F E B R UA R Y 2 0 16

SYSTEMS
PUMPSANDSYSTEMS.COM

The Leading Magazine for Pump Users Worldwide

SMART
PUMPING
Enhancing security & increasing
uptime with intelligent controls

K A L A M A Z O O R I V E R R E M E D I AT I O N D I V E R T S 5 . 9 B I L L I O N G A L L O N S | 3 Q U E S T I O N S A B O U T U S I N G I oT
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2

W ith 2016 now in full swing, Pumps & Systems is looking toward the future. As
technologies and services continue to evolve with each passing year, our desire is
to keep you up-to-speed with the latest innovations while not neglecting the processes
EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
aarchibald@cahabamedia.com • 205-278-2843
and concepts that have long guided the pump industry.
SENIOR TECHNICAL EDITOR: Mike Pemberton
In this issue, we focus on smart pumping—modern, computer-based capabilities that mpemberton@cahabamedia.com
allow pump users to monitor and control their systems reliably, safely and efficiently. 205-314-8279
While some believe the pump industry has been behind the times in terms of technology MANAGING EDITOR: Amelia Messamore
adoption, many companies are expanding their product and service portfolios to include amessamore@cahabamedia.com
205-314-8264
smart pumping software and intelligent controls. As end users begin to implement these
MANAGING EDITOR: Martin Reed
new capabilities, they are seeing reduced life-cycle costs, lower energy consumption and mreed@cahabamedia.com • 205-278-2826
more reliable system operation. MANAGING EDITOR: Savanna Gray
As an example, a German fl ame retardant manufacturer recently incorporated sgray@cahabamedia.com • 205-278-2839
frequency converters to control its cooling water pumps and saw a reduction in energy CONTRIBUTING EDITORS: Lev Nelik,
consumption by 80 percent. Turn to page 34 for full details on how intelligent controls Ray Hardee, Jim Elsey
yielded these significant energy savings. CREATIVE SERVICES
On page 30, we continue our coverage of smart pumping with an overview of how DIGITAL PROJECT MANAGER &
alternative control technologies can handle large volumes of data. You also don’t want SENIOR ART DIRECTOR: Greg Ragsdale

to miss “3 Questions to Ask Before IoT Implementation” (page 38), which outlines best ART DIRECTOR: Melanie Magee

practices for Internet of Things adoption on an industrial scale. WEB DEVELOPER: Greg Caudle

While smart pumping may be the future, ensuring that your equipment can withstand DIGITAL COMMUNITY MANAGER: Amy Cash
harsh conditions is an age-old problem. On page 24, we help you meet the challenges of PRINT ADVERTISING TRAFFIC: Lisa Freeman
lfreeman@cahabamedia.com • 205-212-9402
harsh operating environments with coverage of rugged seal technologies (page 24) and
tips for safely incorporating new hydraulic fluids in your assembly (page 27). CIRCULATION
This month, the Pumps & Systems team will be traveling to Tucson, Arizona, to AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
participate in the Hydraulic Institute 2016 Annual Conference on Feb. 11-15. We look lmasaoay@cahabamedia.com • 205-278-2840
forward to seeing many of you there. In the meantime, if you have any questions,
ADVERTISING
concerns or suggestions, please don’t hesitate to let us know. We love hearing from
NATIONAL SALES MANAGER: Derrell Moody
readers and welcome your feedback. dmoody@pump-zone.com • 205-345-0784
ACCOUNT EXECUTIVES:
Mary-Kathryn Baker
mkbaker@pump-zone.com • 205-345-6036
Mark Goins
Managing Editor, Amelia Messamore mgoins@pump-zone.com • 205-345-6414
amessamore@cahabamedia.com Addison Perkins
aperkins@pump-zone.com • 205-561-2603
Garrick Stone
EDITORIAL ADVISORY BOARD gstone@pump-zone.com • 205-212-9406
THOMAS L. ANGLE, P.E., MSC, Vice WALT ERNDT, VP/GM, Crane Pumps & HENRY PECK, President, Geiger Pump &
President Engineering, Hidrostal AG Systems Equipment Company MARKETING ASSOCIATES:
BRYAN S. BARRINGTON, Machinery JOE EVANS, Ph.D., Customer & Employee MARIANNE SZCZECH, Director, Global Ashley Morris
Engineer, Lyondell Chemical Co. Education, PumpTech, Inc. Marketing and Product Management,
Pump Solutions Group
amorris@cahabamedia.com • 205-561-2600
KERRY BASKINS, VP/GM, Milton Roy LARRY LEWIS, President, Vanton Pump and
Americas Equipment Corp. SCOTT SORENSEN, Oil & Gas Automation Sonya Crocker
Consultant & Market Developer, Siemens
R. THOMAS BROWN III, President, WILLIAM LIVOTI, Business Development
Industry Sector scrocker@cahabamedia.com • 205-314-8276
Advanced Sealing International (ASI) Manager/Energy Efficiency Specialist,
WEG Electric Corporation ADAM STOLBERG, Executive Director,
CHRIS CALDWELL, Director of Advanced Submersible Wastewater Pump
Collection Technology, Business Area TODD LOUDIN, President/CEO North
American Operations, Flowrox Inc. Association
Wastewater Solutions, Sulzer Pumps,
ABS USA MICHAEL MICHAUD, Executive Director, JERRY TURNER, Founder/Senior Advisor,
Hydraulic Institute Pioneer Pump
JACK CREAMER, Market Segment Manager
– Pumping Equipment, Square D by JOHN MALINOWSKI, Sr. Product Manager, DOUG VOLDEN, Global Engineering Director,
Schneider Electric John Crane PUBLISHER: Walter B. Evans Jr.
AC Motors, Baldor Electric Company, A
BOB DOMKOWSKI, Business Development Member of the ABB Group KIRK WILSON, President, Services & VP OF SALES: Greg Meineke
Manager – Transport Pumping and Solutions, Flowserve Corporation
WILLIAM E. NEIS, P.E., President, CREATIVE DIRECTOR: Terri J. Gray
Amusement Markets/Engineering Northeast Industrial Sales JAMES WONG, Associate Product
Consultant, Xylem, Inc., Water Solutions Manager – Bearing Isolator, Garlock Sealing CONTROLLER: Brandon Whittemore
USA – Flygt LEV NELIK, Ph.D., P.E., APICS, President, Technologies
PumpingMachinery, LLC

P.O. Box 530067

Pumps & Systems Birmingham, AL 35253
is a member of the following organizations: 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, P.O. Box 530067, Birmingham, AL 35253. ©2016 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, ADVERTISING SALES
articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The
opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes 2126 McFarland Blvd. East, Suite A
no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS: Tuscaloosa, AL 35404
We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media Group, Inc.,
permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free 205-345-0784
to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 24, Issue 2.

Februa ry 2 0 1 6 | Pumps & S y st e m s

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4
This issue FEBRUARY Volume 24 • Number 2
COVER COLUMNS
SERIES SMART PUMPING
30 ALTERNATIVE TECHNOLOGIES CONTROL COMPLEX PUMPING PUMPING PRESCRIPTIONS
PROCESSES & SYSTEMS
By Jeff Payne, AutomationDirect.com 12 By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC
PLC-based PACs fill the gap between traditional distributed control
systems and basic programmable logic controllers. Using Pump Efficiency Monitoring to
Make Faster Decisions
34 INTELLIGENT PUMP CONTROL REDUCES
PUMP SYSTEM IMPROVEMENT
ENERGY CONSUMPTION BY 80 PERCENT
By Martin Hoffmann, Colfax Fluid Handling/
34 15 By Ray Hardee
Allweiler Engineered Software, Inc.
A flame retardant manufacturer incorporated Troubleshooting a Piping System
frequency converters to control its cooling water First of Two Parts
pumps.

38 3 QUESTIONS TO ASK BEFORE IOT

COMMON PUMPING MISTAKES
IMPLEMENTATION 18 By Jim Elsey
By Jon Hilberg, Accudyne Industries— Summit Pump, Inc.
Precision Flow Systems
Solid Shaft Designs & Cartridge Seals
A well-planned systems approach to predictive
analytics using cloud connectivity can optimize pumping systems. INDUSTRY INSIGHTS
22 By Mike Pemberton
Pumps & Systems
SPECIAL PUMPS & EQUIPMENT Intelligent Pumping Continues to Evolve
SECTION
FOR HARSH CONDITIONS
24 LIQUID-LUBRICATED DOUBLE SEALS INCREASE STABILITY FOR PTA
PRODUCTION 48
By Andreas Pehl, EagleBurgmann Germany Gmbh & Co. Kg
One facility’s high-speed centrifugal pumps saw improved performance and effi-
ciency after adding custom seals.
27 MATCH HYDRAULIC FLUIDS TO SEAL LIP MATERIAL
By Stephen A. Maloney, Colonial Seal Company
Companies interested in reducing safety hazards and environmental impact should
consider compatibility issues.

PRACTICE & OPERATIONS

DEPARTMENTS
48 PUMPING SYSTEM DIVERTS 5.9
40 EFFICIENCY MATTERS 46 HI PUMP FAQS BILLION GALLONS OF WATER
Peristaltic Pumps Offer Protection in Submersible Vertical Turbine Pump FOR KALAMAZOO RIVER
Mining Operations Intake Designs, Common AC Single- REMEDIATION
By Tom O’Donnell, Abaque, part of PSG Phase Motors By Duane Hargis, Cornell Pump Co.
By Hydraulic Institute
42 MAINTENANCE MINDERS & Rich Goethals, BakerCorp
Creative Coupling Design Saves 50 MOTORS & DRIVES
Downtime at Utility Plant Obtain Maximum Bearing Life &
By Jim Anderson, Coupling Corporation Performance 2 FROM THE EDITOR
of America By Mike Pulley, Bartlett Bearing 6 NEWS
Company
44 SEALING SENSE 53 PRODUCTS
What to Consider When Upgrading or
Changing Pre-Specified Gaskets 54 PUMP USERS MARKETPLACE
By Mike Shorts, FSA Member & President 56 PUMP MARKET ANALYSIS

Februa ry 2 0 1 6 | Pumps & S y st e m s

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s teon
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ru ary 2016
6 NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
RICH GREATTI
FLUID SEALING INTERNATIONAL
CORAOPOLIS, Penn. (Jan. 5, 2016) – Fluid
Sealing International has announced that Rich
Greatti has joined the company as director
of sales and marketing. Greatti brings more
than 30 years of experience in the fluid sealing
industry in sales, engineering and business Rich Greatti
development with a successful track record
that includes international sales, product development as well as
managing a global sales force. He has helped develop several new
sealing products and a successful distribution/direct/OEM network in
the fluid sealing industry. worldfsi.com
CHUCK KELLOGG, HUBBARD-HALL
WATERBURY, Conn. (Dec. 11, 2015) – Hubbard-Hall Chairman/CFO
Chuck Kellogg has received the prestigious Lifetime Achievement
Award at the annual meeting of the National Association of Chemical
Distributors (NACD). Kellogg was one of the founding members of
NACD in 1971 when he and other CEOs recognized the need for the
chemical distribution industry to adopt best practices and become
overt stewards of the chemical distribution process. Kellogg has
remained active and vocal in the association since its founding.
hubbardhall.com
BOB LAUSON, PSG
OAKBROOK TERRACE, Ill. (Dec. 9, 2015) – PSG, a Dover company,
has appointed Bob Lauson to general manager for PSG Grand Rapids
(Blackmer). In this role, Lauson will be responsible for leading the
Grand Rapids organization and will report directly to PSG President
Karl Buscher. He will be based out of the PSG Grand Rapids facility
in Grand Rapids, Michigan. Lauson joined PSG from Terra Sonic
International, where he held the position of president.
psgdover.com/en/blackmer/home
ALEXANDER SEVERT
& JIARAN SUN
WATER PLANET
LOS ANGELES (Dec. 7, 2015)
Water Planet has further
expanded its engineering team
with the addition of Alexander
Alexander Jiaran
Severt as mechanical and
Severt Sun
design engineer and Jiaran Sun
as research and development engineer. At Water Planet, Severt will
provide modeling, fabrication and design support to the membrane
and system design team. Sun will assist with the development
and commercialization of Water Planet’s PolyCera polymer and
membranes. waterplanet.com
Februa ry 2 0 1 6 | Pumps & S y st e m s
HEATHER GREEN, APPLETON GROUP
ROSEMONT, Ill. (Dec. 4, 2015) – Heather Green has been promoted
to director of product marketing for Appleton Group, a division of
Emerson. In this role, Green will work with product management, the
engineering team and global sales for the division’s brands Appleton,
O-Z/Gedney and others to achieve success across multiple industries.
She will report directly to Tim Graff, vice president of engineering for
Appleton Group, within the engineering organization. As leader of
the product management team, Green will guide Voice of Customer
research, identify customer value propositions, define platform
strategy, establish product requirements and improve supporting
overall business processes. emersonindustrial.com
MYLA PETREE
BALDOR ELECTRIC COMPANY
FORT SMITH, Ark. (Nov. 24, 2015) – Baldor
Electric Company has appointed Myla Petree to
the newly created position of director – strategic
program management. In this role, she and
a recently formed team of project managers
will be responsible for organizing, driving and Myla Petree
successfully implementing key projects across a
variety of Baldor locations and products. Petree joined Baldor in 2011
as the company’s director of quality. Petree has a bachelor’s degree
in mechanical engineering from the University of Oklahoma and is an
ASQ Certified Manager of Quality/Organizational Excellence.
baldor.com
MERGERS & ACQUISITIONS
Singer Valve Inc. has joined forces with Channel Co Ltd. for valve
distribution in Jordan.
Dec. 16, 2015
Des-Case has acquired JLM Systems Limited and its OilMiser product line.
Dec. 10, 2015
The IFH Group Inc. has acquired Bowman Manufacturing Company Inc.
Dec. 7, 2015
Watson-Marlow Fluid Technology Group has acquired Flow Smart Inc.
through its parent company Spirax-Sarco Engineering plc.
Nov. 30, 2015
U.S. Water has acquired A and W Technologies.
Nov. 17, 2015
 7

