Chemical Engineering June 2015

J U N E 2 0 15
PUMPSANDSYSTEMS.COM
SYSTEMS
The Leading Magazine for Pump Users Worldwide
Trade Show
Preview
ACHEMA &
EASA
2 Simple Steps to
Choosing the
Right Motor
PLUS: Prevent System Failures In CHEMICAL PUMPING Applications
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2
EDITORIAL
EDITOR-IN-CHIEF: Michelle Segrest
From the Editor

A
s you know, Pumps & Systems is the

only trade publication that covers
motors and drives in every issue. This
month, we head to San Antonio for the
largest motor-related trade show of the
year, the Electrical Apparatus Service
Association (EASA) Convention &
Exposition.
We recently reported (March 2015)
about how to prepare for the new
Department of Energy Electric Motor
The Pumps & Systems and Upstream Pumping teams
Eciency Rule, which takes eect in
visiting the team from Accudyne at OTC in Houston
June 2016. This will certainly be a topic
of conversation at this years EASA event.
Drop by Booth 262 at EASA to visit the Pumps & Systems team.
Original equipment manufacturers and end users should contact their motor suppliers
and prepare a plan to convert their motors to premium ecient designs if they are not
already being used. The performance of more ecient motors may be slightly dierent
because they have less slip and operate at a higher speed. Impeller designs may need
trimming to prevent overloading the motor from increased ow. We will continue to
bring you information, and you can also access it quickly at pumpsandsystems.com.
Be sure and see our cover series on motors and drives in this issue, beginning on page
54, which features two simple steps to choosing the right motor.
This month, Pumps & Systems also attends the largest chemical trade show in the
world. ACHEMA is the premier world forum for chemical engineering and processing
and takes place every three years in Frankfurt, Germany. More than 160,000 visitors
from 111 countries attended the show in 2012, and 3,800 exhibitors are expected to
showcase their products and services this year. We hope to see you there!
The challenge for manufacturers and users of many dangerous chemicals is to
construct, handle and transfer them in a way that eliminates any chance for their release
into the atmosphere. Some of the solutions are addressed in this months Eciency
Matters (page 84). You can also read about how sealless pumps with magnetic couplings
are helping to solve chemical processing challenges (page 88).
Best regards,
Editor, Michelle Segrest

msegrest@pump-zone.com
msegrest@pump-zone.com 205-314-8279
MANAGING EDITOR: Savanna Gray
sgray@cahabamedia.com 205-278-2839
MANAGING EDITOR: Amelia Messamore
amessamore@cahabamedia.com
205-314-8264
MANAGING EDITOR: Michael Lambert
mlambert@cahabamedia.com
205-314-8274
ASSOCIATE EDITOR: Amy Cash
acash@cahabamedia.com 205-278-2826
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
aarchibald@cahabamedia.com 205-314-3878
CONTRIBUTING EDITORS: Laurel Donoho,
Lev Nelik, Ray Hardee, Jim Elsey
CREATIVE SERVICES
SENIOR ART DIRECTOR: Greg Ragsdale
ART DIRECTORS: Jaime DeArman, Melanie Magee
WEB DEVELOPER: Greg Caudle
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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
ACCOUNT EXECUTIVES:
Mary-Kathryn Baker
mkbaker@pump-zone.com 205-345-6036
Mark Goins
mgoins@pump-zone.com 205-345-6414
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gstone@pump-zone.com 205-212-9406
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PUBLISHER: Walter B. Evans Jr.

VP OF SALES: Greg Meineke
VP, EDITOR-IN-CHIEF PUMPS DIVISION: Michelle Segrest
CREATIVE DIRECTOR: Terri J. Gray
CONTROLLER: Brandon Whittmore
Pumps & Systems

is a member of the following organizations:
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PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by 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
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returned. Volume 23, Issue 5.
Jun e 2 0 15 | Pum ps & S ys tem s
EDITORIAL & PRODUCTION
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Birmingham, AL 35209
205-212-9402
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This issue
COVER
SERIES
JUNE
Volume 23 Number 6
MOTORS & DRIVES
54 2 SIMPLE STEPS TO CHOOSING THE
64 BEARING PROTECTION FOR
RIGHT MOTOR
By Mike Stockman, Franklin Electric
Consider more than the efficiency rating to select
the most cost-effective system for the pumping
application.
VFD-DRIVEN, EXPLOSION-PROOF
MOTORS IMPROVES RELIABILITY
By Rick Munz & Adam Willwerth,
Marathon Electric Motors
In plants that process combustible materials,

these motors avoid electrical bearing damage
often caused by energy-saving inverters.
58 HOW TO PREVENT THE MOST FREQUENT

CAUSES OF MOTOR FAILURE Last of Two Parts
By Rob Amstutz, GE Power Conversion
Protecting these two components can lead to longer
equipment life.
54
68 DOC ENGINE TECHNOLOGY PROVIDES

COST-EFFECTIVE TIER 4 COMPLIANCE
By Anne Chalmers, Pioneer Pump
Pumping packages that use a diesel oxidation
catalyst can minimize cost, maintenance and
equipment downtime.
62 STAINLESS STEEL IDEAL FOR EQUIPMENT

IN SANITARY ENVIRONMENTS
By David Steen, Baldor Electric Company
70 ENERGY-EFFICIENT MOTORS CURB
This motor material provides an improved

total cost of ownership for the food and
beverage industry.
ENVIRONMENTAL CRISIS
By Zi Ning Chong, Frost & Sullivan
The Chinese government is promoting greater
automation and optimization of processes to
improve the energy utilization rate.
73 TRADE SHOW ELECTRICAL APPARATUS SERVICE ASSOCIATION CONVENTION
64
SSPECIAL
PECIAL
SECTION
CHEMICAL PUMPS & EQUIPMENT
84 SOLID-BODY AODD PUMPS WITHSTAND
88
88 STOP SEAL FAILURES IN CHEMICAL
& CONTAIN DANGEROUS CHEMICALS

EFFICIENCY MATTERS
By Peter Schten, Almatec
This equipment avoids the risk of leaks and pipe
damage associated with injection mold pumps.
APPLICATIONS
By James Gross, Dickow Pump Company
Sealless pumps improve reliability and safety when
pumping hazardous fluids.
90 TRADE SHOW ACHEMA
COLUMNS
PUMPING PRESCRIPTIONS
COMMON PUMPING MISTAKES
14 By Lev Nelik, Ph.D., P.E.
22 By Jim Elsey
Pumping Machinery, LLC
Summit Pump Company, Inc.
Handling Power Plant Transients
What You Need to Know About

Bearing Oil
PUMP SYSTEM IMPROVEMENT

18 By Ray Hardee
Engineered Software, Inc.
Understand How Valves & Fittings
Affect Head Loss
Last of Two Parts
Last of Two Parts
GUEST COLUMN
32 By Heinz P. Bloch, P.E.
How Oil Viscosity & Temperature
Influence Bearing Function
First of Two Parts
2
8
91
92
96
FROM THE EDITOR

NEWS
PRODUCTS
PUMP USERS MARKETPLACE
PUMP MARKET ANALYSIS
EXPANDING YOUR
PUMPING
CAPABILITIES
VR Series vertical multi-stage pumps are now available in 3, 5, 9, 15, 20, 30, 45, 65,
and 95 m3/h options with all 316 stainless steel hydraulics for superior durability,
efficiency, and performance. The rugged components ensure long operating life in
the toughest applications: water supply and pressure boosting; heating, ventilation
and air conditioning; light industry; water treatment; irrigation and agriculture.
Experience Innovation. Experience Franklin.

franklinwater.com
This issue
SPECIAL REPORT
JUNE
DEPARTMENTS
INDUSTRY UPDATE
36 NEW HI DOCUMENT PROVIDES GUIDANCE ON DYNAMIC ANALYSIS OF
74
ROTODYNAMIC PUMPS
By J. Claxton, P.E., Patterson Pump Company, a Gorman-Rupp company
This 10-year project concluded with the recent publication of recommended guidelines for pump
professionals.
SSPECIAL
PECIAL
SECTION
MAINTENANCE MINDERS
Monitoring Software Enables
Scheduled Maintenance at Oil
& Gas Facilities
By Cynthia Stone
GE Intelligent Platforms
76 MOTORS & DRIVES
INSTRUMENTATION, CONTROLS
& MONITORING
Motor Automation Can Help

Solve Industry Labor Shortage
By William C. Livioti
WEG
42 PROTECT PUMPS WITH ONE ESSENTIAL TOOL
78 SEALING SENSE
By Craig McIntyre, Endress+Hauser
Pump sensors can improve system operation and detect dangerous faults.
47 ELIMINATE CABLING COSTS THROUGH PROPRIETARY WIRELESS NETWORKING

By Dave Eifert & Benjamin Fiene, Phoenix Contact
A German municipal water utility optimized pressure booster stations with automated modules.
New FSA/ESA Gasket

Handbook Offers Guidance
for Equipment Usage &
Troubleshooting
By Mike Shorts
FSA Member
82 HI PUMP FAQS
Corrosion Prevention,
Rotodynamic Pump Speed &
How Harmonics Affect VFDs
By Hydraulic Institute
EDITORIAL ADVISORY BOARD

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
WILLIAM E. NEIS, P.E., President, Northeast

Industrial Sales
BOB DOMKOWSKI, Business Development
Manager Transport Pumping and Amusement
Markets/Engineering Consultant, Xylem, Inc.,
Water Solutions USA Flygt
LEV NELIK, Ph.D., P.E., APICS, President,

PumpingMachinery, LLC
HENRY PECK, President, Geiger Pump &
Equipment Company
DAVID A. DOTY, North American Sales Manager,

Moyno Industrial Pumps
MIKE PEMBERTON, Manager, ITT Performance

Services
WALT ERNDT, VP/GM, CRANE Pumps & Systems
SCOTT SORENSEN, Oil & Gas Automation

Consultant & Market Developer, Siemens Industry
Sector
JOE EVANS, Ph.D., Customer & Employee

Education, PumpTech, Inc.
DOUG VOLDEN, Global Engineering Director,
John Crane
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
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
NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
TONY SWENDSRUD, PSG
OAKBROOK TERRACE, Ill. (April 23, 2015) PSG, a Dover company,
announced that Tony Swendsrud has joined the company as its new
chief financial officer. In this role, Swendsrud will be responsible for
all facets of PSGs financial functions and will report directly to PSG
President Karl Buscher. Swendsrud joins PSG from the Honeywell
Corporation, where he held the position of CFO Analytics Americas.
Swendsrud holds a bachelors degree in accounting from St. Cloud
State University in St. Cloud, Minnesota. He is also a certified
public accountant. He will be based in PSGs headquarters office in
Oakbrook Terrace, Illinois. psgdover.com
HASAN AVCI, GRUNDFOS

SINGAPORE (April 23, 2015) Pump
manufacturer Grundfos has recently appointed
Hasan Avci to head its Strategy, Commercial
Excellence and Marketing functions in the Asia
Pacific region. Avci has been with Grundfos since
2003. Before his posting to Grundfos Asia Pacific
headquarters in Singapore, Avci was the director
Hasan Avci
of sales and marketing for Turkey and the Middle
East region. In his new role, Avcis main responsibility will be to
formulate organizational strategies for performance improvements
across the region. He will also implement commercial processes,
undertake strategic corporate planning, evaluate new business
opportunities and spearhead initiatives to promote business growth.
grundfos.com
MICHAEL RICHART, ESE, INC.

MARSHFIELD, Wis. (April 21, 2015) ESE, Inc.,
has named Michael Richart as the companys
director of business operations. Richart
brings more than 20 years of experience as
a versatile strategic executive. Richart will
lead the sales and business operations areas
of ESE. Throughout his career, Richart has
Michael Richart
helped companies succeed by optimizing the
intersection of data, people, process and technology. Richart received
his Bachelor of Sciences degree in industrial engineering from
Purdue University and his MBA from the University of Wisconsin
Oshkosh. ese1.com
PAUL COOKE, BOSCH REXROTH

CORPORATION U.S.
CHARLOTTE, N.C. (April 20, 2015) Effective
July 1, Paul Cooke has been appointed regional
president Americas and president & CEO of Bosch
Rexroth Corporation U.S. Cooke will continue as
senior vice president sales within the Business
Paul Cooke
Unit Industrial Applications at the headquarters
in Lohr, Germany, until the end of June 2015.
Cooke has more than 30 years of experience in
both industrial technology and general management. He received his
Bachelor with Honors Degree in mechanical engineering from

The University of Newcastle in Tyne, England. Berend Bracht,
current regional president Americas and president & CEO of Bosch
Rexroth Corporation U.S., is resigning from the organization for
personal reasons.
JIM LAURIA, MAZZEI INJECTOR

COMPANY, LLC
BAKERSFIELD, Calif. (April 9, 2015) Mazzei
Injector Company, LLC, has appointed Jim Lauria
as vice president of sales and marketing. Lauria
has been a leader in water and wastewater
for more than 15 years and has had articles
published in prominent water industry
Jim Lauria
publications worldwide. Lauria holds a Bachelor
of Chemical Engineering degree from Manhattan College. Lauria will
be replacing Paul Overbeck who is retiring. mazzei.net
PHIL CARLIN & MICHAEL SAVIGNAC, OPW

HAMILTON, Ohio, & HODGKINS, Ill. (April 2, 2015)
OPW, a Dover company, announced that, as part
of its growth strategy and One OPW initiative, it
has consolidated its OPW KPS, OPW Fibrelite and
OPW Fluid Transfer Group Europe management
teams to create a single business unit, named
OPW EMEA. Phil Carlin has been appointed
Michael
managing director of the new business unit
Savignac
and will report directly to OPW President David
Crouse. Carlin joined OPW in 2000 and has held multiple positions
with the company, including several senior executive positions. He
will be based out of OPW EMEA headquarters in Kungsr, Sweden. In
addition, Michael Savignac joined OPW as vice president and general
manager for the OPW Electronic Systems business unit, succeeding
Carlin. Savignac will provide leadership and overall management of
the Electronic Systems business unit, which OPW formed in April
2014. Savignac will be based at the OPW facility in Hodgkins, Illinois,
and will report to Crouse.
To have a news item considered, please send the information to Amelia
Messamore, amessamore@cahabamedia.com.
MERGERS & ACQUISITIONS

ACOEM Group acquired VibrAlign, Inc.
April 30, 2015
ERIKS Seals and Plastics acquired Seals and Packings, Inc.
April 21, 2015
Lewis-Goetz acquired Action Industrial Group
April 9, 2015
p u mpsa ndsyst ems.c om | J u ne 2015
10
NEWS
AROUND THE INDUSTRY

Danfoss Recognized for Impact
on Technology, Jobs & Local
Partnerships
NORDBORG, Denmark (April 24, 2015)
During a press conference on April 22,
The Economic Development Council of
Tallahassee/Leon County announced
Danfoss as its featured business for the
month of April as part of its Made in
Tallahassee: Produced Regionally, Sold
Globally initiative.
The program is planned as a public
awareness campaign that focuses on
the important role that the research and
development, manufacturing, software
development and technology industries
play in the success of the local economy.
danfoss.com
WERF & WEF Launch

Projects to Further Water
Sector Innovation
ALEXANDRIA, Va. (April 22, 2015) The
Water Environment Research Foundation
(WERF) and the Water Environment
Federation (WEF) are launching
three new projects under the Leaders
Innovation Forum for Technology (LIFT)
program, a joint WERF/WEF initiative
designed to promote innovation in the
water sector.
The first project, Genifuel
Hydrothermal Processing Bench Scale
Technology Evaluation (LIFT6T14), will
evaluate a new biosolids to energy
technology. The project is funded by
WERF, the U.S. Environmental Protection
Agency (EPA) and approximately
10 utilities participating in the LIFT
program. The U.S. Department of Energy
is also providing in-kind support.
The next project, Creating the Space
to Innovate (LIFT8C14), is co-funded by
WERF and WEF to promote the adoption
of innovative technologies and practices.
WERF has also awarded The Canton
Group with a contract to develop a
LIFT Database (LIFT2R14), which
is designed to support new water
technology innovation, collaboration
and implementation for the water
sector. The platform will help deliver
information on water technologies,
facilitate collaboration for speeding
innovation into practice, provide
data from demonstrations and more.
The development of the platform is
supported in part with funding from the
U.S. EPA. werf.org/lift
Truckee Meadows Water

Authority Wins National Award
RENO, Nev. (April 17, 2015) Truckee
Meadows Water Authority (TMWA) has
received the Presidents Award from
the Partnership for Safe Water (PSW).
With this award, TMWAs Chalk Bluff
Water Treatment Plant ranks among
the highest performing water treatment
plants in the country for individual filter
performance. Only 18 utilities across the
country have achieved this award.
The Presidents Award recognizes
achieving Phase IVs stringent individual
filter performance goals for turbidity.
awwa.org
POWER-GEN Europe Launches

the Confidence Index to Build
Industry Expertise
LONDON (April 14, 2015) POWERGEN Europe and its co-located event
Renewable Energy World Europe has
announced the launch of the POWERGEN Confidence Indexa panEuropean study of the regions
power market which will allow power
generation industry practitioners
from across Europe to have their say
on the industry.
The results will be launched in
September 2015, and they will allow
industry decision makers across Europe
to make well-informed choices as they
navigate the next critical stages of the
energy transition.
The report will evaluate the industrys
attitude toward new initiatives and
give companies insight into how these
changes are viewed by the industry.
The survey that feeds into the Index
will be carried out on an annual basis
and allow the industry to track year-onyear trend analysis and comparison.
powergeneurope.com
Xylem Participates in U.S.

Presidential Trade Mission to
the Peoples Republic of China
RYE BROOK, N.Y. (April 13, 2015) Xylem
Inc. participated in the U.S. Presidential
Trade Mission to the Peoples Republic
of China, April 12-17. U.S. Secretary of
Commerce Penny Pritzker and Deputy
Secretary of Energy Elizabeth SherwoodRandall led this Smart Cities Smart
Growth Business Development Mission,
accompanied by representatives from
25 companies.
The trade mission was intended to

help U.S. companies launch or increase
their business operations in China for
sustainable products and services.
Chris McIntire, Xylem senior vice
president and president, analytics and
treatment, and Shuping Lu, president of
Xylem China, represented Xylem on this
mission. xyleminc.com
PTDA Welcomes Three

New Distributor Members
CHICAGO (April 13, 2015) The Power
Transmission Distributors Association
(PTDA), an association for the industrial
power transmission/motion control (PT/
MC) distribution channel, welcomed
three new distributor member
companies: BK Industrial Solutions,
LLC (Beaumont, Texas), SAECOWilson
Limited (Auckland, New Zealand) and
Warrior Industrial, LLC (McKinney,
Texas). ptda.org
SFPUC Completes New

Seismic Upgrades to Drinking
Water Treatment Plant
SAN FRANCISCO (April 10, 2015)
The San Francisco Public Utilities
Commission (SFPUC) together with
San Mateo Board of Supervisors Dave
Pine and Peninsula water agencies
stood on top of a new 11 million gallon
treated water reservoir to celebrate the
completion of a $278 million project
improving the seismic and operational
reliability of the Harry Tracy Water
Treatment Plant located in San Bruno.
The 43-year-old treatment plant
is responsible for treating the
drinking water for more than 1 million
customers in San Mateo and San
Francisco Counties.
The project is part of the SFPUCs $4.8
billion Water System Improvement
Program, which consists of 83 projects
across seven counties designed to
improve seismic and water supply
reliability for 2.6 million people in the
Bay Area. sfwater.org
ABB Opens New Automation

& Power Service Office
in Louisiana
SULPHUR, La. (April 8, 2015) ABB
has opened a new local service office
near Lake Charles, Louisiana. The
office will provide services and support
for ABBs automation and power
Those shiny new bearings

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For more information about

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11
12
NEWS
portfolio including control systems,

instrumentation, analytical products,
low-voltage drives, and power systems
and products.
The new ofice will offer scheduled incenter training, as well as customized
training courses. ABB has also
announed several new investments
in the area. abb.com
Xylem Contributions
Recognized at HIs 2015
Annual Meeting
RYE BROOK, N.Y. (April 2, 2015) Five
employees from the Applied Water
Systems (AWS) business unit of Xylem
were recognized by the Hydraulic
Institute (HI) for their longtime service
to and involvement in HI.
Awards and the team members they
were presented to are as follows:
Mark Handzel, Vice President
Product Regulatory Affairs and
Director, HVAC Commercial
Buildings, Americas Industry
Leadership Award for U.S.
Department of Energy pump
eficiency regulations
Mark Heiser, Test & Validation
Manager Industry Leadership
Award for development of HI
Standard 40.7 and recognition
for completion of standard
development for DOE pump
Paul Ruzicka, Chief Mechanical
Engineer Industry Leadership
Award for development of HI
Standard 40.6 and recognition
for completion of standard
development for DOE pump
Chris Johnson, Global Engineering
Manager, Centrifugal Pumps
Recognition for contributions to HI
standards development
Jim Roberts, Associate
Principal Mechanical Engineer
Recognition for 20 years of
service to the development of HI
standards
xyleminc.com
Powdersville Water District

Receives National Award
DENVER (March 30, 2015)
Powdersville Water is the irst utility
in South Carolina to achieve the
Directors Award in the Partnership
for Safe Waters Distribution System

Optimization Program and one of
only 11 nationwide.
Powdersville Water received this
award for successfully completing a
comprehensive self-assessment of
distribution system operations.
Powdersville Water will be one of a
select group of utilities recognized at
the annual conference and exposition
of the American Water Works
Association in June. awwa.org
AEP Ohio Offers New Energy

