D E C E M B E R 2 0 15

PUMPSANDSYSTEMS.COM

SYSTEMS
®

The Leading Magazine for Pump Users Worldwide

The Evolution of

POWER
GENERATION
Integrate old and new technology to
adapt to a changing landscape.

8 Common Pump
Misapplication Problems

A Practical Guide to
Oil Analysis

Trade Show Preview

POWER-GEN &
2015 Groundwater Expo

ANNUAL PRODUCT SHOWCASE

Circle 100 on card or visit psfreeinfo.com.
2

From the Editor EDITORIAL

SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
aarchibald@cahabamedia.com • 205-278-2843
SENIOR TECHNICAL EDITOR: Mike Pemberton

P umps & Systems magazine has

enjoyed a stellar 2015 and is
proud to have shared it with you. Our
columnists and other experts have
provided information on everything
from upcoming energy efficiency rule
changes to advancements in system
monitoring, from the actions of pump
companies in the case of natural
disasters to challenges faced by today’s
oil and gas industry.
We are especially pleased with our
staff reporting, which in 2015 brought
readers stories from five continents.
Pumps & Systems is truly the voice of
the global pump industry.
mpemberton@cahabamedia.com
205-314-8279
MANAGING EDITOR: Amelia Messamore
amessamore@cahabamedia.com
205-314-8264
MANAGING EDITOR: Martin Reed
mreed@cahabamedia.com • 205-278-2826
MANAGING EDITOR: Savanna Gray
sgray@cahabamedia.com • 205-278-2839
DIGITAL COMMUNITY MANAGER: Amy Cash
acash@cahabamedia.com • 205-314-8274
CONTRIBUTING EDITORS: Lev Nelik,
Ray Hardee, Jim Elsey
CREATIVE SERVICES
Pumps & Systems columnist Ray Hardee (far left)
visited with staff including (from left to right) SENIOR ART DIRECTOR: Greg Ragsdale
Amelia Messamore, Amy Cash, Savanna Gray, Mike ART DIRECTOR: Melanie Magee
Pemberton and Martin Reed in October.
WEB DEVELOPER: Greg Caudle

In 2016, we will continue to provide PRINT ADVERTISING TRAFFIC: Lisa Freeman

lfreeman@cahabamedia.com • 205-212-9402
the most relevant and timely technical articles and case studies that offer solutions
to your pump challenges. Look for in-depth reports on the state of the industry CIRCULATION
worldwide, insights on cybersecurity and the development of the Internet of Th ings in AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
relation to rotating equipment and further coverage of the water, wastewater, chemical, lmasaoay@cahabamedia.com • 205-278-2840
food and beverage, oil and gas, and aftermarket industries. ADVERTISING
We are happy to close out 2015 with our power generation issue. Inside you will fi nd NATIONAL SALES MANAGER: Derrell Moody
an article about remanufacturing in the power generation industry to extend pump dmoody@pump-zone.com • 205-345-0784
life on page 28. On page 34, there is an informative story about how EPA regulations ACCOUNT EXECUTIVES:
encourage innovation, and a feature about advanced engineering that improved Mary-Kathryn Baker
mkbaker@pump-zone.com • 205-345-6036
reliability on a boiler feed pump is on page 36.
Mark Goins
Pumps & Systems staff will be available at the POWER-GEN trade show in Las Vegas mgoins@pump-zone.com • 205-345-6414
later this month. We look forward to seeing some of you there. Visit us at booth 5347. Addison Perkins
In the meantime, the staff of the magazine would like to thank you for your aperkins@pump-zone.com • 205-561-2603
continuing interest in our publication. If you have any ideas or suggestions, please let us Garrick Stone
know. You can always reach me at my email address, aarchibald@cahabamedia.com. gstone@pump-zone.com • 205-212-9406
We would love to hear from you! MARKETING ASSOCIATES:
Ashley Morris
amorris@cahabamedia.com • 205-561-2600
Best wishes, Sonya Crocker
scrocker@cahabamedia.com • 205-314-8276
Alecia Archibald
Senior Editor, Pumps Division

PUBLISHER: Walter B. Evans Jr.

VP OF SALES: Greg Meineke
CREATIVE DIRECTOR: Terri J. Gray
CONTROLLER: Brandon Whittemore

Pumps & Systems P.O. Box 530067

is a member of the following organizations: Birmingham, AL 35253
EDITORIAL & PRODUCTION
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals 1900 28th Avenue South, Suite 200
postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the
right to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and Birmingham, AL 35209
possessions $5, all other countries $15 US funds (via air mail). Call 630-739-0900 inside or outside the U.S. POSTMASTER: Send changes of address and 205-212-9402
form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. ©2015 Cahaba Media Group, Inc. No part of
this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the
factual accuracy of any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the ADVERTISING SALES
authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba 2126 McFarland Blvd. East, Suite A
Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements
contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submis- Tuscaloosa, AL 35404
sion, you grant Cahaba Media Group, Inc., permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any 205-345-0784
medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will not be
returned. Volume 23, Issue 12.

D e c e mb er 2015 | Pum ps & S y st e m s

Circle 102 on card or visit psfreeinfo.com.
4
This issue DECEMBER Volume 23 • Number 12
COLUMNS
COVER
SERIES POWER GENERATION PUMPING PRESCRIPTIONS
16 By Lev Nelik, Ph.D., P.E.
Pumping Machinery LLC
State of Global Efficiency Standards
Last of Two Parts
PUMP SYSTEM IMPROVEMENT
20 By Ray Hardee
Engineered Software Inc.
Troubleshooting Pumps in a System
First of Two Parts

COMMON PUMPING MISTAKES

28 22 By Jim Elsey
Summit Pump Inc.
28 CONSIDER REMANUFACTURING AS PART OF POWER GENERATION 8 Common Pump Misapplication
PUMP MAINTENANCE Problems
By Darrell Howard, Sulzer
A properly structured and managed program can enable large sites with vast INDUSTRY INSIGHTS
numbers of assets to increase productivity while maintaining a plant’s
long-term reliability. 26 By Mike Pemberton
Pumps & Systems
34 EPA REGULATIONS ENCOURAGE POWER INDUSTRY INNOVATION How the Power Industry Can Adapt to a
By Bill Livoti, WEG Changing Landscape
The Clean Power Plan and emphasis on efficiency are moving power utilities to
optimize pumping systems.
2 FROM THE EDITOR
36 ADVANCED ENGINEERING BOOSTS RELIABILITY IN BOILER FEED PUMP 8 FROM THE READERS
By Dr. Gary Dyson, Hydro Inc. 10 NEWS
& Jesse Stinson, Hydro Parts Solutions Inc.
48 TRADE SHOW PREVIEW
This approach incorporated reverse engineering, design verification
and casting simulation to address equipment failure. 84 ADVERTISERS INDEX
40 THREE-SCREW PUMPS OVERCOME COMMON 84 PUMP USERS MARKETPLACE
POWER GENERATION CHALLENGES 88 PUMP MARKET ANALYSIS
By David Bazel, Leistritz Advanced Technologies Corp.
The positive displacement technology handles
backpressure fluctuations, cavitation and air entrainment.
44 CHOOSING THE PROPER VFD CAN
LIMIT HARMONICS
By Jeffery Lovelace, National Power Quality and
Consulting LLC
Facilities predominantly using these drives may face
concern from power utility companies.

40 36
D e c e mb er 2015 | Pum ps & S y st e m s
The Triton Screw Centrifugal Pump combines the benefits of Vaughan’s UNMATCHED
RELIABILITY with the advantages of highly efficient, non-clog performance. Triton’s screw
centrifugal impeller is ideal for handling thick sludges, large solids, shear sensitive fluids
and delicate or highly abrasive material.

- Steep performance curves

- Heavy-duty power frames
- Expedite pumps and parts availability

See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP

Circle 111 on card or visit psfreeinfo.com.

6
This issue
SSPECIAL
PECIAL PRODUCT SHOWCASE
SECTION
68 INNOVATIVE PRODUCTS, TECHNOLOGIES AND SOLUTIONS
FROM SELECTED SUPPLIERS
PRACTICE & OPERATIONS
74 GET THE MOST FROM LUBRICANTS
THROUGH QUALITY OIL ANALYSIS
Last of Two Parts
By Michael Barrett, TestOil
77 VFDS ELIMINATE NEED FOR NEW
GENERATOR
By Greg Miller, Yaskawa
80 GLOBAL WASTEWATER CHALLENGES PLACE
PRESSURE ON AGING INFRASTRUCTURE
Second of Six Parts
By Horst Sturm, KSB
82 IN HAZARDOUS AREAS, EXPLOSION-PROOF
SUBMERSIBLE PUMPS ALLEVIATE
SAFETY WORRIES
By Mike Bjorkman, BJM Corp.
82
EDITORIAL ADVISORY BOARD
THOMAS L. ANGLE, P.E., MSC, Vice
President Engineering, Hidrostal AG
BRYAN S. BARRINGTON, Machinery
Engineer, Lyondell Chemical Co.
KERRY BASKINS, VP/GM, Milton Roy
Americas
R. THOMAS BROWN III, President,
Advanced Sealing International
(ASI)
CHRIS CALDWELL, Director of
Advanced Collection Technology,
Business Area Wastewater Solutions,
Sulzer Pumps, ABS USA
JACK CREAMER, Market Segment
Manager – Pumping Equipment,
Square D by Schneider Electric
D e c e mb er 2015 | Pum ps & S y st e m s
On the Cover: A boiler feed
pump in a power station
(Courtesy of Sulzer)
BOB DOMKOWSKI, Business
Development Manager – Transport
Pumping and Amusement Markets/
Engineering Consultant, Xylem, Inc.,
Water Solutions USA – Flygt
WALT ERNDT, VP/GM, CRANE Pumps
& Systems
JOE EVANS, Ph.D., Customer &
Employee Education, PumpTech, Inc.
LARRY LEWIS, President, Vanton
Pump and Equipment Corp.
WILLIAM LIVOTI, Business
Development Manager/Energy
Efficiency Specialist, WEG Electric
Corporation
DECEMBER
DEPARTMENTS
50 BUSINESS OF THE
BUSINESS
Industrial Internet of Things to
Impact the Pump Business
By Arun Prasath
Frost & Sullivan
52 EFFICIENCY MATTERS
The Case For Metering Pumps in
Power Generation
By Tom O’Donnell, Neptune
Chemical Pump, part of PSG
& Bill Ehrhardt,
McCloud Enterprises LLC
54 MAINTENANCE MINDERS
How to Properly Manage
Piping Loads
By Jack Claxton
Patterson Pump Company,
a Gorman-Rupp Company
58 MOTORS & DRIVES
Pick the Right VFDs for
Progressive Cavity Pumps
74 By Gordon Fenton
SEEPEX Inc.
62 SEALING SENSE
Material Advances Improve
Seal Reliability in Extreme
Application Conditions
By Doug Volden &
Sam Ajram
FSA Members
65 HI PUMP FAQS
Determining NPSH3,
Comparing Axial Thrust &
Evaluating Boiler Circulating
Pumps
By Hydraulic Institute
TODD LOUDIN, President/CEO North SCOTT SORENSEN, Oil & Gas
American Operations, Flowrox Inc. Automation Consultant & Market
MICHAEL MICHAUD, Executive Developer, Siemens Industry Sector
Director, Hydraulic Institute ADAM STOLBERG, Executive Director,
Submersible Wastewater Pump
JOHN MALINOWSKI, Sr. Product
Manager, AC Motors, Baldor Electric Association (SWPA)
Company, A Member of the PAUL SCHLUMPBERGER, President,
ABB Group Pioneer Pump
WILLIAM E. NEIS, P.E., President, DOUG VOLDEN, Global Engineering
Northeast Industrial Sales Director, John Crane
LEV NELIK, Ph.D., P.E., APICS, KIRK WILSON, President, Services &
President, PumpingMachinery, LLC Solutions, Flowserve Corporation
HENRY PECK, President, Geiger Pump JAMES WONG, Associate Product
& Equipment Company Manager – Bearing Isolator, Garlock
Sealing Technologies
MARIANNE SZCZECH, Director,
Global Marketing and Product
Management, Pump Solutions Group
Circle 110 on card or visit psfreeinfo.com.
8
From the Readers
“Efficiency Monitoring Saves
Plants Millions”
SEPTEMBER 2015
Several readers have written to the
Pumps & Systems editorial team and
to Dr. Lev Nelik, author of his regular
column “Pumping Prescriptions,”
asking questions about the
characteristics of 300 and 400 series stainless steel
as discussed in Part 3 of “Efficiency Monitoring Saves
Plants Millions” and in the editor’s note accompanying
“State of Global Efficiency Standards” (Pumps & Systems,
November 2015).
“Rethinking NPSH”
AUGUST 2015
Readers respond to Jim Elsey’s
column, “Common Pumping
Mistakes: Simple Solutions for
End Users.”
Mike Wisnoski, reliability engineer at John Crane, writes:
This was a very good article. It really surprises me just how
many plant personnel misunderstand NPSHA and NPSHR.
What I found that sticks with people, especially engineers,
is explaining it in simple terms.
NPSHA (at pump suction) = the net margin of the fluid
above its vapor pressure.
NPSHR = the net drop through the pump.
Thus NPSHA is greater than NPSHR, or you will fall
below the vapor pressure.
If one understands what it is, then they can easily
calculate it.
De c e mb er 2015 | Pum ps & S y st e m s
Dr. Nelik clears up these questions:
The 300-series (austenitic) is non-magnetic. The 400
series (martensitic), as well as plain carbon steel, are
magnetic. Actually, sometimes the 300 series has a slight
magnetic pick—usually the cast parts, but in most cases,
it is not magnetic.
To read Dr. Nelik’s entire series, visit
pumpsandsystems.com/efficiency-monitoring.
Jim Elsey replies:
Thanks for the kind comment about the article. I write
about real issues that I witness on a daily basis in the
real world. It is my intent to help the current and next
generation of engineers, operators and technicians in the
pump business. NPSH is surely one of those areas that trips
up a lot of people. Your point is also good. Actually whatever
method helps the people understand and remember
correctly is fine as long as you get to the correct answer.
JOIN THE DISCUSSION
Become a member of our LinkedIn
group, Pumps & Systems, to participate
in pump-related discussions with more
than 20,000 industry professionals.
Follow us on Twitter
@PumpsSystemsMag
Like us on Facebook
Pumps & Systems
 9

pu mpsa ndsyst
Circle 107ems.c om
on card or |visit
D ecpsfreeinfo.com.
emb er 2015
10 NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
MARK JOHNSON, IWAKI AMERICA
HOLLISTON, Ma. (Oct. 27, 2015) – In support of
Iwaki America’s soon-to-be-launched Iwaki Air
brand of air-operated double diaphragm pumps
(AODD), the company has added Mark Johnson
as the business development manager of AODD
pumps. Johnson comes with a long history of
employment in the pump industry, including Mark Johnson
having spent the majority of the last 10 years
involved in product management, operations,
sales, marketing and business development of AODD
pumps regionally and globally. iwakiamerica.com
EDWIN LAABS, MP PUMPS
FRASER, Mich. (Oct. 27, 2015) – MP Pumps has
announced that Edwin Laabs has joined the
company’s management team as the global
vice president of sales and marketing. Laabs
brings extensive experience in industrial sales
and marketing to the MP team. Laabs has
worked with OEMs and industrial distribution Edwin Laabs
for 31 years. He serves on the Industrial Supply
Association’s Board of Directors.
mppumps.com
GERAUD DARNIS, ITT CORPORATION
WHITE PLAINS, N.Y. (Oct 20, 2015) – ITT
Corporation has elected Geraud Darnis to its
Board of Directors. Darnis, 55, is president
and chief executive officer of UTC Building
& Industrial Systems. Darnis announced
his retirement from United Technologies
Corporation (UTC) effective January 2016. He Geraud Darnis
has held a number of executive leadership
positions during his more than 30-year career
with UTC. He served as president and CEO of the Climate, Controls &
Security business; president of Carrier Corporation and UTC Power;
and president of Carrier’s operations in the Asia-Pacific and Europe,
Middle East and Africa regions. itt.com
FRED WIESLER, QUA
CANONSBURG, Pa. (Oct. 20, 2015) – QUA has
announced that Fred Wiesler has joined the
company as director of sales and marketing.
Wiesler brings more than 30 years of experience
in the water industry in both engineering and
business development along with a successful
track record that includes international sales
Fred Wiesler
and marketing, bringing new product lines
to market, managing a global sales force
and developing business with OEMs and other industry suppliers.
Wiesler’s experience encompasses a wide range of water treatment
technologies. quagroup.com
De c e mb er 2015 | Pum ps & S y st e m s
MARCUS PILLION, TRITEC SEAL LLC
SWARTZ CREEK, Mich. (Oct. 15, 2015) – TriTec
Seal LLC has named Marcus Pillion as CEO.
Pillion will be responsible for TriTec’s global
strategic operations with a primary focus on
expanding current seal thought leadership and
overall company growth. In his career, Pillion has
been involved in numerous facets of business, Marcus Pillion
including general management, sales, marketing,
engineering, supply, installation and service.
Pillion has more than 22 years of experience in the pump, seal and
engineered systems industry. tritecseal.com
THOMAS MORRISON & ROB
MONTENEGRO, GRUNDFOS
DOWNERS GROVE, Ill. (Oct. 14,
2015) – Grundfos has appointed
Thomas Morrison as vice
president of service and Rob
Montenegro as vice president of
municipal sales. Morrison will Thomas Rob
oversee the pump manufacturer’s Morrison Montenegro
service group across all business
units and sectors, including commissioning, energy analysis/audit,
service agreement and part specialists, and factory service centers.
Morrison will retain his business development responsibilities within
North and South America for the water utility segment. Montenegro
will lead water utility sales, which includes a range of water supply
and wastewater applications solutions for municipal markets.
grundfos.com
CARL W. SMITH, VAL-MATIC
ELMHURST, Ill. (Oct. 8, 2015) – Val-Matic’s vice
president of sales and marketing, Carl W. Smith,
will retire on March 31, 2016, after a 32-year
career with Val-Matic Valve and Manufacturing
Corp. During his tenure, Smith opened new
markets for Val-Matic across the globe in
international sales, and he later became national Carl W. Smith
sales manager. As vice president of sales and
marketing, he helped launch several new valve products and built
a successful representative network in the water and wastewater
industry. valmatic.com
DEAN TAYLOR, DXP/PHOENIX
PHOENIX, Ariz. (Oct. 5, 2015) – As part of its
western region expansion, DXP/Phoenix has hired
Dean Taylor as mechanical engineer/technical
sales. Taylor began his career with Parker
Hannifin as a field service technician for heavy-
duty mining equipment. He also has served with
Metso Minerals as wear products specialist for
Dean Taylor
mining and industrial equipment. dxpe.com
 11

EVENTS Chemical Metering Pumps and Flowmeters

Lateral & Torsional
Rotodynamics for Centrifugal &
for Successful Water & Waste Water Treatment.
Reciprocating Machinery
December 8–9, 2015
Southwest Research Institute
ÛBHAT*LNK
Laneop]hpe_ÛIapanejcÛÛ
Û
®

San Antonio, Texas Ejfa_pknÛLqil

210-522-2537 Three Models
Available with Feed
POWER-GEN International Rates Ranging from
December 8–10, 2015 0.1 GPH/.03 LPH to
158 GPH/600 LPH.
Las Vegas Convention Center
Las Vegas, Nev. Brushless Variable
Speed Motor.
918-831-9160
Terminal Blocks in
Junction Box for
National Groundwater Remote Connections.
Association Expo & Annual Patented Tube Failure
Meeting (NGWA) Detection, Patented
December 15–17, 2015 Safety Switch,
Las Vegas Convention Center Patented Method for
Extended Tube Life.
Las Vegas, Nev.
IP
P66
Advanced Membrane NE
EMA
A 4X
Technology for Water and ]GY
GY
YN"J
N JU]T
N"JU
U]
Wastewater Treatment
December 16–17, 2015
Century Park Hotel EXCLUSIVE! NEW
Bangkok, Thailand
66-2-933-0077

2016 AHR Expo Flex-A-Prene® is a multi-channel pump

January 25–27, 2016 tube assembly designed by Blue-White
exclusively for Proseries-M® and Flex-Pro®
Orange County Peristaltic Metering Pumps.
Convention Center Flex-A-Prene® is engineered for
Orlando, Fla. optimum performance and
203-221-9232 pressure capability.

International Production &

Processing Expo
January 26–28, 2016
Georgia World Congress Center
OKJE?*LNK Û
Qhpn]okje_ÛBhksiapano)ÛÛ
®

Atlanta, Ga. @alaj`ÛkjÛpdaÛÛ

678-514-1977 Ù__qn]_u
Works with clean or dirty fluids.
Non-invasive Clamp-on ransducers.
Circle 115 on card or visit psfreeinfo.com.

Full Spectrum of Pipe Size Capacities.

MERGERS & “Smart” External Communications.
Selectable Doppler or Transit Time.
IP
P66
ACQUISITIONS T-Track Mounting System for Fast and
Easy Sensor Installation, with Nema
d NE
EMA 4X
]GY
GY
YN"J
N JU]T
N"JU
U]
4X Quick Disconnects.
ITT acquired Wolverine Advanced
Materials
Oct. 5, 2015

GE completes acquisition of Alstom Power

5300 Business Drive, Huntington Beach, CA 92649 USA
and Grid Businesses
Nov. 2, 2015
714-893-8529 • fax: 714-894-9492 • sales@blue-white.com
www.blue-white.com
pu mpsa ndsyst ems.c om | D ec emb er 2015
12 NEWS
AROUND THE INDUSTRY
GE’s Largest Industrial
Acquisition Creates
New Power Division
SCHENECTADY, N.Y. (Nov. 2, 2015)
GE has announced that with the
completion of its Alstom acquisition,
GE Power & Water and Alstom Power
have combined to form GE Power.
Headquartered in Schenectady, N.Y.,
Steve Bolze will serve as president and
CEO of GE Power, leading more than
65,000 employees in more than 150
countries with estimated revenue of
$30 billion.
“We now offer utility and industrial
power plant operators even more
complete, customized ‘one-stop shop’
solutions—not just for developing
new stations but also optimized life
cycle support for existing facilities
to support local energy security. Our
portfolio of technologies includes
the world’s largest and most efficient
gas turbine—the HA, full power plant
components, boilers, steam turbines,
reciprocating engines and more,” Bolze
said. ge-alstom.com
Shell Completes Two
Downstream Divestments
THE HAGUE, Netherlands (Nov. 2,
2015) – Royal Dutch Shell plc (Shell)
has announced the completion of
two divestments from its global
downstream portfolio.
In France, the company has
completed the sale of its Butagaz
LPG business to DCC Energy. The
transaction is a share sale, and all
Butagaz staff, together with the
Butagaz brand, have passed to DCC
Energy. The completion follows the
announcement in May that Shell had
received a binding offer from DCC and
follows consultation with the staff
councils of Butagaz and Shell France,
as well as regulatory approval. Shell’s
other businesses in France—aviation,
commercial fleet, lubricants, retail and
bitumen—are not impacted.
Separately, Shell has also completed
the sale of its 75 percent interest in
Tongyi Lubricants in China to Huo’s
Group and The Carlyle Group, following
regulatory approval. The commercial
terms of the agreement will remain
confidential. shell.com
To have a news item considered, please send the information to Amelia Messamore, amessamore@cahabamedia.com.
De c e mb er 2015 | Pum ps & S y st e m s
SPOTLIGHT
TWO NEW APPS FOR ELECTRICAL & PUMP PROFESSIONALS
(Nov. 3, 2015) – SFA Soft has launched two smartphone apps, Electric Calcs and
Pump Calcs, which are now available for both Apple (App Store) and Android
(Google Play) devices and can be downloaded for free. The free versions allow
access to the basic “Lite” technical calculators. There is a one-time cost of 99
cents for Electric Calcs and $1.99 for Pump Calcs to remove ads and enable the
use of the more advanced “Pro” technical calculators.
The Electric Calcs app is a bundle of 30-plus versatile calculators developed
expressly for professionals designing and installing electrical systems. The
Pump Calcs app is a bundle of 30-plus useful calculators developed specifically
for pumping machinery professionals. sfasoft.com
can slash related emissions by nearly
APATEQ Opens U.S. Subsidiary
half, according to a study released
LUXEMBOURG (Oct. 27, 2015) – APATEQ
by Xylem Inc. The analysis further
has announced the opening of its first
concludes that 95 percent of electricity-
subsidiary in the U.S. The company will
related emissions abatement can be
focus on offering solutions and support
achieved at negative or neutral cost.
services for the treatment of fracking
“Powering the Wastewater
flowback and produced water directly
Renaissance” provides an analysis of
to the U.S. market. The new subsidiary
energy efficiency in the wastewater
will be responsible for all go-to-market
activities around APATEQ solutions in management industry and assesses
North America and will act as a hub how the global water sector can reduce
for all North American cooperation harmful greenhouse gas emissions
partners of APATEQ. apateq.com with existing, proven technologies. The
report, which studied the wastewater
GIW Industries Enters Sales & sector in the U.S., Europe and China,
Service Deal with Outotec assessed 18 distinct abatement
GROVETOWN, Ga. (Oct. 22, 2015) opportunities—from pumps used to
KSB’s U.S. subsidiary GIW Industries transport the water to the blowers used
Inc. has entered into a sales and service to aerate it to the various filtration
partnership with Finnish company systems used to treat it.
Outotec. Outotec is a globally active xyleminc.com
company offering technologies and
services for the metal and mineral University Research Could
processing industries. GIW is part of Increase Sustainable
the KSB Group and manufacturers Manufacturing Systems
slurry pumps that are primarily used CORVALLIS, Ore. (Oct. 14, 2015)
in mining applications. Outotec will Engineers at Oregon State University
sell and service GIW pumps for global have developed a new “sustainable
hardrock mining in the future. development methodology” to address
a social and regulatory demand for
giwindustries.com
manufacturing processes that more
effectively consider their economic,
Xylem Identifies Significant
Energy-Efficiency Opportunity environmental and social impacts.
The work was recently published in
in Wastewater Management
RYE BROOK, N.Y. (Oct. 20, 2015) the Journal of Cleaner Production. It
outlines a way to help designers and
Increasing energy efficiency through
the adoption of readily available manufacturing engineers carefully
consider all the ramifications of their
wastewater management technologies
design decisions and to evaluate the
 13

possible different ways that a product

could be built—before it ever hits the
assembly line.
This movement, researchers say,
evolved more than 20 years ago from an
international discussion at the United
Nations Conference on Environment and
Development, which raised concerns about
the growing scarcity of water, depletion of
non-renewable sources of energy, human
health problems in the workplace and other
issues that can be linked to unsustainable
production patterns in industry.
To aid that effort, OSU researchers created
a new methodology that incorporates
unit process modeling and an existing
technique called life-cycle inventory. This
allowed them to quantify a selected set
of sustainability metrics and ask real-
world questions. This work was supported
by the Boeing Company and the Oregon
Metals Initiative. engineering.osu.edu