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p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
8 NEWS
AROUND THE INDUSTRY
STW Resources Holding Corp
Receives Approval for Water
Permit in West Texas
MIDLAND, Texas (Dec. 16, 2015) – STW
Resources Holding Corp., a provider of
pipeline services, water reclamation
and processing management services
including water desalination, has
received approval from the Middle
Pecos Water District for drilling,
production and transportation of the
water on STW Water’s MRK lease in
Pecos County. Previously, STW Water
applied for a consolidated drilling
and production permit from the San
Andrés formation to be utilized within
the county and exported out of Pecos
County to surrounding areas in need of
water. The company also has the ability
to submit a request to the water district
for a larger permit once it is determined
by a hydrogeologist that the
formation can withstand an increase
in yield without any negative effects.
Additionally, with several prospective
buyers already in place, STW can
begin selling water immediately. The
company anticipates water sales in the
first quarter of 2016, as it has already
received a letter of intent from a
customer to purchase water.
stwresources.com
Xylem Supplies Technology
for Vital Connector Route
in Europe
LANAYE, Belgium (Dec. 10, 2015)
Xylem has designed a water pumping
solution as part of a complex project to
expand the Lanaye Locks in Belgium, a
vital connector route between Northern
and Southern Europe. Xylem’s Flygt
pumps and turbines will regulate water
levels in the canal network and harness
energy from excess water in the Albert
Canal. The addition of a fourth Lanaye
lock (225 x 25 meters) will quadruple
the lock system’s convoy capacity
from 2,000 to 9,000 tons. The pumping
solution, which includes five Flygt 500
kilowatt submersible hydroturbines
with a flow of 18 cubic meters per
second, pumps water back into the
Albert canal, maintaining adequate
levels to accommodate canal traffic
during dry weather spells.
xyleminc.com
To have a news item considered, please send the information to Amelia Messamore, amessamore@cahabamedia.com.
Februa ry 2 0 1 6 | Pumps & S y st e m s
Siemens Joins Notre Dame
to Develop $36 Million
Testing Facility
ATLANTA (Dec. 9, 2015) – Siemens
has announced that it will supply the
University of Notre Dame with the main
motor and variable frequency drive
for its new Turbomachinery Facility.
The facility will be a research and test
facility for advancing the technology
used in gas turbine engines used by the
commercial and military aircraft, power
plant, and the oil and gas industries.
Siemens will provide a 10-megawatt
SINAMICS SM120 variable frequency
drive and a 5-megawatt SIMOTICS
AboveNEMA TEWAC motor.
siemens.com
KLINGER Holding GmbH Forms
KLINGER IGI Inc.
VANCOUVER, Wash. (Dec. 1, 2015)
KLINGER Holding GmbH in Austria has
announced the formation of KLINGER
IGI Inc. as an addition to the group’s
industrial gasketing presence in the
U.S. Headquartered in Wilsonville,
Oregon, with an additional location
in Denver, Colorado, the seals and
gasketing manufacturer is a result of
KLINGER’s acquisition of IGI.
klinger-international.com
China Leads World in Privately
Funded Water Investment
BOSTON (Dec. 1, 2015) – China is firmly
positioned as the global epicenter for
privately financed water investment.
The combined water infrastructure
build-out across 20 provinces accounts
for more than 50 percent of privately
financed treatment capacity added
in emerging markets over the last
decade. According to a new report
from Bluefield Research, China’s
wastewater treatment market has
added more than 20 million cubic
meters per day of capacity from 2013-
2015. The level of annual investment
has surged to more than $5 billion
in 2014. As a result, private firms
now manage about two-thirds of
the country’s wastewater treatment
infrastructure. bluefieldresearch.
com/china-municipal-wastewater-
market-private-player-opportunities-
strategies-2015-2020/
Massachusetts Water
Resources Authority Moves
Forward with Pump System
Optimization Program
PARSIPPANY, N.J. (Nov. 30, 2015)
Massachusetts Water Resources
Authority (MWRA), which provides
wholesale water and sewer services to
2.5 million people and more than 5,500
large industrial users, conducted an
in-house Pump System Optimization
(PSO) Program in November 2015
as a precursor to a pump system
assessment of all its facilities. The
PSO Program was developed by the
Hydraulic Institute for engineers,
operations, facilities, maintenance
and management personnel to
educate their staff about operating
pump systems more efficiently. A.W.
Chesterton Company and WEG Electric
Corp. co-hosted this particular pump
system optimization training course.
mwra.com
World’s Largest 5-Turbine
Commercial Tidal Installation
Put into Service
DEN OEVER/SCHIEDAM, The
Netherlands (Nov. 26 2015) – The tidal
power plant in the Dutch Eastern
Scheldt surge barrier has been put
into service. The commissioning for
the largest tidal energy project in the
Netherlands as well as the world’s
largest commercial tidal installation of
five turbines in an array was performed
by Diederik Samsom, Dutch Labour
Party group chairman. tocardo.com
CENTA and Christie & Grey
Limited Announce Global
Sales Cooperation
AURORA, Ill. (Nov. 16, 2015) – The
management teams of CENTA Antriebe
Kirschey GmbH and Christie & Grey
Limited have announced a strategic
global sales cooperation between their
companies. The agreement allows
the two companies to join forces to
engineer and strategically supply
the industry’s premium “quiet drive”
solutions—combining soft mounting
systems, flexible couplings and
intermediate drive shaft systems.
centa.info christiegrey.com
 9

Q U A L I T Y . S E R V I C E . I N N O V AT I O N . I N T E G R I T Y .

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10 NEWS

Efficient Pump
Selection and
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THE SECOND IN A 6-PART WEBINAR SERIES FOR 2016

With more focus on energy efficiency these days, building owners

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January 28, 2016 How to Read a Pump Curve (now available online)

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May 18, 2016 Vertical Turbine Pumps - Wire-to-Water

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Februa ry 2 0 1 6 | Pumps & S y st e m s

 11

EVENTS
The Process Heat Exchangers:
Applications & Rules-of-Thumb
Short Course
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Feb. 1 – 2, 2016
HTRI Headquarters
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Navasota, Texas
979-690-3250

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Industry in Transition: Navigating
the New Age of Innovation
Feb. 8 – 11, 2016
Renaissance Orlando at SeaWorld
Orlando, Florida
781-471-1175 / arcweb.com
Maintenance Planning &
Scheduling
Feb. 17 – 19, 2016
San Francisco, California
203-783-1582 / newstandardinstitute.
com/product/maintenance-planning-and-
scheduling/
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May 2 – 5, 2016
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National Fire Protection Association ȏ 5DSLGO\3ULPHVDQG5HSULPHV
(NFPA) Conference & Expo 5H3ULPHVFRPSOHWHO\XQDWWHQGHG
June 13 – 16, 2016
Mandalay Bay Convention Center
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p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
12 PUMPING PRESCRIPTIONS
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board

Using Pump Efficiency Monitoring to Make

Faster Decisions

I
n 2015, I wrote a series Nelik’s Response But the numbers are there—
for Pumps & Systems titled Thank you for your question. It in dollars instead of red ink on
“Efficiency Monitoring Saves does not surprise me that the a pump housing. Consider the
Plants Millions.” I gave readers amount of wasted energy seemed 3,000-horsepower (hp) pump
a real-world example of the so high to you. Most folks think in the articles you mentioned.
importance of understanding how more about a piece of machinery’s Multiplying 3,000 hp by 0.746 gives
equipment is performing. Below, reliability than about its efficiency. us 2,238 kilowatts. Multiply that
I answer a question from a reader The thought process is, “If a pump by 24 hours for 365 days, times
about the effectiveness and speed fails too often, water spills all over $0.10 per kilowatt-hour, and it
of plant monitoring systems. the plant, and I get home late for adds up to $2 million. If 10 percent
dinner.” That is personal. But to is wasted, that is $200,000. The
Letter from a Reader look at a running pump to see 10 $125,000 in the articles is adjusted
“I enjoyed your four-part series percent efficiency being wasted, for the pump running less than 100
(Pumps & Systems, July, August, that is often too abstract. percent of time.
September and October 2015)
relating the dynamics of what goes Figure 1 (above). Live data streaming in. Figure 2 (below). Spectral (FFT) data is taken and
displayed continuously by the PREMS system.
on at the plants in an interesting
real-world dialogue format. You
started the set by introducing
the reader to a pump salesman,
Bob, who visits the water plant
and works with a local plant
maintenance manager, Jim, on
measuring the efficiency of his
large pumps. Other people get
involved along the way, and the
amount of savings they discovered
shocked me—nearly $125,000
for a 3,000-horsepower pump. In
Part 1 of your article series, you
said the entire test was done in
less than a day by a system you
referred to as “PREMS,” but you
did not describe what it is. We have
plant monitoring systems in our
plant, but they cost millions, and
I doubt that anything, no matter
how simple that may sound, can be
done in a day. Can you elaborate?”

Jack Francis
Chemical plant employee
Chicago, Illinois

Februa ry 2 0 1 6 | Pumps & S y st e m s


For details of how to measure
efficiency, let me do a brief review.
In March 2007, Pumps & Systems
published “How Much Energy is
Wasted When Wear Rings Are
Worn to Double Their Initial
Value?” Double was picked because
that is the point where most
original equipment manufacturers
(OEMs) recommend replacement
of rings. But such repairs are
costly. Users do not know the worn
dimensions until they pull the
wear rings from the pump.
By measuring efficiency
continually, they can pinpoint the
time when the efficiency value
drops below the value that justifies
the repair and restoration of the
ring clearances to the initial OEM
Circle 111 on card or visit psfreeinfo.com.
recommended values. Continuous
monitoring reconstructs the entire
performance curve, because most
pumps do not “sit” at the same
flow. In response to changes in
the system, the flow changes, and
pressure, power and efficiency
change with it.
A dynamic, live reconstruction
of the performance curve does not
require intrusive periodic testing.
Continuous monitoring makes the
performance curve more accurate
and detailed over time. It would
also tell where the plant typically
runs—something that plants
often do not know.
In regard to the pump’s
reliability and efficiency
measurement system (PREMS)
p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
13
in Part 1 (Pumps & Systems,
July 2015), the key to a good
technology is accuracy and
simplicity. The PREMS is
essentially a box, similar to a
suitcase, that can be installed
for one pump, monitoring it for a
period of time, and then moved as
needed to another pump.
The system transmits through
a wireless cell gateway (or a
local modem), alleviating any
concerns of interfering with
the plant operational system.
Instrumentation measures
pressure, flow and amps, which the
software converts into a complete
pump performance curve (head-
capacity, power and efficiency) that
is displayed on the screen.
14 PUMPING PRESCRIPTIONS

Examining the data over time
reveals that the pump operates
mainly in two regions (see Figure
1, page 12). One region is near
the best efficiency point, but the
other is much closer to the shutoff
head (below minimum continuous
stable flow). The second region is
in the area where internal forces,
pulsations and vibrations are
detrimental to the pump. Vibrations
are measured continually, including
overall values and spectral (Fast
Fourier Transform, or FFT) data
to troubleshoot live. The chart
on Figure 2 (page 12) shows the
first and second harmonics being
predominant (1X and 2X). What
does it tell us? Email me your
answer from the following choices
for a chance to win a discounted
seat at the next Pump School.
a. Rotor unbalance
b. Misalignment
c. Cavitation
d. Both a and b
e. a, b and c
Using Figure 1, we can compare
the original OEM performance,
shown with solid lines, to actual
performance, shown with multiple
data points outlining the evolving
curves. The system provides stand-
alone data acquisition, combining
instrumentation with software,
to present a real, standard pump
curve—live and continually.
Interpretation of data is simple—it
is on the screen. The difference in
efficiency is calculated continually
and translated into yearly prorated
dollars wasted. Th is data can
help users decide between repair
(yearly energy cost vs. repair cost),
adjustments to the system or no
action (if energy cost is small
relative to the quoted repair cost).
For more information, email
me or visit Pump Video Academy
online at pumpingmachinery.
com/pump_school/PVA/pva.htm
(modules #10 and #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.

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Februa ry 2 0 1 6 | Pumps & S y st e m s

 15
A better understanding of complete system operation
By Ray Hardee
Engineered Software, Inc.

Troubleshooting a Piping System

First of Two Parts

144 Formula 1

U
sing the example system In a previous column, we NPSHa = (Pin + Patm - P vp ) x
ρ
in Figure 1, this series discovered that the flow rate
will focus on the process through a pump can be calculated
144
elements found in piping systems. by converting the differential NPSHa = (-2 + 14.7 - 8.8) x =11.5 ft
48.9
In this example, a process fluid pressure to head. Using the pump
is pumped from a storage tank, curve, enter the value for pump Equation 1
Where:
PX-TK-120, through an end suction head on the vertical axis and move
pump, PX-PU-120, specified to horizontally until you intersect the Pin = Suction pressure psig
pass 800 gallons per minute (gpm) pump curve. Then move down to Patm = Atmospheric pressure psia
with 202 feet of head. From the determine the flow rate. Pvp = Fluid vapor pressure psig
pump discharge, the 80 F process Ρ = Fluid density lb/ft3
fluid travels to a heat exchanger,
PX-HX-121, where the fluid is
heated to 120 F. Level control Table 1. Physical properties of the process fluid used in this example
PX-LCV-120 maintains the level Fluid Temp (F) Density (lb/ft3) Viscosity (cP) Vapor press (psia)
in process vessel PX-PV-122 to 15
feet. The system boundaries are Process fluid 80 48.9 0.30 8.8
the tanks PX-TK-120 and PX-VP- Process fluid 120 47.3 0.25 16.4
122. The system contains only one
circuit. Table 1 lists the physical
properties of the process fluid. Table 2. Comparing as observed conditions with cavitation to validated results
Less than six months ago, a Condition/Value PX- PX- PX- PX-LCV-120 PX- PX-PV-122
piping system model was created TK-120 PI-120 PI-121 position* PV-122 psi
ft psi psi level
and validated using the installed
plant instrumentation (values are Current Operation 5 -2.0 65 78% 15 20
shown in Figure 1). The difference
Validated 5 0.4 69.6 69% 15 20
between these values and the
* The value position is not on the operator’s log sheet.
calculated results was less than
2 percent.
The piping drawing shows that Figure 1. Example system consisting of the items making up the system
along with displayed operating data (Graphics courtesy of the author)
the flow rate through the system
is controlled to maintain the level
in the process vessel PX-PV-122 at
15 feet. The system does not have
an installed flow meter, so we must
determine the system flow rate.
One of the easiest methods
is to use a portable clamp-on
ultrasonic flow meter. If operated
correctly, these devices can provide
accuracy of ±1 percent. During
the assessment, the flow meter
indicated a flow rate of 770 gpm.

p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
16 PUMP SYSTEM IMPROVEMENT

In this example, the differential
pressure across the pump is 69.2 pounds
per square inch (psi). Using a process
fluid density of 48.9 pounds per cubic
foot (lb/ft3), we can determine a pump
head of 203.8 feet.
The manufacturer’s supplied pump
curve shows that, with a head of 204
feet, the flow rate through the pump
is 770 gpm. The flow rate calculated
through the pump correlates with the
flow rate obtained with the ultrasonic
flow meter.
Now that we have discussed how the
model was validated with the observed
values, we can troubleshoot.
An operator notifies the shift
supervisor that pump PX-PU-120
sounds like it is cavitating. Additionally,
the pump discharge pressure gauge is
oscillating, another indication of possible
pump cavitation. Table 2 shows the
system’s current operation along with
the validated results.
Table 2 shows that the levels and
pressures at the system boundary tanks
are the same in both conditions, resulting
in the same static head. The pressure at
pump suction pressure PX-PI-120 is -2
pounds per square inch gauge (psig), 2.4
psi less than the validated results. The
pump discharge pressure PX-PI-121 is 67
psi, 2.6 psi less than the validated results.
According to Table 2, the position of
PX-LCV-120 is 78 percent open, greater
than the validated results.
The first step is to determine if these
conditions are the cause of cavitation.
Using Equation 1, we will determine
the net positive suction head available
(NPSHa) at the pump suction based on the
pressure gauge reading at PX-PI-120.
As indicated in Figure 1, the NPSHa
is 11.5 feet. The pump curve shows that
the net positive suction head required
(NPSHr) is 14.3 feet. As a result, the
NPSHa is greater than the NPSHr,
indicating pump cavitation is occurring.
Because the pump is cavitating, the pump
is probably not operating on its curve.
Part 2 of this series will use the
data discussed here to determine the
cause of cavitation and analyze other
system problems.
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.

