Pumps System March 2015

The Leading Magazine for Pump Users Worldwide
Internet of Things
Transforms the Industry
Prepare for the DOE

Electric Motor Rule
Refinery Revamps
1947 Vintage Pumps
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Circle 100 on card or visit psfreeinfo.com.
From the Editor

T
he pump world is buzzing about the Internet of Things (IoT). In fact, the entire world
is talking about it. If you Google IoT youll get more than 25 million results.
The IoT has its own Twitter handle (@TheIoT) that has more than 17,000
followers. There are several websites dedicated to the phenomenon including
alltheinternetofthings.com, which features True Stories from IoT Trailblazers and
claims to have literally everything that can be found on the Internet about the IoT.
Microsoft recently published the top 10 reasons to develop an IoT strategy and how to
capitalize on it. This applies to all industries:
Start with your things. Focus on the right ideas of your business for quick return.
Get more from your existing assets. Start with existing IT assets and build upon them.
Make small changes, see a big impact. Identify one process, product line or location
that matters to you and start there.
4. Improve efficiency. Track condition and performance over time.
5. Connect any asset. Pull in data from multiple devices.
6. Enable innovation. Businesses that learn and adapt will continue to thrive.
7. Increase agility. Collect and analyze data for quick insight into developing trends.
8. Build the ability to scale. Scale from the smallest data point to global deployments.
9. Transform your business. Data is only ones and zeros until you turn it into insights
and business impact.
10. Choose an enterprise-proven IoT partner. Stop running your business and start
making it thrive.
1.
2.
3.
This month, Pumps & Systems brings you detailed insight into The Untapped Potential
of the Internet of Things, with a special report beginning on page 38. The article
explains how this concept can transform the pump industry.
In the 1950s, the pump industry had no connectivity or remote intelligence. By 2020,
it is predicted that pumps will be virtually controlled, monitored, analyzed, operated
and maintained via the Cloud. Many companies have already made progress with
intelligent pump technology. In addition, please read about how a cybersecurity plan can
protect plants from dangerous and costly cyberattacks (page 44).
Meanwhile, dont miss our cover series this month on The Aftermarket (page 62)
which covers leak detection technology, technological solutions for emergency spare
parts, reverse engineering and how to optimize operation with the latest aftermarket
solutions.
EDITORIAL
EDITOR: Michelle Segrest
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
ASSOCIATE EDITOR: Amy Cash
acash@cahabamedia.com 205-278-2826
SR. EDITOR, PRODUCTION & CONTENT MARKETING:
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
PRINT ADVERTISING TRAFFIC: Lisa Freeman
lfreeman@cahabamedia.com 205-212-9402
CIRCULATION
AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
lmasaoay@cahabamedia.com 205-278-2840
ADVERTISING
NATIONAL SALES MANAGER: Derrell Moody
dmoody@pump-zone.com 205-345-0784
ACCOUNT EXECUTIVES:
Mary-Kathryn Baker
mkbaker@pump-zone.com 205-345-6036
Mark Goins
mgoins@pump-zone.com 205-345-6414
Addison Perkins
aperkins@pump-zone.com 205-561-2603
Vince Marino
vince@pump-zone.com 205-561-2601
MARKETING ASSOCIATES:
Ashley Morris
amorris@cahabamedia.com 205-561-2600
Sonya Crocker
scrocker@cahabamedia.com 205-314-8276
PUBLISHER: Walter B. Evans Jr.

VP OF SALES: Greg Meineke
VP OF EDITORIAL: Michelle Segrest
CREATIVE DIRECTOR: Terri J. Gray
Editor, Michelle Segrest

msegrest@pump-zone.com
P.O. Box 530067

Birmingham, AL 35253
EDITORIAL & PRODUCTION
Pumps & Systems

is a member of the following organizations:
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 3.
M a rc h 2 015 | Pum ps & S ys t e m s
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Tell us your story

How do you benefit
from the IoT?
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This issue
MARCH
Volume 23 Number 3
COVER
SERIES
AFTERMARKET
62 NEW 3-D CASTING METHODS PRODUCE
SPARE PARTS FASTER
By Jesse Stinson, Hydro Parts Solutions
& Werner Barnard, Hydro Inc.
Additive manufacturing also improves geometric
tolerances.
66 NEW DETECTION TECHNOLOGY REDUCES

LEAK RISK
By Yvette Schmiz
INTEGRA Technologies
Block and bleed isolation capabilities improve
safety and profits.
68 4 ENGINEERING STRATEGIES THAT CAN

SAVE MILLIONS
By Steven Hunsche
SKF USA INC.
Advanced test analysis tools, remanufacturing and training help end users
solve problems.
72 REFINERY REVAMPS 1947 VINTAGE PUMPS

By Basil S. Elkurd
BP Oil Whiting Renery
COLUMNS
PUMPING PRESCRIPTIONS
24 By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC
Can Deaerators Create Pump Trips?
An Indiana refinery used reverse engineering to solve multiple challenges

with one custom pump.
PUMP SYSTEM IMPROVEMENT

30 By Ray Hardee
Engineered Software, Inc.
How an Oversized Pump Can Harm the
Motor & Increase Operational Costs
SPECIAL SECTION
38 By Mike W. Otten
Discover the Untapped Potential
of the Internet of Things
44 By Gary Williams, MSc, IT SEC

How to Protect Plants from Invisible
Threats
STATE OF THE INDUSTRY

12 Industry Leaders Provide Expert Insight on Key Topics & Trends
Second in a Series
2
8
14
76
96
100
104
FROM THE EDITOR