Indonesia Pipeline Awaits

Policy Clarity
BOSTON, Mass. (Oct. 13, 2015) – Since
launching its 2010 Master Plan, Indonesia
has amassed a sizable water infrastructure
pipeline of 32 public-private partnerships
(PPP) requiring more than US$2.5 billion
of investment in a time of regulatory
uncertainty. Following a 10-year hiatus,
during which no PPP projects were awarded
in the country, two legal decisions in 2015
have shaken the country’s receptiveness to
private water investment.
In February, the Constitutional Court
repealed the 2004 Waterworks Law, and
in March, Jakarta’s court annulled two
concession contracts awarded to private
water players PT Air Aetra (Acuatico) and
PT Palyja (Suez Environnement). A new
Water Law is pending and will be critical to
moving the sector forward once legislated.
Bluefield Research has released a
new Market Insight, Policy Bottlenecks
Challenge Indonesia’s Water PPP Program,
that analyzes the current state of
Indonesia’s market for new water supply
Circle 116 on card or visit psfreeinfo.com.

infrastructure investment and provides

a near-term outlook for development.
Indonesia’s water utility segment,
fragmented since decentralization began
in 2000, now hosts more than 350 firms,
of which more than half are not financially
viable. While smaller water utilities are
short of funds and struggling to meet
performance criteria, the upcoming Bandar
Lampung water supply project tender will
prove to be crucial test for the country’s
policymakers and their commitment to the
PPP program. bluefieldresearch.com

pu mpsa ndsyst ems.c om | D ec emb er 2015

14 NEWS
AuCom Electronics Ltd of New
Zealand Establishes AuCom
North America
FREEDOM, Pa. (Oct. 2015) – AuCom
Electronics Ltd. of New Zealand has
announced a new company, AuCom
North America Inc.
This new company has been
established to service and support the
low voltage and medium voltage soft
starter customers in North America
by providing engineering/application
support, off-the-shelf delivery of
standard product and product
customized to your needs.
aucom.com
Singer Valve Inc. Launches Free
Online Educational Tool for
Control Valves
SURREY, British Columbia (Oct. 8, 2015)
Singer Valve has launched MetroH2O,
an online educational tool for control
valve users.
“We have had a great response from
customers who are using MetroH2O as
FAST TURN AROUND ON PUMP COMPONENTS
On time delivery you can count on
260.724.9430 | HOOSIERPATTERN.COM | 906 N 10TH ST, DECATUR, IN 46733
De c e mb er 2015 | Pum ps & S y st e m s
a training refresher for their operators.
We are hoping to also get an engineering
post-secondary institution on board
to give students a more in depth
understanding of control valves,”
said Mark Gimson, marketing and
business development manager for
Singer Valve.
When a user accesses the Singer Valve
website, MetroH2O is at the forefront
showcasing 11 different valves that are
commonly found in city waterworks.
By clicking on a valve, the user can see
where the valve fits in the system and
a further detailed animation of how it
operates with pressure fluctuations, flow
changes, level variations and pump and
surge control.
The online tool also includes
specification sheets and operating
guides for users that need to design,
maintain or operate the valve. As an
online tool, MetroH2O will continue to
evolve with more interactive features
and additional equipment.
singervalve.com
Cut costs and improve your bottom line
Report Highlights Municipal
Water Market Growth in the
Philippines
BOSTON (Oct. 5, 2015) – Private water
concessions in Manila have driven water
coverage from under 60 to nearly 100
percent between 1997 and 2015 and
created a more positive environment for
private company participation.
Domestic players have emerged
out of this transformation, Manila
Water Company and Maynilad,
which have become benchmarks for
water infrastructure public-private
partnerships in developing countries.
Their success points to private water
infrastructure investment beyond Manila
that hinges on regulations, standardizing
contract structures and guaranteeing
contracts to attract investors.
Bluefield Research has released a new
Market Insight, “The Philippines Extends
Water PPPs Beyond Manila,” which
analyzes emerging opportunities in the
Philippines to develop its municipal
water market nationally.
bluefieldresearch.com
Circle 122 on card or visit psfreeinfo.com.
 15

Circle 105 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

16 PUMPING PRESCRIPTIONS
Troubleshooting & repair challenges
State of Global Efficiency Standards
Last of Two Parts
P
art 1 of this series (Pumps
& Systems, November
2015) discussed the lack of
a formal, comprehensive global
standard on pump efficiency and
the importance of understanding
the difference between actual field
efficiencies of installed pumps
and the initial original equipment
manufacturer (OEM) efficiencies.
As noted in part 1, studies show
that the efficiencies of installed
pumps are commonly reduced
by 10, 20 and often close to 50
percent below the OEM-quoted
(rated) point.4a/b Several factors
can contribute to this trend: wear
over time (clearances), changed
flow conditions, degraded internals
(impellers, casing) and other
issues. When measuring actual
efficiencies, end users should keep
the following factors in mind.
Measurements Errors
Efficiency is the ratio of productive
power (to move flow against
pressure) to total power applied to
the unit by the electric grid (see
Equation 1).
Flow x Pressure x SG
Efficiency =
Input Power
Equation 1
Flow Meters
Flow meters are either not installed
(at least not per each pump) or not
calibrated for a long period of time.
External flow meters (ultrasonic
or similar) require straight piping
De c e mb er 2015 | Pum ps & S y st e m s
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
runs before and after the meter, definition: What power? Is it
as well as knowledge of the piping power delivered to a pump (as
wall thickness, fluid characteristics OEMs report in catalogues or
and many other parameters. Most quoted curves) or to the motor
people would expect a measuring (which is what is actually
instrument to have a value of at accessible)? Is it measured at the
least +/- 0.5 percent. As studies motor box or miles away at the
show, however, reported flow data switchgear junction? Are kilowatts
from the field is often 10 to 30 measured directly or calculated
percent off the mark.5 from measured amps and volts?
Are power factor, motor efficiency
Differential Pressure and line losses taken into account?
Differential pressure (p) is usually
a simpler and easier parameter Measuring Efficiency
to measure, certainly with better A pump rarely operates at a single
accuracy and less expense as point and almost never at the best
compared with flow. efficiency point (BEP).
If an end user were to conduct
Electric Power the same test both today and
Electric power presents a tomorrow, flow would likely
controversy right from the be different. As a result, no
Table 1. A computer program estimates industrially achievable efficiency based on various
factors for the pump user to help address any problems. The following is a sample of the
program output. (Courtesy of the author)
U.S. Units Metric Units
Pump flow (GPM) 2,000 Pump flow (m3/hr) 454
Total pump head (feet) 1,234 Total pump head (meters) 376
Specific gravity (SG) 1.00 Specific gravity (SG) 1.00
Number of stages 10 Number of stages 10
Speed (rpm) 3,600 Speed (rpm) 3,600
Head per stage (feet) 123 Head per stage (meters) 38
~ Impeller diameter (inches) 6.71 ~ Impeller diameter (mm) 170.4
Specific speed (U.S., Ns) 4,348 Specific speed (U.S., Ns) 4,348
Specific speed (metric, ns) 84.3 Specific speed (metric, ns) 84.3
Specific speed (universal, Os) 1.59 Specific speed (universal, Os) 1.59
Efficiency (percent) 81.6% Efficiency (percent) 81.6%
Power (HP) 764 Power (kW) 570

meaningful comparison of these two
efficiency values can be made.
Trending & Online Live
Trending, as noted above, suffers
from lack of flow constancy from one
measurement to the next. Doing a live
test (by opening and closing valves to
construct the entire curve) is a much
better way to have an apples-to-apples
comparison. This method determines
BEP, and all tests are consistently
compared to this BEP. This is certainly
a step in the right direction, but it
requires significant involvement of
plant personnel—including operators
and mechanics—which is why such
tests can be logistically difficult to
arrange. A continual automated test is
a much better approach and is gaining
popularity.7 This method involves
installed measuring equipment and
We Deliver!
sales@tfsealsusa.com
Phone: 1.713.568.5547
Fax: 1.713.758.0388
10620 Stebbins Cir, Suite E
Houston, TX 77043
Circle 128 on card or visit psfreeinfo.com.
17
DISCUSS THE STANDARD
A copy of the International Pumps Efficiency Standard and a list of
the advisory committee members (qualified members are welcome
to send an application to join) are available at pump-magazine.com.
Your feedback, questions and comments will be incorporated into the
standard’s next revision (Revision 3), which is planned to be released
at the next PumpTec Conference. Ongoing updates will be published in
upcoming Pumping Prescriptions columns.
probes that allow the system to acquire specific piece of equipment—how
data continually. Hardware captures reliable and efficient it is. If their
the data, and software converts this equipment is not reliable, they want
data to the actual performance and to know why and what can be done to
compares it with the OEM data. make it more reliable and last longer.
If it is not efficient, they want to know
Pump User Approach how much money the system (pump/
Many end users are not too interested motor) wastes and how it can be
in the philosophy of global concepts improved. End users typically look for a
of energy assessment or in how much specific number, not a general concept.
money can be saved if power plants The current draft (Revision 2) of
become more efficient. These users the International Pumps Efficiency
need detailed information about their Standard does just that. While
Serving Manufacturers and Distributors Over 30 Years!
TFSEALSUSA .COM
TF-P214
packing 100% Pure
Graphite PTFE yarn
PZ05 TF-P241
metal bellow cartridge packing Nomex fiber
mechanical seal and graphite PTFE
pu mpsa ndsyst ems.c om | D ec emb er 2015
18 PUMPING PRESCRIPTIONS
addressing the concepts just
discussed, the standard goes
directly to efficiency evaluation.
It incorporates a computer
program that estimates the typical
industrially achievable efficiency
based on flow, head, speed, specific
gravity and a number of stages
(for multistage pumps) and also
displays power and the expected
typical size of the impeller to
help the pump user evaluate the
immediate and obvious issues in
the application.
Other parameters are also
important, but the main thrust
of the effort is to access the most
important information quickly
and to suggest ways to rectify
any problems. Table 1 shows an
example of the program output (see
page 16).
De c e mb er 2015 | Pum ps & S y st e m s
The standard also provides
a forum for pump users to ask
questions, compare notes and find
ways to make pumps and motors
run longer and more efficiently.
References
1. Maurer, J., “Proposed Pump Efficiency
Standards,” DOE, March 18, 2015
2. Gross, A., “Energy Efficiency Indicators
for Power Drive Systems and Motor
Starters,” September 8-9, 2015,
PumpTec-Israel-2015, conducted at
Israel Water Works Association
3. Bet-Hazavdi, E., “Energy Conservation
for Rotating Machinery via Efficiency
Improvements,” DEC Israel, PumpTec-
Israel 2012
4a. Nelik, L., “Energy/Efficiency Studies by
On-Line Efficiency Monitoring System”
(PREMS-2A) www.doctorpump.com
4b. Nelik, L. and Moskovich, D., “Efficiency
Evaluation for the Vertical Turbine
Pump, Clean Water Well,” Weizmann
Institute Israel
5. Nelik, L., “Flow Measurement Forum,”
2010 www.pumpingmachinery.com/
consulting/flow_measurements/flow_
measurements.htm
6. Nelik, L., “How Accurate is Your Flow
Meter?” Pumps & Systems, October,
2011
7. Pumping Machinery Technology
Program, PREMS-2A (Pumps Reliability
and Energy Monitoring System): www.
pumpingmachinery.com/pump_school/
PVA/pva.htm (module # 11)
Dr. Nelik (aka “Dr. Pump”) is president
of Pumping Machinery, LLC, an
Atlanta-based firm specializing in
pump consulting, training, equipment
troubleshooting and pump repairs. Dr.
Nelik has 30 years of experience in
pumps and pumping equipment. He
may be reached at pump-magazine.
com. For more information, visit
pumpingmachinery.com/pump_
school/pump_school.htm.
Circle 118 on card or visit psfreeinfo.com.
 19

Circle 112 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015
20 PUMP SYSTEM IMPROVEMENT
A better understanding of complete system operation
Troubleshooting Pumps in a System
First of Two Parts
I
n the last three columns
(“Troubleshooting Piping
Systems” in the September,
October and November 2015
issues of Pumps & Systems), we
examined how a physical piping
system can be mathematically
simulated using basic engineering
equations described in hydraulic
textbooks, technical standards and
manufacturer test data. Because
all the calculations are based on
well-understood equations, one
can determine the pressure and
flow rate in the system using
the simulation. We also worked
through an example system to
calculate the head at various
locations within the system and
validate the simulation to the
physical piping system using
installed plant instrumentation. In
the example, all calculated results
closely matched the values on the
installed plant instruments.
This series will evaluate piping
systems for which the calculated
results do not match the displayed
plant instrumentation. The
difference between the calculated
values and the observed values
will allow us to troubleshoot the
example system.
This month’s column in
particular will focus on the
components of the pump and
drive. The objective is not to show
all the possible problems that can
occur in a system; instead, it is to
understand the connections of the
various components of the system
and how to use that information
to identify system problems.
De c e mb er 2015 | Pum ps & S y st e m s
Engineered Software, Inc.
Figure 1 shows the system under
normal operating conditions as
described in last month’s column.
Pump Elements
To begin, it is important to review
conditions associated with the
pump elements that can affect the
system. As discussed in previous
columns, centrifugal pumps always
operate on a pump curve. A pump
is designed to meet a specific
range of flow rates and head
values, and this information is
documented on the manufacturer’s
supplied pump curve. Figure 2
is the manufacturer’s supplied
catalog curve for the pump used
in our example system that was
tested according to Hydraulic
Institute industry standards.
The manufacturer makes this
pump available with impeller
diameters ranging from 13 to
16.75 inches. This approach allows
the manufacturer to design a
pump casing and impeller that
can operate under a range of head
Figure 1. Normal operating conditions for the example fluid piping system as calculated on the
piping system model (Graphics courtesy of the author)
By Ray Hardee
and flow values by changing the
impeller diameter.
The actual impeller diameter
supplied by the manufacturer for
this pump is 14.125 inches and is
shown as a dark line in Figure 2.
High Discharge Pressure
In this example, an operator
making his rounds notices pressure
gauge PI-101 is reading 104 pounds
per square inch (psi), which appears
to be above normal. The plant
engineer must evaluate the system
and determine why the pump has a
high discharge pressure.
The piping system displayed in
Figure 1 was validated more than
a year ago. A comparison of the
two sets of values shows that the
pressure at PI-101 is approximately
16 psi greater than expected from
the piping system model. With this
information, we must determine
first if there is a problem in our
system and, if so, what is causing it.
In cases like this, it is a good
idea to contact the operator
 21

Table 1. Comparison of observed plant instrumentation with the validated piping system model

Condition/ TK-101 PI-100 PI-101 FT-101 FCV-101 PV-102 PV-102

Value level psi psi gpm position* level psi

who reported the As observed 10 6.2 104 1,000 65% 15 25

discrepancy to see Validated 10 6.2 87.8 1,000 73.98% 15 25
if the individual * The value position is not on the operator’s log sheet.
can provide further
details. A good plant Table 1 is a comparison of the supply tank TK-101 is 10 feet in
operator can offer a wealth of current as-observed operating data the current observed operation
information and may be able to and the validated piping system and the validated system model.
provide valuable insight based on model from a year ago. The level and pressure in the
years of experience. The data in Table 1 shows the destination tank PV-102 is the
The operator in this example has flow rate through the system in same under both conditions. Based
extensive plant experience and both conditions was controlled on this, we can eliminate changes
said that it has been more than to 1,000 gallons per minute in the static head between the
six months since the individual (gpm). The only differences in current system and the validated
was assigned to this area of the the observed data are the pump’s system model for the increased
plant. The operator recalled pump discharge pressure and the pump discharge pressure.
discharge pressures at PI-101 position of control valve FCV-101. Next, we will look at the pump
between 85 and 95 psi based Because all items in a system suction pressure as indicated on
on normal plant operation. The are interconnected, the observed PI-100. Because the observed
individual also recalled that PI-100 condition could be caused by any pressure corresponds to the
pump’s suction pressure ranged piece of equipment. The validated previously validated piping system
from 4 to 8.3 psi. piping system model will help us model and the flow rate through
This indicates that the pump isolate the possible causes. the circuit of our piping system is
discharge pressure of 104 psi is My personal preference is to controlled to 1,000 gpm, we can
outside the range of expected first identify each circuit in the assume that no change in head loss
operation. After reviewing the system and then work from the in the pipeline connecting TK-101
current operating conditions and boundaries of each circuit to to the pump suction has occurred.
comparing them with the validated identify the potential problem. As a result, the suction pipeline
results, we can see that something The fact that our example system can be ruled out as a possible
has changed in the system. The consists of only a single circuit cause for an increase in the pump
next step is to determine what simplifies the process. discharge pressure.
happened and why. Table 1 indicates the level in The observed pump discharge
pressure is 16 psi greater than
Figure 2. Manufacturer’s catalog pump curve for the installed centrifugal pump the calculated value of the
PU-101, which is a 6x4-17 end suction pump operating at 1,780 revolutions per validated piping system model.
minute (rpm). The installed pump was supplied with a 14.125-inch impeller by the The abnormal discharge pressure
manufacturer to meet the original design point.
appears to be a result of the pump.
Part 2 of this series will
investigate the possible causes of
the increase in pump discharge
pressure by 16 psi.

Ray Hardee is a principal founder

of Engineered Software, creators
of PIPE-FLO and PUMP-FLO
software. At Engineered Software,
he helped develop two training
courses and teaches these courses
internationally. He may be reached
at ray.hardee@eng-software.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

22 COMMON PUMPING MISTAKES
Simple solutions for end users
By Jim Elsey
Summit Pump, Inc.

8 Common Pump Misapplication Problems

3 Speed
M
isapplication of pumps the temperature departs from
is one of the more the midrange. Consult with the Ambitious salespeople and
frequent field issues I mechanical seal and bearing unwitting customers will
witness. The issues are normally manufacturers for proper materials sometimes misapply a pump based
the result of a lack of knowledge and support systems. There will on speed.
and understanding of the physical also be a requirement for special In a typical situation, these
limits of the machine. lubricants and/or temperature individuals will install a pump
Centrifugal pumps, like all control of the lubricants. that has a speed limit (boundary)
machinery, have specific physical of 1,800 revolutions per minute
limits and boundaries for their
designed application and operation.
2 Pressure (Flange Ratings)
All pumps have a maximum
(rpm) and apply the pump at
3,600 rpm.
The purpose of this column is working and design pressure While they may understand
not to define specific limits but rating. I recently witnessed a affinity laws, they probably
to examine the process of proper user attempting to place a pump do not understand that the
selection and application. with 300-pound fl anges into a subject impeller has (rotational)
What follows is a general system that had more than 900 inertia limits and consequential
checklist of eight potential psi pressure at the suction of the deleterious effects because of high
misapplication issues. Always checkpump. The user thought this was tip speeds (tangential velocity).
with the manufacturer for specific acceptable because the pump itself The speed issues can result from
restrictions. was only going to generate 200 psi. a combination of fluid properties,
How much pressure can a 150- impeller blade torque, erosion,
1 Temperature
During my career, I have installed
pound fl ange be subjected to? There
is no simple answer, but two main
vibration and strength of materials
(think fatigue strength).
scores of pumps with operating factors are the temperature and the While this is not a complete or
fluid temperatures from minus 200 casing metallurgy. definitive list, normally accepted
to 1,000 degrees F and pressures It is acceptable to subject a 150- guidelines from American National
up to 4,500 pounds per square inch pound (fl ange) rated 316 stainless Standards Institute (ANSI) 1.3 are
(psi). In each case, the pump was steel pump to as much as 275 psi as follows:
properly and adequately designed at temperatures below 275 F. For a
for that application—usually 300-pound fl ange in 316 stainless 1. Clean water: 145 feet per second
because the users incorporated the steel, it would be 375 psi at 100 F. 2. Dirty water: 130 feet per second
proper environmental and ancillary The main point is that the 3. Slurry (general): 100 feet per
support systems, often with maximum allowable pressure second
centerline design supports. for the pump design must not be 4. Impellers (nonmetallic) or rubber
Always check the instruction exceeded. The maximum pressure coated impellers: 85 feet per
and operating manual (IOM) the pump will experience is the second
or contact the manufacturer sum of the suction pressure (at its
for applications below 40 F and highest expected level) and the Equation 1 can be used to
above 180 F. Typically, there will maximum developed pressure the calculate the velocity or tip speed.
be a requirement for materials, pump could generate at maximum Note the relationship V= ὠ x r in
isolators, seals and gaskets as speed and impeller diameter. the equation.