Efficiency Program
RALEIGH, N.C. (March 26, 2015) AEP
Ohio, a unit of American Electric
Power, in partnership with Advanced
Energy, has launched the Emotor
Rewind Pilot Program to promote
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EVENTS
Pump School Training: Centrifugal &
Positive Displacement Pumps
June 2-3, 2015
One Midtown Plaza
Atlanta, Ga.
770-310-0866
pumpingmachinery.com/pump_school/
pump_school.htm
American Water Works Association
Annual Conference & Exposition
(AWWA-ACE)
June 7-10, 2015
Anaheim Convention Center
Anaheim, Calif.
800-926-7337
awwa.org
EASAs 2015 Convention & Exhibition
June 14-16, 2015
Grand Hyatt San Antonio & Henry B.
Gonzalez Convention Center
San Antonio, Texas
easa.com/convention
ACHEMA
June 1519, 2015
Messe Frankfurt
Frankfurt am Main, Germany
achema.de/en.html
National Fire Protection Association
(NFPA) Conference & Expo
June 2225, 2015
McCormick Place
Chicago, Ill.
800-344-3555
nfpa.org/training/conference
5th Annual Pumps Hands-on
Training: Maintenance, Energy and
Reliability Conference (PumpTecIsrael)
July 7, 2015
Tel Aviv, Israel
770-310-0866
pumpingmachinery.com/pump_school/
pump_school.htm
IDA World Congress
Aug. 30 Sept. 4, 2015
San Diego Convention Center
San Diego, Calif.
wc.idadesal.org/
Demand Reliability
13
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14
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC,
P&S Editorial Advisory Board
Handling Power Plant Transients

Letter from a Reader
The following comments relate to
scenarios described in Parts 1 and
2 of Can Deaerators Create Pump
Trips? (Pumps & Systems, March
and April 2015), which discuss
handling power plant transients.
Steady ows to and from the
deaerator (DA) and gradual
isentropic thermodynamic changes
from the high to low temperature/
pressure conditions are assumed.
A gradual power plant cool down
period after a shutdown event may
mitigate general or local ashing.
From Part 1 at Point A:
DA total tank volume V =
20,000 gallons = 2,674 cubic
feet (ft3).
Tank liquid (water) volume
(Vliq) = 10,000 gallons =
1,337 ft3.
Mass of tank liquid (mliq) =
Vliq
vf = 76,564 lbm.
Mass of tank vapor (mvap) = 0
lbm (all mass is saturated
liquid at vf).
Total mass of tank contents (M)
= mliq + mvap = 76,564 lbm.
Using the above values, the
calculated specic volume
(v) should agree with the
temperature-specic volume
(T-v) diagram at Point A.
However, calculated v =
V = 0.03492 ft3/lbm.
M
This value is greater than vf
= 0.01746 ft3/lbm from the
diagram. Since the vapor
volume Vvap = mvap x vg =
0 ft3, the analysis might be
J un e 2 0 15 | Pum ps & S ys tem s
However, I would not expect

a DA tank to be either half full
of liquid without any vapor or
completely full of liquid. A more
likely location for Point A might be
to the right of the saturated liquid
state where a two-phase liquid and
vapor state existsPoint A1.
The originally calculated specic
volume, v = 0.03492 ft3/lbm,
represents a liquid and vapor
Using revV and v for
calculations at Point B, X = 0.003%, state at 302 F. If this value is
chosen, a new set of values can be
vapor mass mvap = X x M = 2.3
determined at Point A1 and Point
lbm, vapor volume Vvap = mvap
3
B1: X = 0.17% at B1, Vvap = +23
x vg = 24.5 ft , liquid mass mliq
ft3, and Vliq = -23 ft3. In this case,
= (1-X) x M = 76,562 lbm, liquid
the vapor has enough room for
volume Vliq = mliq x vf = 1,312.3
ft3. Therefore, the total volume and expansion going from a calculated
1,341 ft3 at A1 to 1,363 ft3 at B1.
mass of the tank contents remain
However, while the calculated
the same. However, the vapor
liquid volume has decreased at B1,
volume has increased by the same
amount that the liquid volume has the corresponding liquid mass has
increased. This seems unlikely.
decreased. The less dense vapor
After some trials, it was
must occupy a larger space than
determined
that reasonable
the reduction in liquid volume.
Because there is no additional tank changes in volume and mass occur
if the specic volume is greater
space to occupy, some liquid may
3
be expelled from the 10,000-gallon than about 0.29 ft /lbm for the
given data in this article. If another
DA or excess vapor pressure might
specic volume such as v = 0.5
activate a relief valve.
ft3/lbm is chosen, another set of
Expelled tank liquid may imply
liquid and vapor state values can
that the total mass of the DA tank
be determined at Points A2 and B2:
contents decreases at Point B:
3
Specic volume at Point B is greater X = 4.52% at B2, Vvap = -1.33 ft ,
3
than at Point A. Using vb = 0.018 and Vliq = +1.33 ft . In this case,
the vapor volume has contracted
ft3/lbm at Point B, the calculated
going from a calculated 2,587 ft3
vapor volume is now about 66 ft3
at A2 to 2,586 ft3 at B2. Now, the
at Point B compared with 24.5 ft3
3
calculated liquid volume and mass
if v = 0.01746 ft /lbm. Since the
new liquid volume is now 1,312 ft3, have both increased at B2, while
about 41 ft3 must be expelled from the calculated vapor volume and
the tank at Point B: 66 + 1,312 41 mass have decreased at B2. Vapor
condensation, from state A2 to B2,
ft3 = 1,337 ft3 = the tank volume.
conducted by assuming that
the total tank volume revV =
Vliq + Vvap = 1,337 ft3. In other
words, assume the total DA
tank volume is 10,000 gallons
and completely full of liquid
(water) at Point A. Then, at
Point A on the diagram, v =
revV = 0.01746 ft3/lbm = vf.
M
15
is now the result. This seems to

be a realistic outcome after slowly
cooling. Although it should be
noted that, with v = 0.5 ft3/lbm,
there is a substantial dierence in
liquid and vapor mass and volume
values when compared with the
original calculations from above.
After an emergency trip
situation, there may be ongoing
automatic and/or manual
adjustments as various plant
elements (DAs, pumps, etc.) react
to changing system conditions. If
the liquid+vapor mass (M) within a
xed-volume DA tank can decrease
or increase in response to some of
these changes, maybe the specic
volume is not necessarily constant
at dierent thermodynamic states.
Besides the dynamics occurring
inside the DA tank, I would expect
that any major net positive suction
head (NPSH) problem at the pump
suction might be attributed to
entrained air, not water vapor,
being transferred from the DA
liquid to the boiler feed pump.
Before being shut down, the
injected pegging steam might have
removed most of this air.
In Part 2, I would not expect

a signicant problem at Pump 2
from an interaction at the junction
of its header and the hotter liquid
in Header 1. If the liquid in Header
2 is gradually cooling and owing
past the junction, the temperature
dierence at a junction may be too
gradual for a ashing reaction.
However, for Pump 1, if it is again
started with its header full of 302
F liquid and only 39 psia available
at the junction, there might be an
insucient NPSH condition as
pointed out in the article. Perhaps
Pump 1 would be able to pass
the 50-ft header full of hotter
liquid quick enough to avoid any
signicant damage or pump trip.
Of course, the above analysis
is based on simplied ideal
conditions with gradual
thermodynamic changes. Feedback
from readers with experience in
power plants and the eects of
transients on pumps would be
insightful.
Lee Ruiz
Oceanside, California
Neliks Response
Thank you for your comments.
These are very diligent and
methodical calculations. I have a
few notes to your comments.
Your assumption of the process
being gradual and isentropic
cannot be assumed, because it
is highly transient. This is one
of the reasons it is not easy to
calculate. Several thermodynamic
sub-processes that are highly
time dependent are taking place:
convection from hotter liquid
to colder, phase transformation
and cooling of the vapor that is
evolving back into liquid phase as
it tries to rise through the colder
liquid layer. Perhaps the only safe
assumption for the process is
that it is adiabatic, assuming no
heat loss through the pipe to the
surroundings occurs as a result of
thick insulation.
My assumption that Point A is
liquid that occupies half of the
tank space with zero vapor above it
is problematic. While the pressure
is signicant, a complete absence
of vapor in the space above the
liquid is impossible, as it would
Figure 1. Visualization of vaporization and

re-condensation (Courtesy of the author)
p1 = 69 psi
p2 = 50 psiA
subcooled
266 F
1 FT3
266 F
subcooled
saturated
302 F
1 FT3
302 F
16
imply full vacuum. Because the

uid in the DA is at the saturation
curve or in the subcooled region,
something must be present above
the liquid to maintain pressure.
To explain what keeps the void
above the liquid at pressure in this
case, we would need to understand
more precisely the specics of the
DA design.
Your note is well-placed; if we
instead make a slight adjustment to
starting Point A to be slightly into
a two-phase region, this diculty
immediately disappears. The entire
space above the liquid would be
vapor, the combined volume in the
tank could be treated as the entire
tank (20,000 gallons) instead of
half of it (10,000 gallons), and the
total combined specic volume
would be total tank volume divided
by total mass (which at Point A is
mostly liquid). That would make
the total combined volume double
that if we used only half the tank.
It does not aect Point A but makes
things easier when going to point
B, as we now have a total volume
of the entire 20,000 gallons lled
with a mixturesome liquid and
some vapor. From there, vapor
mass fraction x and volume can
be calculated.
My assumption that the entire
system is a constant volume is
valid, because otherwise, it is
impossible to make any other
reasonable assumptions. For
example, we cannot assume
constant pressure at Point B (As an
example, imagine that the tank had
a free heavy lid that would apply
constant pressure and that the
expanding volume of vapor would
move the lid up).
The tank described in these
articles does not have moveable
boundaries. The only openings
are to the condensate piping and
through the running pumps, but

those are essentially closed (by
running water).
As explained in Part 2, vapor
wants to expand according to a new
pressure to which the surface of the
DA is now suddenly at (Point B).
But it is not a steady state process,
and things are very transient. As
vapor tries to form and oat up,
it encounters a colder layer above
it and condenses back to liquid
almost instantaneouslyat many
orders of magnitude faster than it
takes for vapor to travel through
the suction header of the running
(colder) pump to reach its entrance.
Instead, what likely is happening is
convective cooling of the hotter leg
by the colder leg via this attempted
vaporization and re-condensation
(see Figure 1, page 15).
Imagine that you have two layers
of uid of equal volume, separated
by a very thin membrane. Initially,
69 psi is enough to keep both
liquids subcooled (the lower layer
is subcooled but not as subcooled
as the upper layer). Suddenly,
pressure at the surface drops to
50 psi, at which the top layer is
still subcooled, but the bottom
layer enters the vapor phase. Will
it immediately ash out to many
times more vapor volume? If so,
where will it go?
Assume that the membrane is
thin and raptures as vapor forms.
The bubbles trying to form at the
lower layer would have to meet
the colder layer and return to
liquid form. This would go on for
some time and eventually both
uids would mix at the average
temperature (266+302)/2. If 50 psi
is in a vapor region, the uids will
turn to vapor and ll the entire
can. If the can is very tall, there
will be more space for vapor to
form (if it corresponds to vapor
condition). Initially, however, all

was in two liquid layers. After the
drop of pressure (and if the new
condition is vapor phase), however,
the vapor will expand to take up
the complete volume.
Part 2 shows that, for the
conditions used in the example
and at the resultant average
temperature, no two-phase
situationand thus no vapor
exists. This means the system
experiences no cavitation or NPSH
problem. However, in reality, no
vapor would reach the running
pump because the colder column
is not static and mixing with the
hotter liquid. Instead, while vapor
wants to form and transmit its
energy to heat up cooler liquid,
that liquid is actually in motion,
taking a heated chunk and moving
it toward the pump.
By the time the chunk ows
through the entire length of pipe,
the resultant rise in temperature
of the owing liquid is minuscule.
As a result, it is not even close to
heating the cooler leg substantially.
In other words, it is the DA
temperature that would dictate the
temperature of uid reaching the
running pump.
Dr. Nelik (aka Dr. Pump)

is president of Pumping
Machinery, LLC, an Atlantabased firm specializing in pump
consulting, training, equipment
troubleshooting and pump
repairs. Dr. Nelik has 30 years
of experience in pumps and
pumping equipment. He may
be reached at pump-magazine.
com. For more information, visit
pumpingmachinery.com/pump_
school/pump_school.htm.
17
18

A better understanding of complete system operation
By Ray Hardee
Engineered Software, Inc.
Understand How Valves & Fittings

Affect Head Loss
Last of Two Parts
his series discusses valves

and ttings and evaluates
how these devices aect the
operation of piping systems. Part 1
(Pumps & Systems, May 2015)
covered head loss, K value and
L/D coecient.
CV Coefficient
The CV value is an indication of
the capacity of a valve or tting
and is often used to describe
the performance of control
valves. The CV coecient is often
used to describe the hydraulic
characteristics of elements in a
pipeline. The denition of CV is
the number of U.S. gallons per
minute (gpm) of 60 F water owing
through a valve or tting results
in a 1 pound per square inch (psi)
pressure drop across the device.
For example, if a device has a
CV value of 200, then when 200
gpm ows through the device, a
1 psi pressure drop would occur.
Equation 6 describes the CV value.
CV =
Q
Pin - Pout
SG
Equation 6
Where
CV = Flow coecient (unitless)
Q = Flow rate (gpm)
P = Pressure (psi)
SG = Specic gravity of the uid
(unitless)
The equation can be rearranged
to allow for the solution of the ow
rate for a given pressure drop

and the pressure drop for a given
ow rate.
Q = CV
2
dP = Q x SG
(CV)2
dP
SG
Equation 6 gives the result of using

C V in dierential pressure instead
of head. If a manufacturer provides
information in C V, users must
convert it to dierential pressure,
then convert the results to head
loss. Equation 7 can be used to
eliminate the need to convert from
pressure to head. It allows for
the conversion of a C V value to a
K value.
K = 890.3 x
d4
(CV)2
Equation 7
Where
K = Resistance coecient
(unitless)
CV = Flow coecient (unitless)
d = internal diameter (inches)
Calculating the Head Loss

Using K Value
Regardless of the method used
to arrive at a K value for a valve
or tting, Equation 8 is used to
calculate the head loss resulting
from valves and ttings.
2
hL = 0.00259 KQ4
d
Equation 8
When multiple valves and

ttings in a pipeline have the same
diameter, the K values for each
valve or tting can be added. The
sum of the K values can be used to
calculate the head loss for all the
valves and ttings.
To demonstrate, calculate
the head loss for the valves and
ttings in a pipeline when 600
gpm of water is owing through
the following valves and ttings:
a sharp-edged transition from
a tank to pipeline, a full-seated
globe valve and a strainer with a
CV value of 450. These full-seated
devices are in a 6-inch pipe with a
turbulent friction factor of 0.015
inches. The K values are listed in
Table 1. The resulting head loss
with 600 gpm going through the
pipeline is shown in Equation 9.
Cross Section of Valves &

Fittings
Reference 1 has cross sections of
types of valves and ttings and
the corresponding K values or L/D
coecients. There are too many
types of valves and ttings to
present in this article, but some
attributes can be generalized.
For example, a full-seat ball valve
2
2
hL = 0.00259 KQ4 = 0.00259 11.55 x 600
= 7.95 ft of uid
d
6.0654
Equation 9
19
with its straight-through design has a much lower

L/D value than a globe valve through which the
uid must make four changes of direction and
ow around the valve disk within the ow path.
The type of valve employed is based on many
factors. Leak tightness is an important factor,
but when two types of valves meet the same
requirements, it is recommended to use the one
with the lower head loss.
Another example of ttings with varied loss
coecients are elbows. A short radius 90-degree
elbow has an L/D coecient of 20, but a long radius
90-degree elbow has a L/D coecient of 14. This
may not seem like a signicant loss, but it adds up.
So do the associated costs. The pump must supply
the energy that is lost across the valves and tting.
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Watch it!
Cost of Pipeline Operation

To demonstrate the pumping cost associated with
valves and ttings, calculate the operating costs for
dierent types of valves and ttings. Equation 10
can determine the pumping cost.
Table 1. Calculation of K value for different methods describing valves
and fittings (Graphics courtesy of the author)
Item
Method Coefficient Value
K value
Sharp-edged
transition
0.5
0.5
Globe valve
fT L/D
0.015 x 340
5.1
Strainer
Cv
450
5.95
Learn about it!
11.55
Total K for pipeline
Valve / Fitting Type
K
value
Head
Loss (ft)
Annual Operating
Cost ($)
Elbow short radius
0.33
0.5
$53
Elbow long radius
0.23
0.35
$37
Entrance inward
0.78
1.23
$128
Entrance sharp edge
0.50
0.79
$82
Entrance rounded
0.04
0.06
$7
Experience
E i
it!
Ball
0.05
0.08
$8
Visit us at booth #E18 Hall 9 for a demonstration
Gate
0.13
0.20
$21
Plug
0.29
0.45
$47
Butterfly
0.73
1.14
$118
Globe
5.54
8.58
$893
AROzone.com/ACHEMA
Table 2. The relationship between K values, head loss and annual

operating cost for valves and fittings. The example is for 4-inch valves
and fittings passing 400 gpm.
20
OC =
.746 Q H
247,000 M
OH x $/kWh
Equation 10
Where
OC = Operating cost ($/time)
Q = Flow rate (gpm)
H = Head (feet of fluid)

= Density (lb/ft3)
= Efficiency, M motor, P pump,
V variable speed drive (VSD)
(percent)
1970 Dodge Super Bee
Process Maxum
Do you have flows up to

9,900 GPM (2,000 m3/hr),
heads up to 720 Ft (220 M), speeds
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500F (260C)? Then you need Carver Pump
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With an extended range of hydraulic coverage and
rugged construction, the Process Maxum Series is
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Manufactured in 35 sizes, standard materials
include WCB, WCB/316SS, 316SS and CD4MCu,
with others available upon request. A variety of
options include various types of mechanical seals
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563.263.3410
Fax: 563.262.0510
www.carverpump.com

J un e 2 0 1 5 | Pum p s & S yst e m s
O = Operating hours in evaluation

(hours)
$/kWh = Electrical power cost ($/kWh)
In this example, the pump efficiency
is 70 percent, and the motor efficiency
is 90 percent. No VSD is installed, the
evaluation period is 8,000 hours, and
the cost of power is $0.10/kilowatt-hour
(kWh). This example evaluates 4-inch
valves and fittings with a flow rate of
400 gpm. The results are presented
in Table 2 (page 19).
Every item placed in a piping system
has an operating cost. This should be
considered every time a user specifies a
valve time or adds elbows.
Conclusion
The often overlooked performance of
the multitude of valves and fittings adds
up. They have a compounded effect on
performance in a fluid operation and
need to be taken into consideration for
efficiency planning and optimization.
Next months column will investigate
how the control elements operate and
the role that these devices play in piping
systems and their associated cost.
References
1. Flow of fluids through valves, fittings, and pipe.
(1957). Chicago: Crane
2. Flow of Fluids through Valves, Fittings and
Pipe Technical Paper 410. 2013 Crane Co.
Stamford CT 06902.
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
Assessment. Hardee was a contributing
member of the HI/Europump Pump Life
Cycle Cost and HI/PSM Optimizing Piping
System publications. He may be reached
at ray.hardee@eng-software.com.
Vjg"gZcev"K1Q"{qw"pggf
21
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22