FROM THE READERS
NEWS
TRADE SHOW PREVIEW
PRODUCTS
PUMP USERS MARKETPLACE
PUMP MARKET ANALYSIS
Increased efficiencies and UNMATCHED RELIABILITY allow the Vaughan Chopper Pump
to handle tough stringy solids often with the same motor size as a non-clog pump. Also
included is a back-pullout casing design, allowing external adjustments of clearances and
ease of maintenance.
- Advanced engineering, efficiency, maintainability and performance
- Handles tough stringy solids with the same motor size as a non-clog pump
- New larger sizes, configurations, and cutting-edge flushless seal design
See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP

This issue
SSPECIAL
PECIAL
SECTION
MARCH
DEPARTMENTS
HARSH
CONDITIONS
78 EFFICIENCY MATTERS
48 SUBMERSIBLE PUMPS HANDLE

CORROSIVE SOLIDS AT ETHANOL
TESTING PLANT
By Mike Bjorkman, BJM Corp.
A caustic, high-temperature cleaning solution

puts excessive demand on equipment.
50 MECHANICAL SEAL DESIGN PROTECTS

SUBMERSIBLE PUMPS FROM
ABRASIVE WASTEWATER
By Spencer Reynolds, Vulcan Seals Inc.
Customized seals made from superior

materials can help prevent premature failure
in heavy-duty applications.
52 HARSH LIQUIDS REQUIRE CAREFUL MATERIAL SELECTION

By Ken Comerford, Vanton Pump and Equipment Corp.
Metallics and plastics offer advantages for different applications.
58 CUSTOMIZED COMPOUNDING BOOSTS RESILIENCE IN HARSH CONDITIONS
5 Maintenance Factors that

Help Achieve Optimum
Efficiency
By Mike Winkler
Motion Industries
82 MAINTENANCE MINDERS
Turbine Error Identification
Prevents Costly Outages for
Power Plants
By Brandon Perkins
GE Intelligent Platforms
84 MOTORS & DRIVES

Prepare for the New DOE
Electric Motor Efficiency Rule
By John Malinowski
Baldor Electric Company
88 SEALING SENSE
Updates to Industry
Standards Offer New Options
for Fugitive Emissions Testing
By Philip Mahoney
FSA Member
By Dr. Joel Bell & Will Taber, RTP Company
Reinforcing additives combined with a carefully selected base resin can create a highperformance compound for any application.
PRACTICE &
OPERATIONS
90 HI PUMP FAQS
Recommendations for
Rotary Pumps, Diaphragm
Pumps and VFDs
By Hydraulic Institute
92 TIPS FOR USING PULSATION DAMPENERS IN

The Leading Magazine for Pump Users Worldwide
By Manuel Carcar-Gimeno
HIDRACAR, S.A.
Understanding the equipments operation capabilities and
how to calculate the required size is critical.
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
DOSING OR VOLUMETRIC PUMP SYSTEMS
Image courtesy
of Hydro, Inc.
Internet of Things
Transforms the Industry
Prepare for the DOE

Electric Motor Rule
Refinery Revamps
1947 Vintage Pumps
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.
RALPH P. GABRIEL, Chief Engineer Global, John
Crane
ADAM STOLBERG, Executive Director,

Submersible Wastewater Pump Association
(SWPA)
LARRY LEWIS, President, Vanton Pump and

Equipment Corp.
JERRY TURNER, Founder/Senior Advisor,

Pioneer Pump
TODD LOUDIN, President/CEO North American

Operations, Flowrox Inc.
KIRK WILSON, President, Services & Solutions,

Flowserve Corporation
JOHN MALINOWSKI, Sr. Product Manager, AC

Motors, Baldor Electric Company, A Member of
the ABB Group
JAMES WONG, Associate Product Manager

Bearing Isolator, Garlock Sealing Technologies
Single-source supplier: your partner

for pumps, valves and service
Count on KSB to help you maximize your process efficiencies and
optimize your existing products. We can handle the diagnostics,
repair or casting and machining of aftermarket parts regardless of the
manufacturer. KSB provides reliable service to our customers with
skilled technicians to service or repair your pump around the world.
Contact KSB, your one source partner for your next service or repair
job. www.ksbusa.com
KSB, Inc. . Mid-Atlantic . Phone: (804) 565-8203 . repair@ksbusa.com . www.ksbusa.com
Standard Alloys Inc. . Gulf Coast . Phone: (800) 231-8240 . sales@standardalloys.com . www.standardalloys.com
Precision Pump & Machine . West Coast . Phone: (661) 633-5520 . info@precisionpump.com . www.precisionpump.com
Our technology. Your success.

Pumps Valves Service
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From the Readers

The November issue of Pumps & Systems outlined the integral design features of peristaltic pumpssuch as the heavy-duty hose
that reduce maintenance costs and improve efficiency in dosing applications. Heres what members of the Pumps & Systems LinkedIn
group had to say about this article.
Peristaltic Pumps Handle

Abrasive Chemicals in Water &
Wastewater Treatment
Paul, can you explain the dampeners you mention? What are
they, and how would they provide a more level ow?
Gerald Potapa, Jr. CPD
Sales Engineer
R.L. Deppmann
NOVEMBER 2014
Peristaltic pumps are a marvelous type of pump. They are

much better if you use a dry type of peristaltic pump that
can run dry without a liquid for lubrication or refrigeration
of the shoes and the hose.
Marzio Vallo
Director, Oil & Gs Business
Omel Bombas e Compressores Ltda.
These are interesting pumps, but they dont appear to be able

to provide a constant ow. It looks like they provide a ow
that is, for lack of a better description, pulsed. That may be
a disadvantage in certain lab applications that may require
a steady ow. However, I can think of a number of places
where these would be ideal.
Gerald Potapa, Jr. CPD
Sales Engineer
R.L. Deppmann
The main advantages of peristaltic technology are its

high-suction lift, dry running capability, sealless nature,
low shear, and ability to handle solids (typically 1/3 of tube
outer diameter) as well as abrasive and viscous products. Of
course, as with all technologies, there are drawbacks such as
pulsating ow (can be leveled out with dampeners), higher
cost and more frequent maintenance. However, they have
few wearing partsvirtually hose and lubricant only. Its a
simple and ecient technology for the right applications.
Paul Pilisi
Sales Manager North America
PCM
Gerald, the most common dampener housings are either

made of metal or composite with an internal elastomeric
bladder compatible with the pumped product. The housing
or chamber is sized based on ow and pressurized according
to discharge head. The bladder will then absorb the peak
pulsations and distributeor level outthe ow. Hydraulic
chocs are also considerably reduced, which lengthens the life
of the installation.
Paul Pilisi
Sales Manager North America
PCM
JOIN THE DISCUSSION