De c e mb er 2015 | Pum ps & S y st e m s

 23

V = (N)(D) ÷ (229) speed limits are determined by (which includes rotor weight), surface
Equation 1 the type, size (usually diameter), area, clearances, design (taper
cage design, load, lubrication and lands, for example) and lubrication
Where: temperature. Hydrodynamic (fluid properties.
V = velocity in feet per second fi lm) bearings are limited by load
N = speed in rpm
D = impeller diameter in inches

As an example, the velocity for

a 10-inch impeller at 1,750 rpm is
76.3 feet per second.
Please note that there is also a
minimum speed limit for pumps.
This was not as much of an issue
before the advent of commercially
available variable speed drives, but
it has become more of a problem.
Rotor dynamics can be
complicated, even for small slow-
speed pumps (below 1,750 rpm).
For a general and non-technical
1972 Buick GS Stage 1
discussion, think of all the close
clearances in a pump and the radial
and axial forces that the rotor is Do you have flows
subjected to in normal operation. up to 1,400 US GPM
Some common rotodynamic (320 m3/hr), heads up
to 3,400 feet (1,000 m),
forces are radial forces that pressures up to 1,500 RS Series
result from operation away from psig (100 bar),
best efficiency point (BEP), axial temperatures from 20˚F to
forces mostly on the impeller(s) 300˚F (-30˚C to 149˚C), and speeds up to 3,500 RPM?
Then you need Carver Pump RS Series muscle!
resulting from different pressures
Designed for moderate to high pressure pumping applications,
on areas of varying sizes, shaft the RS is available in five basic sizes with overall performance
loading because of misalignment, to 1,000HP. As a standard, with a product lubricated radial
oscillating suction pressures, sleeve bearing and two matched angular contact ball bearings
for thrust, it only takes a mechanical seal on the low pressure,
changes in the system curve, and suction side to seal the pump. Optional features include ball
vibrations resulting from rotor bearings on both ends with an outboard mechanical seal,
imbalance and/or bent shafts. various seal flushing arrangements and bearing frame cooling.
These features make the RS ideally suited for Industrial and
As the pump slows down, the
Process applications including Pressure Boost Systems,
hydrodynamic stabilizing forces Boiler Feed, Reverse Osmosis, Desalination and
are diminished and the ability Mine Dewatering. Whatever your application,
of the unit to counter the acting let us build the muscle you need!
forces is consequently reduced.
As a general guideline, I normally
recommend that end users keep
the operating speed above Creating Value.
650 rpm. Carver Pump Company
2415 Park Avenue
Always consult with the Muscatine, IA 52761
manufacturer, and keep the fluid 563.263.3410
Fax: 563.262.0510
properties in mind. www.carverpump.com
Note that pump bearings have
speed limits, too. Ball bearing
Circle 117 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

24 COMMON PUMPING MISTAKES
4 Horsepower/Torque
All pump shafts have a speed,
horsepower (HP) and torque limit.
For single-stage pumps, many
manufacturers express this limit
as a horsepower per 100 rpm limit.
Torque is inversely proportional to
horsepower; the lower the speed,
the more torque is applied to the
shaft (see Equation 2).
HP = [(Torque) X (rpm)] ÷ (5,252)
Equation 2
Where:
HP = horsepower in foot-
pounds per minute
Torque = torque in pounds-feet
While most shaft limits are
based on speed, horsepower and
continuous torque limits, the limits
are further reduced if the pump
is driven by an engine (internal
combustion means intermittent,
instead of continuous, torque). If
the pump shaft is side-loaded as
in the case of belt or chain drives,
a striking reduction on the shaft
limits occurs as a result of the
cyclic bending fatigue factor.
5 Viscosity
With the advent of computerized
programs for pump selection,
correcting pump performance for
viscosity is simple. Many users,
however, sometimes overlook the
details of what this does to the
required brake horsepower.
Depending on pump size and
impeller geometry, the viscosity
limits for the average centrifugal
pump will vary from 250 to 700
centipoise, and I have witnessed
many pumps successfully pumping
fluids in excess of 1,000 centipoise.
The following two points are
important to consider:
De c e mb er 2015 | Pum ps & S y st e m s
• An increase in fluid viscosity
negatively impacts the torque
and horsepower limit for the
shaft. Check this viscosity
correction factor to ensure
a satisfactory and reliable
installation.
• You may still be able to pump
the highly viscous fluid with
a centrifugal pump, but there
will be a point of diminishing
returns because of reduced
efficiency. Perhaps you are using
25 HP to pump the viscous fluid
with a centrifugal pump that
would only require 5 HP with a
positive displacement pump.
6 Suction Lift
As discussed in my column “10
Common Self-Priming Pump
Issues” (Pumps & Systems,
September 2015), there are physical
limits to how far a pump can lift a
fluid. I usually recommend 25 feet
as the maximum lift for cold water.
Other fluids with higher vapor
pressures reduce the limit on the
maximum lift. Always complete the
net positive suction head available
(NPSHA) calculations, which will
also involve knowledge of the vapor
pressure of the fluid. Most self-
priming pump manufacturers limit
the maximum fluid temperature
to 165 F.
7 Air Entrainment
Depending on the specific speed
of the pump impeller and other
design factors, the air entrainment
limit on most standard centrifugal
pumps is 12 percent. The
performance will be affected
as the air entrainment
percentage increases, and this
phenomenon eventually will stall
out the pump. Pumps that utilize
vortex style impellers will be able
to handle more air, typically as
high as 24 percent.
8 Nozzle Loading
It has been said that the most
expensive pipe hanger/support
you can purchase is a pump.
All pump manufacturers state
a limit on how much force can
be applied to the pump fl anges
when the equipment is installed
and operated. There are design
maximum allowable forces and
moments in all three planes.
Conclusion
Dozens of additional limits/
boundaries on pumps exist, and,
perhaps if there is expressed
interest, I will write more articles
on the subject. Some added issues
and limits are head generation
per stage and per pump, specific
gravity, metallurgy specific to
fluid properties such as pH or
suspended solids, NPSHA/NPSHR
margins, elevation, orientation
and vibration.
The most important point to
remember is that the next pump
you are putting into service is not
indestructible. Always be aware of
your equipment’s limits.
References
ANSI 1.3 also ANSI B16.4 and 16.5.
Jim Elsey is a mechanical engineer
who has focused on rotating
equipment design and applications
for the military and several large
original equipment manufacturers
for 43 years in most industrial
markets around the world. Elsey
is an active member of the
American Society of Mechanical
Engineers, the National Association
of Corrosion Engineers and the
American Society for Metals. He is
the general manager for Summit
Pump Inc. and the principal of
MaDDog Pump Consultants LLC.
Elsey may be reached at
jim@summitpump.com.
 25
Process Pumps & Steam Turbines

Igpgtcvkpi"Rqygt"hqt"Jwocp"Nkhg."UPO
ZUZGR"YUR[ZOUTY"GVVXUGIN"
YTS"oy"znk"utr "sgt{lgiz{xkx"ot"znk"}uxrj"zngz"vxuj{iky"
GVO<76"vxuikyy"v{svy"gtj"GVO<775<78"yzkgs"z{xhotky"ot"
znk"ygsk"lgizux 4"Znoy"zuzgr"yur{zouty"gvvxugin"{tow{kr "
gjjxkyyky"znk"tkkjy"ul"znk"uor"gtj"mgy"otj{yzx 4

KTKXM_3YG¥OTM"YUR[ZOUTY"
4V\U[PUNKH[HJVUÄYTZ[OH[LULYN`ZH]PUNZHYLYLHSPaLK
}nkt"urj"v{svy"ot"gmotm"vrgtzy"gxk"xkvrgikj"}ozn"nomn"
LɉJPLUJ`SH[LZ[TVKLSW\TWZ([:54V\YW\TW
WYVK\J[ZHUKZVS\[PVUZHKKYLZZLULYN`ZH]PUNZJVUJLYUZ
lgiotm"iroktzy"gixuyy"znk"mruhk4"U{x"n jxg{roi"vu}kx"
YLJV]LY`[\YIPULTHRLZLɈLJ[P]L\ZLVMLULYN`^OLU
zxgtyvuxzotm"nomn"vxkyy{xk"row{ojy4

¥oyoz"{y"gz"
Vu}kxMkt
}}}4yts4iu4pv Huuzn"
=:9;
Circle 108 on card or visit psfreeinfo.com.

YGRKY"ULLOIKY LGIZUX_

ZUQ_U2"PGVGT NU[YZUT2"ZK^GY MRKTJGRK2"IGROLUXTOG HGTMQUQ2"ZNGORGTJ NOXUYNOSG2"PGVGT

1>7393<=9=38<97 1738>73??63>;?: 173>7>3;663>7<; 1<<3838<836=:6
pu mpsa ndsyst ems.c om1>73>893=737777
| D ec emb er 2015
26 INDUSTRY INSIGHTS
Trends & analysis for pumping professionals
How the Power Industry Can Adapt to a
Changing Landscape
T
he U.S. is a global production
leader in energy and a major
consumer of all types of
energy. The Worldwatch Institute
estimates that the U.S. has less
than 5 percent of the world’s
population yet consumes about 26
percent of the world’s energy. Also,
the U.S. produces about 18 percent
of the world’s total electricity
from coal, second only to China.
Although coal has long been a
staple of electrical generation, the
global power community is quickly
moving to decrease coal in favor of
renewable energy sources—wind,
solar, geothermal, hydropower,
biomass and biofuels.
The power industry is
experiencing transformation of
its fuel mix on a large scale. The
major drivers of these changes
are the U.S. Environmental
Protection Agency’s tightening
of the Clean Air Act and Clean
Water Act, as well as the push to
new renewable energy sources and
more efficient power generation
systems. As a result, the Electric
Power Research Institute (EPRI)
projects that power companies will
decommission up to 90 gigawatts
of coal-fired capacity during the
next five to 10 years. These closings
will be in addition to the decrease
in fossil-burning capacity that has
occurred during the past decade.
According to SourceWatch, the
number of power plants burning
coal in the U.S. since 1988 has
De c e mb er 2015 | Pum ps & S y st e m s
Pumps & Systems Senior Technical Editor
dropped approximately 20 percent,
from 57 to 37 percent.
Today, utility companies are
under increasing pressure to build
new infrastructure that will drive
better technical performance and
economic returns while reducing
environmental impact.
Another major issue facing
the power industry is the lack
of a comprehensive national
energy policy. Investor-owned
electric utilities, which constitute
approximately 78 percent of all
power generation in the U.S.,
are hesitant to invest in a new
generating plant without knowing
which fuel source, or mixture of
sources, will be preferred based on
market dynamics and regulatory
requirements.
Energy Conservation
One solution is promoting energy
conservation. This allows plants
to meet current demand without
investing in new types of power
generators. In response, practically
every major power company has a
range of incentives and rebates to
assist their consumers in reducing
their electrical demand.
As power companies continue
to retire base-loaded plants and
replace them with intermittent
power sources such as wind and
solar, the level of uncertainly
concerning a given utility’s ability
to meet demand load in real time
will increase. Plant operations
By Mike Pemberton
are increasingly swinging their
base-loaded, coal-fired boilers to
meet frequent changes in demand.
Because most of these units were
not designed for these swings,
equipment reliability has been
negatively impacted.
While the distributed control
systems are highly capable of
handling load swings, the rotating
assets and their actuators were
designed around base-load
specifications with fi xed-speed
operation. The new reality is the
existing equipment must adapt
to meet process changes in flow,
pressure, temperature and level.
Significant load swings require
flow rate changes across the
affected pumps involved in
the steam production process.
Typically, the only pumps in a
coal-fired power plant that operate
under variable speed control are
the boiler feed pumps. When
the plant changes load based on
demand, the circulating water,
condensate, closed heater drain,
closed cooling, makeup and blow-
down pumps, among others, adjust
flow rate. When these flow rates
change, the pump system will
either run closer to the maximum
mechanical efficiency of the pump
or will run further away from the
best efficiency point (BEP).
During the last decade, in
response to the U.S. Department
of Energy’s 1998 report “United
States Industrial Electric Motor

Systems Market Opportunities
Assessment,” there have been
both a change in how motor
system efficiency is viewed and
a growing use of variable speed
drives. The electric utility industry
understandably was not focused
on internal electrical energy
savings but now realizes that
variable speed operation of
rotating assets has tremendous
value in terms of flexible operation
and process reliability.
Uptime and reliability are
valuable in an industry that must
adapt to rapidly changing load
swings. While motor system
efficiency will not solve all needs
for flexibility, it can and should
have an important role in enabling
Circle 125 on card or visit psfreeinfo.com.
the power industry to reach a
state of equilibrium between the
uncertainty of intermittent power
sources and economizing the
remaining fossil-burning plants.
Reaching a Balance
Federal regulations will continue
to cause the permanent shutdown
of many coal-fired power
generation plants. It may be
initially difficult to attract the
investment capital required to
replace this base-load generation
capability in an environment of
increasing price uncertainty.
The industry will continue to
develop solar and wind generation
because of technology advances
and relatively low capital cost
pu mpsa ndsyst ems.c om | D ec emb er 2015
27
when compared with traditional
fossil sources.
Over time, a balance in
regulations, technology and capital
requirements should be reached,
resulting in a new landscape of
power generation with a mix of
fuel sources that will meet the
needs for a reliable supply of power
from sources that are economical
and sustainable.
Mike Pemberton is the senior
technical editor for Pumps &
Systems. He may be reached at
mpemberton@cahabamedia.com.
28
POWER GENERATION
Consider Remanufacturing
as Part of Power Generation
Pump Maintenance
A properly structured and managed program can enable large
sites with vast numbers of assets to increase productivity while
maintaining a plant s long-term reliability.
BY DARRELL HOWARD
SULZER
T
he power generation sector, like many others, is
under constant pressure to minimize downtime
and maximize productivity. For this reason, end
users expect pump equipment to run for longer
periods with reduced maintenance intervals.
When repairs are needed, they have to be completed
within tight deadlines to comply with ever-shorter
maintenance windows. With such a wide variety of
pumping processes on-site, finding a repair provider with
the necessary skills and experience to deliver full turnkey
service is a challenge.
A great deal of the rotating equipment used in the
power generation sector has been in place for many
years. Pump equipment has been rigorously maintained
and serviced in order to ensure reliable performance.
As service and maintenance intervals increase, the
attention given to maintenance procedures has become
more focused.
Employing a properly structured and managed
program can enable large sites that are equipped with
vast numbers of assets to achieve high productivity levels
while maintaining the plant’s long-term reliability.
Plant Requirements
Successful asset maintenance requires an understanding
of the needs of each piece of equipment, the overall
De c e mb er 2015 | Pum ps & S y st e m s
production process and the implications of taking assets
offl ine. In most cases, assets will have standby systems
that can keep a process operational, even at a lower
productivity rate.
The experience and knowledge of on-site maintenance
engineers provides the most useful information. By
working closely with a repair provider, a facility can
develop an efficient maintenance schedule.
The diversity of pump design and technology used
within the power generation sector means that finding
a repair partner can be a daunting task. The original
equipment manufacturer (OEM) might seem to be the
obvious choice to complete repairs.
However, the presence of a wide range of pump designs
across an entire facility would mean coordinating a
maintenance program with a large number of third-party
organizations. This requires significant administration
efforts and site coordination. As a result, selecting
the most appropriate partner that delivers both OEM
technology and the ability to support equipment
of multiple manufacturers is key to achieving the
maintenance goals of the business.
Service Delivery
Assessing the skills and capabilities of a maintenance
provider is crucial for determining the overall level
 29

Image 1. The 3-D design of the original impeller was created using
coordinate measuring machines (CMMs) which allow for quick on-site
data acquisition. (Images courtesy of Sulzer)

of service that can be delivered. Providing preventive maintenance

services is important, but when a component fails, the priority must be
to deliver a fast turnaround and get the equipment back into service.
Today’s number of complex pump designs in service has led
to a demand for a single-source solution that has the capability to
repair, re-engineer or remanufacture damaged components using
in-house resources.
The alternative—using providers that subcontract repairs to
compensate for a lack of in-house facilities—can increase the
complexity of the project, degrade the communication process and lead
to less dependable repairs.
Those with experienced design capabilities can also integrate
improvements into component design, enabling end users to benefit
from the latest manufacturing technologies and improve both
efficiency and reliability.
Note that for some power providers and first-tier contractors, the
requisite combination of skills and facilities must be available to a Image 2. The service provider was able to offer a full
set of new components, available in just five weeks.

pu mpsa ndsyst ems.c om | D ec emb er 2015

30 COVER SERIES POWER GENERATION
combination of fuel sources from
natural gas and fossil fuels to nuclear
and renewables anywhere in the
world, since power generation is often
a global business.
Circle 127 on card or visit psfreeinfo.com.
De c e mb er 2015 | Pum ps & S y st e m s
Developing a Plan
When partnering with a maintenance
provider, facilities must develop a
program of planned actions and make
contingency plans for unexpected
PowerGen
Booth #
8416
failures. By implementing a carefully
organized plan, these plants can
increase reliability and maximize
productivity by incorporating a range
of techniques and facilities.
At the most basic level, condition
monitoring is a vital tool that can use
vibration, pressure and temperature
monitoring equipment, plus manual
thermal imaging cameras, to provide
important information and detect
early signs of impending failure.
Both of these predictive maintenance
methods do not require stopping
the equipment, and they can
provide regular data for a preventive
maintenance program.
These steps form the basis of
a planned maintenance scheme
that should be supported by
additional information such as
pump performance data, which
can also reveal early indications of
a performance issue. Collectively,
this information enables the on-site
maintenance team to schedule
repairs during planned shutdown
periods, minimizing the impact
on productivity.
Despite these proactive steps,
however, component failures will still
occur. The ability of the repair partner
to react quickly and deliver a solution
will determine the long-term viability
of any maintenance agreement.
One way to facilitate this
partnership is to incorporate an
internal communication structure
that allows a local service center to
deliver the full range of technical
services to end users, while drawing
on the service provider’s engineering
and logistics resources.
Tight Deadlines
One example involves a major energy
provider that required a 21-day
turnaround on two high-speed
boiler feed pumps. The equipment
owner presented a detailed repair
specification that was to be followed
 31

precisely. This particular style of techniques, but the user declined. These machines gather 3-D data and
pump required developing clear A 3-D design of the original allow the obtained dimensions to be
and precise inspection templates, impeller was created using coordinate repeatable to within 0.001 inch. The
instructing and reviewing with the measuring machines (CMMs), which 3-D model was completed within one
shop personnel where and how to allow quick on-site data acquisition. week and the data was immediately
inspect the critical fits, and recording
the required information to meet
the energy provider’s criteria for
initial inspection.
One of the first requirements was a
special cleaning procedure the service
center managing the repair was not
equipped to do. By using the service
provider’s other facilities located
nearby to accommodate the demand,
however, the cleaning procedure was
quickly completed without incurring
any delays. Once complete, the pumps
were returned to the original service
site to begin disassembly.
Inspection of the individual
components determined that some
of the impellers were damaged and
were deemed irreparable. The hub side
plates on at least half of the series
impellers were cracked and required
replacement. The facility had not
planned for this level of damage, and
replacement components are not
typically stored by either the user or
the manufacturer.

Unexpected Developments
Having informed the user of the
unexpected discovery, the service
provider submitted inquiries to the
OEM about the best lead time for
new impellers, which came back as
20 weeks. The service center was able
to offer a full set of new components
available in just five weeks.
The damaged impellers were sent
to one of the service provider’s
manufacturing center, which has
full reverse engineering and design
capability for both hydraulic and
mechanical components. The design
team offered the user an opportunity
to improve the performance
characteristics of the impellers using
the latest design and manufacturing
Circle 119 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

32 COVER SERIES POWER GENERATION

transferred to the engineering and manufacturing Conclusion

departments, where the new designs could start to In today’s world of large-scale pump maintenance,
take shape. repair specialists must have a wide range of skills and
With such extensive and unexpected damage, however, adaptability in order to deliver comprehensive service.
meeting the original program deadline of three weeks Equipment is becoming more complex, and the
was nearly impossible to achieve. facilities required to maintain them are becoming more
Following discussions with the user, the service expensive. Although technology has evolved since
provider proposed to rebuild one of the pumps using much of the equipment in the power generation sector
the best components from both pumps. This required was manufactured, improving reliability and efficiency
moving diaphragms and diff users between the pumps is possible with the right engineering expertise by
and correcting all the fits and clearances to achieve the remanufacturing certain components as part of the
required design specifications. regular maintenance program.
The first pump was completed and returned to the end In the long term, this strategy will help improve
user one day early, while the second pump was completed productivity and reduce the likelihood of unexpected
and shipped on schedule in order to meet the plant’s breakdowns.
operational requirements.
The team approach illustrated in this example Darrell Howard is the repair engineering manager
represents a true turnkey solution with clear for Sulzer at its Houston Service Center. He has
communications delivered through a single point more than 25 years of experience in delivering
of contact. This method allows the end user to remain engineering solutions for rotating equipment,
fully appraised of progress and to make informed especially pumping systems.
decisions when unexpected circumstances arise.

PROTECT PUMPS
฀ ฀ ฀ A ฀ ฀ ฀ ฀ ฀

MONITOR PUMP POWER COMPACT EASY MOUNTING

฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀฀ ฀ ฀
฀ ฀ ฀
TWO ADJUSTABLE SET POINTS
฀ ฀ UNIQUE RANGE FINDER SENSOR
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
4-20 MILLIAMP ANALOG OUTPUT

WHY MONITOR POWER INSTEAD OF JUST AMPS? PUMP POWER

VALVE CLOSING
POWER

PUMPING
AMPS

VALVE OPENING NO FLUID

No Sensitivity
Power is Linear-Equal Sensitivity For Low Loads
at Both Low and High Loads
NO LOAD FULL LOAD NO LOAD FULL LOAD

CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247

WWW.LOADCONTROLS.COM
Circle 123 on card or visit psfreeinfo.com.

De c e mb er 2015 | Pum ps & S y st e m s

 33

Circle 114 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

34 COVER SERIES POWER GENERATION
EPA Regulations Encourage
Power Industry Innovation
The Clean Power Plan and emphasis on efficiency are moving
power utilities to optimize pumping systems.
BY BILL LIVOTI
WEG
W
hile the industrial sector struggles
to survive in the U.S. market, the
Environmental Protection Agency
(EPA) continues to add regulations that
further impact the already slim profit margins for many
industries, especially those that are large power users.
On Aug. 3, the EPA issued its Clean Power Plan for
Existing Power Plants, which requires states to reduce
carbon dioxide emissions by 32 percent (from 2016 levels)
by 2030. Some call this Obama’s “war on coal” because it
will force power utilities to shut down coal-fired power
plants, while supporters claim that the regulations help
address environmental and health concerns. The fleet of
coal-fired plants has already been reduced from a high of
55 percent to today’s level of approximately 38 percent.
While the U.S. government works to reduce emissions
through increased regulations, it has not yet developed
a national energy policy that will give investor-owned
power generators—which make up 78 percent of
utilities—some direction. Still, power utilities are
required to deliver reliable power to the grid on demand.
Energy Efficiency Programs
As a result of this challenge, utilities are implementing
energy efficiency programs. Many of the large progressive
utilities, including Southern Company, Duke and Xcel
Energy, have had programs in place for several years. A
number of nongovernmental organizations (NGOs) have
also stepped up to the plate. Given the potential impact
on profits, the industrial sector would benefit greatly
from more aggressively embracing energy efficiency.
De c e mb er 2015 | Pum ps & S y st e m s
Energy efficiency, however, will only delay the
inevitable. The U.S. industrial sector requires reliable
power to meet production needs. Some industries have
renewed their combined heat and power (CHP) plants to
reduce their dependency on the grid.
To meet electrical power requirements, power
generators must add base load power plants. The path of
least resistance is natural gas combined cycle (NGCC),
which can provide the necessary base load power to meet
grid requirements. The price of natural gas is low because
fracking has reduced the price to almost historic levels.
Will the price remain at this level? If history repeats
itself—and it usually does—the answer is no. As fuel
costs increase, power utilities will pass the cost on to
consumers. Also note that as natural gas prices drop,
utilities reciprocate and pass savings to their customers.
This, however, does not address the issue of reliable
power on demand. As power companies decommission
coal-fired plants, by some estimates as much as 90
gigawatts by 2020, what will happen to the grid? How
can industrial power consumers protect themselves from
power pricing uncertainty? The following data, provided
by the Wall Street Journal on Aug. 10, looks at power
generation from a cost perspective.
Coal-fired power plants: $38.00 per megawatt-hour
Nuclear (existing): $29.00 per megawatt-hour
Hydroelectric: $34.20 per megawatt-hour
NGCC: $48.90 per megawatt-hour
Wind: $106.00 per megawatt-hour
Solar: $120.00 per megawatt-hour
 35

Figure 1. U.S. national average natural gas price/MMBtu

(Reference NYMEX) (Courtesy of the author)
Cost per megawatt-hour for a new NGCC plant is
approximately $73.40 because of the upfront capital
costs. The cost per megawatt (MW) is affected by many
factors but mostly by the facility’s “capacity factor,”
which is the percentage of time it will produce its full-
rated output. A typical condensing steam power plant
such as coal or combined cycle will have a capacity factor
of 85 percent or greater. By comparison, a typical wind
generation facility will have a capacity factor of about 30
percent, while solar is about 18 percent.

