PS - 08 - 2014

OPTIMIZE
PUMPING SYSTEMS
Diligent analysis, rigorous scrutiny
lead to longer system life
AUGUST 2014
PUMP-ZONE.COM
TURBOMACHINERY &
PUMP SYMPOSIA
Trade Show Preview
SEALS & BEARINGS
Tips for Maximizing
PERFORMANCE

6 Considerations
for REFINERY Pump
MAINTENANCE
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August 2014 | Pumps & Systems
From the Editor
T
his month we introduce an exciting, fresh,
modern look to our logo and design that has been
thoughtfully crafted to make the magazine easier for
you to read and navigate. While the look has been
updated, the content remains the same high-quality
technical pumping information that you cant fnd
anywhere but in the pages of Pumps & Systems.
It makes sense that we introduce this change with
a focus on the increasingly vital topic of pump system
optimization. Not long ago, the components of a
pumping system were designed separately, purchased
separately and maintained separately. Tanks to
advancements in technology and increased standards
and awareness and the Hydraulic Institutes devel-
opment of Pump Systems Matter, today the entire system is examined and modifed to
decrease life-cycle costs and save energy.
On average, industrial pumps operate at less than 40 percent ef ciency, and more than
10 percent of pumps run at less than 10 percent ef ciency. Tis impacts the bottom line.
Te cost to pump inef ciently is beyond your wildest imagination, says Mike Pember-
ton, ITT Performance Services Manager and Pumps & Systems Editorial Advisory Board
member. In the past several decades, pump ef ciency has only increased 3 percent by
design. Te biggest advantage in increasing ef ciency is happening with automation and
controls. Te infrastructure is in place, but the question remains, How do we optimize?
Tis year, Pumps & Systems published a three-part series from HI examining the Depart-
ment of Energys pump ef ciency regulation changes (Jan.-March 2014, www.pump-zone.
com). Te series describes how to reduce the burden on U.S. pump manufacturers and support
the DOEs eforts to achieve energy savings and ef ciency improvements in the marketplace.
According to Pump Systems Matter, the most likely candidates for optimization are
large systems, systems with high operating hours, problem systems and production-crit-
ical systems. Te most common red-fag symptoms are high energy costs, throttle valves
that are generally closed, bypass valves/recirculation lines that are generally open, fre-
quent failures or repair requirements, high operating noise levels (especially at the valve
or pump), vibrations in the system and/or pump assembly, systems with multiple parallel
pumps with the same number of pumps always operating, constant pump operation in a
batch environment or frequent cycle batch operation in a continuous process, and systems
that have undergone a change in function. Learn more by visiting www.pumps.org.
You can fnd a wealth of solutions by reading this months cover series, which begins on
page 60. As always, pump ef ciency will be a major topic at the 43rd Turbomachinery and
30th Pump Symposia in Houston, Sept. 23 25. Visit the Pumps & Systems team at Booth
514, and tell us about your pump optimization success stories.
EDITORIAL
EDITOR: Michelle Segrest
msegrest@pump-zone.com 205-314-8279
MANAGING EDITOR: Lori K. Ditoro
lditoro@cahabamedia.com 205-314-8269
SR. EDITOR, PRODUCTION & CONTENT MARKETING:
Alecia Archibald
aarchibald@cahabamedia.com 205-314-3878
ASSOCIATE EDITOR: Michael Lambert
mlambert@cahabamedia.com 205-314-8274
ASSOCIATE EDITOR: Savanna Lauderdale
slauderdale@cahabamedia.com 205-278-2839
CONTRIBUTING EDITORS: Laurel Donoho,
Joe Evans, Lev Nelik, Ray Hardee
CREATIVE SERVICES
SENIOR ART DIRECTOR: Greg Ragsdale
ART DIRECTORS: Jaime DeArman, Melanie Magee
WEB CONTENT EDITOR & WEB ADVERTISING TRAFFIC:
Robert Ring
PRINT ADVERTISING TRAFFIC: Lisa Freeman
lfreeman@cahabamedia.com
205-212-9402
CIRCULATION
AUDIENCE DEVELOPMENT MANAGER:
Lori Masaoay
lmasaoay@cahabamedia.com 205-278-2840
ADVERTISING
NATIONAL SALES MANAGER:
Derrell Moody
dmoody@pump-zone.com 205-345-0784
Mary-Kathryn Baker
mkbaker@pump-zone.com 205-345-6036
Mark Goins
mgoins@pump-zone.com 205-345-6414
Addison Perkins
aperkins@pump-zone.com 205-561-2603
Vince Marino
vince@pump-zone.com 205-561-2601
MARKETING ASSOCIATES:
Ashley Morris
amorris@cahabamedia.com 205-561-2600
Sonya Crocker
scrocker@cahabamedia.com 205-314-8276
PUBLISHER: Walter B. Evans, Jr.
VP OF SALES: Greg Meineke
VP OF EDITORIAL: Michelle Segrest
CREATIVE DIRECTOR: Terri Jackson
CONTROLLER: Tim Moore
P.O. Box 530067
Birmingham, AL 35253
EDITORIAL & PRODUCTION
1900 28th Avenue South, Suite 200
Birmingham, AL 35209
205-212-9402
ADVERTISING SALES
2126 McFarland Blvd. East,. Suite A
Tuscaloosa, AL 35404
205-345-0784
Pumps & Systems
is a member of the following organizations:
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the
right to determine qualications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and
possessions $5, all other countries $15 US funds (via air mail). Call 630-739-0900 inside or outside the U.S. POSTMASTER: Send changes of address and
form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. 2014 Cahaba Media Group, Inc. No part of
this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the
factual accuracy of any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by
the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of
Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any adver-
tisements 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 to edit, reproduce, distribute, publish and adapt your submis-
sion 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 22, Issue 8.
Michelle Segrest with ITTs Margaret
Gan at the 2014 Offshore Technology
Conference. The Pumps & Systems
team returns to Houston for the
Turbomachinery/Pump Symposia in
September.
Editor, Michelle Segrest
2

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Terminal box is rotatable in 90 degrees increments for easy installation
AEGIS
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4

AUGUST This issue
60 STREAMLINED MOTOR
MANAGEMENT SYSTEM BOOSTS
BIOMASS POWER GENERATION
BY Matthias Borutta
Phoenix Contact
Trusted gateway connections allow
for system growth, ef ciency and
consistent maintenance at Swedish
paper mill.
64 INTELLIGENT MONITORING
DELIVERS REAL-TIME
PUMP PERFORMANCE DATA
By Mike Pemberton
ITT Pro Services
An energy ef ciency and reliability
study helped one plant save $1 million
annually by avoiding downtime.
69 CLOSE INSPECTION
SOLVES HIGH THRUST BEARING
TEMPERATURE PROBLEM
By Gary Dyson
Hydro Inc.
Careful analysis identifed the issue
with this multistage oil transfer pump.
73 SYSTEM SELECTION CRUCIAL
FOR LONG WASTEWATER
PUMP LIFE
By Lars Bo Andersen
Grundfos Wastewater
Driving down investment, energy
and maintenance costs translates
into big savings throughout an
installations lifetime.
76 REDUCER FITTINGS DECREASE
PIPE SIZE TO PREVENT FAILURE
By Ross Mahaffey, Aurecon
and Stefanus Johannes van
Vuuren, University of Pretoria
Design of the pump inlet piping can
protect overall operation.
COVER
S E R I E S
PUMP SYSTEM
OPTIMIZATION
COLUMNS
PUMP ED 101
20 By Joe Evans, Ph.D.
Pump Tech Inc.
Tree-Phase Voltage Variation
& Unbalance
PUMPING PRESCRIPTIONS
26 By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC
Simplify the Equipment
Selection Process
PUMP SYSTEM IMPROVEMENT
28 By Ray Hardee
Engineered Software, Inc.
System Validation & Troubleshooting
GUEST COLUMNS
36 By Heinz P. Bloch, P.E.
Pushing Fluid Machinery Leads
to Failure
40 By Amin Almasi
Estimate Pump Installation Costs
DEPARTMENTS
84 EFFICIENCY MATTERS
Smart Air Distribution Systems
Upgrade Traditional AODD Pump
Technology
89 MAINTENANCE MINDERS
6 Refnery Pump Maintenance Tips
94 MOTORS & DRIVES
Te Diferences Between Submersible
& Immersible Motors
98 SEALING SENSE
Expansion Joint Selection Optimizes
Piping Systems
102 HI PUMP FAQS
Understand Specifc Speed & Disc
Diaphragm Pump Coupling
64
60
Volume 22 Number 8
Cover photo courtesy of Colfax Fluid Handling

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Your business cant run
on a fabrication order.
PUMP AND FLUID SYSTEMS
Contact and collaborate with us at pumps@weatherford.com
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Formation Evaluation
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Well Construction
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Completion & Stimulation
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6

This issue
SPECIAL S P E C I A L
S E C T I ON
THOMAS L. ANGLE, P.E., MSC, Vice President
Engineering, Hidrostal AG
ROBERT K. ASDAL, Executive Director,
Hydraulic Institute
BRYAN S. BARRINGTON, Machinery Engineer,
Lyondell Chemical Co.
KERRY BASKINS, VP/GM, Milton Roy Americas
WALTER BONNETT, Vice President Global
Marketing, Pump Solutions Group
R. THOMAS BROWN III, President,
Advanced Sealing International (ASI)
CHRIS CALDWELL, Director of Advanced
Collection Technology, Business Area
Wastewater Solutions,
Sulzer Pumps, ABS USA
JACK CREAMER, Market Segment Manager
Pumping Equipment, Square D by Schneider
Electric
BOB DOMKOWSKI, Business Development
Manager Transport Pumping and Amusement
Markets/Engineering Consultant, Xylem, Inc.,
Water Solutions USA Flygt
DAVID A. DOTY, North American Sales Manager,
Moyno Industrial Pumps
WALT ERNDT, VP/GM, Crane Pumps & Systems
JOE EVANS, Ph.D., Customer & Employee
Education, PumpTech, Inc.
RALPH P. GABRIEL, Chief Engineer Global,
John Crane
BOB LANGTON, Vice President, Industry Sales,
Grundfos Pumps
LARRY LEWIS, President, Vanton Pump and
Equipment Corp.
TODD LOUDIN, President/CEO North American
Operations, Flowrox Inc.
JOHN MALINOWSKI, Sr. Product Manager, AC
Motors, Baldor Electric Company, A Member of
the ABB Group
WILLIAM E. NEIS, P.E., President, Northeast
Industrial Sales
LEV NELIK, Ph.D., P.E., APICS, President,
PumpingMachinery, LLC
HENRY PECK, President, Geiger Pump &
Equipment Company
MIKE PEMBERTON, Manager, ITT Performance
Services
SCOTT SORENSEN, Oil & Gas Automation
Consultant & Market Developer, Siemens
Industry Sector
ADAM STOLBERG, Executive Director,
Submersible Wastewater Pump Association
(SWPA)
JERRY TURNER, Founder/Senior Advisor,
Pioneer Pump
KIRK WILSON, President, Services & Solutions,
Flowserve Corporation
JAMES WONG, Associate Product Manager
Bearing Isolator, Garlock Sealing Technologies
EDITORIAL ADVISORY BOARD
2 FROM THE EDITOR
8 READERS RESPOND
10 NEWS
80 TRADE SHOW COVERAGE
118 PRODUCT PIPELINE
124 PUMP USERS MARKETPLACE
128 PUMP MARKET ANALYSIS
SEALS & BEARINGS
42 CANNED MAGNETIC BEARINGS
MINIMIZE CORROSION IN
OIL & GAS PROCESSING
By Richard R. Shultz
Waukesha Magnetic Bearings
Safely immerse motor compressors
in process gas without risking
costly damage.
45 THE RIGHT SEAL & LUBRICANT
COMBINATION CAN PREVENT
BEARING CONTAMINATION
By James Wong
Garlock Sealing Technologies
Lip and labyrinth seals provide
protection in harsh oil and
gas applications.
PRACTICE &
OPERATIONS
106 ENERGY EFFICIENT VERTICAL
TURBINE PUMPS PROMOTE
SUSTAINABLE MINING EFFORTS
By Petar Ostojic
Neptuno Pumps
Te computational fuid dynamics
process advances highly ef cient pump
designs for dif cult applications.
110 SPECIFIC PUMP & VALVE
FEATURES SERVE LIQUEFIED
NATURAL GAS APPLICATIONS
By Gobind Khiani
Fluor Canada Ltd.
LNG benefts have increased the
demand for this cleaner burning
fuel and associated production and
distribution equipment.
114 DEWATERING PUMPS HANDLE
SAND SLURRIES IN POST-
HURRICANE RECOVERY
By Mike Bjorkman
BJM Pumps
Reconstruction and infrastructure
upgrades require pumps from
durable materials.
50 SELECT SEALS THAT MEET
THE CHEMICAL CHALLENGES
OF HPLC PUMPS
By Jerry Zawada
Trelleborg Sealing Solutions
Abrasive processing and wide
temperature range are some of
the pumping dif culties for high-
performance liquid chromatography.
54 TREATED CARBIDE SURFACES
ENHANCE RUNNING
PERFORMANCE
By Mark Slivinski
Carbide Derivative Technologies Inc.
Tis technology self-lubricates, reduces
friction, and performs in wet or dry
operating conditions.
AUGUST
Borets Equipment is a HPS horizontal
multistage pump manufacturer that
provides pumping solutions with
exceptional customer service.
HORI ZONTAL PUMPI NG SYSTEMS
SERVICE SERVICE
Reliable. Quality. Modular.
Horizontal Pumping System (HPS) by Borets Equipment.
Cost-competitive and customizable for your specific application, the HPS equipment
requires less inventory and delivery time than traditional API 610 multistage, vertical
turbine can and reciprocating pump equipment.
Engineered for reliability, modularity, and quick replacement of components, the HPS
pump has a lower life cycle cost, thanks to minimized downtime and low maintenance
requirement. The result is a reliable, flexible and innovative pumping system.
You provide the application, well provide the Pump Power and Service.
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8
READERS RESPOND
A Salute to
Frank Weis,
From the Editor
MARCH 2014
I was sent your article
while I was at the
American Water
Works Association
conference in Boston. Tank you so
much for writing this and sharing some
of your thoughts on Frank.
I just wanted to share more with
someone, so I decided to give you more
background. Frank was my frst boss
when I joined Smith and Loveless in
1983, fresh out of graduate school. I
wont go into all the engineering details
I learned from just watching him but
wanted to share the personal side.
I worked for, with and shared lunch
with Frank many days over my next
six years of employment. He treated
everyone the same, from the janitor to
the president of the company. He was
friendly to all, had a great sense of hu-
mor, enjoyed pulling pranks on select
employees, and I never, ever saw him be
upset or have a bad day!
We were both alumni of the Univer-
sity of Missouri, and he loved sports,
had coached his kids baseball and bas-
ketball teams and loved to talk sports
of all kinds. He shared his knowledge
with any that asked, but he was the
most humble guy I have ever known.
He went about his work with
a quiet determination and knew
exactly what he was trying to
achieve, even if it didnt ft with
the views of management at the
moment! He had an amazing
infuence on my professional
and personal life, and I tell sto-
ries related to him almost every
week. I left the company in
1989 and moved to Degremont
in Virginia, but his infuence
had more impact on me than
anyone I have worked with since
that time.
I am now back in Kansas City
and was fortunate enough to
attend the 50th anniversary of
Franks work at Smith and Love-
less in 2004. As was typical for Frank,
he didnt want it to be a big deal, so the
ceremony was held on the shop foor.
Several former employees attended,
many who had long since retired!
I knew then how unique Frank was
but have understood this even more
in the years that have passed. As great
a man as he was from the engineer-
ing and invention side, he was an even
better man overall. Te world was a
better place for the time he was here
and for all the individuals that got to
know him.
Andy Mitchell
Director, Business Development
Metawater USA, Inc.
Pumps & Systems Editor Michelle
Segrest responds:
Tank you for reading my column about
Frank Weis (www.pump-zone.com/blog/
salute-frank-weis) and for responding
with these nice comments. Te additional
insight into the life of this legendary pump
innovator is greatly appreciated. Frank
Weis was well respected in the pump
industry and will be missed by all who
knew him.
READERS
responD
To have a letter considered for Readers
Respond, please send it to Michael Lambert,
mlambert@cahabamedia.com.
Frank Weis
10
NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
LARRY LEWIS, VANTON PUMP
HILLSIDE, N.J. (July 10, 2014) The Board of
Directors of the Vanton Pump and Equipment
Corp. voted to name Larry Lewis as the companys
president and chief executive ofcer. Lewis has
served as Vantons president since 2010. Vanton
Pump and Equipment Corp. supplies chemically
inert, thermoplastic pumps and systems that
solve uid containment, dosing and transfer
problems. www.vanton.com
DAVID BOEZI, DANFOSS
BALTIMORE (June 24, 2014) Danfoss hired
David Boezi as senior director, strategy and global
platforms. In this role, Boezi will help Danfoss
tailor its high-efciency compressor portfolio
to respond to changing customer needs that
are being inuenced by new refrigerant and
energy-efciency regulations. Danfoss supplies
technologies that meet the growing need for food
supply, energy efciency, climate-friendly solutions and modern
infrastructure. www.danfoss.com
DICK SHEAR, MULTI W SYSTEMS
EL MONTE, Calif. (June 20, 2014) Multi W
Systems Inc. announced the appointment of
Dick Shear as general sales manager. Multi
W Systems manufactures and distributes
pump systems, electrical controls and related
engineered machinery. www.multiwsystems.com
PAMELA HENRY, WEF
ALEXANDRIA, Va. (June 19, 2014) The Water
Environment Federation (WEF) promoted Pamela
Henry to the position of deputy executive
director. Having been with WEF for more than
25 years, Henry is a seasoned leader who will
oversee a number of key organizational programs
including WEFTEC operations and exhibitions,
advertising and sponsorships, marketing,
communications and creative services, human
resources, and facilities management. WEF is a not-for-prot
technical and educational organization of 36,000 individual members
and 75 afliated Member Associations representing water quality
professionals around the world. www.wef.org
CHUCK HULL, 3D SYSTEMS
ROCK HILL, S.C. (June 17, 2014) 3D Systems announced that Chuck
Hull received the 2014 European Inventor Award in the non-European
countries category in recognition of his invention of the three-
dimensional (3-D) printing technology Stereolithography. Presented
annually by the European Patent Ofce, the award honors inventors
who made signicant contributions to technological progress and
the advancement of society. 3D Systems provides 3-D printing
centric design-to-manufacturing solutions including 3-D printers,
print materials and cloud-sourced on-demand custom parts for
professionals and consumers in materials including plastics, metals,
ceramics and edibles. www.3dsystems.com
EDWARD CRANER, HOLT CAT
SAN ANTONIO, Texas (June 16, 2014) HOLT
CAT named Edward Craner senior vice president,
strategy and marketing. In his new role, Craner
will continue to lead and develop corporate
strategy, marketing and customer experience
initiatives to support sales growth. HOLT CAT
sells, rents and services Caterpillar machines,
engines, generator sets and trucks.
www.holtcat.com
Edward Craner
Larry Lewis
David Boezi
Dick Shear
Pamela Henry
SPOTLIGHT
PUMPS & SYSTEMS LAUNCHES
MIDDLE EAST/NORTH AFRICA MAGAZINE
BIRMINGHAM, Ala. (July 2, 2014) Pumps & Systems, the leading
magazine for pump users worldwide for more than 20 years, expands its
international coverage of powerful technical pumping information to the
Middle East/North Africa region. The premier issue of Pumps & Systems
MENA will launch in early October 2014. It also will be distributed at the
Pumps & Systems booth Nov. 10, 2014, at the Abu Dhabi International
Petroleum Exhibition & Conference, the regions leading conference
for oil and gas professionals. Pumps & Systems MENA will publish
bimonthly in 2015 following the October 2014 launch and will cover case
studies and technical information in the following industries:
Oil & gas (upstream and downstream)
Water & wastewater
Power generation
Food & beverage processing
Building services
Chemical, petrochemical & renery
The regular editorial coverage will also include strategic and insightful
market data from respected market research analysts Frost & Sullivan.
The magazine will be supported digitally with a website,
www.pump-zone.com/mena, and a twice-per-month e-newsletter, Pump
Users Digest MENA. Subscribe to the e-newsletter and magazine at
www.pump-zone.com/mena.
pump-zone. com | August 2014

11
HENRI V. AZIBERT, FSA
WAYNE, Pa. (June 13,
2014) The Fluid Sealing
Association (FSA) announced
the appointment of Henri V.
Azibert as its new technical
director. Pumps & Systems
has partnered with the FSA for
10 years and posted exclusive
Sealing Sense articles in every issue. Azibert
will now coordinate these articles, which provide
the readers of Pumps & Systems with crucial
technical information about mechanical seals,
compression packing, gaskets, expansion joints,
sealing components and molded packing. Azibert
has also joined the prestigious Pumps & Systems
Editorial Advisory Board. FSA is an international
trade association. Members are involved in the
production and marketing of virtually every
kind of uid sealing device in the world. www.
uidsealing.com
JOHN DONAHUE, AWWA
BOSTON (June 12, 2014)
In a spirited event at the
conclusion of the American
Water Works Associations
Annual Conference and
Exposition in Boston, John
Donahue, chief executive
ofcer of North Park, Illinois,
Water District, accepted the ceremonial AWWA
gavel and began his term as president. The gavel
passing ceremony was the culmination of a ve-
day conference that drew more than 11,000 water
professionals and water technology providers to
Boston. The American Water Works Association
is the largest nonprot, scientic and educational
association dedicated to managing and treating
water. www.awwa.org
GREG HEWITT, BALDOR
ELECTRIC COMPANY
FORT SMITH, Ark. (June
9, 2014) Baldor Electric
Company promoted Greg
Hewitt to mounted bearing
engineering manager. In this
role, he will be responsible for
all mounted bearing product-
related engineering and will manage the product
development team in Greenville, South Carolina.
Baldor Electric Company markets, designs and
manufactures industrial electric motors, drives
and mechanical power transmission products.
www.baldor.com
Henri V. Azibert
John Donahue
Greg Hewitt
5300 Business Drive, Huntington Beach, CA 92649 USA
714-893-8529 sales@blue-white.com
www.blue-white.com www.proseries-m.com
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WAS WAS WAS WAS WAS WAS WAS WAS WAS WAS WAS WAS AS ASSHH D H D H D H D H D H D H D H D H D H D H D H D H D H D DOOOW OWN OWN OWN OWN OWN OWN OWN OWN OWN OWN
IP IP IP IP IP IP IP IP IP IP IP IP IP IP IP P66 66 66 66 66 66 66 66 66 66 66 66 66 66 66 66 66 66
Three Models
Available with
Feed Rates
Ranging from
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Smooth, Quiet
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Standard 61
Sonic-Pro S4 accurately measures
flow using the Transit Time
method. It can be used
with water
containing low
levels of chemicals
and up to 5%
particulates.
Optional
communication
protocols include
Industrial Ethernet,
Profibus and Modbus.
Ultrasonic Transit Time
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Inline spool piece (inline fitting).
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Data logging
SONIC-PRO
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12
NEWS
CHARLES WHISMAN, CH2M HILL
DENVER (June 5, 2014) CH2M HILL announced
that Charles Whisman joined the rm as vice
president and U.S. oil and gas operations
manager for the environment and nuclear
market. CH2M HILL provides consulting,
design, design-build, operations and program
management for government, civil, industrial
and energy clients. www.ch2m.com
DAVE MORROW, OPW
LEBANON, Ohio (June 6, 2014) OPW announced the promotion of
Dave Morrow to director of product management for its Chemical &
Industrial business unit. Before this appointment, he was product
manager for OPW Engineered Systems. OPW
Engineered Systems provides loading and
coupling systems for the safe and efcient
loading and unloading of critical hazardous
uids. www.opw-es.com
JOHN MOLNAR,
ARMSTRONG FLUID TECHNOLOGY
TORONTO (June 5, 2014) Armstrong Fluid
Technology announced that John Molnar joined
the company as technical sales representative,
commercial and engineering. In his new role,
he will develop and grow relationships with
engineers, contractors and service dealers in the
Ontario territory.
His main focus
will be working
with standard and
congured building
products and design envelope solutions.
Armstrong Fluid Technology designs,
engineers and manufactures integrated
solutions within the building-oriented
uid-ow equipment industry. www.
armstronguidtechnology.com
Charles Whisman Dave Morrow
John Molnar
A5KAWA AMEklCA, lNC. acquired Solectria
Renewables, LLC
1uly 17, 2014
6E acquired Monsal
1uly 1, 2014
AC0EM acquired FlXTRLASER
1une J0, 2014
DE5CA5E acquired ESCO's sight glass
product line
1une 19, 2014
LACKHAWK 5PEClALT T00L5 acquired
Trinity Tool Rentals
1une 10, 2014
FkANKLlN ELECTklC acquired
Bonbas Leo S.A.
1une 9, 2014
NATl0NAL PUMP C0MPAN acquired
Bayou City Funp
1une J, 2014
MERGERS & ACQUISITIONS

