J U N E 2 0 19

SYSTEMS
PUMPSANDSYSTEMS.COM

The Leading Resource for Pump Users Worldwide

BASICS of
Motors
& Drives
• Variable speed compressors
• Mitigating bearing currents
• Replacing large motors

USE YOUR SENSES FOR

HEALTHY EQUIPMENT

JIM ELSEY:
SOLVING PUMP MYSTERIES

ALIGNMENT VS.
BALANCING
Thanks
for 50 years.

Independent. Experienced. Trusted.

Here’s to another 50 years of uptime.

Hydro's story began in a Chicago neighborhood in 1969. From the beginning, our vision was to be a full service pump
house supporting customers with new pumps, replacement parts and a broad range of repair, field service and
advanced engineering services. We began with a passion for improvement, and a commitment to our customers.

Today, with dedicated aftermarket pump service centers across the globe, Hydro maintains this vision and
continues to build a comprehensive knowledge base in applying, rebuilding, and improving pumps for better
performance and longer life.

Our passion for improvement and commitment to our customers is as strong today as it was in 1969.

Thank you for being part of Hydro's story.

 "Over the past 50 years, we have been very fortunate to have the support
of our customers, colleagues, and business partners whose talents,
counsel, and passion for the pump industry have supported our
accomplishments and continue to fuel our growth."

– George Harris, President and CEO

WORLDWIDE PUMP SERVICES

24/7 Emergency Services

Engineered Pump Repairs
Certified Performance Testing
Wireless Condition Monitoring
Engineering Services
Critical Parts Solutions
Customer Training
State-of-the-Art Technology
In-depth Knowledge of Major Brands
Field Service Support for Installation & Start-up

Watch Video
Circle 101 on card.

Worldwide Service Centers l 800.223.7867 l hydroinc.com/50

2 FROM THE EDITOR

O ptimism. Automation. Emissions.

Affordability. These were the buzzwords
overheard at the Offshore Technology Conference
EDITORIAL
EDITOR-IN-CHIEF: Alecia Archibald
aarchibald@cahabamedia.com • 205-278-2843
EDITOR: Jennifer King
(OTC) in Houston, Texas, in May—and hopefully an
jdking@cahabamedia.com • 205-278-2826
indicator of what the pumps industry has in store.
PRODUCTION MANAGER: Amy Cash
The sentiment from attendees at OTC was that acash@cahabamedia.com • 205-314-8274
the oil and gas market is recovering—one exhibitor MANAGING EDITOR: Drew Champlin
said the lavish displays at the booths showed that dchamplin@cahabamedia.com • 205-314-8264
companies are willing to spend money. Pumps & Systems’ Senior Account CONTRIBUTING EDITORS: Lev Nelik,
Executive Mary Kathryn Baker with Dominik Fry, Jim Elsey, William Livoti
Many credited some of this growth to a resolve
Discflo Pumps Sales Manager Gustavo CREATIVE SERVICES
to operate more efficiently, dive into automated Martinez at OTC 2019.
processes and produce affordable energy, while DIGITAL PROJECT MANAGER &
SENIOR ART DIRECTOR: Greg Ragsdale
reducing their carbon footprint. At the opening session May 6, Jannicke Nilsson, vice ART DIRECTOR: Elizabeth Chick
president and COO of Equinor, said the future will be determined by “having leaders WEB DEVELOPER: Greg Caudle
who are willing to set the direction and are committed to technology and efficiency.” MANAGER OF EMAIL OPERATIONS:
The panel of speakers at the opening session touched on workforce development— Brent Godwin
another hot topic at OTC, and almost every event Pumps & Systems editors attend. CIRCULATION
Nilsson suggested that “we have great stories, but we’re not great at sharing them.” AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
That is where we come in. lmasaoay@cahabamedia.com • 205-278-2840
Highlighting technological advancements and the drive for efficiency are goals at ADVERTISING
Pumps & Systems, as is educating a new generation of professionals. Our July issue will NATIONAL SALES MANAGER:
focus on this topic. Also, the 10 Pump Professionals to Watch nominations are due at Derrell Moody
the end of this month. We want to promote up-and-coming stars and bring attention to dmoody@pump-zone.com • 205-345-0784
opportunities this industry holds. Go to pumpsandsystems.com/10towatch to fi ll out SENIOR ACCOUNT EXECUTIVES:
the nomination form for an employee under 40 at your company. Mary-Kathryn Baker
We love when we hear from our readers. Last month we heard from a couple of you mkbaker@pump-zone.com • 205-345-6036
about a number on page 27 in the May issue—28 billion should be 28 million. Thank you Mark Goins
mgoins@pump-zone.com • 205-345-6414
for letting us know!
Garrick Stone
Another way we are bringing more of those stories to you is through our new Pump gstone@pump-zone.com • 205-212-9406
Industry Insider newsletter, created for OEMs, distributors and industry executives. SALES DEVELOPMENT REP:
Launched May 11, the newsletter brings market trends and research, business Gannon Greene
management tips and opinions and advice from top professionals to readers. Subscribe ggreene@pump-zone.com • 205-278-2876
to Pump Industry Insider, and our weekly Pump Users Digest, at CLIENT SERVICES COORDINATOR:
pumpsandsystems.com/e-newsletter/subscription-form. Carra Barnes
Finally, we are looking forward to hearing the buzzwords at EASA this month. Our cbarnes@pump-zone.com • 205-561-2600
Managing Editor Drew Champlin will be there with the Pumps & Systems team at booth
839, so please stop by and say hello. Be sure to let him know how you think the pumps
industry is looking this year, and what you want to see in our coverage.
As always, thank you for reading!
PUBLISHER: Walter B. Evans Jr.
VP OF SALES: Greg Meineke
CREATIVE DIRECTOR: Terri Jackson
CONTROLLER: Brandon Whittemore
Editor, Jennifer King
jdking@cahabamedia.com P.O. Box 530067
Birmingham, AL 35253
EDITORIAL & PRODUCTION
Pumps & Systems 1900 28th Avenue South, Suite 200
is a member of the following organizations: Birmingham, AL 35209
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue S., Suite 200, Birmingham, AL 35209. Periodicals 205-212-9402
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 ADVERTISING SALES
possessions $5, all other countries $15 US funds (via air mail). Call 205-278-2840 inside or outside the U.S. POSTMASTER: Send changes of address and 1806 6th Street, Suite 200
form 3579 to Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253. ©2019 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 advertise- Tuscaloosa, AL 35401
ments, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descrip- 205-345-0784
tions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media
Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine.
SUBMISSIONS: 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 (with the right to license to third parties) to edit, reproduce, distribute, publish and adapt your submission
in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will
not be returned. Volume 27, Issue 6.

June 2019 | Pumps & Systems

Circle 111 on card.
4
This issue Volume 27 • Number 6
JUNE
COVER
SERIES MOTORS & DRIVES COLUMNS
40 NEW CONSIDERATIONS PUMP SYSTEM IMPROVEMENT
FOR VARIABLE SPEED 14 By Dominik Fry, P.E.
COMPRESSORS Engineered Software, Inc.
By Deana Fu
Should You Upgrade a
Mitsubishi Electric Automation
Pump Drive?
VFDs can extend life by reducing wear
on equipment and motors. COMMON PUMPING MISTAKES
16 By Jim Elsey
44 THE NEED FOR SHAFT Summit Pump Inc.
GROUNDING ON
VFD-DRIVEN MOTORS The Pump Twilight Zone
By Matt Laufik
Electro Static Technology
PUMP SYSTEM STANDARDS
Harmful common mode shaft 21 By William Livoti
voltages can damage motor Senior Engineer
51 bearings and cause premature
machine failure.
General Scope Document:
Project Deliverables

32 UNDERSTAND MOTOR & VFD 46 ENSURE A SUCCESSFUL

INDEPENDENCE TRANSITION WHEN REPLACING
By Miles Mahaffy LARGE MOTORS
Danfoss Drives By Eduardo DosReis
Separation can improve TMEIC J U N E 2 0 19

SYSTEMS
PUMPSANDSYSTEMS.COM

delivery time and allow exact Understand accessories, sizing, The Leading Resource for Pump Users Worldwide

replacement. electrical performance and color.

34 4 INDUSTRY DEMANDS 51 BEST PRACTICES FOR BASICS of

Motors
DRIVING THE POPULARITY MITIGATING BEARING & Drives ON THE COVER
OF ELECTRONICALLY CURRENTS Image courtesy
• Variable speed compressors
• Mitigating bearing currents
• Replacing large motors

COMMUTATED MOTORS By Robert McElveen & of ABB

By Alex Wiegmann Frederick Hoadley USE YOUR SENSES FOR
HEALTHY EQUIPMENT

JIM ELSEY:
SOLVING PUMP MYSTERIES

Nidec Motor Corporation ABB ALIGNMENT VS.

BALANCING

Furnace blower motor design Consider these methods to help

transformation was fueled by new
end user and government standards.
36 GOLF COURSE, SHOPPING
MALL SEE BENEFITS
OF PUMP CONTROL
By Wayne Morris
Invertek Drives USA
This technology can help reduce
blockages, detect damaged equipment
and avoid dry runs, thus reducing
motor stress.
38 EVOLVING HVAC DESIGN
By Seth O’Brien
Eaton
Engineers are eschewing large motors
for less centralized systems.
protect systems from high-frequency
current damage.
2 FROM THE EDITOR
56 A REVIEW OF VARIABLE SPEED
DRIVE TECHNOLOGY 8 NEWS
By William Livoti
Senior pump system engineer 84 ADVERTISERS INDEX
How electronic speed control drives,
adjustable frequency drives, magnetic 84 PUMP USERS MARKETPLACE
drives and steam turbine drives work
to achieve true variable speed control. 88 PUMP MARKET ANALYSIS
59 MOTOR STARTING BASICS
By Blake Bailey
designmotors
Understand these concepts
before starting squirrel cage
induction motors.

June 2019 | Pumps & Systems

Circle 104 on card.
6
This issue
OTHER
REPORTS
22
22 USE YOUR SENSES FOR
HEALTHY SYSTEMS
By Ryan Ossmann
Jenkins Electric
Rely on touch, sound and sight—
and tools that enhance these
senses—for equipment longevity.
24 THE SHIFT TO VARIABLE SPEED
FLUID COUPLINGS
By Bob Wasik
Voith Turbo North America
Power plants with boiler
feed pumps are finding
more efficiency.
28 WEAR RING CLEARANCE FOR
CENTRIFUGAL PUMPS
By Eugene Vogel
EASA
Understand the pump
specific speed to help establish
proper tolerance.
EDITORIAL ADVISORY BOARD
THOMAS L. ANGLE, P.E., MSC,
Geschaeftsleiter (CEO), Swiss Flow
Solutions GmbH
AXEL BOKIBA, Vice President of
Project Management, Pulsafeeder
R. THOMAS BROWN III, President,
Advanced Sealing International (ASI)
KEVIN CLARK, VP, Fluke Accelix
JACK CREAMER, Market Segment
Manager – Pumping Equipment,
Square D by Schneider Electric
BOB DOMKOWSKI, Business
Development Manager – Transport
Pumping and Amusement Markets/
Engineering Consultant, Xylem, Inc.,
Water Solutions USA – Flygt
June 2019 | Pumps & Systems
JUNE
DEPARTMENTS
72 SEALING SENSE
Sealing High-Speed Shafts in
Turbomachinery
By Richard Albery, FSA Member,
John Crane, Inc.
63 USE ULTRASOUND TO OPTIMIZE 76 EFFICIENCY MATTERS
GREASE REPLENISHMENT Prevent Downtime with Pump
By Allan Rienstra Diagnostic Equipment
SDT Ultrasound Solutions By James Farley
Condition monitoring helps manage Griswold
over-lubrication.
79 HI PUMP FAQS
66 FUNDAMENTALS OF SYSTEM Oil Viscosity & Bearing Lubrication
ALIGNMENT VS. BALANCING By Hydraulic Institute
By Larry Ketola
Hines Industries 80 MAINTENANCE MINDERS
Comply with Critical Lead-Free
Differentiating between
Water System Regulations
misalignment and imbalance is
essential to identifying the cause of By Rob Lindquist &
pump failure. Michael Brendel
Emerson Automation Solutions
69 VIBRATION ANALYSIS USING
HUMAN & ARTIFICIAL
INTELLIGENCE
By Craig Truempi &
Dan Yarmoluk
ATEK
A hybrid approach can provide
specialized evaluation for midtier
plants and/or midcritical equipment. 28
JIM DRAGO, Principal Applications TODD LOUDIN, President/CEO SCOTT SORENSEN, Oil & Gas
Engineer, Garlock Sealing North American Operations, Automation Consultant & Market
Technologies Flowrox Inc. Developer, Siemens Industry Sector
WALT ERNDT, Vice President of JOHN MALINOWSKI, Industrial ADAM STOLBERG, Executive Director,
Business Development, Pump and Motor Consultant Submersible Wastewater Pump
Process Equipment, Inc. MICHAEL MICHAUD, Executive Association (SWPA)
JOE EVANS, Ph.D., Customer & Director, Hydraulic Institute JERRY TURNER, Founder/Senior
Employee Education, PumpTech, Inc. WILLIAM E. NEIS, P.E., President, Advisor, Pioneer Pump
GEORGE HARRIS, President & CEO, Northeast Industrial Sales DOUG VOLDEN, Global Engineering
Hydro LEV NELIK, Ph.D., P.E., APICS, Director, John Crane
ROB LAIRD, Engineering Manager, International Center for Pumps CHRIS WILDER, CEO, SEPCO
Sulzer Research and Development, Israel JAMES WONG, Associate Product
LARRY LEWIS, President, Vanton HENRY PECK, CEO, Geiger Manager – Bearing Isolator, Garlock
Pump and Equipment Corp. Pump & Equipment Company Sealing Technologies
WILLIAM LIVOTI, Senior Pump MICHELE SHAUGHNESSY,
System Engineer Vice President Marketing & Sales,
PSG Dover
 PUMP READY
MOTORS AND CONTROLS

WorldDrive Family Premium Efficient Motors

Variable Frequency Drives
Three Distinct Product Lines
• The WD4X: NEMA 4X Enclosure, 1/2 - 30 HP
• The WDGP: General Purpose, 1/2 - 30 HP
• The FC: Flexible Control, 1/2 - 800 HP
From WorldWide and Hyundai
Low Voltage Motors for Every Pump Application
• Standard TC-Frame Motors, 1 - 500 HP
• Jet Pump Motors, 1/3 - 3 HP
• Close Coupled Pump Motors, 1 - 50 HP

Whether you’re driving a single pump or an entire plant, WorldWide Electric

has a full line of industrial electric motors, gear reducers and motor controls.
WorldWide Electric is the exclusive distributor for Hyundai Electric in the US.

Quality. Value. Service. We are WorldWide.

1 (800) 808-2131 | worldwideelectric.net | customerservice@worldwideelectric.net

Circle 107 on card.

8 NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
KLAUS PATZAK, SIEMENS
MUNICH, Germany – Klaus Patzak, currently
managing partner of the Siemens Portfolio
Companies, has been appointed chief financial
officer (CFO) of the new Siemens Gas and Power
business (GP). In this role, Patzak will be responsible
for building the finance governance structures,
steering the activities required for carving out and Klaus
listing, and helping to shape the format of the future Patzak
stand-alone Siemens energy business. In his new role, he will report
to Lisa Davis, CEO of the Gas and Power Business that is to be created.
Via a functional reporting line, he will also report to Siemens CFO,
Ralf P. Thomas.
The finance and transformation expert was most recently CFO of
Bilfinger SE, having previously been CFO of Osram Licht AG. For several
years, Patzak served, among other things, as head of accounting,
reporting and controlling at Siemens AG. Michael Becker will continue
in his role within the GP business with responsibility for the finance
operational activities of the GP Operating Company. siemens.com
BLAKE BAILEY, DESIGNMOTORS
SAINT PAUL, Minn. – On Jan. 1, 2019, designmotors was founded as a
company to serve the design needs of the industrial
motor and generator markets. The company provides
design services for induction, synchronous, and
direct current (DC) machines. The capabilities range
from new product development to low-quantity
custom motor design.
The company serves as an independent
design resource for clients that include motor Blake
manufacturers, rotating equipment service Bailey
providers, as well as end users.
Blake Bailey is the company’s president. Bailey was previously
employed with Louis Allis and Electric Machinery. designmotors.net
PETE MCMUTRIE, OBART PUMPS
MAIDSTONE, U.K. – Pete McMutrie has been appointed sales director
of Obart Pumps Ltd. McMutrie joins Obart from a major distributor of
construction equipment, where for 20 years he was the national and
key account sales manager for many high-profile customers in the
U.K. and across Europe. He was responsible for selling construction and
ground-care products for global brands such as Honda, Stihl, Husqvarna,
Saint Gobain, Yanmar, JCB and many other manufacturers.
obartpumps.co.uk
ENZO RENE GARCIA-BARTOLOMEI, IDA
BOSTON – The International Desalination Association (IDA) has
awarded its Channabasappa Memorial Scholarship to Enzo Rene
García-Bartolomei of Chile for the 2019-20 academic year. The Institute
of Seawater Desalination and Multipurpose Utilization (ISDMU), SOA
(Tianjin, China), is co-sponsoring the 2019-20 scholarship through
a matching contribution to the IDA Sustainable Water Resources
June 2019 | Pumps & Systems
Foundation (SWRF), which will issue a $5,000 matching grant. This
makes the total scholarship value $10,000.
A marine ecologist, García holds a bachelor’s degree in ecology, and
has eight years of working experience.
He is now in his second year of doctoral studies, majoring in Inland
Aquatic Systems, at the Faculty of Environmental Sciences of the
University of Concepción, one of the prestigious environmental science
programs in Chile and the LATAM region.
The topic for his doctoral thesis is “Multidisciplinary Environmental
Approach to the Sustainable Management of Seawater Desalination
Effluents.” Its main objective is to develop a multidisciplinary brine
management strategy based on ecotoxicological, territorial and
normative research. idadesal.org
DUSTIN DAVIS, RDI TECHNOLOGIES
KNOXVILLE, Tenn. – Dustin Davis has been named
the midwest regional sales manager for RDI
Technologies.
Davis has been in the predictive maintenance
industry for more than 16 years. He started his
career as a field service technician, then made
his way to vibration analyst, reliability consulting
engineer and, most recently, a business Dustin
development manager. Davis
Davis holds many certifications: CMRP, ANSI/ISO Cat II Certified
Vibration Analyst, Infrared, MLA II, Motion Amplification, Hazmat
Technician, and Fire Fighter I. rditechnologies.com.
DON TYLER, BCCK HOLDING
MIDLAND, Texas – BCCK Holding Company (BCCK) has appointed Don
Tyler as director of engineering.
Tyler has more than 40 years of combined engineering, design,
project and discipline management experience in the natural gas
processing, industrial wastewater treatment, power, paper and chemical
processing industries.
He has been involved in more than 40 domestic and international
natural gas liquids (NGL) and liquid petroleum gas (LPG) recovery
and liquefied natural gas (LNG) projects with a range of engineering
firms. Among his accomplishments are five NGL recovery patents that
he co-invented, as well as inventing the geothermal energy patent,
“Subsurface Well Completion System Having a Heat Exchanger” (U.S.
Patent 8,672,024 B2). bcck.com
TARA ROBERTS, FOOTHILLS EXPLORATION
LOS ANGELES – Foothills Exploration, Inc., an independent oil and gas
exploration company engaged in the acquisition and development of
natural gas and oil properties in the Rocky Mountains, announced the
appointment of Tara Roberts to the position of vice president of business
development. In this role, Roberts will lead business development
efforts, including the formation of strategic alliances, joint ventures and
identifying, shaping and capturing new business opportunities across
targeted oil and gas basins. foothillspetro.com
 9

MIKE LASSAS,
PROCO PRODUCTS
STOCKTON, Calif. Ð Mike
Lassas has been named
president of Proco Products,
Inc. effective May 1, 2019.
Lassas was born and
raised in Minnesota and Mike
Lassas
attended the University
of Minnesota, receiving a degree in sales and
marketing in 1986. Lassas proudly served in
the United States Navy from 1987 to 1991.
Lassas joined Proco Products in October
1994 as an inside sales/customer service
representative and was then promoted to
assistant marketing/advertising manager in
May 2000. Another promotion came in June
of 2002 when he was promoted to regional
sales manager.
Lassas became a Proco shareholder on Jan.
1, 2008, and then was appointed vice-president,
administration. In his new position as
president, Lassas will handle all the day-to-day
operations of Proco. procoproducts.com

MERGERS &
ACQUISITIONS
Genstar Capital  Acquires Ohio
Transmission Corporation     
April 9, 2019

Elliott Group  Completes Merger of Ebara 
International Corporation
April 12, 2019

Purvis  Acquires Foresight Automation
April 29, 2019

TASI Group  Acquires ONICON
April 29, 2019

ITT  Acquires Rheinhutte Pumpen Group
May 2, 2019 With more distribution channel access than ever to brands you can trust – like
Pioneer Pump® and FPS® – along with onsite expert service, choose Franklin Electric
Sulzer  Acquires GTC Technology   when you arrive at your next water pumping crossroads.
May 2, 2019
Identify your local Franklin Electric sales representative at
Circle 119 on card.

Dover  Acquires All‑Flo franklinengineered.com/contact/locate-salesperson
anklinengineered.com/contact/locate-salesperson
May 7, 2019

To have a news item considered,

please send the information to
Drew Champlin, dchamplin@cahabamedia.com.

pumpsandsystems.com | June 2019

10 NEWS
AROUND THE INDUSTRY
ABB CEO Steps Down
ZURICH, Switzerland – The
board of directors of ABB and
its CEO Ulrich Spiesshofer have
mutually agreed for him to
step down from his role, which
he has held since 2013. The
chairman of the board, Peter
Voser, has become interim
CEO in addition to his current
role, with immediate effect. An
official search to find a new CEO
has been initiated.
Voser, a Swiss citizen, has
been chairman of ABB since
April 2015. Prior to this, he was
CEO of Royal Dutch Shell from
2009-13, and CFO between
2004-09. Between 2002 and
October 2004, he was CFO of
ABB and a key leader behind
the successful turnaround of
the company. Voser also brings
a wealth of experience in board
positions in leading companies
such as a Roche, IBM, Catalyst,
Temasek Holdings and PSA
International in Singapore.
us.abb.com
HI Announces
Board of Directors
PARSIPPANY, N.J. – The
Hydraulic Institute (HI) installed
a new leadership team during
the 2019 HI Annual Conference
at the Vinoy Resort & Golf Club
in St. Petersburg, Florida.
DeLancy Davis, Franklin Electric
vice president and CEO of
Headwater Companies, was
elected to serve as the new
HI president for a two-year
term. John Kahren, president,
SPP Pumps Inc., and owner,
SyncroFlo, Inc., was appointed
to chairman of the board,
replacing John P. White,
chairman of Taco Comfort
Solutions, who had served as HI
chairman since February 2017.
Three new members joined
the HI Board of Directors for
three-year terms: Karl Buscher,
president, PSG Dover and David
June 2019 | Pumps & Systems
EVENTS
J. Wilson, president, pumps AWWA
division, Flowserve, both joined June 9-12
as member representatives; Colorado Convention Center
Howard (H.J.) Dewes, director, Denver, Colorado
marketing and digital, ABB events.awwa.org
Drives, U.S. joined the board
as an associate member NFPA
representative.
June 17-20
Other changes include
Jonathan Wiechers, vice
Henry B. Gonzalez Convention Center
president and general
San Antonio, Texas
manager, Fluid Management, nfpa.org
ARO Ingersoll Rand, who was
appointed to fill an open one- EASA
year term, and Jeff Bredeson, June 30-July 2
president, Hydroflo, who Mandalay Bay Convention Center
was selected as the new vice Las Vegas, Nevada
president of knowledge and easa.com
education for a two-year term.
For an up-to-date roster of Turbomachinery & Pump Symposia
the HI Board of Directors, please Sept. 10-12
visit the HI Board of Directors George R. Brown Convention Center
and Leaders page on the HI Houston, Texas
website. pumps.org tps.tamu.edu
Sulzer Launches WEFTEC
Scholarship for Women Sept. 21-25
in Engineering McCormick Place
HOUSTON – Sulzer has Chicago, Illinois
launched the Sulzer Scholarship weftec.org
for Women in Science and
Engineering directed at female Pack Expo
students studying for degrees
Sept. 23-25
in the areas of engineering,
technology and science. The
Las Vegas Convention Center
scholarship aims to support
Las Vegas, Nevada
and increase the participation packexpolasvegas.com
of women in the engineering
industry. Reflecting its presence Chem Show
and its business needs, Sulzer Oct. 22-24
is currently initiating these Javits Center
scholarships in collaboration New York, New York
with universities in South chemshow.com
Africa, Indonesia, China and
India. These countries were ADIPEC
selected because they combine
Nov. 11-14
a strong Sulzer presence and,
with the exception of China,
Abu Dhabi National Exhibition Centre
a relatively low proportion Adnec, Abu Dhabi
of female engineers. Offered adipec.com
in close collaboration with
selected academic institutions, Power Gen
four initial scholarships will be Nov. 19-21
awarded in each country. Morial Convention Center
sulzer.com New Orleans, Louisiana
power-gen.com
 Let’s visit
at EASA
June 30 - July 2

—
The sign of reliability

For more than 100 years, ABB has developed a reputation for marketing, designing
and manufacturing the most reliable industrial electric motors available. Azima,
Inc. confirmed this in their Reliability Rating Report in which they stated that “ABB
produces the majority of models scoring highest for reliability in 2018.”

When reliability counts, look for the sign of reliability from ABB.