Pump System Optimization

In addition to implementing energy efficiency programs,
the power industry can optimize existing plants—
specifically pumping systems.
The current fleet of coal-fired power plants were
designed to operate at “base load” because of the mix
of renewable energy and the environmental issues
mentioned previously. Coal plants are now “swinging”
plant load to meet grid requirements. As a result, the
plant heat rate/efficiency and reliability are taking a hit.
This is one of the biggest issues confronting the power
industry today. The fact that many of these plants are
40-plus years old only adds to the challenge.
Improving the efficiency of energy systems will be
instrumental in solving the energy and environmental
problems of the future. To improve efficiency, power
generators must embrace new technology when building
or upgrading power supply systems. This requires using
fuels more efficiently so that less damage is done to the
climate and equipment. Higher efficiency means lower
fuel consumption, fewer pollutant emissions, greater
reliability and improved efficiency.
The most important indicator for the energy efficiency
of a power plant is its electrical efficiency. If the plant load
is reduced, the heat rate/efficiency drops. Most utilities
focus on just the heat rate, but other factors should be
considered, including thermal efficiency, capacity factor,
load factor, economic efficiency and operational efficiency.
These factors can be impacted by improving pump system
efficiencies, specifically in critical process areas.
For coal-fired power plants, improvements in efficiency
primarily depend on two variables: increasing the two
steam parameters, pressure and temperature, and
reducing losses in the steam water cycle.
To improve pump system efficiency, one must take
the entire system into account beginning with the input
power. Focusing on individual components for efficiency
improvements can often reduce the overall system
efficiency and potentially the reliability as well.
Efficiency is as much about improving a pump system’s
reliability as it is about reducing energy costs. This is
because greater efficiency reduces wear and tear from
heat and vibration, lengthening the life of equipment and
reducing downtime for maintenance and repairs.
As mentioned, many coal-fired power plants no longer
operate at base-load capacity (33 percent efficiency), so
variable frequency drives (VFDs) on certain fi xed-speed
pump systems can greatly enhance plant performance at
off-peak loads. In these scenarios, VFDs can significantly
improve the unit heat rate by reducing energy
consumption and friction across valves and by allowing
the pump to operate at its best efficiency point (BEP).
Heat rate is equal to 3,412.14 British Thermal Units/
kilowatt hours (Btu/kWh) divided by the thermal
efficiency of the plant (no units), so the answer will be
in Btu/kWh.
VFDs as motor controllers offer other benefits. They
allow soft starts, which reduce inrush/electrical load,
excessive torque and subsequent equipment wear during
startups. They also provide precise speed control and
enable high-efficiency operation of motors at less than
the maximum efficiency point.
Energy efficiency will play a key role in achieving
sustainable growth for both utilities and industrial
customers. Embracing new and innovative technology,
as well as change, will determine the future success of
industry in the U.S.
William Livoti is the power generation
business development manager for
WEG Electric Corporation. Livoti may be
reached at wlivoti@weg.net.

pu mpsa ndsyst ems.c om | D ec emb er 2015

36 COVER SERIES POWER GENERATION
Advanced Engineering
Boosts Reliability in
Boiler Feed Pump
This approach incorporated reverse engineering, design verification
and casting simulation to address equipment failure.
BY DR. GARY DYSON, HYDRO INC.
& JESSE STINSON, HYDRO PARTS SOLUTIONS INC.
P
ump technology requires the extensive use of
castings to form the complex shapes needed
to guide process fluids through the machine.
The shape of these passages is crucial to the
machine’s performance.
Pump designers spend extensive time designing and
optimizing the shapes of these passages to optimize the
machine’s efficiency. Unfortunately, casting processes
cannot always represent the pump engineer’s true design
intent, and the manufacturing processes have a direct
impact on the machine’s reliability and design integrity.
Designers take these processes into account when
proposing their designs, but sometimes the deficiencies
of the casting process become apparent after a major
equipment failure.
One example involved determining the root cause
behind the first-stage failure of a Worthington 12-WCND-
166 six-stage boiler feed pump. The pump exhibited high
vibration and performance degradation, and it was taken
out of service. The inspection determined that a crack had
resulted from a welded core plug.
Examining the Pump
Sand cores are used to form the internal cavities of the
double-suction first stage. The double-suction geometry
of the first-stage volute on this type of machine is
complex because the designer must ensure adequate and
balanced access to the eye of each side of the impeller.
De c e mb er 2015 | Pum ps & S y st e m s
Also important is ensuring the impeller discharge
is transported efficiently from the impeller into the
subsequent stage with minimum losses.
Because of the complexity of the shapes involved, the
sand cores required to form the shapes are also complex.
Core holes are cast into the complex shapes to enable the
foundry to clear out some of the hard-to-access areas—a
necessary feature of this type of casting. Because of the
failure emanating from this area, a process has been
developed to eliminate core holes and prevent failure
caused by core holes and plugs.
A group of experts investigating the problems on
this six-stage boiler feed pump identified a number of
other issues within the passageways by fully examining
internal areas normally only accessible through
destructive processes. They observed areas within the
crossover where poor core fitment had caused a serious
discontinuity within the passageway, as well as poor
chaplet repair processes.
Pump manufacturers have invested heavily in
traditional pattern equipment and, as a result, there
is a reluctance to move away from their casting
methodologies.
Another approach uses advanced reverse engineering,
design verification, casting simulation and additive
manufacturing techniques—rather than traditional
pattern making—to develop a fault-free solution to
the problem.
 37

Reverse Engineering manufacturer (OEM), is to outsource ability in pump and casting design to
There is an important difference the casting capability and expertise to deliver the needed components.
between replication and reverse a foundry. The computational fluid dynamics
engineering. Reverse engineering It is possible to complete this step (CFD) analysis hones in on the
involves an advanced, technologically in-house using a company’s combined optimum design for foundry setup,
robust process that helps to ensure
that the essential geometric details
of each part are captured and the
deviations within each part associated
with the process capability are
eliminated.
This particular process involves
several component steps that include
data capture, which uses 3-D scanning
technology to detail the component’s
internal and external geometry (see
Figure 1, page 38).
The data verification process requires
that a 3-D model be constructed
from the scan data to represent
the component. The data-to-model
transposition undergoes a rigorous
deviation analysis. The analysis
aligns the original scanned data
with the model data and highlights
discrepancies using a color-coding
system (see Figure 2, page 38).

Design Verification
In design verification engineering, the
deviation from the model to scan data
can point toward a number of areas
where design verification can improve
the casting process. Along with a
verification of the passage diff usion,
the design verification process
identified a bulge on the volute wall of
the six-stage boiler feed pump that was
corrected (see Figure 3, page 38).
The design verification process also
analyzes designs from first principles,
and the importance of individual
design features is applied to each
component. This is a key event in
separating manufacturing process
deviations from design intent. PowerGen
Booth #
Casting Simulation 3542
The traditional method applied to
the castings, purchased through a
traditional pump original equipment
Circle 129 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

38 COVER SERIES POWER GENERATION

Figures 1 & 2. Data collection (Figure 1, left) and data discrepancy color
maps (Figure 2, right) in 3-D models (Graphics courtesy of Hydro Inc.)
a process that is applied to
every casting. The CFD analysis
performed on the initial shape
of the pump in question led
to designing the appropriate
riser pattern.
This pattern is crucial to
preventing shrinkage problems
occurring in the casting. A riser
is a reservoir of molten metal
from which the casting can draw
to offset the shrinkage that
occurs as the metal solidifies.
Risers are placed in feed zones—
areas that could give rise to a
shrinkage defect.
Data developed from this
Figure 3. A bulge is identified on the boiler feed pump’s volute wall.
analysis is used to develop a
3-D mold design. The analysis
applies to every casting to ensure
that each design is optimized to
minimize casting defects and
geometry errors.

Final Verification
The final step in the process
involves a detailed verification
and inspection of the casting to
ensure the casting is free from
defects, that it is the correct
shape and that the hydraulic
passages and wall thicknesses
match the designer’s intent.
To perform the verification The failure initiation, caused by the core hole, was
of the casting geometry, a further 3-D scan is taken eliminated as a result of new casting design philosophies,
from the casting. This scan is then compared with the and other casting errors were also eliminated with the
3-D model and the initial casting scan, and a deviation passageways.
analysis is performed to ensure that the passage shapes
are correct and that there is sufficient machine stock on Dr. Gary Dyson is managing director with Hydro Global
the casting. Engineering Services. He has a Ph.D. from Cranfield
University and 30 years of experience in the pump
Conclusion industry in senior positions with many manufacturers.
The first-stage double-suction volute is a complex His expertise includes pump hydraulic performance,
and difficult casting containing many features that, design and reliability improvement.
without due attention, will cause casting defects and Jesse Stinson joined Hydro’s service network in 2012.
geometry errors. He is the vice president of operations for Hydro Parts
Using this process to control the design of the casting Solutions Inc., a Hydro Inc. company created to support
and the passage geometry of the six-stage boiler feed the pump aftermarket with high-quality parts. Stinson
pump resulted in supplying a casting that exceeded the has spent his entire career specializing in castings,
quality of the originally supplied component. specifically for pumps.

De c e mb er 2015 | Pum ps & S y st e m s

Circle 106 on card or visit psfreeinfo.com. pu mpsa ndsyst ems.c om | D ec emb er 2015
40 COVER SERIES POWER GENERATION

Three-Screw Pumps
Overcome Common Power
Generation Challenges
The positive displacement technology handles backpressure
fluctuations, cavitation and air entrainment.

BY DAVID BAZEL
LEISTRITZ ADVANCED TECHNOLOGIES CORP.

R
otary positive displacement screw pumps are requires a single bearing for positioning the rotor set and
used by a wide range of industries, including a single mechanical seal subject only to suction pressure.
oil and gas production, pipelines, refineries, Screw pumps tend to have a record of high reliability
terminals, chemical processing, marine and and low maintenance. Available casing materials include
power generation. Specifically in the power generation aluminum alloy, cast iron, ductile iron, steel and stainless
sector, screw pumps are commonly found in applications steel. Integral relief valves are offered on certain models,
such as bearing and gear lubrication, high-pressure fuel directing overpressure flow either back to suction or to an
injection, fuel forwarding, jacking oil and hydraulic power external bypass line.
for hydro-plant control. Operating as a positive displacement machine is one
Screw pumps can excel in varied industries and services of the screw pump’s top benefits in power applications.
because of their design. They are relatively simple, low- It has a capacity rating based on pump geometry and
maintenance machines with few moving parts. They can rotation speed, minus a small amount of product slip.
efficiently pump a fi xed volume of product within a wide The actual slip is a function of rotor/liner clearance,
range of capacity, pressure and viscosity.
The three-screw pump type is among the most
common for power generation applications. It
features a single hardened-steel power rotor
that performs the bulk of the pumping action,
along with two idler rotors—typically hardened
steel or cast iron—acting as rotating seals. The
rotors operate on a thin product fluid fi lm within
the pump liner that functions as a large journal
bearing, providing support and preventing metal-
to-metal contact.
Additionally, an internal balance line acts
to hydrodynamically balance the rotor set,
nullifying any axial forces and eliminating the Image 1. Re-engineered drop-in replacement pump (Images and graphics courtesy of
need for a thrust bearing. The three-screw pump Leistritz Advanced Technologies Corp.)

De c e mb er 2015 | Pum ps & S y st e m s


Image 2. Vertical pedestal-mounted pump/motor
differential pressure (increasing as pressure increases)
and product viscosity (decreasing as viscosity increases).
Unlike a centrifugal pump in which pressure increases
result in reduced flow—as well as movement away from
the best efficiency point (BEP)—a screw pump will
efficiently deliver a nearly constant volume of critical
lube oil or fuel oil flow regardless of fluctuations in
backpressure. As a result, machinery bearings, gears or
combustion systems will not be starved in the event of a
disturbance, such as a clogged inlet strainer.
The screw pump’s versatility in handling a wide range
of viscosities is also noteworthy. It can efficiently handle
very thin, low-lubricity fuels such as kerosene, ultra-low
sulfur diesel and biodiesel, as well as viscous No. 6 heavy
fuel oil. By comparison, a centrifugal pump’s efficiency
drops as viscosity increases. A screw pump can be ideal for
operators working with heavy fuels or high-viscosity gear
oil and for applications using a common pump for varying
grades of fuel oil.
Air entrainment and cavitation are other key areas
where screw pumps have advantages over other
technologies. Air entrainment involves air or vapor
41
Image 3. Vertical tank-mounted pump/motor
bubbles in the entering fluid, while cavitation refers
to vapor bubbles that form in the pump’s low-pressure
section because of insufficient suction pressure and
implode in the high-pressure section. Centrifugal pumps
can have difficulty handling these issues. Capacity drops
significantly—2 percent entrained air can reduce flow by
about 10 percent—and the resulting noise, vibration and
possible damage to the seal, shaft and impeller present
serious challenges to the operator. In severe cases,
excessive entrained air can cause a centrifugal pump to
vapor lock or lose its prime and ability to pump.
Three-screw pumps are self-priming machines with a
significant ability to tolerate entrained air and cavitation,
and they are not vulnerable to potential vapor lock. Also
available are deaeration features that act to smooth
the pressure rise within the pump, preventing the
sudden implosion of bubbles that would occur during an
otherwise rapid pressure spike.
Additional benefits provided by the screw pump’s
design for power applications include low noise, low
vibration, low shear and a non-pulsating flow. The
virtually pulsation-free flow eliminates the need for
pu mpsa ndsyst ems.c om | D ec emb er 2015
42 COVER SERIES POWER GENERATION
pulsation dampeners, simplifies
piping system design and ensures
a smooth and steady fuel supply to
sensitive combustion systems. A screw
pump’s low-shear effect comes from
its gentle axial movement of product
from suction to discharge. For lube
systems with water contamination,
low shear prevents the formation of
emulsions and their negative impact
on downstream fi lters, strainers
and machinery.
Flexible configuration options can
optimize a screw pump’s location
within a power plant. Screw pumps
can be horizontal baseplate-mounted
with the motor, fl ange-mounted
off a motor horizontally or tank- or
pedestal-mounted vertically.
The vertical tank-mount design
saves space as the pump, with axial
inlet and strainer, sits submerged
De c e mb er 2015 | Pum ps & S y st e m s
THREESCREW PUMP BENEFITS
The features of this design can be a
natural fit for power generation applications.
• Positive displacement to ensure
critical capacity regardless of
backpressure
• High efficiency across a broad range
of pressure and viscosity
• Higher tolerance of entrained air and
cavitation than centrifugal pumps
• Available deaeration features
• Versatility for pumping both low- and
high-viscosity products to 15,000
centistokes (cSt)
• Operates at motor speeds,
eliminating need for a speed reducer
• Low pulsations, vibration, shear
and noise
• High reliability/low maintenance
• Self-priming/low-suction pressure
requirement
• Capacity to more than 3,000 gallons
per minute (gpm)
• Pressure capability over 2,500 pounds
per square inch gauge (psig)
• Single mechanical seal/single bearing
• Available integral relief valve
• Several casing material options
• Horizontal and vertical tank or
pedestal mount configurations
• Custom fabricated casings for drop-in
replacements of older pumps
Circle 120 on card or visit psfreeinfo.com.
 43

inside the oil tank. Discharge flow is piped above the

tank through a mounting plate, which also supports
the vertical motor and relief valve.
The vertical pedestal-mount design is another
footprint-saving arrangement, with the vertical pump
supporting a vertical motor via a steel pump/motor
adapter. These direct motor drive configurations are
Figure 1. A cross-section of a three-screw pump
possible because screw pumps operate at motor speeds
and do not need the added complexity and cost of a
speed reducer.
Certain screw pump models feature a pump as the original pump. Installation cost can be low, pump
cartridge that slides into a fabricated steel casing. This cost is generally lower than an existing pump overhaul,
simplifies maintenance because the cartridge can be and the plant benefits from the latest three-screw
removed without disturbing the pump mounting or pump technology.
piping connections. It also opens up the possibility for the
re-engineered pump concept. Many older power stations
still operate obsolete pumps that are costly to maintain. David Bazel is a sales engineer for Leistritz
Often, these are twin-screw pumps with timing gears, Advanced Technologies Corporation with
four bearings and four seals. a background in the gas turbine power
The three-screw re-engineered pumpcasing, however, generation industry. He may be reached
can often be custom-fabricated as a drop-in replacement at dbazel@leistritzcorp.com. For more
with the same fl ange, shaft and mounting dimensions information, visit leistritzcorp.com.

Unbalance is amongst
Unb a the most common of reliability problems VibXpert® II Balancer
machinery. Structural problems, reduced machine and
in rotating ma A PRÜFTECHNIK product
bearing life, an
and increased vibration all result from unbalance. 1 & 2-plane Field Balancing,
There’s no exc
excuse for unbalance in your plant—stop the costly Vibration Analysis and more!
consequences with the right condition monitoring systems.
Our equipment
equipmen and support are the industry benchmark.
Keep it Runni
Running™.

305.591.8935 | www.KeepItRunning.com
305.5

Circle 124 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

44 COVER SERIES POWER GENERATION

Choosing the Proper VFD

Can Limit Harmonics
Facilities predominantly using these drives may face concern
from power utility companies.

BY JEFFERY LOVELACE
NATIONAL POWER QUALITY AND CONSULTING LLC

V
ariable frequency drives (VFDs) have vastly
evolved during the last 25 years. Hundreds of
articles have been written about their advantages
when used with a pump motor compared with an
across-the-line motor and flow control valve. One primary
benefit occurs when slowing the motor speed leads to
reduced kilowatts, resulting in reduced electrical usage.
When the electrical loading of a facility is predominantly
made up of VFDs, some would view this as a success story.
The power company, however, might disagree because
VFDs can add unwanted harmonics to the system.
Advantages of VFDs
VFD sizes are smaller, their intelligence is greater and the
cost has remained fl at despite other industrial products
following infl ation prices. VFDs dominate variable torque
applications like those found in pumps and fans.
VFDs are noted for their precise motor control output,
but rarely is the VFD’s input discussed. The VFD’s input
configuration sets the stage for how clean the power
consumption will be. Before the advent of VFDs, power
companies had to deal with across-the-line motors.
Lightly loaded motors had poor power factor, and starting
these motors meant short-term heavy demands on the
system. Both would warrant a penalty on the user. VFDs
remove this concern, but with the popularity of VFDs
increasing in facilities, the harmonics content created by
VFDs increases as well. Utilities are taking note of this
new phenomenon. Exploring the VFD inputs can help end
users find clarity about harmonics.
Basic VFD Topology
To change the speed of an alternating current (AC) motor,
the voltage and frequency must be varied proportionally.
VFDs use traditional AC to direct current (DC) conversion
and then invert DC to AC to change both the voltage
and frequency to the motor. This method can best be
explained by splitting the VFD into three parts (see
Figure 1).
In general terms, VFDs use diodes, silicon-controlled
rectifiers (SCRs) or a combination of both to convert the
fi xed AC line voltage into DC voltage. The DC voltage
has some ripple because SCR/diode bridges are not a
perfect rectification and capacitors are used to smooth
out the DC. Transistors are then used to chop up the
DC voltage and re-create a simulated AC waveform. This
method is typically referred to as pulse width modulation
(PWM). The latter two-thirds of the drive are consistent
throughout several types and brands of drives. It is also
the section that receives the most processor control and
Figure 1. Power components used in VFDs to convert fixed line voltage/
frequency to variable voltage/frequency (Graphics courtesy of the author)

De c e mb er 2015 | Pum ps & S y st e m s

 45

Figure 2. Line voltage in its purest form, shown with VFD

non-linear current.

hype of how one technology of volts/hertz control or

sensorless vector control is best. The output section
of the VFD has little effect on how the input section
behaves, so it will be excluded at this point from this
article, and the input section will be explored further.
From the information above, it can be derived that
the line voltage needs to be converted to DC in some
manner. The most common method comprising the
majority of the installed base uses six diodes/SCRs, also
known as six-pulse drives. These drives use standard
three-phase power and have single unit rectification.
No special hardware is required outside the VFD.
However, when six-pulse VFDs are used, they will not
Figure 3. A reactor is placed in front of the VFD. Reactors slow the
behave as a linear load on the system, and this is what current fluctuations and thus reduce harmonics.
first catches the attention of a utility provider
(see Figure 2).
Non-linear loading simply means the current is
not consumed in the same format as the voltage is
supplied by the utility. This may also be referred to as
“harmonic current” because it will have multiples of
the line frequency inside the waveform. For a six-pulse
drive, this is the 5th, 7th, 11th, 13th, 17th and 19th
harmonics. The harmonics created are in the range
of 50-70 percent current harmonics (total harmonic
distortion current, or THDi). If this were the only Electrical and Electronics Engineers (IEEE) has created a
loading in the facility, the utility would say the load is recommendation document referred to as IEEE 519-2014
“harmonic rich” and would likely require the user to add on how harmonics should be limited in various facilities.
a harmonic mitigation device to correct the problem.
However, it was stated earlier that VFDs reduce kilowatt Harmonic Mitigation Options
usage. Why is there concern about harmonics if the user There are several methods to reduce or eliminate the
has actually lowered the amount of usage? harmonics content that a VFD creates. One choice is to
Harmonic currents created by non-linear loading add an inductor, more commercially known as a reactor,
will create a voltage harmonic on the grid, which can to the input of the VFD. These are relatively inexpensive
then affect neighboring consumers of the utility. and will reduce the harmonic content from above 60
Internal harmonics within the end-users’ facility percent to the 40 percent range. This is significant cost
can cause heating in transformers and cabling and and size reduction for a small device (see Figure 3).
potentially erratic problems with sensitive electronics An alternative choice is to use a 12-pulse drive that has
such as programmable logic controllers (PLCs) and two rectification modules with six-phase power. However,
distributed control systems (DCS). The Institute of the utility does not provide industrial consumers with
six phases. A custom-wound transformer is required in
Table 1. Many technologies exist to keep harmonics mitigated. front of the VFD. The transformer uses a voltage phase-
shift to create two new three-phase voltages electrically
Technology Total Harmonic Cost
Distortion (THDi)
displaced 30 degrees apart. The current as seen by the
utility is cleaner and the harmonic content is reduced
6-pulse VFD 50-70% $
below 15 percent. It can be concluded that the 12-pulse
6-pulse VFD with reactor 35-45% $$ configuration is more expensive and requires additional
6-pulse VFD with passive filter 6-10% $$ installation costs (see Figure 4, page 46).
6-pulse VFD with active filter 3.5-5% $$$ These multi-pulse drives configurations continue
in multiples of six: 12-pulse, 18-pulse, 24-pulse and
12-pulse VFD 10-14% $$$
30-pulse. Each continues to need custom configurations
18-pulse VFD 4-6% $$$$ in order to gain the additional phase shifted voltages.

pu mpsa ndsyst ems.c om | D ec emb er 2015

46 COVER SERIES POWER GENERATION

Figure 4. A 12-pulse VFD is an alternate type of VFD that has less

More hardware equals more cost in trade for less harmonics than a six-pulse VFD, but requires a special Delta-Delta/
Wye transformer.
harmonic content. At 18 pulses and up, expectations of
harmonics content are less than 5 percent THDi.

Harmonic Filters
An alternative choice for harmonics correction is to
use harmonic fi lters. These come in many different
configurations, but the two primary options discussed
here are passive and active.
Passive fi lters consist of passive electrical components,
capacitors and inductors, configured to trap or notch
offensive frequencies. These perform best at rated loads
and should be sized accordingly. Expectations with this
device are less than 8 percent THDi. Be aware that the
amount of harmonic correction begins to deteriorate with
Figure 5. A passive filter is a series device that goes in line with the VFD.
passive devices at lighter loads (see Figure 5).
Active fi lters share some components but add
processor-controlled transistors (fast switches) to inject
negative harmonics back into the system. These positive
and negative harmonics cancel out, essentially reducing
harmonic content to levels below 5 percent THDi. Unlike
passive fi lters that are placed in series with the VFD load,
active fi lters are placed in parallel to the VFD load. Active
fi lters cost more than their passive counterparts but
perform better from light loads to heavy loads, since they
actively adjust to changing conditions (see Figure 6).
Reviewing the possible VFDs and their associated Figure 6. An active filter is a parallel device that goes in parallel with
one or more VFDs.
harmonics content provides this tabular form of data and
some estimated costs for each (see Table 1, page 45).

Putting It All Together

To obtain the best overall harmonics mitigation solution,
the end user must view the system as a whole circuit and
consider different combinations of mitigation products
that could be used to prevent a power quality concern.
For example, a company with a bank of 10 40-horsepower
(HP) VFDs might find purchasing a large 400-HP passive
fi lter more economical than individual fi lters at each VFD.
If that same bank of 40-HP VFDs were on booster pumps
that vary speeds (thus a varying load) throughout the
day, an active fi lter would perform better because it is not
system and offer recommendations for unraveling and
load-dependent.
solving the issues. Simulation tools and measurement
At the service entrance of the building, is there a
devices can also help when predicting and passing power
fi ltering method to support the entire structure—
quality requirements from the utility provider.
including harmonics created by high-efficiency lighting
and computing equipment as well as VFDs? Quite possibly
some loads can alter other load harmonics. If only a Jeffery Lovelace, P.E., is the chief engineer for
singular VFD is taken into account, the solution may National Power Quality and Consulting LLC in
seem cost prohibitive when spanning a mass of VFDs. Houston, Texas. Lovelace has 20 years of experience
This is why it is best to consult with a professional with VFDs, automation systems and power quality
who is not concerned with his or her product being the analysis. He may be reached at
solution. A non-biased approach can look at the overall jeff@natpowerquality.com.

De c e mb er 2015 | Pum ps & S y st e m s

 47

Circle 101 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

48 TRADE SHOW PREVIEW
POWER-GEN
International
Dec. 8-10, 2015
Las Vegas Convention Center, Las Vegas, Nev.
B
illed as the world’s largest power generation industry
event, the POWER-GEN International conference is
Dec. 8-10 at the Las Vegas Convention Center.
More than 22,000 attendees from 90 countries and 1,400
exhibiting companies are expected at the event that spotlights
issues, trends and new technologies in power generation. he
conference features more than 50 informational sessions
as well as a host of other educational opportunities for
representatives of the power generation industry.
Featured keynote-session speakers include Joe Mastrangelo,
president and CEO of power generation products for GE Power
& Water; Steve Berberich, president and CEO of California
Independent System Operator; Stuart Hemphill, senior
2015 Groundwater Expo
Dec. 15-17, 2015
Las Vegas Convention Center, Las Vegas, Nev.
A
fter one of the event’s strongest turnouts last year,
the 2015 Groundwater Expo is returning to Las Vegas
Dec. 15-17 with thousands of industry representatives
expected for networking and educational opportunities.
he National Ground Water Association based in Westerville,
Ohio, produces the gathering at the Las Vegas Convention
Center that is among the largest events serving the industry.
Numerous workshops and educational sessions will provide
valuable information about the latest issues afecting
groundwater professionals.
“he 5,245 total registrants at the 2014 NGWA Groundwater
Expo and Annual Meeting … made the show our strongest since
2008,” NGWA Chief Executive Oicer Kevin McCray said on the
event’s website.
De c e mb er 2015 | Pum ps & S y st e m s
The 2015 POWER-GEN International
conference is happening Dec. 8-10 in Las
Vegas. (Image courtesy of Power Engineering)
Exhibition Hours
Tuesday, Dec. 8 11:30 a.m. - 6 p.m.
Wednesday, Dec. 9 9 a.m. - 5 p.m.
Thursday, Dec. 10 9 a.m. - 2 p.m.
vice president of power supply and operational services for
Southern California Edison; Steven Edwards, chairman,
president and CEO of Black & Veatch; and Robert Flexon,
president and CEO of Dynegy Inc.
Conference attendees can participate in sessions in various
tracks to earn professional development hours. Conference
session tracks include microgrids, storage and virtual power
plants; industry trends and competitive power generation;
power project inancing; emissions control; gas turbine
technologies; on-site power; and plant performance.
he gathering is part of Power Generation Week 2015
that spans Dec. 6-10 at the venue in Las Vegas. For more
information, visit power-gen.com.
Exhibition Hours
Wednesday, Dec. 16 12 p.m. - 6 p.m.
Thursday, Dec. 17 9 a.m. - 3 p.m.
Last year’s Expo featured 309 exhibitors occupying 71,600
square feet of exhibit hall space, according to organizers.
here were 41 irst-time exhibitors, which totaled 10 more
than 2013.
his year’s conference highlights will include a presentation
from Ryan Hreljac, founder and assistant project manager
of Ryan’s Well Foundation, which helps with water problems
in some of the world’s poorest developing countries. He will
deliver the conference’s H2O Talk titled “hinking Big at the
Age of Six — How One of Tomorrow’s Leaders is Changing the
World Today” on Dec. 16.
Visit groundwaterexpo.com to ind additional details
about this year’s conference including hotel, registration and
schedule information.
 TRADE SHOW PREVIEW 49

Circle 104 on card or visit psfreeinfo.com. pu mpsa ndsyst ems.c om | D ec emb er 2015
50 BUSINESS OF THE BUSINESS

Industrial Internet of Things to

Impact the Pump Business
Adoption of the IIoT will affect a broad range of market segments, including mining.