13
AROUND THE INDUSTRY
EXONE to Open Combined
Production Service Center
in Italy
NORTH HUNTINGDON, Pa. (June
19, 2014) The ExOne Company
announced the planned opening of
a new combined production service
center and machine sales center in the
Lombardy region of Italy. Said Omar,
most recently ExOnes European sales
director, will be ExOne Italys managing
director. ExOne provides 3-D printing
machines and printed products,
materials and other services to
industrial customers. www.exone.com
WEATHERFORD Opens
Integrated Colombia
Laboratory
BOGOTA, Colombia (June 13, 2014)
Javier Betancourt, the president of
Agencia Nacional de Hidrocarburos
Colombia, marked the ofcial
opening of the new Weatherford lab in
Bogota, Colombia, during a ribbon-
cutting ceremony. This new facility
provides traditional core and uid
analysis combined with specialty
services such as shale rock properties,
geochemistry, wellsite geosciences,
frac uids, drilling uids and elastomer
testing for progressive cavity pumps.
Weatherford International provides
oileld products and services across
the drilling, evaluation, completion,
production and intervention areas.
www.weatherford.com
DYNAMIC INDUSTRIES
INTERNATIONAL LLC Receives
SAGIA License
HOUSTON (June 11, 2014) Dynamic
Industries International LLC
announced that its Saudi Arabian ofce
received its license to operate from
the Saudi Arabian General Investment
Authority (SAGIA). Dynamic
Industries International LLC provides
full-service fabrication, construction
and maintenance services to the
offshore worldwide markets. www.
dynamicind.com
SIEMENS Invests in
Software Grants
RICHMOND, Va. (June 5, 2014)
Siemens announced more than $1
billion of in-kind software grants
for manufacturing programs at
community colleges and universities
in Virginia. The series of in-kind
grants was established as a result of
an industry need for skilled workers
and is designed to support the states
largest industrial employer, Newport
News Shipbuilding, a division of
Huntington Ingalls Industries, and
other companies with local ties such
as Rolls-Royce. Siemens Industry
Sector supplies products, solutions and
services for industrial customers.
www.siemens.com
14
NEWS
AROUND THE INDUSTRY
ABB TURBOCHARGING
Inaugurates Denmark Facility
BADEN, Switzerland (June 4, 2014)
ABB Turbocharging announced a
ceremony that celebrated the opening
of a new service facility in Fredericia,
Denmark. The ceremony also marked
the completion of the amalgamation of
its activities in Norway, Denmark and
Sweden into a single Local Business
Unit. ABB Turbocharging Scandinavia
comprises service stations in Oslo and
Bergen in Norway, Gteborg in Sweden,
and the new central workshop for
Denmark in Fredericia. Additionally,
the company has two service
engineers and a sales team stationed
in Copenhagen. This geographical
footprint will soon be furthered by a
new service point in Troms, Norway.
ABB Turbocharging manufactures and
services turbochargers. www.abb.com
GRUNDFOS, PUB to Collaborate
on Water Technologies
SINGAPORE (June 3, 2014) Pump
manufacturer Grundfos and PUB,
Singapores national water agency,
have signed a memorandum of
understanding (MOU) to collaborate on
the development of water technologies
and solutions. The MOU sets out to
support PUB in its mission to ensure a
robust and sustainable water supply
for Singapore and to continuously
explore new technologies and solutions
to meet current and future water
challenges. PUB is a statutory board
under the Ministry of the Environment
and Water Resources. It is the water
agency that manages Singapores
water supply, water catchment and
used water. www.pub.gov.sg Grundfos
is a pump manufacturer, offering
water solutions with modular, energy
efcient and intelligent products
and services that can be tailored for
industrial, water utility, water supply,
urban and agricultural applications.
www.grundfos.com
EPA Proposes Guidelines
to Cut Carbon Pollution
WASHINGTON (June 2, 2014) At the
direction of President Obama and after
an unprecedented outreach effort,
the U.S. Environmental Protection
Agency (EPA) released the Clean
Power Plan proposal, which for the
rst time cuts carbon pollution from
existing power plants, the single largest
source of carbon pollution in the U.S.
The proposal aims to protect public
health, move the U.S. toward a cleaner
environment and ght climate change
while supplying Americans with reliable
and affordable power. By 2030, the
steps that the EPA is taking will:
Cut carbon emission from the power
sector by 30 percent nationwide
23544 A.W. Chesterton Company, 2014. All rights reserved.
Scan here to see
the 442C in action!
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Visit us at www.chesterton442c.com
Introducing the Chesterton
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The 442C is the latest innovation in split seal technology, combining
superior seal performance with the ease of installation of a cartridge
split seal. Our patented split seal technology addresses the inherent
limitations found in conventional cartridge split seal designs,
minimizing installation complications.
- Cartridge design simpIifies instaIIation and provides superior
sealing reliability
- nhanced performance capabiIities
- 8roadest equipment fit of any spIit seaI
- asy fieId repair
Supplies the NGL industry with products for electric motor
and engine-driven pump skids and booster stations.
Engine Management - Murphys Engine Integrated Control System (EICS)
provides a turnkey engine integration package that ensures extended engine life,
optimized emissions and simplied diagnostics.
Controls - Murphy delivers a complete line of annunciators and
controls that can be packaged to provide optimum performance
and advanced functionality.
Gages & End Devices - Murphy has a
robust and value priced line of gages and
sensors, including vibration sensors, level
maintainers, level switches and more.
For more about Murphys
Natural Gas Liquids products
visit: fwmurphy.com/nglps
Phone: 918-317-4100 1
3
1
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Did You Know? Did You Know?
16
NEWS
AROUND THE INDUSTRY
below 2005 levels, which is equal to
the emissions from powering more
than half the U.S. homes for one year
Cut particle pollution, nitrogen
oxides and sulfur dioxide by more
than 25 percent
Avoid up to 6,600 premature deaths,
up to 150,000 asthma attacks in
children, and up to 490,000 missed
work or school daysproviding up
to $93 billion in climate and public
health benets
Shrink electricity bills roughly
8 percent by increasing energy
efciency and reducing demand in
the electricity system
EPAs mission is to protect human
health and the environment.
www.epa.gov
ABAKAN Increases Direct
Ownership in MesoCoat
MIAMI (June 2, 2014) Abakan Inc.
announced that it has increased its
ownership position in its majority
owned subsidiary, MesoCoat Inc., to a
87.5 percent direct and 89.9 percent
direct and indirect ownership. The
increase is the result of converting an
additional $6.2 million in MesoCoat
investment into equity and exchanging
21 percent of ownership in Powdermet
for 65.3 percent of Powdermets shares
of MesoCoat. Abakan develops,
manufactures and markets advanced
nanocomposite materials, fabricated
metal products and metal composites
for applications in the oil and gas,
petrochemical, mining, aerospace and
defense, energy, infrastructure, and
processing industries.
www.abakaninc.com
WEF, IWA Sign Water
Management MOU
ALEXANDRIA, Va. (May 27, 2014)
The Water Environment Federation
(WEF) and the International
Water Association (IWA) signed a
memorandum of understanding (MOU)
intended to accelerate joint work to
grow and disseminate water knowledge
and to serve and advance the global
water profession. WEF is a not-for-
prot technical and educational
organization representing water
quality professionals around the world.
www.wef.org IWA is a global network
of water professionals that spans the
continuum between research and
practice, covering all facets of the
water cycle. www.iwahq.org
To have a news item considered, please send the information to Savanna Lauderdale, slauderdale@cahabamedia.com.
18
NEWS
EVENTS
PumpTec-USA
Sept. 10 11, 2014
Georgia World Congress Center
Atlanta, Ga.
770-310-0866
www.pumpconference.com
Turbomachinery/
Pump Symposia
Sept. 23 25, 2014
George R. Brown
Convention Center
Houston, Texas
979-845-7417
pumpturbo.tamu.edu
WEFTEC
Sept. 27 Oct. 1, 2014
New Orleans Morial
Convention Center
New Orleans, La.
www.weftec.org
International Association
of Amusement Parks and
Attractions (IAAPA)
Nov. 18 21, 2014
Orange County Convention Center
Orlando, Fla.
703-836-4800
www.iaapa.org
PumpTec-Israel
Dec. 3 5, 2014
Jointly with Electricity-Israel
2014 Conference
Eilat, Israel
770-310-0866
www.pumpingmachinery.
com/conference_2014_Israel/
conference_2014_Israel.htm
POWER-GEN International
Dec. 9 11, 2014
Orange County Convention Center
Orlando, Fla.
918-831-9161
www.power-gen.com
NGWA Expo & Annual Meeting
Dec. 9 12, 2014
Las Vegas Convention Center
Las Vegas, Nev.
www.ngwa.org
AHR EXPO
Jan. 26 - 28, 2015
McCormick Place
Chicago, Ill.
www.ahrexpo.com
W
h
e
r
e

I
n
n
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v
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t
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o
n

F
l
o
w
s
Solutions
For Handling
Dangerous Chemicals
Safe
Award-winning Almatec E-Series Plastic AODD pumps provide safe and reliable
performance when handling the most dangerous acids, solvents, and caustics.
Solid block CNC machining
Polyethylene and PTFE materials, conductive also available for explosion
environments (ATEX)
Ring design structure for improved product containment
Optional features available (e.g. barrier chamber system) for further safety requirements
Dry run ability, self-priming, gentle fuid handling, no rotating parts, no shaft seals
World Headquarters
Carl-Friedrich-Gau-Str. 5
47475 Kamp-Lintfort, Germany
O: +49/2842/961-0
F: +49/2842/961-40
info@almatec.de
www.almatec.de
PSG Euro-Center
22069 Van Buren Street
Grand Terrace, CA 92313 USA
O: +1 (909) 512-1224
miguel.blanca@psgdover.com
Performance
Reliability
Durability
Powerful, reliable and versatile - the PP86S17
diesel pump package
Specications
Model PP86S17
Size 8 x 6
200 x 150 mm
Flow, Max 5,400 USGPM
1230 m
3
/h
340 l/s
Head, Max 440 feet
130 meters
Flow at BEP 3,200 USGPM
730 m
3
/h
200 l/s
Efciency at BEP 75%
310 S Sequoia Parkway
Canby, Oregon 97013
www.pioneerpump.com
(503) 266-4115
The PP86S17 is a solids handling pump that
provides fexibility and reliability. With a wide
performance range of both fow and head, this
general purpose diesel package is the right
choice for food response, sewer bypass, and
dewatering; anywhere you need high effciency
in a portable pump package.
Full Pioneer Pump Product Range
Pump Series Head Range FIow Range Size Range
Pioneer Prime Up to 700 feet 20 - 44,000 USgpm 1.5 - 30 in
Standard Up to 700 feet 20 - 44,000 USgpm 1.5 - 30 in
Centrifugal
Wet Prime Up to 200 feet 20 - 3,500 USgpm 1.5 - 10 in
The PP86S
provides f
performance
general p
choice for f
dewatering; a
I
n my July 2014 column, I
demonstrated that three-
phase voltage variation can
signifcantly afect several alternat-
ing current (AC) motor character-
istics. If that variation is large, it
can also reduce motor life. Voltage
unbalance can be an even bigger
problem and is one of the major
causes of premature motor failure.
A relatively small unbalance of
just 2 percent can reduce expected
insulation life by half.
Calculating Voltage
Unbalance
Unlike voltage variation, unbal-
anced voltage occurs when the
three phases are not at the same
voltage. An example of perfectly
balanced phase voltage is L1/L2 =
460 V, L2/L3 = 460 V and L3/L1 =
460 V. Te average voltage is 460
volts.
An example of unbalanced phase
voltage is L1/L2 = 462 V, L2/L3 =
468 V and L3/L1 = 450 V. Again,
the average voltage is 460 V, but the
unbalance is 2.2 percent. Voltage
unbalance is calculated by the fol-
lowing equation:
Percent unbalance = 100 x
(maximum voltage deviation from
average / average voltage)
In the example above, the
maximum voltage deviation from
the average voltage is 10 V (460
minus 450). Motors from member
companies of the National Electri-
cal Manufacturers Association
(NEMA) are designed to tolerate
no more than 1 percent of voltage
unbalance.
Why does voltage unbalance
shorten motor life? One percent of
voltage unbalance can result in 6
to 10 percent of current unbalance.
Te phase with the lowest voltage
exhibits the highest current, which
increases the operating tempera-
ture of the winding serviced by that
phase. It will also increase the over-
all operating temperature of the
motor. Figure 1 shows the increase
in operating temperature versus
voltage unbalance. As shown, an
unbalance of just 3 percent can
increase operating temperature
by almost 20 percent. At 5 percent
unbalance, operating temperature
will increase by 50 percent.
Temperature Rating
& Insulation Class
Motor operating temperature is the
sum of the ambient temperature
surrounding the motor and the
Three-Phase Voltage
Variation & Unbalance
Last of Two Parts
By Joe Evans, Ph.D.
Pump Tech Inc., P&S Editorial Advisory Board
Figure 1. Overheating because of voltage unbalance
20
PUMP ED 101
temperature rise due to the motor
load. Te temperature rise is usu-
ally measured using the resistance
method. Each insulation class has
a specifc temperature rating. For
example, Class F is rated at 155 C
(311 F). Te temperature rating is
the maximum operating tempera-
ture allowed in order to meet an
average insulation life of 20,000
hours.
Of that rating, 10 C is reserved
for the hot spot allowance. Te
resistance method measures the
average temperature rise in the sta-
tor windings, but at some places
such as the stator slotsthe
temperature can be higher than the
average measurement. Te hot spot
allowance is reserved to protect
these areas. Tis reduces the actual
operating temperature (ambient
plus measured average) to 145 C.
For every 10 degrees over 145 C,
insulation life is reduced by half.
For every 10 degrees below 145 C,
insulation life doubles.
Suppose a motor with Class F
insulation operates at an ambient
temperature of 40 C. Te mea-
sured temperature rise at full load
is 90 C. Terefore, the operating
temperature is 130 C. Te expected
insulation life would be about
50,000 hours or about 2.5 times
the life at 145 C. But at 3 percent
phase voltage unbalance, the oper-
ating temperature increases by 19
percent (155 C) and insulation life
is reduced by 50 percent.
Image 1 shows the windings of
a motor that failed because of high
voltage unbalance. When a motor
loses one phase (single phasing),
the other two phases have to carry
the entire load. As a result, two sets
Voltage unbalance is one of the major causes of premature motor
failure. A relatively small unbalance of just 2 percent can reduce
expected insulation life by half.

21
21
of phase windings are destroyed, and the one that
lost power is unharmed.
Motor Phase Loss & Failure
In the case of unbalance, the winding with the
highest current fails and, usually, the other two
are still functional. In the motor shown in Image
1, one of the phases has failed, one is normal and
the third is beginning to show the efect of higher
temperature. Measuring voltage unbalance and
fxing the cause are much less costly than having
it diagnosed in a motor shop. See Pump Ed 101
in the July 2008 issue of Pumps & Systems for
instructions on diagnosing the cause of unbal-
anced voltage.
Although correcting voltage unbalance is
always best, a few rules can allow operation in
unbalanced applications. For example, if the leg
with the highest current is under the nameplate
full load amperage (FLA), it will safely operate. If
Image 1. Windings of a motor that failed because of high voltage unbalance.
(Image courtesy of EASA)
22
PUMP ED 101

23
Visit Booth 1543
43rd Turbomachinery
30th Pump Symposia
Houston, TX
it is above nameplate FLA but still
within the service factor (SF), it
may still safely operate. As a rule,
if the high current leg is less than
10 percent higher than the average
current, it will probably safely
operate.
A less desirable alternative is
to derate the motors nameplate
horsepower. NEMA suggests
derating horsepower to 75 percent
of nameplate at an unbalance of 5
percent. At 4 percent unbalance,
it is derated to 82 percent. At 3
percent, it is derated to 88 percent,
and at 2 percent, it is derated to 95
percent.
In addition to reduced insulation
life, unbalanced voltage can also
increase electrical costs by decreas-
ing motor ef ciency. At 1 percent
unbalance, ef ciency remains at
the nameplate nominal ef ciency.
However, at 3 percent unbalance,
actual motor ef ciency can be re-
duced by 2 percentage points.
Joe Evans is responsible
for customer and employee
education at PumpTech Inc.,
a pump and packaged system
manufacturer and distributor
with branches throughout the
Pacic Northwest. He can be
reached via his website www.
PumpEd101.com. If there are
topics that you would like to
see discussed in future col-
umns, drop him an email.
In addition to reduced insulation life, unbalanced voltage
can also increase electrical costs by decreasing motor efciency.
24
PUMP ED 101
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W
hen the pump selection
process starts, the
required fow of the is
often the only known variable
for an application. For example, a
system must move 2,000 gallons
per minute (gpm) from a holding
tank to another tank or process.
What size pump do should be
installed? Te size and pressure of
the piping and the power of the mo-
tor must also be determined. Tis
column helps explain how to make
these decisions.
Pump & Piping Size
Te longer the piping, the more
pressure its internal friction will
generate. A good way to pick a pipe
size is to calculate its diameter from
an empirical but simple starting
formula. Tis will help establish an
approximate range. Pipe velocity is
usually between 5 and 10 feet per
second (ft/sec).
Te smaller a pipes diameter, the
faster fuid fows through it. Te
larger the pipe, the more expensive
it is. Also, fowing too slowly may
cause particulate matter to settle
and clog the line, but fowing too
quickly will wear the pipe. Te 5
to 10 ft/sec range is usually a good
starting point. Equation 1 can used
for a more accurate calculation.
V = Q x 0.321 / A
Equation 1
Where:
V = velocity in ft/sec
Q = fow in gpm
A = pipe area in square inches
(in
2
)
In our example,
5 = 2,000 x 0.321 / A
A = 2,000 x 0.321 / 5 =
128.4 in
2
pipe area, or 12.8 inch
diameter
Tis diameter can round to a 12-
inch pipe with a velocity of slightly
more than 5 ft/sec.
Te next step is to fgure out the
amount of pressure in the system
if the pump is 5,000 feet away
from the processdischarge. Tis
determination is more complicated
because some hydraulic informa-
tion is needed. Several options can
provide this information: come to
class, consult a piping friction loss
chart or take my word for it that the
losses for cold water at 2,000 gpm
in a 12-inch, 5,000-foot pipe are
about 70 feet.
With the fow and head deter-
mined, the motor can be sized (see
Table 1). Also, an online Ef ciency
Estimator, which can be found at
www.mj-scope.com/pump_tools/
pump_ef ciency.htm, ofers useful
formulas.
To handle the process specifca-
tions, a single-stage pump was se-
lected. Te Ef ciency Estimator cal-
culated that a 42-horsepower and
84.5-percent pump ef ciency can
be expected from a typical pump.
Tis number can be confrmed with
quotes from pump distributors.
Te Ef ciency Estimator also
suggests an impeller size of 9.77
inches. Tis measurement is a good
way to roughly verify the appropri-
ate sizes of existing pumps. Tis
process provides useful preliminary
information for pump selection.
Motor Size
A 1,800-rpm motor speed was
selected for this process because it
is one of the most common motor
speeds in the U.S. Te horsepower
recommendation can be rounded to
select a 50-horsepower motor. If the
pump is expected occasionally to
operate outside the curve, choosing
a 75-horsepower leaves a margin of
safety.
Simplify the Equipment
Selection Process
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
Table 1. Sizing motors during pump selection
(Graphics courtesy of the author.)
US Units
Pump fow (gpm) 2,000
Total pump head (ft) 70
Specifc gravity (SG) 1.00
Number of stages 1
Speed (rpm) 1,800
Header per stage (ft) 70
Impeller diameter (in) 9.77
Specifc speed U.S. (Ns) 3,326
Specifc speed metric (ns) 64.5
Specifc speed universal (Os) 1.22
Ef ciency (%) 84.5
Power (hp) 42
26
PUMPING PRESCRIPTIONS
NPSHA Calculation
Te suction side must be consid-
ered. My last few columns dis-
cussed pump suction performance.
For example, I discussed how the
system afects the operation and
the relationship between the fow
(as a percent of the best ef ciency
point) and suction recirculation.
Many end users question how much
net positive suction head available
(NPSHA) they need.
If a pump has too little NPSHA, it
could experience suction problems.
Too much NPSHA leads to higher
construction costs. Users must fnd
the right balance. My next column
will describe in detail the beginning
of the selection process. For those
interested in how to calculate the
piping losses estimated (70 feet of
head), my Pump School training
covers this in-depth.
Dr. Nelik (aka Dr. Pump) is
president of Pumping Machin-
ery, LLC, an Atlanta-based rm
specializing in pump consulting,
training, equipment trouble-
shooting and pump repairs. Dr.
Nelik has 30 years of experience
in pumps and pumping equip-
ment. He may be reached at
pump-magazine.com.
If a pump has too little NPSHA, it could experience suction
problems. Too much NPSHA leads to higher contruction costs.
Users must nd the right balance.

27
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I
n the previous article calcu-
lating the cost of elements
in a piping system (Pumps &
Systems, July 2014), the energy
consumed and power cost balanced
exactly to demonstrate the process.
Seldom is life that exact. In the
real-world plant, instruments are
subject to inaccuracy, pumps may
be worn, estimates may be of
or the full system may not be
accurately represented in the design
documents.
Tis months article demon-
strates how cross-validating the
calculated results can ensure the
energy cost balance sheet accurately
refects system operation.
Te key to validating the results
is to use multiple means for arriv-
ing at the operating cost of each
item in the energy cost balance
sheet. If the energy cost balance
sheet does not add up, trouble-
shooting skills need to be employed
to discover the reason for the dif-
ference.
Tis article will continue to
use the example piping system
presented in previous articles (see
Figure 1).

Prioritizing the System
Te pump elements provide all
the energy that enters the system.
Tat energy is then consumed by
the systems process and control
elements.
If the energy cost balance sheet
does not balance, operators should
begin looking for the source of the
problem. Te major energy users
in the system should be examined,
and operators should fnd meth-
ods to cross-validate the initial
estimates.
Pump Performance
In the example, the pumps fow
rate was determined using the
manufacturers pump curve. With
a known fow rate, the pump ef-
fciency can be determined from
the curve.
Because the pump ef ciency is
used in all energy cost calculations,
ensuring the accuracy of the value
is critical.
System Validation
& Troubleshooting
By Ray Hardee
Engineered Software, Inc.
Figure 1. Drawing of sample piping system
(Article graphics courtesy of the author.)
Figure 2. An example showing the effect internal leakage has on pump
performance. Because of internal leakage, the installed pump is not
operating as designed.

29
Inaccuracies can occur in
real-life operating conditions. For
example, if the pump has a worn
impeller and excessive internal
leakage, it no longer refects the
pump curves operation.
Figure 2 shows a pump curve for
the process pump along with an
example of the efect that excessive
internal leakage can have on the
pump curve.
Using the calculated head dif-
ference of 235 feet (ft), the worn
impeller gives a fow rate of less
than the 4,000 gallons per minute
(gpm) used in the previous energy
system balance.
In addition, the ef ciency of a
worn impeller would difer from
the manufacturer-supplied test
curve.
Tis would result in inaccurate
power consumption and operation
costs calculations.
Operators have other options to
determine the fow rate through
the pump, including portable
ultrasonic fow meters.
Tese meters provide a reason-
ably accurate fow measurement
in a pipeline without physically
changing the piping system.
If the observed fow rate on the
temporary fow meter equals the
value determined using the pump
head and the pump curve, the fow
rate is validated, and the ef ciency
is validated by association.
If a power meter is installed on
the motor driving the pump, the
measured kilowatt (kW) value
can be compared to the calculated
power consumed using the pumps
fow, head and ef ciency values as
show in Equation 1, at the bottom
of page.
kW = .746
Q H
247,000
P

M
Equation 1
Where:
Q = fow rate in gpm
H = pump head in ft
= fuid density lb/ft
3
P
= pump ef ciency
M
= motor ef ciency
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If the power into the motor as
read on its power meter is the same
as the calculated power consump-
tion using Equation 1, the pumps
fow, head and ef ciency values are
validated.
If a power reading is not available
for the motor, the motors power
consumption can be calculated by
measuring the current and voltage
supplied to the pumps motor, then
using Equation 2. Te motors power
factor can be read on its nameplate.
P
3Motor
=
3 V I Pf
1,000

Equation 2
Where:
P
3Motor
= motor power in kW
V = voltage volts
I = current amps
Pf = motor power factor
If the calculated value of motor
power equals the pumps power con-
sumption, the pump fow, head and
ef ciency values are validated.
Tank Levels and Pressures
Te tanks and vessels make excel-
lent piping system boundaries. Te
energy at each tank can be deter-
mined by using the elevation of the
liquid level in the tank and pressure
on the liquid surface.
From these values the energy
consumed for the static head compo-
nent can be easily calculated.
Te results can be cross-validated
using installed pressure and level
instrumentation.
Te liquid level can be checked
with a sight glass or by manually
measuring the liquid level in the
tank. Te pressure in a closed vessel
can be compared using the installed
plant instrumentation, installed
pressure gauges or a temporary pres-
sure gauge.
Control Valves
In last months example, the dif-
ferential pressure across the control
valve was calculated by subtracting
the sum of the head losses of the
process elements from the pump
head. Tis approach is easy, but any
errors made in the previous calcula-
tions will compound and can greatly
reduce the energy cost balance
sheets accuracy.
Valve manufacturers defne the
operation of control valves based on
tests that are outlined in published
industry standards. Manufacturers
use the ANSI/ISA-75.01.01 Flow
Equations for Sizing Control Valves
to size control valves for piping
systems. Te data used in valve
sizing can also be used to calculate
the diferential pressure across the
control valve.
Equation 3 shows the basic for-
mula for valve sizing.
C
v
=
Q
F
P

P
1
P
2
S
Equation 3
Where:
C
v
= manufacturer-supplied valve
coef cient
Q = fow rate in gpm
F
P
= piping geometry factor (unit-
less)
P
1
= absolute pressure measured
at valve inlet in lb/in
2
P
2
= absolute pressure measured
at valve outlet in lb/in
2
S = fuid specifc gravity (unit-
less)
Rearranging the control valve
sizing equation and solving for dif-
ferential pressure results in Equa-
tion 4.
dP =
Q
2
S
(C
v
F
P
)
2

Equation 4
In the example system with a fow
rate through the level control valve
of 2,500 gpm, the control valve posi-
tion is 65 percent. According to the
manufacturers data for the control
valve, the C
v
at this position is 391.
Te F
P
of .9996 was calculated
by the manufacturer and included
in the valve data sheet. Te spe-
cifc gravity of the process fuid was
calculated at .993. Te fow rate
through the level control valve was
measured at 2,500 gpm. Inserting
the values into Equation 4 provides
the diferential pressure across the
control valve.
Converting the control valves
diferential pressure of 40.6 pounds
per square inch (psi) to feet of fuid
results in a head loss of 94.3 ft. Tis
result for the control valve calcula-
tion validates the number from last
months calculations.
Process Equipment
Te diferential pressure across the
process equipment was calculated
using the pressure drop data sup-
plied by the manufacturer and the
dP =
Q
2
S
(C
v
F
P
)
2

=
2500
2
.993
(391 .9996)
2
= 40.6 psi
If the calculated value of motor power equals the
pumps power consumption, the pump ow, head
and efciency values are validated.