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Februa ry 2 0 1 6 | Pumps & S y st e m s

 17

Circle 151 on card or visit psfreeinfo.com.

p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
18 COMMON PUMPING MISTAKES
Simple solutions for end users
Solid Shaft Designs & Cartridge Seals
T
his month’s column
focuses on whether to use
shaft sleeves in overhung
centrifugal pumps (Type OH-1
per American Petroleum Institute
[API] 610 designation). The most
common OH-1 pump type is the
American National Standards
Institute (ANSI) B73.1M. The
practice of using cartridge-type
mechanical seals on solid pump
shafts (in lieu of sleeved shafts)
is not new or radical. While the
benefits of building a pump in this
manner are real and measurable in
most instances, a large percentage
of pump owners will not change.
Background
I would estimate that shaft sleeves
have been used on pump shafts for
at least 100 years. My 1919 edition
of Pumping Machinery by Arthur M.
Greene mentions “sacrificial shaft
liners.” I do not know exactly when
the first pump shaft sleeve was put
into service, but I assume it was
not long after someone adjusted
the packing incorrectly on an
expensive pump.
Shaft sleeves serve multiple
purposes. The most important is to
protect the main pump shaft from
wear caused by packing abrasion,
followed closely by prevention of
erosion and corrosion. In some
pump designs, the sleeve serves
additional purposes. For example,
in some horizontal split-case
pumps, the sleeve also serves
(in conjunction with a threaded
shaft nut) as an adjustable means
Februa ry 2 0 1 6 | Pumps & S y st e m s
By Jim Elsey
Summit Pump, Inc.
to axially locate the impeller on mechanical seals. Most present-day
its respective mechanical and designs will not damage the shaft
hydraulic center in the casing. or shaft sleeve during installation,
The sleeve is designed to be the operation and subsequent removal
inexpensive and replaceable part. from service. Even O-ring fretting
It is easier and less expensive to of the shaft or shaft sleeve is
change a sleeve than the whole eliminated in most new designs.
shaft. Users who have packing in
their pump consider the sleeve a Figure 1. An example of stiffness ratio
calculations (Graphics courtesy of
must-have design feature.
the author)
In 1905, the mechanical seal
as we know it was invented, but
it was not commonly used until
after World War II. Fifty years
ago, most centrifugal pumps in
industrial and commercial services
still had packed stuffing boxes.
Pumps with mechanical seals
were uncommon and expensive.
Later in the 1970s, many users
began to use simple mechanical
seals because of safety concerns,
stricter Environmental Protection
Agency (EPA) regulations, and the
cost of both lost product and flush
fluids. These simple seals were Figure 2. An example of a sleeved pump
eventually displaced by component shaft design with ample diameter to
type mechanical seals. Prudent maintain a low stiffness ratio
pump users continued to use
the existing shaft sleeve designs
because the component seals
were held in place by tightening a
number of set screws. The torqued
set screw points damaged the shaft
sleeve surface. These “dog marks”
(damaged metal surfaces) from
the set screws were an accepted
negative side effect because of
the shaft sleeve’s status as an
inexpensive and replaceable part.
In recent years, most pump users
have switched to cartridge-type
 19

Non-Contacting
Flow Measurement
When the American Voluntary Standards
(AVS) pumps and the forerunners of
and Control
the modern ANSI pump (B73.1M) were
designed in the late ’50s and early ’60s, Measure Flow
packed stuffing boxes were standard. If
these pumps were to be redesigned today,
from Outside
they would use cartridge-type mechanical the Pipe
seals, and the design length of the shaft
from the radial bearing to the impeller Designed for dirty
would be shorter. or aerated liquids
When a packed pump is operating, the like wastewater,
packing acts like an additional line bearing slurries, sludge
because of the hydrodynamic properties and liquids with
of the close clearances between the shaft bubbles or solids
sleeve and the packing. Th is “consequential
and beneficial phenomenon” mitigates shaft
deflection caused by any unequal radial DFM 5.1 Doppler
Flow Meter
forces acting on the impeller.
Without packing around the shaft (for
The clamp-on ultrasonic sensor installs in
example, when a seal is used), the shaft
minutes without shutting down flow. Start-up
will deflect more, especially if the pump
is easy with the built-in keypad and simple
is not operating near the best efficiency
menu system.
point/best operating point (BEP/BOP).
Pump operation at or near shutoff (far left
side of the curve) and at runout conditions Low-Flow or No-Flow
(far right side of the curve) away from the
preferred operating region results in shaft Pump Protection
deflection, which causes premature bearing
and mechanical seal face wear, shortening
the life of these critical components.
The ability of a shaft to resist deflection
is a direct function of the overhung length
and the shaft diameter. Th is is commonly
referred to as the shaft stiff ness ratio,
DFS 5.1 Doppler
shaft deflection ratio, or the L over D ratio Flow Switch
(L 3 / D4). The lower the ratio number, the
better the shaft will resist deflection. The
formula for calculating the ratio factor
Works with a clamp-on sensor for pump
is based on the simple cantilevered beam
protection, flow control and high or low flow
Circle 113 on card or visit psfreeinfo.com.

deflection formula. alarms. The LED bargraph displays flow rate

Many of the factors in the beam and relay state.
deflection formula cancel each other out
when applied to an overhung pump shaft.
As a result, the revised formula is simply
the length (L) of the shaft as measured from
the centerline of the radial bearing position
to the centerline of the impeller (take L to
the third power) divided by the diameter 888-473-9546
of the shaft in this area (D) to the fourth info@greyline.com
power, or L 3 / D4 (see Figure 1).
www.greyline.com

p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
20 COMMON PUMPING MISTAKES
A smaller shaft diameter results in
a higher stiff ness ratio, which is not
a desired attribute. Without delving
into a protracted formula derivation,
the strength of the shaft material is of
little importance, but the modulus of
elasticity (Young’s modulus) does come
into play. Most common shaft materials
share similar ranges for the modulus of
elasticity. If pump shafts are breaking,
the cause is usually cyclic fatigue, not
material strength. So a stronger material
is not the answer, but preventing or
reducing deflection is.
When a pump is purposely designed
to incorporate a shaft sleeve, the
original shaft diameter in the packing
and mechanical seal area is typically
machined down to a smaller diameter
of some incremental distance (D) to
accommodate the corresponding sleeve.
Februa ry 2 0 1 6 | Pumps & S y st e m s
Some manufacturers’ processes design
and machine the shaft differently. Either
way, the end result is that the shaft has
a smaller diameter on the overhung
portion. The smaller diameter yields
a higher shaft deflection ratio, which
means the shaft will deflect more for a
given radial force. More deflection will
result in deleterious effects on the seal
and bearings.
Note that the presence of the sleeve
does not contribute to the stiff ness
factor, no matter how tight the fit. The
sleeve is not an integral part of the
shaft and does not become a factor in
the equation.
In the past, most pump shafts
were generously over-designed/sized
to transmit some amount of torque
(horsepower) at some speed range, but
most shafts were not designed for high
side loads (like belt or chain drives) and
cyclic fatigue factors. Current designs
are taking these side load factors more
into consideration.
Current Practices
Many pump owners continue to use old
design shaft sleeves when using new
design cartridge mechanical seals. There
are some good reasons, such as corrosion/
erosion mitigation, for continuing this
practice. In most cases, however, there
is no other reason than “that is the
way we have always done it.” I would
say that, for a given system (curve) and
the consequential pump operation on
its curve, the pump life would be much
longer if the shaft design was solid versus
sleeved. The pump would be more reliable,
and the mean time between failure and
repair (MTBF/R) would be longer.
Circle 116 on card or visit psfreeinfo.com.

In some modern OH-1 pump models,
the incorporation of a shaft sleeve is
by design and is an acceptable practice
because the shaft deflection ratio is
already very low as a result of a generous
shaft diameter in the sleeve area. X-17
ANSI pumps (ANSI sizes A105, 110 and
120) are one example (see Figure 2,
page 18).
Many pump manufacturers also
offer solid pump shafts that are made
of different materials in the wetted
(sacrificial) versus non-wetted areas.
Furthermore, most ANSI pump
manufacturers offer an optional shaft of
larger diameter for given midrange sizes
(for example, MT, or medium-sized shaft
and bearing systems, versus LT, or large
sized, models).
Even with sleeve construction, the
deflection ratio between the two models
Circle 121 on card or visit psfreeinfo.com.
21
of different shaft diameters is significant. Shaft runout, or total indicator
The difference between the smaller (MT) reading, with a sleeve design is harder to
sleeved shaft and a larger (LT) solid shaft control because of the added surfaces and
is dramatic. associated tolerances. The allowable shaft
ANSI B73.1M has set tolerances for runout on a solid shaft is 0.001 inches
allowable shaft deflection at the stuffing and 0.002 inches for a sleeved shaft. As
box area of the shaft over the allowable a final design note, any sleeve design
operating range. needs to allow for thermal expansion and
Pumps in compliance with this contraction.
specification are not allowed more than Even when we know we should
0.002 inches of deflection. Simply implement change, some habits are hard
looking at the L/D ratios is one way to break.
to evaluate the pump, but it is equally Are you operating your overhung
important to calculate the radial loads for pumps with cartridge seals and still
your specific operation and the resultant using shaft sleeves? I would like to
shaft deflection. hear why.
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. 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.
p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
22 INDUSTRY INSIGHTS
Trends & analysis for pumping professionals
Intelligent Pumping Continues to Evolve
A
n intelligent pump is
more than a pump; the
product is a combination
of a pump, process instrument(s)
and variable frequency drive
(VFD) with related intelligence
embedded in the microprocessor
motherboard. While variable speed
drives (VSDs)—both mechanical
and electronic—have been applied
to pumps for decades, the drives
on intelligent pumps were the first
commercially available VFDs that
used pump protection logic to alert
end users during upset conditions.
Today, several manufacturers offer
intelligent pumps with varying
performance monitoring and
asset protection capabilities. An
intelligent pump also typically
includes standard process control
functions, such as proportional-
integral-derivative control (PID)
and power (kilowatt) consumption
monitoring.
The fi rst intelligent pump was
introduced near the beginning
of the new millennium. Th is
technology has been instrumental
in changing many facets of the
pump industry. One change has
been the development of a new
understanding that control valves
do not have to be the de facto
flow control device for pump
systems. Embedding pump
intelligence into VFDs also has
led to the view that the pump—
along with the instrumentation
and control valves—is a key
component of industrial
automation architecture.
Februa ry 2 0 1 6 | Pumps & S y st e m s
Pumps & Systems Senior Technical Editor
Advantages of
Intelligent Pumping
From a process control standpoint,
the primary difference between
a VFD and a control valve is that
the VFD electronically changes
motor speed to maintain flow,
pressure, level or temperature at
set-point, while the control valve
mechanically adjusts its opening to
meet process control requirements.
Both approaches maintain process
flow at the required rate but differ
significantly in how they impact
energy use, equipment reliability
and process control performance.
VFD speed reduction lowers head
(pressure) at the square root of
speed, while flow is reduced at the
cube root of speed. For example,
a small reduction in speed can
result in a moderate head reduction
and large energy reduction. The
reduction in head (pressure) and
the accompanying reduction
in energy usage are primarily
the result of fully opening or
eliminating the control valve.
Standard and intelligent VFDs
provide the same level of energy
savings but can differ significantly
in the amount of maintenance
savings they provide. Embedded
pump protection can alarm, slow
down or turn off the pump when
the system encounters conditions
such as dead-heading, dry-running
or cavitation.
The introduction of intelligent
VFDs signaled the rise of variable
speed pumping as an alternative
to control valves, especially in
By Mike Pemberton
continuous process industries.
For the fi rst time, end users could
use the electronic platform as a
“brain” that learns and adapts
pump performance to changing
process conditions. Th is real-time
adaptability plays a critical role in
achieving process sustainability
through uptime, controllability
and reliability improvements. An
intelligent pump offers far more
information about the pump’s
performance than was ever readily
available in the past.
Limitations to Adoption
While plant operators and
engineers typically configure
standard VFDs through a keypad
or laptop in the motor control
center (MCC), the PID algorithm
and control logic in the VFD are
infrequently used. Normally, the
control engineers opt for using the
same control functions that found
in the distributed control system
(DCS). The DCS then outputs a
speed signal back to the VFD over
an analog cable (4-20 mA), a step
similar to sending an analog signal
to a valve positioner to change the
percent that it is open or closed.
Digital bus communication can be
used, but the majority of plants
built before the new millennium
use analog signals to communicate
from the DCS to the field
instruments and valves.
Because the VFD and DCS are
in different locations, operators
and engineers are often unable
to configure the intelligent pump
 23

fi rmware from the DCS. Th is on the DCS. This could make the the availability and utilization
restriction causes the embedded intelligent pump compatible with of pump intelligence. The DCS
pump intelligence in the VFD to multiple VFD brands and different and related information systems
be underutilized. voltage ratings. The end user could could be able to both configure
While this was an issue with purchase the VFD separately from and display multiple capabilities,
the fi rst generation of intelligent software package and combine the including the following:
pumps, the growth of wireless two using wired or wireless digital • Alarm and control actions
communication, the Industrial communication. In this scenario, with data logging, time
Internet of Th ings (IIoT) and cloud the pump intelligence could access stamps and trends
computing have made it possible the DCS database as well as receive • Real-time pump and
to overcome these limitations. data from the VFD. By accessing system curve visibility with
Today, multiple parameters can data from both control elements, mechanical efficiency
be transmitted from the MCC the level of intelligence could • Real-time horsepower and/
to the DCS. Access to the pump- potentially be expanded. or kilowatt consumption and
protection logic from the DCS can While intelligent pump specific energy
lead to more visibility and higher technology has made significant
utilization rates. advances in asset protection, the
Mike Pemberton is the senior
An alternate approach use of wireless communication,
technical editor for Pumps &
could be to use a third-party cloud computing and/or third-
Systems. He may be reached at
software package with the pump party software offers new
mpemberton@cahabamedia.com.
intelligence and load that program approaches that can increase