By Arun Prasath
Frost & Sullivan

T
he Industrial Internet of
Things (IIoT) is a growing
trend across all major
industries and has significant
implications for the global economy.
Companies have begun to realize
the importance of IIoT in day-to-
day activities and operations. They
understand that adopting these
technologies will help them develop
new operational capabilities,
get more accurate information
and improve their bottom lines.
Operational efficiency is one of
the key attractions of IIoT, and
early adopters are focused on these
benefits. Incorporating IIoT also can
generate more data, and translating
that data into information and
knowledge can help improve system
functions and yield new insights
into operations.
“smart” pumps, which are able to
deliver diagnostic data directly into
the hands of original equipment
manufacturers (OEMs) and end
users. In the current scenario,
however, only around 2 percent
of suppliers offer IoT services to
help users effectively analyze and
monitor pumps.
Some estimate that 30 percent
of abrupt pump failures in extreme
working conditions result in
significant downtime, which
equates to a decrease in end user
productivity by up to 20 percent.
The deployment of IIoT and
Industry 4.0 is expected to increase
operational efficiency by up to 45
percent and provide a fairly quick
return on investment (ROI) for
Figure 1. The changing industrial landscape (Courtesy of Frost & Sullivan)
manufacturers. During the last
several years, only a few pump
manufacturers have embraced
the IIoT concept. Still, adoption is
expected to increase in the short-
to mid-term future.
Global Mining Slowdown
The global mining industry is an
important component in the global
economy, but it is at a crossroads.
Across the globe, the productivity
of mining and mineral extraction
has declined by 20 percent over the
past seven years, despite the push
for increased output.
Industry growth is expected to
be slow because of adverse global
trends such as slowing economies,
skilled-labor shortages and falling

Impact on the Pump Industry

The pump industry is incrementally
moving to the next level to
overcome current manufacturing
and operational challenges.
Adoption of innovative
technologies and emerging global
megatrends will change the way
the industry operates in the future.
The advent of IIoT is shaking
things up in the global pump
industry. Connecting components
to the Internet of Things (IoT)
can turn traditional pumps into

De c e mb er 2015 | Pum ps & S y st e m s

 51

commodity prices. Companies facing these challenges

are looking for every opportunity to improve their
performance. They are more willing to depart from
traditional operational approaches to achieve positive
outcomes in the marketplace, creating more emphasis
on minimizing equipment downtime, controlling costs
and improving safety. They are more focused on future
growth through expanded production, without losing
sight of operational efficiency and cost optimization.

The Silver Bullet

IoT can allow mine operators to unlock the benefits of
information technology products and services. IoT is
changing the mining industry by making it safer, more
efficient and more automated. It is making jobs more
high-tech, allowing more people to work remotely.
Remote sites use a wide range of complex equipment,
and monitoring equipment health and performance is
an enormous task. Large mining companies are moving
from reactive to proactive maintenance by leveraging
condition monitoring and predictive analytics solutions
to eliminate sudden equipment problems and allow
continuous real-time equipment monitoring. IIoT
enhances the case for mining companies to invest in
condition monitoring and predictive analytics.

A Long Way to Go
Mining is a multifaceted industry with complex
operations and is highly process-intensive. One
example of this process focus is water, which is crucial
for the mining industry. The water cycle in mining is
complex and must align with the entire mine life cycle.
To create a successful water strategy, the mining
industry is realizing that IIoT can be a key enabler.
Because IIoT can positively impact ROI, some foresee
that the adoption curve will steepen noticeably. IIoT
likely will drive efficiencies during the next five years.
While the present volatile economic scenario creates
the perception that significant adoption could be a long
Circle 121 on card or visit psfreeinfo.com.

way off, economic realities and converging trends (such

as the shortage of skilled labor and environmental
issues) could create a tipping point sooner than later.

Arun Prasath is an industrial automation and process

control industry analyst for Frost & Sullivan,
North America and India. Prasath has an
MBA in marketing and operations from
BIM, Trichy, India, and a bachelor’s degree
in mechanical engineering from AAMEC,
Tanjore, India.

pu mpsa ndsyst ems.c om | D ec emb er 2015

52 EFFICIENCY MATTERS

The Case For Metering Pumps in

Power Generation
This type of equipment may be ideal for power plant water-handling operations that require
ferric sulfate and sulfuric acid.

By Tom O’Donnell, Neptune Chemical Pump, part of PSG

& Bill Ehrhardt, McCloud Enterprises LLC

W
hile power plants a number of specific operational definition, an ion-free solution.
in the U.S. require stages. The first involves the This is another critical stage in the
trillions of gallons water’s passage through a clarifier, power generation process because
of water each year, various where any large, solid impurities only demineralized water can be
substances in significantly more are removed. Next, the water heated in the boilers to create the
precise measurements are needed travels through a fi lter, where steam that generates power.
to transform the liquid into any dissolved solids—not visible Ferric sulfate is used in the
ultra-pure water for boilers that to the naked eye—are removed. clarifying and fi ltering stages of
help generate electricity. These These initial pretreatment stages power generation. Because it is a
compounds commonly include are critical because, from there, coagulant, it interacts with solid
ferric sulfate, which is a crystalline the water moves through a particles in the water and causes
salt that is soluble in water and demineralizer that cannot handle them to clump together, making
used as a coagulant, and sulfuric water containing solids. it easier for the particulates to be
acid, which is a highly corrosive and When water is demineralized, removed. The sulfuric acid is used
toxic mineral acid that is soluble most of the positive and negative in the demineralization process to
in water at all concentrations. In ions are removed, creating, by balance the water’s pH level and
power plants, ferric sulfate helps
remove solid particulates from
water, and sulfuric acid is used to
control the pH, or alkalinity, of the
water used in boilers.
Ensuring that proper doses
and flow rates of ferric sulfate
and sulfuric acid are reliably
achieved is important for power
plant operators. To ensure the
proper concentration and flow
of ferric sulfate and sulfuric
acid, hydraulically actuated
diaphragm metering pumps may
be an ideal solution. They can help
guarantee that water used in power
generation meets the high levels of
purity required.
Image 1. While power plants use thousands of gallons of water per day when generating electricity,
operations are only completed successfully when precise doses of ferric sulfate and sulfuric acid
The Challenge are injected into the water-purification system. Hydraulically actuated diaphragm metering pumps
The purification of water needed for can help ensure that those dosage rates are consistently and reliably met. (Courtesy of Neptune
power generation occurs through Chemical Pump, part of PSG)

De c e mb er 2015 | Pum ps & S y st e m s

 53

achieve the required neutral state
before it can be heated. Users of
sulfuric acid must also be cognizant
of the substance’s harmful effects,
such as blindness that can result if
it is splashed into eyes or possible
severe chemical burns if there
is contact with skin. As a result,
sulfuric acid must be properly and
fully contained during its handling,
transfer and use.
Though thousands of gallons of
water pass through the clarifiers,
fi lters and demineralizers on an
hourly basis, the amount of ferric
sulfate and sulfuric acid introduced
in the process must be precisely
controlled. In other words, the
amounts must be exact.
For these critical dosing
applications, most power plant
operations feature skids with
chemical-feed pumps that have
electronic stroke controllers
following a 4-20 milliamp (mA)
signal—allowing automatic
adjustment of the pump
capacity—for feeding the
chemicals. The challenge for
the power plant operator is to
identify and deploy the best
pumping technology for the
operation, specifically one that
can reliably and repeatedly
inject the precise amount of
ferric sulfate and sulfuric acid
without leakage or spillage.
Some metering pump designs also
offer specialized stroke-adjustment
capabilities that can allow better
valve performance than competitive
variable-linkage designs. Designs
may also give the valve checks extra
time to seat since they are idle during
the bypass portion of the suction and
discharge strokes. Operators can also
find their desired flow rates in some
of these pumps using a micrometer
dial that can be calibrated to 1
percent increments. Some models
have repeatable accuracy of +/- 1
percent of full scale over the range of
10 to 100 percent of capacity.
These types of pumps may also
offer operational calibration columns
that provide a fast and economical
way to calibrate the flow rate of the
pump and pulsation dampeners that
remove the pulsation created by
the pump’s reciprocating action to
ws
Flo
atio n The Power of
ov
Wh
ereI
nn
Precision
ensure a smooth, laminar flow. Other
features can include injection quills
that provide uniform dispersion of
chemicals to the injection site and
relief valves placed on the discharge
piping in case blockage occurs in the
pump’s discharge line.
Tom O’Donnell is director of
business development with Neptune
Chemical Pump and PSG. He may
be reached at 215-699-8700 or tom.
odonnell@psgdover.com. For more
information, visit neptune1.com and
psgdover.com.
Bill Ehrhardt is president of
McCloud Enterprises LLC, a sales
firm representing various pump
brands in the northern New Jersey
and New York City markets. He
may be reached at 973-697-3525 or
mccloudwje@outlook.com.

One Solution
Hydraulically actuated
diaphragm metering pumps
possess the operational
capabilities and reliability
to perform these crucial
operations in a power plant.
For instance, metering pumps
can handle these applications
because they can be dialed
in to meet specific flow and
dosage parameters, which are
the lifeblood of a power plant’s
water purification process.
Circle 136 on card or visit psfreeinfo.com.
Neptune™ Hydraulically Actuated Diaphragm Metering
Pumps help power plant managers maintain proper water
cycle chemistry in boiler water treatment applications,
while also aiding in the production of ultra-pure water for
boiler water make up. We do this by designing metering For more information, please go to:
pumps that inject precise doses of critical chemicals each psgpumps.com/ps1215n
and every time.
• Repeatable ±1% accuracy of full scale PSG
• Highly accurate 10-turn micrometer dial 295 DeKalb Pike
• EZE-CLEAN™ check valve cartridges can be removed for cleaning North Wales, PA 19454
without disturbing piping USA
• Various materials of construction available for corrosive chemicals P: +1 (215) 699-8700
• Backed by a 3-year warranty F: +1 (215) 699-0370
info@neptune1.com
Ask Us About Neptune’s Custom Engineered Systems Capabilities! neptune1.com

pu mpsa ndsyst ems.c om | D ec emb er 2015

54 MAINTENANCE MINDERS

How to Properly Manage Piping Loads

These forces can have destructive effects if not carefully considered in piping design.

Last of Two Parts

By Jack Claxton
Patterson Pump Company, a Gorman-Rupp Company

I
n part 1 of this series (Pumps a 10-foot length of steel pipe force discussion, only with thermal
& Systems, November 2015), subjected to a 30 F gradient (see effects instead of a pressure force
the effects of mechanical pipe Equation 2). producing the deflection.
strain forces and hydraulic pressure If the end of the piping run The resulting deflection (dpipe)
reaction forces were discussed. opposite the pump is restrained, can be divided by the offset
This article will cover thermal a fairly routine piping run and distance, as before. If this resultant
temperature gradient causes an
reaction forces as well as strategies is less than 0.001 inch per inch
to deal with these forces and some axial deflection that well exceeds with a maximum of 0.010 inch
troubleshooting tips. the 0.005-inch or 0.010-inch when multiplied by the pump
criterion used for the hydraulic fl ange diameter, then the effect is
Thermal Growth or pressure reaction force analysis equivalent to the fl ange parallelism
Contraction Reaction Forces that could also be considered good criterion for mechanical pipe strain
Thermal growth or contraction practice for thermal response and hydraulic pressure reaction
reaction forces typically involve analyses. Applications involving force effects and is, therefore,
those forces generated due to hot or cold liquids that are not acceptable.
thermal expansion or contraction properly engineered can easily Simple calculation methods are
that occurs involving the change distort and crack pump casings presented here for the purpose
in temperature of the piping and cause other issues that are of illustration.
system from the ambient non- detrimental to pump life. More accurate analysis
operating condition to the steady The interaction of the piping methods are available using solids
state operating temperature. with the pump to produce modeling techniques and special
Part of the procedure in such deflection at the pump fl ange
applications is determining what and impose nozzle loads works
dpipe = aecL (∆T)
piping temperatures to use for much the same as in the hydraulic
the analyses, given the range of pressure reaction force discussion
Equation 1
ambient air temperatures and in Part 1 of this series, except
Where:
pumped fluid temperatures. with thermal effects instead
aec = linear expansion
Exterior applications introduce the of a pressure force producing
coefficient for the pipe
additional consideration of sun the deflection.
material, in/in-F
exposure and other weather effects. Orthogonal runs of piping can
L = length of piping run, inches
The effects of thermal movement have similar effects as illustrated
∆T = temperature gradient, F
can be difficult to analyze, yet in the hydraulic pressure reaction
lethal to a pump if not handled
properly, in applications where
such analyses are most applicable. 6.7x10 -6 in
dpipe = aecL (∆T) = ( )(120 in.)(30 oF) = 0.024”
Linear pipe movement is in oF
illustrated by Equation 1. For Equation 2
the sake of illustration, consider

De c e mb er 2015 | Pum ps & S y st e m s


piping anaysis software, where
appropriate, to model the specific
installation characteristics.
Such analyses can consider
the pump, pump support, and
foundation properties to verify
that the pump and piping
interact in an acceptable manner.
Transient loads can also be
assessed through such methods,
as well as performance under
seismic loading, neither of which
has been discussed here. Also,
manufacturers of special fittings
to solve certain piping problems
can assist with specific design
recommendations.
Supports vs. Restraints
Be aware that there is a distinction
between a pipe support and a
restraint such as an anchor that
Circle 126 on card or visit psfreeinfo.com.
55
prohibits movement axially as and thermally induced forces;
well as in other directions. Also, however, some tests by the author
be aware that although it may be on some randomly selected fittings
useful, in terms of simplifying indicate an ability to stretch up to
assumption purposes, to consider a approximately 1/4 of an inch when
subjected to 100 pounds per square
restraint rigid, in reality there will
be some flexibility present. inch of pressure. This is not axially
rigid, and some means to address
Special Flexible Fittings the hydraulic pressure reaction
It is important to understand force is needed when this type of
how the characteristics of any fitting is used near a pump.
special fittings used compare when As another example, when
subjected to loads from each of using flexible mechanical grooved
the three load sources discussed in type couplings, be aware that
this series. Often a fitting design they typically have some amount
handles loads from one or two of linear movement capability,
sources well but introduces loads published by the manufacturer.
on the pump from another source This movement capability
when not applied properly. introduces axial flexibility up to
For example, braided stainless some amount of deflection, but
steel flexible fittings work well in that amount is greater than the
handling mechanical misalignment 0.005 to 0.010 inch range limit
pu mpsa ndsyst ems.c om | D ec emb er 2015
56 MAINTENANCE MINDERS

typically needed at the pump to
avoid introducing a potentially
excessive pressure reaction force on
the pump, so this axial flexibility
must be considered.
Thrust Rods Used with
Special Flexible Fittings
Attention to thrust rod designs
are very important when flexible
fittings are used. For convenience,
designers sometimes use the
standard thrust rod designs used
in the American Water Works
Association (AWWA) M11 manual
for steel pipe.
However, because of the
relative weakness they introduce
as compared with the axial
rigidity of typical adjacent
piping, these thrust rod designs
are generally not acceptable for
use in the vicinity of pumps,
unless indicated by analysis to be
adequate.
For example, studies by the
author indicate the equivalent
axial stiff ness of the M11 thrust rods on fittings near pumps
rod designs to be 1/4 to 1/3 of the than recommended by the M11
equivalent axial stiff ness of the manual is likely needed, and this
recommended piping designs on is a suggested solution that can
which the thrust rods are used. be examined by designers. More
The use of more rods or larger information on thrust rod designs
Table 1. Sources of pump load (Graphics courtesy of Patterson Pump Company)
Load Type Load Source
M Mechanical pipe forces Piping not properly aligned at the time
of installation
P Hydraulic pressure reaction forces Pipe pressure reaction forces not
properly restrained
T Thermal reaction forces Thermal growth or contraction not
properly handled
Table 2. Vulnerabilities of piping systems
Piping Characteristics Vulnerable to Load Source Types
R Rigidly piped (no pipe couplings, Mechanical pipe forces and thermal
expansion joints or other axially reaction forces
flexible fittings)
F Flexible, pipe includes couplings, Hydraulic pressure reaction forces
expansion joints or other axially
flexible fittings

Table 3. Summary of possible piping problems

M P T
Load Type Mechanical pipe Hydraulic pressure Thermal reaction
forces reaction forces forces
Piping Load
Characteristics Piping not properly Pipe pressure reaction Reaction induced
aligned, supports forces not properly on the pump due to
Load Source
inadequate for fluid restrained, induced by thermal growth or
mass pipe internal pressure contraction
Rigidly piped (no pipe Piping alignment is Usually not so Must be addressed
couplings, expansion needed at the time vulnerable in average by proper analysis
joints or other axially of installation. Piping applications but and design that may
R flexible fittings) supports are needed evaluation is needed. indicate the need
to avoid loads due to for special fittings
Piping Characteristics fluid mass. or designs to avoid
problems.
Flexible, pipe includes Usually not so Can be a problem if Can be a problem if
couplings, expansion vulnerable in average flexible fittings are flexible fittings are
F
joints or other axially applications but not used properly and not used properly and
flexible fittings evaluation is needed. installed properly installed properly
Note 1: By no means is this summary intended to substitute for proper piping system analysis and evaluation
Note 2: Higher operating pressures increase vulnerability to hydraulic pressure reaction forces.
Note 3: Higher temperature gradients increase vulnerability to thermal growth or contraction reaction forces.

De c e mb er 2015 | Pum ps & S y st e m s

 57

is also contained in the Hydraulic
Institute publication ANSI/HI 9.6.6,
Pump Piping.
Typical Vulnerabilities of
Piping Systems
Tables 1 through 3 provide general
guidance as to vulnerabilities and
potential problem areas for some typical
piping systems. This information is
not provided as a substitution for
considering all potential load sources for
a particular installation.
First, consider the summary of how
the three categories of pump loads
discussed are generated, as shown
in Table 1. Both approaches have
advantages and disadvantages that must
be carefully evaluated and managed
to produce a satisfactory installation,
without excessive piping loads being
imposed on the pump.
Typical trends to watch for and
recommended precautions are shown
in Table 3. Combining the tables above
produces the generalized overall
summary in Table 3.
there may be a problem that warrants Determining Hydraulic Pressure
further investigation. To determine the Pipe Strain
effects of the fluid mass, the fl anged With the pump not operating, place dial
joint alignment can be corrected as indicators on the pump fl anges (X, Y
applicable, re-bolted, and the system and Z directions). Start the pump. If the
fi lled with fluid with the dial indicators movement exceeds 0.005 inches, there
in place. If the movement exceeds 0.005 may be a problem that warrants
inches, there may be a problem that further investigation.
warrants further investigation.
Determining Thermal Pipe Strain
With the system (and pump) not
Jack Claxton, P.E., has been involved
operating and at ambient temperature,
with pump engineering
place dial indicators on the pump fl anges
for Patterson Pump
(X, Y, and Z directions). Start the system
Company since his
and operate until the temperature
graduation from
reaches a stable normal operating
Georgia Tech. in 1975.
temperature. If the movement exceeds
He is currently vice
0.005 inches, there may be a problem
president, engineering.
that warrants further investigation.

Troubleshooting to Determine
Objectionable Piping Load Effects
Once a system is designed and in place,
tests can be conducted to verify that the
pump is not subjected to excessive loads
from the three load sources discussed
here. These procedures require the use
of six dial indicators or, alternatively,
the use of computer measurement
machine (CMM) technology.
Note that the placement of the dial
indicators should be done so as to assess
movement relative to the foundation.

Determining Mechanical
Pipe Strain
With the pump not operating, place
dial indicators on the pump fl anges
(X, Y and Z directions). Isolate the
pump by closing isolation valves in
suction and discharge lines, and drain
the water. Remove the fl ange bolts. If
the movement exceeds 0.005 inches,
Circle 137 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

58 MOTORS & DRIVES

Pick the Right VFDs for Progressive

Cavity Pumps
There are numerous factors to consider to ensure the best performance with this technology.

By Gordon Fenton
SEEPEX Inc.

O
ne of the greatest device. Therefore, the selection is motor is constructed of three
advantages of a progressive determined solely by voltage and electromagnets (stator) and the
cavity (PC) pump is that current capability. The advertised rotor—a metal that is attracted or
its flow rate is determined solely horsepower (HP) is stated for the repelled by the electromagnets. The
from the pump speed. The PC convenience of being similar to magnetic field created by voltage
pump exhibits pump flow that is motors. The continuous rating and subsequent current causes the
linear and repeatable, like an ideal should always be compared to rotor to chase the magnetic field.
metering pump. These pumps the motor’s maximum amperage. When the rotor cannot keep up
are unique because their starting The VFD’s overload capability with the magnetic field, the motor
torque is often greater than the in percent is a multiple of its draws high current.
operating torque during operation, maximum continuous current and The motor draws the most
but this characteristic creates a not the motor’s full-load amperage. current when it is starting. The
challenge when using variable Only CT or sensorless vector CT peak current the motor produces
frequency drives (VFDs) with PC should be used with PC pumps. is often referred to as locked-rotor
pumps. This article will help with current. This locked-rotor current
better selection of VFDs for most Electric Motor Theory determines the maximum starting
PC applications. For the purpose of simplicity, torque the motor will produce. It
assume that an electric is usually a multiple of full-load
VFD Characteristics
Constant torque (CT) VFDs are
Figure 1. Comparing horsepower required for pumps (Graphics courtesy of SEEPEX)
used in applications where there
is a linear relationship between
power required and equipment
speed. Variable torque (VT)
VFDs are used when the required
equipment power is not linear with
respect to speed, like centrifugal
pumps and fans.
Sensorless vector drives are
becoming the preferred option for
drives. This technology recognizes
many factors that influence
drive/motor performance, and
it monitors them continuously
to optimize performance and
minimize power requirements.
For drive selection, note
the VFD is a purely electrical