31
fow rate obtained from the installed
fow element. In the example, the
heat exchanger pressure drop of
10 psi was assumed based on the
manufacturers supplied data. If the
heat exchanger tubes were fouled
due to internal deposit, the actual
diferential pressure across the heat
exchanger would be greater than
the value used in the energy cost
calculation.
Te diferential pressure across
the process equipment can be
validated by installing temporary
pressure gauges.
Most process equipment has vent
and drain lines installed for main-
tenance.
By installing temporary pressure
gauges on the vent and drain lines
and correcting the pressure values
for any diference in elevation of the
gaugesthe diferential pressure
and head loss across the item can be
measured.
Pipelines
In the example, the head loss in the
individual pipelines was calculated,
then used to determine the head
loss in each circuit of the pipeline.
Tis requires a large number of
calculations.
Te repetitive nature of the calcu-
lations makes this an excellent task
to be performed using a computer.
Online head loss calculators can be
found by performing an Internet
search. Commercially available
computer programs can also greatly
simplify the task.
Problems that could afect the
head loss calculation include fouling
or sedimentation in the pipelines,
partially closed valves, or obstruc-
tions in the pipe, valves or fttings.
Inaccurate determination of the pipe
Problems that could affect the head loss calculation
include fouling or sedimentation in the pipelines,
partially closed valves, or obstructions in the pipe,
valves or ttings.
32
size or schedule, or inaccurate esti-
mates of the number of fttings or
pipe length can also afect the head
loss calculation.
Total System
If the energy cost balance sheet
does not balance, either the mea-
sured plant data or the equipment
(pumps, process components or
control valves) could be causing the
problem.
To confrm the accuracy of the
measured data, check to see that
the instruments are calibrated. Te
instrumentation department can
also make sure the instruments
are accurately reading the process
parameters.
Te frst step is to check for
cavitation throughout the whole
system. Cavitation is caused when
the local pressure drops below, then
rises above, the vapor pressure of
the process fuid. Some of the fuid is
converted from liquid to vapor. Te
vapor bubbles take up extra space
in the fow stream, which causes a
reduction in the mass fow rate.
All standards and calculation
methods used to determine head
loss assume single phase fow. If
cavitation occurs, the calculated re-
sults will not accurately refect what
is happening in the system.
Cavitation is especially trouble-
some in pumps and control valves.
It can be a major source of mainte-
nance problems and should be cor-
rected prior to performing a system
assessment.
Next, the interaction of the
systems components should be
examined. Te best way to accom-
plish this is to compare the current
observed values with previous
observed values.
For example, the average valve
position of the level control valve
increased over time from 65 percent
open to 71 percent open. Te rest of
the measured plant data remained
the same.
Using Equation 4, the head
loss across the level control valve
decreased from the original 94 ft of
loss to 71 ft. Te only explanation
for this change is that the head loss
across the process element increased
S
ee U
s A
t P
um
p
S
ym
posium

B
ooth 903
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34
from the manufacturers published
value of 23 ft to 46 ft. Tis is a clear
indication of fouling in the process
equipment.
Conclusion
Gaining a clear picture of how a
piping system operates is key to as-
sessing the system.
Because most operating plants do
not have suf cient installed plant
instrumentation to provide all the
data needed for the calculations,
many of the values must be calcu-
lated using other well-established
methods.
By performing the calculations
and comparing them to available
operating data, operators can deter-
mine how the system is currently
operating.
Tis information allows opera-
tors to correct any problems that
adversely afect system operation
and perform an accurate assess-
ment of the piping system by
completing an energy cost balance
sheet.
My next few columns will inves-
tigate a variety of plant systems.
Tey will demonstrate what can be
gained with a better understanding
of system operation and what can
be done to reduce operating, main-
tenance and capital cost within
piping systems.
Ray Hardee is a principal founder
of Engineered Software, creators of
PIPE-FLO and PUMP-FLO software.
At Engineered Software, he helped
develop two training courses and
teaches these courses in the U.S. and
internationally. He is a member of
the ASME ES-2 Energy Assessment
for Pumping Systems standards
committee and the ISO Technical
Committee 115/Working Group 07
Pumping System Energy Assess-
ment. Hardee was a contributing
member of the HI/Europump Pump
Life Cycle Cost and HI/PSM Optimiz-
ing Piping System publications. He
may be reached at
ray.hardee@eng-software.com.
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36
GUEST COLUMN
D
espite their simplicity,
centrifugal pumps often
experience repeat failures
that even seasoned maintenance
and reliability professionals have
trouble preventing. Tis four-part
series explains the reasons behind
repeat pump failures and uses a
real-world feld example involving
boiler feedwater pumps. Devia-
tions from best practices or over-
sights can range from seemingly
insignifcant to stunningly elusive.
Tese can combine and often cause
costly failures.
Operating Diferent
Pumps in Parallel
Te negative experience of a
metal producing facility best
demonstrates the consequences of
operating pumps beyond their ap-
propriate fow ranges. Tis example
serves as a reminder of the merits
of conducting in-depth
reliability reviews before
buying process pumps.
Tis case history extends
to the remaining parts of
this series.
Te operating data of
the plants installed in-
strumentation is shown
in Figure 1. Te fow rate
into the destination tank
averages 2,500 gallons
per minute (gpm) to
maintain the tank level.
Tis system currently op-
erates for 8,000 hours per
year to meet the plants production
needs. Te system has operated in
this way since being commissioned
fve years ago.
Pushing Fluid Machinery Leads
to Frequent Failures
Second of Four Parts
By Heinz P. Bloch, P.E.
Image 1. This riveted cage bearing failed because of axial (rotor thrust) overload.
(Article images and graphics courtesy of the author.)
Figure 1. Pump manufacturers usually plot only the net positive suction
head required (NPSHR) trend associated with the lowermost curve. At that
point, a head drop or pressure uctuation of 3 percent exists at BEP ow.
1
Figure 2. A typical head-versus-ow performance curve

37
Tis case history is one of
many examples that validate the
importance of examining the
fow-versus-head characteristics
(the H/Q curves) of pumps. Such
examinations are needed during
the procurement phase of new
pumps and the troubleshooting of
installed but failure-prone process
pumps.
Seven boiler feedwater (BFW)
pumps were installed in the metal
producers boiler house. Two of the
facilitys seven pumps came from
Vendor A, two from B and three
from C. Te respective H/Q curves
from vendors A, B and C were not
identical. By 2009, these pumps
had failed often and randomly. Te
need for a thoroughly experience-
based failure analysis was rec-
ognized. Te analysis pointed to
hydraulic and mechanical issues.
Trough the years, this facility
routinely ran several BFW pumps
in parallel. Fear of failure may
have prompted operating four
pumps in parallel when only three
were required to provide a specifc
fow rate. If running three pumps,
each pump could have operated
closer to its BEP, but operating
four pumps led to a greater failure
risk. In other words, one or more
of these four pumps operated in
the questionable or forbidden low-
fow and high-internal-recircula-
tion range illustrated in Figure 1.
Low-Flow Range
At least two of the pumps had
fat H/Q curves, similar to the
curve in Figure 2. Running in
the low-fow range forced one or
both pumps into the fat portion
of their respective performance
curves. When operating in the fat
range, even a small change in head
(a small change in p) results in
large diferences in throughput.
Controlling and equalizing load
sharing would be dif cult.
In addition, the internal
pump clearances opened as time
progressed. Tis explanation was
in line with the recent escalated
failure frequencies. It led to the
recommendation of investigating
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38
GUEST COLUMN
the minimum fow allowed for these
high-suction-energy, BFW pumps.
Te concept of high suction energy
and what it means in terms of the
required net positive suction head
available (NPSHA)/net positive suc-
tion head required (NPSHR) ratio
and/or reduced allowable operating
range is thoroughly explained in
References 3 and 4.
Internal wear and operation at
lower-than-designed fow afect
the hydraulic thrust acting on a
pump rotor. Tis often contributes
to thrust bearing failures similar
to the one shown in Image 1 and
might even explain the excessive
wear on the worm wheel of one of
the shaft-driven lube oil pumps. In
general, rolling element bearings
with riveted cages should be avoided
in process pumps. Part Tree of this
four-part series will explain why
this is recommended.
References
1. Taylor, Irving, Te Most Persistent
Pump-Application Problems for Petroleum
and Power Engineers, ASME Publication
77-Pet-5 (Presented at Energy Technology
Conference and Exhibit, Houston, Texas,
September 18 22, 1977).
2. Bloch, Heinz P., Pump Wisdom: Problem
Solving for Operators and Specialists, John
Wiley & Sons, Hoboken, N.J., 2011.
3. Bloch, Heinz P. and Alan R. Budris, Pump
Users Handbook, 4th Edition, Fairmont
Press, Lilburn, Ga., 2013.
4. ANSI/HI9.6.3-1997, Allowable Operating
Region, Hydraulic Institute, Parsippany,
N.J.
5. SKF USA, Inc., Publication 100 955,
Bearings in Centrifugal Pumps, Version
4, p. 20, Kulpsville, Pa., 2008.
6. Bloch, Heinz P., Practical Lubrication for
Industrial Facilities, 2nd Edition, Fairmont
Press, p. 179, 2009; Mechanical Seals
in Medium-Pressure Steam Turbines,
presented at the ASLE 40th Annual Meet-
ing in Las Vegas, Nev., May 1985 (later
reprinted in Lubrication Engineering,
November 1985).
Heinz P. Bloch has been a profes-
sional engineer for almost 50 years.
He holds a BSME and an MSME
degree (cum laude) from New Jersey
Institute of Technology and retired as
Exxon Chemical Companys regional
machinery specialist. He authored or
co-authored 18 comprehensive text-
books dealing with lubrication and
uid machinery topics and published
more than 570 technical papers or
articles. Bloch has taught reliability
improvement and maintenance cost
avoidance subjects on six conti-
nents. He continues to write for trade
journals and advises and teaches
machinery reliability improvement
subjects. He may be reached at
heinzpbloch@gmail.com.
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40
GUEST COLUMN
C
ost estimation errors are
common in a variety of
projects. Recent studies
have shown the cost of machinery
can represent 20 to 35 percent of
a processing and manufacturing
projects total cost. Te estimated
costs for new plants and particu-
larly new pump installations are
very uncertain and have increased
in recent years.
Te following concepts minimize
the cost of pump installations:
Maximizing the extent of
manufacturing and installation
in the shop environment
Simplifying a pump packages
transportation and installation
Providing modularized compo-
nents that are easy to change
Reducing on-site personnel
supports and encouraging un-
manned operation
Eliminating as many standby
pumps as possible

Very limited literature is avail-
able on pump cost estimation. Tis
column will focus on the cost esti-
mation of the pump installations in
diferent projects.
Pump Installation
Cost Estimate
Historical data could inform pump
installation cost estimation models
within certain limits. Results have
shown a large cost diference be-
tween diferent regions.
Te economies of concentration
play an important role in cost.
Cost studies have indicated that
pump installation cost components
usually have economies that are
to scale to pump unit capacity and
pump train size.
Te cost estimation of a pump
unit or installation in a plant
cannot be fully accurate, with the
exception of the material cost,
particularly the cost of a pump
package. Tis cost can be estimated
from the pump packages vendor,
and the cost of materials could be
obtained from suppliers. However,
other cost estimations are relatively
inaccurate. Labor costs have much
larger cost overruns compared to
other cost components.
Te following estimation concept
can be employed for a pump unit or
installation:
(Pump Unit Cost) = A (Pump
Package Cost) + B
Te factor A is assigned for all
auxiliaries and accessories required
for each pump package such as
the foundation, civil works, piping
and additional steel structures for
each pump package. Tis factor is
usually between 1.3 and 2.5. Te
pump package cost includes all
skid-mounted facilities such as the
driver and lubrication oil system.
Te factor B is assigned for all
auxiliaries and accessories required
for each pump unit, such as unit
piping, unit utilities, protection
systems, unit pit/drain, unit electri-
cal facilities, safety equipment,
unit steel structures and unit civil
works.
Because the cost underestimating
error is generally larger than the
overestimating error, proper safety
margins for factors A and B are
always encouraged.
Te cost is also a function of the
project size or the pump system
capacity. A proper set of factors
should be developed for a defned
range of the pump unit size and
capacity for a region.
Environmental conditionssoil,
terrain, cost of living, population
density, economies of scale, noise
limits, applicable codes and dis-
tances from pump suppliescould
afect the installation cost estima-
tion and should be considered when
the cost factors are estimated.
Other Costs
Studies on recent pump install-
ations have shown that the cost
of civil works (site developments,
foundations and others) are about 9
to 20 percent of the total cost.
Estimate Pump Installation Costs
By Amin Almasi
Cost studies have indicated that pump installation cost
components usually have economies that are to scale to
pump unit capacity and pump train size.

41
Tey have also shown that the cost
of installation can be approxi-
mately 7 to 11 percent of the total
cost.
Te required man-hours for the
installation and commissioning of
pumps can vary signifcantly. For
packaged pumps, the following
indications should be noted:
For large pump packages (more
than 1 megawatt (MW)), the
installation and commiss-
ioning man-hours could be
between 300 and 900 hours.
For small pump packages (less
than 1 MW), the installation
and commissioning man-hours
could be between 100 and 300
hours.
Case Study
Te frst case study is presented for
a 6 MW pumping unit. Te costs
of electric motor-driven pump
packages are obtained in millions
of U.S. dollars (MUSD):
A 3 MW pump package:
0.9 MUSD
A 1.5 MW pump package:
0.6 MUSD
A 0.8 MW pump package:
0.45 MUSD
Te factor A is estimated at
1.67 for these pump packages. Te
factor B is estimated at 1.5 MUSD
for a 6 MW pump unit. Table 1
compares the cost of these difer-
ent options.
As shown, smaller pumps con-
siderably increase costs. A greater
number of smaller pumps is more
expensive than using a single large
pump.
Te second case study is pre-
sented for small pump installa-
tions. Te following two options
are considered:
Option 1: A 320 kW pump,
$52,000
Option 2: A 200 kW pump,
$42,000

Te factor A is estimated at
1.49 for these small pump pack-
ages. Te factor B is estimated at
$45,000 for Option 1 and $34,000
for Option 2.
Table 2 shows the cost analysis
for two options of small pumps.
Based on Table 2, only about 20
percent total installed cost reduc-
tion could be expected for a pump
38 percent smaller in size. Large
pumps have economies of scale
and low unit cost. In other words,
unit costs of pump installations
usually decrease as pump size
increases.
Table 1. Costs of different pump arrangement options
(Article graphics courtesy of the author.)
Table 2. Cost analysis for two options of small pumps
Pump Unit Rough Cost of
Packages (MUSD)
Rough Total
Cost (MUSD)
Rough Cost
Ratio
23 MW 1.8 4.5 1
41.5 MW 2.4 5.5 1.2
80.8 MW 3.6 7.5 1.7
Pump Option Package Cost Installed Cost Rough Cost
Ratio
Option 1: 320 kW $52,000 $122,000 1
Option 2: 200 kW $42,000 $97,000 0.80
A proper set of factors should be developed
for a dened range of the pump unit size
and capacity for a region.
Amin Almasi is a rotating
machine consultant in Australia.
He is a chartered professional
engineer of Engineers Australia
(MIEAust CPEng Mechanical)
and IMechE (CEng MIMechE)
and a Registered Professional
Engineer in Queensland. He spe-
cializes in rotating machines
including centrifugal, screw and
reciprocating compressors; gas
turbines; steam turbines; engine
pumps; subsea and offshore ro-
tating machines; LNG units; con-
dition monitoring; and reliability.
Almasi is an active member of
Engineers Australia, IMechE,
ASME, Vibration Institute, SPE,
IEEE and IDGTE. He has written
more than 80 papers and articles
dealing with rotating equipment,
condition monitoring, offshore
and subsea equipment, and reli-
ability. Almasi may be reached at
amin.almasi@ymail.com or +61
(0)7 3319 3902.
42

SEALS & BEARINGS
ctive magnetic bearing (AMB) reliability and availabil-

ity levels have surpassed oil bearings after 10 years
of technological advancements. Tese advances have
made an impact on the industry, drawing attention
from major original equipment manufacturers globally.
In 2002, an oil and gas processing company required a bear-
ing for a hermetically sealed integral motor compressor. Te
natural gas from the well contained hydrogen sulfde, which
lead the company to pursue a corrosion-resistant canned
bearing. Finding a reliable bearing for this hermetically sealed
integral motor compressor was a challengebut one worth
the cost. Te solution included sealed bearings and electrical
connectors, which eliminated the need for a costly enclosure
surrounding the motor compressor. Installing the motor
compressor outdoors, without a building or enclosure, saved
the company signifcantly in capital expenditures. Te hermetic
sealing of the bearings and motor compressor also ensured that
emission limits were not exceeded for sites in which operating
licenses limited hydrocarbon emissions.
Process Gas Immersion
Magnetic bearings are an efective solution for many oil and gas
applications because they can be immersed in the process gas. A
canned magnetic bearing with metallic lined stators
segregates the electrical connections and windings
from the corrosive gas. Canned bearings allow for
the placement of the magnet core and windings
behind an impervious pressure-rated barrier
constructed of corrosion-resistant alloy or other
nonmetallic material.
Special alloys ensure that the bearings will not
corrode, protecting the inside of the machine from serious
degradation.
With canned AMB designs, the metallic can separates the
pressurized volume inside the machine from the cavity and
ambient pressures and protects against leakage to the machines
exterior. Te metallic can must withstand the maximum pres-
sure inside the machine, which is equal to the cans diferential
pressure.
A proper design of the metallic can and backing system is
crucial to survive all the temperature and pressure conditions
that the AMBs will encounter during operation.
In one 2006 oil and gas installation, the system has
operated safely in its environment. After 25,000 hours, the
units operation provides 99.9 percent availability to its end
user. In addition, the canned bearings temperature ratings
-', ^^ ÔO OÔ
O - OU O', O-^-
Canned MagnetIc
earIngs MInImIze
CorrosIon In
DII & 6as ProcessIng
` FICHAFD SHULTZ
\''' !N' ''N
SPECIAL SECTION

43
reached 165 C. Other canned bearings have reached 130
C in similar applications.
Managing Corrosion Risks
Magnetic bearings must conform to the corrosion safety
standards for oil and gas applications, such as National
Association of Corrosion Engineers (NACE) MR0175. Te
bearings electrical components are protected from process
conditions, including chemical attack by process gas and
condensates. Te motor compressor can eliminate the use
of dry gas seals, avoiding natural and sour gas damage to
the environment.
Figure 1 has been adapted from NACE MR0175. It
details regions of increasing sour gas corrosion to metal
alloys used in oil and gas processing equipment. Corrosion
is defned by reference to sulfde stress cracking (SSC).
EOG location
memphis, tnks jkask
Because they can be immersed in process gas without
corroding the electrical connections, canned magnetic
bearings offer oil and gas end users a signicant advantage.
(Article images and graphics courtesy of Waukesha.)
Figure 1. A plot of in situ pH against the partial pressure of hydrogen
sulde shows increasing corrosion from Regions 0 (no effect) to 3 and
beyond (highest propensity for SSC).
44

SEALS & BEARINGS
SPECIAL SECTION
Figure 1 shows in what levels of sour gas
service sealed and canned designs may
be applied while still expecting a reason-
able service life, based on documented
corrosion rates. Te dividing line corre-
sponds to a concentration of about 600
parts per million of sulfdes.
A rotor system inside a pressure vessel
also helps cool the motors and bearings
and provides electrical connections that
penetrate the pressure vessel.
Erosion and corrosion can cause
costly damage to a machines interior.
Canned and corrosion-resistant auxil-
iary bearings ofer a beneft to the oil
and gas industry, in which environmen-
tal regulations continue to increase.
Tese bearings can be applied in the
manufacturing of integral motor com-
pressors, externally driven compressors
and turbo expanders.
A canned magnetic
bearing segregates
electrical connections
and windings from the
process gas.
Richard Shultz is the design engineering
manager for magnetic bearing systems at
Waukesha Magnetic Bearings. He has 20
years of industrial experience designing
magnetic bearing systems and auxiliary
bearing systems, specializing in rotor-
dynamics and control system design. He
recently instructed at the Mag-
netic Bearing Short Course
at the Texas A&M Turboma-
chinery Symposium and the
Middle East Turbomachinery
Symposium in Qatar.
Houston Ofce: 8885 Monroe Road,
Houston Texas 77061 USA
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45
ithin the oil and gas industry, the rotating shafts

of equipmentsuch as pumps, motors, compres-
sors, gearboxes and turbinesperform an essen-
tial function in both upstream and downstream
applications. Tis rotating equipment ensures process fow and
the safety of employees and the surrounding community.
Bearings are critical to the reliability of rotating equipment.
If they fail, the equipment has to be repaired or replaced.
Because they support the shaft, bearings are prone to wear
and damage. Lubrication starvation and contamination are
the principal factors that cause premature bearing failure, so
systems have been developed to prevent these issues.
Methods for sealing the gap between a rotating shaft and
the stationary bore have evolved with advances in lubrication
and lubrication delivery systems. Selecting the right seal for a
lubrication system will yield the best bearing protection. Lip
seals and labyrinth seals, also known as bearing isolators, are
the most common solutions.
Lip seals are unidirectional contact type seals. Teir geo-
metry is important for maintaining an optimal radial load on
the shaft to develop a meniscus of oil on which the lip can ride,
which reduces friction and wear on the shaft and lip (see Fig-
ure 1). Depending on the direction of the installed seal, it will
either prevent egress of lubrication or ingress of contamination
(see Figure 2).
Bearing isolators are non-contact seals that provide bidi-
rectional sealing capability. Teir construction includes two
-O '-, -' OO OO
- O' -O - -'-O
` 1AMLS WDN6
'' 'N 'N'
The FIght SeaI & LubrIcant
CombInatIon Can Prevent
earIng ContamInatIon
Figure 1. Formation of meniscus of oil under the lip
(Article graphics courtesy of Garlock Sealing Technologies.)
Figure 2. Direction determines lubricant retention or contaminant exclusion .
46

SEALS & BEARINGS
SPECIAL SECTION
components that rotate independently of each other. Te stator
remains with the bore, and the rotor rotates with the shaft. Be-
tween the stator and rotor is the labyrintha small, contorted
pathway that prevents the egress of lubrication and ingress of
contaminants at the same time (see Figure 3).
Grease Purge
Grease is an easy lubricant to apply and maintain, and it can be
used to prevent contamination. Its consistency makes it easy
to seal within bearing chambers. Most equipment designed for
grease lubrication is equipped with a purge stream. Tis allows
fresh grease to be pumped into the bearing chamber, replacing
degraded or contaminated grease. Grease purging is a common
practice, but should only be carried out with an understanding
of the grease fows efect on the seal.
Lip seals are suitable for use with grease lubrication, since only
one seal installed facing the external environment is typically
needed. Tis confguration prevents contamination of the grease
by water or dirt and allows it to be purged under the lip if the
discharge port becomes plugged or otherwise obstructed. Lip
seals are rarely installed with the lip oriented toward the grease.
Applications in which no grease should ever escape the seal, such
as those in the food industry, are exceptions. In these instances,
a metal case lip seal or cover plate that helps retain the seal in
the bore is recommended. Tis helps prevent the seal from blow-
ing out from purge pressure of the grease.
Operating temperature is an important consideration when
selecting lip seal material. Because grease does not dissipate heat
as well as oil, adding another 100 degrees Fahrenheit to the op-
erating temperature is recommended to ensure that the material
can withstand the heat.
Bearing isolators are also suitable for use with grease lubrica-
tion. Tey can retain grease within the bearing chamber even
during purging. Because of the consistency of grease, the level of
lubrication is not a concern. Bearing isolators are customizable.
If the equipment does not have a grease discharge port or if the
port is obstructed, a special bearing isolator can be designed to
purge the grease through the isolator itself (see Figure 4).
Oil Bath
Oil bath/splash is the simplest type lubrication system. It
requires only minimal maintenance. A side glass or dip stick
should be provided with these systems to ensure that the proper
level of lubrication is maintained. Te level typically should be
at the center of the lowest rolling element of the bearing. With
each rotation of the shaft, the rolling elements distribute the oil
within the bearing.
Tis poses a problem for lip seals. Depending on the size of the
bearing and the speed of the shaft, the lip could be starved of oil
and unable to develop a meniscus. Tis means that the lip would
contact the shaft, grooving it and reducing the seals life.
Bearing isolators are designed for this type lubrication system.
In addition to labyrinths that prevent the escape of lubrication,
they have drain ports to capture excessive oil splash and drain it
back to the sump. With the smaller footprints of todays pumps,
the distance between the bearing and the back of the seal is
reduced, creating a more aggressive splash onto the bearing
isolator. As a result, manufacturers have redesigned drain ports
to capture more lubrication and direct it back to the sump.
Oil Mist
Oil mist is becoming a popular lubrication system, especially
in the oil and gas industry. Oil mist systems are approved by
the American Petroleum Institute (API) 610 specifcation for
centrifugal pumps for the petroleum, petrochemical and natural
gas industries.
An oil aerosol is dispersed within the bearing chamber to
lubricate the bearings. If not vented properly or applied in a
closed-loop oil mist system, the pressure will increase within
the bearing chamber. Tis increased pressure makes capturing
the mist within the bearing housing dif cult because the higher
pressure in the bearing chamber attempts to obtain equilibrium,
carrying the oil mist into the environment.
Figure 3. Components of a bearing isolator with the
labyrinth pathway highlighted in yellow

47
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Figure 4. Custom bearing isolator with purge stream
Lip seals are not recommended because the mist may not be conducive to the
formation of an oil meniscus under the lip, resulting in friction and heat that will
groove the shaft and damage the seal. Specifcally, API 610, 11th Edition, Para-
graph 6.10.2.6 states that lip-type seals shall not be used with oil mist systems or
any other type lubrication system in API pumps.
Te same paragraph stipulates that labyrinth- or magnetic-type end shields
should be used. Magnetic-type seals work like face-type mechanical seals. Two
smooth faces, lapped within two light bands are mated. Force is applied across the
faces either by springs or magnets. Te face material could be bronze, carbon or
ceramic depending on the application temperature, since the seal generates
additional heat as the two faces rub against one another.
Labyrinth seals, such as bearing isolators, could be used, but without modifca-
tion or additional features, they cannot hold back the pressurized oil mist. One
way to combat this is the addition of a mechanism to block the pathway to the en-
vironment. Tis could be an O-ring, felt or a molded polytetrafuoroethylene ring
in diferent cross-sections. Tese rings are strategically placed along the labyrinth
and typically have frictional contact with either the isolator or the shaft.
Recent advances in bearing isolators include the ability to be used in submerged
or fooded conditions. Tese hybrid bearing isolators combine the benefts of a
non-contact, labyrinth-type seal and a contact-type seal to hold a full head of lu-
brication (see Figure 5). Tis makes them suitable for use in oil mist applications to
prevent the mist from migrating into the atmosphere. Operators should note that
these hybrid bearing isolators could be made of steel, which is a sparking material.
48

SEALS & BEARINGS
SPECIAL SECTION
Conclusion
Seals and lubrication systems can be combined in many ways. Te wrong pairing can
lead to premature bearing failure, downtime, lost production, shorter maintenance
intervals, and costly equipment repairs and replacement.
Figure 5. Hybrid bearing isolator with contact
points within the labyrinth to retain oil mist or a
full head of lubrication in ooded condition
James Wong is the associate product
manager for the bearing isolator product line
at Garlock Sealing Technologies. He has ex-
tensive experience in industrial sealing tech-
nology in dynamic and static applications.
He started his career as a product engineer
designing and testing seals for dynamic
application, including eld experience solv-
ing challenging applications. Currently, he
manages the entire bearing isolator portfolio
at Garlock. His name appears on several
patent and technical articles pertaining to
bearing isolators. Wong also has
presented in seminars around
the world on the subject of
bearing protection. He may be
reached at james.wong@
garlock.com.
Stop by B
ooth #1130 at the
2014 Pum
p/Turbo Sym
posium

Show
in H
ouston

49
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50

SEALS & BEARINGS
SPECIAL SECTION
igh performance liquid chromatography (HPLC) is a

chemical analysis technique with wide applications,
from food and medical safety to manufacturing.
HPLC can detect vitamin D levels in blood serum or
performance enhancing drugs in urine. Te technique has even
been used to synthesize blood and determine DNA evidence in
forensic investigations.
In biotechnical and pharmaceutical manufacturing, HPLC
enhances the production process by increasing separation
ef ciency, improving resolution and shortening analysis time.
Instrumentation and system automation have evolved to keep
pace with the quality of materials that support HPLC and its
applications.
How HPLC Works
HPLC passes a liquid sample through a column of a particular
absorbent solid material that reacts at divergent rates from an
analyzing solvent. Te rate of reaction and how the solution
separates identify the original components. Tis technique can
determine all the materials in a solution based on known reac-
tions to base chemicals and solid state materials.
HPLC instruments include a sampler, pumps and a detector.
Te sampler brings the mixture samples into the mobile phase
stream, which carries it into the column. Te pumps deliver the
desired fow and composition of the mobile phase through the
column. Some mechanical pumps mix multiple solvents in ra-
tios changing over time, creating a composition gradient in the
mobile phase. Te detectorultraviolet-visible spectroscopy,
photodiode arrays (PDAs) or mass spectrometry are commonly
- O -O O
^-U - - O^
O U^ O U'
O O^- ',UO
O^-O-,
` 1LFFY ZAWADA
'' 'N ''N
SeIect SeaIs
That Meet
the ChemIcaI
ChaIIenges of
HPLC Pumps
In HPLC applications, the
use of seals that offer low
coefcients of friction and
robust dynamic and static
sealing is recommended.
(Article images courtesy of
Trelleborg Sealing Solutions.)