By Jim Elsey
Summit Pump, Inc.
What You Need to Know About Bearing Oil

Last of Two Parts
ost pump bearings fail

long before their design
life span. The American
Petroleum Institute (API) typically
requires a minimum bearing life
(L10) of 25,000 hours, and ANSI
B73.1 specication for horizontal
ANSI pumps species a minimum
L10 bearing life of 17,000 hours at
maximum load and rated speed.
Prudent end users frequently
request bearings with more
than 40,000 hours L10, but most
bearings do not reach that many
hours of operation before failure.
More than half of pump bearings
fail as a result of contamination,
excess heat or both. Preventing
this introduction of contaminates
is easier and less expensive than
removing them. Some studies
suggest removing contaminates
can be eight to 10 times more
expensive than prevention.
Oil Contamination
This premature failure rate
is typically the result of
contamination of the oil not a
fault of the bearing or pump
manufacturer. Dirt, wear particles
and other foreign debris as well
as improper bearing installation
procedures can contribute to
contamination that leads to
reduced bearing life.
Other forms of contamination
include heat and air in the form
of air entrainment and aeration.
Increased levels of heat and air lead
to increased oxidation rates.
One of the most common sources

of contamination, however, is
water, which is often introduced
because of improper storage and
handling. During pump operation,
water can leak into the bearing
housing from external sources
such as area wash down, spray
from failed mechanical seals (or
packing) or leaks from equipment
near or above the pump. Another

common method of water
introduction is condensation
through machine aspiration
(moisture laden air is drawn in due
to pressure dierentials).
For example, a pump running
steady state at a given temperature
above ambient for ve days is shut
down on Friday at 4 p.m. As the
Figure 1. Oil level on bottom ball of the bearing (Graphics courtesy of the author)
23
pump cools, the ambient air is drawn into the

bearing housing where it cools and the moisture
condenses, releasing the entrained water into the
housing where it mixes with the oil.
According to sources at the SKF Bearing
Company, 250 parts per million (PPM) water in
the lube oil will reduce bearing life by a factor
of four, and another source states that 0.002
percent water in the oil will reduce the bearing
life by 48 percent. According to other sources, the
reduction of oil contamination levels from the
ISO 21/18 to the ISO 14/11 will increase bearing
life by a factor of 7.
Because water in the oil is invisible at low
levels, a lab should test the oil using the Karl
Fisher method or the end user should conduct
a simple sizzle test in which the oil is quickly
subjected to a hot surface temperature of 250 to
300 degrees F. A hot plate is commonly used, but
a metal spoon or aluminum foil with a butane
lighter can also be used. If more than 800 to
1,000 PPM water is present in the oil, a sizzle
sound can be heard when the oil temperature
exceeds 212 to 220 F. If the oil sizzles, too much
water is present in the oil. Because the sizzle
test can have dangerous side eects, always
check with plant safety procedures before
conducting the test.
Companies that strive for longer mean time
between failures (MTBF), mean time between
repairs (MTBR) and improved plant reliability
select their oil or grease based on equipment
requirements and properly match them with the
oil properties. They also store and allocate the oil
using controlled and clean methods.
I have seen end users store oil drums upright,
outside and unprotected with an open bung. I
have also seen mechanics draw oil from drums
into used paper coee cups or soft-drink cans.
When confronted, they reply, That is the way we
have always done it, and we are not having any
bearing or oil problems, or I washed out the
container rst.
If a pumps bearings are not lasting three to
eight years, the plants equipment lubrication
practices should be questioned. Check with your
oil supplier, or consult articles, books and other
publications that discuss these subjects. The
October 2006 issue of Pumps & Systems magazine
explores this topic, and I highly recommend any
lubrication for horizontal pumps

from 5 to 250 BHP. The oil is
contained in a sump in the housing
with the bearings. The machine is
designed so the oil level for proper
operation is at the middle of the
bottom ball in the bearings.
temperatures will require line,

sleeve or plain journal bearings
for radial support (hydrodynamic
journal bearings) and tilted shoe
Bearing Lubrication Methods (pad) designs for thrust bearings.
Methods and designs that are
Selection of a bearing design
acceptable for ANSI specication
for a specic service will, to a
pumps may not be acceptable for
large degree, determine how it is
lubricated. Depending on the pump API, process, marine and power
generation applications where HP
speed, type of service, horsepower
(HP) range and size, dierent types can often exceed 70,000 brake
horsepower (BHP) with speeds in
of bearings are available.
A properly selected oil-lubricated excess of 6,000 rpm.
Because most end users at the
ball or roller bearing will work
high end of the HP and speed
for most applications less than
spectrum are aware of oil types,
200 HP, 400 F (uid temperature)
best practice lubrication techniques
and 3,600 revolutions per minute
and bearing selection, this article
(rpm). For some smaller and lower
temperature applications (less than will examine the middle and
lower range.
320 F), grease-lubricated bearings
Oil splash lubrication may be the
may also work well. Larger pumps
most common method of bearing
at higher speeds and system
books and technical papers on this
subject by Heinz Bloch (see page
30), Alan Budris or Rojean Thomas.
Oil Levels
Oil levels higher than the middle
of the lowest ball bearing will
have negative consequences and
increase oil temperature and air
entrainment. Both of these factors
accelerate the oils oxidation rate
and reduce oil and bearing life.
For splash lubrication, the oil level
should touch the very bottom of
the bottom ball in the bearing.
If the oil drops below the ball or
the outer race, the bearings could
be damaged. If the level is too
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low, the bearing could experience

temperature runaway, which is
when the bearing gets hot quickly
and is permanently damaged.
Variations on splash lubrication
design include ingers, discs, oil
rings and several other methods/
types of lubrication.
One note of caution is that
rings must be close to perfectly
concentric, and the pump shaft
must be level for the rings to work
correctly. I have rarely seen the
ring remain round, especially after
the rst maintenance overhaul. If
not initially leveled, the pump may
not remain level either. Problems
may also arise if the design ratio
of ring to shaft diameters is not
correct. Critical speed can also be
an issue. While the rotor may be
above the rst critical speed, the oil
ring speed is typically at 50 percent

of the shaft speed and may be
rotating close to critical frequency.
Other types of lubrication
include grease (with ball bearing
variations of shielded/unshielded
and sealed), oil mist, oil purge and
forced oil feed (oil is pumped to the
bearings for the larger HP pumps
and some marine applications).
Most motor bearings are greaselubricated, so it is important to
know if they are open, shielded,
sealed or a combination of these
options. If they are shielded on one
side, the best practice is to place
the shielded side toward the grease
tting. I have seen many end users
who order pumps with greased
bearings still add oil to the housing
simply because the installation,
operation and maintenance manual
(IOM) did not specically say not

to. Running the pump with greased
bearings and splash oil lube at the
same time is an incorrect solution.
Oil Changes
The rst oil change should be
conducted at a shorter interval
than subsequent changes to
eliminate the contamination that
occurs from startup and run-in
operations. Most ANSI and some
API pump manufacturers will
state that the rst change should
come at 200 operating hours and
subsequent changes at 2,000 hours
or 3 months, whichever comes
rst. The intervals depend on
operating temperatures and how
contamination ingress is managed.
Some operations will require more
frequent oil changes, and others
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26
can operate for several years. Oil sample analysis

and experience will aid in decisions regarding oil
change intervals.
Consider how often oil is changed in a car. If a
car was driven at 60 miles per hour for 24 hours a
day and 7 days a week for one year (8,760 hours in a
year), it would drive 525,600 miles.
You would never drive a car that many miles
without changing the oil.
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Automatic Oilers
Several automatic oiler types and brands are on the
market. The question to ask is whether the oiler is
vented to atmosphere or to the housing. Old designs
vented to atmosphere, but that is how moisture
gets to the bearing housing and oil. The new best
practices are to vent the oiler to the housing and
keep the housing sealed.
The old method was to also vent the housing,
but that was a source of contamination. The
vents should be eliminated or, at the very least,
used with a desiccant breather or an equalizer
expansion chamber.
Lip Seals Versus Bearing Isolators
For more than a hundred years, lip seals have
served the industry well. While they are simple and
inexpensive, end users should consider replacing
them with the more modern and ecient bearing
Figure 2. Cross section of bearing isolator
27
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28
The modern bearing isolator will, on average, last eight to 10 years

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isolators. Lip seals, regardless of the

manufacturer, will, at best, only last
about 3,000 hours in service. After
approximately four months of operation,
they will fail and potentially allow
water or other contaminants to enter
the bearing housing. The advent of the
bearing isolator is what has allowed
many pump manufacturers to extend
their warranties from one to ve years.
The modern bearing isolator will, on
average, last eight to 10 years and, if
properly managed, even longer. During
that time, the isolator will not wear/
score a groove on the shaft and, for the
most part, will prevent the introduction
of contamination to the bearing housing
at both operating and static conditions.
Bearing isolators can be of the labyrinth
or contacting face design, and there are
numerous designs and manufacturers.
The majority of bearing isolators
are orientation specic; they normally
have a drain hole (expulsion port) that
should be in the 6 oclock position. If
the port is not at the correct position,
the isolator will not perform properly.
For some types of ANSI pumps, the
outboard isolator will have numerous
evenly spaced expulsion ports because
the housing it ts into can be rotated
when setting the impeller clearance.
The nal position will not be a xed
parameter as it is in other designs, so the
isolator incorporates numerous ports to
satisfactorily operate in any position.
Overfilling the Bearing Housing

One of the most common problems
I see in the eld beyond not reading
the instructions is the over lling of
the bearing housings with oil. Bearing
isolators (labyrinth style) will purge any
excess oil from the housing. A common
misconception is that the isolator
29
DSI full page
30
has failed, but it is just doing its

job. The oil will continue to be
expelled until the level is below the
expulsion port.
Setting the automatic oiler
level incorrectly is the next most
common mistake in the industry.
Please refer to the manufacturers
instructions for the proper
procedure. Hint: The level in the
oil bulb is not the level of the oil
in the pump housing nor is it the
centerline of the connecting pipe.
Conclusion
Centrifugal pumps are shipped
without oil in the bearing housings;
consequently, the end user must
ensure that oil is in the housing
before startup. The oil must be
of the proper viscosity. The oil
viscosity selection is based on
expected temperatures of the oil

and bearings. The oil supply source
should be clean, and the oil must
remain uncontaminated between
changes. In addition, the oil must
be at the proper level in the bearing
housing. Too much oil is just as
bad, if not worse, than too little oil.
Most bearings fail because of
contamination from water and/or
heat. Labyrinth or magnetic face
type seals (bearing isolators) can

help prevent water introduction
and contamination. Desiccant
breathers or automatic oilers that
vent to the housing in lieu of the
atmosphere can also reduce the
introduction of water.
Read more online
pumpsandsystems.com/
commonpumpingmistakes.
Jim Elsey is a mechanical engineer who has focused on rotating

equipment design and applications for the military and several large
original equipment manufacturers for 43 years in most industrial
markets around the world. Elsey is an active member of the American
Society of Mechanical Engineers, the National Association of Corrosion
Engineers and the American Society for Metals. He is the general
manager for Summit Pump, Inc., and the principle of MaDDog Pump
Consultants LLC. Elsey may be reached at jim@summitpump.com.
Worldwide Electric
1/2 horiz

31
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32
GUEST COLUMN
By Heinz P. Bloch, P.E.
How Oil Viscosity & Temperature

Influence Bearing Function
First of Two Parts
By Heinz P. Bloch, P.E.
ome will know from their

experience with automobiles
that thicker oils, such as
Society of Automotive Engineers
(SAE) 30, are more appropriate
for warm summer months. But
thinner oils, perhaps SAE 10, can
help prepare a vehicle for winter
driving. Figure 1 illustrates where
these motor oils t in comparison
to the industrial oil designations
used today.
Thick oils are more viscous
and may not readily ow into the
bearings. Users can heat the oil
or avoid oil rings and other riskinducing lube application methods
by using smarter means. They can
use a jet of oil (oil spray) or convey
the oil mixed with compressed
air in the form of an oil fogalso
called oil mist. Whatever the user
chooses, he or she must guard
against using the thinnest oil
found on the market to avoid the
problem of inadequate oil lm
strength and thickness.
Lube Oils for Process Pumps

The MRC Engineers Handbook
states, In general, the oil
viscosity should be about 100
Saybolt Universal Seconds (SUS)
at the operating temperature.1
If for some reason a bearing was
operating at 210 degrees F, Figure
1 would call for a lubricant with
an International Organization
for Standardization (ISO)
viscosity grade (VG) somewhere

between 220 and 320. But that
is unrealistically thick for most
process pump bearings. Oil rings,
if used, would probably slow down
and malfunction in such viscous
oils. Oil overheating may be an
additional concern.
Figure 2 shows a graph from
SKF that is time-tested and widely
applicable.3, 4 It depicts the required
minimum (rated) viscosity v1 as
a function of bearing dimension

and shaft speed.3 A bearing with a
mean diameter of 390 millimeters
(mm) at a shaft speed of 500
revolutions per minute (rpm) would
require v1 = 13.2 centistokes (cSt).
For another example, if a bearing
was mounted on a 70-mm shaft
rotating at 3,600 rpm, we might
assume that the bearings outside
diameter (OD) is twice its inner
diameter (ID), or 140 mm. The
Figure 1. Oil viscosity comparison chart per common industry conversion

practice (Courtesy of the author)
33
Figure 2. Required minimum (rated) viscosity v1 as a function of bearing
dimension and shaft speed.3 A bearing with a mean diameter of 390 mm at a
shaft speed of 500 r/min will require v1 = 13.2 cSt. (Courtesy of SKF)
bearings mean diameter would be 105 mm. To

simplify, consider it 100 mm, and travel up from
100 to a location midway between the 3,000
and 5,000 rpm lines in Figure 2. In this instance,
one could operate with a lubricant which, at the
bearing operating temperature, is somewhere
between 8 and 9 cSt.
Note that a bearings operating temperature
must be known to determine what ISO VG is
needed. The operating temperature derives its
combined thermal input from bearing load and
lube oil frictional drag. Unnecessarily viscous oils
will become hot. Figure 3 (page 32) is helpful in
this regard. Note that Figures 2 and 3 were drawn
years ago and apply to mineral oils. If users choose
premium grade synthetic oils, they will enjoy a
sizeable safety factor in lube applications.
Using lubricants with viscosities in excess of
those needed may generate excess heat and actually
work against operators. However, thicker oils have
their place, and MRC had to cover all the bases with
their 100 SUS rule-of-thumb.
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34
GUEST COLUMN
Reliability professionals would like to see pump bearing

housings with no oil rings, no need for constant level lubricators and
few, if any, repeat failures. They start with the right lubricant.
That said, a large bearing (200

decimeters) in a slow speed gearbox
(200 rpm) requires an operating v1
of 40 cSt. Figure 3 shows that ISO
VG 100 (or higher) oils would be
needed here.
Real-World Example
In a recent case history, ISO VG
100 was applied to a large pump
where ISO VG 68 mineral oil or its
equivalent ISO VG 32 would have
suced. An ISO VG 32 synthetic
is the bearing life equivalent
of an ISO VG 68 mineral oil.
The synthetic ISO VG 32 runs
considerably cooler than the
mineral oil equivalent.
With ISO VG 100 mineral oil, the

oil-misted radial bearing ran a few
degrees in temperature lower than
it had with conventional sump and
oil ring lube. The user was pleased
but expressed disappointment at a
triple-row thrust bearing running
as hot as before190 F.
A premium formulation
synthetic ISO VG 32 would have
been sucient and would have
given the user everything a solid
reliability professional could have
asked for.
Reliability professionals would
like to see pump bearing housings
with no oil rings, no need for
constant level lubricators and
Figure 3. For a required viscosity (vertical scale), the permissible bearing

operating temperatures (horizontal scale) increase as thicker oils are chosen
(diagonal lines). Users enter the vertical scale near 9 cSt and move toward the
right, where the line intersects with oils ranging from ISO VG 22 through ISO
VG 320. If the user selects ISO VG 32, he or she might start the pump and verify
that its oil temperature had leveled off at no greater than 75 C. Alternatively,
the user might choose ISO VG 68 and verify that its operating temperature
does not exceed 100 C (212 F). The information in this figure is per common
rule of thumb, using average viscosity improvers. (Courtesy of the author)
few, if any, repeat failures. They

start with the right lubricant.
Why, with all that, is the radial
bearing cool? After all, it is also
surrounded by the thick ISO VG
100. It is cool because it has no
load. The load is in the triple-row
thrust bearing, and that creates
temperature in addition to the
frictional temperature mentioned
earlier in this article.
Part 2 of this series will examine
which temperatures are reasonable,
which are high and which are out of
allowable range for rolling element
bearing housings and pump
bearing housings.
References
1. MRC Engineers Handbook, General
Catalog 60, Copyright TRW, 1982
2. Bloch, H.P.; Improving Machinery
Reliability, Gulf Publishing Company,
Houston, TX, 1983, 1993
3. SKF America, General Catalog,
Kulpsville, PA (2000)
4. Bloch, H.P. Pump Wisdom: Problem
Solving for Operators and Specialists,
John Wiley and Sons, Hoboken, NJ, 2011
Heinz P. Bloch has been a

professional 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 may be reached at
heinzpbloch@gmail.com.
35
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36
SPECIAL REPORT
INDUSTRY UPDATE
New HI Document
Provides Guidance on
Dynamic Analysis of
Rotodynamic Pumps
This 10-year project concluded with the recent publication of
recommended guidelines for pump professionals.
BY J. CLAXTON, P.E.
PATTERSON PUMP COMPANY, A GORMAN-RUPP COMPANY
he Hydraulic Institute (HI) recently announced

the publication of a new document, ANSI/HI 9.6.8
Dynamics of Pumping Machinery, that addresses
the need for guidance on dynamic analysis of
dierent pump applications.
Developed through a large cooperative committee of HI
pump manufacturer members, HI Standards Partners and
HI Associate Members, almost all HI rotodynamic pump
member companies were represented at various times
during the 10-year period required to produce this
new document.
The Dynamics of Pumping Machinery document
was initiated in 2005 during a revision of the 2000
edition of HIs normative vibration standard, ANSI/
HI 9.6.4-2000 (since superseded by ANSI/HI 9.6.42009), when the committee recognized that guidance
information pertaining to dynamic analysis contained
in that standard was best addressed in a separate
guideline document.
The concept was to create a document that provided
guidance to the pump industry regarding recommended
best practices for dynamic analysis of pumps and
pumping equipment across the immense scope of pump
types and applications addressed by HI Standards (see
Figures 9.6.8.1.2a, 9.6.8.1.2b and 9.6.8.1.2c, page 38).
A pressing need exists in the market for guidance on

pump dynamic analysis. Over the past few decades, an
accelerated trend in the use of variable speed drives (a
trend most likely to continue) is making it increasingly
dicult to avoid resonance and vibration issues. While
analytical tools and techniques have been developed to
address these challenges, no comprehensive guidebook
has been available that discusses the use of standard tools
and techniques from a standards perspective. Most other
guidelines pertain to specic product types or markets.
In consideration of the full scope of equipment
congurations and application characteristics associated
with various rotodynamic pumps, a single approach does
not address all needs. No existing directives provide
guidance on what tools should be used across various
applications, dierent markets and diverse products.
These and other issues are addressed by HIs new
Dynamics of Pumping Machinery.
Dierent preventive measure techniques are available;
some are simple, while others are complex. While most
pumps do not require analyses when purchased, some
applications need complex analyses and others require
something between the extremes. In other words, one
solution does notand cannott all.
Dynamics of Pumping Machinery provides guidance on
37
While analytical tools and techniques have been developed to address these
challenges, no comprehensive guidebook has been available that discusses the
use of standard tools and techniques from a standards perspective.
what types of dynamic analyses should be

performed on dierent pump installations.
It provides assistance for choosing the
right level, if any, of dynamic analysis
required to ensure the suitability of the
pumping machinery design, recommends
standard approaches and outlines what to
consider in certain situations. However,
the guidebook does not address how
to perform the details of the various
analyses. Special training and education
is typically required to perform analyses
within the full scope of this guideline.
The publication should complement the
objectives of organizations that provide
analysis tools and training or education
services to the industry.
As Dynamics of Pumping Machinery
serves as an information resource (not
a normative standard), compliance is
voluntary except as cited in contractual
agreements. The document can be used
to facilitate agreement among various
contractual entities involved in pump
procurement between the user (or
purchaser) and manufacturer (or supplier).
It is the prerogative of the document
user to decide on the degree of the
analysis, including whether to perform
additional analyses beyond those
recommended as a standard approach.
The pump manufacturer also can oer
guidance on the type of analysis relevant
for the specic installation and assist with
application of guidelines. Most important,
the guideline was developed to facilitate
coordination with the pump manufacturer
or supplier as an integral part of the
decision-making process.
Despite the broad scope of the guideline,
various specialty topics are excluded,
including seismic analysis considerations,
analyses involving certain considerations

38
SPECIAL SECTION
INDUSTRY UPDATE
Figure 9.6.8.1.2a. Rotodynamic pump types - overhung (Graphics courtesy of Hydraulic Institute)
of hydraulic excitations such as acoustic/pressure

pulsation analysis and analyses involving computational
uid dynamics (CFD) methods. Rotor stability analysis
is also outside the scope of the analyses conducted as
standard procedure. However, a rotor stability analysis
may be considered optional; some discussion is provided
regarding when such analyses are appropriate. Vibration
level acceptance criteria are excluded but addressed
in ANSI/HI 9.6.4 Rotodynamic Pumps for Vibration
Measurements and Allowable Values.
Dynamics of Pumping Machinery can be applied to
new equipment, existing equipment, eld modications
or re-rates (if dynamics characteristics are changed), and
eld troubleshooting. Evaluation scenarios may include
rotodynamic pump dynamic response, foundation support
eects, drive systems, ancillary equipment, and eects of
local foundation and piping systems.
The vast majority of rotodynamic pump applications
involve standard products produced from established
designs, and the user needs only to install the pumping
equipment in accordance with HI standards and the
manufacturers instructions to attain satisfactory life
and service. However, some applications involve custom
congurations that require additional engineering eort,
such as a substantially new pump design, signicant
pump modication, adaptation of a standard design to a
non-typical application, dierent physical arrangement
and dierent operating conditions. Applications also exist
in which the dynamic characteristics are signicantly
inuenced by the installation, such as piping systems,
Figure 9.6.8.1.2b. Between-bearings pump types

and classifications
39
Chemical Metering Pumps and Flowmeters
for Successful Water & Waste Water Treatment.
BHAT*LNK
Laneop]hpe_Iapanejc
Ejfa_pknLqil
Three Models
Available with Feed
Rates Ranging from
0.1 GPH/.03 LPH to
158 GPH/600 LPH.
Brushless Variable
Speed Motor.
Terminal Blocks in
Junction Box for
Remote Connections.
Patented Tube Failure
Detection, Patented
Safety Switch,
Patented Method for
Extended Tube Life.
Rotor lateral
Rotor torsional
Structural, including Reed frequency
analysis
For the purpose of categorization, the

guideline introduces three levels
of analysis for each of the three analysis
types:
Level 1 - Simple calculations

performed using standard or derived
equations
Level 2 - Intermediate methods that
involve basic mass elastic modeling
using commercially available software
tools such as nite element analysis
Level 3 - Advanced methods involving
multiple specialty programs and
complex methodologies, typically
undertaken by specialists
To guide the document user to the

appropriate analysis level, the following
tools and discussions are provided:
Decision matrix and uncertainty

values table to help quantify risk and
uncertainty
Market inuences considerations
Market trends considerations
Cost and lead time considerations
Examples of typical analysis types

are discussed in three sections, with
a section outlining each specic level
of analysis (Level 1, Level 2 and Level
3). Recommendations for numerical
procedures for Level 2 and Level 3
analyses are provided in an appendix.
Several other useful appendices address
term denitions, typical input data
requirements for the various analyses,
IP
P66
NE
EMA
A 4X
]GY
GY
YN"J
N JU]T
N"JU
U]
EXCLUSIVE! NEW
Flex-A-Prene is a multi-channel pump

tube assembly designed by Blue-White
exclusively for Proseries-M and Flex-Pro
Peristaltic Metering Pumps.
Flex-A-Prene is engineered for
optimum performance and
pressure capability.
OKJE?*LNK
Qhpn]okje_Bhksiapano)
@alaj`kjpda
__qn]_u
Works with clean or dirty fluids.