Become a member of our LinkedIn
group, Pumps & Systems, to participate
in pump-related discussions with more
than 18,000 industry professionals.
Follow us on Twitter
@PumpsSystemsMag
Like us on Facebook
Pumps & Systems
Chemical Metering Pumps and Flowmeters

for Successful Water & Waste Water Treatment.
BHAT*LNK
Laneop]hpe_Iapanejc
Many readers use the Pumps &

Systems LinkedIn group to post
questions, share best practices and
discuss pump-related challenges and
solutions. One senior site manager
inquired about the best way to turn
twin-head pumps.
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.
Twin-Head Pumps
Mark Bean
Senior Site Manager
Vear Mechanical & Electrical Services Ltd.
There will be an arrow on the

casing. Make sure the impeller is
aligned for the same direction of
rotation. Running the pump alternately
in both directions is not recommended.
You may nd it to be too expensive in
labor time/cost to open and reassemble
the pump if the impeller is not correctly
placed. You also need to check for
shaft seals. If seals are designed for
unidirectional operation, you will
need to relocate the seals as well. I had
designed and built a similar renery
pump with a 400-horsepower drive
in 1978. I took care to ensure that the
seals were bidirectional. Loss of large
seals on such pumps can result in
signicant equipment downtime.
Ratnakar Mankad
Director
Akaar Founders Pvt. Ltd.
IP
P66
NE
EMA
A 4X
]GY
GY
YN"J
N JU]T
N"JU
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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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5300 Business Drive, Huntington Beach, CA 92649 USA

714-893-8529 fax: 714-894-9492 sales@blue-white.com
www.blue-white.com
p u mpsa ndsyst ems.c om | Ma rc h 2015
How do you decide which way to

turn twin-head pumps? That might
seem like an odd question, but I am
replacing three twin-head pumps
with new equipment, like-for-like.
The existing pump motors contrarotate (one clockwise and the other
counterclockwise), but I have no idea
how to determine how the pump
manufacturer has congured the
new pumps.
10
FROM THE READERS
See what Pumps & Systems

readers are saying on Twitter...
One reader responds to the January article, Washdown

Pump Motors Provide Reliable Sanitary Operation by
David Steen of Baldor Electric Company.
To have a letter considered for publication, please send it to

Amelia Messamore, amessamore@cahabamedia.com.
11

12
STATE of the
INDUSTRY
2 0 1 5
Industry Leaders Provide Expert Insight

on Key Topics & Trends
Second in a Series
Patrick Taylor
President
(since May 2013)
Viking Pump
Viking Pump delivered one of its strongest years on record
in 2014. The momentum will carry the organization well
into 2015 and is driven by strategic and tactical actions put
in place during the past few years. This, coupled with the
vertical market performance in the chemical and oil and
gas sectors, delivered outstanding organic growth.
While there is momentum going into this year for
Viking Pump and many other industrial companies in
North America, several unstable economies around the
world will continue to impact industrial companies
much like they did in 2014. It is my opinion that the
companies that excel over the next few cycles will focus
on a few key initiatives.
First, to take advantage of high-growth regions as well
as capturing market share in slower growing regions,
companies will need to invest in their commercial
teams and processes. Making an investment in channel
management and key accounts teams makes a positive
dierence in providing value to our customers. In
addition, interrelated go-to-market processes that align
an organizations capabilities to the needs of the end user
will provide valuable solutions.
Also, superior talent will make the dierence in any
companys ability to achieve their goals. For Viking,
building great global teams is job No. 1. Th is focus
starts directly within global organization and extends
to its go-to-market partners. I believe you will see
manufacturers continue to focus on talent acquisition and
accelerating the development of their associates in 2015.
Patrick Decker
CEO
(since March 2014)
Xylem, Inc.
The single biggest trend going on in the pump industry
right now is a focus on energy eciency. It is being
driven by regulations in the industry as well as the needs
and demands of our clients. Most people do not realize
that about 7 percent of the total cost of the energy

space is tied to water management, which is an exciting
opportunity for us.
We see a return to growth in North America as we see
some of the stalled municipal spend beginning to vault.
There is a lot of pent up infrastructure rebuild in the U.S.
that needs to be dealt with, and we are beginning to see
growth in our backlog pretty signicantly in that part
of the world. Europe continues to be amongst challenges
both in terms of political and macro-economic issues,
but we see continuing growth in our pump business there
as well. We look at regions such as the Middle East and
China, South America and India not so much as low-cost
manufacturing bases anymore. It is really a matter of how
we support growth in these markets by being global.
As many people know by the launch of Pumps &
Systems MENA, there is a tremendous appetite for
technical knowledge and expertise in this region. I am
so excited about what we are doing there because it is
not just localization of manufacturing capabilities; it
is also localization of research and development (R&D)
and engineering resources. Most of the water solutions
around the world today are being developed in regions
that are facing scarcity and other issues.
We are continuing to do more things as a company to
become more lean in our processes and be more ecient
as a company. There are opportunities to be faster,
smarter, more agile and, therefore, more cost ecient.
Th is will continue to be a cornerstone of our story as a
company. But at the end of the day, we are here to grow
this company.
One of the things that drew me to Xylem is the ability
to marry social value creation with economic value
creation. People hear me talk about this a lot. I believe
companies need to be here for a higher purpose than just
making money. There is no greater place to do that than
in the water space.
Growth is a big deal for us. We have struggled with
growth, in general, as an industry in the past three to
four years. Now we are beginning to see opportunities to
accelerate that. First and foremost, we want to accelerate
protable growth. There are four dierent areas we are
focusing on. One is growth in emerging markets and
the investments there. Second, we want to expand our
presence in the industrial use of water. We are building
13
what we are calling an industry-vertical market. We