51
usedgenerates a signal proportional
to the amount of sample component
emerging from the column and allows for
quantitative analysis of the sample com-
ponents. Instrument control software
usually ties into the HPLC instrument
and provides data analysis. Addition-
ally, a high scan-speed detector capable
of collecting enough data points across
an analysiss narrower peaks has often
improved the production process.
HPLC Pumping Challenges
All piston pumps have multiple replace-
ment parts, such as check values, piston
seals and pump piston rods. When work-
ing with HPLC instruments, biotechnical
and pharmaceutical manufacturers pay
close attention to the parts and materials
entering their supply chain in terms of
their pumping needs.
Seals in HPLC pumps must deliver
exceptional leak tightness, high resis-
tance to wear and tear, low coef cient
of friction and no extrusion into gaps.
An HPLC pump seal should withstand
aggressive and abrasive processing and
ofer excellent temperature capabili-
tiesoperating in a range from -253 C to
300 C (-423 F to 572 F). Recommended
seals can work at high speeds up to 15
meters per second (49 feet per second).
Check valves (inlet and outlet) prevent
fow from a high-pressure area into the
low-pressure area inside the HPLC pump
head. As a result, the pumps piston can
deliver a mobile phase fow through
the column at high pressure. A properly
functioning check valve opens and closes
quickly and provides a secure seal across
a wide pressure range. Check valves in
HPLC pumps fail more often than other
HPLC parts, such as pistons or piston
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Long-lasting instrumentswith lifespans from ve to
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having a more common role in HLPC instrument upkeep.
52

SEALS & BEARINGS
SPECIAL SECTION
Jerry Zawada is life sciences segment
manager for Trelleborg Sealing Solutions.
He has worked with Trelleborg
for more than 14 years and
was previously vice president
for a startup life sciences
company. He may be reached
at tssusa@trelleborg.com.
seals, because they are exposed to repeated mechanical stress at
high pressure. Failed check valves are also dif cult to identify.
Unlike external pump leaks, internal pump leaks do not lead to
a substantial drop in pressure, and HPLC software programs will
not detect them.

Service Kits Increase Longevity
Long-lasting instrumentswith lifespans from fve to 20
yearshave led to instrument maintenance repair organizations
(MROs) having a more common role in HLPC instrument up-
keep. MROs now make service kits for HPLC part replacements
because of instrument longevity. For example, pump manu-
facturers and MROs can remove metallic
spring energizers from an HPLC system
because the energizer can afect production
results in some cases.
Some MROs have developed specialized
kits based on consults with operations per-
sonnel to determine what parts, supplies and
packaging requirements will ensure a cus-
tomers instruments and machines continue
to run smoothly. Tese organizations partner
with material suppliers to ef ciently manage
inbound and outbound logistics through sup-
ply chain services.
Te Future of HPLC
HPLC is the largest product segment in the
analytical instruments industry. Te techno-
logy serves several industries for research
and development purposes, quality control
and process engineering applications. Im-
provements in system automation, robotics
and instrument design are propelling growth
in the HPLC market.
China and India are driving the market for
analytical instruments in Asia, with Latin
America ofering good growth prospects. Te
rise in drug discovery and generic pharma-
ceutical production, as well as rapid indus-
trialization, has fueled the HPLC market in
these regions. Industry research forecasts the
HPLC pumps market crossing the $100 mil-
lion mark in 2014.
Te global market for HPLC systems and
supporting accessories is projected to reach
$3.7 billion by 2015.
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54

SEALS & BEARINGS
SPECIAL SECTION
n article in the June 2009 issue of Pumps & Systems

detailed a new technology to treat the surface of
silicon carbides. Te treatment is not a coating and
not homogenous with depth. Since the publication of
this article, independent parties have tested the treatment and
returned the results from several applications.
Tis article summarizes some of those tests.
Background
Te technology involves treating a fnished
silicon carbide (SiC) component with a specifc
chemistry that etches the silicon from the sur-
face of the SiC and leaves behind the carbon.
Tis process occurs at the nanoscale. Te
silicon is removed, and the carbonwhich was
initially reacted with the silicon and sintered
into the SiC substrateremains in its original,
covalently-bonded crystal lattice. During the
reaction, the carbon further reorganizes into
various nanospecies and creates a treatment
zone as shown in Image 1.
Tese transmission electron microscope im-
ages are taken at diferent depths within this
treatment zone. Its outer zone is mostly planar
graphite and disordered carbon, giving the sur-
face a controllable, low coef cient of friction in the range of 0.08
to 0.12. Nanocrystalline diamond combined with the carbon
and graphite emerges further down into the surface. Eventually,
all these constituents merge with the virgin SiC, where SiC and
all carbon nanospecies are present.
O'O, ''U-, OU O
-O O^ O O, O- OOO
` MAFK SLIVINSKI
'' ''\'\ 'N' 'N
Treated CarbIde
Surfaces Lnhance
FunnIng Performance
Image 1. Transmission electron microscope images taken at different depths within the
treatment zone (Article images and graphics courtesy of Carbide Derivative Technologies.)

55
As the surface runs in, it operates at the
robust zones in which graphite, carbon
and nanocrystalline diamond provide
a tough,low-friction running surface.
Because it is not a coating, and the carbon
is covalently bonded to itself and the
supporting SiC substrate, this technol-
ogy cannot delaminate, spall or peel of.
Compared with current sealing surface
solutions, the resulting treated surface
runs cooler, longer and withstands
signifcant periods of dry running. It has
never delaminated in 25 years of rigorous
testing.
Te 2009 article showed results from
fashing hot water tests. Specimens in
that series were run for 24 to 100 hours
at 250 F and 140 pounds per square inch
(psi).
Te specially treated specimens exhib-
ited minimal wear scars on the mating
rings between 1.7 and 4.4 micrometers
(m), but the untreated SiC specimens
wear scars were between 47 and 173 m.
Furthermore, the specially treated sur-
faces were still smooth, but the untreated
surfaces were heavily grooved.
New Tests
All the recent tests, detailed in this section,
had the hard/hard running combination of
a treated SiC surface against another SiC-
treated surface.
Mechanical Seals
A seal pair was run in rigorous water test
in conditions that typically damage seal-
ing faces, as shown in Figure 1. Te water
test lasted for 350 hours. Next, the pump
was drained, and the seal was run for
another 75 minutes in dry nitrogen before
a temperature spike stopped the test. Tis
Compared with current sealing surface solutions, the resulting treated
surface runs cooler, longer and withstands signicant periods of dry
running. It has never delaminated during 25 years of rigorous testing.
56

SEALS & BEARINGS
SPECIAL SECTION
test proved extensive wet- and dry-running capabilities,
even after running under rigorous wet conditions. No leak-
age occurred throughout the combined test.
Tis mechanical seal test included stressful water condi-
tions followed by dry nitrogen conditions. Most demonstra-
tions in stressful water conditions, including deionized
water, caused the water to fash or simulate other intermit-
tent dry and high-temperature running conditions. Tese
tests, which typically destroy plain SiC sealing faces, have
ranged in duration from 24 to 1,000 hours. Treated sealing
faces survive such conditions with smooth faces even after the
rigors of the test.
Dry nitrogen is dif cult to seal with plain, fully contacting seal
faces. Te 2009 article showed that treated surfaces actually ran
with lower friction in pin-on-disc tests than in ambient air. Several
mechanical seal tests in dry nitrogen have been conducted. Some
were fully dry, without the pump being wet before the dry running.
Specialized treatment for silicon carbide surfaces has survived tests
in dry air or nitrogen for durations ranging from 45 minutes to four
hours at aggressive pressure velocity conditions of between 6,000
and 80,000 psi-feet/minute (ft/min). Te surfaces typically did not
groove. Tey remained smooth and continued to provide a good seal-
ing surface. Tese tests demonstrate that treated seal faces run well
in dry air or nitrogen environments. Tis performance characteristic
can provide long-running life for pure dry mixer seals and lightly
loaded safety seals.
Another mechanical seal example tested automotive water
pump seals. Te industry standard stress test for these products
includes a 15-minute dry-running test. Te seal face materials
currently used in this industry have dif culty meeting this stan-
dard. Figure 2 shows the results of a seal assembly subjected to
fve tests, at increasing shaft speeds, for one hour and 15 minutes
of total dry-run time. Te seal assembly was allowed to cool to
ambient temperature between runs. Some
tests of the untreated assemblies were
stopped before 15 minutes had elapsed.
Te results showed erratic temperature
behavior from the untreated seal rings
and damage to the elastomer bellows. Te
cumulative wear from the fve tests was
a 20-m wear scar on the mating ring. In
contrast, the treated seal faces ran at low
temperatures with normal trends. Te
proflometry showed no discernible wear,
and the seals did not leak under a 25-psi
air pressure leak test.
Tese results demonstrate that treated
seal faces enable dramatically longer run
times in normally lubricated situations.
Tey also survive extended fashing or dry-running conditions
for much longer than other solutions. Field examples have shown
that this technology lengthens the running life in fashing
hydrocarbon service by a factor of 12. Since the surfaces remain
smooth even after fashing or dry running, they survive through
process upsets that would normally require shutdowns for pump
repair because of seal damage. Tis is because the treated seal
faces stay smooth and enable the pump to recover, be rewetted
and run after a process upset without the seal leaking.
Emissions are directly proportional to seal wear. Te low wear
and resistance to grooving of treated seal faces also provides
signifcantly lower fugitive emissions for single-seals. All these
features lengthen plant maintenance cycles.
Bearings
Te treatment also enhances the performance of bearings. One
manufacturer demonstrated improved dry startup capability in a
hydrodynamic bearing contained in a downhole pump. In opera-
tion, the pump runs dry for fve to 10 seconds at startup before
dirty water foods the bearing chamber. A test was performed
in dirty water with 35 stop/starts25 forward and 10 reverse.
While this test typically destroys SiC hydro pads and thrust
plates, the treated components were unharmed. Te components
were able to be reused in another pump and placed into service.
Image 2. The treated thrust plate (left) and thrust pads (right) with no
discernable wear at twice the normal maximum load
Figure 1. Results of a mechanical seal tested for 350 hours in water
followed by 75 minutes of running in dry nitrogen

57
Image 2 shows the results of a hydrodynamic bearing test
with treated components. Te test was conducted in water with
a load that increased incrementally until twice the normal
load-bearing capability was reached. As the image shows, the
components experienced no discernible wear. Proflometry
measurements also showed no discernible wear. Te assembly
may have been able to support even higher loads.
While treated components have not been tested in the sleeve
bearing parts of mag-drive pumps, it is expected that they
would protect equipment from damage during dry running.
Specially treated SiC components have been demonstrated to
run well when mated with certain metallic components. Tis
fexibility makes the technology ideal for protecting mag-drive
pumps with either metallic or carbide shafts from damage dur-
ing dry running.
Conclusion
Tis technology allows an improved running surface to be
synthesized on a fnished SiC component in a net shape, size
and roughness process that does not add any new material or
require post-treatment polishing. Te surface derives from the
virgin SiC, where the silicon is etched out of the surface while
the carbon already contained in the SiC stays in its original crys-
tal lattice and transforms into carbon nanospeciesincluding
planar graphite and nanocrystalline diamond.
Te resulting surfaces demonstrate the ability to run for
extended periods wet, dry and during fashing. After operat-
ing in demanding conditions, the surfaces are still smooth and
able to seal. Tis technology allows fuid-handling equipment to
be rewetted and run after process upsets without stopping the
fuid loop to repair damaged mechanical seal rings. Because of
While treated components have not been tested in the sleeve bearing
parts of mag-drive pumps, it is expected that they would protect
equipment from damage during dry running.
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SEALS & BEARINGS
SPECIAL SECTION
decreased friction, seals employing this
technology run cooler. Tis reduces fash-
ing conditions and enables the seal to sur-
vive the fashing. Te dramatically reduced
wear and grooving directly translates
to signifcantly reduced emissions from
single seals. Dry nitrogen performance
allows long duration and quiet running for
pure dry mixer applications. Load bearing
capability for hydrodynamic bearings can
be substantially increased, and dry run-
ning capability for sleeve bearings can be
enhanced.
All these benefts are possible with
hard/hard surface pairings. Te technology can have a posi-
tive impact on plant maintenance cycles, equipment mean time
between maintenance and mean time between failures. Te
technology is currently available in sizes up to 8-inch diameter
and beyond with capability for 36-inch marine propeller shaft
seals including submarines.
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Fax: +33 (0) 3 86 46 42 10
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Superior safety, product containment with seal-less design
Clears lines, maximizes product recovery from compressor efect
Consistent fow rates over a long period of time
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Mark Slivinski is president of Carbide Derivative Technologies
Inc. and former vice president of global technology for John
Crane International. He may be reached at mslivinski@carbid-
ederivative.com. For more information on CDT treatment for
silicon carbide surfaces, visit www.carbidederivative.com.
Figure 2. Results of multiple 15-minute dry-running tests on the same seal

59
Increased load capacity for longer pump life
Increased stiffness for less shaft deection
Improved raceway surfaces for less friction
Improved geometry for reduced vibration
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60

aper production requires large amounts of power. Te

Smurft Kappa plant in Pite, Sweden, uses its own bio-
mass boilers to meet part of its energy needs. Te clean-
ing system in place for the high-performance steam generator
includes a specialized motor management solution to ensure
uninterrupted motor operation.
At the Smurft Kappa Kraftliner Pite paper plant in north-
east Sweden, 520 employees produce about 700,000 metric
tons of Kraftliner paper per year. Kraftliner is a special type of
raw paper made of fresh fbers and serves as the base material
for manufacturing high-quality corrugated cardboard packag-
ing. Te Swedish plants annual power consumption is about
520,000 megawatt hours (MWh). Biomass boilerswhich burn
organic material such as wood generate 58 percent of that
power, creating added value through ef ciency and sustainabil-
ity..
Te Pite production site consists of a pulp mill with two
soft-pulp digesters and one hardwood digester and a paper
mill with two paper machines. Two boilers produce the energy
needed for the mill. One recovery boiler combusts the black
liqueur from the process, and a biomass boiler uses mostly the
bark from the wood-handling system. Te steam from the boiler
passes across two steam turbines that generate more than half
the electricity required by the mill. Tis self-produced electric-
ity is a green option because fossil fuel is
only required during the startup process.
Lower Costs for Cleaning Routines
A special steam cleansing technology boosts
the ef ciency of the power generation system. A high-performance
boiler must be kept clean, ensuring high-ef ciency degrees, high
availability and minimal ash corrosion. Pressurized steam dis-
sipates the soot, increasing the ef ciency compared with conven-
tional methods.
Te cleansing technology also permits cheap, aggressive fuels
for natural, ef cient powering. Te boilers are cleaned with
automatic motorized 8-meter-long cleaning lances that spray
pressurized steam onto the boilers heat surfaces. A specialized
motor management program controls and monitors the motors
during this cleansing process.
Ef ciency & Maintenance Challenges
Te previous electrical drives in Smurft Kappas high-perfor-
mance boiler were complex and dif cult to use. Te system
required mechanical contactors for reversing the rotational
direction of the steam cleansing systems motors and digital
outputs for clockwise and counterclockwise control.
UO --, OO -''O O ,^
O, , -O O ^--
- O - ^''
` MATTHIAS DFUTTA
''N'` N
StreamIIned Motor
Management System
oosts Iomass
Power 6eneratIon
PUMP SYSTEM OPTIMIZATION

61
Analog inputs handled the power input,
and digital inputs analyzed the return
signals. Wire connected all the devices and
individual switching cabinets.
Documentation and controller program-
ming were time-consuming with the exist-
ing system. Adding drives to the setup was
a major undertaking that required expert
project management.
In addition, the switching cabinets left
little room for new additions. Consistent
maintenance was not efective because
of multiple componentssuch as drives,
input/output (I/O) modules, measuring sen-
sors, terminal blocks and contactors.
Te existing systems drives were three-
phase asynchronous motors. A screw
conveyor moved the lance in and out of the
boiler to blow the soot of surfaces.
The Pite site produces about 700,000
metric tons of Kraftliner paper per year.
Smurt Kappa Kraftliner Pite in northeast Sweden is one
of the Smurt Kappa groups 350 production sites. (Article
images and graphics courtesy of Phoenix Contact.)
62
PUMP SYSTEM OPTIMIZATION COVER S E R I E S
Each screw conveyor was ftted with two mechanical or
inductive limit switches. When the screw conveyor reached the
end or start position, the rotational direction had to reverse.
Te limit switches were prone to dirt build-up, which made
their signal information for reversing the rotational direction
less reliable. Inadequate cleaning could, in a worst-case sce-
nario, damage or destroy the motor.
3.
Fewer Wires, More Space
Te new motor management system provided several advantag-
es to the steam cleansing system. Te program, which included
motor management, hybrid motor starters and a feldbus gate-
way, detected worn sootblowers before failure.
Fewer I/O modules were required, reducing wiring and docu-
mentation, and the compact device dimensions opened more
installation space.
Bus gateways allowed for system expansion during system
operation. Te gateway forwarded the process data from multiple
motor management modules to the control unit, while electronic
motor management units (EMMs) handled monitoring and drive
protection with active power monitoring.
Te solution also included hybrid motor starters, which provided
non-wearing motor switching. Relays and the system cabling solu-
tion quickly and reliably coupled the feld devices to the controller.
No Need for More Sensors
Te 22.5-millimeter electronic motor management unit has
built-in current transformers to directly read input currents up
to 16 amperes.
If the applications output is higher currents, other EMM mod-
ules read them in combination with external current transformers.
Te range of available components works for all power ratings.
Because the EMM can be easily inserted on the existing mo-
tor cable, the operator was provided access to all the measure-
ments for easy and cost-efective motor and system monitor-
ing. Te ease of installation eliminates the need for additional
sensors. Te module can retroft existing systems, keeping the
system up-to-date with all current status values.
The motor management units compact dimensions
save considerable space compared with similar components.
The steam cleansing system uses high-pressure steam to blow the
soot off the high-performance boilers heating surfaces.
The switching cabinets contain a solution that
includes motor management, hybrid motor starters
and a eldbus gateway.
Figure 1. Network integration of the motor manager as shown in a
Probus structure

63
Separate mechanical or non-wearing semiconductor contactors
switch three-phase loads. Te digital output of the motor manage-
ment modules implemented on- and of-switching. Motor manage-
ment supplied the data for any application, such as monitoring and
protecting pumps, controlling valves or tool machines, or analyzing
the systems power consumption.
Te choice of control system connectionwhether independent
or feldbusdoes not impact the systems data collection.
Trusted Connections
Trough the programs feldbus gateway, which is certifed according
to European Norm 50170 as specifed by Decentralized Peripherals,
level V1, 31 motor management modules can be connected to each
other. Te pluggable design means no wiring is needed (see Figure
1). All process data is transferred to the control system.
Te feldbus gateway also supports a fail-safe. If any malfunc-
tions occur, the switching behavior can be modifed. Te gate-
way also features additional digital inputs and outputs. If com-
munication is based on the Profbus DVP1 system, the device is
connected to the network using a general station description.
In addition, the system support permits increased fexibility
for the entire system: parameter setup, monitoring and diagno-
sis of the motor management devices.
Motor management supplies the data for any application, such as
monitoring and protecting pumps, controlling valves or tool machines, or
analyzing the systems power consumption.
Matthias Borutta studied electrical engineering with a
focus on measuring technology at the Gttingen University
of Applied Sciences. In 2000, he wrote his nal thesis in the
eld of automation. Since 2001, he has been
product manager for electronic load relays
and solid state relays in Product Marketing
ELR for Phoenix Contact. He may be reached
at mborutta@phoenixcontact.com or
+49 5281 946-3112.
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64
he years leading up to the new millennium saw a rapid evolu-

tion of industrial communication networks from analog to
digital. By 2000, information technology tools were becoming
integrated into fuid handling products and systems. Tis marked
the beginning of pump and automation technology convergence.
Process instruments, control valves and stand-alone control-
lers developed from individual hardware units to microprocessor
embedded devices that could be digitally linked into a computer-
based process management system. Intelligent pumps also joined
the march forward in 2000. Today, smart centrifugal pumps with
variable frequency drive (VFD) controls are becoming an integral
component of the industrial process automation architecture.
Hard-wired communication systems in feld devices are being
replaced by wireless communication as the new standard. What
does this communication revolution mean for the traditional
pump and automation industry?
Te migration from hardware to software enables new services
that were practically undeliverable in the past. Widespread
information fow from process assets helps plant operators make
better life-cycle-cost decisions and perform true predictive main-
tenance in real time, without needing to collect data manually.
Tese changes drive stakeholder innovation and proftability.
Te old paradigm of business gives way to the life-cycle-costing
approach. Organizational structures and stakeholder perceptions
are changing. Suppliers are moving from selling commodity
products and services to rendering unique, value-added services
that are highly customized.
While all this may seem vague, new approaches are becom-
ing part of industrial automation and fuid handling systems
practice and management. Te plan-do-check-and-act cycle now
should mean making sound fnancial decisions that win today
and in the future rather than frst cost decisions that win today
and fail decidedly in the future.
As an example of these changes, consider one pulp mills mainte-
nance strategy for dealing with a vat dilution pumping system that
was causing repeated component and system failures and process
downtime. Tis approach included looking at the system holistically
and also considered the use of more intelligent components. Deci-
sions were ultimately made based on life-cycle costs.
Case Study
Regular pump breakdowns and undue wear resulting from heavy
control valve throttling can cost companies millions each year.
InteIIIgent MonItorIng
DeIIvers FeaI-TIme
Pump Performance Data
, , -O '-', UO, 'O O '-
- 1 ^''O -U-'', , -OO OO^
` MIKL PLMLFTDN
' '' '\'
Widespread information ow from process assets helps plant operators
make better life-cycle-cost decisions and perform true predictive
maintenance in real time. (Article images courtesy of ITT Corporation.)

65
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66
In one case study from 2001, a paper mill bleach plant was sufer-
ing fnancial losses from an oversized pump. After assessing the
problem, plant personnel contacted a plant operation specialist.
Te mills energy team determined that nearly two-thirds
of the facilitys valves were less than 50 percent open. Many of
them were less than 25 percent open. One key pump system had
a capacity of 6,500 gallons per minute (gpm), but the average
load was only 2,750 gpm52 percent of total capacity. Te peak
fow demand was only 5,200 gpm.
Te 10-inch ball-valve installed in a 14-inch discharge line was
undersized. Te large pressure drop and associated vibration were
causing valve wear, pipe cracks, gasket leaks and frequent down-
time. Also, it was dif cult to keep the control
loop tuned, which required manual operation
of the modulating valve. Te pump experi-
enced almost 10 failures per year, all of which
occurred while the pump was running and
during startup and shutdown.
A pump is more susceptible to catastroph-
ic damage during startup and shutdown
than at any other time. Tis is primarily
because of large pressure changes and water
hammer across the pump system compo-
nents. But the initial shock to the system
upon startup involved more than pressure.
Tere was also thermal shock from 220 F
(104 C) fltrate entering the pipes when the
pump motor was started.
Te mills reliability engineers conducted
a thorough examination of the system. Tey
determined that automated gate valves,
which open slowly as pipes warm to avoid
thermal shock and cracking, plus new operat-
ing procedures would provide incremental
improvements and a reduction in failures.
In addition to the gate valve automation,
the plant operation specialist recommended
installing a low-voltage motor and VFD, oper-
ated in pressure control mode, for the three
vessels the pump was feeding.
Stabilizing the control loops and reduc-
ing pressure inside the system turned a
frequently failing pump into a properly
functioning component of the system. Te
bleach plant witnessed $18,000 in energy
savings in 2002. Energy savings in the same
process had climbed to $32,000 in 2013 as
energy costs increased. Beyond the ef cien-
cy improvement, plant representatives also
reported that the systems-based solution
saved them more than $1 million annually
in downtime and repair costs.
A Systems Approach
Plants havent been clamoring to invest in
ef ciency for several reasons. One is simply
a lack of experience with the methods and
techniques used to raise ef ciency.
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67
When components break, operators tend to buy what they think
already works to replace them.
When deciding to modify systems, ef ciency improvements
may feel unnecessary. No one wants to interrupt day-to-day
operation of the plant to overhaul functioning equipment or
systemsespecially if they arent part of the plants specialized
production equipment. However, critical
subsystem issues in many plants have too
long been ignored. Engineers and suppli-
ers are still oversizing pumps, for a variety
of reasons. Some prepare for increased de-
mand, imagining future capacity increases
that never come.
Pump optimization activities allow an
increase in the level of condition monitor-
ing through broader use of intelligent mo-
tors, pumps with embedded chips, VFDs
and wireless vibration monitoring. Tese
tools ofer real-time information on pump
system performance.
Pumps are not considered to be an inte-
gral component of the process automation
architecture. As a result, plant informa-
tion systemssuch as distributed control
systems (DCS) and computerized mainte-
nance management systems (CMMS)
typically lack continuously monitored
asset data for diagnostic use.
Although the DCS monitors most of
the key process parameters required
for traditional process control, up to 60
percent of the pump systems lack a fow
measurement on the discharge line. For all
practical purposes, almost all of the work
orders and asset information is manually
entered into the CMMS.
Furthermore, other underlying assets,
including compressors, blowers, fans
and control valves, are rarely connected
to the CMMS. Te lack of information
is a missing link in an e-manufacturing
strategy. It can mean that large potential
cost savings go unrealized. According to
the ARC Advisory Group, up to 40 percent
of manufacturing revenues are devoted
to maintenance and up to 60 percent of
scheduled maintenance checks and motor-
driven systems are unnecessary.
With consideration given to proper
mounting, alignment and lubrication,
the three primary determinants of pump
reliability are speed, distance operated
from BEP and impeller diameter. If a mill optimizes 30 percent
of existing pump systems, overall mill process availability will
dramatically increase while pump seal and bearing failures will
signifcantly decrease.
Reliability improvements can be predicted, and past work
orders and CMMS records can be used to estimate annual
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68
maintenance costs. In many cases, process control
benefts can be identifed in terms of reduced raw
material variability, and life-cycle-cost savings can
be estimated based on current costs compared with
optimized costs.
Making decisions based on long-term operating
costsrather than keeping a large safety margin
that allows unnecessarily high flow production
will create an opportunity for the plant of the fu-
ture. This kind of plant will be available, adaptable
and sustainable as required. This thought process
needs to be implemented and is increasingly be-
coming a regulatory requirement.
The latest advances in technology offer
real-time information on pump performance,
helping plant operators make more informed
decisions related to their service.
DP Pumps - Expanding to
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Profitability.