479.646.4711
baldor.abb.com Circle 113 on card.
12 NEWS

Preview: EASA Exhibition

Hours
June 30-July 2
Mandalay Bay Resort & Casino Sunday, June 30
Las Vegas, Nevada 12:30 p.m. – 5 p.m.
Monday, July 1
Noon – 4 p.m.
T he theme for the Electrical Apparatus Service Association
(EASA) 2019 convention is “Navigate the Future.”
The convention will feature a wide-ranging program
EASA is an
international
trade organization
Tuesday, July 2
9 a.m. – Noon
addressing current business and management issues. consisting of
A key feature of the EASA Convention is the three-day more than 1,800
exposition featuring the industry’s leading manufacturers electromechanical
showing the latest in electric motors, drives and controls, sales and services firms in nearly 80 countries. Through its
pumps, generators and other electromechanical equipment. many engineering and education programs, EASA keeps
The exposition features an open-floor format for attendees members up to date on materials, equipment and recent
to talk face-to-face with companies that serve the electrical technology related to sales, service and maintenance of
apparatus industry. motors, generators, drives, controls, pumps and other
“Attendance at the EASA convention is open to all: members electromechanical equipment.
and nonmembers,” said Linda J. Raynes, EASA president and The keynote speaker at the event will be Mike Staver, an
CEO. “The technical program is a unique opportunity for author, speaker and coach. He will speak at 10:30 a.m. on June
plant engineering and maintenance personnel to learn about 30 about “Navigating the Future with Courageous Leadership.”
the latest practices to improve their operations and reduce For registration and program information, please visit
their downtime.” easa.com/convention.

Review: OTC 2019

May 6-9
NRG Park
Houston, Texas

T
he Offshore Technology Conference (OTC) celebrated 50
years in 2019, and the outlook for the oil and gas indus-
try was positive in Houston. “I think there’s optimism,”
Newpark Drilling Fluids President Timothy J. Armand said.
“We feel the industry has managed to understand how we can
operate in this climate. The market is going to slowly come
back. I’d rather it slowly come back than it ramp up to some
place and have a hiccup.”
More than 2,300 exhibitors from 40-plus countries show-
cased at OTC; international exhibitors made up 52 percent of
those displaying at the conference. More than 59,000 people
from 100 countries were in attendance.
“We are seeing tremendous activity,” said Eric Bucci, segment
manager, oil and gas Americas for Trelleborg Sealing Solution.
He noted that companies invested more on their booths this
year—an indication that things are looking up. “Customers are
spending more
money,” he said.
Eric Junk- (Left) Newpark Drilling Fluids President
ers, president Timothy J. Armand with Pumps & Systems
of HYTORC Editor Jennifer King.
said he was
pleased with the outcome of the show. “It’s been good. We’ve
been coming for over 30 years, and it’s the place to be—our key
customers are here, as well as our key targets,” he said.
Red Wing Shoe Company Vice President of Global Sales and
Distribution Tito Warren said he has seen three economic
cycles of downturn and comeback in his career. “All parts of the
world are coming back,” he said. “The cycle from start to finish
is getting tighter. To turn the spigot off really fast is a little
scary. The industry has gotten really good at reacting to the
economic forces.”

June 2019 | Pumps & Systems

 Circle 109 on card.

Call Us!
1-800-523-3382
14 PUMP SYSTEM IMPROVEMENT
Should You Upgrade a Pump Drive?
R
ecently, there has been plenty
of talk about energy efficiency
in the pumping industry.
According to the Hydraulic Institute
(HI), pumping systems account for 40
percent of industrial energy usage, and
HI has established a new energy rating
label system. The labeling applies to
new pumps, and the vast majority of
pumps have been in service for many
years. If there is an issue in a facility, the
maintenance team usually knows which
pumps are underperforming. Without
a good understanding of the overall
system, it can be frustrating to pinpoint
the issue. Today, we will focus less on the
actual efficiency of the pump, but instead
on the interactions with the motor, and
whether adding some kind of variable
speed control is worthwhile.
Recently, I ran into the following
scenario where a single pump delivered
the flow rates in Image 1. This is a typical
4x3-10 end suction pump operating at
3,560 revolutions per minute (rpm) and
under 50 horsepower (hp) on the smaller
to midsized range. The pump looked to
be slightly oversized, but was performing
decently. When looking at costs in this
scenario, I will use the national average
for commercial electric prices of 11 cents
per kilowatt hour (kWh).
Notice in Image 1 that they are
spending roughly $25,000 per year
Image 1. Fixed speed pump costs (Images courtesy of the author)
Flow Hours Pump Power (hp) Cost ($)
(gpm) (year) (efficiency)
400 4000 68.5 38.2
350 1000 65.7 35.9
300 3000 62.1 33.3
250 500 57.5 30.5
Total = 24955.2
June 2019 | Pumps & Systems
By Dominik Fry, P.E.
Engineered Software, Inc.
operating the midsized pump. It
varied from 22.8 to 28.5 kW or in the
30- to 40-hp range, not accounting
for inefficiency in the motor. And, the
efficiency of the pump is falling as the
operating point keeps pushing back on
the pump curve.
When we compare this to the variable
speed pumping costs, we see savings of
more than $5,000 in energy per year in
Image 2. But, the bulk of the savings are
not from the pump efficiency. To get the
full picture, we look at the pump curve.
When looking at the pump curve in
conjunction with the system curve a large
disparity is shown. Image 3 shows the
operation at the lowest flow rate of 250
gallons per minute (gpm). The system
curve intersects the pump curve at 400
gpm, which indicates little throttling
is necessary at the highest flow rate.
Tracing the curve back to 250 gpm, we
can see that the pump will put out 275
feet of head, while the system resistance
is only 100 feet, resulting in a large
amount of energy that must be dispersed.
This is lost energy. The savings with the
variable speed pump are realized because
the pump can scale back its speed to
achieve the desired flow rate, instead of
needing to throttle the flow downstream
with a control valve. If we look at the
same operating condition except with
a variable frequency drive (VFD) pump
Image 2. Variable speed pump costs
Flow Hours
(gpm) (year)
12557.6 400 4000
2949.1 350 1000
8197.2 300 3000
1251.3 250 500
(Image 4), the pump’s operating speed
would reduce to 2,220 rpm, which would
achieve the 250 gpm flow rate desired.
This flow rate is now achieved using
just 10 hp when the original fi xed speed
pump was consuming more than 30 hp.
There may be room for additional
savings. Notice in this system, the
resistance curve starts essentially at
zero and goes up with the flow rate. This
indicates that the majority of the energy
from the pump is used to overcome
the frictional forces in the pipe and
components as opposed to pumping up
in elevation. This system was operational
almost continually, so there is no room
to slow the flow rate. Tank sizes and
incoming flow rates also impact the
necessary flow rate. If the system were
in operation part time, then additional
savings could be generated from
operating at a lower flow rate and longer
length of time. These incremental steps
can have a large effect over time. As the
flow rate drops below 200 gpm, the power
drops under 5 hp, which is approaching a
90 percent power drop from 400 gpm.
Now is when the decision of whether
or not to upgrade gets shifted onto the
individual user and their circumstances.
Depending on the age of the motor,
it may not be able to accept a VFD
controller, though there are always
workarounds and new products. In some
Speed Pump Power Cost ($)
(rpm) (Efficiency) (hp)
3560 68.4 38.2 12557.6
3100 68.3 25.9 2126.3
2700 68.2 16.6 4075.5
2220 68.1 9.7 401.8
Total = 19161.2
 15

Image 3 ( left). Fixed speed pump operating at 250 gpm. Image 4 (right). VFD pump operating at 250 gpm

areas of the Northwest, energy rates are
significantly below the national average.
Meanwhile, the rate may be double or
even triple in places like Alaska and
Hawaii. The price of drives vary widely
depending on the size and manufacturer,
as well as what conditions it is rated for.
One school of thought is to have fewer
components in the system so there are
fewer parts that can break.
In this scenario, we also saw the pump
Dominik Fry, P.E., is Engineered
running closer to its best efficiency point
Software, Inc.’s business development
(BEP), which should improve mean time
engineer and has nearly a decade of
between failure (MTBF). Finally, many
experience in the energy industry
of these upgrades can be subsidized by
while working on some of the nation’s
local utilities. Demonstrating the savings
largest energy projects. Fry earned a
through software and before/after power
Bachelor of Science at Montana State
readings can significantly cut the cost
University. For more information, visit
of upgrading depending on your local
eng-software.com.
energy alliance.

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Circle 128 on card.

pumpsandsystems.com | June 2019

16 COMMON PUMPING MISTAKES
The Pump Twilight Zone
P 1
eople of a certain age, and those
that enjoy TV reruns, may
remember the show called “The
Twilight Zone.” In each episode, there
was always a surprise plot twist and a
subsequent moral or lesson at the end.
In my career, I have witnessed many
pump issues that I have assigned to
this zone of unexplained reasons for
pump failure.
At first I was “mentally fi ling” them
simply as pump mysteries, but later
I just started calling it the twilight
zone because no one seemed to know
what caused the problem. I learned—
after some time, persistence and
acknowledgment to the twilight of
unexplained things—there was always a
good lesson at the end.
Before going further, I want to add a
disclaimer: I am not blaming anyone
for the issues that occurred. There are
guilty parties all around and no names
will be used.
It is the intent of this article that we
all learn from the lessons they teach. All
of these examples are true; I present the
issues first and the answers follow.
What Is this Twilight Zone?
I am talking about that warped period of
time between when the pump is shipped
from the factory and subsequently
started up. I am talking about the
time and place between the pump
being removed for repair and when it
is reinstalled. I am talking about the
unexplained changes that occur when
pump “A” is pulled from the system and
pump “B” is installed in its place.
This is the interim dimension I
previously called the magic and mystery
place. Lately, this is the dimension I refer
to as the twilight zone.
June 2019 | Pumps & Systems
By Jim Elsey
Summit Pump Inc.
The case of the missing impellers. Do troubleshooting process, including
not blink twice, or you will miss it. that they had not worked on the steam
PROBLEM: In a steel mill in the
central Midwest, a six-stage boiler feed
pump is pulled from service for routine
maintenance to reestablish the original
operating clearances. Note that the pump
is driven by a multistage steam turbine.
The pump operated in excellent fashion
for more than eight years of continuous
service, but it was time for an overhaul.
The pump was rebuilt and returned to
the customer by the OEM repair center.
Upon initial startup, the pump operated
smoothly, but the hydraulic performance
was markedly off. The flow and head were
both diminished when compared to the
manufacturer’s published performance
parameters. The upset customer
proclaimed that the repair center had left
out a few stages (impellers) during the
repair. This pump was originally designed
as an eight-stage pump, but was built for
this customer as a six-stage pump. This
is a common practice where blanks are
used for impellers when a lower discharge
pressure is required. The customer was
suggesting the pump was now a four-
stage in lieu of a six-stage pump.
The manufacturer’s engineer was called
in to troubleshoot the issue. He arrived at
the site and went through all the normal
performance checks including vibration,
valve lineup, rotor settings and the
validation of differential pressure and
flow. He considered that it was possible
for two stages to be left out of the rotor,
but not likely, and besides the OEM
repair center vehemently insisted the
pump had six stages.
Initially, all the indicators appeared to
be an issue with low speed. The customer
advised several key points during the
turbine during the outage and that the
operating speed was the first thing they
checked when the issue appeared. The
turbine/pump speed had been validated
using a calibrated strobe tachometer
(stroboscope) at exactly 3,600 revolutions
per minute (rpm). Luckily, the young
pump engineer had plenty of experience
with steam turbines and stroboscopes.
SOLUTION: No missing impellers
In the first case, the pump factory
engineer had extensive experience
with turbines, steam governors and
stroboscopes. He knew how easy it was
to get an incorrect reading from the
stroboscope if you were not properly
trained. The steel mill stroboscope
operator had focused on a coupling bolt
to “freeze” the rotor at some speed, which
he thought was 3,600 rpm because he
had no reason to suspect otherwise. The
turbine was really operating at 1,800
rpm, and the stroboscope operator was
seeing a multiple image (two coupling
bolts appearing as one).
For stroboscope work, it is important
to always focus on an object that is
unique from a shaft circumference
perspective, like a key or key seat. If you
must use a coupling bolt, then mark one
in some way so it differs from other bolts
(glow paint works well in these cases).
The customer did not previously
mention that the turbine governor valve
(W-TG-10) had been rebuilt while the
pump was out for overhaul. The factory
engineer who discovered the root cause
was given the honor of ceremoniously
adjusting the steam governor setting to
bring the unit up to the correct speed of
3,600 rpm where it performed like new.
Circle 114 on card.
18 COMMON PUMPING MISTAKES

2 The case of the hot transformer, and

a cool solution.
Note: a centrifugal pump operating in
the wrong direction still produces flow in
the correct direction and the customer’s
4 Seized rotor redux: watch out for
dead ends.

PROBLEM: Scene: an electric power rudimentary sight glass flow indicators PROBLEM: Similar to the preceding
generation plant on the eastern seaboard. could not differentiate between 600 example, this multistage boiler feed for a
At a 20-year-old power plant, a generator gallons per minute (gpm) and 1,200 gpm. boiler feed pump at a factory somewhere
step-up transformer (GSU) has severely The correct rotation was established for in the middle of the country was rebuilt
overheated at full load since the day it all pumps, the power plant was started in a nearby repair shop and reinstalled.
was installed. Consequently, the unit was up and the transformer was energized. The pump operated for about 10 minutes
derated and operated at 85 percent of full For the first time in 20 years, the and seized up. The pump was returned
load. The derated transformer thereafter transformer did not overheat at full load. to the repair shop to be rebuilt and
limited the power output of the entire sent back, where the same scenario
power generating station.
Fast forward 20 years and the
thermally handicapped transformer
3 The reoccurring seized rotor—
the definition of insanity.
reoccurred. On the third attempt, a pump
engineer and consultant were brought in
by the customer for oversight purposes.
is scheduled for new dielectric oil and PROBLEM: At a steel mill in the
all new gaskets. Additionally, all six Midwest, an eight-stage segmented SOLUTION: Seized rotor
transformer oil circulation pumps are to casing pump is sent to a repair facility The consultant examined the system and
be rebuilt. (Sidebar: Power transformers for a complete overhaul. The pump is operation and maintenance procedures.
use circulating transformer oil systems returned and installed. During the It did not take long to determine the
to serve both as an insulating dielectric setup, the millwrights discover that the reason for the pump failures.
and as a heat transfer cooling medium.) pump rotor will not rotate by hand. The In any piping system when there is
The pumps were sent to the factory vendor is informed that the pump rotor is a section of pipe that has no flow (also
repair shop on an expedited basis for apparently seized. known as a dead leg or trap), it becomes
remanufacture and returned to the The pump is sent back to the repair a place for the rust, scale, dirt and
site. The customer performed a pre- shop to be disassembled and inspected. debris to accumulate and deposit. The
installation check for proper rotation The pump shop finds nothing wrong— suction line for the boiler feed pump was
and noticed the pumps were rotating they reassemble the pump and send it blocked when the pump was removed,
in the wrong direction. The customer back to the customer. But again, the but the system was still operating using
demanded warranty compensation from millwrights are not able to rotate the the other parallel pumps. The dead leg
the factory to fi x the issue. The factory rotor due to an apparent rotor seizure. was collecting the foreign debris in the
engineer stated that it was impossible The pump is sent back to the shop, where system. When the pump was reinstalled
for these pumps to be operating in the again it is disassembled and inspected to and the suction line opened, the pump
wrong direction unless the customer had find there is nothing wrong. The pump was flushed with the collected debris. The
reversed two of the three phases on their is returned to the customer a third time, debris lodged in the wear ring fits, and
power leads at the site. The customer but on this occasion the sales engineer the pump seized.
vowed that no lead changes had occurred. decides to accompany the pump.
The factory engineer was on the next
plane to the site. SOLUTION: What is going on over
at the plant?
5 Going the wrong way on a one-way
street; you can’t have it both ways.

SOLUTION: The cool solution
The factory engineer was confident the
transformer pump motors were correctly
wired because of their in-house quality
assurance/quality control (QA/QC)
program. On arrival at the job site, and to
his surprise, the engineer confirmed that
the pumps were actually rotating in the
wrong direction. In fact, the pumps had
been rotating in the wrong direction for
20 years.
The engineer accompanied the rebuilt
pump to the mill and witnessed the work
crew lift the pump off the truck using a
small crane with two lifting straps—each
attached to one end of the pump shaft.
By improperly lifting the full pump
weight on the shaft at both ends, the
segmented casing rings were shifted out
of alignment, consequently locking the
pump rotor. Never lift a pump of this
type by the shaft.
PROBLEM: Scene: the “oil patch” in
the upper western U.S. where we have
a single-stage group 3 ANSI pump on
oil service in a middle stream process
application. The local pump distributor
contacted the factory with an issue: the
pump would run for a day or two and
then seize and fail. They pulled the pump,
rebuilt and returned it to service. The
pump would again operate well for a few
days, and the issue would repeat.

June 2019 | Pumps & Systems

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Circle 108 on card.

pumpsandsystems.com | June 2019
20 COMMON PUMPING MISTAKES

The OEM engineer asked for photos of
the damaged parts and more information
on the operation. Based on those, it
appeared as a clear and simple case
of running the pump in the wrong
direction. But, the distributor had their
most experienced serviceman on the job
who had personally checked for proper
rotation three separate times. Time for
some fresh eyes to visit the job site.
SAME-
SHIPM DAY
AVAILAENTS
BLE
SOLUTION: One-way pump
The mechanic was 100 percent correct.
The pump was operating in the correct
direction. The essential information left
out of conversations and drawings was
that the system had multiple pumps
in parallel with the subject pump. The
discharge check valve for this pump
would randomly and intermittently stick
in the open position. When this pump
was not operating under power, it was
forced in the reverse direction by flow
or pressure from the other pumps. The
impeller and casing were now acting as
a hydraulic turbine. Because most ANSI
pumps use an impeller that is screwed on,
the impeller would back off and seize to
the casing during reverse operation.
Conclusion
I have a long list of pump issues that fit
into this twilight zone, but these are
some of my favorites. These show that
inexperienced personnel are frequently

PERMANENT BEARING
assigned to startup. Assumptions are
made, no instructions are ever read,

PROTECTION
nor is any OEM consulted with prestart
questions. Almost no pump installation
is “plug and play.” There are alignments

THAT’S WHAT WE DO... to conduct, driver rotational checks to

make, mechanical seals to set, oil to add
and piping to vent. Educate yourself and
At Inpro/Seal®, we are dedicated to providing increased equipment reliability through avoid that dimension in time and space
engineering excellence, superior sealing technology and unmatched customer support. known as the twilight zone.

The new IP66 rated VB45 Bearing Isolators are the next generation of Bearing Isolator Jim Elsey is a mechanical engineer
technology. The VB45-S™ Bearing Isolator’s compact design, with only a 0.625 in. who has focused on rotating
(15.88 mm) overall length, provides premium contamination protection and lube equipment design and applications for
retention to maximize rotating equipment reliability. The VB45-U™ Bearing Isolator offers the military and several large original
superior bearing protection for both oil and grease lubed equipment. Its unique, unitized equipment manufacturers for 48 years
rotor design accommodates axial movement. in most industrial markets around the
world. Elsey is an active member of
To learn more about increasing equipment reliability with permanent bearing the American Society of Mechanical
Engineers, the National Association of
protection, visit www.inpro-seal.com.
Corrosion Engineers and the American
Society for Metals. He is the general
Visit Us At EASA - Booth 406
manager for Summit Pump Inc.
June 30 - July 2 | Las Vegas, NV
and the principal of MaDDog Pump
Consultants LLC. Elsey may be reached
at jim@summitpump.com.
Circle 121 on card.

June 2019 | Pumps & Systems


General Scope Document:
Project Deliverables
T
his month, we will discuss
the sixth component of the
general scope document (GSD):
project deliverables.
Developing a general scope of work
document is an important part of doing
business. Your statement of work not
only spells out specific phases and
details for a project, but it also helps
tell the story of the work you plan to do.
The scope of work your business plans
to do will be spelled out in the project
deliverables section.
The project deliverables portion is
yet another critical part of the general
scope document. Simply stated, project
deliverables are the products or outputs
that the successful completion of
the project is intended to produce. A
deliverable is a product or service created
to achieve a project objective. Seems
straight forward, right?
When you embark on a project, it
should be obvious what you are going
to create, right? Unfortunately, that
is not always the case. That is why it
is important to define and capture
the description of the intended
deliverable(s). The team needs enough
details (from each stakeholder with
vested interest in the project) to know
what it is producing or developing, and
how to measure the outcome during
testing and review. Perhaps most
important of all, the team needs to be
sure of what the stakeholders want and
that they will approve the final result.
Project deliverables is where many
projects fail to achieve the desired
results. Why? Because many general
scope documents fail to clearly define the
project deliverables. This one critical step
can spell disaster during the owner’s
PUMP SYSTEM STANDARDS 21
By William Livoti
Senior Engineer
acceptance process and
most certainly when you are
validating the cost benefits of
said project.
Clarity is Power
What should be included
in the project deliverables
statement? This is somewhat
redundant but bears
repeating: A clear definition
of the result of the successful
completion of the project.
Among project management
deliverables, there is a Image 1. Components of a general scope
distinction between project and process document (Image courtesy of the author)
deliverables. As stated earlier, a project
deliverable is a result, while a process • head (process)
deliverable is the path you take to • flow (process)
achieve that result. Process deliverables • mean time between repair
include things such as the scope of work (reference standard)
and a statement of work. A scope of work • horsepower (limits)
sets the intentions for the project at the • voltage (limits)
start and includes such things as the
project stakeholders, project goals and This is not a comprehensive list of
objectives, and intended deliverables. project deliverables. However, it does
Like the objectives they serve to give you a general idea of what should be
achieve, deliverables must be specific included in this portion of the general
and measurable. If a deliverable is scope document.
not specific or does not directly serve Next month, we will discuss the
the objective, it has no place in the owner’s acceptance criteria. I have always
project plan. The measurable aspect found this portion of the general scope
of deliverables means they must meet document to be a lively discussion when
defined acceptance criteria (the owner’s preparing a document for distribution
acceptance criteria). to a third party for a quote. Again,
Listed below are a few examples of attention to detail is critical.
project deliverables. Each item is specific
and measurable.
William Livoti is retired after more than
• vibration (reference standard)
40 years in the pump industry. Livoti
• system efficiency (over operating
is a member of the Pumps & Systems
envelope)
Editorial Advisory Board. He may be
• type of pump or configuration
reached at wlivoti@outlook.com.
• speed (range or limitation)
pumpsandsystems.com | June 2019
22 AFTERMARKET

Use Your 
Touch
Touching a motor or pump while in operation is not advised.
Users can still use “technical touch” through devices such as

Senses for 
thermal cameras, temperature guns and temperature probes.
Each of these can effectively measure the thermal condition
of the motor or pump. The bearings can be monitored for
elevated temperatures and temperature rise rates.

Healthy  If a unit is on a periodic maintenance route, adding in a

simple temperature gun check can let the user know whether
it needs to be monitored more closely or if it is in good

Systems  
working order. If elevated temperatures are detected, the user
can monitor the unit more frequently to determine the rate of
temperature increase. If the unit is noncritical or small, the
rate of temperature increase can help the user to determine
how soon it needs to be replaced.
Rely on touch, sound and sight̶ If it is a critical application or a unit that is more
economical to repair, monitoring also allows for the planning
and tools that enhance these  of downtime for scheduled maintenance. Probes are typically
mounted to the unit and communicate directly to control
senses̶for equipment longevity. systems for automated shutdown. These same practices can be
applied to motor stators to determine if a winding is running
at or above designed temperature.
BY RYAN OSSMANN
Trending this data allows the end user to lower the
JENKINS ELECTRIC 
occurrences of unplanned downtime and catastrophic failure.

Hearing

W
e use our five senses—sight, smell, hearing,
touch and taste—every day to make
decisions about the world around us and about
our own well-being. Our senses help keep us
going and alert us to danger.
Motors and pumps do not have the luxury of senses. They
depend on the senses of human beings to keep them alive.
Here are some tips on how to use the senses to keep the
equipment, and plant, running efficiently and productively.
Nothing sounds better to a repair facility than a perfectly
humming motor in the final test stages. It means that all
systems are in proper working order and the equipment is
ready for installation.
Sound can also be the first clue that a problem exists.
If a motor or pump is making a high-pitched whine, it is
possible that the bearings are failing. Or, if it is a belt drive
application, the sound could be a belt slipping.
An end user should know how their equipment sounds

Images 1-5.
Listening
and watching
equipment can
help end users
detect issues
early. There are
sensors and
other testing
devices to
assist users.
(Images
courtesy of
Jenkins
Electric)

June 2019 | Pumps & Systems

 23

when it is in good working condition. Then, it will be easier to
detect the change in sound when an issue is present.
Sound can also be used to determine inadequate lubrication
levels in bearings—the No. 1 cause of bearing failure.
Ultrasonic grease guns use ultrasound to ensure that the user
has the proper amount of lubrication for the application. The
devices to perform this work come in many configurations for
a variety of applications.
Sight
Unless a piece of rotating equipment is designed to shake
(like a sifter) or vibrate (like a hopper motor), it should run
smoothly. A visual inspection will let the end user know if a
vibration technician needs to be brought in.
Vibration can come from many points in a rotating system.
Performing a vibration analysis will help pinpoint the issue.
Each cause of vibration has a marker on a spectrum that
allows the analyst to determine its severity. If the user has
a system that incorporates a motor coupled to a pump, a
vibration analysis will allow the analyst to determine which
of the units needs the repair.
This method also shows unbalanced components, cavitation
and misalignment. Cavitation can point to wear rings that are
out of tolerance, or a deeper issue within the system. Proper
alignment ensures that bearings and coupling components do
not fail prematurely.
From the moment it leaves the factory, every piece of
equipment has a time-to-failure. It is part of the user’s job to
meet or, if possible, extend that time. Users should employ
these sensory checks as part of a daily routine and discuss
preventative maintenance strategies with the motor shop.
When combined, these efforts will increase understanding
of why equipment fails, and hopefully prevent it as long
as possible. This should allow users to schedule outages
on failing equipment and keep the facility running as
efficiently as possible, with lower operating costs and reduced,
unplanned downtime.
To see more photos, visit
pumpsandsystems.com/
sensesforhealthyequipment
Ryan Ossmann is the repair operations manager at Jenkins
Electric. He is a trained machinist with more than 22 years of
experience in the motor repair industry. For more information,
visit jenkinselectric.com.