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p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
24
SPECIAL SECTION
PUMPS & EQUIPMENT FOR HARSH CONDITIONS
Liquid-Lubricated Double
Seals Increase Stability for
PTA Production
One facility s high-speed centrifugal pumps saw improved
performance and efficiency after adding custom seals.
BY ANDREAS PEHL
EAGLEBURGMANN GERMANY GMBH & CO. KG
T
he production of purified terephthalic acid
(PTA) poses unique challenges for centrifugal
pumps. For increased safety and reliability, some
facilities with this process have incorporated
custom-engineered liquid-lubricated double seals. Th is
new technology meets the ever-increasing product
performance requirements of leading PTA producers.
HP reactor feed pumps—in many cases, integrally
geared high-speed centrifugal pumps—play a vital role
in the purification stage of crude terephthalic acid (TA).
These pumps deliver TA slurry, which contains TA powder
suspended in demineralized water at a high temperature,
into a hydrogenation reactor, where a reaction with
hydrogen removes contaminants from the solution.
PTA is the predominant raw material for production
of high-purity polyester resin, which is widely used in
the production of polyester fiber, polyethylene
terephthalate (PET) bottle resin, polyester fi lm and
engineering plastics.
Operational reliability of the HP reactor feed pumps
is critical for maintaining stable operation of PTA
purification plants, and mechanical seals are among the
most critical pump components because of high-speed
and high-pressure service requirements.
In one particular application—for one of the world’s
largest PTA producers—the selected centrifugal pump
was configured as a horizontally mounted, integrally
geared two-stage pump with a single double-ended output
Februa ry 2 0 1 6 | Pumps & S y st e m s
shaft, which operates at a rotational speed of 6,200
revolutions per minute (rpm) with impellers attached on
each end. The two stages are piped up to operate in series
to develop the required head rise, and the fi rst-stage
discharge feeds the second-stage pump suction. Th is
setup boosts the Stage 2 seal chamber pressure to 80 bar,
or 1,160 pounds per square inch (psi).
The seals for the application were engineered as a
cartridge-design double seal face-to-face arrangement
for Stage 1 and as a tandem oriented face-to-back dual
seal arrangement for Stage 2, which splits the total
differential pressure between two seals and maintains
suitable pressure velocity (PV) parameter levels. The
seal support system utilizes flush supply to both pump
stages, which helps to protect the product side seals from
plugging with TA slurry.
Technical Challenges
One of the main technical challenges in this application
pertained to the barrier/buffer fluid. Instead of using
the more common ambient-temperature demineralized
water as a barrier/buffer liquid that is usually supplied
from the PTA plant centralized seal-support system, the
facility requested to use plant return water at the normal
temperature of 70 degrees C (158 F), with a maximum
temperature of 80 C (176 F). The potential problem
with using plant return water as barrier/buffer liquid
under these conditions is an adverse seal environment

characterized by inadequate heat dissipation and poor
lubrication of seal faces resulting from a loss of fluid fi lm
from vaporization.
An additional technical challenge was reverse
pressurization of the Stage 2 process side seal during
pump startup and shutdown. During the startup
sequence, this seal is reverse-pressurized by the buffer
fluid introduced into the seal support system before
the pump main driver is turned on. Under transient
conditions, while the pump is ramping up to full speed
and reaching full discharge pressure, the pressure applied
to the seal is reversed, causing the seal to hang up. The
same problem occurs in opposite order during pump coast
down to shutdown. The original seal design was modified
to incorporate new features to overcome seal hang-up
associated with the secondary seal.
The demanding requirements of this facility required
an application-specific solution. Once the performance
specification had been drawn up, the development and
design stage began. The seal and pump manufacturers’
teams met to analyze the operating points in detail.
This provided precise performance calculations and a
computer-aided design for the sliding elements.
The new double seals were based on a special
high-pressure seal from the manufacturer’s existing
product portfolio. Specifically, the team opted for the
25
Image 1. Pump in operation (Image and
graphic courtesy of EagleBurgmann)
efficient high-pressure seal. In contrast to conventional
mechanical seals from the standard range, high-pressure
seals have one important special feature: the seat
rotates on the shaft while the seal face—with its spring
backing—is stationary in the housing. This seal concept
provides additional stability at high speeds. At sliding
velocities of 20 meters per second (66 feet per second)
or more, the springs should be stationary so they do not
absorb vibrations and deform.
Optimized Design
Design improvements to the seal technology, including
the use of ultra-high-performance materials, were made
to guarantee stable running across the entire operating
range. While the regular seals use silicon carbide ceramic
material for both seal face and stationary seat, the
stationary seal face for this application was based on the
silicon carbide variant BuKa 30. Th is material has a high
carbon content, making it an ideal solution for media
with poor lubricating properties, such as water. BuKa 30
impresses with its effective emergency running properties
and tolerance to dry running.
The seal was further optimized to guarantee functional
reliability, even in the marginal ranges. A loosely fitted
seal face provides additional safety against tipping and
tilting. Another technical feature of the high-pressure
p u mp
m p s a n d s y s te m
mss . co m | Fe b ru ary 2016
26 SPECIAL SECTION PUMPS & EQUIPMENT FOR HARSH CONDITIONS

Figure 1. Double seal in tandem arrangement. The

yellow parts are rotating, blue are stationary, and
gray shows the shaft and housing.
seal developed for the PTA application is the
incorporation of high-precision grooves in the seal faces.
The depth and geometry of these grooves were specified
with accuracy. At low pressure, the grooves promote
lift-off of the seal faces by creating a positive pressure
cushion, and they quickly establish a stable operating
state. At high pressure, the grooves have a stabilizing
effect because they prevent the gap from opening further.

Field Tested
Combining all these measures resulted in sophisticated
sealing systems in both tandem and back-to-back
versions. These cover the range of applications up to 100
bar (1,450 psi) and 9,000 rpm and ensure functional
reliability. The liquid-lubricated double seals cope with all
operating parameters, and constant sealing performance
is reliable, even when exposed to considerable pressure,
Andreas Pehl is technical sales support for mechanical
temperature and speed fluctuations.
seal applications at EagleBurgmann
The seals, which are designed as easy-to-fit cartridge
Germany in Wolfratshausen. He joined
systems, were extensively tested and confirmed in
EagleBurgmann in 2010. He has a degree in
dynamic test runs in the test field. The new double seals
industrial engineering from the University
have also proven their worth in the many integrally
of Applied Sciences, Munich. For more
geared pumps that were bought into service in China in
information, visit eagleburgmann.com.
2014 in one of the world’s largest PTA facilities.

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Februa ry 2 0 1 6 | Pumps & S y st e m s

 SPECIAL SECTION 27

Match Hydraulic Fluids

to Seal Lip Material
Companies interested in reducing safety hazards and environmental
impact should consider compatibility issues.

BY STEPHEN A. MALONEY
COLONIAL SEAL COMPANY

I
n the sealing industry, compatibility influences the
ability to form a chemically stable system. Using
the wrong hydraulic fluid could result in a violent
reaction that is disastrous for the entire hydraulic
assembly. The fi x is not simple; it could cost thousands of
dollars in repairs and lost production time. To avoid these
problems, users should ensure that the lip material or
sealing material is compatible with planned media. Any
biodegradable upgrades or media improvements must
also be compatible with the sealing elastomer.
Each year the U.S. uses about 200 million gallons
of hydraulic oils. Of this volume, approximately 165
million gallons are mineral-based fluids. These types
of mineral-based oils function at temperatures as low
as -40 C to as high as 150 C with some exceptions.
When choosing the right fluid, it is essential to assess
physical and performance properties along with any
original equipment manufacturer (OEM) approvals or
specifications. Most fluid suppliers should be able to
provide a product data sheet so that the design engineer
can discern the best solution for the application.
Mineral-based fluids include specialty fire-resistant
hydraulic fluids and environmentally friendly,
biodegradable fluids. The International Organization for
Standardization (ISO) acknowledges four major groups
of fire-resistant hydraulic fluids: high-water containing
fluids (HFA), invert emulsions (HFB), water glycols (HFC)
and water-free fluids including synthetics (HFD).
Along with being fire-resistant, the chemical
characteristics of HFA fluids are almost identical to that
of plain water. As a result, this type of fluid is typically
used in equipment that has been intended for use with
Image 1. It is important to consider how hydraulic fluids will affect
the hydraulic seal. (Graphics courtesy of Colonial Seal Company)
water and is subjected to an open flame. HFA fluids
are most commonly used in steel mills and coal mines.
However, because these are fire-resistant fluids and not
fire-proof fluids, HFA fluids can still ignite and burn,
given the right conditions.
HFB fluids are made up of emulsions of water caught
in oil with 60/40 oil-to-water composition. Th is type of
fluid can sometimes perform to the level of petroleum oil
and offers greater lubrication and corrosion resistance
compared with HFA fluids. Its water content also acts as
an extinguisher in case of a fire.
The most frequently used fire-resistant hydraulic
fluid category is water glycols (HFC). While these fluids
are comprised of only 35-45 percent water, they also
include unique thickeners that boost viscosity. While
HFC fluids can be used to run equipment designed for
oil, severe damage to machine parts can occur due to an
overwhelming environment if the speeds, temperatures
or pressures are not monitored properly.

p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
28 SPECIAL SECTION

Variable Speed Controls for Pumps

HFD fluids are classified as synthetic
because they contain neither petroleum
oil nor water. Polyol esters have an
organic makeup that is biodegradable.
HFD fluids are also compatible with
system materials and provide exceptional
hydraulic fluid performance. However,
HFD fluids are more than double the cost
of petroleum oil and are typically only
used when the situation demands fire
resistance and biodegradability.
Because governments have become
#HASSIS)0s.%-!)0s.%-!)0s.%-!8)0
more vigilant with environmental
Provides variable speed control for AC Induction, DC, PMSM and EC motors, 1/50 to 5 HP. regulations, it is increasingly important
115, 208/230, 400/460 VAC – 50/60 Hz 1ø and 3ø Input. to use a more eco-friendly fluid. For a
When a standard off the shelf drive will not meet your needs, KB will work product to be labeled an “environmentally
with you to develop a custom drive solution, Ready to Use “Out-of-the-Box.” acceptable fluid,” more than half of it
must decay within 28 days of exposure
KB Electronics, Inc. to the atmosphere. The fluid must be
12095 NW 39th Street, Coral Springs, FL 33065-2516 nontoxic after passing a series of aquatic
  s&AX  
/UTSIDE&LORIDA#ALL4OLL&REE  %XT Designed and
toxicity tests on fish. The most common
WWWKBELECTRONICSCOMsE MAILINFO KBELECTRONICSCOM Assembled in USA base for these environmental fluids is
vegetable oil (or more specifically canola/
rapeseed oil). Although they cannot
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be used as a direct replacement, the
lubrication and anti-wear properties will
be comparable to those of petroleum oil.
While eco-friendly fluids are becoming
more available, the problem is that none
of the current options can be used as
a direct replacement in hydraulically
powered equipment. There are drawbacks
to using a minimally toxic hydraulic fluid.
These fluids may be more vulnerable to
oxidation and have a poor performance
record in extreme cold weather, resulting
in coagulation and problems cold
starting. To increase stability and prevent
problems with viscosity, vegetable
oil producers have turned to genetic
engineering to alleviate problems with
biodegradable fluids.
If a plant decides to change the
hydraulic fluid used in an assembly,
personnel must consider the
compatibility of the replacement fluid
with the internal components of the
machinery, ensuring that the seal lip
material is compatible with the chosen
application media. These materials range
from standard nitrile Buna rubber, Viton
and ethylene propylene diene monomer
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Februa ry 2 0 1 6 | Pumps & S y st e m s

 29
Table 1. Fire-resistant hydraulic fluids and their features
ISO Makeup H2O ISO Comments
Classification Content Temperature
Range discovered that the user had switched
HFA High-water Less than 5 to 50 C Chemical characteristics are to a fire-resistant hydraulic fluid so
containing 80% similar to water. that he could create a safer working
fluids environment. No research was done
HFB Invert Less than 5 to 50 C Because of its water content, on how this change would impact
emulsions 40% it can act as an extinguisher his machinery and its components,
should a fire occur. including the seal.
HFC Water Less than -20 to 50 C The most commonly used The result was that the ethylene
glycols 35% hydraulic fluid propylene diene monomer seal was
HFD Water-free None -20 to 70 C The chemical makeup is not compatible with the new fluid.
fluids, synthetic, and the fluid The seal was absorbing the fluid at an
including contains no water or oil and is accelerated rate, causing the seal lip to
synthetics safe for the aquatic ecosystem. swell. This swelling caused increased
rubber to polytetrafluoroethylene In a real-world example, a user wear on the seal, resulting in decreased
(otherwise known as Teflon). experiencing premature hydraulic seal life and unacceptable leakage.
Understanding how a seal material will seal failure thought he had been sent Contact your fluid or seal supplier for
interact with various fluids is the first either the wrong seal or the incorrect reference charts. They will have first-
step to finding the right match. seal material. The seal provider hand compatibility knowledge.
When choosing hydraulic
oil, consider both viscosity and Stephen A. Maloney founded Colonial Seal Company in 1994. He retired as a colonel
temperature. To prevent early internal in the U.S. Marine Corps in 2008. He has a Bachelor of Science in management
component failure, the viscosity grade and technology from the U.S. Naval Academy and a Master of Science in systems
must match the operating temperature. management from the University of Southern California.
The quality of the hydraulic should not
be a factor; if it is not compatible, a
system failure could result.
If the operating temperature of a
hydraulic system is below the suggested
level for the viscosity grade, the fluids
can congeal. Solidified oil will not
flow freely through the system, which
can cause component seizures. The
solidification can cause media to lose
the ability to lubricate the hydraulic
piston and increase the coefficient of
friction undergone by the seal lip. The
increased wear and heat will cause the
seal lip to quickly deteriorate.
When switching to an eco-friendly
hydraulic fluid, be prepared for
different results from the interaction
of the seal lip material and the fluid.
Eco-friendly fluids can cause a shorter
life for a traditional nitrile seal.
Fluorocarbon is the best material
for users who go this route. Always
check with the fluid supplier before
switching. Because biodegradable fluids
have a different chemistry composition
than petroleum-based fluids, the
interaction with the seal lip materials
could be an issue.
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p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
30 COVER SERIES SMART PUMPING
Alternative Technologies
Control Complex Pumping
Processes & Systems
PLC-based PACs fill the gap between traditional distributed control
systems and basic programmable logic controllers.
BY JEFF PAYNE
AUTOMATIONDIRECT.COM
B
ecause of the complicated nature of pump
flow and pressure control, industrial plants
have often incorporated control of complex
pumping and related systems using distributed
control systems (DCSs) or expensive specialized
controllers. In the past, many programmable logic
controllers (PLCs) were not up to the task, so engineers
and designers turned to DCSs or similar controllers,
which, in some cases, can lead to higher costs and
complex implementation.
Today, new alternatives allow monitoring and control
of these complex systems with programmable automation
controllers (PACs), saving considerable expense and
simplifying implementation.
The PAC, or PLC-based PAC, fi lls the gap between the
DCS and basic PLC. It has the hardware and software
required to monitor, control and communicate with these
pumping systems (see Figure 1, page 32).
Advanced Process Control
Complex pumping systems often require advanced
process control (APC), which goes beyond proportional-
integral-derivative (PID) control and can include methods
such as model predictive control, inferential control and
sequential control.
PID is sometimes insufficient because the process that
needs to be controlled has a long dead time, is non-linear
or presents other difficulties.
Februa ry 2 0 1 6 | Pumps & S y st e m s
Various APC control methods and algorithms are
supported in DCS platforms but not in most PLCs.
PLC-based PACs, on the other hand, can execute many
APC algorithms and typically have some built-in
APC capability.
Some APC methods require complex custom coding, a
programming technique supported by DCS platforms but
not by most PLCs. The PLC-based PAC solves this problem
because it allows users to create custom code, encapsulate
it and integrate it into the overall controller program.
When APC is required, a PLC-based PAC provides many
of the capabilities of a DCS but at a lower cost and with
simpler implementation. Pushing a basic PLC to perform
APC is impossible in some cases, and even high-end
PLCs can require an extraordinary amount of effort to
implement APC.
Interfacing to Instruments
Pumping systems for applications such as custody
transfer often contain a large number of instruments
and analyzers. Typical instrument types include flow,
pressure, temperature and density. Many of these
instruments are multivariable, measuring several
parameters at once. Modern pumping systems often
employ smart instruments with a built-in, two-way
digital data link, rather than simple instruments with
a 4- to 20-milliamps (mA) output proportional to the
measured variable.