69

multistage BB5 difuser machine in oil transfer service
in the Middle East had been in operation for many years
without problems. After a routine maintenance strip
down and rebuild, the pump experienced a high thrust bearing
temperature of 105 C, which caused it to alarm and shut down.
Te temperature range had previously been 75 C to 85 C.
Tis case study describes the method used to solve the high
bearing temperature problem and outlines the fow physics
that contributed to the high thrust bearing temperature. Te
customer contacted an engineering services company after the
original pump manufacturer failed to remedy the problem.
Te companys forensic approach to this problem involved two
distinct methodologies:
Diligent and in-depth analysis of site data relating to
the problem
Rigorous scrutiny and analysis of the pump geometry and
build against the background
Te engineering services company identifed several scenarios
that could cause this temperature rise, then narrowed down the
list to establish a root cause.
Site Data Analysis
Te behavior of thrust bearing pads during startup is seldom
investigated. Te temperature rise of the pads can be attributed
to two distinct causesthrust developed during startup and
environmental and oil conditions (see Figure 1).
Te signifcant fnding from this data was the temperature
rise associated with thrust. Te pump could not achieve the
temperatures measured prior to maintenance in its current
condition. Te total thrust bearing temperature includes the oil
temperature and environmental conditions.
CIose InspectIon SoIves
HIgh Thrust earIng
Temperature ProbIem
-U' --', OO U
Û'-, O' - U^
6AFY DYSDN
'`' 'N
Figure 2. Meridional ow interactions of a pump running at
partial capacity
Figure 1. Behavior of thrust bearing pads based on thrust and
environmental conditions (Article images and graphics courtesy of
Hydro Inc.)
70
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i
n
f
o
.
c
o
m
Based on comparisons with previous site data, both the thrust and oil cooling had
altered. Analysis of the temperature data at the motor bearings, which were experi-
encing oil temperature increases of 10 to 15 C, further supported the conclusion.
Pump Analysis
Analysis of the pump build procedures also revealed that a change in thrust quan-
tity was causing a high pad temperature. Tis machine can be susceptible to thrust
changes due to the axial position of the impeller with respect to the difuser.
Te engineering services company investigated the build process and discovered
that the original bearing housing had not been used in the rebuild. Te axial posi-
tion of the rotors had not been reset correctly, unlike the bearing clearance.
Tis machine has an adjustment ring behind the thrust collar that is used to
account for build tolerances in the components stack. Fitting the new bearing as-
sembly afected the rotor positioning. Te adjustment ring had been reftted without
ensuring that the rotor centralization had been carried out correctly.
Te direction of the thrust further complicated the scenario. Trust bearings
on this machine are designed to run with the thrust on the inboard pads. When a
pump runs back to a lower fow, a thrust reversal afects the outer pads.
Although this pump was not running at its best ef ciency point, its operat-
ing fow was not reduced enough to cause a thrust reversal. Scrutiny of site data
indicated that this pump had always thrust to the outboard pads regardless of any
process changes over time.
Some pump manufacturers fne-tune the thrust behavior of their machines by
adjusting the size of the balance drum and bush based on their initial performance
test results. If this process is too time-consuming, manufacturers adjust the axial
position of the rotor with respect to the difuser to modify the thrust and bearing
temperature.
Tis rotor setting data is easily overlooked on rebuild, especially since the actual
rotor centralization is rarely checked on strip-down. Tis means it cannot be re-
stored after a component change.
Hydraulic Instability and Hydraulic Trust
As a pump operates at partial capacity, the fow becomes increasingly unstable. Both
the impeller and rotor experience an increase in unsteady fow interchange.
Traditionally, this fow regime interaction has been illustrated as in Figure 2 in
the meridional plane (see page 69). Although this image is helpful in understanding
the fow physics, the true picture is far more complex.
Figure 3 illustrates the complex nature of the fow that develops within the im-
peller when the pump operates at extreme part load. Point A illustrates the develop-
ment of a discharge vortex that commences on the hub at the impeller discharge.
Point B illustrates the boundary of this interaction with the inlet backfow recir-
culation within the impeller eye. Tis inlet backfow recirculation is also illustrated
in detail in Figure 4.
At partial capacity, the fow exits the impeller eye at the hub inlet angle and spi-
rals down the suction channel impinging on splitters of the previous stage.
Te meridional view clearly depicts these two unstable fow interactions with the vor-
tex that exists within the gap between the channel ring and impeller shroud (see Point C
in Figure 2, page 69).
Tis vortex accounts for the developed thrust within this pocket. Any disruption
to this vortex leads to a more unpredictable thrust regime.

71
c
i
r
c
l
e

1
7
1

o
n

c
a
r
d

o
r

v
i
s
i
t

p
s
f
r
e
e
i
n
f
o
.
c
o
m
Figure 3. Complex ow interactions of a pump running at partial capacity
Figure 4. Illustration of 3-D inlet backow recirculation
72
Dr. Gary Dyson is managing director with
Hydro Global Engineering Services. He has a
Ph.D. from Craneld Univer-
sity and 30 years of experi-
ence in the pump industry in
senior positions with many
manufacturers. His expertise
includes pump hydraulic
performance, design and
reliability improvement.
Te centralization efect of the rotor within
this channel infuences both the development
and speed of this vortex. Te space available
for the vortex is either increased or decreased
so boundary layer efects begin to dominate.
Solution
The solution to the high thrust bearing
temperature problem lay in a combination
of contributing factors, each needing in-
depth understanding of pump technology
and flow physics.
The following actions returned the pump
to an acceptable temperature:
Oil temperature correction: A thermo-
static valve was disabled during pump re-
moval. On commissioning, this valve was
left in an inoperable position, which kept
the oil from passing through the cooler.
Te engineering services company identifed the problem and
returned the valve to the appropriate setting.
Rotor centralization: Te rotor centralization had been ad-
justed to of-center by the original equipment manufacturer
to limit the thrust on the outer pads (see Figure 5). Te en-
gineering services company restored the rotor to the correct
position relative to the difuser, which put the thrust bearing
temperature within an acceptable range.
Thrust compensation modification: The
engineering services company is now
suggesting modifications to the machine
to correct the thrust balance based on
the actual site operating conditions. This
new thrust compensating modification
will be designed to ensure the thrust is
on the inner thrust pads, giving the bear-
ing an extended operating range.
Tis case study illustrates the problems
that can arise if a meticulous approach is
not adopted for even a routine maintenance
activity. Severe operational problems can be
prevented by repair practices that diligently
record every aspect of the pump repair.
Figure 5. Rotor with poor centralization

73
ife-cycle cost calculations for wastewater instal-

lations can produce huge savings over time
for wastewater companies. Te life-cycle costs
summarize the total cost of a wastewater installation,
and the pump system plays a major role. It is the key
element to ensuring the installations long-term cost-
efectiveness.
Total lifetime costs normally include planning,
design, purchasing, investment, installation, com-
missioning, energy, maintenance and operation, and
downtime costs. A system can also incur environmen-
tal and disposal costs at the end of its lifetime. Te
pump system has the highest impact on the lifetime
cost of the wastewater installation. However, only
three of the costs listed above play a signifcant role
in the pump systems contribution to life-cycle costs:
investment, energy and maintenance.
Investment
Te initial procurement cost is often seen as the best way to
ensure low cost. Meeting investment budgets means keeping
in mind that the cost of operation, maintenance and disposal
could be fve to 20 times higher than the initial investment.
Tis is why municipalities and contractors increasingly con-
sider the requirements for performance, reliability and energy
consumption when purchasing a pump system.
Energy
Decision makers might think that the energy cost of the pump
is easy to calculate. But many things must be considered when
determining the energy cost of a pumpsuch as wear, variable
load, installation and clogging.
If the wrong wastewater pump is chosen, the media content
leads to wear, costly breakdown and 3 to 5 percent lower ef-
fciency for every year the pump is not maintained.
OO ^, , -O ^--
O -'- O - OUOU -
-''-O '^
` LAFS D ANDLFSLN
''N' \\'
System SeIectIon
CrucIaI for Long
Wastewater Pump LIfe
Involve different people to ensure that all aspects of the pump purchase are
considered. (Article images and graphics courtesy of Grundfos.)
74
Most pump brands make it possible to restore ef ciency loss.
Some have a replaceable wear ring, while others have built-in trim-
ming that allows adjustment of the impeller clearance using outside
bolts. Because wear also afects non-replaceable parts of the pump,
full restoration of ef ciency is impossible.
Te design of the pump impeller is a key issue, since a simple design
with large free passage and no inserts or moving parts will wear less
than a design without these features, thus ensuring a high ef ciency
over the pump lifetime.
Te pumps duty point is seldom constant and varies over the
course of a day, a year and a pumps lifetime. Users should look
for a pump with a fat ef ciency curve. Tis ensures high ef cien-
cy over a wide duty range and determines whether the pump is
using a variable speed drive. If the pump is running with variable
speed, a pump with a duty point to the right of the curve should
be selected. When adjusting the speed downward, the pumps
duty point moves to a part of the curve with higher ef ciency.
Te energy saved when operating with a variable speed drive de-
pends heavily on the system curve. Te savings potential decreases
if the static head is small compared to the friction losses. It increases
in a system with large friction losses compared to the static head.
A variable speed drive can also signifcantly infuence the clogging
frequency of the pump, as the water velocity might fall below the
self-cleaning velocities in the system.
When installing a pump system, measures should be taken
to avoid leakages, especially where the connection between the
pump and the installation equipment is metal-to-metal (see Fig-
ure 2). Tese connections become more susceptible to leaks as the
system gets older. Seals or gaskets should be placed at all joints.
More leakages mean a greater loss of energy.
A small diameter in the rising main leads to increased head
requirements and energy consumption, because small pipes amplify
the pipe friction losses of the installation. A small rising main also
increases the leakage fow. To avoid high losses, the water velocity
through the pipes should be kept low. Te exact maximum velocity
depends on the length and roughness of the pipes, but as a rule, the
velocity should not exceed 3 meters per second (m/s).
Avoiding velocities that are too low is also crucial. Low veloci-
ties can cause sedimentation and deposits to build in the pipes,
increasing friction losses and energy consumption. Manual pipe
cleaning may become necessary to clear the pipes, adding to
maintenance costs.
For horizontal rising mains, a minimum of 0.7 m/s is recom-
mended, while a vertical rising main should be dimensioned for a
velocity of no less than 1 m/s. Tis is especially important in pump
systems with variable operation. Variable speed drives can heavily
infuence water velocity, so take care that the pump is not always
running at a low speed. Te self-cleaning velocity in the pipes other-
wise might not be achieved.
More than installation clogging, impeller design relates
directly to energy cost. Te improved nonclogging capability of
an impeller is normally achieved by using semi-open impeller
designs, but these designs cause ef ciency loss.
New developments now combine the best of both worlds by hav-
ing nonclogging, high-ef ciency impellers with large free passages,
no inserts and no moving parts.
The design of the pump impeller is a key issue because a simple design with
large free passage and no inserts or moving parts will wear less than a design
without these features, thus ensuring a high efciency over the pump lifetime.
Figure 2. Conventional pump with metal-to-metal discharge connection
Figure 1. Wear of impeller clearances with different impeller designs

75
Maintenance
Maintenance costs are often dif cult to estimate.
Planned maintenance costs will vary depending on many dif-
ferent factors, such as:
Pump value
Pump maintenance costs
Operational experience
Pump failure consequences
Pump failure probability
System design
With small, inexpensive pumps or pumps that are dif cult to
maintain due to their placement, planned maintenance activities
might be kept to a minimum, while large, expensive pumps might
get the full range of planned and predictive maintenance.
Stocking recommended spares can make planned maintenance
less expensive and more intuitive for operators. Tis allows worn
parts to be changed without special tools or training. Choosing
a pump with built-in analogue sensors allows monitoring of the
pumps condition and enhances maintenance planning.
Unplanned maintenance costs can be easily predicted
based on an operators familiarity with the pump brand and
its service friendliness. To determine the cost of the repair,
take into account the following:
Maintenance to be performed on the pump
Time required for maintenance activity
Number of personnel involved
Spare parts cost for maintenance activity
Fast spare part availability also ensures that unplanned mainte-
nance can be conducted quickly and reliably.
Lars Bo Andersen has worked at Grundfos for the past 18
years in various positions. Starting as a product engineer
in 1996, he progressed to project manager
to develop pump selection tools support-
ing life-cycle cost calculations according to
best practices from EuroPump and the U.S.
Hydraulic Institute. He is currently the global
product manager for wastewater based in
Bjerringbro, Denmark.
305.591.8935 | www.KeepItRunning.com
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76
he design of pump inlet piping defnes the result-

ing hydraulic conditions experienced at the pump
inlet/impeller. If the design fails to produce a
uniform velocity distribution at the pump inlet, noisy
operation, random axial load oscillations, premature
bearing or seal failure, cavitation damage to the impeller
and inlet portions of the casing, and occasional damage
on the discharge side due to liquid separation can occur.
Any of these issues could lead to pump failure (ANSI/
HI 9.6.6., 2009). Part of the pump inlet piping design
includes the selection of reducer ftting type.
A reducer ftting is typically used in pump station
pipe work to reduce the size of the suction pipe to match
the size of the pump suction end fange. Reducer ft-
tings used in pump inlet pipe work are divided into two
typesconcentric and eccentric reducers. Te two types
of reducer fttings can be described as:
Concentric reducerTe reduction of the pipe size is
achieved by decreasing the diameter of the ftting at
a constant rate over a specifed length, maintaining
symmetry around the ftting (see Figure 1).
Eccentric reducerTe reduction of the pipe size is achieved
by decreasing the diameter of the ftting at a constant rate
over a specifed length, maintaining one side of the ftting
horizontally (see Figure 1).

Design guidelines, pump operating manuals and design
standards mostly prescribe the selection of an eccentric reducer
with the fat side on top for horizontal fow to the pump. Tis
confguration prevents air pocket accumulation at the upstream
end of the reducer (see Figure 1). Te non-uniform velocity dis-
tribution results from the acceleration of fow along the eccentric
reducers sloped side resulting in an unbalanced force that is not
addressed. An unbalanced force on the impeller could lead to
potentially detrimental radial thrust harmonics.
Feducer FIttIngs Decrease PIpe
SIze to AvoId FaIIure
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` FDSS MAHAFFLY, ''N
N STLFANUS 1DHANNLS VAN VUUFLN
'N'\''` ' ''''
''' ' \ ''
Figure 1. Difference between eccentric and concentric reducers
in pump inlet piping (Article graphics courtesy of the authors.)
Figure 2. Calculation of reducer angles
Number of pipe diameters
a
Reducer Concentric Eccentric
1 pipe size reduction 0 (<10)
b
0 (<20)
b
2 pipe size reduction 0 (<20) 1 (<30)
Table 1. Minimum straight length required before suction inlet
a
Minimum required straight pipe length before pump suction inlet = diameter x
number of pipe diameters
b
Te angles given are the maximum per side for standard commercial fttings.
Nonstandard fttings having a greater angle per side should use the number of pipe
diameters corresponding to that angle, regardless of the number of pipe reductions.

77
Abstract from the Design Standards
ANSI/HI 9.6.6 American National Standard for Pump Piping
for Rotodynamic Pumps (P4, 2009) specifes the following for
the selection of reducer type in pump inlet piping: A concentric
reducer is recommended for vertical inlet (suction) pipes or
horizontal installations where there is no potential for air vapor
accumulation.
Eccentric convergent reducers are normally used for horizon-
tal installations where there is potential for air vapor accumula-
tion. Te fat side shall be located on top, unless the inlet (suc-
tion) line approach from above, in which case either a concentric
reducer or eccentric convergent reducer (with the fat side on the
bottom) should be used.
ANSI/HI 9.8 American National Standard for Pump Intake
Design (P21, 1998) states, Tere shall be no fow disturbing
fttings (such as partially open valves, tees, short radius elbows,
etc.) closer than fve suction pipe diameters from the pump.
Fully open, non-fow disturbing valves, vaned elbows and reduc-
ers are not considered fow disturbing fttings.
Tis standard eliminates any reference to the possible fow
distribution that could be generated by the reducer. Tis stan-
dard (P28, 1998) also requires that, Time-averaged velocities at
the pump suction in a piping system shall be within 10 percent
of the cross-sectional areas average velocity.
Tis requirement can be used to assess the extent of fow
disturbance caused by a reducer. ANSI/HI 9.8 also recommends
a maximum fow velocity of 2.4 meters per second (m/s) in the
suction pipe work.
ANSI/AWWA C208 American Water Works Association Stan-
dard Dimensions for Fabricated Steel Water Pipe Fittings (P7,
2008) directs the length of a reducer (L
r
) to be calculated with
the following formula.
A reducer tting is typically used in pump station pipe work
to reduce the size of the suction pipe to match the size
of the pump suction end ange.
305.591.8935 | www.KeepItRunning.com
Unbalance is amongst the most common of reliability problems
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78
Ross Mahaffey is a professional engi-
neer at Aurecon, an international group
of consulting engineers, where he is the
lead 3-D design engineer for pipelines
on a large bulk water transfer system in
South Africa. He is a civil engineering
graduate from the University of Pretoria
and has a postgraduate
degree in water resource
engineering. He may be
reached at
ross.mahaffey@
aurecongroup.com.
Stefanus Johannes van Vuuren holds an
MBA and Ph.D. in engineering from the
University of Pretoria. He has worked with
the Department of Water Affairs, Wind-
hoek Municipality, consulting engineering
rms, contractors and
international academic
institutions. He may be
reached at
fanie-vanvuuren@up.ac.za.
L
r
= 4 (D
L
D
s
) Equation 1
Where:
L
r
= Length of the reducer
D
L
= Larger pipe diameter
D
s
= Smaller pipe diameter
Te reducer angles for the ANSI/AWWA C208 were calculated
with the method in Figure 2 to compare it to the requirements in
Table 1. Te calculated angles are:
ANSI/AWWA C208 Eccentric Reducer Angle = 14.04
ANSI/AWWA C208 Concentric Reducer Angle = 7.13
Te minimum number of straight pipe lengths required is
determined by the number of pipe reductions, regardless of the
reducer angle staying constant. For a single pipe reduction, the
standard ANSI/AWWA C208 reducer has no
requirement for downstream pipe lengths
before the pump.
In the second part of this series, the rec-
ommendations presented in ANSI/HI 9.6.6
will be assessed using computational fuid
dynamics and compared to the ANSI/HI 9.8
and ANSI/AWWA C208 requirements.
References
1. ANSI/AWWA C208-07. 2008. Dimensions for fabri-
cated steel water pipe fttings. American Water Works
Association, Denver.
2. ANSI/HI 9.8-1998. 2000. American National Stan-
dard for pump intake design. Hydraulic Institute, New
Jersey.
3. ANSI/HI 9.6.6-2009. 2009. American National
Standard for rotodynamic pumps for pump piping.
Hydraulic Institute, New Jersey.
4. VAN VUUREN, S.J., VAN DIJK, M and STEENKAMP,
J.N. 2004. Guidelines for efective de aeration. WRC
Report No. 1177/2/04. Water Research Commission,
Pretoria.
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80
TRADE SHOW COVERAGE
PUMP & TURBO
43rd Turbomachinery
30th Pump Symposia
Sept. 22 25, 2014
George R. Brown Convention Center
Houston, Texas
Exhibition Hours
Tuesday, Sept. 23 Noon 2 p.m.
2:30 p.m. 7 p.m.
Wednesday Sept. 24 Noon 2 p.m.
2:30 p.m. 6:30 p.m.
Thursday Sept. 25 9:30 a.m. Noon
T
he 43rd Turbomachinery & 30th Pump Symposia feature a technical program
and international exhibition, complete with full-size equipment and hundreds of
companies. Tis is the only meeting organized by users for users. Te members
of the Advisory Committee are recognized leaders in the rotating equipment and power
generation community. Te event promotes professional development, technology
transfer, peer networking and information exchange among industry professionals. For
more information, please visit pumpturbo.tamu.edu.
1. Network with industry professionals
Meet with more than 5,500 turbomachinery
and pump professionals gathered together
in one location. Last year, 91 percent of
attendees said attending was important or
very important to establishing their contacts
in the industry.
2. Learn about new technologies
Attend lectures to learn about cutting-edge,
emerging turbomachinery or reciprocating
compressor technologies that have been
successfully feld tested.
3. Have questions answered on the spot
Whether it is a troubleshooting question
for a current vendor or a question to an
expert about the efectiveness of condition
monitoring on rotating equipment, the
symposia provide answers.
4. Leverage your training budget
Choose from more than 100 technical sessions
to attend. Industries covered include oil and
gas, chemical and petrochemical, mining and
minerals, water, power, and manufacturing
and repair.
5. Talk to the experts
Beneft from face-to-face interactions
with more than 200 industry experts who
will lead the technical program and with
representatives from more than 320 exhibiting
companies ready to discuss their products or
services.
6. Find solutions to existing problems
In addition to meeting with company
representatives in the exhibit hall, attendees
can talk about their problem in a discussion
groupa forum to address problems
attendees bring to the foor and fnd solutions
to those problems through dialogue.
7. Bank on a history of success
Tis year marks the 43rd Turbomachinery and
30th Pump Users Symposia.
8. Gather information for purchases
Te exhibit hall features full-sized equipment,
knowledgeable representatives and more than
320 companies.
9. Beneft from an event designed with
the user in mind
Pump & Turbo is developed for the industry, by
the industry. An advisory board, comprised of
leading experts from more than 50 companies,
selects the technical program specifcally to
address industry needs.
10. Tap into the energy capital of the
world
Houston is home to more than 5,000 energy-
related frms, and it has a broad industrial
base in the energy, aeronautics and technology
industries.
Top 10 Reasons to Attend Pump & Turbo 2014
Lecture P4: A Lateral
Rotordynamics Primer on
Electric Submersible Pumps
(ESPs) for Deep Subsea
Applications
Discussion Group P11: Subsea
Pumps and Drivers
Discussion Group P1/T1:
Monitoring Vibration and
Other Critical Machine
Conditions
Tutorial P10: So What Did We
Learn About Pumps During the
Past 20 Years?
Pump Case Study (Session 18)
FEATURED TECHNICAL PROGRAM
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Te US Dept. of Energy and leading pump
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As pump systems are designed, Excess
Capacity Margin (ECM) is added to the
base fow requirement - either to compen-
sate for increased future demand or simply
as a safety margin.
Unfortuntately, ECM leads to excess
energy consumption. Because the pump is
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Air gap spacer shims can be installed to
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Te larger the air gap, the slower the load
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>> INTRODUCING
Pumps & Systems MENA provides timely and powerful technical
information to end users in the expanding pump industry of the
Middle East and North Africa region.
Design. Repair. Efficiency. Maintenance. No one covers the many facets of the pump and rotating
equipment industry like Pumps & Systems. Engineers, operators, consultants and maintenance professionals
who read our magazine know we are the number one source for technical pump information. Now, were taking
our coverage to the expanding Middle Eastern/North African region. Pumps and the systems surrounding them
are crucial to the economy and growth of this part of the world. Pumps & Systems MENA covers pumps and
related operations in every issue, bringing relevance and clarity to end users worldwide.
Bahrain
Kuwait
Oman
Qatar
Saudi Arabia
United Arab Emirates
Content will focus on these and other
Middle East and North African countries.
DISTRIBUTION
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will be distributed to
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84
EFFICIENCY MATTERS
F
or more than 50 years, air-
operated, double-diaphragm
(AODD) pumps have played
a role in many companies modern
global manufacturing and fuid-
handling operations.
Te original pump concept has
changed little over time and works
because of its simple operation and
construction.
With a major focus on operating
improvements and cost reductions
from businesses, AODD pump
manufacturers have introduced
new air distribution systems (ADS)
to increase pump ef ciency and
meet these demands. Te new ADS
technologies range from electronic
controls to mechanical innova-
tions. However, the resulting sav-
ings in compressed air usage and
increase in pump ef ciency vary
for each system.
Tis article presents the results of
head-to-head comparisons of AODD
pumps with diferent ADSs and the
fnal data acquired during those
tests. Te results help illustrate the
impact that diferent ADS tech-
nologies have on air consumption,
energy use and overall fow rate.
Te Challenge
In AODD pump operations, energy
use is directly related to the rate at
which the pumps use air to drive
each stroke during the pump-
ing cycle. With increasingly high
energy costs, facility operators un-
derstand that the initial purchase
and installation of a new pumping
system is only a small part of the
total cost of ownership (TCO) and
operation. Te routine costs of en-
ergy and maintenance remain the
primary cost drivers in the TCO.
Much like cars, pumps can be
rated according to ef ciency. Te
goal is to use the least amount of
air to pump the greatest amount of
product. Te ultimate objective is
to reduce the rate of air consump-
tion in relation to the product fow
rate and minimize the amount
of air that is not creating product
yield (therefore, wasting energy)
during the pumping cycle.
If attained, this combination can
positively impact an operations
bottom line. Te proftability is
Smart Air Distribution Systems Upgrade
Traditional AODD Pump Technology
Head-to-head comparisons show decreased compressed air use and enhanced ow.
By Carl Glauber
Manufacturers have introduced new air distribution systems to improve AODD pump efciency. (Article
images and graphics courtesy of Wilden.)