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Circle 131 on card.

pumpsandsystems.com | June 2019

24 AFTERMARKET
The Shift to Variable Speed 
Fluid Couplings
Power plants with 
boiler feed pumps are 
fi nding more effi  ciency.
BY BOB WASIK
VOITH TURBO NORTH AMERICA 
Power[ %]
T
he ability to operate a parabolic
machine—such as a boiler feed
25
pump in a power plant—at
variable speeds while following
the pump curve is now considered a 0
0 25
highly efficient method of operation.
Many power plants are opting to retrofit
fi xed-speed boiler feed pumps to variable Image 1. Variable speed pump operation versus operation of the same pump at fi xed speed
(Images courtesy of Voith Turbo North America)
speed fluid couplings, a change that
has the potential to save on energy and
maintenance costs. Further, the couplings can provide space
savings, allowing limited footprints to be used efficiently.
Cost savings can be achieved with the flexibility of variable
speed fluid couplings, along with the process changes that are
instituted when they are added to a system. When installed
in a combined-cycle power plant with an output greater than
500 megawatts (MW), the retrofits typically have a payback
period of two years or less.
The construction boom of the early 2000s brought dozens
of combined-cycle power plants online. During this period,
many boiler feed pumps were installed with variable speed
drives (VSDs). The majority of these are driven by variable
speed hydrodynamic fluid couplings. This type of drive
system can provide a robust and relatively simple method
of regulating speed. The parabolic operation of the variable
speed fluid coupling matches that of the centrifugal pump or
fan, making the VSDs a preferred method of speed control.
In the most typical setup, a hydrodynamic coupling
regulates the power transmitted between the driver—most
commonly an electric motor—and the driven machine. For
the purposes of this article, a boiler feed pump is the machine
being driven by the variable speed fluid coupling.
There is no mechanical connection between the input
June 2019 | Pumps & Systems
Main Shaft Power of Boiler Feed Pump
100 Throttle Control
75
Power Savings Variable Speed
Coupling
50
Energy Savings of
US$ 180,000 per year
for a base load CCPP
with 425 MW
50 75 100 110
Flow [%] Test Block
shaft and output shaft. The primary wheel, or pump wheel, is
mounted on the coupling input shaft. The annular chamber
that surrounds both rotating wheel assemblies is also
mounted to the primary wheel and input shaft. The secondary
wheel, or turbine wheel, is mounted on the coupling output
shaft. Power is transmitted between the primary and
secondary wheel by oil.
Operating Principles
In the typical scenario, the drive motor is started and brought
up to speed. Oil is then pumped into the rotating primary
wheel or annular chamber and collects centrifugally along
the inner diameter of the shell. The oil is accelerated by the
rotating primary wheel, converting the mechanical energy
of the drive motor and primary wheel assembly into kinetic
energy. The oil is then accelerated into the secondary wheel.
As the oil reacts against the secondary wheel, the kinetic
energy is converted back into mechanical energy, and power
is transmitted between the two wheels. The amount of power
transmitted is regulated by controlling the amount of oil that
passes between the two wheels.
As power is applied to the load from the boiler feed pump,
the output shaft begins to rotate. The amount of oil allowed
Circle 105 on card.
26 AFTERMARKET

energy in all conditions. When the flow of the

pump is throttled, large portions of that energy
is wasted. The valves used to choke off the flow
can experience internal wear from cavitation
and become an expensive maintenance issue.
Besides unnecessarily wasting energy, the
throttle mechanism can be a maintenance-
intense piece of equipment. Cavitation and
valve seat damage repairs can be costly.
Power plant operators are realizing that
retrofitting of variable speed into their pump
drivetrains can provide process benefits along
with energy conservation. The benefits include:
• stepless speed variation over a wide
speed range
Image 2. A variable speed fluid coupling and its parts
• load-free starting for electric drive motors
• limited torque transmitted from
hydrodynamic circuits to ensure protection
Pump power is proportional to the head of drivetrain equipment
times the flow • reduced speed operation much of the time for boiler feed
pumps, which can reduce wear within the system and
extend maintenance intervals
H%

160 System throttled

System throttled
Difference Head • changed rate of speed follows the requirements
140

System unthrottled
of the process
120
• torsional dampening from the hydrodynamic circuit
100 • reduced transient torque spikes
80 n=100%
• eliminated need for a freestanding lube oil skid because all
lube oil is provided for drive motor and pump
60 90%

40
70%
80%
Energy Conservation Realized
20 Speed reduced
60% Variable speed fluid couplings provide the opportunity to
n=50%
deliver energy use savings for motor operation and for the
0
02 04 06 08 01 00 120 Q% operation of the driven equipment.
Electric motors can reach efficiencies of more than 90
Image 3. The energy consumption for a fi xed-speed operation
versus a pump driven by variable speed percent when operated at their rated loads and speeds. The
use of a variable speed fluid coupling allows for full speed
motor operation and reduced power consumption in less-
to remain in the rotating section of the coupling is controlled
than-full load conditions. (See Image 1)
by the position of a scoop tube, which is inserted into the
More savings can be achieved by reducing the power
rotating shell. The more oil delivered to the “circuit” between
required to operate the pump at a lower point along its
the primary and secondary wheels, the more power is
designed performance curve. When dealing with centrifugal
transmitted. As the transmitted power increases, the rotating
equipment, the power required is a cube function of the
speed of the driven machine also increases. Likewise, with
operating speed.
decreases in the amount of oil in the circuit, the speed of the
driven machine also decreases.
Effective speed control is achieved by the position of the
scoop tube in the rotating equipment and changing position
as required. A control loop that monitors pump speed versus
Robert Wasik has worked at Voith since 1990
the coupling scoop tube position is the typical control scheme.
and serves as retrofit manager for the United
States and Mexico. Wasik may be reached at
Variable Speed Benefits
717-767-3261 or robert.wasik@voith.com. For
Operation of the pump at fi xed speed in all required flow
more information, visit voith.com.
conditions results in the motor consuming the same level of

June 2019 | Pumps & Systems

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Circle 116 on card.
28 AFTERMARKET

Wear Ring Clearance for 
Centrifugal Pumps  
Understand the pump specifi c speed to help establish 
proper tolerance.

BY EUGENE VOGEL
EASA

O
ne of the most common
repairs on centrifugal pumps
is replacing worn or damaged
wear rings. To restore efficient,
reliable operation and prevent catastrophic
pump failure, it is critical to restore
proper clearances between the stationary
casing wear ring and the rotating
impeller wear ring. Although many pump
manufacturers provide clearances and
dimensions, some do not. There are plenty
of aging pumps around from now-defunct
manufacturers for which dimension data is
simply not available.
In such cases, the rule of thumb that follows provides some Images 1 & 2. Rear wear ring and balancing holes to limit axial thrust
guidance for acceptable running clearances, or the minimum (Images courtesy of EASA)
running clearance chart in American Petroleum Institute
(API) Standard 610 can be used as a guide.
GENERAL GUIDELINES FOR NEW WEAR RINGS
Suction Side Wear Rings vs. Rear Wear Rings • General – up to 5 inches diameter
Before proceeding, it is worth mentioning that there are 0.010 + 0.002 per inch of diameter
basically two types of wear rings—suction side wear rings
• General – 5 to 10 inches diameter
and rear wear rings—each of which serves its own purpose.
0.015 + 0.001 per inch diameter
Suction side wear rings are designed to limit the flow
of pumpage from the higher pressure discharge side of • For galling materials, add 0.005 inch
the impeller to the lower pressure suction side. Excessive
clearance of these rings can result in increased flow across the
suction side and a volumetric loss of efficiency.
Rear wear rings, when present, work in tandem with Open vs. Closed Impellers
balancing holes that pass through the suction eye to lower the Pumps with closed-style impellers will include a casing wear
suction pressure behind the impeller and inside the rear wear ring and possibly an impeller wear ring that is fitted to the
rings (see Image 1), limiting the axial thrust force. Excessive outside diameter (OD) of the impeller suction eye, both of
clearances of rear wear rings can result in high axial thrust which are suction side wear rings. These impellers may also
forces that can damage the thrust bearing. have rear wear rings that control axial thrust.

June 2019 | Pumps & Systems

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NATIONAL PUMP COMPANY / GORMAN-RUPP INDUSTRIES / AMT PUMP COMPANY
Circle 103 on card. © 2019 The Gorman-Rupp Company 570-CORP
30 AFTERMARKET
Image 3. Specific speed is related to head/flow.
Pumps with open-style impellers generally do not have
suction eye wear rings, but they often have rear wear rings.
Wear Ring Clearances & Specific Speeds
Wear ring clearances are more critical for certain types of
impellers than others. The difference involves the relationship
between the head and flow characteristics of the pump, which
are described by the “specific speed” of its design. Note that
the specific speed is not the pump’s rotating speed but simply
a ratio of flow to head.
The higher specific speed impellers (to the right in Image 3)
produce high flow but low head. Low specific speed impellers
(to the left in Image 3) produce greater head at lower relative
flow rate.
Wear ring clearances are more critical for low specific
speed impellers than for those with high specific speeds.
Because these impellers have greater pressure differentials,
any leakage across the wear rings will represent a greater
percentage of the total flow than it would for high specific
speed impellers.
Wear Ring Clearance Guide
Manufacturer’s tolerances are always the best guidance
for evaluating as-found wear ring clearances and fitting
replacement wear rings. When these are not available, the
following guidelines work well for common water service
pumps (municipal water, wastewater, HVAC applications, etc.)
and apply to both suction side and rear wear ring clearance.
Another alternative is to consult the minimum internal
running clearances chart in the API Standard 610 (API STD
610/ISO 13709). As illustrated by the example in Image 4,
the values in the API 610 chart are very close to the general
guidelines provided for new wear rings provided.
June 2019 | Pumps & Systems
Image 4: API 610 minimum internal running clearances chart
value comparison
Wear ring Wear ring General guideline
diameter diameter
5 in. (125 mm) 0.017 in. (0.43 mm) 0.020 in. (0.50 mm)
10 in. (125 mm) 0.022 in. (0.55 mm) 0.025 in. (0.64 mm)
The API 610 chart provides values for wear ring diameters
from 2 inches to 26 in. (50 millimeters (mm) to 650 mm) in
28 increments.
The API 610 chart provides minimum, not maximum,
clearances for pumps used in petroleum processing
applications. Minimum clearances are specified since tighter
clearances would risk contact between the rotating and
stationary components, likely resulting in a catastrophic
machine failure.
Therefore, when fitting new wear rings and manufacturer’s
tolerances are not available, the API chart values provide a
good guideline.
Note that wear ring clearances are always specified in
diametric measurements—i.e., the difference between the
inside diameter (ID) of the stationary ring and the OD of the
rotating ring. That means the actual running clearance is one-
half the diametric clearance.
The guidance provided above can be useful for designing
replacement wear rings when manufacturer’s tolerances are
not available. It can also be helpful for evaluating as-received
clearances and deciding if replacement is necessary. Some
manufacturers recommend replacing wear rings when
clearances have increased by 40 percent of the original
specified clearance. This recommendation is good for pumps
in common water service applications and for impellers in the
mixed-flow range of specific speed.
As described above, pumps with low specific speed
impellers should be held to tighter clearances, whereas pumps
with high specific speed impellers have more leeway.
Conclusion
Proper wear ring clearances are a fundamental concern for
ensuring efficient and reliable pump operation. The guidance
provided here should help pump users and service providers
achieve those objectives.
Eugene Vogel is a pump and vibration
specialist at EASA. He may be reached at
314-993-2220. EASA is an international
trade association of more than 1,800 firms
in about 80 countries that sell and service
electromechanical apparatus. For more
information, visit easa.com.
Stray Electric Current:
Meet Your Match

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hybrid ceramic or ceramic-coated versions featuring our proprietary
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©2019

Circle 106 on card.

32
MOTORS & DRIVES
Understand 
Motor & VFD 
Independence
Separation can improve delivery  The efficiency regulation requirements are dictated
time and allow exact replacement.
BY MILES MAHAFFY
DANFOSS DRIVES
M
otor independence is a premise that the
variable frequency drive (VFD) selection should
not be tied to a specific motor and, conversely,
the motor selection should not be limited
by a VFD. By decoupling the selection of a motor and VFD,
users can select the appropriate motor for their application
based on performance, energy usage and availability. Motor
independence is important as users explore the use of motors
beyond the traditional three-phase induction variety.
Driven by Motor Efficiency
The standard three-phase induction motor (also known as
three-phase asynchronous) has long been the motor of choice
for commercial and industrial applications. The design of
these motors continues to evolve as government regulations
increase the demand for higher efficiency levels. Electric
motors are a prime target for improvements in efficiency to
reduce the global use of electricity, and motor manufacturers
are responding. Today’s induction motors feature lower
current requirements and offer improved efficiency.
The desire for improved efficiency is leading to the
use of other three-phase motor technologies to gain
greater electrical capability. Permanent magnet (PM) and
synchronous reluctance (SynRM) motors are two possible
options. PM motors can be used in both constant and variable
torque applications, making them suitable for a wide range of
applications. They can also be used in applications requiring
high torque and low speed and potentially eliminate the need
for a speed reduction gearbox.
PM motors use permanent magnets imbedded in the rotor
June 2019 | Pumps & Systems
of the motor to generate the rotor magnetic field. Using
magnets instead of inducing current in the rotor (such as in
an induction motor) can improve the efficiency of the motor.
The initial costs of these motors are typically higher, but
lifetime operational costs may offset this.
SynRM motors use induced magnetic reluctance in the
rotor to develop torque. Because there is no current flow in
the rotor, the losses are reduced compared to an induction
motor. These motors are more suitable for variable torque
applications, such as fans and centrifugal pumps, due to lower
starting torque. The cost of SynRM motors is lower than PM
motors since they lack the permanent magnets.
locally. In the United States, federal regulations 10 CFR
431.25 through 431.26 set the standard for efficiencies
of motors produced with the latest revision for standard
National Electrical Manufacturers Association (NEMA)
motors updated in 2016. In the European Union (EU), the
minimum efficiency levels are specified by Regulation (EC)
No. 640/2209, with EU Regulation No. 4/2014. With each
revision of the standards, the efficiency levels become stricter,
potentially requiring the use of new motor technologies.
Motor Selection
An equipment manufacturer or end user will need to begin
selection of the motor based on the application. Power and
voltage are the two easiest variables to consider. Other more
complex variables make the decision more challenging:
starting torque, load type (variable or constant torque), peak
torque required (breakdown torque), environment, etc.
The type of motor selected depends on the application
applied. Standard induction motors are versatile and can be
used on several applications. If higher efficiencies are desired,
a PM or SynRM may be beneficial. If a PM motor is selected,
should it be a surface PM motor or an internal PM motor?
Both types have different characteristics and challenges when
controlling them with a VFD. SynRM motors have their own
distinct control requirements.
In addition to the above factors, motor selection must
consider availability.
Users are faced with several issues:
• local suppliers who can provide quick delivery in
the event of failure
• the availability of an exact replacement or an
equivalent motor
• the cost of keeping a spare motor if an exact
replacement is required
VFD for Control
The selection of the VFD should be based on current, voltage,
application and environment, and not its ability to control the
 33

motor. This is motor independence.

Control electronics have improved so
that multiple-control algorithms can
exist in one VFD to control most three-
phase AC motor technologies. Typically, a
parameter selection is all that is needed
Real time remote monitoring with
to indicate motor type. An automated
identification process that can detect Flowrox Smart SolutionsTM
variations of motors could be used.
The advantage to equipment
● Remote monitoring ● Maintenance ● Reporting & Analytics
manufacturers and end users is having
to support only one VFD for multiple
applications and motors (plus perhaps
a second VFD for small motors for
Enhance your performance with Smart Solutions™
cost purposes). ● Monitor your pump remotely 24/7 with any mobile device / PC
An installed motor could be changed ● See pump speed, flow, media temperature, pressure, tank levels
to a different motor type if, in the future, ● Get equipment condition & problem notifications
it becomes a requirement or if the motor
● Use analytics tools for preventive maintenance
fails and needs to be replaced. However,
if a motor is tied to a VFD type, that ● Get high security standards
flexibility goes away.
The idea of matching a specific VFD
to a specific motor has the advantage IIoT Connecting
Your Equipment:
of implied responsibility of pairing.
● 3D modelled environment
Conversely, selecting a VFD that controls
of your equipment or plant
all motor types provides flexibility. ● Online asset monitoring
Another advantage of motor ● Maintenance alerts prior to
independence is evident when there is equipment interruption
● Document & Maintenance
no motor VFD match for the application. Flowrox MalibuTM Management
Enables online monitoring of any brand
For example, the VFD will be in an pumps, valves and filters.
● Utilizing 3G/4G/LTE/WIFI
environment that requires a higher
enclosure class, such as Type 4, but the
VFD paired with a specific motor is only
available in Type 1 or Type 12 enclosures.
Another situation may arise if the
motor must be replaced but the exact
substitute is not available, requiring the
replacement of both the motor and VFD,
which can add costs.

Miles Mahaffy is the senior product

marketing manager for Danfoss Drives.
Circle 117 on card.

He graduated with a degree

in electrical engineering
from Queen’s University at
CE 197
Kingston, Ontario, Canada.
SIN ASK FOR MORE: www.flowrox.com
Follow us:
7

For more information, visit 888-356-9797

danfoss.com.
M
FL

OW
R O X.C
O sales-us@flowrox.com

p u m p s a n d s y s t e m s.c o m | J une 2019

34 COVER SERIES MOTORS & DRIVES

4 Industry Demands Driving 
the Popularity of Electronically 
Commutated Motors
Furnace blower motor design transformation was fueled by new 
end user and government standards.

BY ALEX WIEGMANN 
NIDEC MOTOR CORPORATION

C
hanging expectations from end users,
supported by new government
energy efficiency standards and
advances in materials and electronics,
are fueling a shift in demand from traditional
induction motors to electronically commutated
motors (ECM) in heating, ventilation, air
conditioning and refrigeration (HVACR).
Most notable is the rapid pace of the switch
to ECMs, commonly referred to as brushless direct current
(BLDC), or brushless permanent magnet (BPM), motors.
Despite their alternative names, these motors share many
common features.
All are electric motors that have brushless permanent
magnets and have been integrated with a tuned variable
frequency drive (VFD). Because they use electronics to control
the voltage and current applied to the motor, ECMs do not
waste power inducing the rotor field.
To understand the growing popularity of today’s ECMs,
it helps to understand the four industry demands they have
been designed to address.
Image 1. Constant torque motor designed for dual blower application
such as fan coils and single packaged vertical units. (Images
courtesy of Nidec Motor Corporation)
the long-time industry standard known for its simplicity, low
cost and reliability. Most induction motors are connected to
a line voltage rather than electronic drive, so they operate at
a discrete speed dependent on the motor’s load. This means
that as static pressure changes due to a clogged fi lter or
inadequate duct work, the motor operating speed can result
in lower airflow.
Some residential and commercial end users typically prefer
airflow that is consistent and silent. They may not want to
hear the sound of a furnace kicking on and off or the sound of
air flowing through the ducts and across their desk or dining
room table.

1 Improved End User Comfort

The same complaints have been echoed in homes and
offices around the world since the invention of HVACR. Some
people are too hot, and others are too cold, all depending on
the space where they are located and whether or not an air
blower is operating at the time. And, many complain that the
system is too loud.
Noisy, uneven heating conditions can be a result of furnace
blowers and air handlers that are driven by induction motors,
These are the kinds of performance problems that can be
addressed by an ECM, with electronic controls that enable
it to be quickly and quietly ramped up or down, while also
delivering a stable or constant air flow. Because these motors
can operate within tight tolerances, they are able to deliver
airflow within 5 percent of demand to specific areas, helping
to eliminate hot and cold spots.
Hot and cold spots may also be improved by operating
ECMs in circulation mode.

June 2019 | Pumps & Systems


Constant circulation pushes conditioned air out of the
ductwork and into the building to maintain a more constant
temperature. In addition, low-speed, low-power consumption
circulation that continually pushes air through the fi lter can
improve air quality.
In larger commercial buildings, ECMs can do more than
control a single unit. Premium ECMs include feedback
capacity, allowing central controls to monitor airflow
throughout the building.
By providing instant feedback on the variations in
demand throughout a building, the units can support smart-
building goals.
If a motor experiences a higher-than-expected load, it may
signal a clogged fi lter or other maintenance need, creating
future opportunities for predictive maintenance.
Greater Energy Efficiency
2 Because blowers are one of the biggest energy consumers
in a residential or commercial furnace, the motors that
power them are a primary target for energy efficiency
improvements.
That is one reason why up to 50 percent of residential
furnace blowers have been upgraded with ECMs in the last
decade. Commercial systems are following close behind.
The motor driving a furnace blower or air-handling unit
operates at less than full output much of the time, reaching
full output during times of peak demand.
A traditional induction motor operates most efficiently at
full load. A motor’s efficiency drops when it is operated under
slower speeds.
By using drives and permanent magnets, ECMs can suffer
less efficiency loss at slower speeds, resulting in a flatter
efficiency curve and higher overall efficiency. They also
meet the reduced wattage needed to comply with Seasonal
Environmental Efficiency Ratings (SEER) requirements.
Switching to ECMs is a cost-effective “bolt on” energy
efficiency upgrade that can be made to a furnace blower
today. An ECM can operate at about 85 percent efficiency at
full load.
ECMs that meet IE4 efficiency levels have been shown to
offer up to 91 percent system efficiency for the motor, drive
and fan. In some cases, that exceeds the efficiency required
by the National Electrical Manufacturers Association
(NEMA) for a premium-efficient motor alone. At that level of
efficiency, a single 5-horsepower (hp) motor can reap energy
savings of $180 to $250 a year.
Greener Solutions
3 In March, New Mexico became the third U.S. state to set a
100 percent renewable energy goal when it passed legislation
requiring the state’s utilities to be completely carbon-free by
2045. Other states are joining them to varying degrees with
35
Image 2 (left). NEMA 56 frame ECM designed for condenser fan and
refrigeration applications. Image 3 (right). Constant torque motor
used in many residential and commercial furnaces, heat pumps and
air handlers
regulations designed to reduce carbon footprints and meet
other energy reduction and efficiency targets.
These green requirements are trickling down from states
to end users, driven largely by utilities that are providing
incentives to lower demand. Among those incentives are
rebates for switching to ECMs. Likewise, commercial building
programs such as Leadership in Energy and Environmental
Design (LEED) reward owners who use these high-efficiency
motors in support of the certification process.
Even without these incentives, there are practical reasons
that lead building engineers and managers toward ECM
usage. ECMs can be a simple way to lower building energy
usage and reduce energy costs.
Regulatory Compliance
4 The U.S. Department of Energy (DOE) is adding a little
push to other efforts to incentivize the transition to ECMs.
New regulations that are now—or soon will be—coming
online are increasingly prescribing the use of ECMs.
There are many opportunities to design these motors so
they address the precise needs of the HVACR industry—and
the people—they will ultimately serve.
End users can reach out to OEMs, and OEMs can reach
out to motor suppliers, to share goals for the next generation
of ECMs.
Whether there is a need for preventive maintenance
features or new protocols or controls to drive these motors,
manufacturers are interested in developing products that
address these needs.
Alex Wiegmann is market manager for HVACR
for Nidec Motor Corporation. He may be reached
at alex.wiegmann@nidec-motor.com. For more
information, visit nidec.com.
pumpsandsystems.com | June 2019
36 COVER SERIES MOTORS & DRIVES

Golf Course, Shopping Mall 
See Benefi ts of Pump Control 
This technology can help reduce blockages, detect damaged equipment 
and avoid dry runs, thus reducing motor stress.

BY WAYNE MORRIS 
INVERTEK DRIVES USA

I
n the increasingly competitive domestic
and international processing markets,
businesses are constantly looking at
ways to reduce costs and increase
profitability. The pump systems industry is
helping end users achieve this through the
integration of technology, such as variable
frequency drives (VFD).
VFDs designed specifically for pump control
can help achieve energy savings of at least 20 to
30 percent in most pump control applications.
Combined with associated technology, some
VFDs can ensure efficient control of multiple
pumps as well as avoiding pump downtime by
reducing blockages, detecting burst pipes and
avoiding dry runs.
Here are two case studies showing how VFDs
helped save money and increase efficiency.

VFDs Keep Golf Course Green Image 1. A shopping mall installed four VFDs for each pump, giving
more control over how much water is pumped. (Images courtesy of
One example is a Professional Golfers’ Association Invertek Drives)
championship 18-hole golf course that had been using a single
150-horsepower (hp) pump and a 150-hp drive to control its The VFD technology
underground irrigation system serving its 72-hectare (178 allows multiple pumps to
acre) course. The way the system was set up meant the entire work together to ensure
course was irrigated even if greenkeepers wanted to target optimized efficiency.
certain areas. The system is arranged
If the existing pump or drive was out of service, the whole so that one VFD is the
system would be inoperable, leaving the course without master and the other three
irrigation. The system was also inefficient, using water that follow behind it. The
was not needed. master controls the other
Four VFDs were introduced as part of the solution. The four VFDs to maintain a Image 2. The VFDs can be
VFDs are now used to control four 25-hp pumps that target constant system pressure controlled independently
depending on demand.
zoned areas of the course. within the pump system.