Image 1. Each of these smart Coriolis
mass flow meters provides hundreds
of parameters of information related
to measurement, diagnostics and
calibration. A PLC-based PAC is
well-suited to interface with these
instruments and to handle the large
volumes of data they produce. (Images
courtesy of AutomationDirect.com)
For example, custody transfer applications often use
mass flow meters because they can precisely measure
the amount of liquids transferred from one owner to
the next regardless of product density. Coriolis meters
measure multiple variables including flow, density and
temperature and are most commonly used to measure
mass flow.
These variables are sent to the control system along
with diagnostic, calibration and other information.
A typical Coriolis meter used in custody transfer will
transmit hundreds of parameters to the control system
over a digital data link, presenting data storage and
handling challenges.
Plants often employ analyzers to measure parameters
related to the chemical composition of oil and other liquid
hydrocarbons. Like smart instruments, analyzers are
usually connected to the control system via a two-way
digital data link and often transmit more than a hundred
parameters to the control system.
31
Complex pumping systems commonly employ smart
valves. Like smart instruments and analyzers, smart
valves communicate large amounts of data with the
control system over two-way digital data links.
A DCS will have built-in communication capabilities
for a number of the process control protocols used by
smart instruments, smart valves and analyzers. While a
PLC will have more limited communications capabilities,
a PLC-based PAC will have an extensive array of built-in
communication ports and protocols, with the ability to
expand through plug-in communication modules.
Data Handling
Smart instruments, smart valves and analyzers
produce large amounts of data (see Image 1). A DCS
can handle the storage and processing of this data, but
a PLC generally cannot. A PLC-based PAC provides the
needed data capabilities at a lower cost and with simpler
implementation than a DCS.
p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
32 COVER SERIES SMART PUMPING

Image 2. A PLC-based PAC has the capability to accommodate thousands of I/O points of many different types, a feature often required for control
and monitoring of complex pumping systems.

With integrated mass storage devices such as removable
USB drives and microSD cards, PLC-based PACs can
manage large amounts of data locally in the controller.
Custom utilities in the programming software allow
data logging on the memory device and configuration of
the trigger for rate-of-data storage. Data is stored in a
comma-separated variable fi le format, making it simple to
read and manipulate the information.
Most PLC-based PACs have the option to remove the
memory device from the controller and then download
fi les directly to a PC or laptop. Built-in Web server
functionality allows access to this data from almost
anywhere using any standard Web browser. Users just
need to type in the Internet Protocol (IP) address of
the PLC-based PAC, and with the proper connectivity
provisions and security considerations, they have instant
access to the data fi les.
It will easily support thousands of I/O points and have
the program space necessary to handle these more
complex applications.
Another benefit of a PLC-based PAC is the tag-based
control environment, which gives the flexibility to assign
data types—and by extension, memory allocation—as
FIGURE 1. PLCBASED PAC
CAPABILITIES FOR COMPLEX CONTROL
• APC
• Structure text language for complex functions
and calculations
• Sequential function charts for process control
• Integration with smart instruments, smart
analyzers and valves

Lots of I/O • Can store large amounts of data

Refineries and power plants often have thousands of • Advanced data handling
input/output (I/O) points, many of which are analog
• Can handle thousands of analog I/O points
and related to the control and monitoring of pumps and
related systems. A PLC-based PAC can handle many • Easy to integrate with higher level
I/O points, even when the majority of them are analog computing systems
(see Image 2). The available memory in a PLC-based
PAC is more comparable to a DCS than a typical PLC.

Februa ry 2 0 1 6 | Pumps & S y st e m s

34 COVER SERIES SMART PUMPING

Intelligent Pump
Control Reduces Energy
Consumption by 80 Percent
A flame retardant manufacturer incorporated frequency converters
to control its cooling water pumps.

BY MARTIN HOFFMANN
COLFAX FLUID HANDLING/ALLWEILER

G
erman company ICL-IP Bitterfeld
GmbH has been producing
phosphorus-based flame retardant
since 1997. Its plant in Bitterfeld-
Wolfen employs about 80 people. Many of the
steps in the production process—from the
phosphorus and chlorine starting materials
to the final products (phosphate ester)—
involve exothermic reactions. Much of the
released heat is led away in water-cooled heat
exchangers. A centralized cooling tower runs
almost continuously—about 8,250 hours per
year—to provide the required cooling water.
Water temperature varies seasonally from
19 to 25 degrees C. The flow rate can be as
high as 1,100 cubic meters per hour (m3/h),
resulting in a cooling capacity of up to 6
megawatts (MW).
In 2011, plant managers analyzed
the processes in the cooling tower. They
discovered that the three cooling water
pumps running in parallel ran continuously
against throttle fl aps, even under partial-load
conditions and reduced thermal loads in the
plant. It resulted in an unfavorable hydraulic Image 1. The three cooling water pumps with a capacity of 360 cubic meters per hour and
operating point and poor efficiency. maximum delivery head of 52 meters (Images courtesy of Dr. Kurt-Christian Tennstädt)

Februa ry 2 0 1 6 | Pumps & S y st e m s

 35

Thermal utilization of the cooling tower

normally fluctuates between 50 and 100
percent as a result of seasonal factors and
varied usage by individual consumers
during normal operations. Average
utilization is about 70 percent.

Energy Efficiency a Core Concern

A 2014 company-wide program to improve
energy efficiency systematically identified
additional weak points in how energy is
used. For the cooling water pumps, new
motors and speed control with frequency
converters produced significant savings.
With this foundation, Production
Manager Dr. Jürgen K. Seifert developed a
technical concept for controlling the three
pumps in a way that adapts to the cooling
water’s continually changing needs while
eliminating the inefficient method of using
throttle fl aps. Before implementation, Image 2. At the main cooling tower, the fourth pump at the far right is a reserve pump
multiple simulations indicated a high and it is not automatically included in control.
potential for savings with a projected
return on investment (ROI) of two years.
The pump control is central to the
new concept. The system utilizes three
frequency converters and includes cascade
functionality. The 75-kilowatt (kW) IE4+
synchronous reluctance motors achieve an
efficiency of 96 percent, an improvement
over previous motors (built in 1996) with
about 90 to 92 percent efficiency. They
even run efficiently under partial load. As
a result, procurement costs are amortized
in two to three years. Experience in a
previous round of optimizations showed
that converting control over the cooling Simple, Reliable
tower fans to frequency converters also
achieved significant savings. Efficient
Vapor Recovery? LPG Transfer? Natural Gas Boosting?
Frequency Converters Replace The answer is the FLSmidth® Ful-Vane™ rotary vane compressor!
Manual Intervention Built robustly for long service life, it has only three moving parts. Combined with low operating speeds
In the past, the pumps ran at a constant which minimizes wear and vibration, it is designed to not only outlast other compressors, but save you
money on power and maintenance costs.
1,450 liters per minute (l/min). They were
regulated with throttle fl aps located at • Suitable for natural gas, flare gas, bio gases, LPG vapor, and ammonia refrigeration
• Carbon fiber vanes last longer than traditional blades
the pump outlet on the discharge side. • Variable flows with VFD and/or bypass
This configuration brought the pumps • Single stage to 3000 SCFM, two-stage to 1800 SCFM
into the performance curve range where • Discharge pressures to 250 PSIG
• Made in the USA for over 80 years
the drive motors were not overloaded
(counterpressure at the consumer side is Find out more at www.flsmidth.com/compressors

only about 3.5 bar at full hydraulic load).

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p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
36 COVER SERIES SMART PUMPING
While this type of control can destroy energy, it is
usually unavoidable in situations that consist of a fi xed-
speed pump and a system with low counterpressure. In
this case, the throttle fl aps helped hold the pressure at
a constant 4.8 bar at the pump outlet, regardless of the
actual need for coolant. This achieved a constant power
consumption at the motors of 68 to 75 kW, at which
point each pump was expected to stabilize near its rated
capacity of 360 m3/h.
As an initial energy-saving measure after the analysis,
one or two pumps were switched off during partial-load
operations, such as when consumers (heat exchangers)
were turned off. But this approach is difficult because
the remaining pumps must be monitored continuously
to make sure they do not become overloaded. If loads
suddenly change, engineers must be prepared to
undertake rapid manual interventions.
Frequency converters help solve this problem by
replacing manual, inconsistent on/off control with a
continuous, intelligent adaptation of pump speeds to
the actual need for cooling water. As a result, manual
interventions are no longer needed. The pumps are
synchronized and run continuously in their optimal
range, and pump discharge pressure remains constant.
The cascade feature automatically switches pumps on and
off as requirements change on the consumer side.
CASE STUDY AT A GLANCE
Challenge
• Significantly reduce energy costs
• Convert the entire cooling system within one week
• Flexible pump speed with constant discharge
pressure to all consumers
• Elimination of valves; no change to cooling
reliability at full load, even if one pump fails
Solution
• Use frequency converters to control the pumps for
precise adaptation of capacities to current need for
coolant
• Optimization of impellers in the centrifugal pumps
Results
• Energy savings of more than 80 percent
• Several thousand euros saved after just one month
• Savings in operation of the cooling tower
• Efficiency of all pumps increased to 85.3 percent
Februa ry 2 0 1 6 | Pumps & S y st e m s
Smooth Switch
The facility completed the practical execution of the
upgrade in close contact with the pump supplier. The
manufacturer has long developed intelligent controllers
for cooling water pumps in systems where the need
for cooling water frequently changes, whether due to
fluctuating cooling water temperature or because of
varying loads imposed by the process.
Because of this experience, the manufacturer was
able to quickly provide a suitable solution for the plant.
“Only rarely have I experienced such a smooth project
execution,” Dr. Seifert said about the experience at the
plant. “They immediately understood our concept and
executed it with precision.”
The upgrade and reconditioning of the three water
pumps was completed within the facility’s one-week
production downtime window. The manufacturer even
recalculated the impellers and replaced them with the
maximum size impellers. The optimized impellers, which
are driven at the optimal speed, allow the pumps to
achieve an efficiency of 85.3 percent.
After only one month, the power costs for the cooling
tower were several thousand euros lower than before.
Because of this success, the facility has short-term plans
to convert other pumps with dynamic requirements to
this control concept.
Image 3. The numerous heat exchangers at various locations in the plant
are connected to the main cooling tower with lines of different lengths.
This places elevated demands on the intelligence of the pump controller.
A specific minimum preliminary pressure must be ensured even at the
most distant cooler and in every operating state. Pump output and speed
are displayed on the control panel.
Potential for Savings INDUSTRIES:
In many cases, energy consumption in • Chemical Process
such systems plays only a secondary • Refinery
• Oil & Gas Municipal
role and is often neglected. Even at the • Food Process Markets
Bitterfeld plant, energy costs make up a • Water/Wastewater
comparatively small proportion of overall PRODUCTS:
production costs. But the new controller • ANSI Process
• API610
reduced power requirements for cooling by • Centrifugal
50 to 60 percent, or about 1,000 megawatt- Solids-handling
Self-prime
hours (MWh) yearly. The investment paid
• Centrifugal MUD
for itself within one year, faster than • Air Operated Double
predicted by the simulations. Even when Diaphragm Pumps
all three pumps are running under full
load, energy requirements drop from 75
to 37 kW per pump. The energy required
to run the cooling tower now accounts for
a much smaller proportion of the total
energy consumption of the plant. All of
the money that is saved flows directly into
Pinnacle-Flo, Inc.
operating results .
The Bitterfeld plant demonstrates the
potential for savings that can be found in
industrial systems with oversized pumps Circle 131 on card or visit psfreeinfo.com.
that were dimensioned and installed years
ago with excess reserves . In this case,
the energy savings totaled more than 80
percent. As prices for frequency converters
drop and the technology becomes more
accessible, the use of intelligent controllers
SUPER/DR DIAPHRAGM METERING PUMP
makes more sense even for higher-output
systems. The question of "How reliable
are the electronics, and what happens
ecise Chemical Metering
if a frequency converter fails?" is less of
an issue. The technology is mature, and,
because of optimized control, two of the

~
three pumps at the Bitterfeld plant can
cover a large portion of the plant's needs if
a frequency converter were to fail. • CH£M-PRD •
~ C!l

Martin Hoffmann has a master's

degree in industrial engineering and
works as a product manager at the
Radolfzel\location of Colfax Fluid
Handling/Allweiler. He focuses
on energy efficiency and
optimization of operating
costs. He may be reached
at martin.hoffmann®
colfaxfluidhandling.com.
Circle 125 on card or visit psfreeinfo.com.

pumpsandsystems.com I February 2016

38 COVER SERIES SMART PUMPING

3 Questions to Ask Before

IoT Implementation
A well-planned systems approach to predictive analytics using
cloud connectivity can optimize pumping systems.

BY JON HILBERG
ACCUDYNE INDUSTRIES̶PRECISION FLOW SYSTEMS

T
he term the Internet of Things (IoT) has grown in
usage, both within the business world and
Collection and storage
society as a whole. But for many people, of machine sensing data
the concept is unclear. The phrase often
means different things to different people.
In simple terms, IoT is the concept
of connecting any device with an on/
off switch to the Internet and other
Assimilation
devices. Because of the declining of data
costs of sensors, connectivity and
processing power, enterprise
adoption of IoT is gaining
significant momentum.
A recent study by ABI Research Secure
Visualization cloud-based network
forecasts massive growth in
IoT adoption across industries,
with the number of business-
to-business IoT connections
rising to an estimated 5.4 billion
globally by 2020—roughly four
times what it is now. Mobile
While this vast network of Integration
Data analysis
interconnected devices is often
associated with consumer goods such
as cellphones and automobiles, the
adoption of this concept is spreading to
many industrial arenas, including pumps
and metering technologies—also known as Figure 1. A whole-product solution (Courtesy of Accudyne Industries)

the Industrial Internet of Things (IIoT).