85
determined by the volume of air
being consumed and the energy
required to compress it.
In addition to wasting energy,
air overflling unnecessarily
stretches the diaphragm. Tis
stretching produces excessive
diaphragm wear, resulting in more
frequent replacement and down-
time and increased operating
costs. Although the technology
is more than 50 years old, AODD
pumps can still be made more
ef cient by recent ADS evolution.
Tese developments better control
the air fow and prevent wasteful
air overflling, which reduces air
consumption and operating and
maintenance costs.
Two primary methods control
air fow and prevent overflling
by cutting of the air supply to
the air chamber before the end
of the pump cycle: electronically
controlled and mechanically actu-
ated ADSs.
Te electronic control method
has two shortcomings. First, the
electronics raise an additional set
of maintenance and operational
concerns, including the prohibi-
tion of their use in explosive
environments, such as mines, and
an inability to be submerged.
Second, electronic ADS technol-
ogy requires a learning period
of 30 to 40 seconds during which
it monitors the operation of the
pump before it can estimate when
to cut of the air supply prior to
the end of the stroke. Tis can
result in erratic and sometimes
wasteful fow rates during the
learning period.
During the time period from
the end of each stroke to the
completed shift of the valve, the
air is allowed to overfll the
air chamber without any corre-
sponding displacement of fuid.
Tis volume of compressed air is
entirely wasted.
Te mechanically actuated
method is a simple and extremely
efective way to control the air
with each stroke and prevent
wasteful overflling.
Te air is constantly mechani-
cally controlled to maximize ef-
fciency, minimize complexity and
maintenance considerations, and
allow for operation in explosive
and submerged pumping environ-
ments.
Te Controlled Comparisons
To create real-world conditions to
measure the efectiveness of dif-
ferent ADS technologies industry-
wide, a controlled, objective
head-to-head test was arranged
comparing several AODD pumps
that were ftted with traditional,
electronically controlled and me-
chanically actuated ADSs. Com-
mon conditions of service that are
seen in the feld were replicated in
the laboratory.
Although the technology is more than 50
years old, AODD pumps can still be made
more efcient by recent ADS evolution.
The all new...
Introducing the worlds most energy efficient
pump in its class. Period.
Achieves up to a 60% savings in
air consumption over competitive
AODD pump technologies
More yield per SCFM
Easy to maintain (fewest ADS parts
of any AODD pump competitor)
See the proof at
prooshift.com/proof
Grand Terrace, CA 92313-5607 USA
T: +1 (909) 422-1730 F: +1 (909) 783-3440
www.wildenpump.com
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86
EFFICIENCY MATTERS
Tis simulated application re-
quired each pump to produce a fow
of 320 liters per minute (lpm)85
gallons per minute (gpm)against
a head pressure of 2.1 bar (30 psi).
To achieve a fair comparison be-
tween these competing pumps, each
pump was run at the inlet air pressure
needed to meet the common condi-
tion of service. Air-consumption data
was then recorded (see Table 1 for the
results for four pumps).
Te Solution
The data gathered in the objective
AODD testing show that Pump
Dwhich used the ADS that
restricts air flow into the filling
air chamber to minimize wasted
compressed airhad better
performance in all three points of
measurement.
It had the lowest air consump-
tion in standard cubic feet per
minute (SCFM), the lowest strokes
per minute and the highest volume
of fuid pumped per SCFM.
Pump D averages an overall 30
percent reduction in air consumption
compared with Pumps A, B and C.
It also provides the largest reduc-
tion in air consumption among the
four pumps while still managing
the best overall volume of fuid
moved per stroke, requiring the
fewest strokes per minute.
Te air-restricting ADS in Pump
D is a new way to look at how pneu-
matic pumps operate.
To combat overflling, the ADS
used in Pump D restricts the air
fow into the flling air chamber at
the end of the pumps stroke, which
minimizes the compressed air that
Table 1. In a controlled head-to-head laboratory test comparing eight AODD pumps operating
under common parameters seen in the eld, this sample of four illustrates Pump Ds standout
results and the wide range of energy and strokes required to achieve similar uid output.
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87
is wasted. Te air control spool of
this ADS meters the air to prevent
overflling without reducing prod-
uct yield.
Te result is decreased air
consumption with maximum
operational ef ciency and fow
rates. Unlike the electronic ADS so-
lution, Pump Ds ADS requires no
electrical power source and has no
delayed learning period after each
startup.
Conclusion
Although reliably used in appli-
cations for more than 50 years,
AODD pumps can be enhanced
to deliver greater ef ciency and
cost savings through improved
ADS technology that prevents air
overflling.
While end users understand that
AODD pumps featuring new ADS
technologies can deliver results
that support their shrinking bud-
gets and operating margins,
Table 2. Pump Ds ADS saves air consumption and energy while maintaining desired ow rate.
0
10
20
30
40
50
60
70
80
90
100
S
C
F
M
Pump A Pump B Pump C Pump D
71.8
49.5
65.8
42.6
The air control spool prevents overlling
without reducing product yield.
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EFFICIENCY MATTERS
Pump Ds ADS sets it apart from
the competition.
Tis ADS addresses the overfll-
ing waste of traditional AODD
pumps, providing considerable
savings by decreasing air consump-
tion while maintaining the same
fuid-volume output. Tis ADSs
lower strokes-per-minute rate
compared with the other systems
delivers maintenance advantages
because of the minimized wear and
tear during operation.
Carl Glauber is the Diaphragm
Pump product manager for
Wilden Pump & Engineering Co.,
LLC, Grand Terrace, California, a
manufacturer of AODD pumps.
He may be reached at carl.
glauber@wildenpump.com or
718-213-7602.
For more information, visit
www.wildenpump.com. Wilden
is an operating company
within Dover Corporations
Pump Solutions Group (PSG),
Oakbrook Terrace, Illinois. PSG
is comprised of several pump
companiesincluding Abaque,
Almatec, Blackmer, Ebsray,
Finder, Griswold, Maag, Mouvex,
Neptune, Quattroow and
Wilden. For more information,
visit www.psgdover.com.
To view a video documenting
the laboratory pump demon-
stration, visit
www.prooshift.com/proof.
This ADS addresses the overlling waste of traditional AODD
pumps, providing considerable savings by decreasing air
consumption while maintaining the same uid-volume output.
Unless youre considering Total Cost of
Ownership in your operations, the savings
promoted by your diaphragm pump
supplier may be smoke and mirrors.
ARO is the true leader when you
calculate the different factors associated
with pump applications such as price,
energy usage, repair cost and downtime.
Contact ARO to reveal your
Total Cost of Ownership.
Flow rates up to 275 GPM (1041 LPM)
ARO Tech Support: 800.483.4981 E-mail: arohotline@irco.com arozone.com
ARE YOUR PUMP
OPERATING SAVINGS
REALLY AN ILLUSION?

89
MAINTENANCE MINDERS
F
ew industries can tolerate the
unscheduled downtime of
critical equipment. In refnery
operations, it can have particu-
larly serious implications. For an
operation that runs 24 hours per
day year-round, the lossesin both
production and proftabilitycan be
staggering.
Rotating equipmentpumps, mo-
tors, compressors and pillow block
bearingsrepresents a key refnery
component that, without proper
planning, can become a refnerys
Achilles heel. Tis article presents
six tips that help prevent unsched-
uled downtime because of rotating
equipment failure.
Invest in the Right
Equipment
Flexibility is the key. What may have
been the right equipment in the
past may not be the right equipment
today. Many facilities were origi-
nally designed to handle a certain
fuid and have pumps and peripheral
systems designed to accommodate
that fuid.
Today, diferent feedstocks in a
wide array of viscosities ofer price
and proftability advantages. A refn-
ery must accommodate the diversity.
Retroftting the right pumps and
related equipment into existing op-
erations improves ef ciency. Larger,
two-screw pumps can work better
than a battery of smaller, specialized
pumps in some applications. Two-
screw pumps are rotary, self-priming
positive displacement pumps, typi-
cally double-ended or double-suction
to achieve higher fow rates.
Te screw pump design better
handles fuids with more solids
content and a product viscosity
range from 0.5 to more than 1 mil-
lion centistokes. In refneries, screw
pumps provide fexibility and quick
payback to owners.
Decontaminate Lubricants
Every piece of rotating equip-
ment in a refnery needs lubrication.
At some point, fushing, varnish
removal, reservoir maintenance and
fuid replacement will be required.
Particle contamination is the biggest
threat to rotating equipment lubrica-
tion and a leading cause of bearing
failure.
A refnerys maintenance staf is
responsible for its lubrication pro-
gram, but these specialists also have
other duties. A lubrication program
can divert time and money from op-
erations. Successful refneries often
6 Renery Pump Maintenance Tips
Outside lubrication experts help improve protocols and minimize downtime.
By Marcus Pillion
Colfax Fluid Handling
Rotating equipmentpumps, motors, compressors and pillow block bearingsrepresents a
key renery component that, without proper planning, can become a renerys Achilles heel.
(Article images courtesy of Colfax Fluid Handling.)
1
2
90
MAINTENANCE MINDERS
partner with a frm specializing in
lubrication maintenance. External
lubrication experts have experi-
ence that allows them to antici-
pate issues before they occur.
Be Honest with
Outside Experts
Any partnership with an external
maintenance frm should be
based on candor and trustlike
that of a patient and doctor. A
lubrication expert can only help
a refnery if the facilitys mainte-
nance personnel willingly shares
information on current and past
equipment operations.
Has a single pump or motor
been a problem in the recent
past, or does it create a recur-
ring issue? Do certain systems
respond diferently during
temperature changes? Honest
communication is critical from
The most common cause of failure during
the lubrication of rotating equipment and
bearings is particle contamination.
3

91
the beginning for an efective
maintenance program.
A well-equipped lubrication
partner will know what to ask
during the auditthe frst step
toward a partnership. Refnery
maintenance staf members
should brace for some tough
questions. Te more raw data
the maintenance experts have
available, the faster the audit can
be completed. Afterward, the
refnery will be one step closer
to its maintenance goal: clean,
contaminant-free lubricants
delivered in the right amount, at
the right time, for every piece of
rotating equipment.
A lubrication maintenance
program built on trust goes
beyond the basics. Te program
overlooks nothing in the lubrica-
tion process, even considering
92
MAINTENANCE MINDERS
intangibles such as a facilitys
employee safety program. Re-
fneries reap the benefts: new
lubricants; new delivery meth-
ods; and longer, more sustainable
lubricant life.
Tink Outside the Box
Facility maintenance manag-
ers often understand their lubri-
cant needs. However, an expert
may recommend new lubricants
that can help optimize rotating
equipment operation.
Changing to oil mist lubrica-
tion is an example. Oil mist is
not new. Te lubrication method
has been around for nearly half a
century. Newer oil mist systems
have replaced their older, more
wasteful ancestors, delivering
precise lubrication that extends
bearing life compared with al-
ternative lubrication methods.
Refnery owners and personnel
should consider outside sugges-
tions. At the same time, they
should pay more attention to
the ordering, storage, handling,
disposal and recycling of the
facilitys lubricants.
Often overlooked, improper
storage and handling can intro-
duce contaminants to the lubri-
cation system that may cause
facility-wide problems.

Schedule Regular
Inspections
After the maintenance partner
develops a lubrication plan, the
next step involves regularly
scheduled inspections. Te re-
sults determine how the main-
tenance program will be revised
and updated. Te plan becomes
a living document that adapts as
refnery conditions change and
new equipment and operations
are added.
Regularly scheduled inspections are required to ensure that a pre-planned
maintenance program satises the renerys operation requirements.
4
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93
Regular inspections also help
refneries manage their sustain-
ability programs, essential to any
modern-day oil and gas process-
ing operation.
Leakage oil reclamation ser-
vices alone can ofer bottom-line
benefts that include identifying
high lubricant use areas for recla-
mation and establishing purifca-
tion methods through frst- and
second-stage fltration.
A properly documented,
verifed program is critical to
complying with Environmental
Protection Agency and safety
standards.
Join the Global
Community
A partnership with a rotating
equipment and lubrication expert
can pay of and help refnery per-
sonnel learn best practices from
around the globe. What works
for a refnery halfway around the
world may be the remedy to a
dif cult problem plaguing other
facilities. Relying on a partner to
provide new ideas to optimize a
facilitys rotating equipment is
a value-added service that can
beneft the refnery in the future.
Marcus Pillion
is the director
of engineering
and marketing
for the reliability
services division
of Colfax Fluid
Handling, which owns and oper-
ates COT-Puritech, LSC, Sicelub
and Total Lubrication Manage-
ment. He may be reached at
marcus.pillion@
colfaxuidhandling.com.
6
94
MOTORS & DRIVES
M
otor manufacturers rou-
tinely answer questions
about the diferences
between submersible and immers-
ible motors and the applications
best served by each design. While
end users ultimately decide which
motor best fts their need, this ar-
ticle explains how the designs dif-
fer and provides information that
will help end users make informed
decisions.
Submersible Motors
Municipal and industrial wastewa-
ter markets use submersible mo-
tors for both wet and dry pit appli-
cations. Tese are totally enclosed,
non-ventilated (TENV) motors.
Wet pit motors use the ef uent for
cooling and are designed to run
continuously while submerged.
Tese standard designs are also
rated to run in air for 15 minutes
when conditions require it.
Tese motors can also be de-
signed for continuous operation in
dry pit applications by de-rating
a larger horsepower motor frame.
Tis allows the motor to dissipate
heat while running continuously in
a dry pit application that only ex-
periences fooding under unusual
conditions, such as heavy rains or
a backup in the system.
Submersible motors are rugged
and corrosion resistant, mak-
ing them suitable for demanding
applications. Te motors have
cast iron frames and end plates.
Most motors come standard with
316 stainless steel hardware and
416 stainless steel shaft material.
Submersible designs are available
for hazardous and nonhazardous
locations. An example of a hazard-
ous location is a sewage application
where fammable gases might be
present. Tese locations require
an explosion-proof motor design.
Explosion-proof motors are UL
(Underwriters Laboratories) listed
and CSA (Canadian Standards As-
sociation) certifed for Division 1,
Class 1, Groups C and D with a 1.0
Service Factor and T2A tempera-
ture code.
Submersible motors use cast
iron frames that are precision
machined for tight fts between
the parts. Machined fts have
grooves with O-rings to prevent
water ingress to the motor. An
epoxy flled, non-wicking cable cap
assembly protects the motor from
moisture that could enter through
the opposite drive end of the mo-
tor. Typically, two separate cables
exit the cable cap epoxy potting
compound; a four conductor power
cable and a fve conductor control
cable. Standard lengths vary from
25 to 30 feet, but other lengths are
available upon request. Tis cable
should never be used to lift the
motor.
Te drive end of submersible mo-
tors is a critical part of the design.
Since the motors are designed to
run continuously while submerged
in water or ef uent, they include
features to keep water out. An oil
flled chamber and a mechanical
The Differences Between Submersible
& Immersible Motors
How do end users choose, and what are each types ideal applications?
By Bobby Bowen
Baldor Electric Company
Many submerged motors rely on
the efuent to stay cool and run
continuously while submerged. (Article
images courtesy of Baldor Electric
Company.)

95
seal serve this function. Also,
a moisture monitoring probe is
used to detect moisture entering
the chamber.
Te drive endplate has a special
design that includes a chamber
flled with oil. Te oil acts as
a barrier to trap moisture and
provide suf cient time for shut
down if water enters the motor. It
also lubricates the upper part of
the mechanical seal.
Te mechanical seal keeps
moisture out of the motor.
Some companies use a Type 21
mechanical seal as its standard
submersible motor seal. Tis
seal uses an inner and outer
seal arrangement. It has both a
stationary face and a rotating
face. As previously stated, the
upper part of the mechanical
seal is lubricated by the oil in the
endplate chamber. However, the
lower part is lubricated by the
pumped liquid. Carbon ceramic
is the standard seal face mat-
erial and is used in applications
with relatively clean ef uent.
Tungsten carbide, which is used
with more viscous fuids, is the
most popular seal face material.
For the most demanding slurry
type applications, seal faces with
tungsten carbide are an option.
Pump manufacturers specify
what type seal is necessary.
Moisture probes are necessary
because seals wear, and the po-
tential for moisture to enter the
motor increases over time. Tis
sensing system, consisting of two
probes with a resistor between
them, is placed in the oil inside
the endplate. Te probes are con-
nected to a customer-supplied
control module that sounds a
warning alarm or shuts down the
motor if a change in resistance is
detected. Tis ensures that the
motor is shut down before any
damage occurs. Worn seals will
need to be replaced.
Tis motor confguration is
predominantly used for applica-
tions in which the motor will be
submerged at all times.
Immersible Motors
Immersible motors, on the other
hand, are specifcally designed to
be operated in a dry environment
that might food under unusual
circumstances. One companys
immersible design was developed
for an end user who needed a
more cost efective alternative
to the more expensive, oversized
submersible frame motors used
for continuous in air operation.
Immersible designs use TENV
enclosures in smaller frames and
totally enclosed blower cooled
(TEBC) enclosures on larger
frames. Tey have a sealing sys-
tem that allows reliable operation
for two weeks while submerged
under a maximum depth of 30
feet of water. Te immersible
design has been proven with ex-
Moisture probes are necessary because seals
wear, and the potential for moisture to enter the
motor increases over time.
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MOTORS & DRIVES
tensive tests, including disassembly
and inspection to ensure dryness
and structural integrity.
Te TEBC design runs continu-
ously in air and has a separate
horsepower motor running an
external fan for constant velocity
cooling. An end user-supplied foat
switch turns of the blower motor
if the water reaches a level near the
cooling fan. Te opposite drive end
is totally enclosed, and the fan and
blower motor are mounted sepa-
rately to ensure that moisture will
not enter the motor from the op-
posite drive end. Tese motors are
also built with precision machined
cast iron frames and endplates with
grooves and O-rings to prevent
water ingress to the motor.
Te drive endplate is designed to
keep moisture out by using a dual
oil seal confguration that is packed
with heavy, moisture resistant
grease. Tis endplate does not have
an oil chamber like the submersible
design.
Another mechanical feature
of the immersible design is an
explosion-proof style conduit box
that uses a sealing compound and a
non-wicking epoxy-sealed cable as-
sembly to prevent water from
entering through the electrical con-
nection at the motor. Tese motors
use the same power and control
cable confguration as the submers-
ible motor design. Other standard
features include: two normally
closed thermostats, motor space
heaters and a regreasable lubrica-
tion system.
Lastly, the immersible design has
the beneft of reducing costs over
the traditional immersible pump
confguration, which uses a non-
immersible vertical pump motor
mounted more than 20 feet above
the pump and employs a jack shaft
to reach it. Te immersible mo-
tor mounts directly to the pump.
Tis confguration eliminates the
construction and installation costs
incurred by building a motor sup-
port structure.
Conclusion
Application conditions should be
the deciding factor between im-
mersible and submersible motors.
Immersible designs are more cost
efective, but the submersible de-
sign is a better ft in an application
that requires continual submer-
gence.
Bobby Bowen is a marketing prod-
uct specialist, Denite Purpose Mo-
tors, for Baldor Electric Company. He
has been with Baldor since 2001 and
has held the positions of mechanical
designer, applications specialist and
international sales engineer.
Immersible designs have a sealing system that
allows reliable operation for two weeks while
submerged under a maximum depth
of 30 feet of water.
Immersible motors are specically designed to be operated in a dry
environment that might ood under unusual circumstances.
January/February 2014
Technology and Services for Oil & Gas Operations
TTechnology
May/June 2014
d S i f OOOOOOOOOi iiilll & G O
ations
y and Services for r OOOOOOOOOOi Oi iilll & Gas Operations
y
May/June 2014
erations
March/April 2014
Drilling
Well Completion
Froducrion Arrilcial Lilr
lls|ore Su|sea
Warer Handlin_ & Trearmenr
nsrrumenrarion, Conrrols & Monirorin_
Alrermarker Farrs & Services
Midsrream Frocesses
Secondary il Fecovery
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98
SEALING SENSE
W
hen discussing expan-
sion joint selection, the
conversation typically
focuses on the quality, durability
and capabilities of the expansion
joint. However, the expansion
joints role in the overall energy
ef ciency and optimization of the
piping system is often overlooked.
All piping systems require some
degree of fexibility. Inadequate
fexibility can lead to a catastrophic
system failure that could even be
life-threatening, making fexibil-
ity an important consideration in
expansion joint selection.
Rubber expansion joints provide
maximum fexibility with their
resilient construction and all-
directional movement capability.
Rubber expansion joints can handle
axial, lateral, angular and torsional
movements. Tey can also absorb
vibration and accommodate piping
misalignment.
Te rubber expansion joint pro-
vides these benefts in the smallest
space possible, reducing the piping
systems size and overall footprint
for greater overall energy ef ciency
and system optimization. Tis level
of performance cannot be achieved
with alternatives such as large pipe
loops, metal expansion joints or
grooved couplings.

Section-by-Section System
Optimization
Te expansion joint selection and
application process often requires a
systematic and sometimes tedious
approach. First, the proposed piping
should be divided into individual
sections (straight runs or L- or
Z-shaped bends) by choosing tenta-
tive anchor locations. Each section
can then be optimized and later
rejoined with the complete piping
system, resulting in a completely
optimized, ef cient system. Tis
process will require additional con-
sideration for the following:
Capabilities and limitations
of diferent anchor types,
including main, directional or
intermediate
Piping code (ASME B31.1,
ASME B31.3 or others)
Location of various equipment,
branch connections and space
restrictions
Available support structure and
load limitations on piping and
equipment
Operating conditions including
temperature and pressure
Amount of thermal and/or ex-
ternal movements anticipated
Need to absorb noise and vibra-
tion and to compensate for
misalignment
Need to provide access to piping
and equipment
Need to absorb shock loads
Required cycle life
Capabilities and limitations
Expansion Joint Selection Optimizes
Piping Systems
Different material and design combinations offer application-specic advantages.
By Lloyd Aanonsen
FSA member
A typical expansion joint (Article images courtesy of FSA.)

99
of diferent expansion joint
designs, including unre-
strained and restrained ar-
rangements
Unrestrained Designs
Unrestrained designs are the sim-
plestand often most economi-
calsolution to expansion joint
selection.
Tese designs primarily relieve
thermal stresses in rigid piping
systems by absorbing axial move-
ment. Te use of main anchors
with numerous guides at specifc
spacing becomes critical.

Lateral movements can be
achieved by using a directional
main anchor. Te unrestrained ex-
pansion joint will commonly have
a cycle life in the tens of millions.
The unrestrained expansion joint will
commonly have a cycle life
in the tens of millions.
A single-arch unrestrained rubber expansion joint
circle 177 on card or visit psfreeinfo.com circle 176 on card or visit psfreeinfo.com
INNOVATION CUSTOMIZED
PUMP, PELLETIZING & FILTRATION SYSTEMS
Maag Automatik Inc. 1500 Continental Boulevard Charlotte, NC 28273, USA
P +1 704 716 9000 MaagAmericas@maag.com www.maag.com
High-Quality gear
pumps for
conveying polymer
melts, chemicals
and even lubricants
Customized strand-
and underwater
pelletizing systems
for any requirements
and preferences
Filtration systems
for maximum perfor-
mance and reliability
for numerous
applications
Your partner for
pump, pelletizing
and ltration
systems
100
SEALING SENSE
It also reduces noise and vibra-
tion, compensates for misalign-
ment, and absorbs shock and an-
chor loading, provided the support
structure and adjacent equipment
does not have loading limitations.
Te joints can also provide access
to piping and equipment when
a self-retracting design or an
adjustable installed length is not
required.
Although this type of piping
system uses a very traditional
approach, other solutions are
more ef cient and eco-friendly.
Tese systems tend to occupy a
signifcant footprint and require
more piping and greater support
structure.
Restrained Designs
An alternative approach that uses
restrained designsincluding
universal, hinged, gimbal, pressure
balanced and dismantling expan-
sion jointsmay be used to absorb
axial, lateral, angular, torsional and
combined movements. Te pressure
thrust forces in these designs are
often self-restrained, allowing for
intermediate anchors and fewer
guides. Tese designs are extremely
helpful with space or structural
limitations or with load limita-
tions on piping and equipment.
A universal restrained design, for
example, relieves thermal stresses
in perpendicular runs by absorbing
lateral movements.
Restrained designs ofer many of
the same benefts of unrestrained
designs, but they have improved
energy ef ciency and system
optimization. Restrained designs
can also provide access to piping
and equipment in a self-retracting
design while allowing for additional
adjustments to the installed length.
Tese systems tend to have a much
smaller footprint because the pip-
ing length, pumping requirements
and need for structural support are
greatly reduced.
Conclusion
Each expansion joint arrangement
has characteristics that make it par-
ticularly suitable for a given applica-
tion. In some cases, two or more
solutions may be possible, allowing
the designer to maximize energy
ef ciency and system optimization.
While the arrangements covered in
this article are the most common,
a combination of materials and de-
signs is available to create the most
efective solution for even the most
demanding application.
Next Month: What are the
benefts of the new plan 03?
We invite your suggestions for article topics as
well as questions on sealing issues so we can
better respond to the needs of the industry.
Please direct your suggestions and questions to
sealingsensequestions@fuidsealing.com.
Restrained designs offer many of the same benets
of unrestrained designs, but they have improved
energy efciency and system optimization.
Universal restrained design
102
HI PUMP FAQS
What are some
differences between
specic speed and
suction specic speed for
a rotodynamic pump?
Te Hydraulic Institute defnes
specifc speed as an index of pump
performance (developed total head).
It is determined at the pumps best
ef ciency point (BEP) rate of fow,
with the maximum diameter impeller
and at a given rotative speed. Specifc
speed is expressed by the following
equation:

n
s
=
n(Q)
0.5
(H)
0.75
Where:
n
s
= specifc speed
n = rotative speed measured in
revolutions per minute
Q = total pump fow rate measured
in U.S. gallons per minute
(cubic meters per second)
H = head per stage
measured in feet (meters)
It should be noted that
when calculating specifc
speed using units of cubic
meters per second for fow
rate and meters for head per
stage, 51.6 is the conversion
factor for specifc speed in
U.S. gallons per minute and
feet (metric 51.6 = U.S.
customary units).
Te usual symbol for
specifc speed in U.S.
customary units is N
s
.
Suction specifc speed
is an index of pump
suction operating characteristics.
It is determined at the BEP rate of
fow with the maximum diameter
impeller. (Suction specifc speed
is an indicator of the net positive
suction head required [NPSH3]
for given values of capacity and
also provides an assessment of a
pumps susceptibility to internal
recirculation.) Suction specifc
speed is expressed by the following
equation:

S =
n(Q)
0.5
(NPSH3)
0.75
Where:
S = suction specifc speed
n = rotative speed, in revolutions
per minute
Q = fow rate per impeller eye
measured in U.S. gallons per minute
(cubic meters per second)
= total fow rate for single suction
impellers
= one half of total fow rate for
double suction impellers
NPSH3 = net positive suction head
required in feet (meters) that will
cause the total head (or frst-stage
head of multistage pumps) to be
reduced by 3 percent
When suction specifc speed is
calculated using cubic meters per
second and meters, the conversion
factor to suction specifc speed in U.S.
gallons per minute and feet is 51.6.
Te U.S. customary symbol N
ss
is
sometimes used to designate suction
specifc speed.
For more information about
specifc speed and suction specifc
speed, see ANSI/HI 1.1-1.2
Rotodynamic (Centrifugal) Pumps for
Nomenclature and Defnitions.
Understand Specic Speed & Disc Diaphragm
Pump Coupling
By Hydraulic Institute
Figure 1. Mechanically coupled disc diaphragm