are mapping the needs of our customers to understand
the gaps in what we oer today and how that aects
R&D priorities and acquisitions.
We are also focusing on increasing our innovation,
and we have increased our investment in that area.
Those are the priorities. Many Pumps & Systems readers
know we have some of the best pump brands in the
world. We are proud of them and will continue to
invest in them. We are equally excited about expanding
our testing and treatment capabilities. We have the
broadest oering in the water industry, and we are
not done yet. We are nding that our customers
around the world, especially in these emerging
markets, really gravitate toward an integrated oering.
We combine the power of data and information along
with the pumps.
Scott Aiello
General Manager
(Since January 2013)
Warren Rupp, Inc.
Growth in 2015 will come while we continue to navigate

dynamic global markets. We have seen solid growth over
the last two years by driving strategies and focusing on
key markets and geographies. Companies will need to
continue to be nimble to execute in changing markets.
We will continue to develop our talent and teams to
identify and execute in the markets that best align our
products, channel and end markets.
The unknowns that we are experiencing in markets
such as oil and gas require us to leverage the experience
we have developed to execute in changing markets. For
these reasons, it is essential that we align our eorts to
improve commercial productivity for our company, our
channel and our end markets.
We are excited about the opportunities and challenges
ahead in 2015. Additionally, we are proud at Warren
Rupp, Inc., to celebrate our 50th anniversary. We have
the responsibility to further the legacy that Mr. Warren
Rupp began in 1965. Our product innovation, customer
solutions and growth will be based around the need to
solve problems for our end users in key markets.
Visit pumpsandsystems.com
to read analyses and forecasts from other
industry leaders.
14
NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
JOHN MALINOWSKI,
BALDOR ELECTRIC COMPANY
FORT SMITH, Ark. (Feb. 9, 2015) Baldor Electric
Company has named John Malinowski Senior
Industry Affairs Manager. In this role, John
will represent Baldor and its parent company
ABB in various U.S. associations promoting the
companies positions on industrial electric motor
John
policies, regulations and standards. Malinowski,
Malinowski
currently the general product manager for
general purpose and severe duty motors, has been with Baldor since
1982. baldor.com
RICHARD THOMPSON,
EBARA FLUID HANDLING
ROCK HILL, S.C. (Jan. 7, 2015) Richard
Thompson was appointed vice president, Ebara
Fluid Handling Division (FHD), and will assume
full management and overall operations of
the division. Thompsons appointment is part
of an executive management transition as he
Richard
succeeds Martin Perlmutter, who has served as
Thompson
Ebara FHDs president for more than 16 years.
As part of the transition, Perlmutter will continue to support and be
involved with FHD and Ebara in an advisory role until March 31.
pumpsebara.com
DANIEL S. ANDERSON, ASAHI/AMERICA

ST. LAWRENCE, Mass. (Jan. 22, 2015) Asahi/
America, Inc., announced the promotion of
Daniel S. Anderson to the office of president and
CEO. The announcement was made to Asahi/
America employees Dec. 11, 2014, by former
president and CEO Hidetoshi Hashimoto, who will
remain with the Massachusetts-based company
Daniel S.
as chairman of the board of directors. Anderson
Anderson
has been with Asahi/America since November
1988 as senior vice president of sales and marketing. He assumed his
new position Jan. 1. asahi-america.com
ANTHONY MILANDO, XYLEM INC.
SPOTLIGHT
Terry Henshaw, Pumps & Systems columnist,
recently completed a book on net positive
suction head (NPSH), arguably one of the most
important yet complex aspects of pumps. The
content of the book, titled NPSH: The Achilles
Heel of Pumps, is largely based on the series of
articles Henshaw wrote for Pumps & Systems in
2009 and 2010. I believe that NPSH is the most
important, and yet, most misunderstood of all pump characteristics,
Henshaw says in the books preface. Ive read numerous articles,
technical papers and letters on NPSH. Many have been enlightening,
some have been shallow, and some have contained significant
misinformation. The purpose of this book is to draw together that
available knowledge which is reasonable, logical and hopefully useful
to those who select, apply, operate and/or troubleshoot pumps; and
also, hopefully, to dispel some of the numerous misconceptions about
NPSH. The 168-page book is available on Amazon.com. Read more
about NPSH at pumpsandsystems.com/understanding-npsh.
MARK DAGOSTINO, POWER-FLO PUMPS & SYSTEMS

GARDEN CITY PARK, N.Y. (Jan. 22, 2015) Power-Flo Pumps &
Systems appointed Mark DAgostino as vice president of sales. Jerry
Dicunzolo, president and CEO of Power-Flo Technologies stated, I
have known and respected Mark for many years and am looking
forward to working with him to accomplish our goals.
powerflopumps.com
JAY ORELLANA, TOUCHSENSOR

