciation for how other blatino@reliability.com.
to support a RCA effort, the reactive departments perceive given
work would decrease over time, situations. When this occurs, it
as many problems would not exist affects future decision making
anymore. This would free up the time because they tend to take into
of the people that we have as reactors, consideration why people do
and better utilize them in proactive what they do. This empathy
activities such as RCA, predictive results in a more synergistic
maintenance, etc. operation and a more educated
workforce.
OBJECTION: IMPROVEMENT
WORK CAN WAIT UNTIL Moraleresearch shows that
RESOURCES ARE AVAILABLE failure rates tend to be higher
If this is the prevailing attitude, in organizations that have poor
pack up your RCA bags because morale. Why? Because when
these resources will never be made our workforce feels alienated
available. This is where management their focus is distracted with the
support is a must. We must make emotional baggage they carry.
accommodations in our work order This distraction causes errors in
systems to effectively implement RCA decision making which lead to
recommendations through assigning physical failures. By allowing the
them a higher priority. If this is not workforce to demonstrate their
done, then they are back burner knowledge of how the process
items and will likely never get done. works and to solve problems
This will have resulted in a lot of work utilizing their experience, their
on behalf of the RCA team and a lot of morale is improved along with
cost in their wages while they were on their ownership over their work.
these teams. The larger impact will be How much is this worth to the
on the morale of the team, as they put organization?
their best effort forward and no one
listened. This is where the program- These are just a few of the intangible
of-the-month paradigm originates. benefits of conducting RCA. Although

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 29


MAINTENANCE SOLUTIONS

Reliability Starts
from the Ground Up
Outlining the benefits of polymer
concrete baseplates
By Scott Sapita, BaseTek, LLC

A
solid foundation is a proven way to increase the mean otherwise require an expensive alloy or corrode standard
time between planned maintenance for most types cast iron or steel. Polymer concrete systems eliminate the
of rotating equipment. Pump bases and foundations need for additional protective coatings or periodic upkeep
constructed of polymer concrete provide many benefits and maintenance activities.
over their cast and fabricated metal counterparts. Often
referred to as a poly, granite, or mineral cast baseplate, this FASTER INSTALLATION
material is a special combination of well-defined grain size Polymer concrete baseplates will not twist, bend, or
aggregates bound to a thermoset epoxy or vinyl ester resin. diaphragm like most metal designs. This eliminates the need
Manufactured in a controlled environment during a transfer for time-consuming field adjustment during installation. Most
molding process, these materials can be cast to precision designs also incorporate threaded leveling inserts along with
tolerances while offering the high mechanical properties a bottom surface ready for adhesion to grouting material
suitable for most industrial applications. without modification or special preparation. Bases can either
be stilt mounted or grouted in place like a conventional
VIBRATION DAMPING hollow design.
The polymeric matrix of the material provides damping
ratios 20-30 times greater per identical geometry than steel
or cast iron materials. Rotating equipment is often associated
with its stability under the influence of various disturbances
and polymer bases can effectively minimize vibrations
without the need to increase the mass size of the component.

PRECISION MOUNTING
Cast mounting surfaces are typically flat within 0.002 inches
per feet, which reduces soft-foot and speeds alignment.
Threaded insert holes are typically cast in place or
located with a CNC machine to insure precise location and
perpendicularity, which eliminates bolt bound conditions
often occurring with inexpensive metal bases. Difficult
to machine features can easily be cast in place. Thermal
expansion rates of most polymer concrete formulations are
considerably less than cast iron and maintain the consistent
alignment of equipment in a wider range of operating
conditions.

CORROSION RESISTANCE
Advanced resin systems along with inert natural aggregates
provide excellent protection from many fluids that would

30 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


Grouting a polymer concrete
baseplate requires considerably less
labor and material. Grout volumes
are greatly reduced resulting in less
material and labor to pour. Greater
skill is often required in grouting a
hollow steel frame to insure all voids
are eliminated as grout is intended
to be in 100 percent contact with
the underside surface for proper
performance and vibration damping.
Since the solid pre-cast polymer
concrete base will maintain structural
integrity without requiring grout,
many potential installation errors can
be easily avoided. Stilt mounting a
polymer concrete assembly takes
advantage of the structural stability of
the mounting surface while allowing
the equipment to react to the forces
and moments of the piping system.

PROVEN RELIABILITY
In addition, polymer concrete materials
offer low levels of heat conduction,
act as an excellent electrical insulator,
are non-magnetic, and resist water
absorption. Mechanical properties
are suitable for most indoor-outdoor
environments found in the process
industries.
The proven reliability of polymer
concrete baseplates for rotating
equipment is rapidly expanding as the
features above continue to add benefit
for applications of most every shape
and size. By combining a consistently
flat, vibration damping structure that is
easy to install and maintain, polymer
concrete baseplates will continue to
be the choice of Reliability Personnel
worldwide.

Scott Sapita is co-founder and

MPT
managing partner of BaseTek, LLC

?
in Middlefield, Ohio. Scott has over
twenty-eight years of experience WANT
in the rotating equipment market
including product design, product
TO
management and industrial sales. He READ
carries a BS in marketing from the
University of Dayton. Contact him at
MORE
scott@basetek.com. Modern Pumping Today

Providing Solutions for the Worldwide Pump Industry


Visit www.ModernPumpingToday.com today!

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 31


PUMP SOLUTIONS

The Benefits of
Internal Gear
Pumps in Industrial
Operations
Enhancing the processing of dangerous chemicals
Part 1 of 2
By Chrishelle Rogers, Maag Industrial Pumps / PSG

I
t is no stretch to say that pumps production process. Whether handling oftentimes challenginghandling
make the world of industrial lube oils, paints and coatings, or characteristics. If a pump is the weak
manufacturing go round. Every working in applications from heat link in the production process, then the
day, thousands of industries around transfer to chemical processing, entire operation will be compromised,
the world rely on various pumping pumps must reliably, efficiently, and with the downtime required for
technologies to move raw materials safely transfer a dizzying array of repair or replacement eating away at
and end products through the fluids, all of which have uniqueand production quotas and the bottom line.

Chemical processors must deal with many fluids that are dangerous and difficult to handle. In order to fashion a handling and transfer operation that optimizes reliability, efficiency,
and safety in their operations, many are making the decision to install and rely on internal gear pumps.

32 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


No acid, polymer, resin, or caustic has the same handling characteristics, which makes pump versatility a primary concern for chemical processors. Maag G Series Internal Gear
Pumps overcome many handling concerns by featuring a method of operation that can successfully and safely transfer fluids of differing viscosities and chemical makeups.