De c e mb er 2015 | Pum ps & S y st e m s

 59

current that ranges between 1.5 the VFD, which

Figure 2. Examining starting torque capacity
to 6 times the motor’s full load is found on the
amps (FLA). This surge of current nameplate.
is what a PC pump relies on to
be able to overcome the pump’s Preparing VFD
starting torque. Factors that have Operation
the potential to limit the motor Selecting the PC
starting torque include a conductor pump involves
that is too small or too long, a experience and
circuit breaker that is too small, or knowledge of
minimal VFD overload capability. the product and
A motor’s maximum starting application. After
torque is directly proportional to selection, the
the current that it can absorb for starting torque,
a short period of time. The more running torque and
it can absorb, the more torque the pump revolutions
motor can produce. per minute (rpm)
When starting a motor across- range are known
the-line, this is only limited by entities.
conductor sizing. The VFD acts Considerable
like a fi lter between the line and thought should be
the motor. The fi ltering limits the given to selecting
amount of current based on the the gearbox ratio
VFD’s design. with respect to
Most modern-day VFDs have the rpm range of
this overload capability of 150 operation when
percent for 30 seconds and 180 using a VFD.
percent for 5 seconds. Some can It is beneficial to choose a gear greater starting torque than
even handle 200 percent for ratio that is as high as possible running torque.
short periods. The percentages and places your maximum VFD Increasing the gear ratio gives
are in relation to the maximum frequency close to 85 hertz (Hz) the mechanical advantage by
continuous current rating of because a PC pump requires requiring less HP to generate the
required torque. Selecting gear
ratios in this manner can mean
Table 1. An example of the potential effects of different gearbox ratios for substantial power savings (see
the same pump Figure 1).
Pump Characteristics Consider the example in Table 1.
Starting torque 207 pound-feet (lb.-ft.) Both Case A and Case B will work
for the hypothetical application;
Operating torque 120 lb.-ft. however, Case B will have no issues
Rpm range 100 to 400 rpm starting using a motor two-thirds
the size of Case A (see Figure 2).
Case Studies
Case A will require more motor
Case A Case B horsepower and starting torque to
Ratio 1750/400 = 4.375 1750/290 = 6.034 start the pump. The initial capital
VFD Overload 150 percent 150 percent cost savings and power saving over
ownership can be large.
Hz 15-60 Hz 21-83
Operating HP 9.14 HP 9.14 VFD Parameters of Interest
Starting power 10.51 (This pump will require 7.62 (This pump only Most VFDs have multiple
a 15-hp motor to operate.) requires 10 hp to operate.) parameters that can assist in

pu mpsa ndsyst ems.c om | D ec emb er 2015

60 MOTORS & DRIVES
situations where the starting
torque is marginal. Some motors
respond better to these changes
than others; however, they
should be checked as soon as there
is an issue with starting the pump.
Below is a list of these parameters,
along with descriptions and advice:
Acceleration/deceleration time:
This is the time period the VFD will
take to increase or decrease speed
from current speed to a new speed.
It is a fi lter that will help limit
the maximum amount of current
generated during starting. This
value is usually listed in seconds.
Appropriate values range from 1
to 15 seconds. Shorter time allows
more current to be produced, plus
more torque and heat. Values from
3 to 7 seconds usually meet most
applications without creating
unnecessary mechanical stress.
Circle 144 on card or visit psfreeinfo.com.
De c e mb er 2015 | Pum ps & S y st e m s
Starting overload capability: In
some drives, you can adjust this
parameter to purposely limit
the maximum current the drive
will use to start the motor. In
most cases, this should be left at
factory settings, which are usually
drive maximums.
Carrier frequency: Carrier
frequency controls how often
the voltage is modulated in the
waveform. The most noticeable
effect of raising the value is
lessening motor/VFD whine as
it passes outside of the range of
human capabilities.
Increasing carrier frequencies
increases motor thermal stress and
sometimes reduces the maximum
current capability. The rule of
thumb is to leave this at the lowest
value and only raise it if you have
the extra capacity and auditory
restrictions that you cannot
meet otherwise.
Motor overload: This parameter
is usually in the form of a
percentage. Taking the full load
amperage from the motor’s data-
plate and multiplying by 100 and
dividing the result by the VFD’s
maximum continuous current
rating gives the correct percentage.
In most cases, the possible values
range from 30 to 100 percent.
Motor overload type: Motor
overload type usually has two
options. One will be speed
compensated and the other will
be non-speed compensated. Speed
compensation should be used
whenever the motor fan speed
is proportional to motor speed
(non-blower-cooled). Non-speed
compensated should be used in
instances where the motor is cooled
Comprehensive
Industry Coverage
• Positive Displacement Pumps
• Centrifugal Pumps
• Specialty & Other Pumps
• Industrial Valves
• Pneumatic & Hydraulic Valves
• Industrial Automation & Process Control
• Electric Motors & Drives
• Actuators
• Compressors
• Custom Research
• White Papers
Frost & Sullivan evaluates and implements
effective growth strategies. We employ 50
years of experience in partnering with Global
1000 companies, emerging businesses and
the investment community from more than
40 offices on six continents.
Visit us at www.frost.com
For more information, contact Liz Clark
at 210.477.8483 or liz.clark@ frost.com
Circle 140 on card or visit psfreeinfo.com.

by a fan that does not change
speed according to motor speed
(blower-cooled).
Fixed boost: Fixed-boost
parameter is rarely needed and
almost always overused. This
parameter sets the drive power’s
minimum voltage. As we stated
before, the voltage in a constant
torque application should be in
a linear relationship with speed.
This parameter will override it
at low speeds and not let the
voltage fall below the preset value
percentage. For example, if the
parameter was set to 40 percent,
a 460 VAC drive could not lower
the voltage below 0.40 times 460
VAC or 184 VAC. The problem with
the increased voltage is it will only
temporarily help in starting, but
always contribute to the motor
overheating. Always keep this
Circle 139 on card or visit psfreeinfo.com.
parameter at 0 percent. If the need
arises to change it, check, check
and recheck other parameters.
Otherwise, this may be creating
another problem.
Drive mode: The available
parameters for this selection
will vary according to the drive
manufacturer and drive capability.
In all cases, it should only be set
to one of two selections. The first
selection would be “constant volts/
Hz,” which would be for drives that
do not incorporate vector control
capability. The other option will be
“vector speed CT” control for
drives that incorporate vector
control capability.
Motor rated voltage: This
sounds trivial, but this cannot be
stressed too much in the world
of dual-voltage motors. The drive
voltage must be the same as the
Circle 143 on card or visit psfreeinfo.com.
pu mpsa ndsyst ems.c om | D ec emb er 2015
61
motor voltage, and the motor must
be appropriately wired for the
same voltage. Additionally, this
parameter should be set for that
same voltage.
Motor rated current: This
parameter must be set to match the
motor nameplate full load current
in amperes.
Gordon Fenton is the
engineering manager at
SEEPEX Inc., specializing in
the optimization of electrical
and mechanical processes to
increase manufacturing
throughput. Fenton has
more than 20 years of
experience with PC
and various other
pumps.
62 SEALING SENSE
Material Advances Improve Seal Reliability in
Extreme Application Conditions
Diamond technology can also promote safety and provide exceptionally low emission sealing
of critical equipment.
By Doug Volden & Sam Ajram
FSA Members
D
uring the past 10 years,
the industry has devoted
extensive investment
efforts to the research and
development of advanced seal face
materials capable of extending the
application performance range
and mean time between repairs
(MTBR) of mechanical seals in
pumps, compressors and other
fluid-handling rotating equipment.
Much of this research involving
universities, material development
companies, laboratories and
mechanical seal companies
focused on diamond-like (DLC)
and surface-grown diamond
fi lm coatings on conventional
mechanical seal face material
substrates. For today’s end users,
diamond fi lm and diamond-like
fi lms provide solutions that
enhance reliability, promote
safety and provide exceptionally
low emission sealing of critical
equipment across many difficult-
to-seal fluids particular to the oil
and gas industries. Diamond fi lm
combines the physical properties of
diamond with the most advanced
seal technologies available.
Seal designers admire the
physical properties of diamond for
its chemical resistance, hardness
and durability. However, early
forms of synthetic diamond
developed in the 1950s using a
high-pressure, high-temperature
De c e mb er 2015 | Pum ps & S y st e m s
(HPHT) process were primarily
used in commercial applications
where their abrasive properties
were beneficial; they had little
tribological value in the highly
polished running surfaces of a
mechanical seal interface.
Chemical vapor deposited (CVD)
diamond, developed in the late
’60s, is the result of an industrial
process that creates a vapor-phase
reaction that converts gases into
a solid fi lm on a prepared surface.
Because its deposition lends
itself to varied complex shapes,
conventional CVD diamond has
been used to improve cutting tools.
However, early development efforts
in the area of mechanical seal face
fi lms incorporated diamond grains
that were microns in size. These
microscopic diamond grains proved
less than optimal for tribological
performance requirements because
they require significant and
costly secondary post-deposition
operations to achieve a viable
surface fl atness. As a result, they
could not become a commercially
justified material alternative.
More recently, scientists at
Argonne National Laboratory
invented a new method of
manufacturing CVD diamond
that renders a continuous fi lm
comprised of diamond grains that
are 3 to 5 nanometers in size,
a thousand-fold smaller than
EXAMPLES OF FIELD INSTALLATIONS
Case 1:
Industry: Oil and gas
Pump shaft size: 1.000 inch
Fluid: Sour water (traces of ammonium
bisulfide)
Seal pressure: > 420 pounds per square inch
(psi)
Speed: > 20,000 rpm
Temperature: 104 F
Previously: Siliconized graphite vs. tungsten
carbide
Currently: αSiC vs. diamond on αSiC
Improved MTBR by 100 percent, from 3-4
months to 10-11 months
Sealing faces in very good condition when
evaluated after 10 months running
Case 2:
Industry: Oil and gas
Pump shaft size: 1.000 inch
Fluid: Condensate-water
Speed: 10,000-15,000 rpm
Temperature: 180 F max
Previously: Carbon vs. tungsten carbide
Currently: Graphite loaded SiC vs. diamond on
αSiC
Improved MTBR by 100 percent, from 10-12
months to 2 years
Sealing faces in very good condition at
shutdown for other reasons at 2 years running
Case 3:
Industry: Chemical/pharmaceutical
Mixer shaft size: 8.000 inches
Fluid: Contact lens solution/dry running
Speed: < 10 rpm
Temperature: 250 F max
Previously: Graphite loaded SiC vs. tungsten
carbide
Currently: Diamond on αSiC vs. diamond on αSiC
Excellent results being achieved against past
performance
 63

those on cutting tools. The transition

from fi lms of large micron-sized grains
to nanocrystalline that are smooth
when deposited provided a surface
finish requiring less post-processing to
make them useful in mechanical seals.
This was a step toward a reproducible
diamond fi lm seal face with the hardness
of natural diamond, lower friction
characteristics than conventional seal
face such as silicon carbide (αSiC), and
excellent wear capability.
While diamond crystalline structure
control and deposition processes
have advanced considerably to the
point of reasonable global commercial
availability and adoption by several
seal manufacturers, diamond fi lms are
not without limitations and inherent
application constraints. The development
path has had to overcome numerous
technical challenges and varied field
performance results. Researchers and Circle 134 on card or visit psfreeinfo.com.
developers had to understand the
relationship between crystalline grain
size, fi lm adhesion capability and the
tribological effects on seal interface
lubrication. Overcoming intermittent
fi lm delamination under high-stress
conditions continues to be an area of Visit Booth 7646
research and solution application testing. at POWERGEN
A key factor in determining seal Houston, Texas
performance capability is the coefficient
of friction value associated with a
specific seal face material combination.
Internally validated measurements
by a Fluid Sealing Association (FSA)
member company confirm that the use of
micro-crystalline diamond significantly
reduces the coefficient of friction when
compared with other conventional
seal face material combinations. This
benefit is evident when comparing hard
against hard-running face materials. The
measured coefficient of friction when
running hard faces versus αSiC was
reduced by more than 50 percent when
running diamond versus diamond or
αSiC versus diamond on αSiC substrate.
Point solution performance testing
was also completed in hot water, steam,
Circle 133 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

64 SEALING SENSE
propane and abrasive slurries to stress
the coating robustness and better
define the application performance
range capabilities of diamond faces
when compared with traditional αSiC
faces. In an accelerated-wear, 100-
hour hot water test at conditions of
250 F, 140 pounds per square inch
gauge and 3,450 revolutions per
minute, diamond versus diamond faces
showed significantly less wear to both
surfaces, cooler interface temperatures,
lower power consumption and longer
seal life projections. The hot water test
results in Table 1 show the dramatic
wear resistance of the diamond surface
compared with uncoated αSiC. The
accelerated hot water wear test uses
an aggressive set of conditions that
standard uncoated αSiC is unable
to withstand, exhibiting grooving
approaching 4,000 micro-inches and
Simple, Reliable
Efficient
Vapor Recovery? LPG Transfer? Natural Gas Boosting?
The answer is the FLSmidth® Ful-Vane™ rotary vane compressor!
Built robustly for long service life, it has only three moving parts. Combined with low operating speeds
which minimizes wear and vibration, it is designed to not only outlast other compressors, but save you
money on power and maintenance costs.
• Suitable for natural gas, flare gas, bio gases, LPG vapor, and ammonia refrigeration
• Carbon fiber vanes last longer than traditional blades
• Variable flows with VFD and/or bypass
• Single stage to 3000 SCFM, two-stage to 1800 SCFM
• Discharge pressures to 250 PSIG
• Made in the USA for over 80 years
Find out more at www.flsmidth.com/compressors
De c e mb er 2015 | Pum ps & S y st e m s
Table 1. Wear resistance of diamond surface compared with uncoated αSiC
Pre-Test / Post Test
Mating Ring Radial Slope
Mating Ring Wear
Primary Ring Wear (inches)
carbon wear in excess of 0.001 inches.
The post-test diamond surfaces were
nearly unchanged. In actual abrasive
slurry testing, paired diamond faces
showed less wear than conventional
hard-face material combinations.
The potential benefits of diamond
faces include: enhanced reliability in
marginal lubrication applications;
improved resistance to dry running
and upset conditions; improved wear
in abrasive media; lower coefficient of
Circle 132 on card or visit psfreeinfo.com.
Carbon vs. Diamond vs.
Uncoated αSic Diamond
Pre-Test / Post Test
< 23 µ” / > 500 µ” < 23 µ” / 63 µ”
0 µ” / 4000 µ” 0 µ” / < 300 µ”
0 µ” / 0.001” – 0.002” 0 µ” / < 24 µ”
friction; and lower energy use.
Diamond surface technology
is expanding the tribological and
application performance limits of
existing seal designs and improving
user equipment reliability and uptime
on critical services. Recommended
applications include abrasive
environments, slurries, viscous fluids,
hot water, poor lubricating fluids and
multiphase fluids.
While diamond surfaces represent an
exciting advance in sealing technology,
users should exercise caution and
discuss the detailed engineering analysis
provided by the seal supplier on each
potential application. Diamond coating
adds considerable cost to a conventional
seal face. Users must take into account
cost versus economic benefit in any
application by comparing current and
projected MTBR, and performing an
assessment of risks of applying diamond
where performance has not been
validated through testing.
Next Month: Valve packing
installation and consolidation
We invite your suggestions for article topics as well as
questions on sealing issues so we can better respond
to the needs of the industry. Please direct your
suggestions and questions to sealingsensequestions@
fluidsealing.com.

Determining NPSH3, Comparing Axial Thrust &
Evaluating Boiler Circulating Pumps
By Hydraulic Institute
What is NPSH3, and
what are the methods
for determining the
NPSH3 of a rotodynamic
submersible pump?
NPSH3 is the net positive
suction head available to a pump
under test at a constant rate
of flow when the pump head is
decreased by 3 percent as a result
of cavitation caused by a decreasing characteristics of rotodynamic
available suction head. Sometimes
NPSH3 is referred to as net positive arrangement is shown in Figure
suction head required (NPSHR);
however, a pump’s NPSHR must
be higher than the NPSH3 for
the pump to operate without
head reduction, and it may need
to be higher than the NPSH3 for
long-term reliable operation. For
more information on the required
margins above NPSH3, refer to
ANSI/HI 9.6.1 Rotodynamic Pumps
Guideline for NPSH Margin.
The NPSH is established
through the datum elevation of
Figure 11.6.7.2a. Suction throttling NPSH test setup
the impeller. The flow toward the
pump must be uniform and free of
undue disturbances. A pump tested
with suction piping may require a
flow-straightening device before
entering the pump. Arrangements
for cooling or heating the liquid
in the loop may be needed to
maintain the required temperature.
Multiple arrangements can be
used to determine the NPSH3
submersible pumps. One
11.6.7.2a. The pump is supplied by
a constant-level supply through a
throttle valve followed by a section
of pipe containing straightening
vanes or a minimum of seven
diameters of straight pipe to
straighten flow. This arrangement
decreases the turbulence produced
by the throttle valve and makes
possible a more accurate reading of
suction pressure at the pump inlet.
This simple arrangement usually
is satisfactory for NPSH greater
Figure 11.6.7.2b. Variable-lift NPSH test setup
pu mpsa ndsyst ems.c om | D ec emb er 2015
65
than 3 meters (10 feet); however,
the turbulence at the throttle valve
tends to accelerate the release of
dissolved air or gas from the liquid
as the pressure on the liquid is
reduced. A test made with this
arrangement usually indicates
higher NPSHR than what would be
expected with deaerated liquid.
Figure 11.6.7.2b shows a second
option. The pump is supplied by a
sump in which the liquid level can
be varied to establish the desired
NPSHR. Be careful to prevent
entrained air or vortexing as the
liquid level is varied. The priming
connection should be installed
above the eye of the impeller,
either in the discharge pipe or on
the pump.
For more information on
test methods for rotodynamic
submersible pumps, refer to ANSI/
HI 11.6 Rotodynamic Submersible
Pumps for Hydraulic Performance,
Hydrostatic Pressure, Mechanical,
and Electrical Acceptance Tests.
66 HI PUMP FAQS
How does axial thrust
compare among impeller
types for a rotodynamic
vertical pump?
The net axial downthrust
force is carried by the pump shaft.
The shaft will stretch under this
load. Before the pump starts, any
stretch that occurs is the result
of the sum of the static forces.
The thrust load will increase after
the pump starts because of the
addition of dynamic forces.
The dynamic forces creating
thrust on a vertical turbine
pump enclosed impeller result
from the difference in pressure
distributions on the upper and
lower shrouds along with the force
from the change in momentum of
the flow through the impeller (see
Figure 2.3.3.2.3a).
The semi-open impeller has
only an upper shroud (see Figure
2.3.3.2.3b). The difference in
pressure distributions along the
shroud’s backside and vaned side
is typically greater than between
the upper and lower shrouds of
an enclosed impeller. Semi-open
impeller axial thrust is higher
than that of the enclosed impeller.
The axial flow pump impeller
has no upper or lower shroud;
Figures 2.3.3.2.3a, b & c. The first (left) shows the enclosed impeller plain top shroud, the
second (middle) displays the semi-open impeller and the third (right) illustrates the enclosed
impeller with back ring and balance holes.
Circle 135 on card or visit psfreeinfo.com.
Figure 2.3.3.2.3a Figure 2.3.3.2.3b
De c e mb er 2015 | Pum ps & S y st e m s
vanes are attached directly to the
hub. The axial thrust generated
is primarily from dynamic forces
created by interaction of the
propeller vanes with liquid.
The impeller back ring with
balance holes configuration
reduces axial thrust (see Figure
2.3.3.2.3c). Back rings may be cast
integrally into impellers with a
top shroud. They are used when
pump total axial thrust requires
reduction. The flow through
balance holes in the impeller
hub shroud, combined with the
leakage past the balance ring,
reduces efficiency. Increased
leakage through clearances that
results from wear of the back
ring arrangement may cause an
increase in downthrust. For more
information about axial thrust for
vertical rotodynamic pumps, see
ANSI/HI 2.3 Rotodynamic (Vertical)
Pumps for Design and Application.
What information is
available regarding boiler
circulating pumps for
combined-cycle power
plant service?
Boiler circulating pumps
circulate water within the boiler
to enhance boiler operation.
They take suction from a header
Figure 2.3.3.2.3c
 67

IQV"UNWTT[A
connected to the bottom of the boiler
drum and discharge through additional
tube circuits. This means the water
pumped is at boiler temperature and
pressure. For this reason, standard boiler
circulating pumps must be designed for
high temperature (usually between 300
and 600 F [150 and 315 C] depending on
boiler size and rating) and high pressure
(corresponding to boiler temperature
and water vapor pressure). For small
boilers, with relatively low temperatures
and pressures, conventional overhung
pump designs may be suitable for boiler
circulating service.
Boiler circulating pumps must
Ftknnkpi"Owf"
develop enough head to overcome the dlorworu0eqo Ecug"Uvwf{<
friction of the tube circuits; however, the
combination of high temperature and
pressure results in sealing conditions that Pgy"Hqt"4237"/"ZR/M¥P"Ugtkgu"
require special sealing systems. Because of Gzrnqukqp/rtqqh.""HO."E1WU"crrtqxgf"
*Encuu"K."Fkxkukqp"3."Itqwr"E"("F+
the relatively low head requirements, the
pumps are single-stage with single-suction Circle 130 on card or visit psfreeinfo.com.
impellers and a single seal chamber.
This creates a problem of unbalanced
axial thrust, which may require special
pump bearing systems or balancing
arrangements. An alternate solution is
to use pumps of wet-motor construction,
where the pump and the motor are inside
the pressure vessel, eliminating sealing
and unbalanced axial thrust issues. Such
special pumps are welded into the boiler
piping. For higher temperatures to 685 F
(365 C) and pressures from 1,800 to 2,800
pounds per square inch (psi) (124 to 193
bar), special pump designs are required.
For more information about pumps used
in combined-cycle power plants, see HI’s
guidebook Power Plant Pumps: Guidelines
for Application and Operation to Maximize
Uptime, Availability, and Reliability.

HI Pump FAQs® is produced by the Hydraulic

Institute as a service to pump users, contractors,
distributors, reps and OEMs. For more
information, visit pumps.org.

Circle 138 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

68

ALIGNMENT/VIBRATION
CONDITION MONITORING

ANNUAL COUPLINGS

PRODUCT
FLOW METERS
LEVEL CONTROLLERS

SHOWCASE MAINTENANCE PRODUCTS

MOTORS & DRIVES
PACKAGED PUMPING SYSTEMS
PUMPS
Innovative products, SEALS
technologies and solutions VALVES
from selected suppliers VIBRATION ANALYSIS/DATA
COLLECTION

ALIGNMENT/VIBRATION CONDITION MONITORING COUPLINGS

PoxyStand Pump Pedestals
Speciically designed for PoxyBase pump
baseplates, PoxyStand provides a rugged
and cost-efective foundation that is
quick and easy to install. Constructed
of Zanite PLUS, these epoxy-based
structures ofer substantial vibration
damping, corrosion resistance and
thermal stability while simplifying
installation. PoxyStand (hollow
construction option available) adapts
to most applications and can be mounted
on an existing solid surface or buried
below grade.
Customizable Self-Aligning
Vibration Pipe & Tube
Analysis Couplings
Leonova Diamond Tuf-Lok ring grip
or Emerald are pipe couplings are
rugged portable low-cost, heavy-
vibration analysis duty self-aligning couplings for high-
instruments pressure, to 150 pounds per square inch
suitable for gauge, or full-vacuum rated applications.
any industry. Tuf-Lok pipe couplings install quickly
Instrument and software packages and easily, reducing costs. Reinstallation
are customized to it users individual is also fast and easy. hey are ideal
condition monitoring needs and budget. for applications where assembly and
Vibration analysis in single, dual or disassembly are required. hey are
three-channel simultaneous available in 2-inch (50 mm) through
measurements from 6,400 line 10 10-inch (250 mm) pipe sizes and are
Khz, up to 25,600 line 40 Khz, SPM made for use on plain end pipe,
HD for rolling-element bearing, plus regardless of pipe wall. No machining
lubrication analysis and more. or grooving is required to maintain
pipe or tube integrity.

BaseTek LLC SPM Instrument Inc. TUF-LOK International

877-712-2273 1-800-505-5636 608-270-9478
info@basetek.com info@spminstrument.com info@tuflok.com
basetek.com leonovabyspm.com tuflok.com
Circle 301 on card or visit psfreeinfo.com. Circle 317 on card or visit psfreeinfo.com. Circle 313 on card or visit psfreeinfo.com.

D e c e mb er 2015 | Pum ps & S y st e m s

 ANNUAL PRODUCT SHOWCASE 69
69

FLOW METERS LEVEL CONTROLLERS MAINTENANCE PRODUCTS

Operations &
Maintenance
Software:
Operator10
& Antero

Variable Area Flow Meters
Variable area vane and piston flow meters
from Universal Flow Monitors Inc. are
designed to measure flow of lubricant,
coolant and flush to pump seals.
These reliable and widely used meters
provide rate, total and two adjustable
set points when equipped with the new
HART protocol transmitter. Optional
mechanical switch backup offers
redundancy in challenging applications.
Universal Flow Monitors Inc.
248-542-9635
ufm@flowmeters.com
flowmeters.com
Circle 314 on card or visit psfreeinfo.com.
PSL 5.0 Pump Station
Level Controller
Ideal for sewage pump stations, lift
stations, wet wells and tank-level control
with a non-contacting ultrasonic sensor
mounted above the liquid, the new
Greyline PSL 5.0 Level Controller offers
six independently programmable control
relays for pump or valve control, level
alarms, dialers, temperature alarm and
echo-loss alarm.
Greyline Instruments
888-473-9546
info@greyline
greyline.com
Circle 321 on card or visit psfreeinfo.com.
An operations
and maintenance
data management
software, Antero CMMS allows users to
track equipment and work orders, along
with inventory, ordering and receiving.
Operator10 is a robust and user-friendly
solution for plant operational data
management and reporting needs. These
tools come with technical support and
services that are focused on making the
software easy to use.
AllMax Software Inc.
800-670-1867
sales@allmaxsoftware.com
allmaxsoftware.com
Circle 300 on card or visit psfreeinfo.com.