TECHNOLOGIES
WHEATON, Ill. (Jan. 19, 2015) TouchSensor
Technologies announced the promotion of Jay
Orellana to business development manager
LevelGuard. Orellana joined TouchSensor in 1999
serving as new product launch manager as well
as in other business development roles. Prior to
Jay Orellana
joining TouchSensor, he served as senior product
engineer for Underwriter Laboratories for 10 years. Orellana has a BS
in electrical engineering. touchsensor.com
RYE BROOK, N.Y. (Jan. 22, 2015) Xylem Inc. appointed Anthony
Milando as senior vice president for continuous
improvement and business transformation. In this
newly created position, Milando will be responsible
for driving operational excellence and process
Motion Industries to acquire
simplification across the organization, reporting
Miller Bearings, Inc.
directly to President and CEO Patrick Decker. He will
Jan. 14, 2015
also serve as a member of the companys senior
leadership team and will be based at the companys
Bentley Systems, Incorporated,
global headquarters in Rye Brook, New York.
acquired C3global
xyleminc.com
Jan. 13, 2015
MERGERS & ACQUISITIONS
L.B. Foster Company to acquire

Chemtec Energy Services, LLC
Jan. 5, 2015
3D Systems acquired botObjects
Jan. 5, 2015
15
CRAIG PAULSON, PSG
SEAN KURTZ, DANFOSS
OAKBROOK TERRACE, Ill. (Jan. 12, 2015) PSG, a Dover Company,

appointed Craig Paulson as vice president of human resources. In this
position, Paulson will be responsible for aligning the human resources
strategies with PSG business strategies as the company continues
to grow organically and through acquisition. He will report directly
to Karl Buscher, president of PSG. While at Waukesha Bearings, he
led the human resources functions for all of the U.S.-based and
some international manufacturing facilities. Paulson has a Bachelor
of Science degree in industrial sociology and a Master of Science
degree in human resources and labor relations from the University
of Wisconsin, Milwaukee. He will be based out of the PSG corporate
offices in Oakbrook Terrace, Illinois. psgdover.com
BALTIMORE (Jan. 6, 2015) Danfoss named Sean

Kurtz general manager and director of operations
for its compressor manufacturing facility in
Arkadelphia, Arkansas. In this role, Kurtz will
provide leadership to the facilitys management
team and daily production processes, as well as
execute the companys global business strategy
Sean Kurtz
at the local level. Kurtz joins Danfoss with
more than 24 years of experience in plant, project and engineering
management related to high-speed/high-volume manufacturing in
automotive, aerospace, business equipment and heavy equipment
industries. Most recently, he was director, U.S. manufacturing,
at Klein Tools, a manufacturer of non-powered hand tools and
measuring devices. Kurtz holds a masters degree in operations
management from Northern Illinois University and a bachelors
degree in mechanical engineering from Lawrence Technological
University. danfoss.us
JEFF LEEPER, EBARA

ROCK HILL, S.C. (Jan. 8, 2015) EBARA Fluid Handling has appointed
Jeff Leeper as senior application specialist. Leeper will be responsible
for internal and external customer product applications support,
including preparing quotations and submittals, order preparation
and after-sales support. Leeper brings a wealth of experience and
valuable technical knowledge to EBARA. He started his career with
Goulds Pumps and held several positions in applications, sales and
support for the ITT Goulds Industrial Products Group. For the past 10
years, he has held positions with Sulzer Pumps in sales of new pumps
and repairs for the chemical, paper and power industries. Leeper
holds a B.S. in mechanical engineering from Grove City College in
Pennsylvania. pumpsebara.com
ANDREW M. CRAWFORD, PENTAIR

NORTH AURORA, Ill. (Jan. 5, 2015) Engineering
firms, end users, contractors and purchasers
have a single point-of-contact to readily source
all of their industrial and marine fire protection
systems and equipment. Andrew M. Crawford,
known as an expert in industrial pumping
systems and equipment, is leading this initiative
Andrew M.
Crawford

16
NEWS
for Pentair. With Crawfords appointment, Pentair Engineered Flow

is forming a national distribution network in the U.S. and Canada.
Pentair Engineered Flow has full sourcing responsibility and control
over all necessary components and replacement parts. Pentair plans
to increase its distribution network with the addition of dedicated
industrial fire distributors focused on oil and gas, marine, power/
utilities, chemical and manufacturing industries as full service
providers. pentair.com
MIKAL HAYES, SEPCO

ALABASTER, Ala. (Nov. 24, 2014) SEPCO, Inc.,
announced Mikal Hayes as the new applications
engineer aiding in the design and development
of SEPCOs mechanical seals and redesign of
existing systems. Hayes helps support new
product development, product improvement,
testing and costing. He also uses both
Mikal Hayes
mathematical and hands-on approaches to solve
problems, modify designs, develop new methods and maintain data
in engineering systems. sepco.com
ELAINE THOMAS RECEIVES

TECHNICAL & OPERATING MEDAL
TACOMA, Wash. (Jan. 8, 2015) On Dec. 11, 2014, Elaine Thomas, the
director of metallurgy at Bradken-Energy, became the first woman
to ever receive the Steel Founders Society of Americas (SFSA) Charles
W. Briggs Memorial Technical & Operating Medal for her career

contributions in metallurgy. The Technical and Operating Medal
recognizes outstanding scientific or engineering contributions to the
technical or operating advancement of the steel foundry industry.
In 1969 the medal was renamed the Charles W. Briggs Memorial
Technical and Operating Medal in recognition of the activities of C.W.
Briggs from 1938 to 1968.
Elaine Thomas began her career at Bradken-Energys Tacoma
facility (formerly known as Atlas Foundry) in 1977 where she has
spent almost 40 years working and managing operations in the melt
shop, weld engineering, heat treating, chemistry and mechanical
testing labs. Thomas currently serves on multiple committees,
including the SFSA Specifications Committee (current chairman),
SFSA High Alloy and
Heavy Section Research
Committee, and ASTM
A01.18 Subcommittee for
Cast Steel.
Thomas also received a
scholarship in her name
which is presented to
the school of her choice.
Thomas chose to award
the scholarship to her
alma mater, Washington
State University.
bradken.com