SURVEYING THE OPTIONS among the most important. With manufacturing operations,
Industrial manufacturers have a wide manufacturing operations governed positive displacement internal
range of pump options to choose by operating budgets and expenses, gear pumps can offer the precise
from when outfitting their facilities. equipment acquisition costs and and consistent transfer of highly
There are also a number of factors subsequent maintenance are also demanding fluidsin this case,
that go into their choice of pumping primary concerns. dangerous chemicalsthat is
technology. Operational reliability This article will illustrate that while critical in creating a reliable,
and being able to meet very specific all pumping technologies can have efficient, cost-effective, and safe
fluid-handling requirements are their positive points in industrial- pumping system.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 33


PUMP SOLUTIONS

THE CHALLENGE OF intricate that there are several unit manufacturing process and stands out
CHEMICAL PROCESSING AND operations within the process, from above the others in its importance:
MANUFACTURE cracking, distillation and evaporation, fluid transfer. Often over-simplified
Chemical processing and manufacture to gas absorption, scrubbing and as transporting fluid from one point
is one of the most complex industrial solvent extraction, among others. to another, fluid transfer in chemical
operations in the world. In fact, the Within that family of unit operations, manufacturing is so much more.
chemical-manufacturing process is so one touches every stage of the Fluid transfer is a spectrum of
applications, with responsibilities
all along the chemical-production
chain. For example, thin or viscous
raw materials can be transferred
to storage tanks or blending and
mixing tanks. Final formulations can
be transferred to holding tanks, and
finished products can be loaded
into IBCs for delivery or consumer
packaging.
In many cases, chemical-
manufacturing processes require the
use of dangerous chemicals, such
as strong acids, caustics, solvents,
resins, and polymers. Despite their
inherent danger, these substances
are necessary for the manufacture
of thousands of consumer goods or
facilitate other industrial processes.
The challenge for users of these
dangerous chemicals is to construct,
handle, and transfer them in a
reliable way.

A LOOK AHEAD
Next month, well take a closer look
at the benefits positive displacement
internal gear pumps have continually
offered pump users seeking reliability
and cost-effectiveness when handling
raw materials and finished products
with a specific breakdown of Maags
own G Series Internal Gear Pumps.

Chrishelle Rogers is the global gear


pump product manager for Maag
Industrial Pumps, Grand Terrace,
California, and PSG, Oakbrook
Terrace, Illinois. Ms. Rogers can
be reached at 909.222.1309 or
chrishelle.rogers@psgdover.com.
Maag Industrial Pumps is a leading
brand of internal gear and screw
pumps and a product brand of PSG, a
Dover company. For more information
on Maag Industrial Pumps or PSG,
visit to www.psgdover.com.

34 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 35
DEWATERING SOLUTIONS

Copper Mine
Quadruples Pump
Wear Life
GIW Enduraclad increases
operations from 450 hours to 2,000
By Ronnie Willis, GIW Industries

C
opper mining involves working with some of the When considering replacement parts, manpower, and
harshest materials in the world. As a result, mining revenue lost due to downtime, the costs the copper mine
companies must carefully monitor wear of their was facing on a regular basis were staggering. They
slurry pumps and schedule frequent shutdowns to replace desperately needed a solution for more efficient operations.
worn parts. The cost of this maintenance goes far beyond
just the price of parts; downtime and lost revenue can run FINDING A BETTER WAY
into hundreds of thousands of dollars. GIW offered the South American copper mine the answer.
An LSA centrifugal slurry pump was installed in a tailings
SEVERE WEAR RAISING COSTS booster application where GIW's exclusive Enduraclad
KSB's subsidiary, GIW Industries Inc., has produced material was applied to the new suction liner.
success at a South American copper mine.The GIW With the application of this new material, the mining
Minerals product solution quadrupled pump wear life and company has been able to extend wear life up to 2,000
created dramatic savings for the mine's tailing pumping hours and also improved wear life of other related pump
operations. The South American company had struggled parts. This success comes from years of hard work and
for years to reduce maintenance downtime in its tailings innovation from GIW's team of hydraulic and metallurgical
operations. engineers.
Tailingsthe material left over after the valuable metal
has been extractedconsist of very fine particles that are
highly abrasive in slurry. The material was wearing out
pumps more quickly than other equipment in the tailings
line, increasing the frequency of downtime. They were
having such severe wear that they were repairing the
tailings pumps every 400 to 450 hours.

SIDE-BY-SIDE COMPARISON

Metal Liner at 450 Hours Enduraclad Liner at 550 Hours


LSA centrifugal slurry pump

36 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


When Enduraclad made its debut materials and processes that be even greater improvements
in 2009, its uses were limited. It was can improve pump wear life for in the future with enhanced
only applied to suction liners and customers like the South American Enduraclad material. GIW believes
increased wear life up to three times. copper mine. Metallurgical experts solutions that add value to their
But since then, its capabilities have are already testing new cladding products will meet and exceed
expanded to allow coating on other materials that will last even longer their customers expectations for
essential parts and enables it to than the current ones, and there may continuous improvement.
provide even greater longevity for
GIW pumps.

GETTING YOUR
MONEYS WORTH
Although Enduraclad-bonded parts
might be more expensive, they are
well worth the price. They will cost
more than uncoated parts, such as
suction liners, buy end-users save on
costs by using fewer parts, reducing
maintenance costs, and not suffering
the downtime revenue loss. To remove
and replace the parts on one of these
pumps requires two to four people
working with tools and lifting devices
for 6 to 8 hours. So the longer a
company can keep the pump running
with nobody touching it, the more
operational costs they will save.
Economy is just one of the things
GIW values and tries to deliver to
its customers. Users are seeking
partners concerned with their best
interest, who are not just developing
these really specialized materials and
processes and charging higher prices.
GIW is continually looking for ways to
reduce the cost of materials to provide
a product that serves customers'
needs and fits their budgets.