Non-invasive Clamp-on ransducers.
Full Spectrum of Pipe Size Capacities.
Smart External Communications.
Selectable Doppler or Transit Time.
T-Track Mounting System for Fast and
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www.blue-white.com
mounting and drive systems. In these

applications some type of dynamic
analysis may be needed.
The Dynamics of Pumping Machinery
guideline addresses three types of
dynamic analyses for pumps and
pump trains:
40
SPECIAL SECTION
INDUSTRY UPDATE
From a practical perspective, a 10 percent separation margin

obtained in the field is typically satisfactory to avoid unacceptable
vibration response amplification.
vertical structure natural frequency considerations,
vertical motor Reed frequency considerations and a
suggested analysis reporting format.
Two very important appendices contain sample
specications; one features sample specications for
applications involving motor Reed critical frequency
properties. These appendices provide simple cut-andpaste sample specication wording for use in contract
specications. This feature helps facilitate the proper
specication of dynamic analysis.
Use of suggested wording in these appendices produces
clear specications that can be understood by all parties
across contractual boundaries.
The appendices with sample specications are
organized by analysis level, analysis type and pump type
(when applicable) for ease of use while assuming that
the specier already has decided upon the appropriate
dynamic analysis and the desired minimum frequency
Figure 9.6.8.1.2c. Rotodynamic pump types vertically suspended
separation margin to be obtained through the analysis.

Lines are left blank to outline specications of the
minimum frequency separation margin desired through
the analysis for each analysis type and level.
The guidebook discusses recommended separation
margins. Note that often for cases involving variable
speeds with multiple excitation sources, successful
solutions using a desired margin may not be
obtainablea situation that is amplied by the use
of higher margins. As natural frequencies need a safe
landing area by design, large required margins by analysis
can make this more dicult. The broadly used 25 percent
marginespecially in the past when most pumping
equipment was constant speed and analysis tools were
limitedmay not always provide the best approach for
the challenges presented by todays applications.
From a practical perspective, a 10 percent separation
margin obtained in the eld is typically satisfactory to
41
avoid unacceptable vibration response

amplication. Of course, by analysis,
a higher separation margin than 10
percent is recommended appropriate to
the expected inaccuracy of the analysis.
However, Dynamics of Pumping
Machinery informs the user not to
speciy the margins unnecessarily high,
as this can be detrimental. In
the end, however, the specier
voluntarily chooses a desired separation
margin and inserts this information
in the sample specication wording
provided by the document for use in the
contract specications.
Users of the Dynamics of Pumping
Machinery are invited to direct
any comments or suggestions for
improvement to Peter Gaydon of
the Hydraulic Institute at pgaydon@
pumps.org.
The author would like to thank the committee
participants for their signicant and prolonged
eorts in producing ANSI/HI 9.6.8 Dynamics
of Pumping Machinery, including the following
individuals for their substantial individual
contributions:
Mick Cropper, Director - Technology, Sulzer

Pumps (US) Inc., Vice Chair
Bill Marscher, President, Mechanical Solutions,
Inc., Steering Committee Participant
John Anspach, John Anspach Consulting, Steering
Committee Participant
Jack Claxton, P.E., has been involved

with pump engineering for Patterson
Pump Company in Toccoa, Georgia,
since his graduation from Georgia
Tech. in 1975. He has served as the
Engineering Department head since
1980 and is currently vice president,
engineering. He served as the chair of the
Hydraulic Institutes Vibration
Committee from 1995-2012.
Since 2005, he has chaired
the Hydraulic Institutes
Dynamics of Pumping
Machinery committee.
42
SPECIAL SECTION
INSTRUMENTATION, CONTROLS & MONITORING
Protect Pumps with

One Essential Tool
Pump sensors can improve system operation
and detect dangerous faults.
BY CRAIG MCINTYRE
ENDRESS+HAUSER
modest investment in sensors can improve

the reliability and performance of expensive
pumps and pumping systems. In some cases,
spending a few hundred or a few thousand
dollars on instrumentation can protect a $50,000 pump
from serious damage, prevent process upsets, help
protect personnel from injuries and stop the spillage of
dangerous materials.
Pump protection starts with having the proper ow,
temperature, pressure and level sensors to monitor key
functions (see Figure 1, page 44). If the sensors are not
included when the pump was installed, they can be
added later.
Flowmeters can transmit process diagnostic
information to a maintenance management or control
system using a eldbus digital data link such as
EtherNet/Internet Protocol (IP). The maintenance
department can access this information to identify and
even predict certain problems. The controller can use the
information to optimize pump operation and perform an
orderly shutdown if necessary.
For example, process diagnostic data from a Coriolis
owmeter can indicate empty pipe detection (EPD),
density shift, temperature shift and other information.
This data can be used to nd and diagnose problems
and to recognize minor issues before they grow into
substantial problems. The EPD diagnostic can trigger an
alarm to the control system, which can shut the pump
down to prevent dead head or dry running damage.
Flowmeter vendors provide this kind of information
in real time. Depending on the eldbus, owmeters can
also provide diagnostic data directly to technicians in the
eld (see Image 1). EtherNet/

IP, for example, allows devices
to be polled by a condition
monitoring or automation
system to determine if any
diagnostic alerts need to
be sent to maintenance
personnel.
An industrial computer
equipped with asset
management, maintenance,
condition monitoring or human-machine interface
(HMI)/supervisory control and data acquisition (SCADA)
software can access real-time data and diagnostic
information directly from the devices. This data can then
be used to improve decision making and to implement
better real-time control.
Low-Cost Protection
A pump is dead-headed when it is operated at zero ow.
If no uid enters the impeller, friction leads to increased
uid temperature. The temperature can rise until uid
ashes into vapor, disrupting cooling ow to the pumps
bearings and packing. If sustained, this can cause
excessive wear, damage or an explosion.
A ow switch installed at the pump inlet can be set
to generate an alarm when the ow rate into the active
pump drops below a preset rate. A calorimetric ow
switch can indicate a low/no ow condition, allowing
personnel to shut down equipment before damage occurs.
As described in a recent American Institute of
Chemical Engineers bulletin, pumps that are accidently
43
Basin installation in Lake Ariel, Pennsylvania

(Images courtesy of CRANE Pumps & Systems)
Image 1. With a laptop or a

network station, a technician
can access diagnostic data
directly from flow, level,
pressure, temperature and other
transmitters connected to an
EtherNet/IP fieldbus network.
(Images and graphics courtesy of
Endress+Hauser)
blocked o can explode even if they

are pumping water. Some pumps have
instrumentation such as low ow, high
temperature or high pressure interlocks
installed to prevent running while
blocked in. These safety systems should
be properly maintained and tested.
A pump runs dry when insucient
uid is delivered to the suction side. If
a pump is allowed to run dry, it can cost
thousands of dollars to recondition the
pump or repair the damage.
An EPD switch can detect this
condition and allow for corrective
action (see Image 2). Electronic EPD
switches are more reliable than oat-sensor EPDs in some
applications. For example, a skid builder had problems
with oats sticking because material in the uid coated
the oats. The skid builder installed electronic EPD
switches, and false trips completely stopped, with no
pump failures related to switch malfunctions or burnt
pump packing reported.
Image 2. A simple $400

switch with EPD keeps this
pump from running dry.
EPDs are also available built in to some owmeters.

Most pump systems need a owmeter, so users can easily
specify one with EPD.
A temperature sensor can sometimes identify
overheating problems caused by low or no ow.
One temperature sensor uses thin- lm technology to
react seven times faster than standard temperature
sensors, giving additional time for corrective action.
44
SPECIAL SECTION
INSTRUMENTATION, CONTROLS
& MONITORING
Under Pressure
Centrifugal pumps have a specied
performance window of operating
curves. Those using variable frequency
drives (VFD) moving frequently out of
the best eciency point (BEP) window
or moving too far away from it may
produce damaging stress. Installing
the proper sensors helps identify
problems before the pump is damaged
and can allow planned actions to
minimize impact on maintenance and
operation resources.
For example, installing a pressure
sensor on the pumps suction side to
measure net positive suction head available (NPSHa) can help show whether
a pump is running within the proper performance curves. Temperature
or pump vibration monitoring sensors can indicate mechanical problems,
and EPD or low/no ow sensors can indicate when pumps are having
performance issues.
Highway Addressable Remote Transducer (HART) is a digital data
standard that superimposes information on 4-20 milliamp (mA) wiring
from instruments. A self-powered WirelessHART adaptor can be added
to existing 4-20 mA
analog instruments
with HART. This
adaptor transforms the
HART signals to their
wireless equivalent
and transmits this
information to a base
station.
Using wired or
wireless HART,
pressure, temperature,
ow and other
instruments can
provide pump
condition information
to maintenance
management and
control systems.
Suction pressure,
discharge pressure,
temperature readings
and other information
can be transmitted
using this method.
Pressure dierential
across the pump
Figure 1. Sensors monitor pump performance by measuring
can be determined
suction and discharge pressure, temperature, seal-pot level and
from the dierence
other variables.
between the measured
45
Figure 2. Temporary/fi xed

simultaneous measurements
of pump suction, discharge and
differential pressure (i.e., valve
blocking, filter/strainer loss,
density/viscosity, adequate
NPSHa) with single loop wired/
wireless transmitter
Checking Seal Pots

Pumping systems that handle toxic, hazardous or corrosive
uids cannot tolerate leaks. In such cases, a pump may have a
double or tandem seal using a compatible liquid injected into a
seal chamber to serve as a barrier uid.
If any hazardous product leaks across the inner or primary
YG"DWKNF"OQTG"VJCP"LWUV"OQVQTU0
suction and discharge pressures. A single

multivariable pressure device that can
measure suction pressure, discharge
pressure and dierential pressure
without capillary tubing is now available
(see Figure 2). HART- and wireless
HART-based digital information can be
transmitted from temporary or permanent
installations.
To avoid cavitation, the NPSHa must be
greater than or equal to the net positive
suction head required (NPSHr). Monitoring
the suction head can help identify
conditions that can damage the pump.
Several factors can change the NPSHr,
including increases in ow rate, uid
density or changes to the head pressure in
a supply tank in front of the pump.
Level switches can be installed near the
bottom of feed tanks to detect low NPSHa
conditions on the suction side of a pump if
the static level elevation is near or below
the pump centerline (see Image 3, page
46). The output of a level switch gives an
alarm or stops a pump if it is in danger of
cavitation.
High-pressure or vacuum conditions
may impact some applications. Ceramic
pressure sensors that measure abrupt
vacuum or pressure changes without
being damaged can be used in these
situations. Ceramic sensor pressure
transmitters can tolerate a great deal of
direct physical diaphragm abuse without
aecting calibration.
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W0U0"OQVQTU"ku"c"tgikuvgtgf"vtcfgoctm"qh"Pkfge"Oqvqt"Eqtrqtcvkqp0"Pkfge"Oqvqt"Eqtrqtcvkqp"
vtcfgoctmu"hqnnqygf"d{"vjg""u{odqn"ctg"tgikuvgtgf"ykvj"vjg"W0U0"Rcvgpv"cpf"Vtcfgoctm"Qhhkeg0

46
SPECIAL SECTION
seal, it enters the seal chamber and mixes

with the barrier uid. Improper control
and maintenance of the seal environment
can result in total seal failure and
unsafe leakage.
Supply tanks called seal pots serve as
a reservoir of clean, pressurized barrier
uid for double or tandem seal assemblies.
Fluid loss would result in catastrophic
failure of the seal and dangerous
conditions. For this reason, operators
must know if the uid level drops too low.
Seal pots generally have either a highlevel or low-level liquid switch, or both,
depending on the application. Seal pot
head pressure is monitored as well.
The low-level switch indicates barrier uid loss. The
high-level switch indicates hazardous product leakage
across the primary seal and into the seal chamber, which
adds uid volume and raises the seal pot level. Switch
outputs connected to the maintenance management of
control systems allow for corrective action.
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Eqoogtekcn
Owpkekrcn
Image 3. Level switches can be installed

near the bottom of a tank to prevent
pumps from reaching NPSHa conditions
that can result in cavitation.
A More Efficient System

Proper piping, valve and pump design can prevent
conditions that cause damage or failure. For example,
an automatic ow control device or a recirculation line
between the discharge and source lines ensures enough
ow though the pump to prevent overheating or damage.
Operation outside specication cannot always
be ensured by piping design, so instrument-based
monitoring should be considered.
In the real world, precise pump
sizing and piping design does
not always occur. Automated
monitoring and control help
deal with these and other
unexpected situations.
Pumps are vital, expensive
systems that consume a great
deal of energy and are expensive
to rebuild or replace. Adding a
few sensors to a system can help
Kpfwuvtkcn
pumps run more eciently and
identify problems before they
become serious.
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eqpvtqn"rcpgnu."ugrvke"vcpm"cnctou."
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nkijv"eqoogtekcn"crrnkecvkqpu0
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fgukipgf"eqpvtqn"u{uvgou"dwknv"vq"
kpfkxkfwcn"urgekhkecvkqpu"hqt"owpkekrcn"
cpf"kpfwuvtkcn"crrnkecvkqpu0"
PRIMEX
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yyy0rtkogzeqpvtqnu0eqo

Craig McIntyre is the

chemical industry manager
with Endress+Hauser in
Greenwood, Indiana. He holds
a Bachelor of Arts in physics
from Greenville College and an
MBA from the Keller
Graduate School of
Management. He
may be reached at
craig.mcintyre@
us.endress.com.
47
SPECIAL SECTION
Eliminate Cabling Costs

Through Proprietary
Wireless Networking
A German municipal water utility optimized pressure booster
stations with automated modules.
BY DAVE EIFERT & BENJAMIN FIENE
PHOENIX CONTACT
s Andres Suazo discussed in an article last

month (Pumps & Systems, May 2015), todays
industrial engineers have many ways to
monitor and control remote pumps, including
wired Ethernet, wireless cellular systems and proprietary
wireless systems. This follow-up article takes a closer look
at proprietary wireless systems. It will highlight how one
public water utility in Germany used a wireless system to
monitor tank levels and eliminate costly cabling.
Wireless technology continues to evolve. Many
manufacturers oer license-free proprietary wireless
radios. This technology has been widely accepted, thanks
to its reliable performance. Typical applications include
wireless I/O (replacing wired connections between eld
devices and control systems) or data radios (replacing
wired serial connections between intelligent devices).
Proprietary wireless modules use ISM bands. The

frequencies in the U.S. are as follows:
900 MHz (902 to 928 MHz)
2.4 GHz (2.4 to 2.484 GHz)
5 GHz (5.18 to 5.825 GHz, but not continuous)
Figure 1. In FHSS, the data hops from one frequency to another.
Although FHSS has low data rates, it has the highest tolerance for
interference. (Images and graphics courtesy of Phoenix Contact)
License-Free Proprietary Wireless Technology

In 1985, the Federal Communications Commission (FCC)
made several frequency bands available without a license
under certain conditions. These industrial, scientic and
medical (ISM) license-free frequencies would eventually
be adopted by industrial radio manufacturers and nd
their way into industrial applications.
48 igrqygteqpxgtukqp0eqo
SPECIAL SECTION INSTRUMENTATION, CONTROLS & MONITORING
49
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50
SPECIAL SECTION
Image 1. The pressure boosting

station is used as receiving
station from where the level
signal is transferred to the
central control room
Multiple radio networks can operate at any nearby

location or time on these frequencies. The transmissions
must avoid interfering with one another. Radios in the
ISM bands spread their signals among various frequencies
within the given band while allowing other radios to
operate in the same space. These radios use techniques
such as frequency hopping spread spectrum (FHSS), direct
sequence spread spectrum (DSSS) or orthogonal frequency
division multiplexing (OFDM).
FHSS is the most common method of transmitting the
data. In FHSS, the data hops from one frequency to
another (see Figure 1). Although FHSS has relatively low
data rates, the technique is appropriate for most SCADA
tasks and has the highest tolerance to interference.
Security is a key advantage of proprietary wireless
technology. Although the wireless engine and the
frequency range for a wireless device might be known (for
example, FHSS, 900 MHz), it would be extremely dicult

for an outsider to discover how that device works. This
creates a built-in barrier that prevents intruders from
intercepting or manipulating data transmitted on the
network. These wireless modules are usually encrypted.
Industrial applications also have requirements that
commercial installations do not. Wireless modules for
industrial use often require IP20 protection for cabinet
installation and IP65 protection for outdoor use. Many
locations will also require approvals for hazardous
locations, such as Class I, Zone 2, ATEX and IECEX.
Water Utility Networking

Lage, Germany, relies on a 233-mile network of water pipes
to supply drinking water to 9,000 homes in and around
the town. The annual demand is more than 380 million
gallons. More than 18 springs supply the water, which
51
Multiple radio networks can operate at any nearby

location or time on these frequencies. The transmissions must
avoid interfering with one another.
is then pumped to three water treatment plants. Eight

elevated towers store the drinking water.
Three pressure boosting stations maintain the constant
pressure necessary for the network. Computers in the
central control room in Lage are networked to monitor
most of the elevated towers and pump stations. The
computers indicate the operating states, document
the inows and outows, and statistically evaluate the
amount of water pumped. The system automatically
activates the pumps in the pressure boosting stations if
the level is not met. If a fault occurs, the system alerts the
on-call personnel or noties external technicians.
One of the elevated towers supplies approximately 1,200
residents of two local communities with drinking water.
Before the system was automated, an employee had to go
to the tower every day to manually read the level. Now,
the system constantly monitors the digital signal from
the level sensor in the elevated tower. If an error occurs,
personnel in the central control room receive immediate
notication so they can respond as quickly as possible.
Transmitting the signal to the central control room
from this remote location was particularly dicult, as the
elevated tank is at the edge of a forest and is connected
neither to the central control room nor power from the grid.
The next station that can be used to transfer the valuea
pressure boosting station connected to the central control
roomis approximately 1,000 yards away (see Image 1).
Solution Advantages
Public water utility employees in Lage chose a wireless
system with a stand-alone solar power system to provide
an independent power supply. By selecting both a wireless
I/O signal radio system and a stand-alone solar power
system, employees were able to eliminate the need to lay
any cable. This saved between $25 and $35 per foot for
digging trenches and routing cables.
We were won over not only by the lower costs
compared with the cable solution but also by the simple
commissioning and reliable operation, said Erhard
Heissenberg, who is responsible for water recovery
and supply at Lage public services.
The wireless link was set up based on the unidirectional

operating I/O system, which transfers two digital
switching signals and an analog signal between the
transmitter and the receiver. Although trees restrict the
line of sight between stations, antennas easily span the
1,000 yards. These wireless modules were specically
developed for transferring small amounts of data over
distances of several miles.
Image 2. The preinstalled control cabinet reduces the wiring

costs of the solar system; the wireless module automatically
establishes the wireless connection once the supply voltage
is connected.
52
SPECIAL SECTION
The universal solar module bracket enables the angle of

inclination to be set in various stages, allowing the solar system
to be used at virtually all latitudes.
In Germany, transmission power is limited to 100

milliwatts (mW), and the frequency band is 2,400 MHz
(2.4 GHz). In the U.S., the transmission power at 2,400
MHz is similar, but up to one full watt of transmission
power can be used at 900 MHz to drive the signal further.
Solar Power
The elevated tank is not connected to the public electrical
grid, so power must come from another source. The public
water treatment utility chose a solar power supply designed
specically for wireless applications.
The prewired control cabinet accommodates all
components needed to supply power to the wireless module
(see Image 2).
The universal solar module bracket enables the angle
of inclination to be set in various stages, allowing the
solar system to be used at virtually all latitudes. The

solar modules generate enough electric power to supply
the wireless module or other devices with energy and
to recharge the solar batteries. The system can supply
sucient solar power even on short, dark winter days.
The continuous wireless monitoring not only
reduces physical visits to the remote elevated tower;
it also increases process reliability and, in turn, plant
availability, Heissenberg said.
Simple Installation & Commissioning

Installation and commissioning of the wireless system
was straightforward, as the wireless link can be set
up without any parameterization and programming,
Heissenberg said. We obtain additional reliability by
monitoring the wireless link.
53
Power and status LEDs can be

directly seen at the device. An
isolated radio frequency link
contact and the analog RSSI signal
allow the remote diagnosis of the
wireless link. Faults resulting from
other wireless systems operating in
parallel are almost completely ruled
out, because wireless I/O modules
communicate in the license-free 2.4
GHz frequency bandwidth along
more than 600 channels selected on
a pseudo-random, FHSS basis.
By using wireless modules, we
have saved ourselves a lot of time
and money, Heissenberg said.
Moreover, they are reliable and
especially easy to set up.
The wireless link has been
operating trouble-free for more
than ve years. Since the local
telecommunications company
discontinued the dedicated leased
lines that previously connected other
elevated towers to the central control
room, we will replace quite a few
underground cables with a wireless
solution, Heissenberg said.
Dave Eifert is the

industry manager,
Water/Wastewater, for
Phoenix Contact, USA.
In Eiferts nearly 10
years with Phoenix
Contact, he has also worked in
automation and project sales roles.
Benjamin Fiene started his
professional career at Phoenix
Contact with training as IT
systems engineer. Since 2005, he
has worked in Communication
Interfaces Product Marketing,
where he is the contact person
for radio products
(Bluetooth, Trusted
Wireless), antennas
and systems for
autarkic power supply.
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The Power of Knowledge Engineering