June 2019 | Pumps & Systems

 37

The master VFD also ensures that if one or more drives is out
of service, the remaining available drives can take control of
the pumping requirements, ensuring continued irrigation for
the course.
The system can also detect low pressure, such as a leak in
the system, blockages and dry-runs. This ensures that the
motors are not placed under stress, reducing maintenance or
We’ve got
replacement costs. the right
motor
The new targeted approach for the irrigation system
means the golf club can cut water usage and reduce costs
overall. The golf course noted savings that were an immediate
return on investment.
for your
Slashing Costs at Shopping Mall
application
In another case, a large shopping mall achieved 30 percent
savings in water and energy costs by implementing VFDs. The
retail location reduced its monthly $448,900 utility bill almost
immediately.
At the shopping mall, there was no control over how much
water was being pumped through the system compared to the
actual demand. So, in this instance, the system had at least
three pumps that were in constant use, even at quiet times.
Four VFDs were installed for each pump. Now, with the use
of VFD technology, each of the four pumps can be controlled
independently depending on demand.
This control ensures that the optimum number of pumps
is in operation. When demand falls, some pumps can be put
to sleep or the speed can be reduced. In some cases at the
shopping mall, on average only two pumps have been required.
This results in lower energy consumption and less wear and
tear, extending the life of the pumps.
In addition, the system is never shut down. If a drive or
pump is out of service, then operation transfers to another
drive or pump. The drives can also detect and clear pump
blockages, provide dry-run and burst-pipe protection.
NovaMAX ¨

The result is an optimized water supply ensuring little waste,

reduced costs and increased savings. The award-winning line of SyMAX®
While the mall’s owners had hoped for 15 percent savings, and NovaMAX® motors delivers high
they say 30 percent savings have been realized since the drives torque performance meeting IE4 and
even proposed IE5 efficiency standards
were installed in January 2018. in a variety of applications including:
data centers, ventilation, pump,
compressors and more.
Read more motors and drives content at
Try our savings calculator at
pumpsandsystems.com/motors
www.novamaxmotor.com.
ECM made Easy™
Circle 127 on card.

Wayne Morris is vice president of Invertek
Drives USA. For more information, visit
invertekdrives.com.
www.regalbeloit.com
Creating a better tomorrow™...
Regal, Creating a better tomorrow, ECM
Made Easy, Marathon, NovaMAX and SyMAX
are trademarks of Regal Beloit Corporation or
one of its affiliated companies.
©2018, 2019 Regal Beloit Corporation, All
Rights Reserved. MCAD18067E • SB0196E

pumpsandsystems.com | June 2019

38 COVER SERIES MOTORS & DRIVES
Evolving HVAC Design
Engineers are eschewing large 
motors for less centralized systems.
BY SETH OʼBRIEN
EATON
I
n terms of efficient pump operation, proper maintenance
of pumping systems remains essential, but new
technologies offer more cost-controlling options than
those installed 20 years ago. For years, the pump was
overlooked as an opportunity to improve the performance
and reliability of heating, ventilation and air conditioning
(HVAC) systems. System operators relied on old, but reliable
practices. Building designers used best practices from years
prior. When pumps failed, technicians simply replaced them
with new ones with the same characteristics.
Things are changing rapidly. Manufacturers have made
improvements in designs and construction materials and
many advancements in HVAC operations are being applied
to pumps and their operations. Levels of operating efficiency
are reaching levels unheard of even 10 years ago. System
performance is also improving with an increase in reliability
and a reduction of maintenance requirements. Here are more
key questions and answers about how variable frequency
drives (VFDs) relate to pumping systems today.
How are VFDs driving changes to systems?
A new generation of intelligent pump controls, VFDs
can offer improvements in pump reliability as well as system
performance. They can adjust better to system load changes,
control pump operations and provide control over a wider
range of load conditions and offer smoother pump startups.
Are there innovative ways to impact energy
efficiency?
A growing trend in the motors and drives market is
a transition from single, large horsepower motors running
HVAC systems to a less centralized model in which smaller
motors are used to run loads throughout a system.
June 2019 | Pumps & Systems
Image 1. VFDs can increase the performance, reliability and
efficiency of HVAC systems with advanced algorithms that
can continuously optimize energy savings. (Image courtesy
of Eaton)
How does changing to smaller, less centralized
systems impact operations and maintenance?
Reducing the reliance on one major system running
everything offers a backup for individual zones, improving
reliability and uptime. The system can be more energy
efficient because of the ability to fine-tune each zone of the
system based on individual needs. One large system can
only be controlled by a few factors without complex control
schemes and additional equipment.
What else can impact energy efficiency?
An increase in the use of VFDs can impact energy
efficiency providing the ability to ramp systems up or down
according to the demand of the facility. The energy efficiency
benefits of VFDs are well known, but they also can offer
comfort benefits as well.
Does this affect the energy costs?
Motors represent a great deal of untapped, relatively
easily obtained energy savings. They can be the key to high
efficiency. We can see a significant reduction in energy costs
simply by adding a VFD into the same application where an
across-the-line starter or a contactor once was. Also, an often-
overlooked benefit of VFDs is that the constant low airflow
helps create a more comfortable environment.
 39

How else are manufacturers Seth O’Brien is the product manager, HVAC variable frequency drives,
tuning systems to impact energy Industrial Controls Division, Eaton. He holds a bachelor’s degree from
efficiency? the University of Florida and is an MBA candidate with the University
of Wisconsin. For more information, visit eaton.com.
Advanced algorithms that
automatically and continuously optimize
the energy savings from VFDs in a
given application are also impacting
energy efficiency. Certain algorithms VFD-Induced Shaft Voltages
can continuously fine-tune the electrical
output to reduce energy spent while Kill Bearings!
maintaining desirable conditions within
a facility. These algorithms are becoming
more standardized and more critical.
For more than 40 years, VFDs have
been a critical component of efforts to
improve efficiency. Their fundamental
usage has remained the same, while
technology has evolved—yielding drives
that are better able to reduce energy
consumption and improve reliability
while extending equipment life.
Today, new algorithms deliver energy
savings and stability, and establish a
new level of efficiency for commercial
buildings. A novel control algorithm Electrical bearing damage Protect motor bearings with
for VFDs reduces the input power of an causes unplanned downtime AEGIS® Shaft Grounding Rings
induction motor used to drive a variable VFD-induced electrical discharges can By channeling VFD-induced discharges
torque load. The algorithm adjusts the blast millions of pits in metal bearing safely to ground, AEGIS® Shaft Grounding
surfaces. These discharges burn and Rings prevent electrical bearing damage.
motor’s operating point based on its load
contaminate bearing grease, drastically Proven in millions of installations
conditions, provides power savings and reducing its effectiveness. They also worldwide, they provide unmatched
improves energy efficiency. result in bearing fluting failure and protection of motors against electrical
End users are driving these trends as costly, unplanned downtime — bearing damage, motor failure, and
they seek the lowest energy costs while often in as little as 3 months! unplanned downtime.
maintaining a comfortable environment.
Download your free copy
For existing systems, what can of the AEGIS® Bearing
be retrofitted to modify energy Protection Handbook:
consumption and impact costs? www.est-aegis.com/pump

For their part, contractors can Register your AEGIS® Protected

play the same role on the retrofit side. Fluting Damage motor for a FREE 2-Year Warranty:
www.est-aegis.com/warranty
Some retrofits are easier than others,
but there is flexibility to provide
solutions to fit customers’ needs. For Visit us at
example, manufacturers are developing EASA 2019: Booth 824
VFD products that have virtually the
same footprint as a typical across-
1-866-738-1857 | sales @est-aegis.com
the-line product. That allows full VFD
functionality inside the same footprint.
Circle 122 on card.

pumpsandsystems.com | June 2019

40 COVER SERIES MOTORS & DRIVES

New Considerations for 
Variable Speed Compressors  
VFDs can extend life by reducing wear on equipment and motors.

BY DEANA FU
MITSUBISHI ELECTRIC AUTOMATION

C
ompressed air and refrigeration
systems are the heart of any
manufacturing facility and consume
up to 30 percent of a typical plant’s
energy. In a typical screw compressor,
the starting and stopping cycles can be a
significant drain on energy and can wear on
the mechanicals producing large fluctuations
in pressure. This can have a detrimental effect
on production processes and product quality,
as well as cycle-time delays.
In some cases, capital, maintenance and
Image 1. Typical screw compressor (Images courtesy of Mitsubishi
energy costs can be reduced by specifying Electric Automation)
variable speed drive (VSD) options for different
fan, pump and compressor applications within the plant. By
controlling the speed of a motor, variable frequency drives
(VFDs) adjust energy use to need. By varying motor speed to
meet the demand, VFDs can practically eliminate the excess
energy used when running at a fi xed speed.
Using VFDs in compressed air systems can reduce wear on
pneumatic tools and equipment, as well as the compressor
motors. Optimizing compressed air flows in manufacturing
operations can reduce scrap caused by contaminated products
or malfunctioning equipment and maintain energy efficiency
by not over-treating compressed air.
While energy savings can be achieved at all reduced
capacities, the best energy savings are realized in applications
where the running hours are long, with a high proportion in
the mid- to low-capacity range. Image 2. Typical facility
Some designs stop the compressor when a lower speed of
around 20 percent is reached, while others may unload at 40 Energy savings of 30 to 40 percent are feasible in variable
to 50 percent, with an unloaded power of 10 to 15 percent. speed compressed air systems, since the VFD can run at
Field conversion of an existing compressor to VSDs must lower speeds at a constant basis, acting as make up supply
consider the electric motor, the proposed rotor speed at 100 when needed, or reducing volume when demand drops. Loads
percent capacity, and the reduction of air end efficiency at are matched precisely, and the cycling of compressors is
reduced speeds and capacity. minimized as gradual motor starts reduce inrush currents.

June 2019 | Pumps & Systems

 41

VFDs can require less energy to start Multi-Tube

Delivers
and stop a motor through preset ramp
rates than across-the-line starts without
a drive. For compressed air or gas
systems, this can provide a more reliable

4X LONGER
and constant supply, precise temperatures,
humidity and additional capacity
when needed.
Using today’s controls in the drives,

Tube Life
or those tied to a controller or system
programmable logic controller (PLC),
provides accurate and efficient air or
gas compression. It is common, even in
a retrofit, to monitor real-time external is
conditions and adjust the drive speed to ISO 9001:2015
Certified
match demand.

Motor Technology
Makes a Difference
Recent advances in motor technologies
have improved the efficiencies of VFDs
on compressors. The use of synchronous
reluctance motors has helped improve
low-speed performance, offering constant
torque performance and accuracy. These
motors are efficient because the current
does not flow to the rotor, so there is no
secondary copper loss. Magnetic flux is
generated by the permanent magnets, so
less current is required to drive the motor.
The power density of the synchronous
reluctance motor is greater than an
induction motor, so it produces more
power at a smaller size. Synchronous
reluctance motors can also continuously
deliver high torque at low speed and run
cooler with less stress.
IP66

Bringing IIoT to Compressor Usage NEMA 4X

WASH DOWN
Communication options provide the key
to optimizing efficiencies of the overall
system, regardless of the application. This
improves availability of the machines,
quality of the products and processes
they support, and maintenance expenses.
ProSeries Flex-Pro A3 ®

PERISTALTIC METERING PUMP

®

Today’s drive technologies have embraced

Circle 120 on card.

the use of Ethernet communications so

cascaded drives in a multicompressor S
ND PO
D IA MO

NS R

system can balance themselves by

O

communicating to each other. Visit us at

Adding Ethernet communications BOOTH
3425
allows the VFD to communicate to 714-893-8529 • sales@blue-white.com • www.blue-white.com

pumpsandsystems.com | June 2019

42 COVER SERIES MOTORS & DRIVES
Image 3. Ethernet communication diagram
remote monitoring systems for preventive maintenance
and performance monitoring. Mobile users can have
real-time monitoring and alarms sent directly to their
smartphones or remote monitoring stations to mitigate
any downtime. Accumulating actual runtime performance
data of the compressor system provides the user or OEM
the ability to determine failure mode probabilities, typical
anomalies to be expected in the systems and predetermined
corrective actions. These actions can include service work
orders and parts orders when downtime is anticipated. The
advancements in industrial internet of things (IIoT) offerings
from VFD vendors has enabled compressor OEMs to offer
service enhancements and uptime guarantees matched to
energy performance and compressor availability.
When looking at VFD options for compressor and/or pump
systems, be aware that each generation produces higher
efficiencies, integrated PLC functions, improved diagnostics
and communications, and improved environmental operating
characteristics. Today’s VFDs typically include built-in PLC
logic, safety functions, open loop detection, adjustable modes,
Image 4. Torque diagram
June 2019 | Pumps & Systems
communication over Ethernet, wireless and mobile operating
panels, diagnostics that reflect sensor inputs from outside the
drive, and flexible ramp rates and alarm settings to provide
maximum adaptability.
Built-in cascade control and peer-to-peer communications
provides critical regulation and coordination without the
need for an external controller or PLC. Distributing operating
hours across multiple drives and motors is a function of
improved cascade control when sized to maintain 100
percent capacity even when a failure occurs. The system
design may accommodate capacity at 150 percent in order to
provide mechanical cycling to save operating hours between
compressors and still allow for a failure or downtime on a
component of the system while it maintains 100 percent
operating capacity.
Diagnostics also monitor the motor and load for
abnormalities such as cavitation, bearing damage, clogged
pipes and vibration issues, creating alarms and reacting with
either vibration compensation or limiting performance until
corrective actions are taken.
It is now commonplace for compressor and pump providers
to offer remote monitoring services that tap the knowledge
resident in the VFD. From locations miles away, machine and
process behavior are monitored and reported. Through remote
monitoring and the use of analytics, either through the
OEM or the user’s own algorithms, predictive maintenance
is used to prevent unwanted downtime and improve overall
equipment availability and reliability.
For OEMs deploying remote monitoring services, operating
expenses such as spare parts inventories and service
schedules can be minimized through accumulation of fleet
information on runtime performance and user behaviors.
Deana Fu is a senior product manager at Mitsubishi Electric
Automation. Fu has a Bachelor of Science in electrical and
computer engineering from Cornell University. For more
information, visit mitsubishielectric.com.
 FREE WEBINAR

IIoT Advanced Analytics

& Retrofits
JUNE 20, 1 P.M. EASTERN

Presenter: Seth Tate

Learn how to accelerate your facility into the 21st century’s
With 14 years
Industrial Internet of Things (IIoT) approach without bogging down
of experience
your engineering and IT resources. Machine learning and anomaly in equipment
maintenance and
detection can transform your asset life and plant efficiency.
reliability, Seth Tate
supports Sulzer
Rotating Equipment
This webinar will include information about:
Services as a Technical Advisor. Tate has
• Performing the right maintenance at the right time been a pipeline SME, refinery engineer and
mechanical seal engineer. He contributes
• Monitoring common wear-out failure modes for early detection to the efforts of SMRP and is a certified
reliability leader through AMP. These
• Correcting potential random failures before they cause experiences have enabled him to become
irreversible damage an expert in providing technical direction,
supervision, and repair training, both
for the Sulzer team and customers to
troubleshoot challenges of rotating
A few case studies will be presented to show lessons learned in equipment maintenance and repair, as
improving reliability, efficiency and performance of physical assets well as to deliver economically justified
long-term solutions.
with the help of IIoT.

Sponsored By
register now!
pumpsandsystems.com/webinars
44 COVER SERIES MOTORS & DRIVES

The Need for Shaft Grounding 
on VFD‑Driven Motors
Harmful common mode shaft voltages can damage motor bearings and 
cause premature machine failure.

BY MATT LAUFIK
ELECTRO STATIC TECHNOLOGY

I
n the quest for energy efficiency and machine
automation, more engineers, facility managers, and
building owners are turning to variable frequency
drives (VFDs). As one of the most promising “green”
technologies available, VFDs allow users to operate motors at
less than full speed while maintaining the required torque.
In fact, VFDs can reduce an electric motor’s power
consumption, saving 30 percent or more in electric energy
costs. VFDs, however, can require additional protection for
the equipment.
VFD-induced common mode shaft voltages can damage
bearings through the process of electrical discharge
machining (EDM), which can shorten electric motor bearing
life and reduce the reliability of these systems.
To mitigate these voltages, long-term shaft grounding
is essential. An effective way to protect electric motors
from electrical bearing damage is to install circumferential
conductive microfiber shaft grounding rings.
Most VFDs use pulse width modulation with insulated
gate bipolar transistors to control switching. The output of
these drives includes a fluctuating common mode voltage
that electrostatically induces voltage on the motor shaft.
This shaft voltage tends to discharge through the bearings,
possibly causing EDM bearing damage.
Shaft voltage can be measured using a digital
oscilloscope—with a bandwidth of 100 megahertz (MHz) or
higher—by touching a conductive microfiber probe tip to the
spinning shaft of a motor.
Without a circumferential conductive microfiber shaft
grounding ring, shaft voltage will discharge through the
motor’s bearings (or those of coupled equipment), then
through the motor’s housing to achieve electrical earth
ground. The shaft grounding ring protects motor bearings
Image 1. VFD-induced shaft voltage bearing discharges produce
micron-sized pitting (left) known as frosting and fluting (right), a
washboard-like pattern in the bearing raceway resulting in complete
bearing failure. (Images courtesy of Electro Static Technology)
by offering an alternate path to ground for shaft voltage—
directly from the motor shaft through the ring to the motor’s
housing (ground), avoiding the bearings altogether.
Without shaft grounding, EDM erodes the rolling elements
and the bearing raceway surface (Image 1), causing premature
bearing failure. These frequent discharges create millions of
micron-sized pits, called frosting, on the bearing raceway.
As frosting damage increases over time, a phenomenon
known as fluting occurs. Concentrated pitting at regular
intervals along the raceway surface that form washboard-like
ridges, fluting can cause excessive noise and vibration. By the
time this noise can be heard, bearing failure is imminent.
The most reliable way to minimize electrical bearing
damage and ensure the reliability of VFD-driven motors
and systems is a circumferential microfiber motor shaft
grounding ring that protects the motor’s bearings as well as
those of attached equipment. This technology is available
from motor manufacturers that install it inside or outside

June 2019 | Pumps & Systems

 45

the machine at the factory. Field retrofit

products are also available.
A caution: most electric motor
MASSIVE
manufacturers offer “inverter-rated,
inverter-duty, or inverter-ready”
machines, implying the motors are
already protected. The VFD protection
WATER SAVINGS
85% REDUCTION IS COMMON
incorporated into these motors is the use
of “inverter class” magnet wire for the
motor windings required under National
Electrical Manufacturers Association
(NEMA) MG1 Part 31 guidelines.
Inverter-class magnet wire protects the
motor from spontaneous winding shorts
and subsequent corona failures, both of
which would typically occur within the
motor’s warranty period.
And while inverter-class magnet wire
protects inverter-duty, inverter-rated,
inverter-ready, and VFD-rated motors
against spontaneous winding shorts and
corona failures, it offers no EDM bearing
fluting protection.
If any motor fails due to EDM bearing
fluting damage, the manufacturer’s Patented Product
warranty may not apply.
Electric motors that are correctly
designed to operate sustainably on a VFD
must include circumferential microfiber How?
o Through
oug Automatic
uto at c Flush
us Reduction
educt o
shaft grounding rings. The addition of this
technology to an electric motor provides a CLOSE CLEARANCES LIMIT FLOW TO PROCESS
warranty against bearing fluting.
Most electric motor OEMs offer product The PackRyt®® Sealing System is a unique stuffing box sealing arrangement that
lines that are inverter-rated, inverter- incorporates a bearing and flush channel system together. The one-piece bearing
duty, inverter-ready with circumferential and lantern ring, made from the same material, ensures the lantern doesn’t spin,
conductive microfiber shaft grounding collapse, or expand in the stuffing box which can result in failure.
rings factory-installed.
Ask a preferred electric motor OEM
EASY TO MIMIC. IMPOSSIBLE TO MATCH.
or electric motor distributor if they
supply machines with this level of VFD
protection. For trouble-free operation,
always specify circumferential microfiber
shaft grounding on any machines that will
be controlled by pulse width modulated
Circle 118 on card.

insulated gate bipolar transistor VFDs.

ROTATING SHAFT SEALING EXPERTS

Matt Laufik is global sales manager for Call us to find out why reliability and maintenance managers are moving to our patented solutions!
Electro Static Technology. He may be
MADE IN THE U.S.A.
reached at matt.laufik@est-aegis.com. Designed and
64 Servistar Industrial Way Phone: 413-564-5202 Manufactured
For more information, visit est-aegis.com. Westfield, MA 01085 Fax: 413-564-5203 in Westfield, MA

pumpsandsystems.com | June 2019

46 COVER SERIES MOTORS & DRIVES

Ensure a Successful Transition 
when Replacing Large Motors 
Understand accessories, sizing, electrical performance and color. 

BY EDUARDO DOSREIS 
TMEIC

C
onsidering the long history of electric motors
powering the industrial world, it is no surprise when
the need arises to replace a large induction motor.
This article details what should be considered when
attempting to replace an outdated or failed machine with a
new induction motor.
Many factors could lead to the replacement of a motor,
including defects, a desire to operate at higher efficiencies
or a demand to achieve higher power factors. Every case is
different and specific to each operation. However, there are
universal considerations that should be accounted for when
upgrading a large induction motor.
Frames within the National Electrical Manufacturers
Association (NEMA) range of small to medium industrial
motors are not complicated to replace due to the universal
dimension standards. However, medium- or high-
voltage motors do not have dimensional standardization.
Additionally, unlike motors with power less than 500
horsepower (hp), large motors are not required to maintain
comparable torque or current levels from manufacturer
to manufacturer.
FC V
AB
Unless the end user intends to rebuild the foundation,
these high-power ratings and frame dimensions require
detailed attention to verify the mechanical interchangeability
of an upgraded motor, in addition to an accurate evaluation of
the electrical performance.
The following are critical mechanical and electrical
considerations required to ensure a successful transition
when replacing large motors.
Mechanical Interchangeability
Images 1, 2 and 3 illustrate the dimensions that the
replacing motor needs to match to be considered a “drop-in
replacement motor.” The descriptions of each dimension
in Table 1 explain their relevance. Included is a column to
indicate the similar nomenclatures of the International
Electrotechnical Commission (IEC) standard.
Motor manufacturers must ensure the proposed
replacement motor is capable of matching shaft dimensions,
shaft height, the position of assembly holes and the BA
dimension. All other dimensions may vary.
It is the end user’s responsibility to ensure the new motor
does not interfere with equipment
surrounding the motor, pipes and other
utility and architectural structures.
S If provided the opportunity for a site
walkthrough, the manufacturer’s
application engineer can assist in
U-R

N
observing space limitations.
W
The end user could request the
D
relocation of terminal boxes and water
Key Depth

V H
and oil connections to be closer to the
¿U existing terminal boxes and connections.
2F
B BA N-W
2E It is possible to accommodate the request
A
by locating all terminal boxes on the
Image 1 (left to right). Motor side. Image 2. Motor end view. Image 3. Shaft details (Images same side of the motor, but an exact
courtesy of TMEIC)
match is unlikely.

June 2019 | Pumps & Systems

48 COVER SERIES MOTORS & DRIVES

Table 1. Explaining relevance for “drop-in replacement motors”

NEMA Equivalent Description
letter IEC letter
The distance between centerlines of mounting holes (end the existing motor outline drawing to evaluate
2E A
view) and quote a frame with matching dimensions. If no
The distance between centerlines of mounting holes (side drawing exists, the motor OEM cannot guarantee
2F B
view) interchangeability of the equipment.
D H The centerline of the shaft to the bottom of feet
H K The diameter of the assembling holes on the feet Coupling
The distance from the centerline of the mounting hole in the Most motors couple directly to fans, compressors,
BA C
nearest foot to the shoulder on drive end shaft. If no shoulder, pumps and other process machinery. In this case,
it is the centerline of nearest foot mounting hole to the
housing side of the N-W dimension the motor outline drawing will provide the necessary
shaft dimensions.
U D The diameter of the shaft extension
However, in applications where the motor couples
S F Width of keyset
through a sheave and belt or a tapered, hydraulic
R G Bottom of keyset or flat to the bottom side of shaft or bore coupling, the motor manufacturer should request
U-R GE
The depth of keyway at the crown of the shaft extension at the details exceeding the basic dimensions of the shaft
drive end
to replicate a shaft end for a tapered hydraulic
The length of the shaft available for the coupling hub. On a coupling. The motor owner can provide a drawing
V —
straight shaft, this value is the minimum
with these details.
Distance from end of the housing to shoulder on both tapered
W — and straight shafts (when no shoulder exists, it is a clearance In most cases, due to radial forces applied to the
to allow for all manufacturing variations) shaft, belt-sheave couplings require a particular
N-W E Length of the shaft extending from the shoulder at the drive end bearing, end shield and high-strength steel for the
shaft. This is not included in standard products.
Table 2. Checklist for motor owners before sending in quote request to application engineer Image 4 and Table 2 provide a checklist for belt and
Nomenclature Description Inches sheave data collection to consider before a quote
Dm Motor sheave pitch diameter (in) request is sent to the application engineer.
D Driven sheave pitch diameter (in)
Accessories
CL to CL Center to center distance between sheaves (in)
Unless specifically requested, the end user can
Ws Face width of motor sheave (in) request the same model be provided to ensure the
The distance between the centerline of the motor same controls and interfaces are used.
L
sheave and end shield (in)

B
Distance from end of the motor shaft to CL of sheave
face (in)
H Height between motor shaft CL and driven shaft CL (in)
Also, the following information is required
Type of driven load
2
Inertia (LbFt ) of driven load referred to the motor shaft (speed)
The weight (lb) of motor sheave
Number of belts
Belt size (in)
Belt type
Shift toward the drive end or the nondrive end and locate
the power cables entry point to the same side as the existing
terminal box. This reduces pipe bending. Using flexible
conductors yields easier assembly.
When applicable, water and oil inlet and outlets should
be on the side of the motor with existing connections,
but adjustments to incoming pipes may be required. It is
important for the end user to understand this possibility
ahead of time, no later than the proposal stage.
During the initial process, the project’s engineer will use
Color
Some facilities have color-coded equipment. Before
the issuance of a proposal, manufacturers should
ask whether the client permits the use of the motor
manufacturer’s standard color. If not, request the
Munsell or RAL color codes.
Electrical Performance
Torque is vital to a successful motor replacement.
The new motor must be able to accelerate and drive
the existing equipment without exceeding the locked
rotor time. In some cases, too-fast acceleration is
detrimental to other equipment. The new motor must provide
enough breakdown and locked rotor torque values, as well as
the same revolutions per minute (rpm), power and current.
New motors should provide equal or better efficiency when
compared to legacy equipment.
To evaluate motor suitability, the end user should provide
the speed-torque curve of the existing driven equipment,
plus the total inertia on the motor shaft. In many of these
cases, this information is not available from the driven
equipment manufacturer.