CONTINUOUS IMPROVEMENT
IS A MUST
GIW is constantly looking at new

Ronnie Willis is senior product


manager of new materials at GIW
Industries, Inc., a full subsidiary of
KSB. Through the GIW Minerals
product brand, KSB strives to be an
innovative partner that provides you
with the best and longest wearing
slurry solutions. We are your partner,
today and in the future. For more
information, visit www.ksb.com.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 37


MOTOR SOLUTIONS

Turning Away
from Tradition
NORD screw conveyor drive proves itself
compact, reliable, and cost-effective
By Alie Foy, NORD Gear Corporation

C
ompanies around the world reliable transmission of power to the dry to semi-fluid materials from
have come to rely on screw driven shaft. free-flowing to sluggish at very steep
conveyor drive systems for Depending on the type of conveyor, inclines and are totally enclosed for
reliable drive solutions to meet the different applications can see dust and vapor-tight requirements.
demands of transporting bulk material. significant benefits right away. For
For these critical applications, open, example, shaftless screw conveyors THE ALTERNATIVE TO
two-way communication between have proven ideal for handling sticky TRADITIONAL SCREW
OEMs and end-users is essential to and sluggish bulk materials and are CONVEYOR DRIVES
help drive customers with an accurate equally well-suited for material with The NORD Screw Conveyor Package
assessment of each individual high moisture content. offers a compact and cost effective
application. To understand the In addition, screw feeders and live alternative to traditional screw
demands of industry, a manufacturers bottom conveyors incorporate either conveyor drives. Closely stepped
goal should be to provide users with a a single or multiple gearbox design speed reduction ratios combined
drive assembly that will reliably serve and provide a means of moving a with a directly coupled gearmotor or
the needs of a plant for many years to wide variety of material from bins or NEMA C-face input design eliminates
come. hoppers at a constant and controlled the need for top motor mounts,
For example, NORDs screw rate of flow. This type of conveyor is pulleys, belts, or guards. Minimizing
conveyor packages, with their rugged one of the most accurate and efficient parts and eliminating the belted input
output seal and innovative CEMA to meter bulk materials. Lastly, vertical systems provides for easier system
drive-shaft, are designed for reliable screw conveyors are ideal for elevating maintenance, increased reliability,
performance in screw conveyor
applications. Some of the industries
that rely on screw conveyors include
agriculture; oil and gas; chemicals
processing and handling; stone, glass,
and concrete, food products, and
wastewater treatment.

BUILDING A MORE RELIABLE


DRIVE ASSEMBLY
NORD's industry leading ratio range
allows for the elimination of external
rotating components such as V- or
synchronous-belt drives. Eliminating
the belt drive results in a safer and
more reliable drive assembly. By
combining high quality gearing with
a leak free design, NORD delivers

38 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


direct drive motor options (Integral
Clincher SCP Unit Helical-Bevel SCP Unit
or C-face). Furthermore, there is no
Torque Capacity Up to 53,100 lb-in Up to 42,480 lb-in belt maintenance or belt guarding
Power Range 0.16 60 horsepower 0.16 30 horsepower required. The advanced design means
reduced parts, higher reliability, and
Ratio Range 4.32:1 1,585.08:1 8.09:1 4,246.38:1
space savings while also providing
Output Speed 1.0 405 rpm 0.41 216 rpm higher efficiency and more direct
Efficiency Up to 97% efficient Up to 95% efficient torque transfer. More than just an
alternative to tradition, the NORD
CEMA Drive Shaft Sizes 1- / , 2, 2- / , 3, 3- / inches
1 2 7 16 7 16 1- / , 2, 2-7/16, 3, 3-7/16 inches
1 2
Screw Conveyor Package is a
step beyond.
and superior drive performance. gap seals (0.03 inch gap) on either
NORD screw conveyor drive options side of the grease filled felt packing
feature a UNICASE reducer housing, seal. Drive shaft material evacuation
Quadrilip reducer shaft sealing and ports in the flange help protect the
Alie Foy is marketing specialist for
optional high capacity output bearings drive system from debris. A slight lead NORD Gear Corporation and can be
with CEMA standard flange mounting taper on the reducer shaft provides for reached at alie.foy@nord.com. As a
and CEMA drive shafts ranging from easy mounting and removal, allowing privately-held, family owned company,
1-1/2 to 3-7/16 inches. for some screw pipe misalignment and Nord believes in the long term with
a global perspectiveproviding a
The Screw Conveyor Package reduced bearing loads.
broad range of products, the highest
(SCP) design is available for both quality standards in mechanical and
CLINCHER Parallel Shaft gear units BENEFITS FOR END-USERS electronic technologies, continued
and Helical-Bevel Right Angle gear For end-users, the NORD Screw reinvestment into production,
units. The CEMA flange assembly Conveyor Package offers many and a global presence. For more
information, visit www.nord.com.
offers superior protection against benefits even beyond the reduced
unwanted debris with its dual Viton cost, from the large ratio range to

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 39


P OW E R G E N E R A T I O N S O L U T I O N S

Reliable Energy
Is Looking Up
Down Under
U.S. software integrator fuels
Australian utility automation
By Steven W. Schwabe, Woolpert

U
.S. software integrator Woolpert, with support from Denver, this team met challenging deadlines that enabled
enterprise consulting firm gViz, has implemented AAD to conduct improved customer service at a lower cost.
Cityworks, an asset and work management solution, With the client thirty hours away by plane, we
for ActewAGL Distribution (AAD). AAD, based in Canberra, worked both onsite during Australian business hours
provides power to more than 195,000 electric customers and domestically on opposite schedules, says Dave
and another 134,000 gas customers in the Australian Feuer, Woolperts director of information technology and
Capital Territory and New South Wales, and it is one the management consulting. We were essentially working
largest joint-utility companies in Australia. in shifts, each group furthering the project while another
Cityworks, developed by Azteca Systems, is the only group slept.
GIS-centric asset management software available. Feuer notes the pace of the project was equal to working
Woolpert, Cityworks first Diamond-level Implementation sixteen to twenty hours per day.
Partner and a Strategic Development Partner, has been For about nine months, it was all hands on deck, he
delivering enterprise asset management solutions built on says. We took the system live as we were still developing
Cityworks for over twenty years. some interfaces and continuing to roll out integrations and
other system enhancements.
ENHANCED SERVICE FOR ENHANCED FEATURES Woolperta national architecture, engineering and
The implementation of this solution went live with the core geospatial firmalso is among the domestic leaders in
Cityworks software in July 2014. Since then, Woolpert
has steadily supplied the AAD team with product
enhancements and integrations to the existing software,
such as Oracle Financials and Gentracks Velocity Billing
solution.
These have delivered improved AAD operational
management and efficiency within the utilitys electrical
division. This project enables AAD to route and track work
assignments more easily by automatically converting
customer calls into actionable work for the maintenance
and operations staff.

GOING THE EXTRA MILE, FROM MILES AWAY


Woolpert assembled a team of six full-time resources
dedicated to delivering this business-critical solution. For
Woolpert, with support from gViz, implemented Cityworks asset and work
nearly nine months, working both in Australia and from management solution for ActewAGL Distribution, based in Canberra, Australia.

40 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


Institute of Asset Management (IAM) certification, with thirteen
professionals certified.
In Australia, as in Europe, the IAM standards are very highly
regarded, but most U.S. companies have been late to that party,
said Feuer, who is IAM certified. We were pleased that AAD
came to America to get support with its overall asset management
program, knowing we adhere to these elevated international
standards.