17
18
NEWS
AROUND THE INDUSTRY

MWV & RockTenn Agree
to Combination Creating a
Global Packaging Provider
RICHMOND, Va. and NORCROSS, Ga.
(Jan. 26, 2015) RockTenn Company
and MeadWestvaco Corporation have
announced that they have entered into
a definitive combination agreement to
create a global provider of consumer
and corrugated packaging, NewCo, in
a transaction with a combined equity
value of $16 billion. The combined
company, to be named prior to closing,
will have combined net sales of $15.7
billion and adjusted EBITDA of $2.9
billion, including the impact of $300
million in estimated annual synergies
to be achieved over three years.
Steven C. Voorhees, CEO of RockTenn,
will serve as CEO and president of
the combined company, and John A.
Luke Jr., chairman and CEO of MWV,
will become non-executive chairman
of the board of directors. The board
will be comprised of eight directors
from RockTenn and six directors from
MWV. The combined company will
maintain its principal executive offices
in Richmond, Virginia, and will have
operating offices in Norcross, Georgia.
rocktenn.com mwv.com
Atlas Copco Ranks 23rd

Among Worlds Most
Sustainable Corporations
COMMERCE CITY, Colo. (Jan. 23, 2015)
Atlas Copco ranks 23rd among the
2015 Global 100 Most Sustainable
Corporations in the World index, a
list presented Jan. 22 at the World
Economic Forum in Davos, Switzerland.
The company was also listed first
overall in the machinery industry. This
is the ninth time that Atlas Copco has
appeared in the Global 100 rankings.
Atlas Copco sustainability initiatives,
both globally and in the U.S., include
boosting customer energy-efficiency
by at least 20 percent between 2010
and 2020, decreasing CO2 emissions,
working actively to eliminate
corruption and promoting access
to clean drinking water in countries
in need. In the U.S., sustainability
initiatives include purchasing
renewable energy certificates to offset
carbon emissions, reducing energy
consumption through investments and
SPOTLIGHT
ABB & Solar Impulse Get Ready for Historic
Round-the-World Flight
ZURICH (Jan. 20,
2015) ABB will
accompany Solar
Impulse and its
crew on the planes
flight around the
world powered only
by energy from the
sun. Solar Impulse,
based in Switzerland,
announced that it
will begin its historic
flight between late
February and early
March in Abu Dhabi.
In 2014, ABB
and Solar Impulse
formed an
innovation and technology alliance to advance a shared vision of reducing
resource consumption and increasing the use of renewable energy. Three
ABB engineers have joined the Solar Impulse team to help improve control
systems for ground operations, enhance the charging electronics for the
planes battery systems and resolve obstacles that emerge along the route.
On the planes 40,000-kilometer route, pilots Bertrand Piccard and Andre
Borschberg will share duties as the aircraft stops in cities including Muscat,
Oman; Varanasi and Ahmedabad in India; Chongqing and Nanjing in China;
and Phoenix, Arizona. It will also stop in Europe or North Africa.
Among challenges before the mission concludes in Abu Dhabi in mid-2015
will be a non-stop flight of five days and nights from China to Hawaii. The
plane, powered by 17,248 solar cells, will soar higher than Mount Everest each
day, while fully charging its batteries to stay aloft during the night. abb.com
upgrades, and establishing programs to

increase recycling rates.
The Global 100 Most Sustainable
Corporations in the World index
evaluated 4,609 publicly listed global
companies, which are measured
against key sustainability indicators
such as safety, performance and
revenues in relation to consumption of
energy and water. atlascopco.us
FSU Unveils Powerful

Electrical Testing System
TALLAHASSEE, Fla. (Jan. 15, 2015)
Florida State Universitys Center for
Advanced Power Systems (CAPS) has
unveiled a new 24,000-volt direct
current power test system, the most
powerful of its kind available at a
university research center throughout
the world. The new system will give

CAPS the ability to test electrical
equipment in real-world conditions,
and companies looking to build nextgeneration power equipment will be
able to test those in the Tallahasseebased facility. The new test facility
has a 24,000-volt direct current with a
capacity of 5 megawatts.
To create the new system, the center
put together four individual 6-kilovolt,
1.25-megawatt converters that can be
arranged in any combination, in series
or parallel connection, to form a flexible
test bed for medium voltage direct
current (MVDC) system investigations.
The MVDC system was built based on
CAPS specifications by ABB Inc., as
a technology demonstrator geared
toward research activities. fsu.edu
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and analog I/O. Communicate via built-in Modbus or an
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Ironhorse AC motors are available in rolled steel (1/3

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ratings. Our premium efficiency models meet current
NEMA standards from 1 to 150 hp, and start at $155.
Ironhorse DC motors are available in TENV and TEFC
rolled steel enclosure styles. Their space-saving
designs feature a NEMA 56C flange and removable
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Marathon Electric inverter-duty motors

have been carefully selected to be performance
matched with our DURApulse and GS series AC drives.
They are available in 1/4 to 100 hp with 1200 and 1800
RPM base speeds. Dual 230/460V and 575 VAC models are
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the #1 value in automation
NEWS
AROUND THE INDUSTRY

Pump Market to Exploit
E&P Activities in Global
Oil & Gas Industry
LONDON (Jan. 14, 2014) Escalating
investments in the exploration and
production of conventional oil and
gas is propelling the adoption of
pumps around the world. The Western
hemisphere will lead the way in uptake
as production surges owing to the
shale oil and gas boom in North
America, oil sands in Canada, and
conventional reserves in Brazil,
Venezuela and Mexico. New deep-water
and ultra-deep-water reserves in
Asia-Pacific will contribute further to
oil and gas production, and in turn, the
sale of pumps.
New analysis from Frost & Sullivan,
Global Pumps Market in the Oil and Gas
Industry, finds that the market earned
revenues of about $10 billion in 2013
and estimates this to reach more than
$14 billion in 2020. The study covers
centrifugal and positive displacement