54
MOTOR TECHNOLOGY
2 Simple Steps
to Choosing
the Right Motor
Consider more than the eciency
rating to select the most cost-eective
system for the pumping application.
BY MIKE STOCKMAN
FRANKLIN ELECTRIC
very pump industry professional faces the

challenge of choosing the most ecient system
for a particular application. This process is
complicated by the uncertainties of eciency
regulations, mandates and parameters, especially when
eciencies alone do not tell the whole story. Sometimes
the most ecient motor is not the best choice.
By using two simple calculations, pumping
professionals can determine the best motoras well as
the best pump and drivefor each application.
To help both consumers and installers, nearly every
product sold today features an energy cost or energy star
rating. Industry standards and regulations developed by
a coalition of industry experts help control these ratings,
including multinational organizations such as The
National Electrical Manufacturers Association (NEMA)
and International Electrotechnical Commission (IEC).
The goal of these organizations is to help individuals
and power companies save money on energy and
infrastructure costs by reducing confusion in methods of
measurement and providing consistency in terminology
and product labeling. This standardization minimizes
incorrect measurements, misleading nomenclature
and false competitive advantages. All reputable
manufacturers support and collaborate with agencies
like NEMA and IEC to maintain the professional
standards of the organization. For this reason, users must

ensure all of their products adhere to these standards.
Pump users often gravitate toward motors that report
the highest eciencies because they believe this decision
will lead to future cost savings. This, however, is not
always the case and is another reason end users must
check the standards rst. Companies that do not adhere
to the standards could label their products as super
ecient, for example, or make similar false claims.
In many cases, the terms used on product labels are
convoluted. For example, a company could invest in
the original design of a 100-horsepower (HP) system,
increase its eciency by 16 percent and label it super
ecient. According to the standards, however, this
55
Image 1. Analyze both the capital
expenditure and the total energy cost
of the pumping system to identify the
motor that is truly the most efficient for
an application. (Images and graphics
courtesy of Franklin Electric)
eciencies is a vital part of choosing equipment, end

users must go beyond eciencies to select the ideal motor
for an application. For example, submersible motors
are generally 80 percent ecient, while similar surface
motors are 90 percent ecient. Based on these numbers
alone, one would assume that a submersible motor is
less ecient. This, however, is not necessarily the case.
Incorporating pump end eciency in the assessment and
evaluating horsepower requirements based on motor
speed is vital.
Two simple calculations can help end users go beyond
basic eciencies to select the ideal motor for a particular
pumping application.
Step 1. Measure WWE

The rst step is to measure true eciency by analyzing
the complete wire to water eciency (WWE) of the
pumping system (see Equation 1).
One-hundred percent eciency is impossible if any
component within a system is less than 100 percent
ecient. Consider the following examples.
Example 1. 50-HP, 2 Pole (3,600 RPM) pumping system:

The system has an 84 percent ecient motor, 45 percent
ecient pump and 99 percent ecient control/drive. Its
WWE is 37.42 percent (see Equation 2).
This system has a 90 percent ecient motor, 76 percent
ecient pump and the same 99 percent ecient control/
drive. Its WWE is 67.72 percent (see Equation 3).
Every motor and pump manufacturer is required
to publish full load eciency data for standard rated
products. Be aware of data accuracy, and note that
improvement in design does not meet the criteria for

premium eciency. While the new product is 54 percent
ecient compared with the previous product that was
only 38 percent ecient, the
minimum eciency required for
WWE = [(motor eciency) (pump eciency) (control/drive eciency)] 100
a premium label is 68 percent.
Equation 1
Despite the fact that this product
has been improved, it still does
not meet the premium eciency
(0.84 motor 0.45 pump 0.99 control/drive) 100 = 37.42% WWE
Equation 2
requirements. In this way, agencies
and certifying bodies prevent
manufacturers from making claims
(0.90 motor 0.76 pump 0.99 control/drive) 100 = 67.72% WWE
that do not meet the standards.
Equation 3
While understanding standard
SERIES
MOTOR TECHNOLOGY

In the previous example, the system was 37.42 percent
ecient. The motor consumes 49 kW/HR (50-HP motor
from Figure 1) operating 24/7 for 30 days for a total of
35,280 kW consumed. At $0.20 per kW/HR, the power
cost per month is $7,056 (see Equation 4).
This system seemed to be the clear eciency leader at
67.72 percent ecient. The more ecient motor in a
line shaft turbine system is four-pole (slower speed)
but requires a 60-HP motor to generate the same head
and ow. Again, operating 24/7 for 30 days, this motor
consumes 62 kW/HR and 44,640 kW per month for a cost
of $8,928 (see Equation 5).
Figure 1. When analyzing pump efficiency, look at the head point of an
efficiency curve rather than solely using the BEP that most pumps list.
METERS FEET
EFFICIENCY
Web- or app-based sources for eciency ratings are

generally updated more frequently than printed
documents are.
As the industry evolves, changes are inevitable. A
subtle change has a multiplicative eect on total system
eciency. For this reason, end users should research the
same eciency data for pumps and controls/drives.
When choosing the proper motor eciency, users
should be aware that most motors will have a full load
(FL) and a service factor (SF) eciency rating, which will
depend on the load point from the pump. When selecting
the load point, reference the total HP requirements
needed. If the HP is at the rated full load point, use FL
eciency. If the load point is at the SF rating, use SF
eciency. The correct eciency rating is as important as
the total system eciency.
Most pumps will list a best eciency point (BEP). To
establish the pump eciency, look at the head point on
the eciency curve (see Figure 1). Gather the control/
drive details, and simply plug the data into the formula.
Analyzing these values closely is important because
they represent a cost position. Looking only at total
system product eciency as noted above ignores the
energy consumed by the system. Dierences in speed
and HP can result in higher energy costs, even when the
eciency ratings seem to indicate high eciency.
Users must also consider the needs of their
applications. Some systems may run for only a couple of
months out of the year, while others may run every day to
supply water to a city/municipal system. For systems that
will run for years, the cost of operation is paramount.
While the energy cost for a continuous run system will
be much higher than that of a short run, the savings
calculation is similar. The amount of savings will be
diminished by the amount of run time.
HEAD
COVER
US GPM
Step 2. Measure energy cost

The second calculation regarding eciency determines
energy cost. All power companies charge for kilowatthours (kW/HR). The rate varies by location and provider,
so the following examples will use $0.20 per kW/HR.
Regardless of whether an application is submersible or
surface-mounted, motor speed and horsepower must be
analyzed to determine kW/HR used. Whether a user is
installing a submersible pumping system, a line shaft
turbine or a centrifugal system, the calculations are the
same. Note that the control/drive will have an eciency
point to include. This will provide the complete system
cost. Examples 1 and 2 analyze energy cost using the
same two pumping system examples from Step 1.
M3/H
METERS FEET
NPSH
56
US GPM
M3/H
RECOMMENDED OPERATING RANGE
49 24 30 = 35,280 kW/HR $0.20 = $7,056

Equation 4
62 24 30 = 44,640 kW/HR $0.20 = $8,928
Equation 5
57
Image 2. The submersible motor shown here
may actually be a more efficient option than
a surface motor, depending on the pump
and drive/control it is paired with.
To learn more about

industry standards, visit
nema.org or iec.ch.
determining motor and pump eciencies is an

important preliminary step. But when calculating the
nal system cost, users must include both the capital
expenditure and the energy cost of the system. In many
cases, the most ecient system may not be the most
cost-eective system.
Measuring eciency and energy cost oers more
insight into total cost of ownership.
The more ecient pumping system consumes

more watts and costs more to operate, so it might
not necessarily be the best choice for a continuous
run application. When choosing a pumping system,
Mike Stockman is the senior portfolio manager for

motors at Franklin Electric and has more
than 20 years of experience in surface and
submersible motor applications. For more
information, visit franklinwater.com or call
260-824-2900.
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58
COVER
SERIES
MOTOR TECHNOLOGY
How to Prevent the

Most Frequent Causes
of Motor Failure
Protecting these two components can lead to longer equipment life.
Last of Two Parts
BY ROB AMSTUTZ
GE POWER CONVERSION
otors represent a significant energy

expense for any industrial plant. To
minimize cost, users can ensure their
motors run as efficiently and reliably as
possible. Operators should focus on caring for bearings
and windings, the two components that most commonly
lead to motor failure.
Last months Motors & Drives column (Pumps &
Systems, May 2015) detailed some common causes of
premature bearing failure, such as lubrication and
vibration, and steps that motor users and manufacturers
can take to prevent these problems. Part 2 of this series
will focus on winding failures.
Winding Failures
After bearing failures, winding failures are the next
highest failure mode in motors. Windings fail because of
temperature, coating or caking on the frame, overloading,
and other problems.
An industry rule of thumb states that for every
additional 10 degrees C of winding temperature, the
winding life drops by a factor of 2. Conversely, every
10-degree reduction in winding temperature doubles
the winding life. A common practice is to specify Class
F insulation with Class B rise. Figure 1 shows the
differences in temperature for the three most common
insulation systems used in motors.
Simply specifying Class F insulation with Class B

rise gives the user a 25-degree reduction in winding
temperature under its limit, which should increase
winding life by a factor of 5. If a user specified Class H
Figure 1. Winding temperatures of different insulation classes
(Graphics courtesy of GE Power Conversion)
59
insulation with Class B rise, winding life

would increase by a factor of 9. This can
cover a lot of misapplication issues.
Figure 2 shows a real-world example of
what a user can do to improve winding
life. In the top two photos, the motor is
covered in pulp, and the external surface
temperature is 74.4 C. When the motor
was cleaned, however, the external surface
temperature dropped to 35.8 C. This simple
action could result in an increased winding
life by a factor of 8, assuming the winding
temperature also dropped 40 C.
Service
Motor users can also have some control
over service factor. Running a motor into
its full service factor of 1.15 normally
increases the winding temperature by more
than 10 C. Simply running the motor into
the service factor can cut the winding life
in half.
Figure 2. Temperature measurements of a motor in a paper mill

60
COVER
SERIES
MOTOR TECHNOLOGY
Motors are usually run into

service factor for one of two
reasons. First, unforeseen
events can happen in the eld.
This is exactly why service
factor existsto ensure the
motor can operate higher than
its nameplate power in case of
unforeseen circumstances. This
should be temporary, and the
root cause should be investigated
and corrected.
Second, sometimes motors
are knowingly sized to run into
service factor to reduce the
initial cost. A simple exercise
will demonstrate why this
should be avoided. Assume that a
75-horsepower (HP) motor costs
an end user $6,700. Assume that
a 60-HP motor costs an end user
$5,700. The actual values are less
important than the dierence
in price.
At rst glance, $1,000 seems
like a large dierence. Assume
that a system is being developed
that requires a 69-HP load
from the motor. A 60-HP motor
operating at 1.15 service factor
could theoretically drive that
load. The National Electrical
Manufacturers Association
(NEMA) Premium eciency level
for a 60-HP motor operating at
60 HP in a 25 C environment
is 95.0 percent. However, the
eciency of this motor could
drop by more than an entire
NEMA band to 94.4 percent at
1.15 service factor.
This reduction in eciency is
caused by higher temperatures
leading to higher resistances in
the stator and rotor, resulting
in higher I2R losses. A 75-HP
motor operating at 75 HP in a
25 C environment is required to
be 95.4 percent ecient. At 69
HP, this motor could actually
increase in eciency up to 95.7
percent ecient. Both motors

meet the Department of Energy
legislation for premium ecient
motors. Assuming the motor
runs 365 days per year and 24
hours per day and assuming
the electricity cost is $0.07 per
kilowatt-hour, the 75-HP motor
running at 69 HP saves $541
per year compared with the
60-HP motor. In less than two
years, only the electricity cost
dierence will make up for the
dierence in initial cost.
The temperature rise also has
implications. If both motors
were designed at Class B rise
at 1.0SF, which is a common
specication, the 60-HP
motor running at 1.15 service
factor will have a temperature
rise of approximately 105 C.
The 75-HP motor, however,
will have a temperature rise
of approximately 70 C. If
both motors have the same
insulation system and the same
expected relationship between
temperature rise and insulation
life, the 75-HP motor will run 35
C cooler than the 60-HP motor.
This would result in winding life
increasing by a factor of 7.
About 80 percent of the
winding rise turns into bearing
temperature rise on the drive
end bearing of a totally enclosed,
fan-cooled (TEFC) motor. In
the example, using the 60-HP
motor and operating it into
service factor means that the
bearing will be 28 C hotter than
using the 75-HP motor at 70 HP.
According to SKF, every 15 C of

increased temperature results in
a halving of the grease life. This
means grease life will decrease
by a factor of 4 as a result of
using an undersize motor.
Manufacturer &
End User Actions
Bearing and winding failures
account for almost threefourths of motor failures.
Motor manufacturers can help
prevent these failures by using
bearing caps and end shields
that fully protect bearings from
contamination, building motors
with low vibration levels, using
greases that are commercially
available and identifying the
grease for the end user. They can
also improve motor winding life
by using low-temperature rises
coupled with high-temperature
insulation systems.
End users can increase the
bearing and winding lives in their
motors by specifying things like
Class F (or H) insulation with
Class B rise and low vibration
levels (0.04 inches per second).
The end user can also ensure
that the motor is properly sized
to keep the temperature rise
down, which will help prevent
the system design from forcing
the motor to run into its service
factor. Together, manufacturers
and end users can ensure that
they are setting themselves up
for success by having a properly
designed system that will ensure
a reliable and long motor life.
Rob Amstutz is a senior application engineer with GE Power Conversion

focusing on 1- to 1,000-HP motors. He spent 20 years
in various engineering, information technology and
commercial operations roles at GE. He holds a Bachelor of
Science degree in mechanical engineering from Purdue
University and a Masters of Business Administration from
Indiana Wesleyan University.
61
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62
COVER
SERIES
MOTOR TECHNOLOGY
Stainless Steel Ideal for

Equipment in Sanitary
Environments
This motor material provides an improved total cost of ownership for
the food and beverage industry.
BY DAVID STEEN
BALDOR ELECTRIC COMPANY
ince their inception more than 100 years ago,

the two main types of motors in use have been
open drip proof (ODP) and totally enclosed
fan-cooled (TEFC). When a motor is operated in
a dry environment with little or no exposure to water or
contaminants, the ODP motor is a viable choice. TEFC
is typically the motor choice for equipment exposed to
moisture or the environment.
As industry demands increased and sealing
technologies improved during the latter part of the past
century, manufacturers were able to do more to protect
motors from the environment. With the growth of the
food industry, guidelines were created to ensure that the
equipment used to produce food was clean and sanitary.
The washdown motor was the result.
Early washdown motors include painted white motors,
which provide a clean appearance and improved sealing
(compared with general purpose motors), and paint-free
motors, which provide a combination of aluminum
and stainless parts with no painted surfaces. The more
costly cousin to these rst two lines of motors is the
stainless steel motor.
Although the varieties of washdown motors have
increased over the years, many end users still buy motors
based on the price tag, looking for the most cost-eective
design that will provide the best longevity. Because of
this paradigm, some users may not be willing to pay 40
to 50 percent more for a stainless steel motor. In the past
several years, however, motor users have embraced the
Epoxy encapsulated stainless steel pump washdown motor

(Courtesy of Baldor Electric Company)
idea of total cost of ownership, which goes beyond the

initial purchase price.
Washdown motors are generally categorized in three
categories, listed here in order of price and feature set:
painted white washdown, paint-free aluminum and
stainless steel. Many end users, particularly those in large
food processing facilities, may utilize all three. Painted
washdown motors still oer users a good value in that they
can use them in a variety of wet or dry applications that
see some levels of moisture and some light washdown.
Others may upgrade an area of the plant to a paint-free
motor, which utilizes a combination of stainless steel and
processed aluminum components (no paint). These motors
also have better shaft seals and can withstand higher water
pressures and some cleaning solutions.
In the most harsh applications, however, the stainless
steel motor is the motor of choice, as it uses a number
of the best technologies available, such as fully welded
conduit boxes, O-rings in endplate to stator joints
and enhanced sealing around the shaft exit points.
Understanding these feature levels will greatly improve
the end users ability to apply the proper motor to the
proper application.
63
When evaluating total cost of ownership, value is a vital

factor. While white washdown motors are still widely
accepted and used more than stainless motors, the food
industry is beginning to recognize the value of spending
the extra money on a premium ecient stainless product.
Stainless steel motors continue to gain acceptance,
and much of the need for them in the U.S. is driven by
the passage of the Food Safety Modernization Act. This
act covers facilities registered with the Food and Drug
Administration (FDA) under the Bioterrorism Act of
2002. This law gives the FDA the authority to shut down
a food processor or other related facility that indicates
by reasonable belief that a hazard exists. A shutdown
for an indenite period of time can have far-reaching
implications for a food processor. The purpose of the law is
to ensure beyond any reasonable doubt that all equipment
in a facility does not pose any risk or even an appearance
of risk that would cause a negative FDA inspection.
Stainless steel motors can help provide this assurance.
One point of contention with washdown motors,
especially foot-mounted designs, has been the perception
that food can collect in crevices. Most motor designs

contain models that have crevices around the motor feet
that can collect food, which can lead to contamination.
When selecting a stainless motor, users should consider
equipment that has smooth corners and minimal
crevices or areas that can collect contamination. Better
use of seals around the motor shaft, such as dual seals
or labyrinth seals, as well as O-rings used in place of
traditional caulk-style materials have also improved
washdown motors over the past several years.
While these designs are more costly up front, stainless
steel premium ecient motors are key to improved total
cost of ownership and a more sanitary environment.
David Steen is the product manager for Baldor Electric
Companys Definite Purpose Motors. Steen
has worked for Baldor, a member of the ABB
group, for 22 years and has a background in
mechanical design engineering. He may be
reached at 479-646-4711 or
david.steen@baldor.abb.com.
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64
COVER
SERIES
MOTOR TECHNOLOGY
Bearing Protection for

VFD-Driven, Explosion-Proof
Motors Improves Reliability
In plants that process combustible materials, these motors avoid
electrical damage often caused by energy-saving inverters.
BY RICK MUNZ & ADAM WILLWERTH
MARATHON ELECTRIC MOTORS
new line of explosion-proof, inverter-duty motors

provides a solution to the problem of electrical
bearing damage caused by energy-saving
inverters (also known as variable frequency
drives) in petrochemical plants and other facilities that
process combustible materials.
These motors are designed with longer and tighter
tting joints (also called ame paths) that, in the event of
an explosion in the motor, cool the escaping gases enough
that their energy is insucient to ignite when they exit
the enclosure. These new explosion-proof motors with
bearing protection meet the requirements of National
Fire Protection Agency (NFPA) Division 1 and Division
2, Class I and Class II while protecting the bearings from
inverter-sourced shaft voltages.
First of its Kind

Safety standards prohibit the external mounting of
potential arc-producing devices (including conventional
grounding brushes) in Division 1 or Division 2 hazardous
locations. However, installation in a Division 1 motor
enclosure is permissible, as long as the previously described
ame path is not compromised. This internal-mount design
is approved by Underwriters Laboratories (UL).
The new National Electrical Manufacturers Association
(NEMA) premium explosion-proof motors carry an
ingress protection (IP) rating of IP 54 as published by
the International Electrotechnical Commission (IEC)
for severe-duty motors regularly exposed to water
spray, chemicals or particulates. Available from 3 to

50 horsepower, these stock motors include a Class F
insulation system and are name-plated 60/50 Hertz,
190/380 volts at the next lower horsepower.
Types of Hazardous Locations

The NFPA standards dene Class I areas as areas where
ammable gases or vapors are or may be present in
sucient quantities to produce ignitable or explosive
Figure 1. Typical of high-amplitude EDM discharges, this

waveform shows the buildup of voltage on an ungrounded motor
shaft, followed by a discharge. The vertical line indicates a sharp
drop in voltage. (Graphics courtesy of Marathon Electric Motors)
65
mixtures. Class II areas are those where combustible dusts, such as grain
or coal dust, are or may be present.
A Division 1 location is one in which ignitable concentrations of
ammable gases, vapors or dusts may be present in ambient air, either
continuously or intermittently, during normal operations or maintenance.
Division 2 locations are those in which ammable gases, vapors or dusts
may be present intermittently but are normally conned and can escape
only if there is a rupture of the vessel or system in which they are contained.
Explosion-proof motors are not required in Division 2 locations.
Shaft grounding devices are not permitted on non-explosion-proof
motors that will be used in Division 2 locations, even if they are installed
inside the motors. This is because non-explosion-proof motors are not
designed to fully contain an arc-induced explosion within the enclosure.
End users seeking bearing-current protection for a Division 2 location
should consider purchasing a Division 1 (explosion-proof) motor with
suitable protection from bearing currents.
In here,
downtime is
not an option.
usa.siemens.com/perfectharmony
SINAMICS PERFECT HARMONY

delivers uptime, all the time.
Whenever youre on the clock,
hazardous chemicals keep you
on your toes. And when a
critical process fails, lost
production concerns are
second only to safety.
In the chemical and
petrochemical industry,
operating conditions will never
be perfect but at least your
drives can be.
10,000+ drives sold
50+ years industry experience
How Inverters Cause Bearing Failure