LOOKING OUT FOR CUSTOMERS


The bulk of the work on this project is complete, but Woolpert
Woolpert Discipline Director Kirk McClurkin and Project Manager Steve continues to support AAD by evaluating ideas on their issue log,
Schwabe discuss the software implementation with ActewAGLs Mark
Chenery and Chris Kelly at ActewAGL offices. scoping, and developing system enhancements, and additionally
delivering the advanced functionality the AAD-user community
needs to meet its operating requirements.

Woolpert delivers value to clients by strategically blending engineering


excellence with leading-edge technology and geospatial applications.
Woolperts mission is to help its clients progressand become more
progressive. For over 100 years and with more than 25 offices across
the United States, Woolpert serves the needs of federal, state, and local
governments; private and public companies and universities; energy and
transportation departments; and the United States Armed Forces. For
more information, visit www.woolpert.com or call 937.531.1258.
Phase Manager Jamie Munro and Market Director Dave Feuer work in a
makeshift office in the Woolpert teams apartment in Australia.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 41


PROCESSING SOLUTIONS

Minimizing Leaks
and Environmental
Hazards for Fluid
Transfer
ARO Station provides a safe solution
for processing needs
By Fausto Lotti, ARO Fluid Management

T
ransporting and securing its exposure. The risks with chemical 1 inch, 1- inch, or 2 inch Expert
hazardous material handling are a daily reality and the Series Pumps (EXP) ARO diaphragm
while also minimizing its ARO Station was designed to protect pump. With the capability to pump
exposure are the twin goals of any operators as well as the environment material from 1,320 to 7,900 gallons
processing engineer. Many of the during the transfer of these materials. per hour, the ARO Station can be
fluids transferred during chemical calibrated to pump the appropriate
processing can be corrosive to DIFFERENT PUMPING OPTIONS quantity for each application. Use of
equipment or dangerous to operating The ARO Station can accommodate the ARO Station increases the safety
staff. And although well-maintained three different size pumps, the of chemical installations during the
connections in the piping or pumping
system is a must, Ingersoll Rand
has introduced a product that thinks
outside the box by putting a pumping
system inside the box: the ARO
Station.

REDUCING LEAKS AND FUMES


The ARO Station is a customized
solution that houses an ARO pump
and piping in a durable housing in
order to reduce leaks and fumes
during chemical transfer from one
container to another. Standing
independently from a truck, the ARO
Station helps operators comply with
changing environmental regulations,
while enhancing operator safety.
ARO understands the importance
of transporting and securing
hazardous material and minimizing One of two sizes of the Expert Series Pumps (EXP) ARO diaphragm pump can be placed inside the ARO Station.

42 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


"The risks with
chemical handling Fausto Lotti is marketing leader for ARO Fluid Management. ARO is a leading worldwide
manufacturer of fluid handling products expertly engineered to deliver performance and

are a daily serviceability, enabling customers to achieve the best total cost of ownership. For eighty-
five years ARO has been helping customers solve their most complex fluid handling
challenges to keep their business moving. For more information, contact 800.495.0276 or
reality and the arohotline@irco.com.

ARO Station was


designed for
protection."
unloading process by reducing risks
of water hammer that occur during
the pressurization of the tanks.
A leak detector that communicates
possible leakage, helping to minimize
air pollution and risk from fumes.

A heater to prevent freezing in


extreme situations.
An alarm that monitors the level of
liquid in the tank and whether the
system is running dry.

IMPERVIOUS TO CORROSION
Made of high-density polyethylene,
the ARO Station is impervious
to corrosion, and features a drip
collection tray that can hold up to 52
gallons of fluid. The ARO Station can
be used as a free-standing pump
solution or it can be equipped with
wheels for mobility. Compact and
ready for use, the ARO Station is a
standardized skid size thus reducing
integration costs.

MAKING SUCCESS FLOW


Ingersoll Rand introduced the ARO
Station pumping system at the 2015
ACHEMA tradeshow in Frankfurt,
Germany, to an enthusiastic crowd
of professionals in the compressed
air and gas systems and services,
power tools, fluid management, and
material handling equipment industry.
Ingersoll Rand product experts
interacted with attendees, answering
questions and demonstrating the
details of how the new closed
pumping system could benefit their
facilities and operations.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 43


V A LV E S & C O N T R O L S S O L U T I O N S

Managing Assets,
Saving Time
StruxureWare SCADA Expert ClearSCADA
software fills the markets need
By Brad Shaw, Schneider Electric

A
cross a range of industries and automation, Schneider Electric, Enhanced WebX user interface
connected to oil and gas has also announced the release of Process information is available
or water and wastewater, StruxureWare, an add-on to SCADA anytime, anywhere through any
companies are experiencing a Expert ClearSCADA that continues device with HTML5 cross-browser
worrisome trend. As a great number of to improve on the user experience support for trends, alarm lists,
long-time technical experts retire, they and provide functionality based event lists, and queries.
are not being replaced by an equal on customers needs. Template
number of younger skill workers. expressions save engineers time Extended integration of telemetry
However, companies requirements during implementation; alarm hardwareEnhanced integration
to manage assets dispersed over summaries help pinpoint maintenance with the Realflo software, a flow
large areas has not diminished, and issues faster, and the seamless measurement application, now
Schneider Electric has recognized integration with a tier-2 historian including support for Realflo
the growing need for integrated and facilitates data accessibility across the Liquids 6.91, plus native support
automated control systems that todays entire enterprise. for well-known third-party flow
workforce can operate reliably and computers via a new oil and gas
efficiently. EXPANSIVE FUNCTIONALITY, EFM Driver suite.
REDUCED OPERATING COSTS
SAVING ENGINEERS TIME These functionalities are part of a Increased system securityA
Schneider Electrics new open and software platform that is designed substantial increase in security
scalable software for telemetry and to lower the overall operating costs features includes enhanced
remote SCADA applications, SCADA of remote assets while providing a user account security, auditing
Expert ClearSCADA, controls budgets complete, comprehensive overview of of the system security through
throughout each project, captures site operations. Other features include: a dedicated security event
relevant and reliable data from remote list and dedicated security
and challenging locations, logging queries.
and also minimizes
system security risks. By providing remote
This software improves configuration capabilities
the user experience and collecting data from
with better maintenance multiple ClearSCADA
tools, improved data systems into a central
accessibility, and enhanced enterprise repository,
security in telemetry ClearSCADA software
and remote SCADA helps reduce costs
applications. while providing
Cementing its position crucial, business-
as a global specialist EcoStruxure Web Services-ready, SCADA Expert ClearSCADA seamlessly integrates relevant data across all
in energy management products and systems from the Schneider Electric business segments. operational levels.