The integrated sensor technology and network
connectivity afforded by an IIoT architecture can link

Februa ry 2 0 1 6 | Pumps & S y st e m s


individual pieces of pumping equipment, or an area-wide
group of pumps, to a cloud platform. Such connectivity
provides real-time, password-protected data access to
anyone with an Internet connection from anywhere
in the world. By collecting and migrating this data to
a Software-as-a-Service (SaaS) platform, the user can
perform real-time, historical and predictive analytics.
To deliver a fully connected pump management
system that affords real-time, predictive analytics,
developers must answer three questions about any
proposed IIoT architecture.
1. How “smart” do the pumps need to be? Industrial
plants must make informed decisions about the type
of hardware that will be required—from sensors and
controllers to protocol-agnostic intelligent gateways—
to link each pump, valve or related piece of equipment to
the Internet.
2. How will the pumps be connected to the Internet
using a cloud platform? Will this platform be developed,
owned and operated in house, or licensed from a third
party such as Google or Microsoft’s Azure cloud services?
An important consideration related to the choice of cloud
platform centers is the software that will be used to track,
analyze, interpret and report the vast quantities of data
that will be generated. Does the developer plan to package
and provide software via an SaaS offering to clients, or
will the software simply be used as a means to deliver
predictive analytics and reports?
3. How will the facility keep data secure? With so many
devices—many with multiple sensors and controllers—
streaming data into the cloud, how will developers ensure
that the information remains secure? While many cloud
platforms have robust cybersecurity measures built in,
new threats frequently arise that require additional
levels of protection. Developers must choose the level
of security that makes the most practical and economic
sense for their application. For example, does a single
pump require the same level of security as a larger, more
mission-critical systems control network?
With a common platform in place that addresses
sensing hardware, connectivity and security, the
developer can then shift to managing the assets—
individually, as a group or both. At the single pump level,
the IoT concept allows the end user to remotely monitor
pump activity by reviewing the real-time sensor data
streaming into the cloud-based software, which displays
pump readings through a dashboard interface.
39
If a sensor detects a problem with the pump—for
example, a diaphragm material that becomes too thin
or a motor that begins to draw a higher amperage—a
signal alerts the user on his or her office computer
or smartphone.
The user can then review all pump information in real
time and assess the cause of and solution to the problem.
The plant can quickly deploy personnel to the pump to
confirm the problem and make the appropriate fi x before
the pump fails completely—a predictive maintenance
solution that keeps costs and time to a minimum while
making more efficient use of personnel.
The IoT concept has led manufacturers to be unsatisfied
with selling just a single component to the end user.
Instead, they are beginning to take more ownership of
the full system by providing multiple components that
improve the operating efficiency of an entire process.
This whole-product concept may have far-reaching
positive implications for both the manufacturer and
the end user. For example, a large tractor manufacturer
several years ago began a program of using sensors to
monitor the operation of its tractors.
The company soon realized that if they were properly
configured, these same sensors could measure moisture
content in the soil. Tying that data into weather forecasts,
the manufacturer could generate reports that help
farmers decide which days of the month are best for
planting a given crop. By embracing the power of the IoT
as a true whole-product solution, the company opened
previously undiscovered business opportunities.
In the same way, the IIoT can offer new opportunities
beyond merely providing smarter pumps. It could enable
better predictive analytics and preventive maintenance
to help end users fi x pump problems before failures occur.
Also, the IIoT’s data analytics and reporting provide
pump manufacturers with more detailed information
about the operation of their systems in the field, which
could benefit product development.
If the reporting suggests common modes of failure
or design fl aws, manufacturers can proactively make
changes to eliminate these problems and deliver
better-performing pumps—often before they even hear
a complaint.
Jon Hilberg is global manager of industrial
automation and digital strategy for
Accudyne Industries—Precision Flow
Systems. He may be reached at
jon.hilberg@accudyneindustries.com.
p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
40 EFFICIENCY MATTERS

Peristaltic Pumps Offer Protection in

Mining Operations
This design overcomes the challenges of exploring and extracting valuable resources.

By Tom O’Donnell
Abaque, part of PSG

T
he challenges to creating alternative is using saline water The Big Squeeze
a successful mining that comes from the ocean or The operational characteristics of
operation—whether underground sources. Saline peristaltic pumps have remained
digging for gold, cement, coal, water, however, can mean a basically unchanged for nearly
petroleum products or salt—are high wear rate on equipment. 140 years. The pump’s operation
both daunting and numerous. • Safety: Only equipment uses alternating contraction and
Specifically, the technological certified for use in explosive relaxation of the hose, produced
challenges run a wide gamut: atmospheres and with by the turning of a rotor outfitted
potentially hazardous products with rollers, also called shoes.
• Material handling: This requires can be reliably and safely used The flexible hose has smooth
reliable and highly efficient in mining operations. walls. It is attached to the pump
equipment that needs minimal casing and as the shoes compress it,
maintenance and can operate Mine operators should consider the fluid moves through the hose.
in production areas that require positive displacement peristaltic As the hose returns to its resting
frequent blasting to free ore. (hose) pumps as a way to defeat shape following the squeeze by
• Processing: Equipment must the challenges inherent in the the shoes, it creates an almost full
deal with crushing and grinding exploration and extraction of vacuum that is able to draw the
rock, as well as the leaching and the world’s most valuable and next amount of fluid into the pump
flotation of complex or difficult- important mined commodities. casing through the inlet piping.
to-treat ores.
• Environmental issues/waste Figure 1. An example of an advanced peristaltic pump shows a seal-free design that eliminates
management: Mine operators leaks and product contamination, which enables it to handle some of the toughest pumping
applications in the mining industry. (Graphics courtesy of Abaque, part of PSG)
must have systems that will
adequately handle and remove
tailings, waste rocks and leach
piles. They must also control
acid drainage and heavy-metal
releases to prevent damage to
surrounding freshwater and
groundwater supplies.
• Water management: Operators
have been working to identify
sources of water supply during
the extraction process to
avoid competing with other
industries (such as agriculture
and manufacturing) for
this precious resource. One

Februa ry 2 0 1 6 | Pumps & S y st e m s

 41

Figure 2. The design and operation of peristaltic pumps enable them to deliver a constant
rate of fluid displacement and maintain high volumetric consistency, even after millions of
pumping cycles.
The shoes and hose are protected by a
lubricant that cools the pump casing,
eliminating any temperature spikes
that could be damaging.
The design and operation of
peristaltic pumps enable them
to deliver a constant rate of fluid
displacement and maintain high
volumetric consistency, even after
chemical compounds, susceptible • Hypalon: Strongly resistant to
millions of pumping cycles. Other
to cracks during operation or prone chemicals, temperature extremes
operational characteristics include the
to rupture when handling particle- and ultraviolet light
ability to run dry for extended periods,
laden fluids should not be used. Hose • Buna-N: Highly wear resistant to
self-prime, handle small solids and
materials that can eliminate leakage oil products
abrasives, and offer low-slip product
concerns include:
flow. Peristaltic pumps are also seal-
free, which eliminates any leak or
• Natural rubber: Ideal for use with Tom O’Donnell is director of business
cross-contamination points.
diluted acids and alcohols, with development for Abaque and PSG, a
These operational features make
excellent abrasion resistance Dover Company. He may be reached
peristaltic pumps ideal for mining
• Ethylene propylene diene monomer: at 215-699-8700 or tom.odonnell@
operations that require the transfer
Possesses a high chemical resistance psgdover.com. For more information,
of abrasive or viscous slurries and the
to concentrated acids, alcohols visit psgdover.com.
handling of fluids that contain large
and ketones
pieces of particulate matter, such as
rocks or pebbles. The pump’s simple
method of operation and ability to
remain volumetrically consistent
enable it to be used in 24/7 operating
cycles, which are common in mining ws
n Flo
operations. Most peristaltic pump
models are equipped with reversible-
ere
Inn
ov
ati
o
Pump with
operation capabilities, which provide
the versatility to pump in both
Wh Confidence
directions. ATmosphères EXplosibles
(ATEX)-certified and Conformité
Européenne (CE)-certified models
are regulated for use in potentially
explosive or hazardous atmospheres.
There have been significant
upgrades in the type of hose
materials used. These have been With more than 20 years of experience in the most
demanding applications, the new and improved
critical innovations because the hose Abaque™ Peristaltic Hose Pumps can handle your
is the only component that comes in toughest pumping needs – from abrasive and aggressive to
shear-sensitive and viscous fluids. Abaque pumps currently
contact with the pumped medium. operate in some of the most demanding environments
By choosing the proper hose including mining, water and wastewater treatment, energy,
material, mine operators can safely chemical process and OEM applications.

pump a wide range of fluids without
the threat of leaks or spills.
Next-generation hose types can
cut down on “hose fatigue” that can
result in failures. Hose materials
that are incompatible with certain
• Patented Hose Holding System improves reliability
• Stronger and lighter rotor design
295 DeKalb Pike
• Seal-less design eliminates leaks and contamination
North Wales, PA 19454
• Can run dry, self prime, and operate in forward or reverse
USA
• Flow rates to 339 gpm, and discharge pressures to 217 psi
P: +1 (215) 699-8700
For more information, please go to: psgpumps.com/ps216ab F: +1 (215) 699-0370
info@neptune1.com
Ask Us About Our Engineering Capabilities! neptune1.com

Circle 129 on card or visit psfreeinfo.com.

p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
42 MAINTENANCE MINDERS

Creative Coupling Design Saves Downtime at

Utility Plant
Some pumps were running with high vibration levels, while the disc couplings were failing
on a regular basis.

By Jim Anderson
Coupling Corporation of America

A
combined-cycle utility solutions that would eliminate the For a coupling to survive this
plant had eight feed downtime while minimizing the amount of misalignment at the
pumps in the heat recovery investment of time and capital. current distance between shaft
steam generator (HRSG), and the The operators discussed a ends, the angular misalignment
horizontal multi-stage pumps were higher misalignment coupling. In capability per hinge would have
driven by 2,500-horsepower (hp) the current layout, the distance to be at least 0.6 degrees. To allow
motors. Some pumps were running between shaft ends was 8 inches. for all other non-parallel and axial
with high vibration levels. Over a For a typical disc coupling misalignment while still providing
few years, a dozen disc couplings with an angular misalignment some extra margin for error, the
failed. The cause of the coupling capability of 0.25 or 0.3 degrees angular misalignment capability
failures was not a mystery. In each per disc pack, the total maximum per hinge would have to be closer to
train, pipe strain in the system allowable parallel offset would be 0.7 or 0.8 degrees.
was causing the pump shafts to between 0.030 and 0.035 inches. Another strategy was to increase
move significantly as the fluid Considering the misalignment the distance between the hinge
temperatures increased. numbers previously stated, one can points of the coupling by a close-
The thermal growth was see why couplings were not lasting. coupled design. Hinge points are
different on each pump. Some had
greater horizontal movement, and
some moved more vertical ly. The
pumps’ movement was tracked over
long periods of time and plotted
using Permalign equipment.
As an example, one pump had a
maximum horizontal movement
of 0.042 inches with a vertical
maximum movement of 0.015
inches, although the movement
was hardly predictable. At some
points, the pump would grow in the
positive vertical direction, and at
other times, it moved lower than
the starting position.
While correcting the pipe strain
would be ideal, it was not feasible
because of the time and expense.
As a result, the plant operators Figure 1. A typical flexible spacer coupling layout (Graphics courtesy of Coupling Corporation
looked at potential alternative of America)

Februa ry 2 0 1 6 | Pumps & S y st e m s


Figure 2. A typical close-coupled flexible coupling layout
defined as the imaginary plane about
which a flexible element (disc pack or
diaphragm pack) bends to accept an
angular misalignment. Normally this
style of coupling would be used when
the shafts of the driving and driven
machines are positioned very close
together. Figure 1 shows a “spacer”
coupling layout, while Figure 2 shows
a typical close-coupled layout.
In many close-coupled designs,
the flexible elements of the coupling
are positioned on the back of the
hub—closer to the machine housing
and further away from the end of the
shaft. This style can be synonymous
with reduced-moment couplings
as well. The result is an increase
in the effective distance between
hinge points of the coupling by
approximately the combined length
of the two shafts, whereas a normal
spacer coupling layout has a distance
between hinge points slightly
shorter than the distance between
shaft ends.
In this particular case, a close-
coupled design seemed like a good fit
because both shafts were more than
5 inches long, which, combined with
the 8 inches between shaft ends,
would give enough space to allow for
a distance between hinge points of
Figure 3. A combination of spacer and close-coupled
coupling halves
at least 18 inches. At that distance, a
coupling with 0.3 degrees of angular
misalignment capability would
probably work, although 0.4 degrees
would give a larger safety margin.
This strategy seemed like a good
option until one other detail was
discovered: an obstruction on the
pump side that would not allow
the larger diameter of the flexible
element to be installed.
Finally, a combination of a spacer
and a close-coupled coupling could
work. Because of the diameter
restriction, a normal hub could be
used, bolted to a spacer center section
with a flexible element. On the motor
side, without diameter restriction,
a close-coupled style coupling could
increase the distance between hinge
points (see Figure 3).
With the dimensions of the
shafts, this “hybrid” coupling layout
could provide about 13 or 14 inches
between the coupling’s hinge points.
With that much distance, a coupling
with 0.3 degrees of misalignment
could not provide enough extra
misalignment margin to run safely.
So a higher misalignment coupling
would still be needed to meet the
needs of the large thermal growth.
The final solution came in the form
p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
43
of a high-misalignment coupling
with 0.5 degrees of misalignment per
hinge. With that amount of flexibility,
the coupling can handle about 0.115
inches of parallel offset, which is
enough to have a large safety margin
on the misalignment.
The plant decided to try one
coupling using this style. It was
installed on one of the more
problematic units. After installation,
the vibration issues on that unit
were reduced to normal level. The
only remaining question was how
long the coupling could last running
at those high misalignments. The
first installation was about five years
ago, and the coupling is still running
successfully.
Since the original installation, the
plant has upgraded the remaining
units with the same new coupling,
and the results have been similar.
Jim Anderson is vice president of
Coupling Corporation of America,
which designs and
manufactures high-
performance and high-
misalignment couplings.
For more information,
visit couplingcorp.com.
44 SEALING SENSE
What to Consider When Upgrading or Changing
Pre-Specified Gaskets
An important first step in the process is asking the question “Why do I need or want to
change my gaskets?”
By Mike Shorts
FSA Member & President
U
sers at some point in
their gasketing careers
will have to consider
alternative gaskets (styles and/or
manufacturers) to replace those
currently approved and installed at
their facilities.
Before they can evaluate the
gaskets, they must ask, “Why
do I need or want to change
my gaskets?” The answers will
vary depending on the person,
department, facility and corporate
environment:
• The application has changed,
and the existing gaskets
no longer work or are not
working as well.
• The department or company
is looking to save on its
short-term or long-term
gasket spend.
• The service from the gasket
supplier has changed, and
a new supplier is being
considered to better fit the
service and support needs.
• The application remains the
same, but gaskets seem to
have started to fail sooner
than the historical average.
• Someone is looking for longer
service life to improve the
return on investment (ROI).
• Environmental regulations
impose new or different
requirements.
Februa ry 2 0 1 6 | Pumps & S y st e m s
One individual’s specific “why” past has limited the type of gasket
may be different from another’s to be used due to allowable load.
within the same company, even Because products are made on
if they have access to the same different equipment using different
information. But only once the recipes, installation parameters
“why” has been established can the can vary enough to require more or
“what” to change be considered. less minimum loading in order to
One of the first places to start is establish a leak-free seal. Changing
to cross-reference existing gasket the gasket may make sense,
specifications for equivalency but additional training might
with the replacement candidates. be required to ensure that new
Compare published typical physical installations are safe.
properties information from the Next, determine if any
manufacturers. Sometimes this application changes have occurred
comparison can be confusing, within the system. Perhaps some
because manufacturers do not new equipment was installed
always publish all of the detailed that has boosted line pressure or
information that may be needed for insulating jackets have cooled or
analysis. A quick cross-reference increased the media temperature.
can be done by comparing the These changes often are not
American Society for Testing and amended to the master process
Materials (ASTM) F104 line callout flow chart and are left as a subset
numbers associated with each of the original fi le, making them
material (see Figure 1).
Most manufacturers
Figure 1. An example of an ASTM F104 callout number
publish for each of their (Courtesy of FSA)
products a complete F104
callout number that uses
a specified format for easy
comparison of data.
Additional gasket
parameters, such as
gasket factors, may
exhibit enough difference
to require changes to
installation procedures.
Perhaps a fl ange stress
design restriction in the
 45