Because inverters can save 30 percent or more in energy costs, they have
been cited as a key technology for those wishing to make their processes
more energy ecient. However, inverters cause voltages and currents that
can damage bearings. In fact, the costly repair or replacement of failed
motor bearings can oset much of the savings an inverter yields and
severely diminish the reliability of an entire system.
Although it is now common knowledge that two-level inverters cause
unwanted motor shaft voltages, many end users who purchase three-phase
alternating current (AC) induction motors do not realize that models
labeled inverter-duty or inverter-ready might not be equipped to
prevent bearing damage. While many such motors have inverter-rated
insulation systems to protect their windings, their bearings are often
ignored. If they are to be used with inverters, they need bearing protection.
Bearing damage is
often overlooked
until it is too late to
save the motor. In
fact, electrical damage
has become the most
common cause of
bearing failure in
inverter-controlled
AC motors.
In 1993, inverter
manufacturers
introduced the rst
1,200-volt insulated
gate bipolar transistors.
Transistor turn-on
Figure 2. The very small voltage discharges (2-3 volts) shown
above are typical of motors with a shaft grounding ring installed. time dropped from 2
These continuous small discharges prevent the accumulation
to 0.5 microseconds or
of high voltages on the motor shaft and the damage their
less. The old 230-volt
discharges can cause to bearings.
inverters were replaced
66
COVER
SERIES
MOTOR TECHNOLOGY
Figure 3. Unlike conventional shaft grounding brushes that wear

out quickly and are easily fouled by oil, grease or dust, the shaft
grounding ring lasts for L-10 life of the motor bearings and is
unaffected by contaminants.
by 460-volt and 575-volt models. These faster rise times

and higher voltages increased motor shaft voltages
dramatically, resulting in a sudden global increase of
bearing failures during the 1990s.
One motor manufacturers decision to provide a motor
shaft grounding ring in these motors resulted from years
of rigorous testing. In the mid-1990s, the manufacturer
began investigating the phenomenon, with the goal of
nding a viable, cost-eective solution.
The companys research identied three simple means
to protect motors from inverter-sourced shaft voltages.
1.
2.
3.
Install an effective common mode fi lter at the

output of the inverter. Although these lters work,
they are expensive, take up space and often require a
dedicated power transformer at the inverters input.
Replace both of the motors standard bearings
with bearings that have ceramic rolling elements,
which block the inverter-sourced high frequencies.
These bearings are expensive and often have long
lead-time from the manufacturer. Further, insulated
bearings are not permitted on Division 1 or Division
2 motors because the bearings conduct static
charges produced by fan belts or plastic cooling
fans. Insulated bearings could permit random static
charges to accumulate to levels high enough to ignite
combustible gases or dusts.
Provide an effective high-frequency shaft ground
to bleed voltages to a safe level.
Effective Shaft Grounding

In most instances, the economical solution is a
maintenance-free, long-life microber shaft grounding
ring that protects attached equipment and the motors
bearings. NEMA Standard MG1-2009 (Revision 1-2010),
Section IV, Part 31, Denite-Purpose Inverter-Fed
Polyphase Motors, states: Shaft voltages can result in
the ow of destructive currents through motor bearings,
manifesting themselves through pitting of the bearings,
scoring of the shaft and eventual bearing failure.
The NEMA standard also points out that insulating
the motor bearings will not prevent the damage of other
shaft connected equipment. When the path to the
bearings is simply blocked by insulation, the damaging
current seeks another path to ground. This other path
can go through a pump, gearbox, tachometer or encoder,
which can sustain bearing damage of its own.
Unlike conventional single-point-contact brushes, the
bearing protection ring encircles a motors shaft with
multiple contact points for far greater eectiveness.
Conductive microbers line the entire inner circumference
to completely surround the shaft. This design boosts the
rings electron transfer rate. Providing very low impedance
from shaft to frame, the ring safely and eciently bleeds
damaging currents to ground, bypassing a motors
bearings entirely. And because the microbers work with
little or no contact, they do not wear out like grounding
brushes. Most grounding brushes also require extensive
maintenance and replacement. Metal spring-pressure
brushes, for example, are easily contaminated by corrosion
or clogged by debris. Carbon-block (graphite) brushes have
an another drawback: They are susceptible to hot-spotting,
in which an arc briey fuses the brush to the motor shaft.
Some other mitigation attempts, such as the
installation of ceramic bearings, can shift damage to
connected equipment. Other methods aimed at reducing
bearing current are eective but only for the short term.
Conductive grease, for example, quickly loses much of its
lubricity, resulting in excessive mechanical wear.
The bearing protection rings design maintains
electrical contact between its microbers and the motor
shaft to divert harmful shaft voltages whether or not the
microbers are touching the shaft. This ensures that the
ring will last the life of the motor regardless of motor
speed, even in the presence of contaminants.
Without physical contact, electron transfer is
accomplished through three distinct processes that
work simultaneously.
1. Tunneling of electrons. This mechanism is based on
electrons to tunneling across an insulating barrier
and works for gaps smaller than 2 nanometers (nm).
67
Figures 4, 5 and 6. The shaft grounding ring maintains electrical contact with the motor
shaft, whether its microfiber brushes are in physical contact with the motor shaft or merely in
proximity to it. If physical contact with the shaft is broken, electron transfer is accomplished
through three distinct processes: tunneling of electrons (Figure 4, left), field emissions of
electrons (Figure 5, center) and the Townsend avalanche of gaseous ions (Figure 6, right).
3.
Field emissions of electrons. Field emission is a form of quantum

tunneling where electrons move through a barrier in the presence of
a high electric eld. It provides grounding across gaps of 2 nm to 5
micrometers (m).
Townsend avalanche of gaseous ions. This results from the cascading
eect of secondary electrons released by collisions and the impact
ionization of gas ions accelerating across gaps greater than 5 m.
Conclusion
VFDs oer improved control of ow rates, pressures and other key process
variables in chemical processing and other explosion environments, but
virtually all inverter-driven motors are vulnerable to bearing damage.
Until recently, the shaft grounding brushes used to protect motor bearings
actually posed an explosion risk in explosion environments. To address
these challenges, a motor manufacturer has recently introduced a line
of explosion-proof motors with bearing protection designed specically
for VFD operation in these environments. The bearing protection makes
motor life more predictable and allows chemical plants to schedule routine
maintenance (or replacement) of the motors in order to avoid costly
unscheduled downtime.
Rick Munz, product manager for Regal-Beloit Corporation, is

responsible for Marathon and Century branded commercial
and industrial motors. He is a graduate of UW Wisconsin with a
Bachelor of Science in marketing and economics.
Adam Willwerth, sales and marketing manager for Electro
Static Technology, has extensive experience in industrial product
development and commercialization. He holds a Master of
Business Administration degree from Southern New Hampshire
University and a Bachelor of Science degree in management
from the University of Maryland.
Out here,
downtime is
not an option.

When your rig is anchored 20
miles offshore without a speck
of land in sight, service calls
arent simple. And when your
pipeline has to pump 150,000
barrels a day to stay on schedule,
uptime is everything.
In the oil and gas industry,
operating conditions will never
drives can be.
99.99% availability
Advanced Cell Bypass
2.
68
COVER
SERIES
MOTOR TECHNOLOGY
DOC Engine Technology

Provides Cost-Eective
Tier 4 Compliance
Pumping packages that use a diesel oxidation catalyst can
minimize cost, maintenance and equipment downtime.
BY ANNE CHALMERS
PIONEER PUMP
he U.S. Environmental Protection Agency (EPA)

has adopted a comprehensive national program
to reduce emissions from diesel engines.
Implemented in a series of progressively more
stringent tiers, the new standards require reductions in
carbon (soot), hydrocarbons from fuel and lubricating oil,
metallic particles, and watery sulphuric acid.
Until this year, diesel engines have had to comply
with the Tier 4 Interim standard, which specied lower
emissions but did not reach the full goal.
Beginning Jan. 1, 2015, the new Tier 4 Final standard
requires all new diesel engines used in o-road equipment
to meet substantial reductions in emissions. To meet the
full Tier 4 standards, diesel pump package manufacturers
are required to use engines with advanced emission
controls. Tier 4 requires all diesel engines to have
reductions in particulate and nitrogen oxide emissions.
While previous generations of diesel engines could
achieve the lower Tier 3 and Tier 4 Interim standards by
managing emissions within the combustion chamber,
Tier 4 Finals more stringent standards require an aftertreatment device.
In addition to these EPA standards, California and
other states have either implemented or are considering
additional carbon emissions that regulate the total
emissions allowed for a given project. The contractor
operating the equipment or holding the permit is
responsible for compliance. Contractual elements
sometimes require the person renting the

pump package to state that the equipment is
in compliance with all ordinances. This is of
particular concern for companies with large
eets of diesel pump packages that move
equipment from state to state.
Tier 4 Final compliant pump packages
have been available on the market for the
past year, but most are either expensive custom solutions
or have older engines to which a diesel particulate lter
(DPF) has been added.
DPF-congured engines rely on lters to remove soot.
Their primary disadvantage is that they require regular
regeneration cycles in which high heat is created to burn
the accumulated particulate from the lter.
These regeneration cycles require engine downtime,
and they also carry a substantial risk: If the regeneration
cycle is missed or delayed, the clogged lter can damage
the engine, often requiring factory repair. To avoid this
risk, DPF engines require substantial monitoring to
ensure regeneration cycles are occurring eectively and at
the proper times.
Because the regeneration cycle creates a disruption in
pump operation, jobs with a high volume of in ltration
may require a second pump on-site to run while the rst
pump undergoes the regeneration cycles.
A better solution for pumping involves an engine with a
diesel oxidation catalyst (DOC). DOC-congured engines
69
use a catalytic converter to promote oxidation of exhaust gas components by

oxygen, which is present in diesel exhaust. When passed over the catalyst, carbon
monoxide, hydrocarbons and particulates are oxidized, forming
harmless products.
The advantage of DOC engines is that they do not require regeneration cycles,
which minimizes maintenance, downtime and risk of expensive factory repair.
One manufacturer of EPA-compliant pumps has developed a Tier 4 Final
pumping solution that combines a 4-, 6- or 8-inch pump and an L4 DOC engine,
which has been specically designed for Tier 4 Final compliance, minimal
complexity and low installed cost.
The water-cooled, four-cylinder inline engine has a simple exhaust
aftertreatment. It is electrically controlled and has cooled, external exhaust gas
recirculation that eliminates the need for regeneration cycles. The engines DOC
enables maintenance-free operation under all ambient conditions.
Anne Chalmers, PMP, is the strategic marketing manager at

Pioneer Pump and the vice president of marketing for the Portland
Chapter of Project Management Institute (PMI). She may be
reached at achalmers@pioneerpump.com.
Around here,
downtime is
not an option.

When you have a city of 3
million relying on you for power,
shutdowns are serious business.
And when an outage occurs,
losing the lights is the least of
your worries.
In the power generation
industry, operating conditions
will never be perfect but at
least your drives can be.
#1 drive sold worldwide
50+ patented technologies
DOC Tier 4 Final engines do not

require regeneration, eliminating
disruptions in pump operation.
(Courtesy of Pioneer Pump)
70
COVER
SERIES
MOTOR TECHNOLOGY
Energy-Ecient Motors
Curb Environmental Crisis
The Chinese government is promoting greater automation and
optimization of processes to improve the energy utilization rate.
BY ZI NING CHONG
FROST & SULLIVAN
s the worlds largest energy consumer, China is

projected to consume two times more energy
than the U.S. by 2040. According to Chinas
12th Five-Year Plan (20112015), the annual
investment in power generation is expected to be more
than 5.3 trillion renminbi. Although thermal power is
expected to experience a tight control on its investment,
nuclear and other renewable power generation segments
are expected to attract more investment because of their
energy-saving and environment-protection capabilities.
China is the worlds largest coal producer and accounted
for 47.7 percent of world production in 2013, up from 43
percent in 2009. Its dominance as a consumer is even more
pronounced; it represented 50.2 percent of world coal
demand in 2012. The Chinese government has launched
an initiative to close down some coal-mining operations to
streamline the sector and improve safety standards.
After quantifying the impact of coal dependency, China
has paid billions of dollars for economic loss resulting
from environmental pollution. The worsening pollution is
now forcing the Chinese government to curb the problem
by further sacricing economic growth.
According to statistics, the electricity consumption of
industrial motors in 2011 was about 2.6 trillion kilowatthour (kWh), accounting for 75 percent of the total
industrial electricity consumption. The average eciency
of Chinas motors is 3 to 5 percent lower than that of
foreign countries, and the eciency of motor systems
is 10 to 20 percent lower than that of other countries.
The impact of inecient electricity use is creating
environmental problems and economic repercussions.
The pressure to ensure energy conservation, emissions
reduction and environmental protection has caused

manufacturers to turn their attention to high-eciency
motors. Because motor energy conservation has become
vital to industrial energy savings, motor eciency
remains one of the highest priorities for manufacturers.
As a result, many companies are planning comprehensive
upgrades to improve motor eciency.
China set a mandatory target of reducing its energy
intensity per unit of GDP by 20 percent in the 11th Five
Year Plan (2006-2010) and targeted 16 percent reduction
during the 12th Five-Year Plan (2011-2015). Strong
nancial incentives and regulatory policies have been
established to help the Chinese government achieve its
energy conservation and emission reduction targets.
China has also pledged to reduce its carbon intensity per
unit of gross domestic product by 40 to 45 percent from
the 2005 level by 2020. The Ministry of Industry and
Information Technology of the Peoples Republic of China
has stated that the motor eciency upgrading is a trial to
promote industrial energy conservation.
In 2013, China established the Motor Energy
Eciency Improvement Plan (20132015) for long-term
consideration and sustainable development. A 1 percent
increase in motor eciency is expected to save more
than 26 billion kWh of power in a year. A 5 to 8 percent
increase in motor eciency would save an amount of
power equal to two to three times the generation capacity
of the Three Gorges Hydropower Station.
The market condition in China, however, is slowing
the growth of the high-eciency motor market.
Manufacturers must improve motor capabilities and
optimize the motor industrial structure through
71
Because downtime is not an option.

SINAMICS PERFECT HARMONY delivers uptime, all the time.
When your cracked gas compressor

fails, production concerns are
second only to safety.
When a power outage occurs,
losing the lights is the least of
your worries.
#1 drive sold worldwide
And when your product is under

as much pressure as you are,
uptime is everything.
Operating conditions will never
drives can be.
Siemens equipped the SINAMICS PERFECT

HARMONY drive with 50+ patented
technologies proven to increase the
reliability of critical processes.
Its the only drive available today that
features Advanced Cell Bypass, and its
modularity provides a scalable solution
that achieves 99.9% availability.
With more than 10,000 drives sold,
the SINAMICS PERFECT HARMONY is the
No. 1 selling drive in the world because
its the most trusted.
p u mpsa
u ne 2015
Circlendsyst
117 on ems.c
card orom
visit| Jpsfreeinfo.com.
72
COVER
SERIES
MOTOR TECHNOLOGY
reorganization, elimination and integration to guarantee

the supply of high-eciency motors.
To promote high-eciency equipment, manufacturers
should comply with the compulsory motor eciency
improvement standard and eliminate low-eciency
motors from the market. End users must prohibit loweciency motors in new and reconstructed projects. The
goal of high-eciency motor promotion is to launch new
projects to carry out energy conservation improvements
in motor systems.
As manufacturing systems are becoming increasingly
complicated, managing the entire system through
manual labor alone has become more dicult. As a result,
automation is becoming more widely accepted because
of its convenience, eectiveness and labor savings. At
the same time, the demand for sophisticated motors
is increasing. This rise in demand generates potential
revenue growth opportunities and stimulates enterprises
to improve design, manufacturing and processing, which
will ful ll market needs and accomplish more work per
unit of electricity consumed.
Because they are constructed with improved
manufacturing techniques and superior materials,
energy-ecient motors usually have higher quality and
service factors, which increase reliability. While
energy-ecient equipment is able to handle higher
temperatures and other harsh conditions, maintenance
and service are still signicant and critical factors.
Downtime leads to a drop in productivity, which aects
protability. For this reason, maintaining motors
according to proper instructions is crucial. Motors also
require proper ventilation and periodic inspection to
maintain energy eciency.
Because motors are used in large quantities with long
running times, selecting energy-ecient equipment
provides signicant energy-saving potential. As a result,
decreasing a motors energy loss and increasing its
output eciency are now issues of concern worldwide,
particularly in China, where a major focus for the Chinese
government is energy savings and reduction in emissions.
As a key component of Chinas energy conservation
project, the motor energy eciency improvement plan is
systematically and strictly regulated and implemented. The
trend is toward greater automation and optimization of
processes to both improve the energy utilization rate and
control energy consumption and pollutant emissions.
Zi Ning Chong is a research associate of
Industrial Automation & Process Control for
Frost & Sullivan. Chong holds a bachelors in
journalism from Nanjing University, China.
She may be reached at zining.chong@frost.
com. For more information, visit frost.com.

Visit us at
Booth
262
TRADE SHOW COVERAGE
Electrical Apparatus Service

Association Convention
June 14-16, 2015
Grand Hyatt & Henry B. Gonzalez Convention Center
San Antonio, Texas
Exhibition Hours
Sunday, June 14
Monday, June 15
Tuesday, June 16
1 p.m.4:30 p.m.
Noon 4 p.m.
9 a.m. Noon
he Electrical Apparatus Service Association, Inc., (EASA)

is an international trade organization of more than 1,900
electromechanical sales and service irms in 62 countries. hrough
its many engineering and educational programs, EASA keeps its members
up-to-date on materials, equipment and state-of-the-art technology. he
EASA Convention is an annual event for electrical industry professionals.
his year, the event will be held in San Antonio, Texas.
EASA provides manufacturers and end users of motors and drives
with an opportunity to network. Attendees have access to technical
sessions and opportunities for optional service center tours. Many
types of electrical equipment will also be on display during the event,
and attendees can learn about updates and changes in the industry.
EASA at a Glance
Electromechanical industry
exhibition
Spouse/guest social package
Education programs
Youth/teen package
Variety of registration options
Family-friendly optional tours

Networking opportunities
National Fire Protection

Association Conference & Expo
June 22 25, 2015
Exhibition Hours
McCormick Place
Chicago, Illinois
Monday, June 22
Tuesday, June 23
Wednesday, June 24
he worlds leading advocate of ire prevention and an

authoritative source on public safety, the National
Fire Protection Association (NFPA) develops,
publishes and disseminates more than 300 consensus
codes and standards intended to minimize the possibility
and efects of ire and other risks. NFPA membership
totals more than 65,000 individuals worldwide. he NFPA
Conference & Expo is an annual event for ire, electrical and
4 p.m. 8 p.m.
11 a.m. 4 p.m.
10 a.m. 2 p.m.
building safety professionals. he 2015 conference will be

held in Chicago, Illinois.
he event provides an opportunity for attendees to hear
from experts in the industry, gain up-to-date knowledge
and network with fellow ire protection professionals.
he exhibition hall will include more than 300 solution
providers. here will also be opportunities to earn
continuing education units (CEUs).
73
74
MAINTENANCE MINDERS
Monitoring Software Enables Scheduled

Maintenance at Oil & Gas Facilities
Remote monitoring allows facilities to plan maintenance effectively before
defects result in downtime.
By Cynthia Stone
emote monitoring software

helps industrial facilities
know when a problem
arises before it leads to system
failure. With the large number of
components in operation at oil
and gas facilities, early warnings
can prevent small problems from
turning into big expenses.
Loose Bolt on a Lube Oil

Cooler Motor
A software monitoring solution
recently detected a gradual
increase in cooler vibration on
a lube oil cooler motor at an oil
and gas facility. Given the speed
and load on the machine, cooler
vibration was expected to be
around 0.15 inches per second (in/
sec). However, actual values were
reading up to 0.22 in/sec. The
software provider notied the end
user in a weekly report and began
tracking the issue on weekly calls.
After investigating the issue,

the end user discovered a loose
motor mounting bolt. The user
subsequently tightened the bolt,
and the vibration reading came
back to model prediction (see
Figure 1).
The oil and gas facility used the
notication to schedule a planned
intervention to address the increased
cooler vibration. If the issue had not
been addressed, the motor could
Figure 1. Cooler vibration increased up to around

0.22 in/sec. The user investigated and found a
loose motor mounting bolt. The user tightened
the bolt, and the vibration reading came back
to model prediction. (Graphics courtesy of GE
Intelligent Platforms)
Figure 2. Lube oil header temperature stepped

up to approximately 146 F (63 C), with the model
prediction at approximately 133 F (53 C). The
user found that the increased lube oil header
temperature was caused by a cooling fan being
inoperable due to a defective bearing on the fan
motor. The user replaced the bearing and placed
the cooling fan back in service. The lube oil header
temperature returned to model prediction.
75
have failed completely, which would

have led to a loss of lube oil cooling
and an unplanned shutdown.
Defective Bearing on a Lube