44 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


SCADA EXPERT CLEARSCADA The combination of template increasing regulatory compliance,
The SCADA Expert ClearSCADA configuration and object-based ClearSCADA software helps
system foundation is built using open architecture simplifies scalability provide continued operations and
standards, naturally providing industry- for oil and gas and water and uses integrated tools that maintain
leading integration with external wastewater installations while also the integrity of data records, even
business and IT systems. Critical establishing a relevant system for in the event of interrupted field
infrastructure management business the entire system lifecycle. With the communications.
systems, including GIS and ERP,
can share data with SCADA Expert
ClearSCADA using open SQL ODBC
and OLE-DB standards. Interchanging
data with a wide range of controllers
and PLCs, and other process systems
can be done seamlessly using
extensive OPC interfaces. SCADA
Expert ClearSCADA client and server
API facilities provide ultimate flexibility
using the latest in OLE and .NET
software technologies.
All SCADA Expert ClearSCADA
facilities can securely interoperate
with business and IT systems to turn
asset and infrastructure SCADA data
into valuable business information.
Additionally, SCADA Expert
ClearSCADA is EcoStruxure Web
Services-ready, which has the goal of
seamlessly integrating products and
systems from the Schneider Electric
business segments. This enables quick
and easy exchange of information
such as real-time data, historical data,
and alarms.

Brad Shaw is the ClearSCADA


software product manager at
Schneider Electric, a global
specialist in energy management and
automation with operations in more
than 100 countries. Schneider Electric
offers integrated solutions across
multiple market segments, including
leadership positions in non-residential
and residential buildings, industries
and machines manufacturers,
utilities and infrastructure, and data
centers and networks. Focused
on making energy safe, reliable,
efficient, productive and green,
the company's 170,000 employees
achieved revenues of $30 billion
dollars in 2014, through an active
commitment to help individuals and
organizations make the most of their
energy. For more information, visit
www.schneider-electric.com/us.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 45


SEALING SOLUTIONS

Mechanical Seal
Energy Audits
and Their Value
Part 1 of 4
By Tom Grove and Heinz Bloch

E
nergy Management is critical Energy Czar. The International vast majority of mechanical seals
to operational efficiency. Standards Organization recognizes the are deployed in process pumps at
Reviewing energy use in each importance of energy management refineries, petrochemical plants,
link of the supply chain of a business in the ISO-50001 Standard for Energy pulp and paper plants and a host of
can produce significant benefits. Management Systems. other industries. With the exception
Increasingly, industrial companies Mechanical seals are energy of gas-injecting seals (available on
are making a commitment to energy consumers. They are components very few pumping services), all other
control by staffing energy management which prevent fluid leakage from mechanical require a flush liquid in
positions. These positions may even the shaft region of process pumps the seal cavity. This flush liquid can
be referred to as the Corporate and other rotating equipment. The be supplied in different quantity and

KEY DELIVERABLES
Investment Profile to Return-On-
Piping Plan Energy Cost
Scope of Savings Priorities Deploy Corrective Upgrade Investment Summary
Savings Range
Strategy - Estimated Expectation

Priority 1: Chemical Recovery Boiler Evaporators.


Check 30 to 40 Water Injection points through Seal Less than 5 months to
Piping Plans on pumps tied to 6 Effect Evaporators. less than 7 months
Scope of savings 100 GPM injection elimination $254,500 to $364,300 $150,000
on 130 F temperature using $ 4.00 / 1,000 lbs Evaporator limited mills
of steam and 85% Evaporator Efficiencies saves improve throughput
50,000 MMBTUs

Priority 2: Condensate Recovery Pumps Water Sewage and


Inspection of Separation Pumps operating with Chemicals: $33,760
continuous leakage. 10,000 lbs/hour loss on 8000 Annual Fuel Savings: $88,000 $50,000 Less than 5 months
operating hours with average boiler efficiency of
80 % and makeup water of 55 F Total $ 121,760

Priority 3: Reheat Applications including Pulp


8 GPM typical for
Mill and Kamyr Continuous Digesters, requiring
excess injection Typically less than
continuous high pressure seal water injection Variable
9 months
ranked by differential temperature and GPM
$20,370 Reheat
injection rates

Table 1: Format of recommendations delivered in a typical Seal Energy Survey

46 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


at different pressures so as to carry well as benchmarking the seal water in relation to the mechanical seal
away heat and provides the separating quality using laboratory analysis. region will be helpful. For the sake
liquid needed between seal faces. The mechanical seal manufacturer of uniformity, the suction flange for
Many mechanical seals have served explained the scope of the savings the process fluid is shown on the left.
their respective users, but technology opportunity in a Statement of Key Accordingly, the impeller is mounted
updates will prove quite revealing to Deliverables: The key deliverable on the left end of the shaft and the
some. is to identify the cost and provide discharge flange is shown at the
all of the technology options to set top. While the impellers are shown
OBJECTIVES OF MECHANICAL a strategy for improvement. The with balance holes to balance the
SEAL ENERGY AUDITS deliverables are separated into pressures to the left and to the right
The objective of periodic audits is to priorities (see Table 1). of the suction eye, not all impellers
point out and quantify the monetary or services will require this balance.
value of installing modern products. AUDITS START WITH EXPLAINING The seal chamber (stuffing box) is
Doing so will, in some cases, reduce API PIPING PLANS depicted with a mechanical seal in
or avoid downtime and maintenance A mechanical seal audit starts with place.
expenditure. In other instances, the listing and explaining the API Piping
audit can detail energy improvement plans deployed on the equipment at a
opportunities associated with particular plant. Although API refers
alternative flush liquid application to the industrial standards issued by
plans. In the pulp and paper industry the American Petroleum Institute, the
seal water piping plans deserve mechanical seal and compression
special attention. The focus is on the packing details of non-API compliant
cost of reheating and/or evaporation of centrifugal pumps will be similar. In
seal water, if the seal water is injected all cases graphically depicting the
into the process stream. The cost approximate cross-section of a pump Figure 1: API Plan 02
to reheat and further evaporate this
injected seal water can be eliminated
by using the right flush plan.
Technology exists to eliminate injected
seal water.
The second objective is to
describe in detail the American
Petroleum Institute (API) Seal Piping
Plan specifications and summarize
how each plan is deployed on the
equipment. The selection of the API
Piping plan can prolong the life and
reliability of the equipment; however,
this can also have a significant
impact on energy usage and energy
efficiency.
Using a concise survey form,
a major and highly innovative
mechanical seal manufacturer
physically inspected each piece
of equipment and documented as
much information as was available.
The data elements included the seal
arrangement, the seal piping plan and
the process temperature. Because
it is critical to dovetail the energy
saving solution with improvement
in equipment reliability, additional
data was gathered. This included
seal operating temperatures to
measure piping plan efficiency as