MOTORS & DRIVES PACKAGED PUMPING PUMPS: CENTRIFUGAL

VARIOspeed
Constant
Pressure
Controls
VARIOspeed
constant pressure controls offer an
economical, pre-engineered solution
using a factory-programmed variable
frequency drive (VFD) in a NEMA 1 or
3R enclosure with a user-friendly keypad
and backlit display for easy installation/
setup. The VFD automatically controls
the pump speed to maintain a constant
discharge pressure. Applications include
submersible deep well, booster and
irrigation pumps. The equipment is UL/
cUL listed and includes a five-year
limited warranty.
SJE-Rhombus
888-342-5753 or 218-847-1317
sje@sjerhombus.com
sjerhombus.com
Circle 312 on card or visit psfreeinfo.com.
SYSTEMS
Grundfos
PACOpaQ HVAC
Packaged
Pumping
System
The PACOpaQ is
a fully integrated
heating, Boundary Layer/Viscous
ventilation and air conditioning (HVAC) Drag Pump
packaged pumping system designed
for chilled and hot water distribution, Using Discflo’s innovative Discpac
condenser water, geothermal loop, and technology reduces wear on pump
district heating and cooling. The system components, resulting in longevity, lower
pairs reliable centrifugal pumps with the operational costs and saving hundreds of
intelligence and efficiency of a dedicated thousands in maintenance and product
HVAC control, automatically determining loss. The combination of abrasion
the most efficient speed and optimum resistance, gas-entrained pumping,
number of pumps needed to meet desired no degradation and non-emulsifying
flow and pressure. laminar flow makes the disc pump the
ideal choice for tough applications.
Grundfos Discflo Corporation
913-227-3400 619-596-3181
ordersupport-gpu@grundfos.com sales@discflo.com
grundfos.us discflo.com
Circle 304 on card or visit psfreeinfo.com. Circle 302 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

70 ANNUAL PRODUCT SHOWCASE

PUMPS: CENTRIFUGAL PUMPS: CENTRIFUGAL PUMPS: CENTRIFUGAL

PEMO Submersible
Pumps
• The PEMO
submersible pumps
are designed for
heavy-duty slurry
applications. PumpWorks Industrial ANSI &
ANSI Centrifugal Pump • High-efficiency Industrial Pumps
motor with power
EnviroPump and Seal offers centrifugal The ANSI and industrial pump line,
ranging from 1 to
pumps, upgrade and retrofit packages 100 horsepower and PumpWorks Industrial, offers premium
to improve the life and performance of speeds from 735 to standard attributes such as carbon
existing centrifugal pumps. Modular 3,500 revolutions steel wet ends, carbon steel bearing
bearing frame/seal systems are currently per minute. housings, 316 stainless steel shafting
adaptable to nearly 200 different makes, • Standard capacity to 700 cubic meters and flinger disc splash lubrication.
per hour (3,082 gallons per minute). The line meets or exceeds B73.1-2012
models and sizes of ANSI pump
• Maximum pressure up to 7 bar (103 requirements. Distributed by DXP
manufacturers. Sizes available range pounds per square inch).
up to 8 x 10 x 17 inches in 316ss and Enterprises Inc. and manufactured and
• Double mechanical seals (silica carbide tested in the U.S., the line offers price,
duplex stainless steel, with power from or widia wear rings); oil-lubricated.
5 to 250 horsepower. delivery and quality for virtually any
• Motor overload protection and
moisture detection. fluid-processing application.
EnviroPump and Seal PEMO Pumps PumpWorks Industrial
678-324-4481 39-02-250731 713-956-2002
sales@enviropumpandseal.com fperissi@pemo.com sales@pumpworksindustrial.com
enviropumpandseal.com pemo.com pumpworksindustrial.com
Circle 303 on card or visit psfreeinfo.com. Circle 323 on card or visit psfreeinfo.com. Circle 320 on card or visit psfreeinfo.com.

PUMPS: CIRCULATOR PUMPS: CIRCULATOR PUMPS: DIAPHRAGM

Grundfos
COMFORT PM
Recirculating
Pump
The Grundfos
COMFORT PM New Iwaki Air AODD
AUTO residential Pump Series
circulating VARNA Products XD-4
pumps set the Iwaki’s air-operated double diaphragm
standard for The XD-4 is a quiet-running vane pump, pumps are available in multiple corrosion-
intelligent and energy-efficient hot water ideal in a wide variety of resistant materials to meet a wide range
recirculation by learning and adapting to transfer and circulating applications with of application demands and are available
the household’s consumption patterns. non-corrosive fluids such as oils, fuels in sizes from ¼ to 3 inches. Incorporated
The powerful AUTOADAPT function and coolants. It can produce more than in the design is the innovative, patent-
allows eight of 10 installations to rely on 60 pounds per square inch at voltages pending Looped-C air-motor spool-valve
this feature to automatically select the of 10 to 26 VDC. As a positive displace- which greatly improves on/off switching
optimal setting. For the installer, that ment pump, it will self-prime and is more reliability, operational efficiency and air
means plug and play and walk away. efficient than a gear pump. valve component life.

Grundfos VARNA Products Iwaki America

913-227-3400 530-676-7770 508-429-1440
ordersupport-gpu@grundfos.com sales1@varnaproducts.com info@iwakiamerica.com
grundfos.us varnaproducts.com iwakiamerica.com
Circle 305 on card or visit psfreeinfo.com. Circle 315 on card or visit psfreeinfo.com. Circle 308 on card or visit psfreeinfo.com.

D e c e mb er 2015 | Pum ps & S y st e m s

 ANNUAL PRODUCT SHOWCASE 71
71

PUMPS: MAGNETIC DRIVE PUMPS: METERING PUMPS: ROTARY

Magnetic Drive
Submersible Pumps
YD-GWN series is
a plastic (carbon
fiber polypropylene)
and magnetic drive
submersible pump. Other specifications
are: nonmetallic, no lubrication oil
and corrosion-resistant. The pump is
capable of withstanding chemicals such
as hydrochloric acid and may be used
in temporary/intermittent service with
hypochlorite. Maximum temperature is
167 F. Motor output is 1.5 horsepower/
3 phase/460 (option 220V) volts. The
maximum total dynamic head is 47
feet, with a maximum flow of 80 gallons
per minute. The pump is also available
in 1/3 horsepower/1 phase/115 volts.
World Chemical USA Inc.
888-860-3364
wca@worldchemicalusa.com
worldchemicalusa.com
Circle 324 on card or visit psfreeinfo.com.
IX-D Direct-
Drive Digital
Controlled
Metering
Pump
The new
IX-D150 and
IX-D300 sizes
expand the IX Series direct-drive,
Eclipse External Gear Pump
digitally controlled metering pump to a Eclipse represents a dramatic advance
maximum capacity of 80 gallons per in pump technology; it is one of the
hour (300 liters per hour) and a most simple and reliable pumps on
pressure rating up to 150 pounds per the market today. Because of its front
square inch (10 bar). Enhanced control pull-out design, service only takes
features include fully scalable analog minutes, reducing process downtime and
input, adjustable maximum output, maintenance costs. It is commonly used
keypad batch start/stop, scalable analog
for applications in industries such as
output, proportional pulse output and chemical processing, petrochemical and
programmable output relays. water treatment. Add the RV Controller;
it is an ideal combination.
Iwaki America Pulsafeeder Engineered Products
508-429-1440 585-292-8000
info@iwakiamerica.com pulsa@idexcorp.com
iwakiamerica.com pulsa.com
Circle 309 on card or visit psfreeinfo.com. Circle 311 on card or visit psfreeinfo.com.

PUMPS: SLUDGE/SLURRY PUMPS: WASTEWATER SEALS

Series 800
Vertical Heavy-
Duty Sump Pump
The Series 800 vertical
heavy-duty sump Grundfos SL Submersible
pump is offered in a Wastewater Pump Series
variety of materials,
including cast iron, 316 The Grundfos line of SL submersible
stainless steel fitted, wastewater pumps are designed to
Heinrichs’ HN 8-WD
all 316 stainless steel, handle raw, unscreened sewage, Leak-tightness is critical for hydraulic
Alloy 20, Hastelloy effluent, large volumes of surface applications. That is why the HN 8-WD
and CD4MCu. With water and process water in municipal, plugs are frequently used by mobile
dozens of model sizes available, customer utility and industrial applications. hydraulics and drive engineering
requirements for pumping abrasive and In motor ranges from 1.5 to 15 worldwide. The plugs, with integrated
corrosive liquids can be satisfied with horsepower, these solids-handing pumps elastic sealing form-ring, are easy to
capacities ranging up to 3,000 gallons per are designed for permanent submerged assemble and tight. Available with FKM
minute, heads of 230 feet, temperatures installation in applications such as or NBR, from M 6 to G 2½ inches, in
of 350 degrees F and depths of 26 feet. network-pumping stations, wastewater yellow zinc and Cr-6-free plating.
treatment plants and other municipal and
commercial applications.
Vertiflo Pump Company Grundfos Heinrichs USA LLC
513-530-0888 913-227-3400 859-371-4999
sales@vertiflopump.com ordersupport-gpu@grundfos.com mail@heinrichs-usa.com
vertiflopump.com grundfos.us heinrichs-usa.com
Circle 316 on card or visit psfreeinfo.com. Circle 306 on card or visit psfreeinfo.com. Circle 307 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

72 ANNUAL PRODUCT SHOWCASE

SEALS VALVES VIBRATION ANALYSIS/

Wear Parts & Seals
• Products supplied worldwide to more
than 40 countries
• ISO 9001:2008 certiied quality
system since 2005
• RB SiC, SSIC, TC, carbon graphite,
zirconia, alumina
• Seal faces/pump bushings/thrust
washers
• Valve balls/seats/stem bushings
• Mechanical seals/rotary unions
• Each product is precisely inspected and
documented prior to shipment.
Junty International LLC
312-752-7095
info@juntyusa.com
juntyusa.com
Circle 310 on card or visit psfreeinfo.com.
DATA COLLECTION
Parker Angle Body Valves
Parker Angle
Body valves are
pneumatically
actuated with
aluminum or
304 stainless
actuator housings Vibroport 80/Vibrotest 80:
for exceptional The All-Rounders
durability. he dual he Vibroport 80 and Vibrotest 80 are
stem bearings ofer the newest generation of vibration
“true” guidance while the spring loading analysis and data-collection instruments.
on packing glands provides tight sealing.
Designed with powerful balancing
hey have stainless bodies, a dampened capability, these portable, all-purpose
closing, anti-water hammer design, instruments are easy to use and lexible
pressures up to 232 pounds per square for use in a wide range of industries.
inch and sizes from 8 inch to 2 ½ inch he Vibroport 80’s large screen works
NPT. hey handle corrosive solutions at perfectly with in-house measurements.
temperatures up to 356 F and conform to he Vibrotest 80 is a compact version,
94/9/CE speciications. ideal for in-house and ield balancing.
Parker Fluid Control Division Schenck Trebel Corporation
860-827-2300 631-242-4010
parkerfcd_sales@parker.com therese.dambrosia@schenck-usa.com
parker.com/fcd schenck-usa.com
Circle 322 on card or visit psfreeinfo.com. Circle 319 on card or visit psfreeinfo.com.

D e c e mb er 2015 | Pum ps & S y st e m s

Circle 113 on card or visit psfreeinfo.com.
74 PRACTICE & OPERATIONS

Get the Most from Lubricants

Through Quality Oil Analysis
An effective program can increase the reliability and availability of machinery
while minimizing maintenance costs.

Last of Two Parts

To view Part 1
By Michael Barrett of this series, visit
TestOil pumpsandsystems.com/
oilanalysis.

A
n oil’s viscosity is drain intervals, high operating of antioxidants. Oil oxidation
considered its most temperatures or the presence of causes acidic byproducts to form.
important property. The water or another oxidation catalyst. High acid levels can indicate
most common technique for Increased viscosity can also be the excessive oil oxidation or depletion
measuring viscosity is following result of excessive contamination of the oil additives, and they can
ASTM D445 using a viscometer. with solids, as well as topping off lead to corrosion of the internal
A small sample of the oil is drawn with a higher grade lube. components. By monitoring the
into a calibrated capillary tube in a A decrease in the oil’s viscosity acid level, the oil can be changed
constant temperature bath. Once is most commonly due to before any damage occurs.
the sample comes to temperature, contamination with fuel or a An oil analyst is looking for
it flows a predetermined distance solvent. An oil’s viscosity also can a sudden increase. When oil is
down the tube. The viscosity is be affected if the wrong oil is used fl agged for high acid levels, it
the product of the flow time and for top off or replenishment. indicates accelerated oil oxidation,
tube calibration factor. The results and the oil should be changed
are reported as the oil’s kinematic Acid Number as soon as possible. If any of the
viscosity in centistokes (cSt). Acid number (AN) is an indicator of remaining highly acidic oil is
Industrial oils are identified by oil health. It is useful in monitoring left, it will quickly deplete the
their International Organization acid buildup in oils due to depletion antioxidants in the new oil.
for Standardization viscosity grade
(ISO VG). The ISO VG refers to the
oil’s kinematic viscosity at 40 C
(104 F). An oil’s weight commonly
refers to its kinematic viscosity
at 100 C (212 F). The weight of
multi-grade oils is represented by
the second number in the rating.
A 10W30 would be 30-weight oil.
The 10 before the W, which stands
for winter, refers to how the oil
performs in cold weather.
When an oil’s viscosity increases,
it is usually due to oxidation, Image 1. Base number testing measures the reserve alkalinity in a lubricant. The
degradation or contamination. amount of reserve alkalinity in a lubricant is critical for certain oils.
(Courtesy of TestOil)
This is the result of extended oil

De c e mb er 2015 | Pum ps & S y st e m s

 75

Acid number is measured by present in oil. A small volume of the

titration using ASTM D974. This lubricant is dropped onto a hot
method involves diluting the oil plate and, if bubbles or crackles
sample and adding incremental occur, water is present.
amounts of an alkaline solution If a crackle test is positive,
until a neutral endpoint is reached. further testing is needed to
The AN of a new oil will vary quantify the amount of water by
depending on the base oil additive using Karl Fischer titration by
package. A rust and oxidation ASTM D6304. A measured amount
oil will usually have a very low of oil is introduced into a titration
AN, around 0.03. An anti-wear chamber. This solution is titrated
or extreme pressure oil will have with Karl Fischer reagent to a
a slightly higher value, typically specific endpoint. The amount of
around 0.5. Engine oils commonly reagent used and the sample volume
have a higher AN, around 1.5. are calculated and converted to
parts per million (ppm) or percent
Base Number by mass.
Base number testing is similar to Low levels of water (<0.5
AN testing except the properties are percent) are typically the result
reversed. The oil sample is titrated of condensation. Higher levels
with an acidic solution to measure can indicate water ingress. Water
the oil’s alkaline reserve. ASTM can enter a system through seals,
D4739 is the most commonly breathers, hatches and fi ll caps.
used method. Internal leaks from heat exchangers
Many oils, especially motor oils, and water jackets are other
are fortified with alkaline additives potential sources.
to neutralize acids that are formed When free water (non-emulsified)
as a result of combustion. In diesel is present in oil, it poses a serious
engine applications, acid is formed threat to the equipment. Water
in the combustion chamber when is a very poor lubricant and
moisture combines with sulfur promotes rust and corrosion to
under pressure. the components. Dissolved water
Measuring the base number will in oil (emulsified) will promote
help ensure that a sufficient amount oil oxidation and reduce the oil’s
of additives have been added to load-handling ability. Water in
the oil to help resist oxidation due any form will cause accelerated
to acid. wear, increased friction and high
The base number of oil is highest operating temperatures. If left
when the oil is new and decreases unchecked, water will lead to
Circle 131 on card or visit psfreeinfo.com.

with use. Condemning limits are premature machine failure. In most

based on the application. The base systems, water should not exceed
number should not drop below half 500 ppm.
of its original value. Base number
values for new engine oils vary Particle Count
greatly based on the application. Particle count testing is a way
to monitor the level of solid
Water Contamination contamination in oil. Two types of
Water contamination is detrimental automatic particle counters are used
to any lubricant. A simple crackle to test oil cleanliness: light blockage
test is used to determine if water is and pore blockage.

pu mpsa ndsyst ems.c om | D ec emb er 2015

76 PRACTICE & OPERATIONS
The light blockage technique
involves passing a sample through
a small orifice that has a laser light
source on one side and an optical
sensor on the other side. Particles
interrupting the light beam are
counted, and size is determined by the
degree of light blockage. Light blockage
particle counting is not effective when
oil is contaminated with water or when
air is entrained in the oil. Water or air
bubbles can be counted as particles,
causing erroneous results.
The pore blockage or flow decay
technique passes the sample through
a mesh fi lter. As a fi lter clogs,
the sample’s flow is slowed. The
amount of flow decay is calculated,
and the particle count can then be
extrapolated. Because water droplets
and entrained air will not restrict the
fluid flow, there is no interference from
these contaminants.
Results are reported as particles per
milliliter in six size ranges: >4, >6, >14,
>25, >50 and >100. ISO Cleanliness
Codes are then assigned for particles
in 4, 6 and 14 micrometer (µm)
ranges (ISO 4406:1999). The result
is reported by three numbers with a
slash between them; the first number
refers to particles in the >4 µm range,
the second to particles in the >6 µm
range and the third in the >14 µm
range. The lower the numbers in the
ISO Cleanliness Code, ISO 4406, the
cleaner the fluid.
Particulate contamination is a
measurement of the effectiveness of
fi ltration and can indicate excessive
external contamination. Advanced
machine wear also causes increased
particle counts. Generally, the lower
size ranges indicate contamination
and silt, while the larger size ranges
point to wear problems.
Ferrous Wear Concentration
In some cases, a particle count is not
effective because the sample
is inherently dirty and fi ltering
the oil may not be plausible. A
De c e mb er 2015 | Pum ps & S y st e m s
particle count indicates that the
sample is extremely dirty, but it
does not give any indication of ferrous
wear. In gearboxes, ferrous wear
may be more important than overall
particle count. In such an application,
ferrous wear concentration is a good
substitution for a particle count test.
A wear particle analyzer quantifies
the amount of ferrous material present
in a sample of fluid. A measured
amount of the sample is inserted
into the analyzer, and the amount of
ferrous material is determined by a
change in magnetic flux. This change is
converted into ferrous concentration
in ppm. Using this method, there
are no interferences with non-
ferrous particles.
One advantage of a ferrous debris
monitor is that it will measure ferrous
wear debris in all types of oil, from
gearbox lubricants through hydraulics.
It will also measure ferrous wear
debris found in grease. A similar
test to the ferrous debris monitor
is DR (direct read) ferrography. DR
ferrography collects positively charged
particles on two light sources and
measures the amount of blocked
light to determine the level of ferrous
contaminants present in an oil.
Although these two tests provide
the same information, they are not
interchangeable.
Analytical Ferrography
Analytical ferrography is used to
separate solid contamination and
wear debris from a lubricant for
microscopic evaluation. Spectroscopy
cannot measure wear particles larger
than 7 µm. While particle counting,
ferrous wear concentration and DR
ferrography can detect larger particles,
they cannot qualify their composition
or origin. Analytical ferrography can
visually analyze wear particles at a
microscopic level to identify their
composition and origin.
A diluted oil sample flows over a
specially treated slide positioned at
an angle over a strong magnet. The
ferrous (iron) particles are attracted
to the magnet and deposited onto
the slide in decreasing size as the oil
flows down the substrate. Nonferrous
particles are deposited randomly while
ferrous particles line up in chains as a
result of the magnetic flux. The result
is a microscopic slide with the particles
separated by size and composition.
Microscopic examination of the
debris reveals information about
the condition of the equipment.
Observing the concentration, size,
shape, composition and condition
of the particles indicates where and
how they were generated. Particles
are categorized based on these
characteristics, and conclusions can
be drawn regarding the wear rate and
health of the machine.
The composition of the particles can
be identified by color. Heat treating
the slide causes specific color changes
to occur in various types of metals
and alloys. The particle’s composition
indicates its source, and the shape
reveals how it was generated. Abrasion,
adhesion, fatigue, sliding and rolling
contact wear modes each generate a
characteristic particle type in terms of
its shape and surface condition.
Solid contaminants can also be
visually identified provided they
are of a commonly found origin.
Sand and dirt, fibers, oxidation
products, rust, and metal oxides are
examples of contamination debris that
can be identified.
Michael Barrett has worked at TestOil
for 23 years in a variety of positions.
He is responsible for directing TestOil’s
marketing and sales efforts. Barrett
has a BA in economics
from Kenyon College
and a master’s degree in
business administration
from Case Western
Reserve University.

VFDs Eliminate Need for New Generator
An influent pump station in Washington incorporated control technology
that improved system efficiency and energy savings.
By Greg Miller
Yaskawa
D
uring the 2014 rainy
season, a crucial
influent pump station
in the growing northwest city
of Marysville, Washington, was
at capacity for storm flows. Its
three influent pumps needed to
be upgraded to increase capacity.
The existing 25-horsepower
(HP) (18.7-kilowatt [kW]) pumps
were barely able to keep up and
overheated in maximum flow
conditions. Facility managers
determined that 38-HP (28-kW)
pumps were the maximum size
that would fit in the existing
space and not exceed the motor
control center (MCC) starter size.
While these new pumps would
Image 1. VFDs eliminate inrush and improve the DPF
(Images courtesy of Yaskawa)
provide the required flow rates for
projected storm flows, the facility
team was unsure if the existing
standby 125-kW diesel generator
would be able to run three 38-kW
pumps. If direct-on-line starters
(or even soft starters) were used,
the generator would not be able to
handle the inrush current.
The Options
Variable frequency drives (VFDs),
however, eliminate inrush and
improve the displacement power
factor (DPF). The generator vendor
did not have sufficient records on
this older generator to determine
maximum motor starting ability
or suitability for VFD loads. But
pu mpsa ndsyst ems.c om | D ec emb er 2015
77
without VFDs, the existing full-
voltage starters could start only
two of the larger pump units on
generator power.
Soft starts, such as solid-state
reduced voltage starters, were
not a solution either. While soft
starts reduce inrush current, they
apply 60 Hertz (Hz) to the stator
immediately, making the motor
operate in the 100 percent slip
region. One-hundred percent slip
with full voltage will generate
rated locked rotor torque (LRT)
with a corresponding locked rotor
current—typically 120 percent
torque and 660 percent amps,
respectively. With reduced voltage
starters, torque varies by the
square of the voltage change. So
at 60 percent voltage, the LRT is
approximately 36 percent of rated
LRT or, in this case, roughly 43
percent (120 percent x 0.36 =
43.2 percent).
This low torque can be a problem
when starting a clogged pump.
At 60 percent voltage, the inrush
current is approximately 250
percent, which can raise an issue
with a limited supply—in this case,
the generator.
Power factor (PF) can also be a
problem with a solid-state starter
because PF is directly related to the
percentage of voltage output. Sixty
percent start voltage equals 0.60
PF, which also effectively increases
the generator load.
78 PRACTICE & OPERATIONS

The Solution
Because the facility did not have a
budget for a replacement generator,
the team decided to reduce the
load on the old generator by
incorporating VFDs.
In the last fiscal year, each of
the three pumps was increased
from 25 HP (18.7 kW) to 38 HP (28
kW), and the existing full-voltage
starters were replaced with VFDs.
Installing VFDs in place of the
existing full-volt starters benefited
the generator in two specific ways:
1. Inrush current on pump start
was reduced from 600 percent
to less than 20 percent without
sacrificing starting torque.
Because a VFD starts the motor
with design slip (nameplate
slip), 150 percent rated motor
torque is available at start.
2. Maximum speed and associated
kW load were easy to adjust Image 2. Pump gallery with three new pumps
downward.
minute (gpm) to 2,500 gpm at Testing Performance
Installing VFDs in place of full speed, 2,300 gpm at 95 Two tests were run to assess the
full-volt starters also improves percent speed and 2,100 gpm at impact of these changes. In the
process efficiency. 90 percent speed. Because the first test, all three pumps were
Using a longer acceleration generator and regulator were older, engaged at 100 percent speed
ramp minimizes surges in the 3 percent line reactors were added while running on generator power,
influent fi ltration lagoon. The new to the VFDs’ built-in 3 percent and the total kW load was 86
pumps each increased the flow direct-current (DC) link chokes kW (69 percent) of the 125 kW
from the original 1,700 gallons per as a precaution. rated capacity. The total flow was
measured at 5,100 gpm with the
present total dynamic head.
KEY PLAYERS IN THIS UPGRADE While the pumps individually
can produce up to 2,500 gpm,
City of Marysville, Washington – Dennis Roodzant,
the piping system and influent
wastewater maintenance lead
tank level restrict the total flow.
City of Marysville, Washington – Roy Alderman, The PF was 0.93 DPF, and the
SCADA/telemetry administrator total harmonic distortion (THD)
Preferred Electric – Lorne Wallitner, installing contractor measured 26 percent.
Apsco Inc. – Joseph Kerncamp, pump supplier (WEMCO HYDROSTAL) While this test proved the
success of the VFD installation,
Dykman Electrical – John Riggs, VFD distributor
the generator vendor expressed
Yaskawa America – Greg Miller, regional drive specialist concern about long-term reliability
Cummins NW – Paul McGinnis, distributor field service engineer because the generator used shunt
excitation and had a non-isolated
regulator. A $3,000 retrofit (in the

De c e mb er 2015 | Pum ps & S y st e m s


subsequent budget cycle) included a permanent-magnet
pilot generator for excitation and an isolated regulator.
A post-generator retrofit test showed the generator
output THD was reduced from 26 percent to 11 percent
by using isolated excitation. The generator load at full
speed—all pumps—was also reduced from 86 to 82 kW.
79
U N M AT C H A B L E E X P E R I E N C E
I N F L OW C O N T RO L
TRANSACTIONS
Jordan, Knauff & Company is a knowledgeable and
experienced provider of a comprehensive line of
investment banking services to the pump, valve and
The generator vendor now claims this standby generator

will last for another 20 years.
Prior to the generator excitation retrofit, the VFD
speeds were limited to 90 percent. Even at 90 percent
speed, the gpm was still 23 percent more than the
old full-speed pumps, and the generator load was 75
percent of the new full-speed load (0.75 X 86 kW = 65
kW or 52 percent load). These conditions allowed for the
additional harmonic heating in the generator until the
retrofit could be accomplished.
The full-speed tests showed that operating all
three pumps at full speed provides more flow than
presently required. The VFDs have been dialed back to
88 percent max speed for normal operation, which will
provide energy savings and reduced pump wear. The
power utility is interested in doing measurements and
evaluation for a potential energy rebate.
Conclusion
The existing standby generator was an older design.
Most present designs have permanent-magnet generator
(PMG) exciters and isolated regulators. Adding VFDs did
raise a harmonic question with the generator vendor.
Measuring harmonics and total load during load testing
revealed that, with simple line impedance added to the
inherent DC link impedance, the THD did not present
the anticipated problem of regulation.
The VFD also provided a tool to dial the total load
down below the capacity of the generator to handle the
pump load with VFD harmonics. For less than the cost
of a larger generator sized to use direct-on-line start,
VFDs were installed to bring the existing generator up
to the task. The VFDs also had features that extend the
life of the pumps and provide energy savings.
Greg Miller is Yaskawa’s Northwest VFD specialist and
regional representative. He has served 10 years
as a motor control designer for Electric
Cranes, 12 years as a UL 508A panel shop
manager and VFD application specialist, and
11 years in water and wastewater
VFD sales.
½PXVEXMSRMRHYWXVMIW±*PS['SRXVSP²
Our lines of business include: selling companies,
raising debt and equity capital, and assistance
SREGUYMWMXMSRW
To learn more about Jordan, Knauff & Company,
contact any member of our Flow Control
XIEQ %GGIWW SYV *PS[ 'SRXVSP VIWIEVGL EX
[[[NSVHEROREYJJGSQ¾S[GSRXVSP
+'SSO.SVHER.V (EZMH%/EOEVIOE
Managing Principal Senior Associate
GN$NSVHEROREYJJGSQ HOEOEVIOE$NSVHEROREYJJGSQ
 