June 2019 | Pumps & Systems

call for
NOMINATIONS!

10
TO WATCH
PUMP
PROFESSIONALS

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under 40 years old in the pumps industry.

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more contest information and to fill out the nomination
form for the best and brightest in your company!

Nominations will be closed by 11:59 p.m. ET, June 28. Winners will be
announced in the December 2019 issue of Pumps & Systems magazine.

To nominate someone
VISIT
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50 COVER SERIES MOTORS & DRIVES

D
B
H
Dm
CL to
CL Ws
Image 4. Belt and sheave data requirements
The end user should provide records of the original motor’s
datasheet, speed-torque curves and thermal limit curves for
the motor application engineer to consult. Photography of
the existing motor’s nameplate is of no use. On occasion, an
end user may accept a motor with dissimilar dimensions and
make the necessary site adaptations.
It is important to understand the deviations owners are
willing to accept. It may not be required to provide a “drop-in
replacement.” Even so, the electrical performance data is still
a must, unless the driven equipment is changing. When the
shaft height of the replacing motor is below the height of the
existing unit, it may be possible to provide a transition base
to match the foundation holes. The opposite makes a direct
replacement impossible without foundation changes. Work
closely with the application engineer for certainty.
Replacing Motors of the Same Manufacturer
Replacing motors of the same make and model could be
perceived as being risk free and relatively straightforward.
Many people assume the only necessary information is the
corresponding motor model number. However, even in these
cases there are potential risks.
Consider, for example, an original motor that has been
modified. If the motor’s original nameplate is secured to the
frame and provided as the motor identity and only frame of
reference to the application engineer, the miscommunication
could result in delays and extra cost. It is essential to
understand if the motor to be replaced was ever modified and,
if so, deviations the user is willing to accept.
In cases where a “drop-in replacement” is not required, the
electrical performance data remains necessary unless the
driven equipment has changed.
Eduardo DosReis is sales manager at TMEIC.
He earned degrees from the University
of Notre Dame and Pontifical Catholic
University of Campinas. For more
information, visit tmeic.com.

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June 2019 | Pumps & Systems

 MOTORS & DRIVES COVER SERIES 51

Best Practices for Mitigating 
Bearing Currents
Consider these methods 
to help protect systems from 
high‑frequency current damage.

BY ROBERT MCELVEEN & FREDERICK HOADLEY
ABB

B
earing currents have been around in one form or
another since Tesla’s invention of the induction
motor in 1887. A recent search of the Institute
of Electrical and Electronics Engineers (IEEE)
Xplore database revealed more than 4,200 papers written
and archived discussing this subject. Of these, roughly
half were authored in the last 10 years, indicating that the
understanding of these currents continues to grow through
experimentation and analysis. Understanding the mechanism
by which bearing currents are generated provides insight into
best practices for remediation.
Bearing currents occur when voltage is induced on the
motor shaft that is high enough to overcome the breakdown
voltage of the bearing lubricant. There are two typical paths
for this current to flow. The first is from the shaft, through a
bearing, and through the motor or load frame to ground. The
second path is for the current to circulate from one end of the
shaft, through a bearing, through the motor frame, into the
opposite bearing and back into the shaft.
The source of the induced voltage on the shaft can vary,
depending on several factors. For fi xed frequency, line-
powered motors, the bearing currents are internally sourced,
which means the net flux encircling the shaft is caused by
magnetic imbalances inherent to the machine. Electrical
steel, for example, is not totally homogenous, resulting in flux
paths that are not perfectly symmetrical. This asymmetrical
flux results in time-varying flux lines that enclose the shaft.
As Faraday’s law explains, this time varying net flux gives
rise to current flow down the shaft and through the bearings.
As C.T. Pearce stated in 1927, “if it were possible to design a Image 1. An external source of shaft voltage exists for induction
perfectly balanced and symmetrical machine, both theory motors operated by adjustable speed drives. (Images courtesy of ABB)

pumpsandsystems.com | June 2019

52
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June 2019 | Pumps & Systems
COVER SERIES MOTORS & DRIVES
Image 2. Sources of induced voltage on the shaft may vary.
and practice indicate that no bearing current could exist.”1
Small shaft voltages [on the order of 500 millivolts (mV)] can
lead to bearing currents above 20 amps.
Common Mode Voltage & Bearing Current
For induction motors operated by adjustable speed
drives (ASDs), such as inverters or variable frequency drives
(VFDs), a second, external source of shaft voltage exists.
This external source is a result of the voltage wave shape
provided by the inverter. Unlike balanced, three-phase sine
wave operation, VFDs create switching patterns where the
instantaneous average voltage to ground is not zero.
This instantaneous voltage is referred to as common mode
voltage (CMV). The voltage changes rapidly in magnitude with
respect to time (high dV/dt), so its frequency content can be in
the MHz range. As the current through a capacitor is defined
by the equation I=C*dV/dt, this rapidly changing voltage
can result in capacitively coupled currents from the motor
windings to ground through several paths.
The impedance of a capacitor varies inversely with frequency.
High-frequency currents (such as those from a VFD) can flow
through paths normally considered to be insulators such as
stator slot liners, stator-to-rotor air gap or the grease fi lm
between the bearing race and balls.
The key to mitigating these currents is to provide low
impedance ground connections or alternate conductive paths
 53

Providing to Our Customers

for Over 135 Years

BALANCING MACHINES & SERVICES

FOR ALL INDUSTRIES
Image 3. Proper grounding is a major factor in preventing bearing
damage due to circulating currents. Moment Weighing Solutions

to ensure the current is channeled away from the bearings.2 Balancing Tooling
Image 4 (page 54) shows four potential paths for high- Vibration Analysis Equipment
frequency currents caused by inverter usage. The path in red
is a capacitively coupled current from the stator to the rotor High Speed Facilities
through the air gap, with a return path through the motor Balancing Service
bearings and ultimately to the drive ground. Current may
flow through the motor bearing if the shaft is bonded to the Machine Calibrations
frame (through bearing ball contact) at the instant the dV/dt
Schenck Academy Seminars & Training
transition occurs in the CMV.
Discharge current may flow if the bearing first acts as an Equipment Upgrades
insulator, then becomes a conductor (due to ball spacing or
Repairs
grease fi lm thickness combinations). Discharge current may
also flow if the voltage across the bearing grease fi lm exceeds Spare Parts
its breakdown voltage.
The green current path is also due to capacitive coupling
between the stator and rotor (across the air gap). In this case,
the current flows through a conductive coupling, through Visit us at
the load bearing and load ground, ultimately to the drive The Difference is EASA 2019
ground. Discharge current may flow just as with the previously
Quality. Booth #1019
described red path case. Damage to the load bearing and/or
coupling may occur.
The stator winding to frame/shaft current is shown
The Difference is
Circle 124 on card.

in yellow. This current flows through the stator winding

insulation (which capacitively conducts at high frequencies)
and through the motor frame, the motor bearing, the motor
shaft, the conductive coupling, the load bearing, the load
ground and finally to the drive ground. Current flowing in this
manner can damage both the motor and load bearings as well 1(888)873-2352
schenck-usa.com | sales@schenck-usa.com

pumpsandsystems.com | June 2019

54 COVER SERIES MOTORS & DRIVES
Image 4a (top). Common mode voltage for three-phase sinewave voltages. Image 4b
(bottom). Common mode voltage for three-phase PWM voltages
as the coupling. The preferred path, to
prevent bearing damage, is the stator
winding to ground path shown in blue.
In this case, no current flows through
the motor or load bearings.
Bearing Current Remediation
There are many possible ways to reduce
the magnitude and paths of current
flow shown in Image 4. For inverter-fed
motors, reducing or eliminating the
CMV addresses the problem at its source.
However, the CMV is a function of the
drive design and cannot be addressed on
existing applications.
June 2019 | Pumps & Systems
For this reason, it is necessary to
investigate other means to reduce or
eliminate this problem. If multiple
current paths are present, multiple
remediation methods may be required.
Methods that have proven results
include:
• improving the high-frequency
ground connection from the motor to
the drive and from the motor to the
driven equipment
• insulating the bearing on the
opposite drive end (ODE) of the
motor
• using two insulated motor bearings
Image 5. Pumping application
• using a shaft grounding brush across
the drive end (DE) motor bearing,
which could be mounted inside the
motor housing or outside
An important ground path is the
connection between the motor and
inverter. Cables that provide continuous,
low resistivity shielding around the
three-phase conductors should be
used. The termination of the cable
shield should be made by landing these
connections on a ground surface free of
paint at both the drive ground bus and
at the motor frame.
It is also important to properly ground
the frame of the motor. Stator winding
to frame currents has the highest
potential magnitude of all capacitively
coupled currents discussed. Low
impedance ground straps should be used
to bond the motor frame to the driven
equipment frame. A combination of
solutions that reduces or eliminates all
paths of bearing current flow is shown
in Image 6, where most these high-
frequency currents will return to the
drive through the motor cable shield and
little will return to the drive through the
building ground.
 55

Drive Frame
Stator
Load

Rotor Coupling
As shown, an ODE insulated bearing
is used with a shaft grounding brush
Shielded Cable
on the drive end. Good high-frequency
Ground Bus
bonding (such as a flat-braided cable)
is used between the motor and load.
The insulated ODE bearing prevents
potential current flow through it. The
shaft brush provides a lower impedance
path around the DE bearing. The
Drive
bonding cable between the motor and Frame
Stator DE
load creates a lower impedance path ODE Bearing Load
Bearing
around the bearings in the load. Rotor Coupling

Conclusion Shielded Cable Grounding

Bearing currents have existed since the
induction motor was invented. CMV
induced currents are a phenomenon
resulting from high switching
frequency drives. Proper grounding is
a major factor in preventing bearing
damage due to circulating currents.
Protecting an installation from bearing
current damage requires a thorough
understanding of the inverter/motor/
load system. Identification of potential
high-frequency current paths is crucial
to providing an effective solution.
References
1. C. Pearce, “Bearings Currents - Their Origin and
Prevention,” The Electric Journal, August 1927.
2. R. F. Schiferl &. M. J. Melfi, “Bearing Current
Remediation Options,” IEEE Industry
Applications Magazine, August 2004.
Robert McElveen Jr. is a
senior project engineer
for ABB Motors &
Mechanical, Inc. He may
be reached at robert.
mcelveen@us.abb.com.
Brush
Ground Bus
Bonding
Cable
Image 6a (top). Paths of common mode currents from stator to ground, back to drive.
Image 6b (bottom). Paths of common mode currents from stator to ground, back to drive
through the cable shield
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Our seals and grounding brushes are
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Frederick “Rick” Hoadley is

principal consulting applications
engineer for ABB Motion.
He may be reached at
rick.l.hoadley@us.abb.com.
For more information, visit Look for the Stars!
us.abb.com. orionseals.com • 513-765-8110
Circle 141 on card.

pumpsandsystems.com | June 2019

56 COVER SERIES MOTORS & DRIVES

A Review of Variable Speed 
Drive Technology
How electronic speed control drives, adjustable frequency drives, 
magnetic drives and steam turbine drives work to achieve true variable 
speed control. 

BY WILLIAM LIVOTI
SENIOR PUMP SYSTEM ENGINEER

Editor’s Note: This is part 2 of 2 in a series.

I
n a February 2019 Pumps & Systems article,
we reviewed how, over the years, the pump
Image 1. Basic drive system (Images courtesy of the author)
industry has been introduced to more
advanced and versatile methods to control
pump speed.
To achieve true variable speed control, we are looking at the
following methods or technologies: fluid drive, eddy current
drive, wound rotor motor, adjustable voltage direct current
(DC), adjustable frequency alternating current (AC), magnetic
drive and steam turbine. Part 1 of this series reviewed fluid
drive, eddy current drive and wound rotor motor. This article
will review the other methods or technologies.
Electronic Speed Control Drives:
Adjustable Voltage DC
The oldest electronic speed control methods are the DC
drives, which are also known as DC motor speed control
systems. The speed of a DC motor is directly proportional to
armature voltage and inversely proportional to motor flux;
either armature voltage or field current can be used to control
the motor speed. DC motors have become expensive and most
DC motor speed control systems have been retrofitted with
an AC motor and AC variable speed drive. AC variable speed
drives are less expensive, more available and more efficient
than DC systems. Many DC drive systems have been replaced
where possible with AC variable frequency drives (VFDs).
Adjustable Frequency Drives
A VFD is the most popular method to control the speed of an
electric motor driven pumping system.
A VFD is defined as an electronic device used for controlling
the rotational speed of an AC electric motor by controlling the
frequency and voltage of the electrical power supplied to the
motor. A basic drive system consists of an AC motor and VFD
managed by a control system (Image 1).
A method of control is required to vary the speed of the
drive. This control method can be as simple as an on/off
switch and a speed potentiometer controlled by the operator.
More complex systems often incorporate a programmable
logic controller (PLC).
Larger systems will usually use a distributed control
system. This is basically a host computer running a software
package that allows the operators to both monitor and control
their overall system by one or multiple interface screens.
The drive has an embedded microprocessor that
governs the overall operation of the VFD controller. This
microprocessor has an operating system firmware that is not
accessible to the VFD user. User-defined programming and
parameter adjustment is usually done through the operator
keypad. This allows the user to customize the VFD controller
to meet specific process, motor and equipment requirements.
Unlike the other speed control methods discussed in this
article when applying a VFD, the following concerns must be
addressed to ensure optimum reliability: added heating of
winding (Class F or H Insulation); added winding insulation

June 2019 | Pumps & Systems

 57

stresses; reflective wave or voltage overshoot; added chance of
bearing currents (insulated bearing, grounding brush, earth
ground); added chance of vibration issues; effect on sound
levels; large motor concerns; how VFD will be used and key
details needed to choose large motors for VFDs
The nonsinusoidal VFD waveform contains harmonics
and peak voltage or current in excess of normal sine wave
grid power. On low voltage VFDs, it is common for the motor
to see an additional 10 to 15 degree temperature rise. On
medium voltage VFDs, motors typically see only a 3 to 5
degree temperature rise.
Additional concerns specific to the motor when applying
a VFD: motor torque, speed and temperature; operation
above base speed; running current; starting current; motor
efficiency; sound levels; motor cable length and grounding.
Maintenance
The VFD must be in a clean, fi ltered environment. Heat the
sinks, vacuum away dust and do not use compressed air. If
heavily soiled, used a light natural fiber brush. Do not use a
synthetic brush. For Type 12 enclosures with cooling fans,
replace the air fi lters as necessary.
Conduct a thermal scan, paying special attention to the
connections. Check the cable lug torque. Use a megger to
measure insulation resistance.
The typical life expectancy of a VFD is five to 10 years.
After 10 years, most drive OEMs will discontinue the
manufacturer or replacement parts. In addition, VFD
technology continues to change, making older drives obsolete.
Magnetic Drive
The principle behind a magnetic drive or coupling is like
that of an eddy current drive. The magnetic drive replaces
the physical connection between motor and load with a gap
of air. Motor torque is transferred to the load across an air
gap. Varying the air gap between the magnets and conductor
changes the strength of the magnetic field and, hence,
controls output speed.
A few features of magnetic drive technology:
• No-contact power transfer. This eliminates vibration,
reduces noise, tolerates misalignment, provides
overload protection, extends motor and equipment life
and reduces overall maintenance costs.
• Energy efficiency. The application and load requirements

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pumpsandsystems.com | June 2019

58 COVER SERIES MOTORS & DRIVES
Image 2 (above). Components of a typical
steam turbine driver
Image 3 (below). How an impulse turbine
works vs. a reaction turbine
will determine the efficiency.
• Quality. Technology improves product
quality and optimizes process rates.
• Soft start/stop. Reduces the motor’s
startup power demands and the
resulting brownouts, alleviates paying
for peak power, allows downsizing
of motors, increases motor life and
reduces maintenance.
• Simplicity and ruggedness. System can
be maintained in-house and used in
harsh conditions.
Steam Turbine Drive
Steam power is one of the oldest
technologies in the industrial sector
June 2019 | Pumps & Systems
providing power through the industrial
revolution and into the 20th century.
However, there are some limitations
when applying a steam turbine.
First and foremost, you need steam
and you need a source to generate the
steam. This requirement limits the use of
turbines in certain applications.
The most notable pumping application
for steam turbine drivers is powering
boiler feed pumps.
A steam turbine is powered by the
hot gaseous steam generated by a boiler.
The steam enters the turbine through
a nozzle that controls the speed of the
steam (Image 2). The turbine is fitted
with blades mounted on a shaft that
is coupled to the driven component
(pump) that turn as the steam blows past
them. The blades have tight clearances
that contain the steam, maximizing
the efficiency of the turbine. The steam
expands and cools as it flows through the
turbine blades.
The rotating element (shaft and
turbine blades) are contained in the
turbine’s outer casing.
This casing must handle the high
pressure and temperature produced by
the steam.
There are two types of steam turbines:
• An impulse steam turbine features
a jet of steam from a fi xed nozzle
that pushes against the rotor blades
driving the blades forward (Image 3).
Pressure drops take place in the fi xed
blade (nozzle).
• A reaction steam turbine does not
use nozzles. The rotor blades are
configured to form convergent nozzles
using the reaction force produced as
the steam accelerates through the
nozzles. The steam is directed onto
the rotor by the fi xed vanes in the
stator (casing).
Efficiency
The efficiency of a steam turbine
driver or any engine can be defined
as its ability to convert the input energy
into useful output energy, which is
Efficiency (ɳ) = Output/Input
Equation 1
expressed in Equation 1. Steam turbine
efficiency or isentropic efficiency is
the efficiency that compares the
actual output with the ideal isentropic
output to measure the effectiveness of
extracted work.
Maintenance
Steam turbines require the correct
steam pressure at the turbine inlet and
high steam quality in order to ensure
optimum reliability.
One guideline for maintenance to keep
in mind is that the steam must be of
highest quality. Also, steam supply lines,
valves and casing should be insulated to
prevent loss of latent energy. The steam
supply lines must be properly configured
for condensate removal, correctly sized
drip pockets and steam traps.
Additionally, excessive forces to the
turbine flanges should be mitigated.
They include pipe dead weight, thermal
expansion, thrust and spring rate caused
by different expansion joints.
Impact as a result of improper
installation will result in premature
bearing failure, nozzle degradation,
turbine blade failure or distortion and
premature coupling failure.
Which speed control is best? It
depends on the application and business
model. Also, consider your issues and
concerns—such as energy efficiency,
reliability, uptime, production concerns
or environmental.
William Livoti is retired after more than
40 years in the pump industry. Livoti is
a member of the Pumps
& Systems editorial
advisory board. He may
be reached at wlivoti@
outlook.com.
 MOTORS & DRIVES COVER SERIES 59

Motor Starting Basics
Understand these concepts 
before starting squirrel cage 
induction motors.

BY BLAKE BAILEY
DESIGNMOTORS

Q
uestions about starting electric motors are
common. Motor starting problems resulting from
these questions can be costly and confusing,
leading to production delays and sometimes
catastrophic motor failure. This article will briefly explore
some of the most common questions about the direct online
(DOL) starting of squirrel cage induction motors. Through
proper application, end users can have confidence that their
motors and related equipment will not incur damage during
the starting cycle.

Reading Speed-Torque-Current Curves

Speed-torque-current curves are plots of a motor’s torque and
speed characteristics from zero speed up to no load speed
(practically synchronous speed for an induction motor). All
terms are commonly plotted as either percentage of full load
or in their actual units (e.g. revolutions per minute [rpm],
foot-pounds of torque and amperes). It is conventional for
torque and current to both be plotted on the same graph,
as well as being presented separately as shown in Image 1.
Typically, plots of reduced voltage torque and current, as well
as the load’s speed-torque characteristics, are also given. For
the latter, it is key to obtain the load’s speed-torque curve and
not simply the “running curves” for pumps and fans. Finally,
these graphs can be plotted either horizontally (speed on the
x-axis, torque and current on the y-axis) or vertically (speed
on the y-axis, torque and current on the x-axis).
Key performance information related to motor starting
is shown on speed-torque-current plots. In Image 1, the
intersection of the torque curve at zero speed will show locked
rotor torque (LRT), while the maximum torque value shown
represents breakdown torque (BDT). Both full load torque
(FLT) and current levels (FLC/FLA) are found by drawing
a vertical line from the rated speed point until it intersects
Image 1. Intersection of the torque curve at zero speed will show
locked rotor torque (Images courtesy of designmotors)
both plots. The point on the current plot corresponding to
zero speed will show locked rotor current (LRC/LRA), while
the motor’s no load current (NLC/NLA) is shown by the point
corresponding to the highest speed shown.
Reading Thermal Damage Curves
Thermal damage curves are plots that provide information
about acceleration times, operational time limits at finite
current levels and time limits on operation above full load.
These curves are also known as “thermal limit curves,” “safe
operating time curves” or “acceleration curves.” They are
typically plotted with motor current as the x-axis and time
in seconds as the y-axis on a logarithmic scale. As seen in
Image 2, the plots found closest to the current scale show
motor current during acceleration. These plots, typically at
various voltage levels, intersect the speed scale at a point that
represents LRC and intersect the time scale at the full-load
current point to show anticipated acceleration time.

pumpsandsystems.com | June 2019

60 COVER SERIES MOTORS & DRIVES

There are usually one or two plots shown above the

Image 2. Thermal damage curve
accelerating current curves, which show safe locked rotor
times as well as a “running” or “overload” curve. The safe
locked rotor time (“safe stall time”) plot(s) are intended to
show the number of seconds a motor can safely withstand a
given current level at various voltage levels.
If shown separately, the “cold” curve provides the safe
locked rotor times for the motor when it is first started (the
“cold” condition), while the “hot” curve provides the safe
stall times after a motor has either been recently started or
run under load. It should be noted that Image 2 only shows
a single plot connecting the safe stall time plots in cold
condition with the “overload” curve. The safe stall time plots
should never overlap or come substantially close to the motor
accelerating current plots, as this represents dangerous
heating in the rotor bars and end rings.
The overload curve shows the time that a motor can
safely operate while running at, or above, full-load current.
Typically, the upper bounds of this curve correspond to a
continuous time associated with the motor’s highest safely
rated load level (often the service factor). If this plot is
followed to higher levels of current (and therefore lower

Circle 129 on card.

June 2019 | Pumps & Systems

 61

values of time), it will often be plotted to intersect

the safe stall time curve(s), but most often is shown
to just nearly intersect them.

Locked Rotor Performance

Locked rotor performance encompasses the
motor characteristics related to when a motor is
in a locked (stalled) condition, such as at initial
energization. Locked rotor performance is affected
by combinations of the motor design, driven-load
characteristics and onsite conditions. Typically,
end users will specify locked rotor performance
Image 3. Acceleration time figure
requirements and provide information on the
driven load in addition to installation details such
as typical voltage dip levels or if the motor will be for most loads. For larger motors or specialty applications,
started via a method besides DOL. Typically, the motor design however, finer performance requirements might be in place,
for locked rotor is centered around providing the required which require a motor design with features like a custom
torque while minimizing LRC and potential ill effects on rotor bar shape or specialized rotor alloy. Aside from starting
full-load operation. the motor via a device such as an auto-transformer, special
Most standard commercial induction motors are rated as contactor arrangement, or variable frequency drive (VFD), the
National Electrical Manufacturers Association (NEMA) Design greatest effect that on-site conditions have on locked rotor
B, which provides a reasonable balance between LRT and LRC performance is the customer’s voltage dip level.