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 47


SEALING SOLUTIONS

Heat exchanger

Cooling water out


Flow control
orifice

Cooling
water in
Pumping
ring
Temperature indicator

Figure 2: API Plan 11 Figure 3: API Plan 23

The audit replicated in this four-part series of articles pumps. Figure 1 shows a jacketed cooling (or heating)
assumes that the plant started out with API Seal Flush Plans cavity for occasional applications favoring controlled seal
02, 11, 23 and 32. The audit explains alternatives such as chamber temperatures.
Plans 53A and 54. In Plan 11 (figure 2) product is recirculated from the
Figure 1 shows API Plan 02, a dead-ended seal chamber discharge of the pump to the seal through a flow control
with no flush fluid being injected into the process. There is orifice. This arrangement is selected to increase the
no auxiliary piping connected to the mechanical seal cavity pressure at the seal to the full discharge pressure of
(shown) or the stuffing box, in case braided packing is the pump. The plan maintains pressure above vapor
used. This plan is suitable for sealing cool clean fluids with pressure; the product is less likely to vaporize at elevated
high specific heat, such as water, in relatively low speed pressures.

48 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


Pressure indicator e.g. boiler feed water. Plan 23 is more efficient than the
Control valve alternative Plan 21 because the cooled process around the
Temperature seal is re-circulated. Plan 21 (not depicted) connects a line
indicator
Flow meter from the pump discharge through a heat exchanger and into
the seal. This creates flow of the cooled process fluid, which
must be reheated as it re-enters the process.
Y Strainer
Plan 32 (figure 4) consists of the injection of a clean
or cool liquid from an external source directly into the
seal chamber. This is selected for duties with dirty or
Seal Purchaser contaminated fluids, high temperature applications,
vendor
polymerizing and oxidizing fluids or media with poor seal /
mechanical packing lubrication properties. Plan 32 is used
on mechanical packing and single mechanical seals
From an energy point of view, this plan is the most costly
Figure 4: API Plan 32 to operate. The seal water used for injection at a particular
site must be known to proceed with the audit. As the plan
If the product is abrasive, care must be taken to prevent
erosion at the seal faces where the recirculation line enters
the seal. Plan 11 is used on condensate and hot water FLOW ESTIMATES
applications. Here, the additional heat generation created by
Plan 32 Pipe Size GPM GPM GPM
the seal faces could cause vaporization. Traditional seals will Schedule 40 Low Psi (20-100psi) High Psi.
fail if a vapor replaces the sealing liquid.
ID 7 14 21
Product is re-circulated, in Plan 23 (figure 3) from the seal
ID 11 23 36
chamber to a heat exchanger and back to the seal chamber.
1 ID 16 37 58
Circulation is created by a pumping ring in the rotating
seal assembly. This plan is used in hot and clean services, Table 2

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ere
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www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 49


SEALING SOLUTIONS

illustrates, a control valve and flow meter control the Pressure gauge
volume of water injected. These controls are frequently External nitrogen
pressure source
removed because of clogging if the seal water quality (normally open)
Pressure
has particulates. switch low
Plan 53A as shown here is the conventional layout
found in the API specification. Plan 53 applications
Liquid filling
are an adaptation from this traditional plan. Plan 53 connection Level
switch high
(normally closed)
is a pressurized barrier fluid circulation system for a (optional)

dual seal configuration. It is used to control the fluid Barrier out


film formation between the inner seal faces in order to Level
switch
extend life. low
Plan 53 differs from Plan 52 in that the secondary Level
Cooling
medium in Plan 52 is called a buffer fluid. A Plan 52 water gauge

system has the buffer at a lower pressure than the seal


Cooling
chamber pressure and the fluid film at the inner seal water
face set is the process fluid. A Plan 53 operates with
a barrier fluid at a pressure higher than the seal Drain
(normally closed)
chamber. This means the barrier fluid is the fluid film at Valve optional

the inner seal face set.


The buffer verses barrier fluid terminology is
an important distinction. This distinction applies to the
way a Plan 54 (figure 6) system is set-up. This plan is
a pressurized external barrier fluid circulation from a Barrier in
central source by a stand-alone pumping unit.
From experience, the term Plan 54 is applied broadly
and collectively. This may take the form of a pressurized Figure 5: API Plans 53 and 53A

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50 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


To external
pressure source
If the Plan 54 re-captures the seal water after it exits the
seal and recycles this water, product contamination does
Barrier
occur.
out

A LOOK AHEAD
A comprehensive audit may include a seal water sample
analysis performed by an independent laboratory. Such
From sampling and analysis is occasionally requested by the plant,
external
pressure but would incur an optional charge. Contaminated barrier
source
fluid systems limit the reliability of the sealing system in
a Plan 54 arrangement. Part 2 of this series will highlight
the energy impact of using API Plans at one particular pulp
mill.

Barrier in

Figure 6: API Plan 54 Tom Grove is an executive vice president at AESSEAL Inc.,
one of the world's leading specialists in the design and
manufacture of mechanical seals and support systems. He
water to drain system or it may be a closed loop system for a can be reached at tom.grove@aesseal.com. Heinz P. Bloch,
single or multiple applications. P.E., is one of the worlds most recognized experts in machine
reliability and is a Life Fellow of the ASME, in addition to
WATER-TO-DRAIN ARRANGEMENT having maintained his registration as a Professional Engineer
in both New Jersey and Texas for several straight decades. As
Illustration A depicts a water-to-drain arrangement. A a consultant, Mr. Bloch is world-renowned and value-adding.
common header is fed by a seal water pump. Supply lines He can be contacted at heinzpbloch@gmail.com.
from the header connect to the pump seal inlet port and go
to a drain through the seal outlet. Flow is not recovered or
re-used.
Pressure is not consistently applied to each pump due to
piping friction losses and flow diversion.
If the primary supply pump to the seal water system is
lost, multiple seal failures could occur. The seal pressure
at each seal can be reduced, if needed. Such pressure
reductions are needed in installations where the header
labeled Alternative Flow must also satisfy higher pressure
requirements, such as wash-down water.

Illustration A: Water-to-drain arrangement

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 51


MODERN PUMPING PRODUCTS

Featured Product
GRIFFCO VALVE
Y-Strainers for Chemical-Feed Systems
Griffco Valve, Inc. introduces its new line of
Y-Strainers designed to enhance the performance
of chemical feed systems. The addition of a Griffco
Y-Strainer to the suction (inlet) side of a chemical
feed pump will prevent debris from entering the
pump and clogging the check valves or damaging
the interior of the pump head.