MEMBER FINRA, SIPC
Circle 142 on card or visit psfreeinfo.com.
NEW: Hydraulic Institute’s Wastewater
Treatment Plant Pumps Guidebook
This new guide provides the
guidance necessary to select
pump types, pump materials,
and auxiliary components so the
wastewater pumping system
performs effectively, efficiently,
and reliably in various plant
operations. Find out what’s
inside by visiting the link below.
Attention Pumps & Systems Readers:
Take 15% off your purchase of this guide
by applying coupon code WWPS15GB
during checkout in the HI eStore at
eStore.Pumps.org/Wastewater
Circle 141 on card or visit psfreeinfo.com.
pu mpsa ndsyst ems.c om | D ec emb er 2015
80 PRACTICE & OPERATIONS
Global Wastewater Challenges Place
Pressure on Aging Infrastructure
Shifting trends in water use and changing sewage composition cause
complex problems for the world’s sewer systems.
By Horst Sturm
KSB
Second of Six Parts
B
ecause of new challenges
in sewage transport and
handling as described
in Part 1 of this series (Pumps
& Systems, November 2015),
innovative solutions are needed
to address the problem of modern
sewage requirements. While pumps
that cut or squeeze are often
specified for difficult wastewater
applications, users must consider
the whole process and compare the
different methods and options.
Experience in drainage
pressure systems over many
years can indicate that cutter or
grinder pumps in large collecting
systems may have side effects.
Some treatment plants claim
that the fouling process is more
likely to begin in the pipework
if chopping or cutting processes
are incorporated. If raw sewage
is ground or chopped in the early
stages, the loads will consist of
small parts and the total surface
area will be much larger than
before. The organic parts will have
this larger contact surface. This
phenomenon causes the fouling
process to begin in the pipework.
Normally, treatment plants
must have full control of the
processes to recycle sewage.
De c e mb er 2015 | Pum ps & S y st e m s
Fouling before treatment may visible in the biological tanks (see
greatly increase odor in the pipes Image 1). These materials cannot be
and pumping stations. recycled at this stage by biological
Biological treatment is a vital treatment. The screen—one of the
part of the process that produces first steps in the treatment plant—
the required water quality of the should remove these non-biological
effluent. However, when substances materials. All the remaining
that are normally fi ltered out by non-biological ingredients are
the screen become smaller, they obstructions in the treatment
have a much higher chance of process. If pumps continue to chop
passing through. Also, the specific the braided wipes and other loads,
weight of the materials is not high treatment plants may increase the
enough for them to settle down disposal and treatment challenges.
later in the precipitation tank. While breaking non-biological
What happens if non-biological materials into smaller parts can
waste makes it to the biological pose challenges for the biological
treatment process? treatment process, these rags
If all equipment is well-designed and fibers in sewage are difficult
and the processes are running for any facility to handle, especially
normally, the activated
sludge is similar to
water but with a brown
mass of bacteria. The
dry substance content,
also called the TS value,
may be approximately 2
to 3, while the bacteria
may be visible as fine
brown substances.
In some systems,
however, pieces
of fibers, hygiene Figure 1. This diagram shows pumps with small free passage that need
to squeeze or chop. The white arrows show the area where additional
products and other energy is needed, and the material affects the wear. (Images and graphic
synthetics may be courtesy of KSB)

Image 1. A sludge tank for biological treatment
contains disposals that should not be found in this
step of the sewage-treatment process.
in the modern world when people
are using more wipes and other
synthetics that enter wastewater.
One possible solution for these
challenges is a type of pump that
could handle any wastewater
load without an extra chopping
process. Some manufacturers refer
to the high efficiencies of pumps
that chop but do not have the free
passage required in the 10 States
Standards from the Great Lakes-
Upper Mississippi River Board.
But the high efficiencies are not
performed in the real wastewater
world. Pumps that are tested in
clean water and do not need a large
free passage (minimum of 3 inches)
show good efficiencies in factory
tests. In real-world operation,
however, these pumps are faced
with large quantities of fibers,
rags and synthetic materials that
negatively affect those efficiencies.
Any cutting, chopping or
shearing process requires
additional energy. Especially in
pump models with retractable
impellers, the reduction in
efficiency is significant (measured
up to 25 percent). Extending the
wear of the clearance to pass the
loads will impair the impeller
blades’ efficiency. Pumps in
Image 2. The biological tank containing sludge is
part of the sewage treatment process.
fiber- and wipe-laded fluids that
have to chop and squeeze cannot
perform at the same efficiencies
certified from tests in clean water.
Engineers who select chopper
pumps often put additional energy
reserves into the motors. Power
use can increase by 25 percent
as compared with normal power,
usually taken for the duty point.
When the pump is in operation,
the shear process begins to wear
much more than for any other
hydraulic because of friction—this
is where the additional energy
travels. It starts at the edge of the
blades, but it does not stop there.
Often, the complete hydraulic
is attacked. After a certain time
operating in wastewater, the pump
will face a decline in efficiency
as compared with water-tested
values. To minimize this effect, the
impeller could be adjusted, but this
effort often will be skipped.
Handling today’s wastewater—
laden with high loads of wipes and
rags—with free passage to get the
fibers through instead of shearing
the load may help prevent:
• high wear and tear on blades
• less efficiency from fast wear
• higher lifetime costs because of
the need for spare parts
pu mpsa ndsyst ems.c om | D ec emb er 2015
81
• higher expenses because of
special hard materials against
the additional wear
• more effort required for
adjusting the impeller
• fouling in the pipework
• odor in the wastewater
collection system
• small parts of synthetics
passing the screen and reaching
biological treatment, where the
tank cannot get rid of it
While some chopper pumps may
pose disadvantages, they can help
prevent equipment breakdowns
in the station. Depending on the
application and specific situation,
different technologies and methods
may be employed. Either way, users
must understand all of the benefits
and disadvantages of each option.
Horst Sturm is vice president of
Business Development at KSB Inc.
Horst has a degree in engineering
with a specialization in energy
technology. He has more than 30
years of experience in pumps and
systems technology in water and
wastewater. For more information
on wastewater challenges, visit
campaign.ksb.com/global-
wastewater-challenges-download.
82 PRACTICE & OPERATIONS

In Hazardous Areas, Explosion-Proof

Submersible Pumps Alleviate Safety Worries
The right equipment can help with concerns in oil and gas exploration and mining, as well
as at chemical plants and refineries.

By Mike Bjorkman
BJM Corp.

I
t only takes a tiny spark or
a sufficiently hot surface to
ignite a deadly explosion.
For many industries that depend
on electrically driven pumps,
explosion prevention is a primary
safety concern.
In the case of chemical plants,
refineries and hydrocarbon
processors, a high potential exists
for explosive vapors to be emitted
by process and other liquids. In
the case of mining and oil and
gas exploration, an explosion’s
potential fuel source is escaping
underground gas from subsurface
pockets, which are frequently
under extreme pressure.
In response to these potentially
destructive situations, electrical
equipment, including submersible
pump motors, can be designed and
manufactured to prevent them
from becoming an ignition source Image 1. Submersible pumps can be designed to prevent
in these hazardous environments. them from becoming an ignition source in hazardous
environments. (Courtesy of BJM Corp.)

Pumps for Hazardous Zones

Safety in these environments
begins with the science of defining
the exact nature of the hazardous
area. This includes understanding
and classifying the explosive
material and its potential for
being present within defined
areas (zones) of the considered
site. In the U.S. and some other
countries, hazardous locations
are defined in an official and
comprehensive publication called
the National Electric Code (NEC),
which is produced and maintained
by the National Fire Protection
Association (NFPA). The NFPA’s
mission includes producing fire
safety standards that are used as
official codes by governments and
other authorities with interest
in safety for construction,
commercial, residential and
industrial sites.
The NEC typically classifies
areas that can contain the
previously mentioned gases as
Class 1, Division 1 in Group C or
Group D. For submersible pump
manufacturers developing products
that are suitable for these zones,

De c e mb er 2015 | Pum ps & S y st e m s

 83

Manufacturers can employ third-party approval agencies, such as

Factory Mutual Insurance, to certify that their products adhere to
standards that make them suitable for duty in hazardous areas.

three key principles guide an
engineered product design:
• Spark-free motor design. The
pump motor must be designed
so its operation will not produce which can provide end users with
electrical sparks, a source for
ignition.
• Engineered flame paths. In
the event that explosive gas
enters and ignites inside of the motor—typically side-discharge
motor housing, the motor’s
design must cause the fl ame to
extinguish before it would exit
the vessel.
• Pressure containment. The
motor vessel’s structure must
be capable of containing the
pressure generated by an
internal explosion without
fracturing.
Manufacturers can employ
third-party approval agencies,
such as Factory Mutual Insurance
(FM), to certify that their products agitator in the liquid for suction
adhere to standards that make
them suitable for duty in hazardous pump that sits above the liquid
areas. The agencies scrutinize the
design details and the quality-
control methods used to produce
any electrical device that may be
approved for use in hazardous
locations.
Submersible pumps
manufactured for hazardous
locations include special
nameplates and other visible
certification marks that signify
they are designed and built for
these zones.
Addressing Safety Concerns
One development that addresses
safety concerns is an explosion-
proof submersible slurry pump,
another option for hazardous
zones. Operators in some cases
previously have used a standard
pump with an explosion-proof
sewage pumps or pumps
designed for water—or units
with pump ends better suited for
the application but with non-
explosion-proof motors.
An explosion-proof submersible
slurry pump can provide various
benefits for handling applications
in hazardous areas. Submersible
pumps can go into the liquid or
slurry. When dealing with a heavy
slurry that contains solids and
liquids, it is much more efficient
and reliable to have the pump and
instead of having a self-priming
and relies on a suction hose and
atmospheric pressure to pull the
slurry into the pump.
A slurry pump using an
agitator could improve the
handling of abrasive slurries.
Not all submersible pumps are
able to handle slurries. For high
concentrations of solids that
tend to settle to the bottom of a
pit or holding area, an agitator
adds velocity around the pump
and keeps the solids suspended
for possibly easier pumping and
effective removal.
The material used to construct
the pipe is also important to
consider. Abrasive materials
typically erode cast iron and other
softer metals. Most dewatering
pumps are made from cast iron
and do not last long in abrasive
applications. The pump must be
able to handle abrasive slurries in
demanding applications.
When considering designs, some
vertical/cantilever pumps have
fi xed installation and sometimes
exhibit shaft breakage and
lubrication problems in drilling
and mining applications. It is
possible that, in moving pumps
with a side discharge connection,
the connection can break off or
be damaged as it is pushed and
pulled into place. Top discharge
pumps are cooled by the pumped
liquid and can pump a pit down to
within inches of the bottom. A side
discharge pump without a cooling
jacket must stay submerged to
avoid overheating, leaving as much
as 3 feet of unpumped slurry.
Mike Bjorkman is vice president
of BJM Corp. and has more than 30
years of experience in the pump
industry. He serves as marketing
and IT director for BJM Pumps
LLC and All Test Pro LLC, both
subsidiaries of BJM Corp. For more
information, call 860-399-5937 or
visit bjmpumps.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

84 PUMP USERS MARKETPLACE

Visit Us At
POWER-GEN
Booth 8016

UÊ-iv‡>ˆ}˜ˆ˜}ÊEÊÃivÊÊ
}ÀœÕ˜`ˆ˜}
Uʈ}…Ê«ÀiÃÃÕÀiÊÊ
À>Ìi`
UÊ-Ì>ˆ˜iÃÃʜÀÊÊ
“ˆ`ÊÃÌii
UÊœÜÊVœÃÌ
Uʈ}…Êi˜`ʫՏ
Tuf-Lok InternationalÊ
*…œ˜i\Ê Èän°ÓÇ䰙{ÇnÊ UÊ www.tuflok.com

Circle 210 on card or visit psfreeinfo.com. Circle 216 on card or visit psfreeinfo.com. Circle 217 on card or visit psfreeinfo.com.

Adver t ise rs
FREE PRODUCT INFORMATION
Visit psfreeinfo.com to request more
information from these advertisers.

Advertiser Name Page RS# Advertiser Name Page RS# Advertiser Name Page RS#

AE Pumps 85 200 NOC Ningbo Ocean Fine Vaughan 5 111

Amtech Drives, Inc. 47 101 Ceramic Technology Co., Ltd. 86 208 Vesco 87 218
Automationdirect.com 3 102 Pinnacle-Flo, Inc. 85 209 Westerberg and Associates 61 143
BJM Pumps, LLC 67 130 Pulsafeeder 27 125 Yaskawa America Inc. 19 112
Blue-White Industries 11 115 Pump Solutions Group /
A Dover Company 53 136
Carver Pump Company 23 117 Annual Product Showcase
PumpWorks 610 55 126
Cat Pumps 18 118 AllMax Software 69 300
PumpWorks Industrial 33 114
CD-adapco 61 139 BaseTek, LLC 68 301
Rotech 84 210
Conhagen, Inc. 31 119 Disclo Corporation 69 302
RuhRPumpen 39 106
Continental Pump Company 86 201 EnviroPump and Seal Inc. 70 303
Ruthman Companies 57 137
Conval, Inc. 75 131 Greyline Instruments Inc. 69 321
Scenic Precise Element, Inc. 87 211
Dan Bolen & Associates, LLC 85 202 Grundfos 69 304
Schaeler Group USA Inc. 9 107
Equipump 86 203 Grundfos 70 305
Schenck Trebel Corporation 37 129
FLSmidth 64 132 Grundfos 71 306
SERO Pump Systems 87 212
Franklin Electric 49 104 Heinrichs USA LLC 71 307
Shin Nippon Machinery 25 108
Frost & Sullivan 60 140 Iwaki America 70 308
Sims Pump Valve Company, Inc. 86 219
Fullo Specialties Co. 42 120 Iwaki America 71 309
Sims Pump Valve Company, Inc. 87 220
Graphite Metallizing Corporation 51 121 Junty International LLC 72 310
Sims Pump Valve Company, Inc. 73 113
Grundfos 15 105 Parker Fluid Control Division 72 322
Skinner Power Systems, LLC 30 127
Grundfos 85 204 PEMO Pumps 70 323
St. Marys Foundry 86 213
Hoosier Pattern, Inc. 14 122 Pulsafeeder 71 311
Stancor Pumps Inc. 13 116
Hydraulic Institute 79 141 PumpWorks Industrial 70 320
Sulzer Management Ltd Rotating
Hydro Inc. IFC 100 Schenck Trebel Corporation 72 319
Equipment Services BC 109
Jordan, Knauf & Company 79 142 SJE-Rhombus 69 312
Summit Pump, Inc. 67 138
KTR Corporation 63 133 SPM Instrument Inc. 68 317
TF Seals 17 128
Load Controls Inc. 32 123 Tuf-Lok International 68 313
hermOmegaTech 7 110
LobePro 86 205 Universal Flow Monitors, Inc. 69 314
Titan Flow Control, Inc. 60 144
LUDECA, Inc. 43 124 VARNA Products 70 315
Titan Manufacturing Inc. 87 214
Magnatex Pumps, Inc. 63 134 Vertilo Pump Company 71 316
Topog-E Gasket 87 215
Master Bond Inc. 85 206 World Chemical USA Inc. 71 324
Trachte, USA 84 216
Megator Corporation 66 135 he Index of Advertisers is furnished as a courtesy, and no
Tuf-Lok International 84 217
Meltric Corporation 85 207 responsibility is assumed for incorrect information.

D e c e mb er 2015 | Pum ps & S y st e m s

 85

EXECUTIVE SEARCH/RECRUITING
find the
RIGHT
“Serving the Pump & THINK PUMP SOLUTIONS adhesive
Rotating Equipment, Valve, THINK GRUNDFOS Master Bond makes it easy
and Industrial Equipment GRUNDFOS PROVIDES COMPREHENSIVE • Epoxies, silicones and UV
Industry since 1969” MARKET COVERAGE THROUGH OUR cures to meet your needs
WELL-KNOWN MARQUEE
Domestic & International PRODUCT BRANDS. • Personal one on
one technical
Specializing in placing: assistance
• General Management • Engineering
• Available in large
• Sales & Marketing • Manufacturing ®

YEOMANS
and small quantities
DAN BOLEN • JASON SWANSON ¾
̶

CHRIS OSBORN

9741 North 90th Place, Suite 200

Scottsdale, Arizona 85258-5065
(480) 767-9000 • Fax (480) 767-0100
Email: dan@danbolenassoc.com
www.danbolenassoc.com
Circle 202 on card or visit psfreeinfo.com.
WWW.GRUNDFOS.US Hackensack, NJ 07601 USA
+1.201.343.8983 • main@masterbond.com
www.masterbond.com
Circle 204 on card or visit psfreeinfo.com. Circle 206 on card or visit psfreeinfo.com.

QHH
Dwvvqp

Gcu{
Fgcf
Nqemqwv
Htqpv

Circle 200 on card or visit psfreeinfo.com.
Circle 209 on card or visit psfreeinfo.com.
6" Rtqvgevu"htqo"gngevtkecn"jc|ctfu
6" UkornkÞgu"PHRC"92G"eqornkcpeg
SwcnkÞgf"vgejpkekcpu"ecp"swkemn{"
fkueqppgev"cpf"eqppgev"rqygt" QHH
Dwvvqp
wr"vq"422C."97jr."822X0
HTGG"Ucorngu"Cxckncdng

800.433.7642 • meltric.com

Circle 207 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | D ec emb er 2015

86 PUMP USERS MARKETPLACE

Circle 201 on card or visit psfreeinfo.com.

Circle 219 on card or visit psfreeinfo.com.

Circle 203 on card or visit psfreeinfo.com.

GO WITH THE PROS!! LOBEPRO ROTARY PUMPS

Important Properties of
LobePro Rotary Lobe Pumps
• Low maintenance - • Space-saving,
“in place” wear part compact design
replacement • Self priming to 25’ wet
Pump Capacities up to 2,656 GPM (604 m³/hr) with
discharge pressure ratings to 175 psi (12 bar)
To learn more or get a custom quote, email PumpSales@lobepro.com
912-466-0304 www.LOBEPRO.com Made in USA
Circle 205 on card or visit psfreeinfo.com.

Circle 213 on card or visit psfreeinfo.com.

Circle 208 on card or visit psfreeinfo.com.

D e c e mb er 2015 | Pum ps & S y st e m s

 87

Circle 211 on card or visit psfreeinfo.com.

Circle 214 on card or visit psfreeinfo.com.

Circle 212 on card or visit psfreeinfo.com.

Solve
dry start
problems with
Circle 215 on card or visit psfreeinfo.com. Vesconite Hilube
bushings
 Increase MTBR
 No swell
 Low friction = reduced
electricity costs
 Quick supply.
No quantity too small
Tollfree 1-866-635-7596
vesconite@vesconite.com
www.vesconite.com
Circle 218 on card or visit psfreeinfo.com.
Circle 220 on card or visit psfreeinfo.com.
pu mpsa ndsyst ems.c om | D ec emb er 2015
88 PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch
By Jordan, Knauff & Company
T he Jordan, Knauf &
Company (JKC) Valve Stock
Index was down 22.1 percent
over the last 12 months, while the
broader S&P 500 Index was up
3.0 percent. he JKC Pump Stock
Index also decreased 16.8 percent
for the same time period.1
he Institute for Supply
Management’s Purchasing
Managers’ Index (PMI) fell slightly
to 50.1 percent for the month of
October compared with a reading
of 50.2 percent in September.
A PMI above 50 signals factory
sector expansion, while a number
below 50 signals contraction. he
New Orders Index increased to
52.9 percent from 50.1 percent,
while the Production Index
increased 1.1 percentage points
to 52.9 percent. he Employment
Index declined to 47.6 percent
from 50.5 percent in September,
the lowest level for this measure of
factory employment since 2009.
he Bureau of Labor Statistics
reported that nonfarm
employment increased by 271,000
in October, which was much
higher than economists expected.
Gains were made in construction,
professional and business services,
education and health services, and
leisure and hospitality. he year-
over-year gain in construction
was more than 3 percent, while
Figure 2. U.S. energy consumption and rig counts
Source: U.S. Energy Information Administration
and Baker Hughes Inc.
De c e mb er 2015 | Pum ps & S y st e m s
Figure 1. Stock indices from Nov. 1, 2014, to Oct. 31, 2015
the service sector increased
2.1 percent year over year,
relecting continued economic
growth. he manufacturing
sector lost a combined total
of 27,000 jobs in the past two
months but was unchanged
for October. Improvements in
the labor market are starting
to lead to increased wages,
which have risen 2.5 percent Source: Capital IQ and JKC research. Local currency converted to USD using
year over year. historical spot rates. he JKC Pump and Valve Stock Indices include a select list of
Because of lower petroleum publicly traded companies involved in the pump and valve industries weighted by
product prices and continuing market capitalization.
employment and economic growth, fuels consumptions, along with Reference
U.S. liquid fuel consumption the increase in reined products 1. he S&P Return
igures are provided
is projected to increase by 1.8 exports, has resulted in U.S.
by Capital IQ.
percent this year compared with reinery utilization rates averaging
an increase of 0.8 percent last 91.2 percent during the irst seven
year, according to the U.S. Energy months of the year, compared with
Information Administration (EIA). 89.4 percent last year. Jordan, Knauff
& Company is an
he consumption growth was led On Wall Street, the Dow Jones investment bank
by gasoline, which is expected to Industrial Average was up 8.6 based in Chicago,
increase 2.1 percent in 2015. As percent, the S&P 500 Index Illinois, that
new petrochemical plant capacity increased 8.1 percent and the provides merger and
increases the use of hydrocarbon NASDAQ Composite rose 9.2 acquisition advisory
services to the
gas liquids (HGL), consumption of percent for the month of October. pump, valve and
HGL is expected to increase this A rise in health care stocks and filtration industries.
year and next, compared with a 1.9 a rebound in energy shares due Please visit
percent decrease in 2014. to a rise in oil prices boosted jordanknauff.com for
more information.
Compared with the same period the markets. Investors were Jordan, Knauff &
last year, gross exports of U.S. encouraged by the possibility of Company is a member
petroleum products are up almost more economic stimulus programs of FINRA.
12 percent through July. More in China and the Eurozone. he
than half of this export growth Federal Reserve Bank also kept
is from HGL. he combination key interest rates unchanged at its
These materials were
of the growth in domestic liquid October meeting. prepared for informational
purposes from sources that
are believed to be reliable
Figure 3. U.S. PMI and manufacturing shipments but which could change
without notice. Jordan,
Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or com-
pleteness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
Source: Institute for Supply Management Manufacturing any investment offering or
Report on Business® and U.S. Census Bureau deployment of capital.
 LOW T H E L E A D
FO L E R
TM

SYSTEM PUMPSA J U LY
NDSYS 2 0 15
TEMS.C
OM

S
The Lead ®
ing Mag
azine fo
r Pump
Users W
orldwide

Efficient Fo
Beverage P od &
AODD Pu rocessing
mps | Do
sing System
s | Peris
taltic Pum
ps

Pump Co Exclusive Coverag

m e
to Texas pany Responds
Flooding
Crisis
Avoid
Pulp & Pa Bearing Failure
GY in
C HN O L O E S
per Appli
cations

RING TE T & SERVIC Tra

FR ACNTG UOPTIMAL EQ U IPMEN R BETTER BUSINESS

Pack Expode Show Preview
& IAAPA
Expo
CHOOSI A FO
5

L DAT
OM

T | 2 01

R WEL IE W
P ING . C

E YOU 15 PREV
OMIZ & TPS
CUST
AU GU S

SHOW
E A MP UM

ADE OVE RY
NDS TR S REC
OIL SA
JU LY /

SA N D
N: OIL
UP S T R

TIO
L SEC
SPECIA

COMPREHENSIVE COVERAGE
RELEVANT CONTENT
CASE STUDIES
WORLDWIDE NEWS
TECHNICAL ARTICLES

To subscribe to our print or digital editions and to sign up for our e-newsletters,
visit our websites and click on SUBSCRIBE.
PUMPSANDSYSTEMS.COM UPSTREAMPUMPING.COM
Circle 109 on card or visit psfreeinfo.com.