(PD) pumps. The need for water and
wastewater management during the
extraction of gas and oil from shale
has added to the demand for pumps.
However, as environmental concerns
threaten market growth, efficient
pumps are gaining importance. In
North America and Europe, refinery
closures affect pump sales, yet
opportunities have opened up for pump
manufacturers in the Middle East
and Asia-Pacific. Rising midstream
investments in pipelines, railcars and
trucks in these regions add to market
potential. frost.com
for accreditation of electric motor

repair service providers. The EASA
Accreditation Program provides
assurance to electric motor end users
that repairs performed at accredited
facilities conform to industry standards
and maintain the reliability and
efficiency of the repaired motor.
These standards are contained in
the American National Standards
Institute approved ANSI/EASA AR100:
Recommended Practice for the Repair
of Rotating Electrical Equipment.
The EASA Accreditation Program
includes more than 70 separate
criteria relating to electric motor
repair that address the initial condition
assessment of the failed motor and
the repair of the motors mechanical
components. Further, the program
addresses repair of the motors
electrical elements including winding
and insulation.
easa.com/accreditation
EASA Announces Industrys

First Electric Motor Repair
Accreditation Program
ST. LOUIS, Mo. (Jan. 8, 2015)
The Electrical Apparatus Service
Association (EASA) announced
the global industrys first program
To have a news item considered, please send the information to Amelia Messamore, amessamore@cahabamedia.com.
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21
22
NEWS
EVENTS
Latin America and Caribbean Oil & Gas
Security Forum
March 17-18, 2015
Bogota, Colombia
latamoilgassecurity.com
INTERPHEX
April 21-23, 2015
Javits Center
New York, N.Y.
888-334-8704 or 203-840-5648 / interphex.com
Pump School Training: Centrifugal & Positive

Displacement Pumps
March 24-25, 2015
One Midtown Plaza
Atlanta, Ga.
770-310-0866
pumpingmachinery.com/pump_school/pump_school.htm
Offshore Technology Conference (OTC)

May 4-7, 2015
NRG Park
Houston, Texas
972-952-9494 / 2015.otcnet.org
How Gear Motor Technology Increases Vertical Pump

Drive Efficiency
April 16, 2015
Pumps & Systems Live Webinar Series
Presented by Baldor
pumpsandsystems.com/webinars
WQA Aquatech USA
April 21-24, 2015
Las Vegas Convention Center
Las Vegas, Nevada
wqa.org/aquatech
American Wind Energy Association (AWEA)

Windpower Conference & Exhibition
May 18-21, 2015
Orange County Convention Center
Orlando, Fla.
508-743-8502 / windpowerexpo.org
American Water Works Association Annual
Conference & Exposition (AWWA-ACE)
June 7-10, 2015
Anaheim Convention Center
Anaheim, Calif.
800-926-7337 / awwa.org

23
24
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
Can Deaerators Create Pump Trips?

First of Two Parts
n this two-part series, how

transient events in process
equipment affect other system
components will be discussed. Part
1 covers how deaerators (DAs) may
be affected by generator trips and
how these deaerator transients may
also affect system pumps.
A power plant includes a complex
array of machinery, pipes, tanks,
fuel, controls and auxiliary
equipment. Figure 1 illustrates a
simplified sketch of this system.
The Steam Generation Process

Fuel heats the boiler to convert
liquid to steam. High temperature
and pressure feed the hot steam
from the boiler to a turbine, which
typically has several stages (high,
intermediate and low pressures).
The system includes additional
components for better efficiency,
control and reliability, but these are
omitted to simplify the article.
Steam turbine shaft rotation is
transmitted to a generator shaft,
and electric current is delivered

to a net. Exhausted steam is
dumped into a condenser where it
is further cooled to complete its
transformation back to cold water,
which a condensate pump sends
to a DA.
The DAs size depends on
the design and the plants
requirements, but a 20,000-gallon
tank with roughly half its capacity
fi lled is typical for a relatively
small power plant.
Figure 1. Simplified diagram of a power plant cycle (Graphics courtesy of the author)
Heat
Steam
Bypass
Valve
Boiler
HP
Pegging
Steam
LP
Generator
Condenser
CP
Condensate
Air Out
Vapor
Air
Bubbles
100
BFP
Liquid
Deaerator
(DA)
20,000 gallons
(half filled)
Big Bubble
Pump in an upset condition following a transient event.
25
The DAs Function

The main purpose of a DA is to remove entrained
air, which is accomplished by extracting auxiliary
(pegging) steam from the low-pressure steam turbine.
This steam heats the water and strips it of most of
the air and keeps the fluid in the
DA at saturation temperature.
The deaerated water flows to the
boiler feedwater pumps (BFP)
inlet, which moves it to the boiler,
and the cycle repeats.
volume, enthalpy (energy), entropy and quality of

the water in its different statesliquid, vapor and
mixed. Figure 2 (see page 26) depicts a temperaturespecific volume (T-v) diagram, with tabulated data
and examples.
Process Transients
Problems that may interrupt
this process include a sudden
reduction or a complete loss
of generator load (a load
rejection condition).
When the generator trips,
steam is bypassed through
the diverting valve around the
steam turbine and is typically
directed into the condenser. A less
common method is to release
the steam directly into a DA or to
the atmosphere.
During roughly the same
time, fuel is diverted from the
boiler, and the boiler begins
to cool. Condensate pumps
continue to operate to keep up
with the cooling steam arriving
at the condenser. Because
the pegging steam has been
diverted to the condenser, it
no longer pressurizes the DA.
The continuous arrival of the
condensate into the DA cools
the liquid. As a result, the
temperature and pressure in
the DA drop. The temperature
falls as the condensate cools
it, and the pressure decreases
because of the loss of pressurizing
pegging steam.
A basic understanding of
thermodynamics provides the
foundation for what happens
next. Steam tables and graphs
contain information about
pressure, temperature, specific
26
For example, tabulated data