103
How do mechanically
coupled and hydraulic
coupled disc diaphragm
pumps differ?
A mechanically coupled disc
diaphragm liquid end contains a
fexible, round diaphragm, which is
clamped at the periphery and in direct
contact with the process liquid being
displaced (see Figure 1, page 102). Tis
type of design is inherently leak free.
Te diaphragm material is typically
a fuoropolymer, elastomer or
fuoropolymer-elastomer composite.
A connecting rod is connected directly
to the diaphragm. Te diaphragm is
not pressure balanced because the
process pressure is acting on one side
of the diaphragm and atmospheric
pressure is acting on the other side.
Tis results in higher stress levels
in the diaphragm. Terefore, these
pumps are typically used for lower
pressure applications. In operation,
the process liquid is admitted through
the suction check valve as the
diaphragm/connecting rod assembly
moves away from the wet end. As
this happens, the suction check valve
closes and the discharge check valve
opens, discharging liquid.
A hydraulic coupled disc diaphragm
liquid end contains a fexible, single
or double confguration diaphragm,
clamped at the periphery and in direct
contact with the process liquid being
displaced (see Figure 2). Tis liquid
end design is also inherently leak
free. Liquid end designs featuring
fexible metallic diaphragms are
available. Tese diaphragms are used
in applications where severe operating
conditions prohibit the use of
fuoropolymer or other elastomers.
In operation, the diaphragm is
moved by a hydraulic fuid, which
is displaced by a reciprocating
plunger or piston. Te stresses in
the diaphragm are minimal because
the process pressure acting on one
side of the diaphragm is balanced
by the hydraulic pressure acting on
the opposite side. Te process liquid
is admitted through the suction
check valves as the diaphragm moves
rearward. As the diaphragm moves
toward the wet end, the suction check
valve closes, and the discharge check
valve opens and discharges liquid.
Liquid end designs may include
provisions such as contour plates,
springs or diaphragm positioning
hydraulic control valves to ensure the
diaphragm does not move beyond its
elastic limits (see Figure 3).
For additional information
regarding various controlled-volume
metering pumps, see ANSI/HI 7.1-7.5
Controlled-Volume Metering Pumps for
Nomenclature, Defnitions, Application,
and Operation.
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.
Figure 2. Hydraulic disc with contour plates
Figure 3. Hydraulic disc with diaphragm positioning valve
S
ulzer has long been a leading service provider for
rotating equipment due to a continued commitment to
deliver advanced, customized service solutions. In an effort
to expand on that commitment and provide customers with
a full portfolio of services, Sulzer has integrated Sulzer
Pumps CSS, Sulzer EMS, and Sulzer Turbo Services
into a single Rotating Equipment Services division. The
new division combines services for pumps, motors,
generators, turbines, and compressors, and expands
Sulzers geographical footprint to over 100 service centers
worldwide.
As a third-party service provider, Sulzer aims to offer
customers an alternative approach to maintenance,
repair, overhauls and upgrades. By leveraging combined
capabilities and integrated service centers, Sulzer is able
to provide customers with a single access point for service,
eliminating the need to source separate vendors for varying
types and brands of rotating equipment.
Pumps
No matter how simple or complex the machine, Sulzer
is dedicated to improving customers pumping systems
and operational reliability. At our expansive network of
service centers, an expert team of engineers and repair
staff respond to industry needs and focus on ensuring the
highest performance for your equipment. Pumps services
include engineered repairs, retrofts, and feld services.
Sulzers Pump Equipment factories are also available to
provide support with spare parts programs, performance
and system analysis, and operation and maintenance
training.
Electromechanical Equipment
With fve electromechanical shops in North America, Sulzer
specializes in a full range of electrical and mechanical
rotating equipment repairs. Services include complete
rotor and stator rewinds and in-shop or onsite mechanical
repairs.
Turbomachinery
Sulzer is recognized as a technically advanced service
provider for turbomachinery. With over 30 years of
experience and continuous investment and development of
in-house repair processes, we are able to provide unrivalled
responsiveness and superior service. Our service centers
feature capabilities ranging from component repair and
parts manufacturing to specialty coatings and at-speed
balancing.
To discover Sulzer Rotating Equipment Services, contact
your local Sulzer representative or visit us at www.sulzer.
com.
Sulzers integrated services division gives customers a new approach to
rotating equipment repair
www.sulzer.com
A New Vision in Service
Sulzer is the leading service
provider for rotating equipment.
Our customized and innovative
solutions help reduce maintenance
time and cost, and improve the
effciency and reliability of your
equipment.
When pumps, generators, electric
motors, turbines, and compressors
are essential to your operations,
you need a service partner you can
trust.
Contact us today to discover your
best service solution.
Sulzer Pump Services (US) Inc.
11518 Old La Porte Rd
La Porte, TX 77571
Phone +1 713 567 2700
www.sulzer.com
Your Service Solution
for Rotating Equipment
106
PRACTICE & OPERATIONS
Energy Efcient Vertical Turbine Pumps
Promote Sustainable Mining Efforts
The computational uid dynamics process advances highly efcient pump
designs for difcult applications.
Fetar DstojIc
NUO 'U^
E
nergy is a strategic input for
the mining industry in Latin
America and worldwide.
Mining requires large amounts
of energy, which drives up total
operational costs. In Chile, mining
companies consume 34 percent of
the total energy produced in the
country and spend approximately
20 percent of their total income on
electricity costs.
According to of cial mining
sources, the copper mining indus-
try is expected to consume 41.1
terawatt-hours (TWh) in 2025, an
increase of 95.5 percent from 2013.
New projects alone will consume
36.2 percent by 2025.
Te worlds biggest copper com-
panies use concentration plants
which are energy intensive and use
the worlds biggest pumpsas their
main production process. In 2013,
concentration plants represented
48.6 percent of the total energy
consumption for the copper min-
ing industry, which is expected to
increase to 64.2 percent by 2025,
reaching 26.4 TWh.
Water is another major concern
in the mining industry. Freshwater
restrictions from scarcity or govern-
ment policy will have an impact
on water availability for future
mining projects. Because of these
restrictions, desalination plants
and seawater pumping systems are
also expected to reach 6.2 TWh,
representing up to 15 percent of the
industrys total energy consump-
tion.
Pump Stations
Several studies have shown that
pumps account for approximately
25 to 32 percent of total motor
energy consumption on an average
industrial site. Governments from
diferent mining countries are con-
sidering applying strict energy ef -
ciency policies to mining companies.
Tese policies will seek signifcant
reductions in carbon emissions and
immediate optimizations (up to 10
percent in Chile, the worlds largest
copper producer).
In recent years, motor manufac-
turers have accomplished great re-
sults regarding energy ef ciency, up
to 96 percent. However, this has not
been the case for the pump industry.
In this new energy-ef cient and
carbon-reduction scenario, pump
designers and manufacturers will
play a key role in delivering highly
ef cient pumps. Energy represents
up to 90 percent of a pumps life
cycle cost, making pumps and pump
stations a huge opportunity to im-
prove energy ef ciency and reduce
carbon dioxide emissions in the
mining industry.
Vertical Turbine Pumps
Vertical turbine pumps (VTP) are
some of the most versatile and reli-
able pump designs in the turboma-
chinery industry. Teir minimal
space requirement, highly ef cient
semi-axial design and pro-gravity
vertical arrangement have made
this type pump popular in several
industries, particularly mining be-
cause of their compact size and ease
of maintenance.
In recent years, engineering and
design capabilities have improved
through mechanical and hydraulic
Image 1. Vertical turbine pump designed using CFD

107
simulation software, advanced
manufacturing technologies
such as three-dimensional (3-D)
printing and computer numeri-
cal control (CNC) machining as
well as the extensive use of
special metallurgies. Tese
changes have allowed
pump manufacturers to
take this pump type to a
new level. Engineers can cus-
tom design vertical turbine pumps,
such as high-head/capacity pumps
or pumps for the transportation
of highly corrosive and abrasive
fuids for heavy-duty applications,
while maintaining the designs
highly ef cient characteristics and
operational advantages.
Energy-Ef cient
Pump Design
Hoping to increase its production,
one copper producer decided to
double its concentration plants
reclaim water pumping capacity.
However, the water quality was a
challenge for most pump manufac-
turers. Te water had a high solids
content concentration, about 20
percent, and high concentrations of
chlorides, about 60,000 milligrams
per liter (mg/L).
Te companys previous pumping
station consisted of 10 standard
short-set vertical turbine pumps
with a capacity of 1,500 cubic
meters per hour (m
3
/h) and a total
dynamic head of 80 meters (m).
Each cast-iron pump had ef cien-
cies below 80 percent. Tis pump
confguration was a poor ft for
this highly corrosive and abrasive
application, requiring operators
to repair and replace these pumps
every three to fve months.
Assisted by computational fuid
dynamics (CFD) and fnite element
analysis (FEA), a pump manufac-
turer custom designed a vertical
turbine pump that met all the re-
quirements for this abrasive service
(see Image 1).
Te pump was designed for a ca-
pacity of 3,100 m
3
/h and a total dy-
namic head of 90 m, obtaining an
ef ciency of 85 percent. Because of
the highly abrasive potential of the
water, the pump was designed to
run at a low speed of 995 rotations
per minute (rpm) or 50 hertz. Te
low speed diminished the abrasive
wear of its internal parts, which
in the case of centrifugal pumps,
is known to be proportional to the
cube of the particles fow velocity.
Because the pump was for a
short-set application, some special
design considerations were neces-
sary to guarantee reliability and
long operational life. All the bear-
ings and wear rings use advanced
polymeric materials with better
lubrication properties. An indepen-
dent axial thrust bearing assembly
supports the pumps thrust and
protects the motor from any dam-
age during startup and operation.
Flanged column pipes ensure pump
and shaft straightness during
operation. A reinforced suction bell
and strainer minimize suction sub-
mergence and prevent the entrance
of large solid particles.
To protect the pump from the
highly corrosive and abrasive water,
duplex 2205 stainless steel was
specifed for all the wet parts of
the pump design. Tis material is
a combination of austenitic and
ferrite stainless steel. It is ideal
for chloride-containing environ-
ments because of its resistance for
localized corrosion types such as
intergranular, pitting and crevice.
Because of this feature, it provides
a better performance than 316L or
Image 2. Vertical turbine pump completely casted in duplex 2205 stainless steel (Article images
courtesy of Neptuno Pumps.)
108
317L stainless steels. It is also re-
sistant to chloride stress corrosion
cracking (SCC), so it was the right
choice for this highly corrosive ap-
plication (see Image 2).
High resistance to fatigue, abra-
sion and erosion also made the ma-
terial suitable for this project. Its
combination of moderate hardness
and high toughness is ideal for the
pumping of water with high solid
concentration.
Te internal geometry of this
CFD-validated pump design was
then 3-D printed directly from
the 3-D computer-aided design
(CAD) fles to strictly maintain all
of its mechanical and hydraulic
characteristics, which ensure its
highly ef cient performance. Tis
3-D printed pump model was cast
using advanced investment casting
technologies by the pump manufac-
turer in-house to guarantee perfect
reproduction and a smooth surface
fnish, both signifcant factors
when striving for high ef ciency.
Te pump was then assembled
and tested. Results showed that the
error between CFD simulation and
the actual pump performance test
was lower than 3 percent. Tis
was well within the 5 percent
allowable tolerance that ISO
9906 for pump performance
tests specifes for ef ciency in its
Grade 2B.
Te installation of these
pumps allowed the end user to
double reclaim water pumping
capacity, reaching approximately
31,000 m
3
/h, with 50 percent
fewer pumps than would have
been required with the previous
pump model. Te new model in-
creased the users system reliabil-
ity with a heavy-duty metallurgy
capable of withstanding this highly
abrasive and corrosive application
for 10 to 12 months before repairs
or replacement become necessary.
Te pump system ef ciency showed
an improvement of approximately
5 percent, reducing energy costs as
well as carbon dioxide emissions to
the atmosphere (see Image 3).
Sustainable Mining
Energy ef cient vertical turbine
pumps are the future for the min-
ing industry because they address
two major issues for todays sus-
tainable mining: energy and water.
New design and manufacturing
technologies, such as CFD/FEA
simulations and 3-D printing, play
a key role in delivering energy-ef -
cient vertical turbine pumps. Tese
pumps can help mining companies
operate sustainable processes and
save them money by improving
their systems reliability and reduc-
ing energy costs. Tey also demon-
strate a focus on the environment
and the mines surrounding com-
munities by reducing the carbon
emissions of the pumping systems
across their entire process.

109
Image 3 (far left). Three vertical turbine pumps in the Andes
Mountains, each with a 3,100-m
3
/hcapacity
Image 4 (left). 1,500-horsepower vertical turbine pumps operating in
parallel in northern Chile at one of the worlds largest reclaimed water
systems
Image 5 (above). Vertical turbine pump arriving at a high-elevation
copper mine in northern Chile
Petar Ostojic is the project and product manager at Neptuno
Pumps based in Iquique, Chile. He earned his Master of Science
in mechanical engineering from the University of Wisconsin-
Madison. Ostojic may be reached at projects@neptunopumps.
com or +56 57 424685. For more information, visit
www.neptunopumps.com or follow the company on
Twitter, @NeptunoPumps.

110
L
iquefed natural gas (LNG) is
natural gas in a liquid form
that is clear, colorless, odor-
less, non-corrosive and non-toxic.
It is produced when natural gas is
cooled to minus 259 F (-161.66 C)
through a process known as lique-
faction.
During this process, the natural
gaswhich is primarily methane
is cooled below its boiling point, and
certain concentrations of hydrocar-
bons, water, carbon dioxide, oxygen
and some sulfur compounds are
either reduced or removed.
LNG is less than half the weight
of water. If spilled on water, it will
foat and then immediately vaporize
if under atmospheric pressure.
LNG Uses
LNG has been used as a clean burn-
ing alternative in power plants and
in thousands of vehicles for decades.
With the substantial growth of
the LNG fuels industry around the
world, the opportunity to use LNG
as a cleaner and lower-cost vehicle
fuel in transportation feets and
heavy horsepower equipment con-
tinues to grow.

LNG Benefts
LNG has many benefts when com-
pared with other fossil fuels. It is
less expensive, has fewer emissions,
and is safer and less likely to ignite.
Cost
On average, LNG costs about 50
percent less than gasoline or diesel
fuel and delivers the same power
and performance. According to the
Federal Reserve Economic Database,
in 2010, the U.S. spent $552 billion
on oil alone, and 61 percent of that
was imported. A 50-percent savings
could bring many benefts.
Emissions
Natural gas is the cleanest burning
fossil-based fuel with 50 percent
lower CO
2
emissions than the next
best option. LNG burns almost com-
pletely, leaving only a small amount
of carbon dioxide and water behind
(CH
4
+ 2O
2
= CO
2
+ 2H
2
O).
LNG produces up to 90 percent
lower emissions than gasoline or
diesel. LNGs reduced amount of
greenhouse gases makes it the clean-
est internal combustible fuel for our
environment. It also burns cleaner
inside engines, resulting in fewer
oil changes and less maintenance.
By replacing the traditional diesel
engine of one 18-wheeler with an
LNG engine, its carbon footprint
reduction is equivalent to removing
324 automobiles from the road.
Safety
LNG is lighter than air. In the event
of a spill, LNG disperses quickly,
unlike petroleum-based fuels that
pool on the ground and create a fre
hazard. It also has a higher ignition
temperature, making it less fam-
mable than gasoline or diesel. In
addition, LNG is non-toxic and non-
Specic Pump & Valve Features Serve Liqueed
Natural Gas Applications
LNG benets have increased the demand for this cleaner burning fuel and
associated production and distribution equipment.
By Gobind Khiani
Fluor Canada Ltd.
The LNG process
Transportation
Refrigeration
Liquefaction
Storage &
Loading
Transportation
& Marketing
Mercury & H
2
S
Removal
CO
2
Removal
Dehydration
Condensate
Removal
Treatment

111
corrosive and will not contaminate
ground water.
Abundance
Canada and the U.S. sit above large
natural gas reservoirs. Some ana-
lysts believe that these reservoirs
contain four times the energy held
in the oil felds of Saudi Arabia.
During the last fve years, shale
reservoirs have revealed natural gas
deposits that doubled previously
estimated recoverable reserves.
Other Benefts
Additional LNG benefts include:
RangeLNG is the only op-
tion for a truck that needs to
travel more than 200 miles.
Compressed natural gas (CNG)
trucks must add multiple tanks,
which increase the vehicles
weight and cost to attain the
same range as an LNG truck.
PressureLNG systems oper-
ate at lower pressure than CNG
[25 to 200 pounds per square
inch (psi) for LNG versus 3,600
psi for CNG].
StorageAs much as 2.5 times
more LNG can be stored in the
same space as conventional
CNG systems, increasing fuel
ef ciencies and range.
HorsepowerLNG ofers
engines that are more than 400
horsepower.
Fuel economyLNG provides
better fuel economy. CNG is
historically 12 to 18 percent
less ef cient.
WeightLNG is denser than
CNG, so more fuel can be stored
in smaller, lighter tanks that
increase ef ciencies.
Fueling speedLNG fuels as
fast as diesel, at 40 gallons per
minute. CNG slow fll takes 6
to 8 hours and fast fll takes 30
to 45 minutes. In addition, only
half of the tank can be flled
because of heat and pressure
buildup. If a feet operates more
than one shift, CNG is not a
viable fuel because the vehicles
will take too long to fuel.
Design Features of Pumps
Used in LNG Applications
Pumps used in LNG service are
integrally mounted on the same
shaft as the motor, which is
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112
submerged without coupling or
mechanical seals in the LNG liquid.
For a retractable in-tank application,
the pumps can be installed inside
the LNG storage tanks in vertical
pump columns with foot valves at
the bottom. Tis removes the pos-
sibility of tank leakage because of
piping or other external problems.
Te pump retraction system permits
the unit to be safely removed from
an operational tank without venting
gas vapor to the atmosphere.
By enclosing the entire unit
within a suction vessel built to an
appropriate pressure vessel code,
such as American Society of Me-
chanical Engineers Standard VIII,
the system becomes safe and simple.
Te pump is factory aligned. It has
no couplings and no auxiliary piping
for seal purge, bearing cooling or
lubrication. Tis makes it a light-
weight, uncomplicated installation.
Key factors to consider for LNG
application pumps are:
Lubrication and cooling systems
Trust equalizing mechanism
Bearing confguration
Junction box assembly and elec-
trical penetration
Cryodynamic inducer design
Vibration monitoring system
Design Features of Valves
Used in LNG Applications
Valves used in LNG service are
designed with an extended bonnet to
avoid freezing the packing at operating
temperatures. Tis allows operations
to cycle valves as required. Valves
manufactured for cryogenic applica-
tions should comply with type tested to
British Standard 6364 or an equiva-
lent standard. Nonmetallic materials
should be restricted to polytetrafuoro-
ethylene (PTFE) and graphite.
Fire-safe design to prevent
internal leakage is achieved by us-
ing resilient sealing materials that
do not decompose or deteriorate
during a plant fre. Te edge of the
metal seat retainer preloaded by the
seat spring comes into contact with
the ball (in a ball valve) to shut of
the line fuid to minimize internal
leakage through the valve bore. Te
seat retainer also compresses. Te
fexible graphite retainer packing
prevents fuid leakage between the
valve body and the seat retainer.
A bidirectional fow sealing
mechanism is employed so that
each of the upstream and down-
stream seats of the valve adequately
contacts the ball with a seat spring.
Line pressure further maintains this
contact method. Te cavity pressure
relief is designed to avoid trapped
volatile liquid releasing into the
downstream fow.
Key factors to consider for valves
in LNG applications are:
Extension bonnetTe
thermal conduction and heat
transmission from the low
temperature fuid should be
suppressed to a minimum while
a cooling efect is provided. Te
packing is not exposed to the low
temperature liquid, and a secure
seal is achieved.
Surface hardening treat-
mentTreatment with stellite
alloy is recommended for better
performance.
Cavity pressure reliefTis
feature should be included.
Seat lappingSeat lapping is
done to achieve bubble-tight zero
leakage when closing a valve. Af-
ter machining a seat to achieve
mirror fnish the seat is lapped
on the lapping machine.
Stem binding prevention
Tis is achieved by having a back
seat in PTFE + PFA (form of fuo-
ropolymer) construction bush.
Low emission type packing
Tis helps avoid compression
creep stress thats caused while
packing stem with packing.
DesignTe design needs to
accommodate the prevention of
abnormal pressure within the
cavity. It should also be designed
to have little to no pressure loss
and be fre-safe.
Gobind Khiani is a professional
engineer with Fluor Canada Ltd. He
has been in the energy and power
business for more than 18 years
and has worked in three countries
(the U.K., United Arab Emirates and
Canada) with more than 10 years in
the Western Canadian oil and gas
industry based in Calgary, Alberta.
He graduated from the University
of Poona in India and completed
his masters in materials and me-
chanical engineering from Schulich
School of Engineering at the
University of Calgary, Alberta. He is
a registered professional engineer
in the provinces of Alberta and Sas-
katchewan. Khiani can be reached
at gobindkhiani@gmail.com.
By replacing the traditional diesel engine of one
18-wheeler with an LNG engine, its carbon
footprint reduction is equivalent to removing
324 automobiles from the road.

113
114
W
hen dealing with a
construction site that
is underwater or where
the water table is just above sea
level, contractors must ensure
that the excavation stays dry and
safe for workers. Tis can be even
more challenging in locations with
conditions afected by water depth
and complications like silt and
sand.
Additionally, these dif cult con-
ditions may vary during seasonal
weather or with the tides. Contrac-
tors need to investigate historical
data and monitor fuctuations in
water levels and speeds of fow to
decrease the risks for workers and
ensure the success of the project.
Te contractor must decide
what pumping equipment to use
based on the hydraulic conditions.
Jobsite conditionssuch as fow
required to mitigate water seepage,
depth of a cofer dam and solids
contentinfuence this decision.
Te contractor usually chooses
between self-priming centrifugal
pumps or submersible pumps.
Self-Priming
Centrifugal Pumps
One weakness of end-suction
centrifugal pumps is their poor
performance when the liquid is
below the pump centerline. Liquid
must be delivered to the pump
so the process can begin. Air on
the suction side of the pump (the
piping and pump casing) needs to
be completely evacuated. If any
air remains in a centrifugal pump,
the pump becomes air bound and
incapable of functioning.
Te self-priming centrifugal
pump, a specialized end-suction
design, creates a vacuum at the
impeller eye to continuously
remove air from the suction line.
Te pump cannot compress the
air during the priming phase, so
the air must be allowed to escape
through the discharge. As air is
removed, atmospheric pressure
forces water through the suction
piping to the pump, allowing the
pump to operate.
Tis self-priming process occurs
automatically once the pump is
started with the initial quantity
of liquid. Sand or solids in the
pumped liquid can complicate the
priming process. Te practical
suction lift limit for self-priming
pumps is about 8 meters (26 feet)
of liquid under ideal conditions.
Self-priming centrifugal pumps
have disadvantages. Any small
vacuum leaksuch as sealing
areas around connectors in the
suction line or pump sealscan
prevent the unit from priming.
Te pump will continuously
pull air from the leak instead of
the air in the suction line, which
keeps the priming cycle from being
completed. Tese leaks are a com-
mon cause of priming failure. Tey
Dewatering Pumps Handle Sand Slurries
in Post-Hurricane Recovery
Reconstruction and infrastructure upgrades require pumps made from durable materials.
By Mike Bjorkman
BJM Pumps
Rebuilding and damage repair after a hurricane or major storm can take years of hard work
and millions of dollars to complete. (Article images courtesy of BJM Pumps.)

115
can be very small or invisible to the
naked eye but still prevent priming.
Te diameter and length of the
suction hose or pipe can also afect
the priming cycles length of time
because of the volume of air that
must be evacuated during pump
priming. Tis extended priming
time can also add heat to the liquid,
which further extends prime time.
Self-priming pumps need to be
as close as possible to the water
source. A location directly above
the cofer dam with few restrictions
reduces friction. Tis can present
problems, depending on the excava-
tion location.
Once the pump is primed and
moving fuid, it will require ad-
equate net positive suction head
(NPSH) to continue pumping with-
out suction limitations.
Without suf cient NPSH, a self-
priming centrifugal pump can ex-
perience cavitation and lose prime.
Lifts through long suction lines,
especially lines containing obstruc-
tions, can be plagued by cavitation
problems that cause unacceptable
noise levels and possible equipment
damage.
If a self-priming pump must lift
water 15 feet or more from the
source to the pumps suction, the
pump capacity could be decreased
signifcantly.
Most self-priming centrifugal
pumps in remote applications
have engine drives. Tese drives
can present their own operational
issuessuch as maintaining fuel
levels for long run times, the en-
gine oil condition and other prime
mover maintenance issues.
Submersible Pumps
Submersible pumps ofer many
operational and application advan-
tages. Tese pumps are submerged
directly into the water for imme-
diate use and unit cooling. Tis
eliminates priming challenges and
extended prime times.
No worker intervention is re-
quired. Te pump is fed without the
need for a suction line.
Submerged pumps are quiet. Cav-
itation is rare and occurs primarily
when the sump is too small for the
installed submersible pumps size.
Tey are also lighter weight and
portable.
Te versatility and low mainte-
nance of submersible pumps make
them an ideal option for dewater-
ing service. No regular mainte-
nance is necessary.
Submersible pumps usually need
to be fully submerged. Te water
around a submersible pump actu-
ally cools the motor.
A storm surge attacks a seawall that protects a coastal city.
116
Case Study:
Reconstructing Galveston
Te sea level along the Gulf Coast
is rising faster than most places
on the globe. Galveston, Texas,
has experienced a 3-foot rise since
the disastrous food of 1900 that
killed thousands of people.
One of the toughest jobs in
rebuilding the infrastructure of a
city that is just a few feet above sea
level is keeping water out of the
construction siteparticularly wa-
ter that is laden with sand. Pump-
ing a water/sand slurry is tough on
pumps, especially aluminum dewa-
tering pumps. Boyer Construction
experienced this condition while
working in Galveston.
Galveston Island, located in
Southeast Texas, runs west to
east and is slightly tilted to the
northeast end, where the city of
Galveston is located. Te north
side of the island opens up to a
protected harbor, and the southern
side faces the Gulf of Mexico.
Before the 1900 hurricane
which still holds the record of
the most deadly natural disaster
in American history with 6,000
deathsthe highest point in
Galveston was 9 feet above sea
level.
After the 1900 hurricane, a
17-foot high, 3-mile long seawall
was built to protect the city and
its people from other storms. Te
entire city was raised to the edge
of the seawall. Ten the island was
sloped down 8 feet above sea level
on the north side, so that water
rising over the seawall would drain
into the bay. Tis engineering feat,
which took more than 10 years,
Dewatering pumps keep construction sites dry in high water table areas.