Available worldwide from Griffco and its distributors,


the new Y-Strainers feature a standard screen perforation of 1/32 inch
with other perforation sizes or a 316 Stainless Steel mesh available on
request. Materials of construction include PVC, clear PVC, and CPVC
with NPT, Socket, or BSPT connections in five standards sizes from 1/2 to 2
inches (DN 15 to DN 50). The new Griffco Valve Y-Strainers have a 2:1 open
area ratio and hex cap for easy screen access, and can be used for horizontal
of vertical installation, the company states. True union, flanged, and European
connections are optionally available.

For more information, call 800-GRIFFCO (800.474.3326),


email info@griffcovalve.com, or visit www.griffcovalve.com.

GORMAN-RUPP
6500 Series Standard Horizontal End Suction Centrifugal Pumps
The new 6500 Series line offers solids and water handling end suction centrifugal
pumps based on the proven technology of the Prime Aire and Prime Aire Plus
models. Featuring model sizes from 3 inches (75 millimeters) to 16 inches (400
millimeters), flows to 15000 gallons per minute (946.4 liters per second), total
dynamic head to 530 feet (161.5 meters), and solids handling capabilities up to 4
inches (101.6 millimeters), these pumps will provide a high level of performance
and efficiency for applications in wastewater treatment plants, industrial facilities,
construction, mining, and agricultural uses. For more information, contact Cyndi
Hoffner at 419.755.1207 or choffner@gormanrupp.com.

ALIGNMENT SUPPLIES, INC.


B.A.T. Belt Alignment Tool
In recognition of becoming the U.S. master distributor of the B.A.T Belt
Alignment Tool, Alignment Supplies is offering a price reduction to
$1,995.00. The B.A.T. Belt Alignment Tool with dual cross firing lasers
and the unique Glowline targets enables users to quickly and easily
see the actual misalignment. The corrective solution and live moves are
observed on both Glowline targets. Users easily and quickly make accurate
corrective moves up to 75 percent faster than other systems. Alignment
Supplies is a subsidiary of Reliability Concepts. For more information, visit
www.beltalignmenttool.com.

52 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


GRUNDFOS
SL Submersible Wastewater Pumps
The Grundfos line of SL submersible wastewater pumps are designed to
handle raw, unscreened sewage, effluent, large volumes of surface water,
and process water in municipal, utility, and industrial applications. The
solids-handing pump series, in motor ranges from 1.5 to 15 horsepower,
is available with two types of impellers: SLV/SuperVortex Impeller and
SL1/S Tube Impeller. The SLV and SL1 pumps are designed for permanent
submerged installation in demanding applications, such as municipal
wastewater, network pumping stations, wastewater treatment plants, public
buildings, housing projects, and other commercial applications. For more
information, visit us.grundfos.com.

ALL-TEST PRO
AT5 Electric Motor Circuit Analysis Instrument
ALL-TEST Pros hand-held electric motor circuit analysis instrument, the AT5,
performs a comprehensive assessment of a motors health for troubleshooting,
predictive maintenance, and quality control of in-service, stored, and incoming
motors. Intuitive on-screen, menu-driven prompts guide users through testing
process. Perform tests directly at motor terminals or, for hard-to-reach motors (such
as submersible pumps), from distances to 1000 feet. Ideal for low-, medium-, and
high-voltage AC motors and DC motors, as well as generators and transformers. For
more information, visit www.alltestpro.com or call 860.399.4222.

BLACKMER
HD943 and HDL943 Oil-Free Reciprocating Gas Compressors
Blackmer, part of PSG, a Dover company and a global leader in positive displacement
and centrifugal pump and reciprocating compressor technologies, is pleased to
announce the release of its new triple-seal HD943 and HDL943 oil-free reciprocating
gas compressor line. Featuring a double-distance piece design with three individual
sets of packing to maintain product purity and prevent oil migration, Blackmer HD943
and HDL943 compressors have been specifically designed for applications that require
maximum leakage control. For more information, contact Thomas L. Stone, PSG director
of marketing, at 616.248.9252 or tom.stone@psgdover.com.

ENOVATION CONTROLS
Murphy PowerCore MPC-10
Enovation Controls introduces its newest controller: the Murphy PowerCore
MPC-10. This general, all-purpose manual/auto start and manual/auto throttling
engine controller is designed with rental applications in mind. Purposed
primarily for applications where a wide array of inputs and outputs are not
required, the MPC-10 is a powerful, rugged controller that supports J1939 CAN
protocols for electronically governed engines as well as I/O for mechanical
engines for fault and safety shutdowns. The MPC-10 follows a standard operating
sequence of twenty-two machine states that happen in a predetermined order.
Machine states can be set to zero if not needed or adjusted to fit the application.
The menu structure is incredibly versatile with the ability to change many
parameters and settings from the face without the need of a PC. For more
information, call 918.317.4100 or visit www.fwmurphy.com.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 53


MODERN PUMPING PRODUCTS

WILDEN PUMP AND ENGINEERING


PS20 102 AODD Pump
Wilden, part of PSG, a Dover company and a worldwide leader in
air-operated double-diaphragm (AODD) pump technology, is pleased to
announce the release of its new PS20 102 millimeter (4 inch) Original
Metal AODD Pump equipped with the energy-efficient Pro-Flo SHIFT Air
Distribution System (ADS). This new high performance pump features the
reliability and energy savings of the Pro-Flo SHIFT ADS while its clamped
configuration allows for easier maintenance, diaphragm replacement and
cleaning. For more information, visit www.wildenpump.com.

CENTIPRO, A XYLEM BRAND


Aquavar SPD Variable Speed Single Pump Drive
The SPD Plus is a true variable frequency controller that adjusts motor
speed to match the hydraulic needs of the system and maintain pressure.
Unlike valve-controlled systems, the energy draw is substantially reduced
during lower flow while operating the pump close to its best efficiency.
Significant energy savings over fixed speed pumps are common. As with
all CentriPro drives, the pressure transducer is included with the drive
so there is no need for separate sourcing and compatibility checks. The
transducer is pre-wired and tested, with internal case grounding. Upsizing
not required. For more information, visit Xylems Applied Water Systems at
www.xylemappliedwater.com.

WIELAND ELECTRIC
ASD-NIB Non-Incendive Barrier
Wieland Electric Inc., a leading global manufacturer of innovative electrical
interconnect technology, has developed a single non-incendive barrier module for
virtually any type of signal, enabling engineers to eliminate the explosion-proof
enclosures and conduit in Class 1, Division 2 environments. The non-incendive barrier
also offers significant cost and space savings compared to traditional intrinsically-safe
(IS) barriers. The ASD-NIB non-incendive barrier minimizes the risk of ignition on the
load side of the module by providing an electrical barrier between control devices
and equipment installed in hazardous environments. This enables standard wiring
practices to be used to connect to end devices in the field, eliminating the need to
install expensive explosion-proof enclosures and conduit. For more information, visit
www.wielandinc.com or call 800.WIELAND (800.943.5263).