Oil Cooling Fan Motor
The software monitoring solution
also detected a step change in the
lube oil header temperature and
thrust bearing temperatures on a
compressor at another oil and gas
facility. Given the speed and load
on the machine, the lube oil header
temperature was expected to
remain at approximately 133 F
(56 C). However, the actual
temperature had increased to
approximately 146 F (63 C). The
Figure 3. The compressor discharge cooler motor

vibration increased from 0.3 in/s (7.6 mm/s) to
approximately 0.5 in/s (12.7 mm/s) . This issue
was caused by defective bearings. The user
changed out the bearings, and the vibration
readings returned to normal.
software provider sent a highpriority email notication to the

facility and began tracking the
issue on the weekly calls.
Upon investigation, the end user
discovered that the step change in
lube oil header temperature was
caused by a cooling fan, which was
inoperable because of a defective
bearing on the fan motor. The
facility subsequently replaced the
defective bearing and placed the
cooling fan back in service. The lube
oil header temperature returned to
model prediction (see Figure 2).
Early notication from the
software solution gave the user
an opportunity to ensure that
replacement parts were on-site to
proactively replace the defective
bearing. If the cooling fan had
not been repaired, the prolonged
elevated lube oil temperature and
associated lower lube oil pressure
would have resulted in accelerated
bearing wear on the compressor.
Bearing Issue on a Compressor

Discharge Cooler Motor
This same software monitoring
solution detected a gradual increase
in the compressor discharge
cooler motor vibration. Values
increased from 0.3 inches per
second (7.6 millimeters per second)
to approximately 0.5 inches per
second (12.7 millimeters per
second). The software companys
support center sent a high-priority

notication to the facility, and they
began tracking the issue.
Upon investigation, the
end user discovered that the
compressor discharge cooler
motor had defective bearings. The
user subsequently changed out
the bearings, and the vibration
readings returned to expected
values (see Figure 3).
Early notication from the
software monitoring solution
provided the oil and gas facility an
opportunity to order replacement
parts and schedule downtime. If
this issue had not been detected, it
would have caused an unplanned
shutdown or a rate reduction,
resulting in production loss and
excessive maintenance costs. The
support center was able to help the
facility verify that its maintenance
action was successful by showing
that actual values returned to
expected values.
Cynthia Stone is a product
marketing manager for Industrial
Data Intelligence at GE. She has
nearly a decade of experience
working in predictive analytics
for power, oil and gas,
mining and aviation.
Stone may be
reached at cynthia.
stone@ge.com.
76
MOTORS & DRIVES
Motor Automation Can Help Solve

Industry Labor Shortage
Process control software reduces costs while increasing process
accuracy and protection.
By William C. Livioti
umping systems account

for a signicant portion
of a facilitys energy use in
many industries. In the majority
of pumping systems, energy added
to the working uid by the pump is
much greater than required by
the process.
System reliability and eciency
are major topics within the
industrial sector, and they are
key to achieving sustainable
growth. Operating pumping
systems reliably and eciently
requires optimum system control
and protection.
With the current and pending
retirement of experienced
workers, who will take care of
this critical equipment?
According to a Government
Accountability Oce (GAO) report
issued in 2006, the percentage
of workers over the age of 55 is
projected to increase signicantly
during the next 20 years, with
this particular demographic group
projected to comprise as much
as one-fth of the nations
workforce by 2015.
A perfect storm appears to be
developing within the industrial
sector, and it seems to be growing
across all industries.
In this particular case, we have
multiple problems. On the upside,
there are solutions.
The number of applications in which induction motors are fed by VFDs is growing quickly.
(Courtesy of WEG)
Automated System Control

The pump industry has successfully
embraced the variable frequency
drive (VFD), and the number of
applications in which induction
motors are fed by VFDs is growing
quickly. Drive technology has
stepped up to the plate to meet
this growing demand and
addressto some degreethe
shrinking workforce.
Energy eciency depends not

only on the motor but also on
system control. VFDs oer high
eciency operation, typically
97 percent or more. Induction
motors also present high eciency
levels, reaching up to 96 percent
or even more in larger machines
operating at rated conditions.
When speed variation is required,
the output changes in an optimized
77
YGI"
Rolled"Steel"Line
PCS is designed to reduce system operation
and maintenance costs while increasing
process accuracy and protection.
Process Control Software

Many systems have multiple pumps
operating in parallel. However, not all
the pumps operate all the time. How
do you balance the operating hours of
these units?
Process control software (PCS)
can address the cycling of pumps.
PCS is designed to reduce system
operation and maintenance costs
while increasing process accuracy and
protection. The software provides
pump control and protection, as well
as system monitoring. PCS can be
applied to any system that requires
constant ow or pressure.
In the right conditions, PCS can:
Reduce system component cost

Improve system reliability
Reduce maintenance costs
Eliminate costly control panels
Reduce system energy
requirements
Reduce overall installation costs
Pump Protection
The right PSC can help prevent dry
well, air in the pump system, blocked
impeller, loss of prime and transducer
loss. It can also help prevent overtorque and cavitation.
PCS monitors system pressure or
ow while referencing low/high set
point and runtime requirements. The
lead and lag pumps are cycled on and
o based on motor run times. Motors
start or stop based on runtime. The
motor with the least amount of
runtime will start, and the motor
with the most runtime will stop. All
pumps are dynamically alternated
based on runtimes and system
set points.
Adapting to the Industry
Pump system control using PCS
technology addresses multiple
issues facing the industrial sector
today. The aging work force, energy
eciency, reliability operations
and maintenance reduction are all
challenges that PCS technology
can address.
William C. Livoti is the business development manager for WEG

Electric Corps Power Generation division. He has more than 30
years of experience in pump industry design, field testing, repairing
and troubleshooting mechanical seals, compressors and pumping
systems. He can be reached at wlivoti@weg.net.
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consumption and leading to high
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systemthe VFD plus the motor.
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78
SEALING SENSE
New FSA/ESA Gasket Handbook

Offers Guidance for Equipment
Usage & Troubleshooting
Professionals can now access comprehensive gasket
information and best practices in a noncommercial format.
By Mike Shorts
FSA Member
he Gasket Division of the

Fluid Sealing Association
(FSA) and the Flange Gasket
Division of the European Sealing
Association (ESA) have been jointly
working on a complete revision
to existing gasket handbooks and
associated documents for the past
three years. This project was led
by a working group consisting of
professionals representing six
FSA Gasket Division members,
the FSA technical director,
and a representative from the
ESA Flange Gasket Division
Technical Committee, along with
collaboration from nearly all FSA
and ESA member companies. The
handbook includes references to
several third-party publications.
It has been a tremendous
undertaking but one that has an
enormous amount of content value
for readers at every level.
The Gasket Handbook is part
of a mutual commitment to
industry and a consensus to
provide technical education
for end users, contractors,
distributors and students. It is
focused on technical information
for gaskets as components of
bolted ange connections. The
handbook is provided in the

public interest to help ensure
bolted ange connection
integrity with maximum safety
and environmental compliance.
It is not a catalogue of gasket
manufacturers products and
technology and is not presented
with commercial intent. The
Gasket Handbook is meant to
act as a complete and modern
noncommercial guide to gasket
users in the best practices for
gasket usage and troubleshooting.
Some may wonder why such a
generic document needs to exist
when individual manufacturers
have relatively detailed resources
of their own. FSA is asked this
question a lot. The answer is fairly
simpleour research indicates
there is a profound interest
in noncommercial gasketing
information. This handbook
is meant to be a fundamental
resource for gasket users and
a complimentary source of
manufacturers commercial data.
Because of the collaborative process
used to create this document, the
reader has access to information
that individual manufacturers may
not be willing to divulge.
Figure 1. The Gasket Handbook Table of Contents

(Graphics courtesy of FSA)
79
Figure 2. Bolts acting like springs (from Chapter 1, Figure 8)
Handbook Contents
Successfully sealing a bolted
ange connection is dependent
on all components of a welldesigned system working together,
eectively and safely. The Gasket
Handbook provides technical
information on gaskets as a
constituent part of a bolted ange
connection, typically employed in
chemical, petrochemical, renery,
power plant and other industrial
facilities. It includes guidance
for plant engineers on specifying
gaskets, for maintenance operators
on installing and troubleshooting
bolted ange connection leaks and
for purchasing personnel on the
important functional distinctions
between gasket types.
Contents include denition
of mechanical considerations
for a bolted ange connection,
important considerations for
anges and fasteners, and
installation best practices, with
a focus on gasket selection
and gasket-to- ange system
interaction. Gasket storage and
handling also are addressed.
Contents are organized for the
reader to quickly and eciently
nd the information needed,
while maintaining important
technical detail. It is intended
to complement plant-approved
documents. The Gasket Handbook
does not address compliance
requirements of regulations
specic to a particular industry,
facility or regulation body.
Therefore, readers should consult
appropriate local, regional,
national or federal authorities for

precise compliance requirements.
It is essential to note that the
condition and maintenance of
the connection will aect and
cause variations in the results
obtained from installation and
use of any gasket. Readers must
Figure 3. Considerations of bolted flange joint

connections (from Chapter 3, Figure 30)
80
SEALING SENSE
The intent of the Gasket Handbook is to consolidate industry and

gasket manufacturers best practices for gasket application and
installation and present this information in the main text.
ensure products and procedures

are suitable for their specic
application by reference to
the manufacturer.
The guidelines in the Gasket
Handbook represent the combined
eorts of member and associate
member companies of FSA and
ESA who have provided material
and technical personnel needed to
complete this work. While it was
developed with a global perspective
in mind, some regional nuances
are highlighted. The members
and associates of FSA and ESA
are established, reputable gasket
manufacturers, producing
quality products in accordance
with modern manufacturing
practices. The suggested procedures
are based on substantial and
proven experience.
Illustrations & Associated

Documents
The Gasket Handbook has been
structured in a deliberate format
that will take the reader through
forces acting on the bolted ange
connection, gasket categories,
gasket selection, installing gaskets,
diagnosing failures and a list
of frequently asked questions.
Accompanying the text are many
high-resolution, 3-D descriptive
graphics and detailed tables that
will assist the reader in fully
understanding the provided
content (see Figures 2 and 3).
The intent of the Gasket

Handbook is to consolidate
industry and gasket
manufacturers best practices for
gasket application and installation
and present this information in
the main text. The reader will nd
extensive supporting information
and references in the appendices
section. These references include
gasket testing standards, general
gasket manufacturing process
descriptions, emission regulations
and legislation information, as
well as a full list of previously
published FSA and ESA technical
articles, along with many other
useful references.
From the Working Group

The Gasket Handbook Working
Group would like to sincerely
thank every member company who
has contributed to the content
and creation of this publication.
Without this dedicated focus to the
project, it would have easily taken
many more years to complete.
The Working Group would also
like to thank industry leaders for
their belief in the tremendous
value of a noncommercial
resource for technical gasketing
information. After downloading
the new Gasket Handbook, please
make sure to thank your gasketmanufacturing supplier for their
contribution to this valuable
industry resource.
Release & Publication

The Gasket Handbook will be
released in two stages to allow
this valuable information to get
into the publics hands as soon
as possible. Chapters 1 through
3 are scheduled to be released in
Spring 2015 and the nal Chapters
4 through 6 are scheduled for
Summer 2015. The full document
will become available later in 2015
to provide the complete resource
in one le or hard copy. It will be
available on a free-to-read basis
through a link on the FSA and ESA
websites and can be purchased
for print and electronic storage
for a nominal fee. Please refer to
all FSA communications via our
website and follow us on Twitter
and LinkedIn for ocial release
updates and link information.
Next Month: What five new types
of expansion joints will be added
to the FSA Expansion Joints
Handbook?
We invite your suggestions for article topics as
well as questions on sealing issues so we can
better respond to the needs of the industry.
Please direct your suggestions and questions to
sealingsensequestions@fluidsealing.com.
TE
C
H
P
N
M
O
U
LOG
P
E
Y
EXPERTS
TH
81
MS
E
T
S
Y
S
adin
The Le
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ump U
id
orldw
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The Cost
of Clean
Water
How pumps play a role in the
WATER-ENERGY NEXUS
IFT OF
EX CL
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CO V ER
U SI V E
E A MP UMP
OM
G E FR
ZA M BI
A LA
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WI
FOOD PROCESSING
BUILDING SERVICES
S U R V IV
THE A
STATE
OF
C H E M I C ANAL
JAN UAR
P O W E R G E N E R AT I O N
UP S T R
ALSO INSIDE THE NEW OIL MARKET: What Can Operators Do to Improve Efciency?
Y
O LO G IT IE S
TE C H N
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P U M P G ES C O M M
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ING . C OM
CLEAENR
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THE G
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THE OI
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L & GA
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REPORT
GAS PO
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FR ACKIN
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SHOW
PREVIEW
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PETROL
EUM SH
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URSE
TURAL
TR ADE
COMPREHENSIVE COVERAGE
RELEVANT CONTENT
CASE STUDIES
WORLDWIDE NEWS
TECHNICAL ARTICLES
To subscribe to our print or digital editions and to sign up for our e-newsletters,
visit our websites and click on SUBSCRIBE.
PUMPSANDSYSTEMS.COM
PUMPSANDSYSTEMS.COM/MENA
UPSTREAMPUMPING.COM
82
HI PUMP FAQS
Corrosion Prevention, Rotodynamic Pump

Speed & How Harmonics Affect VFDs
By Hydraulic Institute
steel). This pump is commonly

used in hydrocarbon services
and some chemical applications.
Stainless steel tted pump:
The casing is made of materials
suitable for the service. The
Factors to consider in the
impellers, impeller rings and
selection of materials for wetted
shaft sleeves (if used) are made
pump components include users
of corrosion-resistant steel
experience, life cycle costs,
with suitable properties for the
regulatory agency requirements
application. This type of pump
(i.e. limits on lead content in
is also used in hydrocarbon and
bronzes that contact drinking
chemical services.
water), required pump life, duty
All stainless steel pump: All
cycle (operating hours per period),
pump parts in direct contact
corrosive and/or erosive properties
with the pumped liquid are
of the uid, hazardous nature
made of corrosion-resistant
of the uid, the potential for
steel with suitable properties
cavitation, and contamination of
for the specic application.
the uid. Corrosive and/or erosive
This pump is commonly used in
properties of uids may vary with
chemical applications.
temperature, concentration of
Rigid polymers/composites:
chemicals or solids, the properties
All pump parts in direct contact
of the solids, velocity, and the
with the liquid are made of
extent of entrained gasses.
rigid polymers or composites
Some frequently used materials
(plastics), either as coatings
are listed below.
or as structural material. This
Bronze-tted pump: The casing
pump type is commonly used in
is cast iron, and the impeller
chemical services.
and impeller rings are made
For more information on
of bronze. This combination is
commonly used for fresh water materials of construction for
pumps, see ANSI/HI 9.1-9.5
at ambient temperatures.
PumpsGeneral Guidelines.
All bronze pump: All pump
parts in direct contact with
the pumped liquid are made
When and how should
of manufacturers standard
speed for a rotodynamic
bronze. This type is often used
pump be monitored?
for pumping seawater.
All iron pump: All pump parts
Monitoring pump speed is
in direct contact with the
a vital part of overall condition
pumped liquid are made of
monitoring for many reasons.
ferrous metal (cast iron/ductile Knowing the pump speed is
iron, carbon steel or low-alloy
important for avoiding a known
What are the best

materials to use in pump
construction to minimize
part corrosion?
critical speed and for monitoring

head and ow rate, net positive
suction head (NPSH) and power.
Monitoring pump speed is also
important for vibration analysis,
avoiding speeds that are harmful
to the drive system design and
maintaining system control.
There are two types of systems
drive pumps: constant speed and
variable speed.
For constant-speed systems,
the motor speed is unlikely to
change signicantly unless a major
electrical problem has occurred.
While the load of a rotodynamic
pump varies with rate of ow, the
changes in speed associated with
the load changes are relatively
slight (less than 2 percent of full
load speed for NEMA Design B
motors). However, changes due to
high or low voltage or loss of power
to one phase on a three-phase
motor may be signicant.
Variable-speed systems rely
on speed change to control head
and rate of ow. These systems
can have the same problems
as constant-speed systems but
may also have unintended speed
changes resulting from a faulty
drive or speed-control problem.
When possible, blocking certain
speed ranges may be necessary to
prevent operation at or near rotor
or structural critical speeds.
Common methods of measuring
speed are strobe light, revolution
counter, tachometer or electronic
counter. Any of these devices
should be able to measure within
0.1 percent.
83

condition monitoring, see
ANSI/HI 9.6.5 Rotodynamic
(Centrifugal and Vertical)
Pumps Guideline for Condition
Monitoring.
What are harmonics,

and how do they
affect variable
frequency drives?
Harmonics are
undesirable voltages and
currents that may appear
on electrical power systems
as a result of certain types
of nonlinear loads, such
as computers, electronic
lighting, welding supplies,
uninterruptible power
supplies (UPS) and variable
frequency drives (VFDs).
When installing VFDs,
operators should consider
the existing harmonic
content and account for any
harmonic impact the newly
installed VFD may have on
the electrical system or the
electrical utility. Harmonics
can be a concern for any
size VFD, whether it is a
500-horsepower (HP) unit
in a building or a 75-HP unit
in an irrigation application.
Operators should review the
existing installationnot
just the current project
with consultants and drive
representatives in order
to nd the most positive
installation solution.
A full-wave bridge rectier
or converter converts
alternating current (AC)
power to direct current (DC)
power, no longer a sinusoid
waveform, and the
capacitor bank acts as
a lter smoothing this
converted voltage. All
AC/DC converters used in

dierent types of electronic
systems can increase
harmonic disturbances
by emitting harmonic
currents directly into the
electrical grid.
Harmonic distortion can
cause overheating of supply
cables and distribution
transformers (reduced
insulation life), LED and
lighting disturbance, nuisance
tripping of circuit breakers,
ancillary electronic equipment
damage and potential faulty
readings, and damage of
backup generators.
An active lter cancels
out most harmonics on the
current line. The active lter
injects equal and opposite
harmonic current onto the
line similar to the way that
noise-canceling headphones
inject noise-canceling signals
into the air around the
wearers ears. As the noisecanceling signal from the
headphone results in the
cancellation of noise, the
active lter cancels out the
harmonics.
variable frequency drives,
see the Hydraulic Institute
Guidebook Variable Frequency
Drives: Guidelines for
Application, Installation and
Troubleshooting.
Comprehensive
Industry Coverage
Positive Displacement Pumps

Centrifugal Pumps
Specialty & Other Pumps
Industrial Valves
Pneumatic & Hydraulic Valves
Industrial Automation & Process Control
Electric Motors & Drives
Actuators
Compressors
Custom Research
White Papers
Frost & Sullivan evaluates and implements

effective growth strategies. We employ 50
years of experience in partnering with Global
1000 companies, emerging businesses and
the investment community from more than
40 offices on six continents.
Visit us at www.frost.com
For more information, contact Liz Clark
at 210.477.8483 or liz.clark@ frost.com
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.