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pumpsandsystems.com | June 2019

62 COVER SERIES MOTORS & DRIVES
Your
Y ourr B
Be
Best
es
st Va
Value
alue
e LRC decreases in basically direct
proportion with voltage, while LRT
in Progressive decreases as approximately voltage
squared and can quickly cause starting
Cavity Pumps issues for processes that start under
load. Careful coordination between the
end user and motor supplier is required
to ensure that a proper motor design is
selected for both onsite conditions and
the load’s profi le to provide reliable,
safe locked rotor performance.
Determining Acceleration Time
Closely related to locked rotor
performance is the acceleration time a
motor takes to start its load. Many of
the same cause and effect relationships
between motor design, onsite
conditions, and load characteristics
hold true for effects on both locked
rotor performance and acceleration
time. In the case of acceleration time,
however, the entire speed-torque
characteristics of the motor and
load must be considered with net
accelerating torque and total inertia
being the most vital characteristics.
There are several methods available
for estimating acceleration time, but
all methods must begin with the motor
and load’s speed-torque curves and
total inertia. The most basic method
divides the speed torque characteristics
up into equal intervals (typically
somewhere around 10 as shown in
Providing a Quality Image 3) and finds the net accelerating
Product at a Fair Market torque available during that period to
Price since 1982 calculate its individual contribution
to acceleration time. Net accelerating
Call or Email: torque is defined as the load torque
920-869-4800 subtracted from the motor torque at a
sales@summitpump.com given point (generally the motor torque
should be at least 10 percent greater
than load torque). Once net accelerating
Circle 137 on card.
torque and time have been found for all
intervals from zero speed to full-load
speed, the times in seconds are added
TM to provide total estimated acceleration
time. For every interval, the total
PUMP, Inc inertia (motor and load reflected to
www.SUMMITPUMP.com motor shaft) must be accounted for, as
June 2019 | Pumps & Systems
high inertia loads (e.g. large centrifugal
fans) can lengthen acceleration times.
Finally, similar to locked rotor
performance, voltage dip and recovery
must be considered, as they will reduce
motor torque available and thus
increase total acceleration time.
Other Related Areas
There are numerous questions
surrounding motor starting that can be
explored outside of this analysis, but
some other points for consideration are:
• a motor’s rated KVA Code Letter
(assigns a “code letter” defined by
NEMA MG-1 that gives an idea of
the motor’s locked rotor current
level when compared to its rated hp)
• how to interpret a large motor’s
acceleration nameplate information
(for example, understanding what
the number of hot and cold starts
means and how to interpret the time
required between them)
• the theory behind safe locked rotor
times and how these values are
derived (principally these are based
on the amount of time anticipated
for critical motor components like
rotor bars, end rings and stator
windings to reach damaging
temperatures)
With this information, end users and
those involved in specifying induction
motors can confidently operate and
select motors for various starting
scenarios. Note: this article has been
written with squirrel cage induction
motors in mind, most of these concepts
are applicable to other motor types,
including wound field synchronous
(with squirrel cage rotor windings) and
wound rotor induction motors.
Blake Bailey is president of
designmotors. He may be reached
at blake@designmotors.net. For
more information, visit
designmotors.net.

Use Ultrasound to Optimize 
Grease Replenishment
Condition monitoring helps manage over‑lubrication.
BY ALLAN RIENSTRA
SDT ULTRASOUND SOLUTIONS
U
ltrasound is a guide to precision grease
replenishment in motor bearings. It is also
known for its versatility for leak detection, valve
assessment and electrical fault detection.
Acoustic lubrication is an integral component of ultrasound
programs. Fewer than 95 percent of all roller bearings reach
their full engineered life span, and lubrication is the culprit
in most cases. In fact, poor lubrication practices account
for as much as 40 percent of all premature bearing failures.
Yet, when ultrasound is used to assess lubrication needs and
schedule grease replenishment intervals, that number drops
below 10 percent. What would 30 percent fewer bearing
related failures mean for an organization?
To understand the role precision lubrication plays in bearing
life extension, it helps to understand basics of bearings, their
lubrication mechanism and how ultrasound helps.
The insides of a bearing consist of four components. The
inner and outer raceways form a path for the rolling elements
to glide on a thin fi lm of lubricant. A metal cage separates the
rolling elements, keeping them evenly spaced to distribute
the load and stop them from crashing into one another. These
components move in concert producing frictional forces from
rotational inertia, surface load, misalignment, imbalance
and defects. Zero friction is impossible, but optimal levels of
friction are achievable with correct installation techniques
and proper amounts of lubricant.
Ultrasound works on the FIT principle—it responds well to
defects that produce friction, impacting and turbulence (FIT).
For motor bearings, two of these phenomena apply: friction
and impacting. Ultrasound detects high-frequency signals
produced when two surfaces slide together or come in contact
with any force. Stage 1 bearing failures happen at the micro
level. Because ultrasound ignores low-frequency audible
signals, it forms the perfect companion for measuring,
trending and analyzing defects despite high levels of noisy
interference encountered on the factory floor.
BEARINGS 63
Ultrasound detectors detect friction and impacting as
acoustic energy from rolling friction and defect impulses.
When lubricant levels are optimum, the energy created is at
its lowest. As frictional forces increase, so does the acoustic
energy. Ultrasound instruments measure friction and
impacting as energy using the scaled value dBµV (decibels/
microvolt). The results are presented as condition indicators,
and there are four of them:
• root mean square (RMS)—an indicator of friction
• maxRMS—an indicator of stability
• peak—an indicator of impacting
• crest factor—which surmises the relationship between
friction and impacts
Condition indicators are most responsible for transforming
ultrasound technology from a simplistic, “point the gun
and pull the trigger” gadget, to being recognized as analysis
and trending technology. Condition indicators add validity
to trending by going beyond the single decibel. If a user
currently uses an ultrasonic gun that does not have condition
indicators, they should question the data.
Benefits of Optimized Lubrication Practices
Optimizing grease replenishment practices will deliver
both fast and longer-term benefits. What are some of the
indicators that your lubrication program is on the right track?
A Change in Quantity of Grease Consumed
Maintenance departments track their grease consumption to
monitor and control costs. A change in consumption is a sure
sign that the lubrication program is on the right track.
Most organizations are guilty of over-lubricating. Expect
lower grease consumption as the program matures. Bad
procedures lead to bearings routinely receiving more grease
than they are designed to handle. The excess ends up being
pushed into the motor casing or purged onto the floor.
pumpsandsystems.com | June 2019
64 BEARINGS
Over lubrication happens when regreasing intervals
are scheduled based on time instead of condition. Control
lubrication tasks with ultrasound to monitor condition
and maintain optimal friction. The time between greasing
intervals increases, resulting in less grease used per bearing.
Fewer Lube-Related Failures
Organizations with optimized greasing programs experience
fewer lube-related failures. Less fi xing and fire-fighting
translates to more creative time for maintenance. That
time can be used to bring more machines into the greasing
program. Additionally, with ultrasound, a user finds many
nontrendable defects. For example, broken or blocked grease
pipes and incorrectly fitted grease paths prevent grease from
reaching the bearing.
Optimized MRO Spares Management
This lubrication program provides better control of grease
consumption, fewer failures and more productivity for
maintenance. A decrease in bearing-related failures
improves spares optimization. Users can share the ultrasonic
lubrication data with a maintenance, repair and operations
(MRO) manager to create a plan to reduce the number of
emergency parts on hand.
MADE IN
USA
A Stejada Company
“It’s all about reliability”
www.enviropumpandseal.com
678-324-4481 Engineered Wood, Food & Beverage,
4364 Winfred Dr Chemicals, Pharmaceuticals,
Waste Water, and more!
Marietta, Ga 30066
Circle 145 on card.
June 2019 | Pumps & Systems
Increased Number of Machines Monitored
One benefit of an effective lubrication program is time: time
allotted to monitoring machines instead of fi xing them; time
allotted to correctly assessing the real needs for lubrication
and; time to look at the big picture.
Take for instance, criticality assessment. Many lubrication
programs begin with small steps. All the “A” critical machines
receive priority. But, what about the rest? With more time
to plan, organize and schedule, the number of machines
acoustically monitored for optimal lubrication increases.
Combine Acoustic Lubrication and Condition Monitoring
Acoustic lubrication can ensure precise bearing lubrication.
The newest technologies on the market combine the power of
onboard lubrication guidance with four condition indicators
for bearing condition assessment.
Problems detected by lube techs can be reported to
condition monitoring teams and elevated to maintenance
once confirmed.
How To Get Started
A well-organized strategy and carefully planned execution of
that strategy can get the ultrasound lubrication program off
on the right foot.
Innovative Pass-Through
Technology
ShinMaywa (America), Ltd. offers the
CNWX Series of heavy-duty,
non-clog submersible pumps for the municipal
wastewater market. CNWX pumps with the SCROLL
impeller have already eliminated clogging problems
in many municipal installations. Explosion Proof (FM
Approved) motors are standard.
Non‑Clog Scroll Submersible Pump
Highly
Effective
Passing
ShinMaywa(America), Ltd.
6135 Park South Drive Charlotte, NC 28210 ■ Phone: 704‑945‑7112
■ Fax: 704‑945‑7101 ■ E‑mail:pump@shinmaywaamerica.com 
www.shinmaywa.co.jp/america/  
Circle 146 on card.

Commitment is required from all levels and this becomes
easier if the program demonstrates structure and cohesion.
Clearly defining and communicating the objectives of the
lubrication program, as well as reporting the progress, is the
best way to create a precision lubrication culture that benefits
the entire organization.
Start by asking, “Why start an ultrasound lubrication
program and what improvements do we expect?” There is no
one easy answer to the question. Saving money is an obvious
benefit that gets the attention of management, but it is not
specific enough.
An ultrasound lubrication program can save money by
reducing grease consumption, raising awareness of the right
types of grease to use, making more effective use of a lube
tech’s time, reducing unwanted machine breakdowns caused
by lubrication failures and extending bearing life expectancy.
Ultrasound-assisted lubrication of plant assets offers
benefits that calendar-based lubrication does not. Lubrication
serves a primary purpose, which is to create a thin layer
of lubricant between rolling and sliding elements that
reduces friction.
It makes sense that the best way to determine the
lubrication requirement of a machine is to monitor friction
levels, not time in service.
PUMP READY
MOTORS AND CONTROLS
Find out how WorldWide can make a difference. Call today!
1 (800) 808-2131 | worldwideelectric.net | customerservice@worldwideelectric.net
Circle 125 on card.
65
Optimizing lubrication of plant machinery with ultrasound
will result in a significant reduction in grease consumption.
Having an ultrasound program in place can lead to cleaner
storage practices, sampling and avoiding mixing greases.
Properly lubricated machines require less energy to run.
Reducing the amount of money spent on grease can lead to
lower energy bills.
Machines that consume less electricity run cooler, and
machines that run cooler often have longer life cycles.
Optimize bearing lubrication to extend the life of bearings
by making sure they have the right amount of grease, but not
too much. When everything is running according to plan,
lube techs will spend less time greasing bearings that do not
need it, resulting in decreased labor.
By monitoring the condition of the machinery’s lubrication,
a user is collecting valuable condition data about the machine
itself. Put this data to work, and advance reliability through
optimized grease replenishment.
Allan Rienstra is the director of business
development for SDT International. He is a
graduate of Simon Fraser University. For more
information, visit sdtultrasound.com.
pumpsandsystems.com | June 2019
66 ALIGNMENT BASICS
Fundamentals of System 
Alignment vs. Balancing  
Diff erentiating between misalignment and imbalance is essential to 
identifying the cause of pump failure.
BY LARRY KETOLA
HINES INDUSTRIES
A
lignment is when all pump, driver and coupling
centerlines fall within the same centerline.
Misalignment occurs when the centerlines are
offset or angular from each other. Balancing is the
act of redistributing the mass of a part so that the mass is
evenly distributed around the part’s rotating axis. Imbalance
occurs when the mass center axis is not aligned with the
geometric axis. The mass center is the midpoint that the
assembly tries to rotate around naturally. The pump impeller
would spin around this axis if it were thrown spinning
through the air.
The farther these two centerlines are apart, the more
imbalance an assembly will see. The end result of balancing is
to align the mass center with the geometric axis.
Pump and drive shafts must be aligned in order for the
assembly to be in alignment. A user must start with a good
pump, driver and coupling in order to dynamically balance
an assembly.
SHAFT CENTERLINE .001”
IMPELLER CENTERLINE
.002” CLEARANCE
Image 1 (left to right). Typical pump assembly. Image 2. Impeller bore to shaft clearance. Image 3. Runout in the shaft pump rebuilding
section (Images courtesy of Hines Industries)
June 2019 | Pumps & Systems
Any components that are not dynamically balanced
can result in accelerated seal and bearing failure. Once
bearing failure occurs, the pump assembly will need to
be rebuilt.
Misaligned external forces mimic those of imbalance
because misalignment causes excess vibration. Misalignment
can be caused by improper assembly of components, shifting
of components after assembly and changes in temperature.
Often, misalignment is the cause of imbalance that cannot
be corrected by balancing.
Lasers and dial indicators are used to measure the runout
of components and verify alignment. In the typical pump
assembly shown in Image 1, the pump should be considered
the baseline because it is usually hard piped and securely
mounted to its base.
All other components should be aligned to the centerline of
the pump. Even with the shafts aligned, an imbalance of the
rotating assembly can occur with a bad coupling.
DRIVER PUMP
COUPLING
SHAFT CENTERLINE
IMPELLER .001”
CENTERLINE
.002
 67

Balancing
The force created by imbalance increases
exponentially with speed. Tolerances for
imbalance are set with operational speeds
in mind.

Force = Imbalance x Speed2

Equation 1

Force imbalance is the imbalance

as measured on a single plane and is
perpendicular to the axis of rotation.
Force imbalance is a condition that exists
when the center of mass is not on the
axis of rotation. Static imbalance by
itself is typically measured and corrected
on narrow disc-shaped parts, such as
a Frisbee. A single plane balance is
required for impellers with the D/B ratio
greater than 6. B is the distance between
the impeller shrouds and 1 inch from
the impeller outside diameter. D is the
diameter of the impeller.
Two plane or dynamic imbalance is the
Circle 133 on card.
unbalance as measured on two separate
planes. Both planes will be perpendicular

Bearing deterioration got you down?

to the axis of rotation and thus parallel
to each other. It is the vector sum of force

Keep Your Pumps Pumping!

and couple imbalance. A two plane balance
is required for impellers with the D/B ratio
less than or equal to 6.
Single plane imbalance requires only
one correction. The amount of unbalance Vibration Analysis Can
is the weight times the radius. This type of
imbalance is a vector, and therefore, must Help You Save the Day.
be corrected with a known weight at a Analyze and trend ISO vibration
particular angle. levels, bearing wear, unbalance,
To correct for two-plane imbalance misalignment, looseness, and more.
requires two unrelated corrections in
two different planes at two unrelated TPI 9080 Vibration Analyzer
angles. The specification of imbalance is $
995.00
only complete if the axial location of the
correction planes is known. Two-plane TPI 9080-Ex: Intrinsically Safe Vibration
imbalance specifies all the unbalance, Analyzer (Class 1, Div 2. IEC Ex/ATEX
which exists in a workpiece. This type Ex ib IIC T4 Gb) also available for
of imbalance can only be measured working in hazardous environments.
on a spinning balancing machine that $3,995.00
senses centrifugal force due to the couple
component of unbalance.
Save the Day! Visit
The allowable imbalance for an
testproductsintl.com
impeller is based on ISO 1940 Grade
or call 800-368-5719.
G6.3. Permissible residual imbalance is a
Circle 138 on card.

pumpsandsystems.com | June 2019

68 ALIGNMENT BASICS

both the shaft and impeller should

U (ounce-inch) = 6.015 x G x W/N (W be inspected to verify if the shaft is
in lb) undersized and/or if the impeller hole
is oversized. The solution is to replace
G = Balance quality grade the shaft and/or the impeller to
W = Rotor weight minimize the shaft to bore clearance.
N = Maximum service rpm
Equation 2

function of balance quality grade (G)

3 Unbalanced impeller component:
This can also cause imbalance
within the assembly. A perfectly
number, rotor weight and maximum
balanced shaft with a minimal
service speed of rotation. Instead of
clearance with an imbalance impeller
using the graph to look up the specific
still causes an imbalanced pump
imbalance value for a given G number
assembly. There are many ways to
and service revolutions per minute
correct imbalance, such as adding or
(rpm), and then multiplying by rotor
removing weight to the assembly. If
weight (taking care to use proper
this is not feasible, the impeller needs
units), U can be calculated by using
to be replaced.
one of the following in Equation 2.
To achieve an acceptable balance
assembly, all three of the above should
Pump Rebuilding
be addressed.
When rebuilding pumps, several
things need to be looked at to define
Benefits
the root cause of imbalance:
There are many benefits of balancing
and aligning pump assemblies:
1 Runout in the shaft: This is one
of the causes of imbalance in the
assembly. Shaft runout will hold the
• decreases vibration—minimizes
wear and increases longevity of
pump assembly
impeller off center therefore creating
• reduces heat and friction—
an imbalance. An example would be
increases the life of bearing
a 200-ounce impeller with a shaft
and seals
having 0.002-inch runout will actually
• diminishes noise—reduces the
offset the pump impeller centerline by
noise to an acceptable decibel
0.001 inch, which would result in a 0.2
(dBA) level
ounce/inch imbalance. To eliminate
• increases system life cycle—less
runout in the shaft, the shaft must be
overall maintenance, downtime
straightened or replaced.
and costs
• increases system life efficiency—
2 Impeller bore to shaft clearance:
This can also cause a pump
unbalance as described in this
less energy to run and operate
• saves time and money—see all of
the above
example. An example is a 200-ounce
impeller with a bore to shaft clearance
Proper alignment and component
of 0.002 inch will actually offset the
balancing are essential for having an
pump impeller centerline by 0.001
efficient, high-performance pump.
inch, which would result in a 0.2 oz/
Circle 135 on card.

in imbalance. An impeller bore to

shaft clearance must be minimized
to ensure a balanced assembly. A
perfectly balanced shaft with an
imperfect clearance will cause pump
imbalance. To minimize the impeller
bore to shaft clearance in a used pump,
Larry Ketola is an engineer at
Hines Industries in Ann Arbor,
Michigan. He may be reached at
info@hinesindustries.com. For more
information, visit hinesindustries.com.

June 2019 | Pumps & Systems


Vibration 
Analysis 
Using Human 
& Artifi cial  Image 1. A 300-hp plant air screw compressor (Images courtesy
Intelligence   alert limits and generates an appropriate alert based on the
A hybrid approach can provide  via text message or email to the user.
specialized evaluation for midtier  automated prescriptive maintenance task is to “field inspect”
plants and/or midcritical equipment.
BY CRAIG TRUEMPI & DAN YARMOLUK 
ATEK
I
magine artificial intelligence (AI) could automate
data analysis to create prescriptive and prioritized
maintenance tasks. What if AI could automatically create
a work order in existing computerized maintenance
management systems (CMMS)? Imagine automating data
collection through the internet of things (IoT) so the user
experience is cost-effective and scalable.
Sound too good to be true?
Believe it or not, it is possible.
Where to Start
Typically, there are three major categories of conditions that
lead to machinery failure:
• Late-stage conditions: imbalance, misalignment, bent
shaft, soft foot, looseness, etc.
• Early-stage conditions: lubrication, early-stage bearing
failures
• Intermittent conditions: cavitation, resonance, speed
related, process related
For late-stage conditions, an AI model views the frequency
band from 2 to 1,000 Hertz (Hz). The AI compares the
amplitude of the vibration to a set of ISO 10816 standard
VIBRATION 69
of Atek)
severity (how much amplitude is in the vibration). Using the
ISO-defined and industry-accepted alerts of 0.2, 0.5 and 1
inch per second (IPS) peak, the AI rules engine sends an alert
For example, when a 0.2 IPS threshold is crossed, the
the machine using human experience and senses of sight,
sound, touch and smell. When an alert condition is present,
human senses are often successful in finding the root cause
of equipment issues. Remote monitoring of spectrum data,
although valuable, is no substitute for physical presence at the
asset to inspect equipment and communicate with operations
about its history and context.
Diagnosing Early Stage Conditions
For early stage conditions, an AI model watches the frequency
band from 1,000 to 30,000 Hz. This range includes ultrasonic
frequencies and compares the amplitude of the ultrasonic
measurement to a set of established alert limits. Ultrasonic
or high-frequency monitoring is relatively new and ISO
or industry standards are limited. Using experience and
industry-proven alerts of 6, 12, and 18 Gs (force of gravity),
the AI model sends an alert via text message or email.
For example, when plant assets are operating between 600
and 6,000 rpm and a 6 Gs threshold is crossed, the automated
prescriptive maintenance task is to field inspect and lubricate.
Again, human experience and senses are used to collect
information relating to the cause of the alert condition.
Tips for the human inspection include:
• asking operations about any changes or insights
• looking or smelling for smoke or hot sensations or
unusual odors
• looking for leaks, spills or broken or loose supports
• listening for rubbing or grinding
Some maintenance technicians use a stethoscope to listen
to bearings to compare a good-sounding bearing with a
pumpsandsystems.com | June 2019
70 VIBRATION
Image 2. A 60-day trend of ultrasonic and vibration data
suspect one. Using an infrared (IR) temperature gun or
camera to inspect for hot spots is another helpful technology.
The user may also check lubrication levels and color in sight
glasses, or for signs of recent greasing. Then, they determine
if it is a greaseable bearing, if it is under- or over-greased, if
the wrong grease was used or if it was auto-greased. If it is
an oil bath bearing, they will also check the oil bath level.
They will determine if the machine is a chronic problem, if it
is running at design or if it has been modified, sped up, load
increased, belt tension increased, etc.
As always, employing an experienced vibration analyst is
a safe bet. However, in midtier plant and/or with midcritical
assets, a hybrid human and AI program can be successful.
Intermittent Conditions
This is where continuous monitoring with permanent or
temporary monitoring stands apart from a monthly route-
based program. With wireless sensors and the IoT, coupled
with the AI models described above, intermittent conditions
can be monitored and root issues can be quickly identified
and resolved.
A common reality of vibration analysis on midcritical assets
is they are typically monitored monthly, quarterly or not at
all. In the route-based predictive maintenance program, the
analyst gathers data monthly, taking 10 or more points per
machine, and conducts a brief inspection of the machine. In
contrast, continuous monitoring gathers fewer measurement
points, and the data is logged and reviewed remote from
the machine, in a control room, plant office, by remote third
party, or all of the above.
Through continuous monitoring with low-installed-cost IoT
sensors, many issues that have perplexed the monthly routine
are resolved. Examples vary from boiler feedwater pumps
that blow a seal on the night shift, to kraft pulpers that
crater a gearbox over the weekend, failed pump seals related
to misalignment from thermal growth, or inconsistent
June 2019 | Pumps & Systems
lubrication practices. Intermittent issues
are best solved with continuous data
coupled with AI to set alert limits.
These systems typically include a sensor,
cellular connectivity and AI in the cloud.
A 45-Day Predictive
Maintenance Case Study
On May 15, a combination ultrasonic/
vibration sensor was deployed to monitor a
300-horsepower (hp) plant air compressor
at a Midwest industrial manufacturing
plant. The sensors were battery-powered
and connected to the bearings using
a two-rail magnetic mount. With
existing cellular, cloud and smartphone
infrastructure, the hardware and system were in place. An
alert system was in place with preset alert thresholds using
a proven AI model. The last step was adding instruction on
what to do when an alert was generated.
A second AI model was used to deliver specific and
customized instructions for each alert and each severity
level of the alerts. This AI model translated the alert to
a prescriptive maintenance task with an understanding
of severity and prioritization, allowing the work to be
appropriately planned and scheduled.
Upon connecting the magnet to the bearing of the
machine, a critical (red) alert was issued based on the
ultrasonic measurement (green trend line), and a work
order was emailed stating: “Field inspect and lubricate
within 10 days.” Within seven days, the compressor was
inspected, but no visible or audible symptoms were noticed.
Moving the ultrasonic/vibration sensor to each bearing of
the compressor, it was clear the motor inboard bearing was
reading high—approximately 36 Gs.
A closer look revealed the grease Zerk had not been greased
in a while. The plant maintenance technician was new to the
plant and was unaware of the plant lubrication practices—
pointing to the need for proper training. It was unclear if or
when the motor was last greased. The plant manager decided
to add grease, resulting in a temporary reduction in the
ultrasonic measurement and then a return to 36 Gs.
Recently, the plant had a failure on the motor of the backup
air compressor. They knew the subject motor had been
in-service for more than 15 years, so they weighed the impact
of an unplanned motor failure versus the cost of repairing
the motor. They decided to change out the motor during the
July Fourth outage, approximately 45 days from the initial
discovery of the fault.
On June 13, they switched to the backup compressor. The
new motor was installed and a month later on July 13 they
switched back to the main compressor. The ultrasonic reading
 71

THE
SINGLE-PHASE
was much lower,
hovering between
PUMP
4 and 6 Gs, but still SOLUTION
occasionally setting
off a minor alert.
On July 20, grease
was added, and the
ultrasonic reading Image 3. Bearing fault found on motor
inboard bearing
was reduced to
the normal range,
hovering between 2 and 4 Gs. 30-100 Horsepower,
A second fault based on overall vibration (blue trend line) was No Three-Phase Required.
also found during initial connection of the sensor. In this case, Pumps using the BELLE™ Motor from Single Phase
the AI rules engine for overall vibration is based on the ISO Power Solutions utilize industry exclusive
10816 standard. This alert condition was minor, and the emailed Written-Pole® technology making it the only pump in
prescriptive task was to field inspect for looseness, imbalance or the world that can deliver up to 100 Horsepower to
misalignment. Again, no visual or audible evidence was present. your pump application from a single-phase line.
The new plant maintenance tech had little history on this • No Flicker
compressor. The overall vibration levels were compared to the • No Harmonic Distortion
• No VFD or Phase Converter
backup compressors and confirmed it was higher. • Robust and Reliable
The compressor was inspected carefully for looseness. • Virtually No Maintenance
One technique was to walk the sensor down the motor from www. SinglePhasePowerSolutions.com
top to bottom looking for a change in vibration levels at 877-430-5634
the different interfaces between motor and sole plate, sole Circle 147 on card.
plate and foundation. No evidence of looseness was found.
Imbalance—a common fault on fans—was temporarily ruled
out. However, this was a motor/compressor combination. Plant
alignment practices were unknown and left up to the mechanical
contractors. A contractor was brought in to check alignment and
a misalignment was confirmed. After aligning the motor, it was
determined that the motor was bolt bound (not enough slot) to
correct the alignment. The team decided the alignment would
be corrected when the motor was replaced at the Fourth of STAND
ND ALONE QUALITY PROVIDING
PROVID
July outage. STAND ALONE
LONE PERFORMANCE
PERFORMA
On startup July 13, the overall vibration returned to its
alert condition and it did not pass the acceptance test. The
contractor was called back to correct the alignment. On July 14
the compressor was started and the overall vibration hovered
around 0.15 IPS-peak (Pk)—a normal reading.