ONSET
HOBO MX2001 Water Level Logger
Onset, a world leader in data loggers, introduces the HOBO
MX2001, the industrys first water level data logger designed
for convenient wireless setup and download from mobile
devices via Bluetooth Low Energy. The MX2001 dramatically
simplifies and lowers the cost of field data collection by providing
wireless access to high-accuracy water level and temperature
measurements right from a mobile phone or tablet. Researchers
no longer need to take a laptop computer out to the field or pull
data loggers out of a well to download data. For more information,
visit www.onsetcomp.com/mx2001.

54 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com


VANTON PUMP & EQUIPMENT
Thermoplastic Chem-Gard CGA Pump
Plant services personnel and pump specifying engineers responsible for handling
corrosive, abrasive, and other aggressive fluids can now use Chem-Gard CGA
thermoplastic pumps, which are inert to such liquids and thereby provide longer
service life than metallic or fiberglass pumps. They meet ANSI B-73.1 standards
and are metal armored, thereby enabling them to handle the same nozzle
loadings as metal pumps. These centrifugal pumps are also offered in other
designs including self-priming, close coupled, mag drive, combination close-
coupled/mag drive, sealless, DIN as well as with motor types that have integral
pump shafts. For more information, call 908.688.4216 or visit www.vanton.com.

TIMKEN
Revolvo Split Roller Bearing Housed Unit
The Timken Company introduces its full Revolvo split cylindrical roller
bearing housed unit line to the North American marketplace. Timken added
the Revolvo line, which is well-known across Europe, to its bearing and
power transmission product line-up when it acquired the assets of Revolvo
Ltd. late last year. Revolvo split cylindrical roller bearing housed units are
widely used by mining, power generation, food and beverage, pulp and
paper, metals, cement, marine, and wastewater end users. The units and
components are fully interchangeable with most split cylindrical bearing
configurations in the market today. For more information, contact Matt Evans,
communications manager, at 234.262.3381 or matt.evans@timken.com.

WELLS LAMONT INDUSTRIAL


FlexTech I2459 Gloves
Wells Lamont Industrial, a worldwide leader and US manufacturer of hand and
arm protection, introduces the FlexTech I2459, an ANSI Cut Level 5 palm
dipped impact glove. Ideal for oil and gas, mining, and heavy construction
environments, the I2459 provides an extra level of protection to the back of the
hand and fingers. The soft and flexible TPR pads protect hands from impacts and
blows. Additionally, the sandy nitrile palm coating maintains a firm grip in wet
and oily applications. Manufactured using a unique blend of high performance
fibers and stainless steel, the I2459 delivers ANSI Cut Level 5 protection in
a form-fitting, comfortable machine knit shell. For more information, email
marketing@wellslamont.com or call 800.247.3295.

BAYCO PRODUCTS, INC.


Nightstick NSP-4608BC Dual-Light Multi-Function Headlamp
Bayco Products, Inc. has introduced their newest Nightstick NSP-4608BC
Dual-Light Multi-Function Headlamp with helmet lamp bracket clip.
Designed to meet the demand of an underserved and growing number
of helmet users, this low-cost and high-quality LED headlamp features a
durable stainless clip that mounts directly to existing helmet lamp brackets.
With five unique lighting modes that include a spotlight for distance and
floodlight for close-up illumination, the Nightstick NSP-4608BC is powered
by 3 AAA batteries (included) at an average retail price of only $34.95. For
more information, visit www.baycoproducts.com.

www.modernpumpingtoday.com Modern Pumping Today | October 2015 | 55


PUMPING TRENDS

The Growth
of Big Green
NuTerras Aaron Zahn on environmentally
responsible and economically viable technology

A
aron Zahn is president material handling more difficult. That knowledge base
and CEO of NuTerra, allows NuTerra to deliver exactly what we say we willor
which is leading the better.
transformation of the wastewater
and organic waste industry to MPT: Government regulations, resource pollution, and
mitigate the global water crisis. increasing energy costs are the three top factors facing
He recently spoke with Modern many municipalities as well as handling and treatment
Pumping Today to explain how facilities. What options can NuTerra provide for cost-
NuTerra has quickly become effective and environmentally sound waste management?
a preeminent developer and
operator of public and private Aaron Zahn: With the resources NuTerra brings to our
organics waste recycling facilities. For more information, clients, the options are practically limitless. We can come
visit www.nuterra.green. into a facility, bring in our technology, and take on that
risk from the private entity or alleviate that risk from the
MPT: What are some of the advantages NuTerra brings public. Typically, we structure our transactions in the form
to projects for managing and implementing biosolid and of public-private partnerships where what we bring to
other material handling solutions? the public sector is our capability and understanding how
technologies can be interconnected to create a successful
Aaron Zahn: The number one advantage is 100 percent project and then maintaining that project over its lifecycle.
success on a lifecycle basis. When youre looking at the The key to success is creating predictable costs. Its
track record of solids handlingbe it biosolids or food unpredictable costs that cause infrastructure difficulty.
waste or most processes with a material handling element When the public sector is unprepared for these costs,
to themthe industry as a whole is proliferated with thats when they have to go back to their rate base for
failures. Often time this is due to working with a waste more revenue.
stream that is regulated like water but managed like
solid waste. Unfortunately, theres never been an industry MPT: Municipalities are frequently caught with
leader or a professional organization that emphasizes underperforming and out-of-date infrastructure. What are
how to operate within the confines of the regulations but some of NuTerras options for these operators?
also engineer systems that take into account the material
handling element. Aaron Zahn: Theres a great deal of innovation in our
About six years ago, we started by aggregating industrywhether it be in energy conservation, energy
wastewater facilities into a database. Were now able to production, resource reutilizationyet at a state level
model exactly their unit cost and how they operate, which regulations are getting more and more stringent. What
then allows us to forecast model of any of our prospective NuTerra can provide is a series of design solutions
clients. When we forecast for a client, we can show them that adapt over a ten- to twenty-year framework. For
where theyre going to spend their money as well as example, many of our designed facilities in Florida are
what to do and what not to do when addressing the solid now providing 100 percent reuse on their water and 100
handling elements of organic waste. For example, we percent reuse on their solids. Were a big believer that
could advise a client not to design an auger system in using less energy is better than producing more, and
excess of 20 feet to avoid replasticizing and making their energy efficiency is at the core of our design solutions.

56 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com