easy to overlook. Changes in pressure or temperature

can affect gasket performance requirements while still
fitting into existing pipe and fl ange design parameters.
A new gasket, though similar on a technical level, may
look or feel different than the gasket currently being
used. These differences can make some stakeholders
uncomfortable. Training may be required to educate
people on the changes, including why they are necessary
and what to expect with the new product.
To upgrade gaskets, the full operating parameters
of the application or system with original design data
should be compared to the current or new design data.
The Fluid Sealing Association (FSA) has developed a
Gasketed Joint Questionnaire for standard and non-
standard fl anges as a starting point for collecting
information. Without complete and accurate data,
making a change could increase the risk of an accident.
Fully assess the parameter(s) necessitating the
upgrade: improved service life, temperature/pressure
changes, a process fluid change, or a change to operating
conditions. The next step is to narrow down new
available material options.
Review the potential gaskets by their published Circle 135 on card or visit psfreeinfo.com.
data to ensure they meet the current or new design
requirements. It is recommended to review the pressure-
temperature graphs for operating safe zones if either
of these conditions has changed over time. Published
data only breaches the surface of the physical and
performance data available. Work with applications
engineers from the manufacturers of the material on the
short list to be able to determine more definitively the
suitability of the product to the application conditions.
Inevitably, someone will need or want to change
from one gasket type/style to another. Determining
why the change is needed is necessary to properly make
the selection of new materials. Once the individual is
satisfied with the reason for making the change, then it
is important to determine what to change.
The analytical criteria previously provided are meant
to be a starting point for a simple cross-reference or
a complete upgrade. As always, it is recommended to
consult the gasket supplier or manufacturer.
Without the “why,” the “what” may not matter.

Next Month: Best practices for safety and reliability

in emission service

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.
Circle 136 on card or visit psfreeinfo.com.

p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
46 HI PUMP FAQS

Submersible Vertical Turbine Pump Intake Designs,

Common AC Single-Phase Motors
By Hydraulic Institute

What intake design • the orientation of the structure What types of alternating
considerations are relative to the body of supply current (AC) single-
important for submersible liquid phase motors are used
vertical turbine pumps? • whether the structure is in centrifugal pumping
recessed from, flush with applications, and
Submersible vertical turbine or protrudes beyond the what are some typical
pumps can be installed in a wet boundaries of the body of applications?
pit or closed bottom can as shown supply liquid
in Figure G.1. Well motor types • strength of currents in the body Many types of single-phase
are recommended for both wet-pit of supply liquid perpendicular motors are used throughout the
type and closed-bottom can type to the direction of approach to commercial and industrial world.
of below-grade suction intakes in a the pumps Listed below are a few types of
rotodynamic pump. • the number of pumps required single-phase AC motors used in cer-
A submersible well-type motor and their anticipated operating tain pumping applications:
normally requires a minimum flow combinations Split-phase: A split-phase motor
of liquid around the immersed is a single-phase induction motor
motor to provide adequate motor For more information on equipped with a main winding and
cooling. For many applications, the design criteria for various an auxiliary starting winding. This
a shroud is required to ensure pump intakes, refer to ANSI/HI type of motor has a switch that
proper cooling flow around the 9.8 Rotodynamic Pumps for Pump deactivates the starting winding
motor. Sizing of the cooling Intake Design. as the motor comes up to speed.
shroud for internal flow velocities
must be referred to the pump
manufacturer. The top of the
shroud must include a cover to
restrict downward flow of liquid to
the pump inlet while allowing for
venting air from the shroud. The
confined flow pathway provided by
the motor cooling shroud is very
desirable in developing a uniform
flow to the first-stage impeller.
The characteristics of the flow
approaching an intake structure
are among the most critical
considerations for the designer.
When determining direction and
distribution of flow at the entrance
to a pump intake structure, the
Figure G.1. Submersible vertical turbine pump (Courtesy of Hydraulic Institute)
following must be considered:

Februa ry 2 0 1 6 | Pumps & S y st e m s

 47

Split-phase motors are used in spa, jetted tub

and aboveground pool pump applications. The
motors are usually rated from 1/6 horsepower
(hp) through 1.5 hp.
Capacitor-start: A capacitor-start motor is a
single-phase induction motor equipped with
a main winding and an auxiliary starting
winding with a series capacitor. Th is type
of motor has a switch that deactivates the
starting winding and capacitor as the motor
comes up to speed. They are usually rated from
1/6 to 7.5 hp. Capacitor-start motors are the
most common type of single-phase motors
found on in-ground pool, irrigation and
dewatering pump applications.
Permanent-split capacitor: A
permanent-split capacitor motor is a single-
phase induction motor equipped with a
main and an auxiliary starting winding
with a series capacitor. The motor does not
have a switch and both the main and
starting windings are always energized. The
motors are typically rated from 1/2 to 15 hp Circle 138 on card or visit psfreeinfo.com.
and are commonly found in dewatering and
irrigation applications.
Capacitor-start, capacitor-run: A capacitor-
start, capacitor-run motor is a single-phase
induction motor equipped with a main and an
auxiliary winding with a series run capacitor. U N M AT C H A B L E E X P E R I E N C E
Both windings and the run capacitor are I N F L OW C O N T RO L
permanently energized. In addition, this TRANSACTIONS
motor has a second capacitor called a start
capacitor that is deactivated by a switch as the
motor comes up to speed. This type of motor Jordan, Knauff & Company is a knowledgeable and
experienced provider of a comprehensive line of
is also called a two-value capacitor motor. The investment banking services to the pump, valve and
motors are usually rated between 1.5 and 15

hp and are commonly found in dewatering and
irrigation applications.
For more information on centrifugal pumps,
refer to ANSI/HI 1.3 Rotodynamic Centrifugal
Pumps for Design and Application.
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

HI Pump FAQs® is produced by the Hydraulic Institute +'SSO.SVHER.V (EZMH%/EOEVIOE

as a service to pump users, contractors, distributors, reps Managing Principal Senior Associate
GN$NSVHEROREYJJGSQ HOEOEVIOE$NSVHEROREYJJGSQ
and OEMs. For more information, visit pumps.org.  

MEMBER FINRA, SIPC

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p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
48 PRACTICE & OPERATIONS

Pumping System Diverts 5.9 Billion Gallons of

Water for Kalamazoo River Remediation
The project was finished ahead of schedule and $4 million under budget.

By Duane Hargis, Cornell Pump Company

& Rich Goethals, BakerCorp

F
or decades, paper mills
along a section of the
Kalamazoo River had
dumped polychlorinated biphenyls
(PCBs) into the waterway. The river
flow then took the contamination
far downstream from the original
source, making a large swath of
southwest Michigan subject to
contamination.
PCBs are linked to an increased
cancer risk, compromised immune
systems in people and animals,
and impaired memory/cognition.
PCB exposure can occur when
people come into direct contact
with contaminated soil or water or
eat fish from an affected waterway.
While the use of PCBs stopped in
the late 1970s, the contamination
has remained in the river bed and
surrounding area.
The federal Environmental
Protection Agency (EPA), in
conjunction with the Michigan
Department of Environmental
Quality, declared an 80-mile
stretch of the Kalamazoo River
as part of a superfund site in
1990. Superfund sites are polluted
locations requiring a long-term
response to clean up hazardous
material contaminations.
The Comprehensive
Environmental Response,
Compensation, and Liability
Act of 1980 (CERCLA) is a
federal law designed to clean
up sites contaminated with
hazardous substances as well as
broadly defined “pollutants or
contaminants,” and it gives the EPA
the authority to clean up locations
such as the Kalamazoo River.
As part of that Kalamazoo River
superfund site cleanup, a two-
and-a-half mile stretch of Portage
Creek, in the Edison neighborhood
of Kalamazoo, required
remediation for PCBs. During
this process, more than 19,000
cubic yards of PCB-contaminated
soil and sediment were removed.
To facilitate the cleanup, Portage
Creek was dammed and diverted
in sections. The sections furthest
upstream were treated first so
the contamination could move
downstream, allowing areas
cleaned above the existing
contamination to remain clean.
The Approach
To provide access to the creek
bed and surrounding area, the
creek was diverted in seven

Image 1. An aerial view of the Portage Creek project shows

pumps with sound-attenuated enclosures. (Courtesy of
Cornell Pump Company)

Februa ry 2 0 1 6 | Pumps & S y st e m s


segments over two years. Work
was completed from late March
through mid-October, when risk of
freezing was reduced. The project
also dealt with various flow rates,
depending on rainwater runoff.
During the working season, the
pump distributor abated sound
in the neighborhood while still
operating the pumps 24 hours a
day to divert flow and avoid backfi ll
flooding. Sufficient pump capacity
to deal with a strong rain event and
uneven flows was necessary.
The project used three 16-inch
discharge pumps with 18-inch
suction, 16-inch discharge, the
ability to handle a 4.5-inch solid,
flow rates up to 17,800 gallons per
minute (gpm), heads up to 240 feet,
and efficiency up to 85 percent.
These pumps were combined with
one 12-inch discharge pump with a
14-inch suction, 12-inch discharge,
the ability to handle a 3-inch solid,
flow rates up to 9,000 gpm, heads
up to 200 feet, and efficiency up to
84 percent.
The distributor also used several
on-call 4- and 6-inch discharge
pumps to dewater Portage Creek.
The system bypassed the flow from
upstream around the work site
and back into the creek below the
ongoing mitigation. The pumps
were able to handle significant solid
sizes because of the unpredictable
nature of items that could be found
in the creek and the amount of
potential plugging solids in the
creek bed. The pumps were driven
off diesel engines and housed in
sound-attenuated packages.
The Process
The remediation portion of the
project began in July 2012.
Working through the summer,
contractors used the pumps
to tackle three sections of
remediation. Pumps were sized to
handle flow rates up to 9,600 gpm.
The four larger pumps dealt with
the main flow, while the smaller
pumps were used as backups and
occasionally addressed areas of
high groundwater seepage.
Spring and summer 2013 were
extraordinarily wet in southwest
Michigan. While the project had
originally been sized for 9,600
gpm, rain flow was pushing
flows to more than 11,300 gpm.
Given the robust nature of 16-
and 12-inch pumps on-site, the
distributor was able to handle the
increased flow without resorting to
additional equipment.
The Outcome
The remediation project was
completed in September 2013
ahead of schedule and more than
$4 million under budget. The
use of pumps with great uptime
reliability, durability, efficiency
and variable flow rate contributed
to those time and cost savings.
The distributor’s know-how in
managing noise levels—with the
need for continuous operation
and on-call backup for large water
events—also contributed to the
project’s success.
Overall, more than 19,000 cubic
yards of soil and sediment were
removed through the project.
It is estimated that more than
5.9 billion gallons of water were
bypassed during the effort—
enough to fi ll nearly 9,000
Olympic-size swimming pools.
The mitigation also opened
up an area in Kalamazoo that
had previously been unused
by residents because of fear of
contamination. The Kalamazoo
Nature Center’s (KNC) Urban
Nature Park borders the mitigation
site. Dr. Bill Rose, president and
CEO of KNC, headed up efforts
to replant the Urban Nature Park
p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
49
with native plants, shrubs and
trees. Plantings were selected to
be suitable for local soils and to
provide optimal habitat for native
bird and butterfly species. A trail
was cut, connecting the Urban
Nature Park to the Kalamazoo
River Valley Trail, affording
walkers, runners and cyclists access
to miles of recreational activities.
“The bypass project is a real win
for Kalamazoo and our community
as a whole,” Dr. Rose said. “What
once had been a blighted, highly
contaminated industrial site is now
an urban oasis where residents
and visitors can have an easy
encounter with nature. The Urban
Nature Park is now a vibrant and
revitalized part of our city. We
hope it will serve as model for
future projects in urban areas
across the nation.”
The senior branch sales
representative for the contractor
in charge of the project
commented, “The durability and
reliability of the pumps met
or exceeded our expectations
throughout the project.”
The Portage Creek project
was a success. The EPA was able
to use the money saved and
available contractor hours to begin
remediation on other sections of
the superfund site.
Duane Hargis is the Northeast
regional manager for Cornell Pump
Company, a manufacturer of
centrifugal pumps for industrial,
agricultural, mining, oil, gas and
municipal uses. He can be reached
at dhargis@cornellpump.com or
503-653-0330. Rich Goethals
is a senior sales representative
at BakerCorp, a provider of tank,
pump, filtration and shoring
equipment rental solutions. He
may be reached at 708-362-2214
or rgoethals@bakercorp.com.
50 MOTORS & DRIVES
Obtain Maximum Bearing Life & Performance
Achieve pump and motor longevity by providing proper storage, avoiding pre-service damage,
and conducting sound handling and maintenance procedures.
By Mike Pulley
Bartlett Bearing Company
A
small percentage of
bearings achieve their
application design life, and
in pump and motor applications,
bearings are the most susceptible
components to premature failure.
The cost of a failed pump or motor
add up quickly, but end users can
take several precautions that help
maximize bearing life.
In most cases, the cost of the
equipment repair is less than 8
percent of the overall expense of
the failure—while downtime costs
usually account for an estimated
90 percent.
Pump users frequently ask
how long certain bearings should
last. The answer depends on the
amount of information that can be
provided at the time the question
is posed. Life calculations can be
run based on furnished application
data, but it is difficult to accurately
predict bearing fatigue.
Bearing life is commonly
measured using an L10 or L10h
calculation, which is a statistical
variation of individual bearing life
that is most often communicated
as life in hours or revolutions.
A bearing’s L10 life, loosely
interpreted from International
Standards Organization (ISO) and
American Bearing Manufacturers
Association (ABMA) standards, is
based on the lifespan of 90 percent
of a group of identical bearings in
a given application. In a nutshell,
Februa ry 2 0 1 6 | Pumps & S y st e m s
it is a calculation of how long 90 typically packaged at the factory
percent of the bearings will last in with a Ferrocote or a thin coat
that given application. of preservative oil. Handling
What makes this equation the bearings with bare hands or
impractical for determining wiping off the preservative can
definite bearing life is that it is reduce corrosion-resistance. If a
based on the load capacity of thin coat of preservative or oil is
the selected bearing, the actual not re-applied, damage can occur.
application loads, the bearing type Bearings should be kept in an area
(ball or roller) and the rotational free from vibration to avoid false
speed (in revolutions per minute brinelling, which is a phenomenon
[rpm]) of the application. The L10 characterized by localized material
life calculation does not consider wear or damage that occurs as
temperature, lubrication and a result of frictional vibrating
other key factors related to pre- contact between surfaces.
service damage that are crucial to Proper mounting is essential to
achieving the designed application bearing life. The correct mounting
bearing life. Proper storage, methods may include induction
treatment, handling, installation heaters, presses or bearing
and maintenance are simply mounting impact tool kits.
assumed. Predicting bearing
fatigue without consideration of Figure 1. The graphic shows an example of a
these variables is problematic. As bearing being heated through induction heating.
(Graphics courtesy of the author)
a result, an estimated 10 percent
of bearings meet or exceed their
calculated fatigue life.
Limit Pre-Service Damage
Proper storage and handling
can limit pre-service damage to
bearings. Standard bearings are
predominantly produced from
52100 steel, a highly refined
steel material that can be prone
to oxidation. If end users do
not handle bearings like they
do other precision equipment,
the longevity of the bearing can
be compromised. Bearings are
 51