Craig Truempi is the director of AI and IIoT

Reliability at Atek. Truempi has an MBA from the
University of Minnesota. He may be reached at
ctruempi@atekcompanies.com. NEMA 3R NEMA FRAME ABOVE NEMA 5800P NEMA FRAME
PUMP PANEL HTA SERIES WPI FRAME ATLAS SERIES WPI HTA SERIES TEFC
(10HP-250HP (300HP-600HP (10HP-250HP
Dan Yarmoluk is the business 1800RPM-1200RPM IN STOCK) IN STOCK)
IN STOCK)
lead AI and data science at Atek.
Yarmoluk holds a master’s degree of data science 480-390-4980 | WWW.BMR-USA.COM
from the University of St. Thomas. He may be
reached at dyarmoluk@atekcompanies.com. For
more information, visit assetscan.com.
Circle 144 on card.

pumpsandsystems.com | June 2019

72 SEALING SENSE

Sealing High-Speed Shafts in Turbomachinery

Understand implications involved with using gas film seals in this application.

By Richard Albery
FSA Member, John Crane, Inc.

R
otating liquid pump
shafts that are
originally sealed with
soft packings mostly use
contacting face seals, also
known as mechanical seals.
Typical rotational speeds are
roughly between 1,000 and
3,600 revolutions per minute
(rpm). In turbomachinery—
such as compressors and
expanders—the rotational
speeds are higher and
mechanical seals would not
immediately appear to be an
option, due to greater rubbing
speeds along with a lack of
liquid cooling and lubrication.
Nevertheless, from the late Image 1. Section of an overhung, integrally geared compressor (Images courtesy of John Crane)
1970s when they were first marketed,
noncontacting mechanical seals, known machines. The latter have shaft sizes up compressor casings driven by more than
as dry gas seals in cartridge form, have to 350 millimeters (mm), approximately one shaft, usually off a central bull gear
been used in most gas turbomachinery. 13 3/4 inches diameter. wheel. They are used in refineries and
The first, and still the bulk, of these Smaller, between-bearing machines chemical plants for a range of processes
dry gas seal applications are through- run at higher speeds. The fastest from simple fuel gas requirements to
shaft or beam machines where the shaft, machines are single-ended or overhung complex multipressure applications.
carrying multiple closed impellers, is shaft types with open impellers in There is presently a growth area in the
supported at each end, also known as individual casings, typically referred to as compression of carbon dioxide (CO2),
“between-bearings” compressors. Shaft integrally geared compressors (see Image which is a difficult-to-seal critical fluid.
speeds range from near 20,000 rpm 1). Such machines vary from single-stage For many reasons, as far as the shaft
down to under 3,000 rpm for the biggest to multiple-stage designs with several seal is concerned, the established
between-bearing compressor applications
may be seen as straightforward compared
to those for overhung machines. The
The fastest machines are single-ended or overhung typical layout of a dry gas seal stage is as
shown in Image 2 (page 74).
shaft types with open impellers in individual casings,
Once the seal is pressurized, a thin
typically referred to as integrally geared compressors. fluid fi lm of the sealed gas separates the
stationary primary ring and rotating
mating ring. The gap between the faces is

June 2019 | Pumps & Systems

 73

CENTRIFUGAL
PUMPS
typically 2 to 4 micrometer (µm) thick, Your
You
ur Best
Be
B es
s Value
st Va
alue
e in S
Self Priming &
but depends on the pressure, speed of the
application and nature of the gas. This ANSI Centrifugal
Cen Pumps
thin fi lm must continue to separate the
faces during significant axial movements
of the shaft. Fortunately, the fluid
dynamics involved are advantageous.
As the gap tries to close, the fluid fi lm
becomes stiffer and increasingly resistant
to the faces coming into contact.
There are two important implications Model SN
associated with using a gas fi lm seal in
this way. First, there is some leakage Model 2196 ANSI
to be considered, but this is small Located in Green Bay, WI
(measured in single or tens of standard- Providing a Quality
liters/minute) because of the small gap.
Second, because contamination is Product at a Fair Market
the most common cause of seal failure, Price since 1982 TM
the inboard area must be supplied
with conditioned process gas, or Call: 920-869-4800 PUMP, Inc
an alternative, to ensure the seal is Email: sales@summitpump.com www.SUMMITPUMP.com
operating on clean dry gas. For the Circle 136 on card.
same reason, it is necessary to avoid
contaminating the seal with liquid
lubricant from the bearing adjacent to
the seal. A separation seal is usually
provided. These range from a simple PUMP MOTOR
labyrinth to a number of contacting
or noncontacting devices, usually of a
double gas-buffered design. BEARING
Dry gas seals are supplied in cartridge
form, most commonly in a tandem PROTECTION
arrangement with the inboard stage
followed by an outboard stage. A
double, back-to-back, inert gas buffered
arrangement is sometimes used. It is • Reduce downtime
possible to have a single-stage seal. This • Save money
is most commonly the case in high-speed, • Easy installation
overhung machines where space for the • Superior
seals is limited. performance
With a single or unbuffered seal,
careful thought must be given to the
nature and destination of the leakage. A
separation device may help. You can extend the life
Although there is a wide range of of your motors and
parameters, a typical between-the- prevent costly damage
bearings compressor may have a shaft to bearings! 1-800-962-4851
size of 120 mm (4 3/4 inches) diameter helwigcarbon.com
and a rotational working speed of around
12,000 rpm. This gives a passing speed
Circle 140 on card.

pumpsandsystems.com | June 2019

74 SEALING SENSE
Image 2. Typical dry gas seal stage
Image 3. Typical dry gas seal arrangements
at the seal faces of about 100 meters per
second (m/s) on a shaft supported at both
ends and driven through a coupling with
a degree of flexibility.
The rotor dynamics in turbomachinery
are usually monitored by measuring
the radial vibrations outboard of the
shaft support bearings. Gas seals
can withstand most normal levels
of vibration in a turbo compressor,
including brief transients into surge at
levels acceptable to the compressor.
The noncontacting face seal is
intrinsically tolerant of radial vibration,
as the faces separated by a fi lm of gas
June 2019 | Pumps & Systems
can easily slide eccentrically against each
other. The seal does not provide much
damping force to, and absorbs little
energy from, such movements.
The stability of the seal under the
axial component of any vibration is
maintained by the stiff ness of the fluid
fi lm and the responsiveness incorporated
into the seal design. The shaft seal
assembly must take up any relative axial
movement between the rotor and the
casing of the compressor.
Between-the-bearing machines
usually have a thrust bearing at one
end of the shaft. This means that, at the
thrust-bearing end of the machine, the
amount of sudden axial movement is
limited in the seal (typically around 0.1
mm to 0.2 mm in operation).
The overhung compressor presents
opportunities to create more arduous
modes of vibration than a beam machine.
The higher speed machines are now
rotating at between 30,000 rpm to
60,000 rpm with a small diameter shaft
supported only on one side of the seal
and driven directly from a large bull
gear. The bearing is adjacent to the bull
gear and the mass of the compressor
impeller carried at the unsupported end
of the shaft. A wide range of resonances
may be generated. There are additional
excitations from various passing
frequencies of the impeller vanes and the
gear drive in close proximity to the seal.
In integrally geared compressors,
the axial thrust in the directly driven
shaft is often taken on thrust collars
bearing against the bull gear. This can
lead to axial modes of vibration that
may be detrimental to the gas seal.
Swashing in the thrust collars will lead
to small synchronous axial vibrations,
but significant oscillations are more
likely to come from the bull gear at
subsynchronous frequencies.
Dry gas seals operated within
integrally geared compressors can often
have design enhancements specifically
to combat some of the idiosyncrasies
of the application. The seal face passing
speeds on high-speed machines can
be in excess of 160 m/s. This, with
the small diameters, leads to large
centrifugal loadings.
The selection of secondary sealing
elements, such as O-rings and
polytetrafluoroethylene (PTFE)-based
seals, is constrained by the pressure and
temperature ranges of the application
and chemical compatibility requirements.
In high-speed applications, also consider
how the sealing element reacts to
centrifugal forces.
Flexible polymer U-ring seals are
energized by a combination of the sealed

Finite element analysis techniques predict the
effects of high-rotational forces, pressures and
temperature effects, which can allow the designer to
accommodate such requirements.
pressure and an integral spring. In
applications where test regimes require
a combination of low-pressure and high-
speed running, the sealing element’s
spring force may be insufficient to ensure
adequate contact loads between sealing
surfaces. Therefore, bespoke polymer
seal designs can be used to address
such issues.
Finite element analysis techniques
predict the effects of high-rotational
forces, pressure and temperature
effects, which can allow the designer to
accommodate such requirements. Focus
is often on sealing elements such as those
between the shaft and main sleeve or
behind the mating ring.
Adverse effects on the seals can be
attributed to torsional vibrations within
the shaft. These may be generated by
unevenness in the gear drive, but also
from the variable speed inverter controls
in electric drives, or variable frequency
drives (VFDs), which may not produce a
completely smooth signal.
The rotating sleeve assembly should
have drive features, such as keys and
lugs, to ensure all parts rotate as one. A
component, like the stationary primary
ring, should have antirotation features
interlocking with metal components.
Areas of intercomponent engagement can
be damaged by vibrational hammering
and fretting.
Another focus of design is the balance
diameter polymer seal. Although not
subject to rotational forces, it should
be free to slide and accommodate the
axial movements of the rotor, whatever
the seal’s state of pressurization. As a
direct result of the means in which the
thrusts on the pinion shafts of integrally
75
Next Month: Offset and reducer
expansion joints considerations
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
geared compressors are managed, the seal suggestions and questions to sealingsensequestions@
should be able to cope with constant axial fluidsealing.com.
deviations. In some instances, the total
accumulated distance travelled by the
balance diameter seal can be thousands
of kilometers over a typical five-year Richard G. Albery is a chartered
installation life. mechanical engineer who graduated
The material combination, contact from Brunel University in
loads and environment of operation London. He has worked
are key considerations when designing for John Crane for 28
these sealing elements. A combination years on dry gas seals.
of tribological performance and robust For more information,
design can ensure integrity over the life visit johncrane.com.
of the seal.
RunfiDryfianfi
KfifipfionfiRunnfing
Pumpsfifififififififififififi
GRAPHALLOY® fifiarfi
parfisfisurvfivfifiupsfifis.
• Self-lubricating
• Non-galling
• Won’t swell
• Corrosion resistant
• Dimensionally stable
• Improved efficiencies GRAPHITE METALLIZING
• -400˚F to 1000˚F (-240˚C to 535˚C) CORPORATION
Yonkers,, NY USA
+1.914.968.8400 • www.GRAPHALLOY.com
Circle 134 on card.
pumpsandsystems.com | June 2019
76 EFFICIENCY MATTERS

Prevent Downtime with Pump Diagnostic Equipment

Predictive maintenance can provide detailed data and actionable repair instructions.

By James Farley
Griswold

P
umps are the heart of fluid-
transfer operations. Unexpected
failure can devastate production
and profits. Operators in the industrial-
manufacturing realm have been looking
for ways to see into the future, to know
when, how and why a pump will need
to be serviced before a catastrophic
breakdown will bring the production
process to a halt.
Over the years, manufacturers have
worked to improve pump reliability and
have developed tools to monitor pump
performance and health. Sometimes
these tools result in little more than a
“check engine light” scenario. There is a
problem, so what is the next step?
Evolving technology allows the pump
and driving motor to be monitored
around the clock via continuous cloud
connectivity. This article illustrates how aligned, operating without cavitation,
the technology works and how it can
optimize pump performance, reliability,
and cost of operation and maintenance.
The Challenge
In most industrial production and
processing plants, unexpected failures
can be devastating to the production
schedule and, by extension, the operator’s plant staff.
bottom line. There are many negatives
associated with pump failures:
• disrupted production
• batch failures
• excessive downtime
• costly repairs
• costs for new parts and shipping
• costs for service calls, which can
include overtime
• lost or compromised revenue
Image 1. A predictive-monitoring system can identify failure modes and provide actionable
repair guidance, monitoring the pump and motor 24/7 with Wi-Fi or cellular access. (Images
courtesy of Griswold, part of PSG)
In many cases, failure can be prevented
if the pump is installed and operated
correctly. At the very least, operators
should ensure that the pump is properly
has properly lubricated bearings,
sufficient baseplate rigidity and more.
Getting these wrong will lead to costly—
and preventable—repairs.
When a pump failure occurs, replacing
the broken component alone may not be
sufficient. Getting to the root cause can
also be difficult and time consuming for
If a mechanical seal fails, for example,
simply replacing it may not prevent a
repeat failure if there is a shaft vibration
issue that should be resolved. Pinpointing
a root cause can lead to hours of if/then
assumptions and trial and error, along
with the chasing of symptoms that may
ultimately require a level of expertise
that can only be provided by a third-
party source.
Furthermore, if the pump is in a
remote location, the level of complexity
is ratcheted up. In these installations, it
is difficult to monitor the pump without
a technician at the site, which brings its
own added costs and safety issues.
Current Industry Solutions
Facilities have focused on deploying
predictive maintenance (PdM)
techniques as a solution to increasing
production reliability since the 1990s.
In the pump industry, PdM uses
techniques such as vibration and
temperature monitoring to observe a
pump’s performance and health during
operation. Early on, PdM was a manual
process where measurements were taken
by hand-held devices, then documented
and analyzed. This process relied on
vibration experts to interpret the data.
The pump industry has taken steps to
deploy advanced technology in PdM as a
way to automate the process.

June 2019 | Pumps & Systems

 77

Table 1. Average cost chart • Tri-axial vibration reading: The

Equipment or Service Average Cost equipment’s vibration signature
produces details regarding its
Rotating Shaft Replacement $700 to $5,000+
health and can be used to identify
Seal Failure $700 to $10,000+ impending bearing failure,
Pump Replacement $2,500 to $30,000+ misalignment, cavitation levels,
Motor Replacement $500 to $30,000+ pipe strain and more.
Coupling Replacement $150 to $1,5000+ • Temperature reading: Elevated
operational temperatures are
Manual Vibration Analysis $1,000+ per unit
a sure indication of upcoming
Onsite Maintenance $50+ per hour bearing failure, inadequate bearing
Process Disruption $$$$ lubrication and other causes of
Total Cost $100,000 or more issues. Studying temperature trends
can help the operator detect thermal-
While some current technologies have Two sensors are installed on the pump, fault signatures, which will provide
automated the data collection, they still and two are installed on the motor. additional insight into when potential
may have limitations: The sensors work in unison to predict breakdowns may occur.
• Complete machine monitoring. Most the health of the pump and motor. This • Electromagnetic reading: Sensors
technologies are designed to monitor capability allows a diagnostic reading are able to monitor the motor’s true
the pump only, even though the pump and analysis of a number of performance revolutions per minute (rpm) and
is only part of the machine. parameters for the pump, motor, coupling proactively diagnose electrical faults
• Not true remote monitoring. The and foundation, including: through the electromagnetic tools.
majority of “remote” monitoring
technologies require technicians to be
within Bluetooth range of the pump
with a mobile device to accurately ws
Flo
gather the data. o n
ati
• No real-time data. Due to the ov
I nn
remote-monitoring restrictions, this e re
Wh
eliminates real-time data, as well as
24/7 monitoring.
• Alarm only. The data collected by
other diagnostic technologies is
equivalent to an alert only with no
clear level of urgency.
• No repair guidance. While there is an
alert to signify a problem, the root
cause is not identified nor any repair
guidance offered.
• No single-source data collection. It
SafeGuard®
is cumbersome to collect the data first predictive
on all machines within the plant
in one easy-to-reference and
pump-monitoring
accessible location. system with
The Solution actionable repair 22069 Van Buren Street
Grand Terrace, CA 92313-5607
There are predictive monitoring systems
that can identify failure modes and guidance USA
O: +1 (909) 512-1262
provide actionable repair guidance, F: +1 (909) 783-3440
monitoring the pump and motor around griswoldpump.com
the clock with Wi-Fi or cellular access.
Circle 139 on card.

pumpsandsystems.com | June 2019

78 EFFICIENCY MATTERS

Check your motor’s health!

Solutions for your maintenance and repair needs. This data is collected, compiled and transferred to the cloud to
be analyzed, using the full capabilities of the industrial internet
Made in Germany
of things (IIoT). The data is analyzed by a series of machine-
MotorAnalyzer 2 learning algorithms that can determine the overall health level
• Portable, light weight battery powered winding tester of the pump and motor, define the root cause of any alerts and
• Winding resistance, inductance, capacity measurements
• Meg, PD, HiPot, Surge, insulation tests generate steps to resolve the issue.
… When a potential issue is identified, the monitoring system
will notify the operator via an automated email report,
identifying the level of alert (whether it needs to be handled
immediately or it is something to be aware of), the root cause, as
well as actionable resolution guidance. The system can identify
more than 20 failure modes. Such failure modes include bearing
failure, coupling misalignment, cavitation, foundation looseness
and others.
Dynamic-MotorAnalyzer
• Measure motor efficiency Field Reliability
• Obtain torque and shaft speed
• Troubleshoot motor and pump together A system was installed on a new ANSI centrifugal pump
…
that used a chilled water loop for a steel-coating company.
Upon installation, the maintenance team completed a
Motor Diagnostic Systems startup checklist. The pump was put into service and sensors
502 2nd St., Unit 1 | Berthoud, CO 80513 | PH: (970) 461-1348 | inside.sales@mdsusa.net
immediately identified two issues: misalignment and foundation
www.mdsusa.net www.schleich.com looseness. The cause of foundation looseness was identified
Circle 143 on card. as a loose foundation bolt. The maintenance team rechecked
alignment with a laser alignment tool and found there indeed
was an issue.
After correcting these, the pump began operating acceptably.
If these issues had not been caught in the early stages, the pump
would have failed prematurely.
After operating acceptably for 11 months, a new alert was
UNMATCHABLE EXPERIENCE IN identified. Sensors identified an electrical fault in the motor
FLOW CONTROL TRANSACTIONS that would lead to motor failure. The end user was alerted of
this fault and was able to replace the motor before a complete
failure occurred.
Jordan Knauff & Company is a knowledgeable and
experienced provider of a comprehensive line of Conclusion
investment banking services to the pump, valve and
filtration industries (“Flow Control”). New technologies take existing pump diagnostic capabilities
and create a holistic way of looking at the pump and motor.
Our lines of business include: selling companies, The capabilities help optimize system uptime while increasing
raising debt and equity capital, and assistance equipment life span and operational safety.
on acquisitions.
This will result in fewer accidents that can have a negative
To learn more about Jordan Knauff & Com- impact on site personnel and the surrounding environment,
pany, contact any member of our Flow while simultaneously meeting the demanding needs of
Control team. Access our Flow Control research
at www.jordanknauff.com/research-library. production schedules and quotas, efficiency, maintenance,
repair and replacement costs, spare-parts inventory and
revenue optimization.
G. Cook Jordan, Jr. David A. Kakareka
Managing Principal Vice President
cj@jordanknauff.com dkakareka@jordanknauff.com
312.254.5901 312.254.5907 James Farley is the product manager for Griswold and PSG.
He may be reached at james.farley@psgdover.com. For more
information on Griswold or PSG, visit griswoldpump.com or
MEMBER FINRA, SIPC
psgdover.com.
Circle 142 on card.

June 2019 | Pumps & Systems


Oil Viscosity & Bearing Lubrication
By Hydraulic Institute
What viscosity oil should be
used with rolling element
bearings?
The viscosity and type of lubricant
used will depend on the bearing design
and service. Rolling element bearings
(Image 1) in process pumps are lubricated
by grease, mineral oil or synthetic
oil. When selecting a lubricant, it is
important to consider that the primary
purpose of oil, or the oil constituent of
grease, is to separate the rolling elements
and raceway contact surfaces, lubricate
sliding surfaces within the bearings and
provide corrosion protection and cooling.
Viscosity is an important property of
a lubricant, which supports the function
of a lubricant in reducing friction and
wear. A protective oil fi lm is required to
perform these functions. The three basic
oil fi lm conditions are referred to as:
1. Full film denotes the presence
of enough lubricant to ensure
complete separation of the moving
surfaces. They are also known as
hydrodynamic full fi lm.
2. Elastohydrodynamic (EHD) is
when a hydrodynamic fi lm is formed
by applied pressure or load. They
are predominantly found in rolling
element bearings.
3. Boundary layer is sometimes
referred to as thin fi lm lubrication
and is usually the result of
insufficient lubricant supply.
Although lubrication is present,
there is not enough to prevent
metal-to-metal contact.
Oil or grease base viscosity selection
is influenced by load, temperature and
speed. If an application involves high
speeds, low loads and low temperatures,
then a low-viscosity lubricant is adequate.
Conversely, if low speeds, high loads and
high temperatures are the parameters,
then a high-viscosity lubricant should
be chosen.
Oil in process pumps is typically
an ISO grade 32, 46, 68 or 100. These
numbers relate to the kinematic viscosity
in centistokes. The oil can be hydrocarbon
oil, although synthetic oils are used for
specific lubrication applications. The
viscosity of synthetic oil is less sensitive
to temperature changes and more widely
used when temperature fluctuations
exist. If temperature also exceeds 100
C (212 F), a synthetic is recommended
because the oxidation rate of mineral oil
accelerates at higher temperatures.
Use of the correct viscosity lubricant
for the speed, temperature and loads
ensures the development of a full oil
fi lm between rotating parts. The
optimum fluid fi lm is sufficiently thick
to allow the rolling elements to function
without metal-to-metal contact with
minimum friction. The functionality of
the lubricant is negatively affected when
the incorrect viscosity is used.
When viscosity is too low, it can cause
mixed or boundary lubrication with
resulting heat generation and component
wear. Excessively high viscosity will
prevent metal-to-metal contact, but will
generate unnecessary heat and loss of
power as the rolling elements are forced
to plow through the oil fi lm.
When is grease used as a
bearing lubricant?
The use of grease is primarily
limited to lower-horsepower pumps
where the parameters are in size and
speed range of rolling element bearings.
HI PUMP FAQS 79
Image 1. Rolling element bearings (Image
courtesy of Hydraulic Institute)
Grease is usually lithium, with a
normal viscosity of 100 centistokes.
This typically has a maximum operating
temperature of 121 C (250 F), but it is
usually limited to a service temperature
of 93 C (200 F). To prevent the loss of
grease and minimize the entrance of
containments, shielded bearings may
be used. Shielded bearings are usually
limited to a maximum operating
temperature of 52 C (125 F).
Advantages to grease lubrication
include being less sensitive to level pump
installation and simplified maintenance.
Disadvantages to grease lubrication
include:
• limited heat dissipation
• overpressurization during
regreasing that can damage
bearing shields (to avoid, follow
manufacturer procedures to prevent
overpressurization)
• higher frictional heat from grease
used with sealed bearings that can
lead to accelerated oxidation of
the grease
For more information on lubrication
of rolling element bearings, refer to HI’s
free white paper, “Proper Lubrication
Methods for Bearings,” at pumps.org
HI Pump FAQs® is produced by the Hydraulic
Institute as a service to pump users, contractors,
distributors, reps and OEMs. For more
information, visit pumps.org.
pumpsandsystems.com | June 2019
80 MAINTENANCE MINDERS
Comply with Critical Lead-Free
Water System Regulations
Understand calculations and specifications.
By Rob Lindquist & Michael Brendel
Emerson Automation Solutions
An engineer at a contracting firm is designing an upgrade for a new public
water system. The engineer is aware there are regulations governing the use
of lead-free components in potable water applications but is confused by the
law’s complex calculations and the number of pumps, valves and components
with lead-free designations.
T
his predicament plays out across
North America as manufacturers,
contractors and operators grapple
with lead content requirements for
potable water systems.
In the U.S. and Canada, these
regulations have seen changes as safety
restrictions tighten. In effect since
January 2014, the laws in these countries
dictate much lower lead content for
certain systems and components than
in the past.
Manufacturers of potable water
equipment and systems—including
reverse osmosis (RO) systems, water
purification plants, and public and
industrial water systems—as well as
equipment maintenance contractors are
affected. There is continued uncertainty
regarding how it will impact the
purchasing and implementation of water
system components.
This article outlines relevant sections
of the law. It then focuses on choices
facing specifiers and purchasers who
need to select products for these systems
to comply. It considers the calculations
that must be made to determine average
lead content. Finally, it discusses
suggestions for evaluating lead-free
products. Following these guidelines
June 2019 | Pumps & Systems
will help OEMs, contractors and end
users to ensure equipment remains
efficient, safe and compliant.
The Law
The U.S. Federal Reduction of Lead in
Drinking Water Act was established on
Jan. 4, 2011, to amend Section 1417 of
the Safe Drinking Water Act (SDWA). It
took effect on Jan. 4, 2014.
The Office of Water of the U.S.
Environmental Protection Agency
(EPA) summarized the amendment in a
December 2013 report:
Effective Jan. 4, 2014, lead-free means:
• not containing more than 0.2 percent
lead when used with respect to solder
and flux
• not more than a weighted average
of 0.25 percent lead when used with
respect to the wetted surfaces of
pipes, pipe fittings, plumbing fittings
and fi xtures
Canadian law reflects the intent of the
SDWA, regulations for low-lead policies
relating to lead content in plumbing
products. Regulators, legislators and
Health Canada approached the lead-free
issue through the national system of
plumbing codes adopted and enforced
provincially or territorially through the
recognized network of plumbing and
health inspections.
The Calculation
For purposes of the SDWA, the weighted
average lead content of a pipe, pipe
fitting, plumbing fitting, fi xture or
system is calculated using the following
statutory formula:
• For each wetted component, the
percentage of lead in the component
is multiplied by the ratio of the wetted
surface area of that component to the
total wetted surface area of the entire
product to arrive at the weighted
percentage of lead of the component.
• The weighted percentage of lead in
each wetted component is added
together, and the sum of these
weighted percentages is used to
calculate the weighted average lead
content of the product or system. The
lead content of the material used to
produce wetted components is used to
determine compliance.
• For lead content of materials that are
provided as a range, the maximum
content of the range must be used.
Doing the Math
A critical part of the law states that lead
content must constitute no more than a
weighted average of 0.25 percent—when
used with respect to the wetted surfaces
of pipes and pipe fittings, plumbing
fittings and fi xtures—for a product to
be considered lead-free. The previous
more permissive standard, in part, called
for pipe and pipe fittings containing 8
percent lead or less. This applies to all
relevant equipment sold in U.S. and
Canada (except water distribution main
gate valves 2 inches or more in diameter).
Under the new law, lead-free is a
cumulative concept. Not every part of
a system must meet that average. In
practical terms, some parts can be over
that number, some at it and some under
it. Specifiers and buyers add up the lead
content of all wetted components to get