84

SPECIAL SECTION
EFFICIENCY MATTERS
Solid-Body AODD Pumps

Withstand & Contain
Dangerous Chemicals
This equipment avoids the risk of leaks and pipe damage associated
with injection mold pumps.
BY PETER SCHTEN
heres an old adageusually credited to Otto Von

Bismarck, the rst chancellor of Germanythat
says, Laws are like sausages. It is better not to see
them being made.
The implication is that reaching the consensus required
to create a new law can be unpleasant, and it may be best
not to know what the ingredients are and how that
consensus was reached.
The same can be said for some industrial processes,
whether it be the rening of petroleum products,
manufacture of pharmaceuticals or the treatment of
wastewater. These processes often require the use of
dangerous chemicals. Among them can be strong
acids and caustics such as hydrogen chloride (HCl),
hydrogen uoride (HF), nitric acid (HNO3), sulfuric
acid (H2SO4), potassium hydroxide (KOH) and sodium
hydroxide (NaOH).
Dangerous solvents are also used, including toluene,
a water-insoluble liquid that can cause severe reactions
in the body, and xylene, a slightly greasy, colorless,
ammable liquid with some level of acute toxicity.
Despite being dangerous, these substances are
invaluable in the manufacture of thousands of consumer
products and the production of components used to
create consumer goods or facilitate industrial processes.
The challenge for manufacturers and users of these
dangerous chemicals is to construct, handle and transfer
them in a way that eliminates any chance for their release
into the atmosphere.
Positive displacement (PD) plastic solid-body airoperated double-diaphragm (AODD) pumps have the
design and construction features necessary to guarantee
full containment of dangerous chemicals without
sacricing high levels of operational eciency.
Image 1. The need to use hazardous or dangerous chemicals in the

manufacture of numerous products or the completion of a wide array of
industrial processes is a fact of life. (Images courtesy of Almatec)
85
These competitive pump styles also have weaknesses

The Challenge
when it comes to the reliable, energy ecient transfer
Risk is an inherent part of handling substances comprised
of dangerous chemicals. Gear pumps, for instance, move
of dangerous chemicals. The release of these chemicals
liquids through the meshing of gears. As the gears wear,
can lead to severe health consequences for humans and
however, the pumps volumetric consistency is adversely
animals, as well as damage to the environment. Safety
when handling these chemicals is
a top concern for those who come
in contact with them. Cost is a
secondary concern. Chemicals are
often expensive, and any loss due to
leakage or release has a direct eect
on the manufacturers bottom line.
However, keeping dangerous
chemicals fully contained is often
easier said than done. Since many
of them are also highly corrosive,
the pumping equipment used
to transfer them is prone to
chemical attack if the materials of
construction are not compatible
with the acid, caustic or solvent.
End users should also consider the
Image 2. The plastic solid-body construction of some AODD pumps eliminates the small
design features of the pump. For
crevices or cavities that can be found in injection-molded models. It is in these crevices that
example, if the design incorporates liquids can accumulate and leak paths can be created.
mechanical seals or packing, they
may be prone to leaks.
Magnetic couplings and doublews
Flo
barrier seals represent attempts
on
i
t
a
to work around the deciencies of
ov
In n
e
r
mechanical seals. These methods,
e
For Handling
Wh
however, have other shortcomings
that limit their eectiveness.
The viscosity range of liquids
transferred by pumps with
magnetic couplings is limited by
the amount of transferable torque
that can be created. The use of
pumps with double seals or barrier
liquids can be impractical because
of the high cost and the level of
maintenance required.
Some common pump styles
Award-winning Almatec E-Series Plastic AODD pumps
that have traditionally been
provide safe and reliable performance when handling
See Us At ACHEMA, Hall 8 Stand D37
used to handle dangerous
the most dangerous acids, solvents and caustics.
chemicals include lobe, gear and
Polyethylene and PTFE materials, machined from solid
PSG Euro-Center
22069 Van Buren Street
blocks, also conductive (ATEX)
centrifugal models. While they
Grand Terrace, CA 92313 USA
Ring design structure for improved product containment
may be constructed of chemicalO: +1 (909) 512-1224
miguel.blanca@psgdover.com
Optional features available (e.g., barrier chamber system)
compatible materials, their design
World Headquarters
for further safety requirements
incorporates mechanical seals. The
Carl-Friedrich-Gau-Str. 5
Dry run ability, self-priming, gentle uid handling, no
47475
Kamp-Lintfort,
Germany
performance of these seals can be
rotating parts, no shaft seals
O: +49/2842/961-0
compromised over time, raising
info@almatec.de
For more information, please go to: psgpumps.com/ps615a
almatec.de
the possibility that leaks will occur
in the process.
Safe
Solutions
Dangerous
Chemicals
86
SPECIAL SECTION CHEMICAL PUMPS & EQUIPMENT

EFFICIENCY MATTERS
Image 3. Harsh chemicals can cause compatibility concerns when used with some types of pumps. One type of AODD pump can be constructed
of plastic materials that are specifically compatible with the chemicals they will handle, which eliminates corrosion and leak concerns.
aected. This results in unreliable ow rates and

increased energy usage. The operation of both gear and
centrifugal pumps can create turbulence in the pumped
liquid, which can lead to shearing that can damage or
alter the liquids chemical properties. Because they are
not true PD pumps, lobe models can be subject to product
slippage, which can make attaining a consistent ow
dicult and result in compromised production rates.
The Solution
AODD pumps avoid these shortcomings. Specically,
plastic solid-body AODD pumps are the preferred choice
in harsh chemical applications. In general, solid-body
AODD pumps are stronger and have a longer life cycle
with less required maintenance. Injection-molded plastic
pumps, however, can have small cavities or crevices in
the body where liquids can accumulate and potential leak
paths can be created. During operation, injection-molded
pumps can also bounce more, which can loosen pipework
and increase the chances for a product leak.
Plastic AODD pumps can be constructed of materials
that are specically compatible with the chemicals
they will handle, which eliminates corrosion and leak
concerns. AODD pumps are dry-run capable, easy to
control and sealless. Their compressible drive medium
permits gentle delivery with attenuated pressure peaks.
Startup is simple, and the space required is considerably
less than that of piston-actuated diaphragm pumps or
eccentric screw pumps.
One type of plastic body AODD pump oers features
and benets for handlers of dangerous chemicals.
Solid-body construction. The pumps are computer
numerical control (CNC)-machined from solid blocks
of polyethylene (PE) or polytetrauoroethylene
(PTFE). The result is a pump that is not prone to
the creation of leak paths and able to operate with

the most dangerous chemicals in the harshest
environments.
Diaphragm and containment ring. The pumps
feature a stainless-steel containment ring and ringtightening structure that helps create consistent hightorque compression. This pulls the components tightly
together and compresses the diaphragm in such a way
that a leak-free seal is achieved.
Image 4. Other positive displacement pump styles,

such as gear and lobe, lose volumetric consistency over
time, leading to higher operating costs. AODD pumps
reliably maintain their flow rates, resulting in optimized
production cycles and energy usage.
87
Full Containment
While we may not want to know what types of dangerous
chemicals, solvents, caustics or acids are used to make
paints, detergents, paper and fertilizer, we know that we
cannot live without them and that we do not want the
dangerous materials to be released to the environment.
That is why full containment of these hazardous,
ammable or explosive substances is a front-of-mind
concern for the plant operators who handle them. Those
concerns can be alleviated, however, through the use of
pumping equipment that has been designed to achieve
full containment of dangerous chemicals.
Image 5. During their operation, injection-molded AODD pumps
can bounce, which can loosen pipework and increase the
chances of a chemical leak. Solid-body AODD pumps are more
stable during their operation, which leads to a higher level of
product containment.
Air control system. The air control system is a lubefree valve with only two moving parts that allows
the pump to achieve superior ow-rate eciency
and air consumption, which lowers the overall cost
of operation.
Material compatibility.
The pumps housing can be
constructed of PE, PTFE, PE
conductive or PTFE conductive,
which allows it to be used
with a wide range of chemical
formulations. Additional
versatility in regard to material
compatibility is realized
through the availability of
ethelyne propylene diene
monomer (EPDM), PTFE/
EPDM and nitrile rubber (NBR)
diaphragms; EPDM, PTFE, NBR
and stainless-steel ball valves;
and PTFE cylinder valves.
Intrinsic safety. Pumps
that are constructed of PE/
PTFE conductive plastics are
intrinsically safe and meet the
requirements of the Explosive
Atmospheres (ATEX) 94/9/
EG directive. This means they
can be safely used in explosive
atmospheres or when pumping
ammable liquids.
Peter Schten is the Almatec product manager

with Almatec Maschinenbau GmbH, KampLintfort, Germany. He may be reached at
peter.schuten@psgdover.com or +49 2842
961-0. For more information, visit almatec.de
and psgdover.com.

88
SPECIAL SECTION
Stop Seal Failures in

Chemical Applications
Sealless pumps improve reliability and safety when
pumping hazardous uids.
BY JAMES GROSS
DICKOW PUMP COMPANY
ealless centrifugal pumps with a magnetic

coupling have become more popular among
end users in the chemical industry. Rare earth
magnets have reduced costs associated with
magnetic couplings by decreasing magnet mass and
required horsepower. This innovation has lowered the
cost of the coupling and the overall operating cost.
Seal failure is one of the most common causes of pump
maintenance and downtime. If the seal fails, uid escapes
along the shaft that connects the motor to the impeller.
Even when maintenance is scheduled, the pump must be
taken out of service to replace the seal.
While mechanical seal technology has improved
over time, the innovations often require additional
equipment. Double mechanical seals, either back-to-back
or in tandem, are common for harsh conditions such as
chemical pumping.
Maintaining the barrier uid in these designs often
means purchasing barrier uid tanks, controls and even
additional pumps. Gas seals are another option but also
require supporting equipment that poses the risk of failure.
At rst, end users only considered sealless pumps
when handling hazardous uids. The initial cost of a
magnetically coupled pump far exceeded a conventionally
sealed design. However, as time passed, operators became
more concerned with total cost of ownership than
preliminary capital outlay.
Magnetically coupled pumps began to show a true cost
advantage. Sealless designs replaced mechanically sealed
pumps that required yearly removal for maintenance.
Service intervals and mean time between failures
extended. Emissions decreased, and safety improved.
Operators now consider sealless pumps for services that
they would not have just a few years agonon-hazardous

applications that are still dicult and costly to seal.
In centrifugal pumps, the shaft transmits torque from
the motor to the impeller. A seal prevents the pumped
uid from escaping down the shaft. The seal includes two
parts, one stationary and the other rotating. Seal faces
are typically made of carbon, tungsten carbide or silicon
carbide (SiC).
In a magnetic sealless pump, the motor torque
rotates a magnet carrier, or drive magnets. The torque
is transmitted through a containment shell to an inner
magnet, or driven magnet. The magnet delivers torque
to the impeller. The magnetic eld creates eddy currents
when it passes through a metallic container. Ceramic
shells prevent eddy currents but can only contain a
Figure 1. Detailed internal circulation flow path for pump with
rear impeller allows for pressure increase prior to heat input.
(Images and graphics courtesy of Dickow)
89
limited pressure. These eddy currents create heat directly

between the magnets, and this heat must be dissipated.
Flow pathsa combination of passageways through
the pump shaft, the housing or bothcarry away the
heat in the pumped uid. The liquid travels from the
pump discharge to the driven magnet and back to either
the suction or discharge. The uid can aect the net
positive suction head if returning to the suction end.
A rear impeller on the driven magnet keeps the uid
under a higher pressure after absorbing heat from the
eddy currents. The pressure protects volatile uids from
ashing after heat is added in the container. The rear
impeller eliminates the need for utility cooling or costly
piping to return the uid to the suction tank.
In sealless pumps, wet end thrust balance is vital. The
Figure 2. Detailed internal circulation flow path for pump
with impeller injection bores allows for fluid to remain above
suction pressure.
Image 1. Sealless pumps deliver torque to the impeller through a

series of magnets within a containment shell. The pumped fluid
carries away the heat generated by the magnets during operation.
wet end oats, so shaft sleeves and sleeve bearings must

handle the radial thrust from the impeller and rotating
wet end. A stable uid lm and hydrodynamic force
support the shaft assembly. The uid does not lubricate
the bearings because they do not come into contact.
Axial thrust loads can pose risks during system upsets.
The wet end is designed to reduce axial force from the
pump, but startup rings, or axial thrust bearings, are
often employed when the system experiences changes.
When the gap between a startup ring and mating
surface closes, the force from the other startup ring
increases. If the suction pressure surges suddenly, the
front startup ring gap would close and the rear startup
ring gap would open. The pump automatically produces
a counterbalancing force in the direction of the pump
suction. When paired with SiC bearing surfaces, this
design allows for the wet end to have no parts that would
be considered routine maintenance parts.
The wearing surface of the shaft sleeves, sleeve
bearings and startup rings is commonly made of carbon
or SiC. The hardness as well as wear and heat tolerance of
SiC make it suitable for nearly any application. A coating
similar to diamond dust on the SiC surface enhances
lubricity and extends life, in case the liquid ow and
stable lm are disrupted.
Sealless pump manufacturers use several materials
for the wetted parts, ranging from cast iron to nickel
alloys, depending on the service. Some common materials
include ductile iron, carbon steel, 316 stainless steel
and duplex stainless steel. Wetted areas, even entire
pumps, are now being made from thermoplastics. These
materials perform well when pumping corrosive uids but
encounter serious limitations in high-pressure or hightemperature applications.
Harsh applications often demand a nontraditional
approach. When selecting pumps for chemical and
petrochemical processing, facility managers should keep
an open mind about how to best face the challenges of
sealing and pump maintenance. Sealless pumps improve
reliability, extend mean time between failures and reduce
total cost of ownership. This technology can have a
signicant impact on savings and safety in any facility, no
matter the application.
James M. Gross is the president of Dickow
Pump Company, located in Marietta,
Georgia. He has been in the pump valve and
related fluid-handling industry for more
than 20 years.
90
SPECIAL SECTION
CHEMICAL PUMPS
& EQUIPMENT
ACHEMA
June 15-19, 2015
Messe Frankfurt
Frankfurt, Germany
CHEMA, the world forum for the chemical engineering and

process industries, returns to Frankfurt with three tiers
of focus: biotechnology, process analysis and industrial
wastewater management. The events last showing, in 2012, drew
nearly 3,800 exhibitors and the selection of topics for this years
event gives a strong indication of beating that number. The emphasis
on important industry topics like analysis and wastewater will
certainly resonate with an audience that is expected to exceed to
the more than 166,000 participants from 111 countries in 2012.
The broad mix of end users, department heads, students and
other industry members will see the latest innovations in process
equipment for everything from abrasives to hydrocarbons to water
treatment. For more information, visit achema.de.
Exhibition Hours
Monday, June 15
Tuesday, June 16
Wednesday, June 17
Thursday, June 18
Friday, June 19
09:00-18:00
09:00-18:00
09:00-18:00
09:00-18:00
09:00-16:00
PRODUCTS
Diaphragm Metering Pumps
Powder Pumps
The ARO 2-inch powder pump
helps operators replace manual
powder processes with a highly
reliable transfer process that
reduces airborne contamination
and powder pack-out. Simplicity
and portability are hallmarks
of the pump. It also features a
patented stall-free major air valve
and a four-way eciency valve.
Circle 204 on card or visit
psfreeinfo.com.
Hayward Flow Control

announces a new line of
metering pumps for chemical
dosing systems and corrosive
environments. The pumps
feature just one design and
footprint with front facing
controls and tube connections
for easy and exible
installation. Available with
analog or digital controls,
the Z Series covers ow rates ranging from 1 to 14 gallons per
hour in just three pump sizes, oers stroke rates from 120
to 300 strokes/minute to cover all application needs, and is
backed by an exclusive two-year warranty.
Grinder Pumps
Zoeller Pump Company
announced the release of a new
Shark Fractional Horsepower
Grinder Series. Designed to handle
dicult residential and small
commercial applications where
sewage ejectors struggle, these 115
volt (V), 12 amp maximum (807)
circuit, all cast iron pumps represent
the worlds rst integral automatic
grinder. Available in 1/2 HP (803),
3/4 HP (805) and 1 HP (807)
models, these pumps oer performance head up to 55 feet.
Oil-lled for optimal heat dissipation, each model oers three
independent cutting channels.
Low Voltage AC Drive

Siemens announced the release of
its new single-axis Sinamics V20 AC
drive, frame size E, with both Low
Overload and High Overload ratings.
With a power rating ranging from 16
to 40 HP at 480V AC, Sinamics V20
drives are available in ve frame
sizes and are designed for material
handling, conveyor, pump, fan and compressor applications.
This compact drive can be connected and installed using the
conventional wall-mounting method, or it can be mounted
with heat sinks pushed through the enclosure wall.
Besides the universal serial interfaces that allow for
connection to Simatic programmable logic controllers, a
Modbus interface is also included for communication with
third-party controls.
Find more products and services in our

online product directory at
pumpsandsystems.com/directory.
To have a product considered for our Products page, please send the
information to Amy Cash, acash@cahabamedia.com.
U N M AT C H A B L E E X P E R I E N C E
I N F L OW C O N T RO L
TRANSACTIONS
Jordan, Knauff & Company is a knowledgeable and

experienced provider of a comprehensive line of
investment banking services to the pump, valve and
PXVEXMSRMRHYWXVMIW*PS['SRXVSP
Our lines of business include: selling companies,
raising debt and equity capital, and assistance
SREGUYMWMXMSRW
To learn more about Jordan, Knauff & Company,
contact any member of our Flow Control
XIEQ %GGIWW SYV *PS[ 'SRXVSP VIWIEVGL EX
[[[NSVHEROREYJJGSQS[GSRXVSP
+'SSO.SVHER.V
(EZMH%/EOEVIOE
Managing Principal
GN$NSVHEROREYJJGSQ

Senior Associate
HOEOEVIOE$NSVHEROREYJJGSQ

MEMBER FINRA, SIPC
91
92

Advertiser Name
Page RS#
ACHEMA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Advanced Technical Staffing Solutions, Inc. . . . . . . . . . . . . . .94
Advanced Engineered Pump, Inc . . . . . . . . . . . . . . . . . . . . . . . .92
All-Flo Pump Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Automationdirect.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Baldor Electric Company. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IBC
BASF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
BJM Pumps/ All-Test Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Blacoh Fluid Control, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC
Blue Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Blue-White Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Carver Pump Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Continental Pump Company . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Dan Bolen & Associates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
DSI Dynamatic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Dykman Electrical, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Eaton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Electro Static Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
FLSmidth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Franklin Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Frost & Sullivan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
GE Intelligent Platforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
GE Power Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Hayward Flow Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Heinrichs USA LLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Hydraulic Institute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Ingersoll Rand/ARO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Jordan, Knauff & Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Junty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Liqua Flow Pump Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Load Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Load Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
LobePro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
LUDECA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Magnatex Pumps, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
MasterBond Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Meltric Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
MISSION Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Motor Diagnostic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Mouvex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Nidec Motor Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
NOC Ningbo Ocean Fine Ceramic Technology Co., Ltd.. . . .95
Pinnacle-Flo, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
PPC Mechanical Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
PSG, a Dover company. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Scenic Precise Element, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Schenck Trebel Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Schneider Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC
SEPCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
SERO Pump Systems, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
121
159
169
122
101
102
119
103
104
146
120
123
162
176
106
136
115
107
138
108
151
124
100
135
152
153
125
154
180
139
126
173
178
127
155
160
171
128
145
129
130
166
140
164
141
174
134
114
167
163
117
147
Advertiser Name
Page RS#
Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Sims Pump Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sims Pump Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
SJE - Rhombus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
SKF /Electric Motor Condition Monitoring . . . . . . . . . . . . . .53
SPX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
St. Marys Foundry, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Summit Pump Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
TF Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Titan Flow Control, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Titan Manufacturing, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Toshiba International Corporation . . . . . . . . . . . . . . . . . . . . . . . 7
148
149
118
179
142
143
116
168
165
170
156
161
109
Advertiser Name
Page RS#
Trachte, USA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Tuf-Lok International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Tuthill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Vaughan Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Vertiflo Pump Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
VescoPlastics Sales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
WEG Electric Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
WEG Electric Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WEG Electric Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Westerberg & Associates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
World Chemical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Worldwide Electric Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Yaskawa America, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
175
158
132
110
172
177
112
111
144
157
181
131
113
MONITOR PUMP PERFORMANCE

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GO WITH THE PROS!! LOBEPRO ROTARY PUMPS
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Otyzx{sktzgzout","Iutzxury"Ktmotkkxy".Vu}kx/
Krkizxoigr"Ktmotkkxy".K,O,I/"
Krkizxoigr"Ktmotkkxy".Vu}kx/
Krkizxu"Skingtoigr"Ktmotkkx
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96
PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

By Jordan, Knauff & Company
Figure 1. Stock indices from May 1, 2014, to April 30, 2015
he Jordan, Knauf &

Company (JKC) Valve Stock
Index was down 16.3 percent
during the last 12 months, while
the broader S&P 500 Index was up
10.7 percent. he JKC Pump Stock
Index also decreased 15.4 percent
for the same time period.1
he Institute for Supply
Managements Purchasing
Managers Index (PMI) was
unchanged and remained at 51.5
percent for the month of April.
he average reading for the last 12
months is 55.2 percent. Positive
areas in the report included a 2.2
percent rise in production (to a
three-month high), a 1.7 percent
increase in new orders and a
4.0 percent increase in exports.
Another positive area of the
report indicates that 15 of the 18
manufacturing segments reported
growth in April compared with
just 10 in March. Negative aspects
included a 2.0 percent decrease
in inventories and a 1.7 percent
decrease in employment.
he Bureau of Economic
Analysis reported that irst
quarter gross domestic product
(GDP) for the U.S. increased at an
annual rate of 0.2 percent driven
by personal consumption and
inventory investment, which were
ofset by decreases in exports,
nonresidential ixed investment,
and state and local government

spending. Private businesses
added $110.3 billion to their
inventories in the irst quarter,
following increases of $80
billion in the fourth quarter
and $82.2 billion in the third
quarter of last year. Current
challenges to economic activity
include a strong U.S. dollar,
Source: Capital IQ and JKC research. Local currency converted to USD using
lower crude oil prices, a West
historical spot rates. he JKC Pump and Valve Stock Indices include a select list of
publicly traded companies involved in the pump and valve industries weighted by
Coast ports slowdown and
market capitalization.
weakness overseas. In the
of transportation consumption in
fourth quarter of last year,
Reference
GDP increased by 2.2 percent led by 2013, is projected to fall 21 percent
1. he S&P Return
by 2040 to be just 47 percent of
nondurable goods manufacturing;
igures are provided
total transportation consumption.
by Capital IQ.
professional, scientiic and
Residential consumption is also
technical services; and mining.
impacted by energy eiciency
he U.S. Energy Information
standards as well as the population
Administration predicts that
Jordan, Knauff
shift toward warmer climates.
domestic energy consumption will
& Company is an
On Wall Street, all indices were
grow at a modest 0.3 percent per
investment bank
based in Chicago,
up slightly for the month. he Dow
year through 2040, less than half
Illinois, that
Jones Industrial Average gained
the rate of population growth. he
provides merger and
0.4
percent,
the
S&P
500
Index
was
energy used in homes is expected
acquisition advisory
up 0.9 percent, and the NASDAQ
to be lat, and transportation
services to the
pump, valve and
Composite rose 0.8 percent. Positive
consumption is forecasted to
filtration industries.
earnings from a broad range of
decline 0.1 percent. Growth is
Please visit
companies, the European Central
predicted in both the industrial
jordanknauff.com for
Banks continued asset purchasing
sector at 0.7 percent and the
more information.
program and Chinas stimulus
commercial sector at 0.5 percent.
Jordan Knauff &
Company is a member
measures helped to raise investors
Energy eiciency standards
of FINRA.
view of the market. First quarter
combined with less travel due to
earnings were up 4.9 percent for
technological and social factors
the more than 60 percent of S&P
account for the decline in the
500 companies that have already
transportation sector. Gasoline
These materials were
prepared for informational
consumption, which was 58 percent reported their earnings.
Figure 2. U.S. energy consumption and rig counts
Source: U.S. Energy Information Administration and Baker Hughes Inc.
Figure 3. U.S. PMI and manufacturing shipments
Source: Institute for Supply Management Manufacturing

Report on Business and U.S. Census Bureau
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 completeness 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.
Save space,
materials and time
with integrated
control gear
Ampgard medium voltage main breaker, motor control and SC9000 EP
medium voltage adjustable frequency drives come together under a
common bus in the industrys first integrated control gear solution
For more information

please visit www.eaton.com/mvmc
or 1-877-ETN-CARE, option 2, then option 7
+
Ampgard
main breaker
SC9000 adjustable
frequency drive
Ampgard motor
control

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