Using the appropriate shaft and
housing seat diameters is crucial
to optimal life and performance.
Common ball and roller bearing
applications with a rotating shaft/
rotating inner ring should have an
interference shaft fit. In most cases,
standard ball and roller bearings
have a radial internal clearance built
into the bearing. The clearance will
be reduced during installation onto
the bearing journal to accommodate
the interference shaft fit and prevent
negative clearance (pre-load). The
slightest oversized or undersized
shaft can shorten bearing life by
more than half. The same is true
for housing fits. End users should
consider referencing shaft and
housing fit charts for ball and
cylindrical roller bearings used
in general and electromechanical
repair applications.
The basic shaft and housing fits on
these charts are accurate for general
lubrication, incorrect viscosity and
contamination. Lubrication separates
contact surfaces, reduces friction and
protects against corrosion. Proper
lubrication can also seal equipment
from the ingress of contaminants
and, in the case of circulating oil,
offer heat displacement.
Many pump applications use
oil for the superior lubricating
properties needed for high speeds.
Oil lubrication serves as a fi lter and
has additional advantages in terms of
the life of the lubricant. One negative
of using oil is that it can be difficult
to effectively and easily seal. Th is
is where sealing grease is generally
used because it is less burdensome.
Grease Compatibility
= Compatible = Not Compatible
There are two options for using grease
with bearings. One option is to use
an enclosed (sealed or shielded)
bearing that is pre-fi lled with the
appropriate amount of grease by the
manufacturer. Users may also choose
an open bearing that will require
replenishment. The overwhelming
majority of enclosed pre-fi lled
bearings are ball bearings as opposed
to roller bearings because grease life
is longer with ball bearings.
Because sealed-for-life bearings are
only sealed for the life of the grease,
one might think that an open bearing,
in an application where grease can
be replenished, would survive much
longer. That is not always the case.
xy

xy
lex

applications and based on standard ro

ro
lex

lex
mp

yd

yd
Annular Bearing Engineering mp

mp
Co

-H

-H
o

Co
12

12
m

Committee (ABEC) precision grade,

C
inu

um

um

um

m
m

hiu

hiu

hiu
normal operating temperatures

diu
r iu
um

lci

lci

lci

ea
ay
Lit

Lit

Lit

Ur
Ba

Ca

Ca

Ca

So
Al

Cl

and normal loads. However, for

special applications that may include Aluminum Complex
high-speed, high-heat, outer ring
Barium
rotation or any non-standard design,
check with the original equipment Calcium
manufacturer (OEM) to obtain their
fitting practices. The OEM designed Calcium 12-Hydroxy
the unit, so taking time to research
Calcium Complex
these specs is important.
Proper storage, handling and Clay
installation can eliminate the cause
of about 30-35 percent of failed Lithium
bearings, and appropriate preventive
maintenance can drastically extend Lithium 12-Hydroxy
equipment life.
Lithium Complex

Apply Correct Lubrication Urea

Lubrication issues account for up to
half of all failed bearings. Failures
may result from insufficient or
excessive lubrication, improper
lubrication methods, incompatible
Sodium
Table 1. Adding incompatible greases can result in a rapid reduction of the
grease life, which translates to accelerated bearing failure.

p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
52 MOTORS & DRIVES
Proper upkeep requires the correct
re-lube intervals, the correct
amount of grease, a compatible
grease and protection against
foreign contaminants.
Some manufacturers may
provide re-greasing interval
charts, which are usually based on
the bearing bore size, operating
speed and bearing type.
A general way to determine how
much grease to replenish is to
multiply the outside diameter of
the bearing in millimeters by the
bearing width in millimeters,
then multiply by 0.005. This will
give you the re-lubrication amount
expressed in grams.
Most of these re-greasing
graphs or charts are based on an
operating temperature of 160
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Attention Pumps & Systems Readers:
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Februa ry 2 0 1 6 | Pumps & S y st e m s
degrees F or below. Depending
on the bearing manufacturer,
suggested re-lube intervals should
be reduced by half for every 25-27
degrees F above an operating
temperature of 160 F.
Additionally, a further reduction
in re-greasing intervals may
be warranted in potentially
contaminated applications
and in vertical applications. If
re-lubrication detail is not known,
it is best to first check with the
pump or motor manufacturer.
If they cannot provide a
recommendation, contact the
bearing distributor or OEM.
When adding lubrication, first
determine what grease is in the
equipment, and make sure to add a
compatible grease. All greases are
made of three main components:
a base oil that can be synthetic
or organic, a base thickener, and
any additives used for desired
enhancements. Pay close attention
to the base thickener. Many types
of thickeners are used, including
calcium, clay, sodium, aluminum
complex, lithium and urea
compound (polyurea).
Mike Pulley has 20 years
of experience in the bearing
industry. Most of his career
has been spent on the OEM
side of the business until moving
to distribution in 2014. He is part
of the Product Management Group
at Bartlett Bearing Company.
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 132 on card or visit psfreeinfo.com.

Notable pump technology products selected by the Pumps & Systems editors:
Variable Speed Drive
Borets has introduced its
AXIOM II variable speed drive,
calling it the first universal
VSD suited for operating
electric submersible pump (ESP)
induction motors, permanent
magnet motors and high-speed
PMMs. The AXIOM II provides
electrical efficiency and power
factor performance through a
range of drive loading, especially
when coupled with the Borets
high-efficiency PMM. The entire system is on average 15
to 20 percent more electrically efficient than a typical ESP
system dependent on the loading of the motor.
Circle 201 on card or visit psfreeinfo.com.
Screw Pumps
Blackmer has announced the
global launch of its S Series
screw pumps after appearing
in the North American
market last July. Available
with or without external
timing gears and bearings,
Blackmer S Series pumps are
self-priming double-ended
positive displacement pumps
that are ATEX-certified for use in explosive or dangerous
environments. Blackmer’s twin and triple screw designs
provide complete axial balancing of the rotating screws,
and their timing technologies eliminate metal-to-metal
contact with the pump.
Circle 202 on card or visit psfreeinfo.com.
Control Panels
Val-Matic is
offering control
panels that
provide efficient,
reliable and
low-maintenance
service to
butterfly, plug and
ball valves that have cylinder actuators. The hydraulic
control panel permits changes to the valve operating
times in order for the valves’ surge characteristics to be
the same as the piping system. Additionally, the electric
control panel connects with the hydraulic control panel
and pump motor controls to allow for remote monitoring
of valve operation and alarm conditions.
Circle 203 on card or visit psfreeinfo.com.
To have a product considered for our Products page, please send the information to Martin Reed, mreed@cahabamedia.com.
PRODUCTS 53
Pump Control
See Water Inc. is offering
the OSS-100 plug-and-play
system that pumps water,
not oil, from elevator pits,
transformer oil containment
areas and underground vaults.
The Oil Smart OSS-100 System,
when combined with a manual
sump pump, will automatically
pump water without the risk
of pumping oil into the environment. The system alerts
maintenance or building personnel in the event of a high
oil or high water condition. The OSS-100 will control any
pump up to 1 horsepower. It includes dry contacts for
building maintenance.
Circle 204 on card or visit psfreeinfo.com.
Programmable Relay
IDEC Corporation has
released its FL1F SmartRelay,
an upgrade to its FL1E
model. The FL1F SmartRelay
addresses market demand for
a programmable relay with
many of the features found
in micro programmable
logic controllers, and it can
accommodate small- to medium-sized original equipment
manufacturer machine control and other applications.
Maximum configurations are 24 discrete inputs, 20
discrete outputs, eight analog inputs and eight analog
outputs. The FL1F SmartRelay has an improved LCD
operator interface.
Circle 205 on card or visit psfreeinfo.com.
Metering Pumps
Wanner Engineering
Inc. has released its new
Model P200 Hydra-Cell
Metering Solutions pumps
that feature new gearbox
reducers with ratios from
60:1 to 5:1. They are
designed for a wide range of
processing applications and
for use in manufacturing facilities. Model P200 pumps
feature a multiple-diaphragm design that minimizes
pulsations, producing smooth, linear flow without the
need for expensive pulsation dampeners. Hydra-Cell
Metering Solutions pumps have a sealless design, and
they can run dry without damage to the pump.
Circle 206 on card or visit psfreeinfo.com.
p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
54 PRODUCTS
Circle 146 on card or visit psfreeinfo.com. Circle 150 on card or visit psfreeinfo.com.

GO WITH THE PROS!! LOBEPRO ROTARY PUMPS Stainless Steel

Cyclone Separator
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To learn more or get a custom quote, email PumpSales@lobepro.com
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AE Pumps ........................................ 54 140 Pinnacle-Flo, Inc. ............................37 131
AIGI Environmental Inc. ............... 13 111 ProPump Services .......................... 45 135
Alignment Supplies, Inc. ................29 123 PSG, a Dover company ....................41 129
AutomationDirect.com .................IFC 100 PumpWorks Industrial....................17 151
BJM Pumps, LLC ............................ 33 124 RuhRPumpen ....................................3 103
Blue-White Industries ....................37 125 Ruthman Companies ........................7 104
Cornell Pump Company ..................11 109 Salem-Republic ................................21 121
Dan Bolen & Associates, LLC .........55 141 See Water Inc. ..................................16 115
FLSmidth Inc. ................................. 35 126 Sims Pump Co. .................................17 120
Frost & Sullivan ...............................52 132 Summit Pump, Inc.......................... 28 130
Graphite Metallizing Corp. ............47 138 TF Seals ............................................14 119
Greyline Instruments Inc. ..............19 113 Titan Flow Control, Inc. ................. 45 136
Grundfos. ...........................................1 101 Titan Manufacturing, Inc...............55 145
Hatz Diesel of America, Inc. .............5 102 Topog-E Gasket............................... 54 146
Hydraulic Institute..........................52 133 Tuf-Lok International .................... 54 147
Industrial Pump & Balance ........... 54 142 Vaughan .........................................IBC 107 Circle 140 on card or visit psfreeinfo.com.
Jordan, Knauff & Company............47 134 Vertiflo Pump Company .................55 148
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Februa ry 2 0 1 6 | Pumps & S y st e m s

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p u mp s a n d s y s te m s . co m | Fe b ru ary 2016
56 PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch
By Jordan, Knauff & Company
T he Jordan, Knauff &
Company (JKC) Valve Stock
Index was down 24.4 percent
over the last 12 months, while the
broader S&P 500 Index was down
0.7 percent. The JKC Pump Stock
Index also decreased 20.8 percent
for the same time period.1
For the second month in a
row the Institute for Supply
Management’s Purchasing
Managers’ Index (PMI) remained
in contraction territory. The
composite index fell to 48.2
percent from 48.6 percent
in December. New orders
and production were both up
slightly for the month but still
at contraction levels. Exports
increased 3.5 percent to 51 percent
for the month, showing expansion
for the first time since April. The
index for prices declined again and
has remained below 50 percent for
14 consecutive months.
Driven by easy credit, cheap
gas and pent-up demand, U.S. car
sales posted a record high in 2015.
Approximately 17.5 million cars
and trucks were sold last year,
compared with the previous high
of 17.3 million in 2000. Sales of
light trucks and SUVs increased 13
percent, while sales of passenger
cars decreased 2 percent compared
with 2014. Ford Motor Company
and General Motors both reported
Figure 2. U.S. energy consumption and rig counts
Source: U.S. Energy Information Administration
and Baker Hughes Inc.
Februa ry 2 0 1 6 | Pumps & S y st e m s
Figure 1. Stock indices from Jan. 1, 2015, to Dec. 31, 2015
5 percent sales gains, while
Fiat Chrysler Automobiles
reported U.S. sales increases
of 7 percent.
Global inventories for oil
and other liquids increased
in each quarter of 2015,
resulting in a net inventory
build of 1.72 million barrels
per day for the year, the
highest rate since 1996. Led
by production growth in Iraq,
total OPEC crude oil and other
liquids production increased 3
percent to 37.4 million barrels
per day in 2015, according to
the U.S. Energy Information
Administration. This sustained
excess supply over global demand
resulted in lower crude oil prices at
the end of the year with the price
falling below $40 per barrel, the
lowest price since early 2009.
The spot price for Brent
international crude oil averaged
$52 per barrel in 2015, 53 percent
below its level in 2014 and 49
percent below the average price
over the 2010 to 2014 time period.
Spot prices for domestic West
Texas Intermediate crude averaged
$49 per barrel in 2015, also down
53 percent compared with 2014.
U.S. production began to decline in
the second quarter of 2015 because
of lower crude oil prices. Despite
this decline, overall U.S. crude oil
Figure 3. U.S. PMI and manufacturing shipments
Source: Institute for Supply Management Manufacturing
Report on Business® and U.S. Census Bureau
Source: Capital IQ and JKC research. Local currency converted to USD
using historical spot rates. The JKC Pump and Valve Stock Indices include
a select list of publicly traded companies involved in the pump and valve
industries weighted by market capitalization.
production increased 7 percent
in 2015 over 2014, reaching the Reference
1. The S&P Return
highest level since 1972.
figures are provided
On Wall Street, the Dow by Capital IQ.
Jones Industrial Average was
down 0.3 percent, the S&P 500
Index decreased 0.3 percent,
and the NASDAQ Composite Jordan, Knauff
& Company is an
fell 0.6 percent for the month
investment bank
of December. For the full year, based in Chicago,
the NASDAQ gained 5.9 percent, Illinois, that
while the Dow and S&P 500 provides merger and
declined 2.3 percent and 0.7 acquisition advisory
services to the
percent, respectively. Concerns pump, valve and
over slowing growth in China filtration industries.
and falling oil prices negatively Please visit
impacted investor sentiment. jordanknauff.com for
more information.
Consumer spending was strong
Jordan, Knauff &
during the year, making the Company is a member
consumer discretionary sector the of FINRA.
largest gainer for the year, which,
along with limited exposure to
the energy sector, benefitted the
These materials were
NASDAQ. prepared for informational
purposes from sources that
are believed to be reliable
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
any investment offering or
deployment of capital.
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