an average product percentage that
must be less than or equal to 0.25
percent lead content. This total wetted
surface area calculation governs the route
to compliance.
How does it work in an application?
Suppose that a manufacturer makes
water treatment systems. The
manufacturing engineer would have
to perform the above lead content
calculation, averaging all of the system’s
relevant components: pumps, valves,
piping, etc.
OEMs must query the manufacturers
of their valves, pumps and other
components to ascertain the precise
internal wetted areas of parts and the
lead content of each part. However, this
data can be difficult to obtain due to
complex component geometries, making
the calculation difficult or impossible.
Instead, a reputable manufacturer
would likely simplify the task by
installing lead-free components,
foregoing the complex calculation. For
example, one supplier’s lead-free brass
valves are an exact replacement for its
conventional brass valves and can be
applied without changing the system’s
design. Also, end users may desire as
many lead-free components in their
products as possible.
The Problem with Brass
Brass is the conventional material
choice for many industrial plumbing and
water system products. However, brass
components often contain lead content
of 2.5 percent or greater. Using just one
brass valve in a potable water system
would require the OEM to perform the
wetted surface area calculation and can
tip the balance of total lead content for a
given product.
Incorporating older, traditional brass
valves could result in noncompliance
with the new law.
Lead-Free Brass
The introduction of lead-free brass
valves and other components has added
81
another option for OEMs and water
systems seeking SDWA compliance. For There are lead-free
example, lead-free brass constructions
are available on some suppliers’ most options that meet
popular lines of general service solenoid the requirements and
valves. These valves incorporate the
same proven performance, reliability and eliminate the need to
quick availability as their brass solenoid calculate lead content.
valve counterparts.
To avoid calculation errors,
selection. No one likes to hold up an
manufacturers and contractors working
entire project or keep a system shut down
with brass valves should use lead-free
waiting for parts.
brass instead of performing the wetted
surface area lead content calculation.
Conclusion
If a brass solenoid valve in the
The discovery of lead in drinking
system must be replaced, a the use of a
water supplies has focused the public’s
corresponding lead-free brass valve will
attention on this important health
ensure SDWA compliance.
issue. The contamination in these
systems was generated by old pipes
Making Sure Lead-Free Is Lead-Free
and components that contained high
The characterization of a component
quantities of lead.
as “lead-free” can be a subjective issue.
The new laws, plus public and
The law only requires manufacturers to
environmental pressures, are driving the
self-certify their products. To ensure
overhaul and upgrade of many public,
successful purchase of a lead-free
industrial and commercial potable
component, look for a manufacturer that:
water systems.
• inspects and analyzes forgings and
The lead-free content laws are
materials to ensure they are lead-free
straightforward but can be complex if the
before entering the production system
SDWA’s wetted surface area lead content
• uses dedicated forging tools for
calculation must be performed. Today,
lead-free production to avoid
there are lead-free equipment options
manufacturing conventional brass
available that will meet the regulations
and lead-free brass products on the
and eliminate the need to calculate
same equipment
lead content. OEMs, contractors and
• forges a highly visible lead-free mark
operators now have choices to ensure
on the product’s lead-free brass
their water systems and equipment meets
components to provide an additional
all requirements for full compliance.
degree of certainty for the user that
the product is genuinely lead-free
Rob Lindquist is senior marketing
manager, Industrial (ASCO) for
Following these guidelines will ensure
Emerson Automation Solutions.
the purchase of a truly lead-free product.
He may be reached at
Plus, system maintenance will become
robert.lindquist@emerson.com.
easier since the LF marking will ensure a
replacement valve is lead-free.
Michael Brendel is product manager,
Industrial (ASCO) for Emerson
Is It Available?
Automation Solutions. He may be
Water system OEMs and contractors with
reached at michael.brendel@emerson.
demanding assembly or replacement
com. For more information, visit
schedules may weigh ordering, shipping
emerson.com/asco.
and delivery times during equipment
pumpsandsystems.com | June 2019
82 PRODUCTS
New & Notable Technology
Products selected by the Pumps & Systems editors
3 5
1 REMOTE TERMINAL UNITS
The MyDro series of remote terminal units (RTUs)
from MISSION COMMUNICATIONS augments
legacy unit functionality with the addition of
enhanced electronics and an onboard, interactive
display screen. MyDro RTUs support 16 digital
inputs, 6 analog inputs, 4 pulse inputs and 2 analog
outputs simultaneously. Over-the-air firmware
upgrades are available, and the LCD touch screen
supports local configurability, while displaying
current RTU statuses. 123mc.com
Circle 201 on card.
2 PACKING SYSTEM
The HydraLoad System from SEPCO features a
high-performance, shaft-stabilizing bearing block;
a separate lantern ring; and high-performance
packing. The bearing’s low coefficient of friction
reduces power consumption. The system also
decreases product dilution and water use by 80
percent. A separate lantern ring eliminates the need
to replace the entire block if damage or clogging
occurs, significantly decreasing the downtime
required for cleaning, removal or replacement when
compared to systems in which the lantern ring and
bearing are connected. sepco.com
Circle 202 on card.
3 PRESSURE TRANSDUCER
The new KD41 pressure transducer combines the
rugged ASHCROFT sensor with CANbus protocol
to provide state-of-the-art digital communication.
Available in CANopen 2.0A and 2.00B, this versatile
transducer is designed to meet the requirements
of a wide variety of applications. The stainless
steel KD41 is available in ranges up to 20,000 psi.
A sealed housing provides IP67 or optional IP69
ingress protection. ashcroft.com
Circle 203 on card.
To have a product considered for this section, please send the information to Drew Champlin, dchamplin@cahabamedia.com.
June 2019 | Pumps & Systems
6
4 LIQUID RING VACUUM PUMP
DEKKER VACUUM TECHNOLOGIES is proud
to unveil the new Vmax Plus, a 10 horsepower
oil-sealed liquid ring vacuum pump for
woodworking & computer numerical control
routing. This technology offers efficiency and
reliability while reaching 29 inches HgV. The
Vmax Plus is designed for increased hold-
down force, lower maintenance costs, smaller
footprint and noise reduction.
dekkervacuum.com
Circle 204 on card.
5 PACKAGED PUMP
RWN PUMP AND FABRICATION is an
authorized distributor of some of the top 6 CENTRIFUGAL PUMP
pump and engine manufacturers. RWN ARGAL’s fiberglass (FRP) centrifugal pumps
fabricates all skids in-house offering silent were conceived for overcoming chlorine and
enclosure options and custom NATM certified seawater issues. The SATURNevo fiberglass
contained trailers. Pumps are quality tested (FRP) range is high-corrosion resistant,
and ready for use before leaving the facility. making it ideal for operations into aquarium,
Types of pumps include: trash and sewage fish farms, electrochlorination, aquatic parks
pumps, high flow pumps, high pressure and more. SATURNevo pumps are available in
pumps, self-priming pumps, vacuum assisted various typology from centrifugal horizontal
pumps, venturi pumps, clear water pumps, to vertical and sump. ARGAL offers air-
diaphragm pumps, wellpoint pumps and skid/ operated double diaphragm (AODD) pumps
trailer mounted pumps. rwnpumpfab.com entirely made of fiberglass. argal.it
Circle 205 on card. Circle 206 on card.

7 12
11
8 of Controllers that connect with Vogtlin or any
10
8 FUSION DAMPENER
New fusion dampeners from GRIFFCO VALVE
combine the technologies of the company’s back
pressure valves and pulsation dampeners into
9 one product in order to simplify a chemical-feed
system installation. They feature large internal
passages so there are no restrictions on flow rate
or pumped fluid cleanliness. The combination
of these two devices into one accessory reduces
the number of joints, hence fewer leak path
opportunities, and provides a smooth, nearly
pulseless chemical-feed system. Body materials of
construction include PVC, CPVC, PP, and PVDF, and
the bladders are available in EPDM, Viton, Hypalon,
and PTFE. griffcovalve.com
Circle 208 on card.
7 COMPRESSOR ROTOR
Solution Strengthened Ductile Iron (SSDI) is a 9 CENTRIFUGAL PUMP
new grade of DURA-BAR continuous cast ductile Fluid Equipment Development Company (FEDCO)
iron with improved strength and ductility that is MSD series multistage centrifugal pump models
an alternative to 1045 steel. Typical applications cover flows and high pressures of feed and
include rotors used in air compressors, hydraulic booster pump applications found in seawater and
manifolds and cylinders. One of the key features brackish water reverse osmosis (RO) desalination.
of SSDI is its enhanced machinability due to the Constructed in duplex stainless steels, this pump
addition of silicon. Machining trials have yielded features customized hydraulics engineered to
productivity increases of approximately 30 provide high efficiencies, patented water bearing
percent with no negative impact in tool wear. product lubrication and fast delivery.
dura-bar.com fedco-usa.com
Circle 207 on card. Circle 209 on card.
83
10 FLOW CONTROLLER
AW-LAKE Company introduces its new PCU Series
thermal mass flow meter or controller to provide
a local display of flow output. Serving as a single-
or multi-channel mass flow controller with up
to four channels, the PCU instruments support
multiple unit networked operations. A large, high-
contrast backlit display offers easy-to-read views
of process variables and programmed setpoints
for each connected device on one screen. They
operate from 15 to 24 voltage DC and provide a
variety of voltage or current outputs. Operating
temperatures range from 32 to 104 F (0 to 40 C).
aw-lake.com
Circle 210 on card.
11 HIGH VOLUME PUMPS
PUMPS 2000 introduces 3-inch high-volume ball
valve and 4-inch high-volume slurry valve pumps.
These air-operated, dual-diaphragm pumps have
flow rates of 416 gpm and 540 gpm, respectively.
Both models use a patented 4-inch air motor.
These pumps have been specifically designed for
mining and tunneling and are ideal for the most
demanding applications in many other industries.
Key features and benefits include: patented
long-life diaphragm and self-cleaning valves; large
solids handling of up to 1.3 inches and 3 inches,
respectively; modular air motor components
that do not require lubrication; high suction lift;
maintenance in place with no end of service life.
pumps2000america.com
Circle 211 on card.
12 ENCLOSURE
TMEIC is pleased to introduce the TMdrive-
Guardian, a NEMA Type 3R enclosure for its
TMdrive-MVe2 medium voltage VFD. The self-
sufficient enclosure eliminates the need to house
the drive in a temperature-controlled industrial
control building or E-house and has the potential
to save companies thousands of dollars and make
EPCM & maintenance a breeze. The new enclosure
further enhances the TMdrive-MVe2, delivering
more ease of use and value to operators.
Circle 212 on card.
pumpsandsystems.com | June 2019
84 PUMP USERS MARKETPLACE

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

ABB Motors & Mechanical . . . . . 113 11 Inpro/Seal . . . . . . . . . . . . . . . . . . . . 121 20
AE Pumps . . . . . . . . . . . . . . . . . . . . 163 84 Integrity Pump & Motor . . . . . . . 132 61
All-Test Pro LLC . . . . . . . . . . . . . . . 131 23 Invertek Drives, USA . . . . . . . . . . 151 85
AutomationDirect .com . . . . . . . . . 115 BC Isomag Corporation . . . . . . . . . . . 104 5
Av-Tek, Inc . . . . . . . . . . . . . . . . . . . . 148 87 John Crane Inc . . . . . . . . . . . . . . . . 105 25
AVI International, Inc . . . . . . . . . . 133 67 Jordan, Knauff & Company . . . . . 142 78
Bartlett Bearing Company . . . . . . 109 13 KIRIS System . . . . . . . . . . . . . . . . . 157 86
Blackmer Pumps . . . . . . . . . . . . . . 128 15 Load Controls . . . . . . . . . . . . . . . . . 129 60
Blue-White Industries Ltd . . . . . . 120 41 Load Controls . . . . . . . . . . . . . . . . . 165 87
BMR USA . . . . . . . . . . . . . . . . . . . . . 144 71 LobePro Rotary Pumps . . . . . . . . 158 86
Continental Electric . . . . . . . . . . . 160 86 Lovato USA . . . . . . . . . . . . . . . . . . . 126 57
Dan Bolen & Associates . . . . . . . . 155 85 Magnatex Pumps . . . . . . . . . . . . . . 152 85
Electro Static Technology . . . . . . 122 39 MasterBond Inc . . . . . . . . . . . . . . . . 149 85
EnviroPump and Seal Inc . . . . . . . 145 64 Metrix Instrument Company . . . 135 68
Equipump, Inc . . . . . . . . . . . . . . . . . 156 86 Milton Roy . . . . . . . . . . . . . . . . . . . 123 50
Flowrox . . . . . . . . . . . . . . . . . . . . . . 117 33 Mitsubishi Electric . . . . . . . . . . . . 116 27
Franklin Electric . . . . . . . . . . . . . . 119 9 Motor Diagnostic Systems . . . . . . 143 78
Gorman-Rupp Company . . . . . . . 103 29 MWI Pumps . . . . . . . . . . . . . . . . . . 161 84
Graphite Metallizing Navi Solutions . . . . . . . . . . . . . . . . 153 85
Corporation . . . . . . . . . . . . . . . . . . . 134 75 NSK Americas . . . . . . . . . . . . . . . . . 130 52
Griswold Pump Company . . . . . . 139 77 Orion Seals . . . . . . . . . . . . . . . . . . . 141 55
Helwig Carbon Products . . . . . . . 140 73 Regal Beloit . . . . . . . . . . . . . . . . . . . 127 37
Hydro, Inc . . . . . . . . . . . . . . . . . . . . . 101 IFC Rotech Pumps & Systems, Inc . . . 162 84
Infosight . . . . . . . . . . . . . . . . . . . . . 166 87 Schaeffler Group USA Inc . . . . . . . 106 31
Schenck Trebel Corp . . . . . . . . . . . 124 53
SealRyt Corporation . . . . . . . . . . . 118 45
ShinMaywa (America), Ltd . . . . . . 146 64
SPPS . . . . . . . . . . . . . . . . . . . . . . . . . 147 71
Sulzer Management Ltd Rotating
Equipment Services . . . . . . . . . . . . 110 43
Summit Pump, Inc . . . . . . . . . . . . . 136 73
Summit Pump, Inc . . . . . . . . . . . . . 137 62
Topog-E Gasket . . . . . . . . . . . . . . . 150 86
TPI . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 67
Tuf-Lok International . . . . . . . . . . 164 87
UNICO Technologies Group . . . . 111 3
Vaughan Company . . . . . . . . . . . . . 112 IBC
Vertiflo . . . . . . . . . . . . . . . . . . . . . . . 154 85
Vesco Plastics Sales . . . . . . . . . . . . 159 86
WEG Electric Motors . . . . . . . . . . 114 17
Worldwide Electric Corp . . . . . . . 107 7
Worldwide Electric Corp . . . . . . . 125 65
Yaskawa America Inc . . . . . . . . . . 108 19
The Index of Advertisers is furnished as a courtesy, and
no responsibility is assumed for incorrect information.

OUR EXPERTS CAN HELP

Every job is different. Our experienced,
licensed engineers will work with you
to design a cost-effective solution that
is the right fit for your application -
potentially saving millions of dollars.

When you need to move large volumes

of water quickly and efficiently - call MWI.

Offering a wide range of axial and mixed

flow pumps with flows from 10K-1M gpm.

Call for a free

project review:
954-426-1500

mwipumps.com

Circle 161 on card. Circle 162 on card. Circle 163 on card.

June 2019 | Pumps & Systems

 85

Super Fast
Curing Adhesive Sub ANSI magnetic drive pumps
IN STOCK, READY TO QUICK SHIP.
RESISTS HIGH TEMPERATURES

• High bond strength

• NASA low outgassing certified
• Glass transition temperature Tg >125°C

Phone: 713.972.8666 | Toll Free: 866.624.7867

154 Hobart St., Hackensack, NJ 07601 USA FAX: 713.972.8665
+1.201.343.8983 ● main@masterbond.com 3575 West 12th Street, Houston, TX 77008

www.masterbond.com www.magnatexpumps.com
Circle 149 on card. Circle 151 on card. Circle 152 on card.

EXECUTIVE SEARCH/RECRUITING

“Serving the Pump &

Rotating Equipment, Valve,
and Industrial Equipment
Industry since 1969”
Domestic & International
Specializing in placing:
• General Management • Engineering
• Sales & Marketing • Manufacturing

JASON SWANSON • JULIAN MUELLER

DAN BOLEN

120 N. 44th Street, Suite 325

Circle 153 on card.
Phoenix, Arizona 85034
(480) 767-9000
Email: jason@danbolenassoc.com
www.danbolenassoc.com
Circle 154 on card. Circle 155 on card.

pumpsandsystems.com | June 2019

86 PUMP USERS MARKETPLACE

Solve
dry start
problems with
Vesconite Hilube Circle 150 on card.

bushings
● Increase MTBR REPLACEMENT • REPAIR • RECOVERING
● No swell • Aftermarket pump parts for most models of
● Low friction = reduced Lobeflo®, Muniflo®, Lobeline®, Vogelsang®,

:
and Borger® Pumps
electricity costs
• Repair of Rotary Lobe Pumps
● Quick supply. • Manufacturer of the Muniflo Rotary Lobe Pump
No quantity too small (originally manufactured by Wemco since 1985)
Tollfree 1-866-635-7596 Are you looking for obsolete LobeFlo® (SSP/MGI) Pump Parts?
vesconite@vesconite.com We are the answer!
www.vesconite.com www.equipump.com | www.muniflopump.com
800-783-5623 | fax 800-693-5623 | info@equipump.com
Circle 159 on card.
Circle 156 on card.

KIRIS SYSTEM
Finally The Proper Tools to
disassemble and assemble
your open and closed
impeller ANSI Pumps. An • Safer, more economical
Ergonomically Safer way
• The correct tool for the job.
to work on your equipment.
Protect Your Craftsman as well • No more slapping or jarring
of critical components by using
as the critical components of
other inferior tools
your equipment by using the
correct tool for the job.
WWW.KIRISSYSTEM.COM
Circle 157 on card.

Why LobePro Rotary Lobe Pumps?

• Low maintenance - • Excellent for abrasives,
“in place” wear part solids & viscous fluids
replacement • Forward and reverse
• Run dry ability pumping operation
To learn more or get a custom quote,
email PumpSales@lobepro.com

912-466-0304 • www.LOBEPRO.com • Made in USA

Circle 158 on card. Circle 160 on card.

June 2019 | Pumps & Systems

 87

MONITOR PUMP PERFORMANCE

• Flow Rate univeRsal PoweR Cell
• One Size Adjusts for
• PumP Condition All Motors, From Small
up to 150HP
• dRy Running • Works on Variable Frequency
Drives, 3 Phase, DC and
• Cavitation Single Phase
• 10 times more sensitive than
• BeaRing FailuRe just sensing amps
• 4-20 Milliamp, 0-10 Volt

Call now FoR youR FRee 30-day tRail

888-600-3247
Circle 165 on card.

To subscribe to our print or digital

• Self-aligning & self
editions and to sign up for our grounding
newsletters, visit our website and • High pressure
rated
click on SUBSCRIBE • Stainless or
mild steel
PUMPSANDSYSTEMS.COM • Low cost
• High end pull

Circle 166 on card. Tuf-Lok International

Phone: 608.270.9478 • www.tuflok.com

Circle 164 on card.

MOBILE
CONNECTIONS
ON THE GO
facebook.com/pumpsandsystemsmag

twitter.com/PumpsSystemsMag
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pumpsandsystems.com | June 2019

88 PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch
By Jordan, Knauff & Company
T
he Jordan, Knauff &
Company (JKC) Valve Stock
Index was down 2.6 percent
over the last 12 months, while the
broader S&P 500 Index was up
10.9 percent. The JKC Pump
Stock Index fell 2.4 percent for the
same period.1
The Institute for Supply
Management’s Purchasing
Managers’ Index (PMI) registered
52.8 percent in April, a decrease
of 2.5 percentage points from
the March reading, signaling the
slowest pace of growth in two and
a half years. The drop can mostly
be traced to two components:
employment, which dropped to 52.4
percent from 57.5 percent, and new
orders, which fell 5.7 percentage
points to 51.7. The fall of new orders
points to a weakening in domestic
demand and continued anemic
growth overseas. Export orders
fell into contraction territory for
the first time since February 2016,
declining to 49.5 percent.
The U.S. economy expanded at
an annual rate of 3.2 percent for
the first quarter of 2019, compared
to a rate of 2.2 percent in the final
three months of 2018. The growth
was boosted by exports, which rose
3.7 percent; an increase in state and
local government spending, which
Image 2. U.S. energy consumption and rig counts
Source: U.S. Energy Information Administration and Baker Hughes Inc.
June 2019 | Pumps & Systems
rose 3.9 percent; and
higher private inventory
investment. Consumer
spending slowed from
2.5 percent in the fourth
quarter of 2018 to 1.2
percent for the first
quarter of 2019. Business
spending on software, Image 1. Stock indices from May 1, 2018, to April 30, 2019
research and development,
Local currency converted to USD using historical spot rates. The JKC Pump and Valve
equipment and structures Stock Indices include a select list of publicly traded companies involved in the pump and
rose at a 2.7 percent rate, valve industries, weighted by market capitalization. Source: Capital IQ and JKC research.
down from 5.4 percent
in the fourth quarter. Residential Reaching an annual average of Reference
investment fell at a 2.8 percent 5.6 million barrels per day, U.S. 1. The S&P Return
annual pace, marking the fifth exports of total petroleum products figures are provided
by Capital IQ.
straight quarter of decline. set a record high in 2018 for the
Primary energy consumption 16th consecutive year. The three
reached a record high of 101.3 largest petroleum product exports Jordan, Knauff
quadrillion Btus in the U.S. in last year were distillate, propane & Company is an
investment bank
2018, up 4 percent from 2017 and and motor gasoline. Propane based in Chicago that
0.3 percent above the 2007 record. exports were greater than gasoline provides merger and
Consumption of fossil fuels grew exports for the third straight year. acquisition advisory
services to the
by 4 percent and accounted for On Wall Street, the Dow Jones pump, valve and
80 percent of U.S. total energy Industrial Average, the S&P 500 filtration industries.
consumption. Natural gas rose Index and the NASDAQ Composite Please visit
jordanknauff.com for
10 percent over 2017 and reached gained 2.6 percent, 3.9 percent and further information.
a record high. 4.9 percent, respectively. Positive Jordan, Knauff &
Driven by the addition of new developments on the U.S.-China Company is a member
of FINRA.
wind and solar power plants, trade war and strong first-quarter
renewable energy consumption hit a corporate earnings strengthened
record high, rising 3 percent during investors’ confidence. The U.S.
the year. Petroleum consumption Consumer Confidence Index rose These materials were
prepared for informational
reached 20.5 million barrels per day to 129.2 in April, up from 124.2 purposes from sources that
are believed to be reliable
last year, its highest since 2007. in March. 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
Image 3. U.S. PMI and manufacturing shipments any investment offering or
deployment of capital.
Source: Institute for Supply Management Manufacturing
Report on Business and U.S. Census Bureau
 LAY WASTE
TO WASTE.

Since 1960, Vaughan has delivered solid

solutions for solids and solutions.
Our innovative, dependable pumps and mixers provide
guaranteed performance in the toughest applications.
Learn more about our unmatched reliability. Contact us
today to see why our versatile pumps and systems are
perfect for your next project.

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Conditioning Pump Chopper

Rotamix

ChopperPumps.com | 360.249.4042 | info@chopperpumps.com

Circle 112 on card.

What’s in your AC Drive?
DURAPULSE
AC DRIVES
STARTING AT
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(GS4-21P0)

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The DURApulse GS4 series of Variable Frequency Drives Upgrade I/O capabilities AND
(VFD) includes many of the same standard features as communications options
our other GS drives including dynamic braking, PID,
removable keypad, plus so much more:
• Single-phase input capability on all 230VAC models
• V/Hz control or sensorless vector control for improved 4 Digital Inputs 6 Digital 6 Relay
speed regulation 2 Digital Outputs Inputs Outputs
• 100kA Short Circuit Current Rating (SCCR)
• 50°C temperature rating plus flange mount capability
for industrial environments
EtherNet/IP™ Modbus
• STO - Safe Torque Off (TUV certified) TCP
• Built-in PLC (up to 10k steps) for drive-related
logic and I/O control
• Built-in analog, discrete, high-speed and relay I/O
with expansion capabilities Research, price, buy at:
• Serial MODBUS RTU/ ASCII and BACnet protocols included
www.automationdirect.com/
• Optional Ethernet cards include MODBUS TCP
and EtherNet/IP™ protocols drives/ac-drives/gs4
• GS4 QuickStart menus simplify configuration
• Smart keypad stores up to four sets of drive configurations
for back-up and transfer to additional GS4 drives
• Fire mode and circulatory control mode
• Field upgradeable firmware
• Free drive configuration and PLC Programming software

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* See our Web site for details and restrictions. © Copyright 2019 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation

Circle 115 on card.