117
was accomplished by pumping a
sand and seawater slurry under ex-
isting buildings to raise the island.
Te seawater ran of, leaving the
sand and building up the island.
Since then, Galveston has experi-
enced other hurricanes, but none
have had the same impact as the
great 1900 storm.
In September 2008, Hurricane
Ike devastated Galveston Island
along with the Bolivar Peninsula
and Gilchrist, Texas, with sus-
tained winds of 110 miles per
hour, and a 22-foot storm surge.
Property damage was estimated at
$29.5 billion, and 135 people died
in the U.S. because of the storm.
Te downtown area of Galveston
had 6 feet of standing water in the
aftermath.
As is always the case after a hur-
ricane impacts a populated area,
the rebuilding and damage-repair
efort took years of hard work and
millions of dollars. One of the
companies that worked to rebuild
Galveston was Boyer Construction.
Boyer Construction is a 20 year-
old construction and engineering
company specializing in civil,
electrical, mechanical and inland
marine construction projects.
Based in northwest Houston, more
than 250 engineers, master electri-
cians and plumbers, equipment
specialists, and skilled fabricators,
have worked on rehabilitation and
infrastructure replacement projects
throughout southeast Texas.
Many of those projects, includ-
ing those in Galveston, required
dewatering pumps on cofer dams
and large excavation jobs. Tese
demanding services require con-
tinual operation, pumping water
that is often laden with silt and
sand. Te combination of continual
cycling with salt and brackish water
minimizes the life of most dewater-
ing pumps.
Looking for help in keeping their
dewatering pumps from wearing
and failing, Boyer Construction
contacted a pump specialist. Te
expert recommended a series of
hard metal dewatering pumps.
Te chosen pump ofered the
fow range and high lifts required
for a broad spectrum of applica-
tions. From 2 horsepower with
fows up to 180 gallons per minute
(gpm) and heads up to 55 feet to 10
horsepower with fows up to 475
gpm and heads up to 117 feet, the
series of pumps is designed and
constructed for harsh services. Te
impeller and wear plate are made
of abrasion resistant chrome iron,
while the agitator and volute are
constructed of hardened ductile
iron, making the pump appropri-
ate for the salt/sand slurry and
solids-laden water Boyer Construc-
tion would encounter. Te integral
agitator is designed to mix settled
solids with pump water to maintain
a steady solids concentration and
discharge volume.
Conclusion
Every jobsite has a specifc set of
pumping conditions. Selecting the
optimum pump for the service
takes the collaboration of a com-
petent contractor and a hydraulic
specialist. Te right choice of
equipment can make a substantial
impact on the timely completion of
the project and the end users bot-
tom line results.
Mike Bjorkman is vice president of
BJM Corp. and has more than 30 years
of experience in the pump industry.
He serves as director of marketing
and IT for BJM Pumps, LLC, and All
Test Pro, LLC. Both companies are
subsidiaries of BJM Corp. He may be
reached at 860-399-5937.
BJM Pumps supplies electrical
submersible pumps to industrial
and municipal markets throughout
the U.S., Canada and South America.
For more information, visit www.
bjmpumps.com.
Boyer Contractors and Engineers
provide timely and cost-effective
solutions for the rehabilitation and re-
placement of infrastructure. For more
information, visit www.boyerinc.com.
Pumps of Houston is a distributor
of water and wastewater pumping
equipment that provides customer-
driven solutions. For more informa-
tion, visit www.pumpsofhouston.com.
One of the toughest jobs in rebuilding the infrastructure of a city
that is just a few feet above sea level is keeping water out of the
construction site particularly water that is laden with sand.
118
PRODUCT PIPELINE
SPM Instrument Inc.
Te Leonova Emerald is a compact,
powerful vibration analyzer in a
carbon fber reinforced casing for
the harshest environments. Fast
Fourier transform vibrations plus
shock pulse for bearing analysis,
infrared temperature, laster tachometer, an electronic
stethoscope, voice recording and user friendly software
are ofered with this monitoring instrument.
Vibration Analyzer
Circle 201 on card or visit psfreeinfo.com
KSB
Te SALINO Pressure
Center combined four
main components
into a single, compact
reverse osmosis system:
a high-pressure pump,
an energy recovery
device, a booster pump and an electric motor. Tis four-
in-one technology and its space-saving design make the
SALINO Pressure Center ideal for decentralized use in
small- and medium-sized containerized systems.
Reverse Osmosis System
CAT Pumps
Te company engineers
high-pressure triplex
pumps that feature
lubricated and cooled
seals for maximum
service. Concentric, high-
density, polished, solid
ceramic plungers provide
a true wear surface that
extends seal life. Te 316
stainless steel manifolds
are designed for strength
and corrosion resistance.
Plunger Pump
Circle 205 on card or visit
psfreeinfo.com
Gas Clip Technologies Inc.
Te Multi Gas Clip (MGC) Pump
portable multi-gas detector has an
internal pump that can run for a work
week without a charge. Low-power
photometric technology allows the
MGC Pump-IR to run fve days without
having to recharge the battery and
only requires calibration in six-month
intervals.
Portable Gas Detector
Dwyer Instruments Inc.
Te new Series CDTA
communicating detector
combines carbon dioxide,
humidity, temperature,
occupancy override and
temperature set point
measurements in one
compact device. Carbon dioxide measurements are taken
using Dwyers Single-Beam, Dual-Wavelength Non-
Dispersive Infrared sensor. Humidity is measured using
a capacitive polymer sensor, and the temperature is
recorded by a solid state band gap sensor.
Carbon Dioxide Detector
Singer Valve
Single rolling diaphragm (SRD)
technology has been added
to the 106/206 PGM Valve
Series. Te 106/206 PGM Series
Control Valves are designed for
particularly sensitive applications
or situations in which the
valves are dif cult to access
and maintain. Tey provide an
integral back-up control and the
ability to signal should the desired function move of-
limits. Tey can also provide an independent override.
Control Valve
Hayward Flow Control
Te patent-pending BYV Series Butterfy Valve incorporates advanced thermoplastic design and
construction for butterfy valves. Available in multiple thermoplastic materials and sizes from 2
to 12 inches/DN50-300, the BYV Series has a robust, one-piece body construction and is lighter
weight than metal valves of equal size.
Buttery Valve

119
Sulzer Pumps Ltd.
Te cooling water pump (CWP)
range type SJT/SJM are
engineered-to-order, single-
stage, mixed-fow vertical pumps
with semi-open impellers,
available in sizes starting from
750 millimeters (30 inches) up
to 1,800 millimeters (72 inches)
nominal impeller diameter and
for specifc speeds (nq) between
90 to 155 (N
S
4,639 to 7,990).
Tey are mainly designed as
cooling water pumps for power
applications but can also be used
in the water market and other
markets.
Ashcroft
Te company ofers a protective
rubber boot for lower connected
types 1000, 1005, 1005P, 1005S,
1005P-XUL and 1005M-XRG
commercial pressure gauges. In
addition to the patented shock-
resistant Power-Flex movement,
the boot provides added
protection if the gauge is struck
while installed or dropped during
portable use.
Cooling Water Pump
Gauge Protection
Complete Service and Repair of
Electric Motors through 19,000
Horsepower and 13,800 volts.
314 Civic Road, La Salle, IL 61301
Call Inman Electric Motors today!
Phone: (815) 223-2288
FAX: (815) 223-7108
www.inmanelectric.com
Inman Electric motors has been a leader in innovative electrical apparatus
service since 1967. Our 70,000 sq. ft. service shop features state-of-the-art
production and testing equipment to provide our customers with the highest
quality of repaired electric motors. We offer complete sales, service and
repair of electric motors through 19,000 horsepower.
Large Motor Repair
High Voltage Testing
12 diameter VPI system
Large Ovens & Cranes
Motor Storage and
Management
Rewinding thru 13,800V
120
PRODUCT PIPELINE
White Knight Fluid Handling Inc.
Te PEM050 electronic metering pump
was released for chemical replenishing,
blending, dosing and spiking
applications. Te PEM050 electronic,
stepper-controlled metering pumps
dispense up to 50 milliliters of high-
purity chemical with 0.01 percent
repeatability at high pressures (60 to
80 psi). Tey feature PTFE fuid paths
and fully supported rolling diaphragms
to maximize chemical compatibility
and discharge pressure capabilities.
Metering Pump
Circle 214 on card or
visit psfreeinfo.com
Bosch Rexroth
Te new A15VSO hydraulic axial-piston pump combines lower noise emissions with
improved ef ciency. It can meet pressure requirements up to 420 bars and recover
potential energy during pump/motor operation. Equipped with a universal through
drive, the A15VSO integrates into the Rexroth line of products and simplifes the process
of combining diferent pumps.
Hydraulic Axial-Piston Pump
Moyno Inc.
Te EZstrip Cake Pump
features a specially
designed feed chamber that
can easily be disconnected
allowing access to the
rotating assembly. Te
rotor can be separated from
the conveyor allowing for the removal of the rotor and
stator all within its own assembled length. With quick
and easy disassembly, maintenance time is reduced by
more than 93 percent for signifcant cost savings.
Cake Pump
Why You Cant Miss
5
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O
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September 15 -17, 2014
The Fairmont, San Jose, CA
GIL 2014: SILICON VALLEY
The Global Community of Growth, Innovation & Leadership
Pumps & Systems magazine subscribers
receive $500 Off through August 31, 2014
Use code pumpsys500 at checkout.
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For more information or to register, go to:
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GIL 2014 Keynotes Include:

121
Roof Sentinel
Solar Roof Pump XD was designed
as an auxiliary pump for older
buildings that have standing
water. It is the frst auxiliary
solar roof pump on the market
with patent-pending smart chip
technology and cold weather
protection. Te Roof Sentinels over-sized 20-watt solar
panel uses the sun to power its 400-gph pump. It has a
battery back-up system that can pump water up to 30
days without any sunlight.
Solar Roof Pump
Waukesha Magnetic Bearings
Te Automated Commissioning System is now available. Te system allows a magnetic
bearing system to be commissioned into operation without the presence of an active
magnetic (AMB) specialist. Featuring computer-based automation, the Automated
Commissioning System is faster than hands-on commissioning procedures. Te systems
computer automation delivers automatic collection and archiving of essential data, which
ensures reduced time required for planned maintenance.
Intelligent Monitoring
Metallized Carbon
Corporation
Te company announced
mechanical seal primary
rings for sealing refrigerants
and other low-viscosity
liquids. Te Metcar Grade
M-44, antimony-impregnated, carbon graphite primary
seal rings self-polish allows the seal faces to run in the
required close proximity. Te rings are ideal for use
with Freon refrigerants, liquid oxygen, liquid carbon
dioxide, propane, ethylene and acetone.
Mechanical Seal Primary Rings

ANSI/HI Standards by Subscription
Unlimited Access to Standards 24/7
ANSI/HI Standards by Subscription are
available in the following eight packages:
Rotodynamic (Centrifugal)
Rotodynamic (Vertical)
Rotodynamic (Centrifugal & Vertical)
Positive Displacement
Rotodynamic (Centrifugal) & Positive Displacement
Rotodynamic (Vertical) & Positive Displacement
Complete Set: Online
Complete Set: Hardcopy & Online
Order the web-based
subscription package for
your application now at:
eStore.Pumps.org/subscriptions
122
PRODUCT PIPELINE
All-Flo Pump Company
Te new High Purity PTFE air
diaphragm pump operates at a
maximum temperature of 248
F (120 C) and is available in
six sizes from inch through
2 inches. Tis pump includes a
single-piece PTFE diaphragm,
integrated vibration pads and a
housing machined from a solid
PTFE block. Te High Purity
PTFE pumps are available with
diferent connection ports.
Diaphragm Pump
psfreeinfo.com
Baldor Electric
Company
Part of a new line,
the Large AC-GPM
induction motor, is
available up to 1,500
horsepower (HP).
Large AC-GPM motors
are available in stock
ratings of 250 to 1,000 HP, 2,300/4,000 volt, totally
enclosed fan cooled (TEFC), foot-mounted designs.
Custom motors are available in 250 to 1,500 HP; 460,
575, 2300/400 volt; TEFC foot-mounted designs.
Electric Motor
E Instruments
Te AQ Comfort is made for
the HVAC professional. Te
all-in-one instruments provides
the latest in indoor air quality
monitoring and real-time
data logging for IAQ analysis
in homes, schools, of ces
and more. Te AQ Comfort
model measures carbon
dioxide, temperature, percent
RH, dew point and wet bulb.
Te magnetic rubber boot is
included. Te instrument is
designed and made in the U.S.
Air Quality Monitor
psfreeinfo.com
Atlas Copco Portable
Energy
Te company announced an
expansion of its dewatering
pump solutions with the
introduction of a new range
of diesel-driven portable
pumps. Te 4-, 6- and 8-inch
dry-prime unitsPAS 4, PAS 6 and PAS 8are best
suited for transporting or lifting water with abrasive
solids in suspension. Te PAS 4, PAS 6 and PAS 8 have
an operating fow range of 50 to 600 cubic meters per
hour with a maximum head of up to 37 meters. Teir
solids-handling capacity reaches up to 76 millimeters.
Dewatering Pump
Val-Matic
QuadroSphere Trunnion Ball
Valve handles fy ash water/slurry,
river water, pump isolation,
crude oil, low steam pressure and
natural gas lines. Te multiple
fow paths through the valve and
the contoured recessed surfaces
of the ball provide self-fushing
to prevent clogging by avoiding
high scale and solids build up.
Te abrasion-resistant ball design is ideal for severe
applications typical of the power industry.
Ball Valve
Milwaukee Tool
Te company ofers two new auto
voltage/continuity testers. For
accurate troubleshooting, the new
units measure voltage, continuity
and resistance with great precision.
Te Milwaukee units deliver
measurements down to the
decimal and display them on an
easy-to-read LCD screen. Te units
automatically determine whether to
test for voltage or continuity and also
identify alternating-current or direct-
current voltage.
Electrical Tester

123
To have a product considered for Product Pipeline, please send the information to Michael Lambert, mlambert@cahabamedia.com.
Adv er t i s er s
A. W. Chesterton Company . . . . . . . . . . . . . . 14 128
ABZ, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 300
ADIPEC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 106
Advanced Engineered Pump, Inc. . . . . . . . .127 301
ALMATEC, Part of Pump Solutions Group 18 129
Badger Meter, Inc. . . . . . . . . . . . . . . . . . . . . . . 39 103
Bal Seal Engineering Inc. . . . . . . . . . . . . . . .124 302
Baldor Electric Company . . . . . . . . . . . . . . . . 25 104
BaseTek, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 162
BJM Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 163
BLACOH Fluid Control, Inc.. . . . . . . . . . . . . . 95 173
Blue-White Industries. . . . . . . . . . . . . . . . . . . 11 126
Borets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 105
Burns Dewatering Services, Inc. . . . . . . . . .127 303
Carbide Derivative Technologies, Inc. . . . .124 304
Carver Pump Company . . . . . . . . . . . . . . . . . . 37 131
Comercializadora FEOC S.A. de C.V. . . . . .109 179
Conhagen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 132
Continental Pump Company . . . . . . . . . . . .124 305
Dan Bolen & Associates, LLC. . . . . . . . . . . .124 306
Dickow Pump Company . . . . . . . . . . . . . . . . . 55 133
DSI Dynamatic . . . . . . . . . . . . . . . . . . . . . . . . . 13 134
Environmental Gasket Co., Ltd. . . . . . . . . . . 12 135
EnviroPump and Seal Inc.. . . . . . . . . . . . . . .125 307
FCX/Pump Pros . . . . . . . . . . . . . . . . . . . . . . . . 35 125
Flowrox Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 136
FLSmidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 164
FluxDrive Incorporated . . . . . . . . . . . . . . . . . 81 124
Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . . .120 161
Fulfo Specialties Co. . . . . . . . . . . . . . . . . . . .119 165
Garlock Sealing Technologies . . . . . . . . . . . BC 109
Godwin, a Xylem brand . . . . . . . . . . . . . . . . . . 52 137
GPM USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 138
Graphite Metallizing Corporation . . . . . . .121 166
Greene Tweed & Company . . . . . . . . . . . . . . . 17 110
Highland Foundry, Ltd.. . . . . . . . . . . . . . . . . . 31 139
Hoosier Pattern . . . . . . . . . . . . . . . . . . . . . . . . 16 140
Houston Dynamic Service, Inc. . . . . . . . . . .125 308
Hydraulic Institute . . . . . . . . . . . . . . . . . . . .121 174
Hydro, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC 100
Ingersoll Rand/ARO. . . . . . . . . . . . . . . . . . . . .88 141
Inman Electric Motors, Inc. . . . . . . . . . . . . .119 167
Jordan, Knauf & Company . . . . . . . . . . . . .111 175
KTR Corporation . . . . . . . . . . . . . . . . . . . . . . . 23 111
Load Controls, Inc. . . . . . . . . . . . . . . . . . . . . . . 24 143
Load Controls, Inc. . . . . . . . . . . . . . . . . . . . . .125 309
LobePro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 325
LUDECA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 75 144
LUDECA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 77 145
Maag Automatik, Inc. . . . . . . . . . . . . . . . . . . . 99 176
Magnatex Pumps, Inc.. . . . . . . . . . . . . . . . . .109 180
Master Bond Inc. . . . . . . . . . . . . . . . . . . . . . .124 310
Meltric Corporation. . . . . . . . . . . . . . . . . . . .125 311
Mouvex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 146
Murphy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 108
National Pump Company . . . . . . . . . . . . . . . . 67 147
NETZSCH Group . . . . . . . . . . . . . . . . . . . . . . . 27 148
NOC Ningbo Ocean Fine Ceramic
Technology Co., Ltd. . . . . . . . . . . . . . . . . .126 312
NSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 149
Orion Engineered Seals, LLC . . . . . . . . . . . . . 72 168
Pinnacle Flo, Inc. . . . . . . . . . . . . . . . . . . . . . . . 87 172
Pinnacle Flo, Inc. . . . . . . . . . . . . . . . . . . . . . .127 324
Pioneer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 19 113
Pump Solutions Group . . . . . . . . . . . . . . . . . . 85 169
PumpWorks 610 . . . . . . . . . . . . . . . . . . . . . . . .44 130
R+W America. . . . . . . . . . . . . . . . . . . . . . . . . . . 51 150
Revere Controls . . . . . . . . . . . . . . . . . . . . . . .111 178
Rogers Equipment Sales, Inc.. . . . . . . . . . . . . 70 170
Ruhrpumpen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 112
Scalewatcher . . . . . . . . . . . . . . . . . . . . . . . . . .125 313
Scenic Precise Element Inc. . . . . . . . . . . . . .126 314
Schaef er.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 114
Schenck Trebel Corp. . . . . . . . . . . . . . . . . . . . .48 151
Schneider Electric . . . . . . . . . . . . . . . . . . . . . . 53 115
seepex, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 152
SEPCO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 153
SEPCO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 315
SERO Pump Systems, Inc.. . . . . . . . . . . . . . .126 316
Sims Pump Co. . . . . . . . . . . . . . . . . . . . . . . . . . 65 116
Sims Pump Co. . . . . . . . . . . . . . . . . . . . . . . . .127 317
Skinner Power Systems, LLC . . . . . . . . . . . . . 32 154
Solcon USA LLC. . . . . . . . . . . . . . . . . . . . . . . . . 71 171
St. Marys Foundry . . . . . . . . . . . . . . . . . . . . .126 318
Standard Alloys . . . . . . . . . . . . . . . . . . . . . . . . 63 155
Sulzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 101
Summit Industrial Products . . . . . . . . . . . . .34 156
Summit Pump, Inc. . . . . . . . . . . . . . . . . . . . .126 319
Teikoku USA, Inc. . . . . . . . . . . . . . . . . . . . . . . .90 159
Titan Manufacturing, Inc. . . . . . . . . . . . . . . . 99 177
Trachte, USA . . . . . . . . . . . . . . . . . . . . . . . . . .127 320
Tuf-Lok International . . . . . . . . . . . . . . . . . .127 321
United Rentals . . . . . . . . . . . . . . . . . . . . . . . . . 33 117
Varisco USA Inc. . . . . . . . . . . . . . . . . . . . . . . .127 322
Vaughan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC 118
Vertifo Pump Company . . . . . . . . . . . . . . . .127 323
Waukesha Bearings . . . . . . . . . . . . . . . . . . . . . 21 142
Weatherford . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 119
WEFTEC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 120
WEG Electric Corp . . . . . . . . . . . . . . . . . . . . . . . 3 121
WEG Electric Corp . . . . . . . . . . . . . . . . . . . . . . 78 160
Wilden . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 157
Yaskawa America, Inc . . . . . . . . . . . . . . . . . . . 49 123
Zoeller Company. . . . . . . . . . . . . . . . . . . . . . . . 22 158
* Te Index of Advertisers is furnished as a courtesy, and
no responsibility is assumed for incorrect information.
Advertiser Name Page RS# Advertiser Name Page RS# Advertiser Name Page RS#
AquaMotion Inc.
A new three-speed hydronic pump
(AM10) is designed to provide a more
energy ef cient and less expensive
circulator. Te rugged three-speed
AM10 circulator is ideal to replace
all circulators up to 26 gallons
per minute. Te four-bolt fange
for mounting in-line or 90-degree
rotation capability make the AM10
ideal for replacement service pumps
in most installations.
Hydronic Pump
Circle 222 on card or
visit psfreeinfo.com
Sodimate Inc.
Teir custom-fabricated
slurry tanks come equipped
with a mixer, waterboard
(with solenoid valves and fow
meters), level control system,
and all connections necessary
for slurry pumping and draining. Typical fabrication
materials include high-density polyethylene (HDPE),
stainless steel or fber glass, and volume can range from
130 to 750 gallons.
Slurry Tanks
124
PUMP USERS MARKETPLACE
www.masterbond.com
Hackensack, NJ 07601 USA
+1.201.343.8983
main@masterbond.com
Technologically
Advanced Epoxies
One and Two Component
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Precise insertion/removal control
Reduced system complexity
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The Bal Seal Canted Coil Spring
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Specializing in placing:
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DAN BOLEN JASON SWANSON
CHRIS OSBORN DEBORAH SHAW
9741 North 90
th
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Scottsdale, Arizona 85258-5065
(480) 767-9000 Fax (480) 767-0100
Email: dan@danbolenassoc.com
www.danbolenassoc.com
EXECUTIVE SEARCH/RECRUITING

125
Scalewatcher

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345 Lincoln St.

Oxford, PA 19363
800-504-8577
610-932-6888
Fax: 610-932-7559
scalewatcher.com
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P 713.928.6200 | F 713.928.9203 | 8150 Lawndale, Houston, TX 77021
www.houstondynamic.com
ROTARY LOBE SLUDGE PUMPS
FOR SLUDGES/SLURRIES/CORROSIVES
912-466-0304 www.LOBEPRO.com Made in USA
MPS
LURRIES/CORROSIVES
To learn more or get a custom quote,
email PumpSales@lobepro.com
Self Priming to 25.
Reversible operation.
Wear plates and housing
segments are customized
for abrasive, corrosive,
and general applications.
Rebuildable design offers
the best of cartridge seal and a
component seal in ONE while
reducing repair costs 50 to 80%.
meltric.com
800.433.7642
Connector + Switch in 1 device
Maximizes Arc Flash Protection
Minimizes PPE Requirements
MOTOR
PLUGS
QUICKLY CONNECT
& DISCONNECT POWER
Safety Shutter
(on receptacle)
OFF
Button
Rated up to 200A, 60hp
126
PUMP USERS MARKETPLACE
Your Best Value in
ANSI Centrifugal Pumps
Model 2196
Green Bay, WI
www.SUMMITPUMP.com

127
5elf-oligning & self
grounding
High pressure up
to150 F5G
Full vocuum
roted
Low cost
High end pull
Tuf-Lok nternotionol
Fhone. 08.270.478 www.tuflok.com
pump.com
Follow us as we explore manufacturing facilities
around the world with videos, photo albums
and in-depth research on innovative technologies
and distinctive processes.
www.pump-zone.com/pumps-systems-tour
128
PUMP MARKET ANALYSIS
By Jordan, Knauff & Company
Wall Street Pump & Valve Industry Watch
These materials were
prepared for informational
purposes from sources that
are believed to be reliable
but which could change
without notice. Jordan,
Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or com-
pleteness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
any investment offering or
deployment of capital.
T
he Jordan, Knauf &
Company (JKC) Valve Stock
Index was up 18.5 percent
during the last 12 months, staying
close to the broader S&P 500 Index,
which was up 21.3 percent. Te
JKC Pump Stock Index was up 34.9
percent for the same time period.
1

Te Institute for Supply
Managements Purchasing Managers
Index (PMI) was 55.3 percent in
June, a slight decrease of 0.1 percent
from May. Te New Orders Index
increased 2 percent to 58.9 percent,
and the Production Index fell 1
percent to 60 percent.
Te U.S. Commerce Department
reported that the gross domestic
product (GDP) declined by 2.9
percent during the frst quarter of
2014. Tis is a much larger decline
than previously estimated in May.
Signifcant declines in nonfarm
inventory investment and net
exports, as well as nonfederal
government spending, business
investment and housing investment,
contributed to the GDP decline. In
the fourth quarter of 2013, GDP
grew by 2.6 percent.
Te U.S. Bureau of Labor
reported that total nonfarm payroll
employment increased by 288,000
in June, and the unemployment
rate decreased to 6.1 percent. Led by
growth in professional and business
services, retail trade, food and
beverage, and health
care, the job gains
were widespread.
Te manufacturing
sector added 16,000
jobs in June with
all of the increase
occurring in the
durable goods area.
Employment gains in
April and May were
29,000 higher than
previously reported.
During the past three
months, job growth has averaged
272,000 per month.
U.S. crude oil production was an
estimated 7.4 million barrels per day
(bpd) in 2013, according to the U.S.
Energy Information Administration,
and is forecast to grow to 8.4 million
bpd this year and 9.3 million bpd in
2015. Previously, the highest annual
average production was 9.6 million
bpd in 1970.
Combined crude oil production
from Texas and North Dakota
reached 4 million barrels per day
in April and now accounts for
48 percent of the countrys oil
production. In April 2010, these
two states produced only 26 percent
of U.S. production. During the
past three years, Texas has more
than doubled its production, while
North Dakota has nearly tripled
its production. During the past
four years, the Gulf of Mexicos
production share has declined from
27 percent to 17 percent.
On Wall Street, the Dow Jones
Industrial Average gained 0.7 percent
for the month of June, while the S&P
500 Index gained 1.9 percent and
the NASDAQ Composite rose 3.9
percent. Technology, media, fnancial
and small-cap stocks all increased
during the month. Investors were
encouraged by the European Central
Banks stimulus measures to aid the
Eurozones recovery and positive
economic data in the U.S. For the
frst half of 2014, the Dow, S&P 500
and NASDAQ were all up with gains
of 1.5 percent, 6.1 percent and 5.5
percent, respectively, with airline,
pharmaceutical and utilities stocks
gaining the most.
Jordan, Knauf
& Company is an
investment bank based
in Chicago, Ill.,
that provides merger
and acquisition
advisory services to
the pump, valve and
fltration industries.
Please visit www.
jordanknauf.com for
further information
on the frm. Jordan
Knauf & Company is a
member of FINRA.
Figure 3. U.S. PMI index and manufacturing shipments Figure 2. U.S. energy consumption and rig counts
Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates.
Te JKC Pump and Valve Stock Indices include a select list of publicly-traded companies involved in
the pump and valve industries weighted by market capitalization.
Figure 1. Stock indices from July 1, 2013, to June 30, 2014
Source: U.S. Energy Information Administration and Baker Hughes Inc. Source: Institute for Supply Management Manufacturing Report on
Business and U.S. Census Bureau
Reference
1
Te S&P Return
fgures are provided
by Capital IQ.
Vaughans Rotamix System sets the standard for hydraulic mixing, providing the customer with
lower operating and maintenance costs, more efcient breakdown of solids and Vaughans
UNMATCHED RELIABILITY. Its perfect for digesters, sludge storage tanks, equalization basins
and other process or suspension type mixing applications.
- Over 1000 installations worldwide
- Optimizes solids contact with its unique dual rotational zone mixing pattern
- 10 Year Nozzle warranty
See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP
info.seals@ihcmerwede.com
www.lhcmerwede.com l www.lhcseallngsoluuons.com
InC Sea||ng So|unons
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to protect your core business
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