within Figure 2 show that at 302
degrees F, 69.07 psia of pressure
is required to keep water at
saturation point A. If the water
were heated further at a constant
pressure of 69.07 psia (shown
as a horizontal line moving to
the right), it would eventually
boil out into vapor, which would
significantly increase its volume.
The volume would be much greater
than the DA tank could hold.
Conversely, if it were to be cooled
at a constant pressure, 69.07
psia in this case, it would become
subcooled, meaning it would be
pure liquid with no vapor. Point A
is a border line at which the vapor
is saturated.
The DA is, however, a fi xedvolume tank. For any vapor to
form within it, the pressure would
need to change. Reduction in

temperature is shown as a vertical
movement downward on the
diagram from Point A to Point B,
at which the liquid reaches the
assumed fi nal temperature of 266
degrees F.
The combined specific volume
(v) is a ratio of the tank volume
(liquid and vapor) to a total
mass of the fluid in the tank.
A half full 20,000-gallon tank
(approximately 2,600 cubic feet)
contains 10,000 gallons of water,
or 1,300 cubic feet. Liquid water
weighs 57.27 pounds per cubic
foot (lb/ft3) at 302 F. The inverse is
0.01746 cubic feet per pound (ft3/
lb), which is the specific volume.
The liquid in the tank weighs:
Point B is in the mixed phase

region. Figure 2 shows the
pressure at 39.20 psia, with fluid
in a two-phase statesome liquid
and some vapor.
The specific volume at that
temperature/pressure is 0.1714
ft3/lb for liquid, shown at the left
intersection with the saturation
curve. The volume at that
temperature/pressure for steam
is 10.70 ft3/lb, shown at the right
intersection. The water quality
(x) is a proportion of gass mass
(Mg ), in this example the vapors
mass, to the total mass (M) of
the mixture, which is shown in
Equation 1.
1,300 x 57.27 = 74,450 pounds
Equation 2 shows the formula for

the average total specific volume.
x=
Mg
Equation 1
Figure 2. The T-v diagram shows the thermodynamics of the transient inside the DA.
(Source: Cameron Hydraulic Data Book, 19th Edition, 2002)
T def. F
T, F
uid
Liq
302
.07
psi
vf
28.81
0.01698
14.27565
10.70033
266.00
39.20
0.01714
284.00
52.44
0.0173
69.07
0.01746
6.286446
89.66
0.01762
4.914144
sia
p
.20
39
= 0.01746
8.144588
320.00
ap
s (V
10.70 = g
vg
302.00
Some vapor
= 0.01714
ft3/lbm
deg. F
Ga
B
ft3/lbm
248.00
or)
69
Saturated
Two phases
266
ia
ps
Pressure
g ft /lb
27
28
x = (v - vf)
(vg - vf)
Equation 2
In this example, v remains

constant because the tank has a
constant volume at:
2,600 / 74,450 = 0.035 ft3/lb
Therefore, the average total
specific volume by mass is:
x = (0.035 - 0.01714)
(10.70033 - 0.01714)
= 0.00167 = 0.17%
Th is does not seem like a lot
by mass, but it is too much by
volume. The mass of the vapor is:
0.17% x 74,450 lbs = 126 lbs
At 10.70 ft3/lb, the volume is:
Once this vapor reaches the

BFPs suction, the effects can
damage the pump. If a pump is
126 x 10.70 = 1,354 ft3
equipped with a suction pressure
transmitter, it will trip. If not,
This is nearly the same volume
severe cavitation and vibration
of vapor as the liquid in the tank,
will result, possibly destroying
which is 1,300 ft3. Th is vapors
volume is too large to be contained the BFP or its mechanical seals,
bearings, etc. Many sophisticated
in the DA.
pump designs can sustain brief
The vapor is drawn into the
violent action, but not for long,
suction pipe because the water
perhaps 10 to 20 seconds. If the
is flowing to the pump. At the
overall plant control does not
same time, a long vapor bubble,
correct the issue shortly after
or a cluster of them, stretches
the generator trips, the problem
the entire length of the 100-foot
will continue, potentially causing
suction header and makes the
the failure of the BFP and other
suction pressure at the pump
plant equipment.
essentially the same as at the DA.
Th is is a sudden loss of 100 feet of
suction head. At this point, mostly Conlusion
vapor is entering the pipe from
This article simplified these power
the DA.
plant processes, so additional
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29
factors affecting these types

of transients and possible
remediation actions must be
considered. One important aspect
not addressed in this article is
the DA tank being only partially
fi lled. The void above the liquid has
significant effects. The specifics of
DA design and operation, however,
are not addressed here. For readers
with a sharp eye who find this
(and perhaps other) omission(s)
significant, please feel free to share
your thoughts and analysis.
How do you handle transients?
The best response will win a free
admission to the next Pump
School sessions.
Part 2, in the April 2015 issue,
will examine how a system that
uses multiple pumps could be
affected by a transient event.
References
1. Cameron Hydraulic Data Book, 19th Edition, 2002
2. Rovnak, J., Wotring, T., Marshall, J., Evaluation of NPSH During Hot Restarts of
Fossil Plants with Deaerators, International Power Generating Conference, ASME,
91-JPGC-Pwr, 23, October 6-10, 1991
Dr. Nelik (aka Dr. Pump) is president of Pumping Machinery, LLC, an

Atlanta-based firm specializing in pump consulting, training, equipment
troubleshooting and pump repairs. Dr. Nelik has 30 years of experience in
pumps and pumping equipment. He may be reached at pump-magazine.
com. For more information, visit pumpingmachinery.com/pump_school/
pump_school.htm.
For a video accompaniment

to this article, visit
pumpsandsystems.com/
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2015 Cat Pumps All Rights Reserved. 15036 1/15

30

A better understanding of complete system operation
By Ray Hardee
Engineered Software, Inc.
How an Oversized Pump Can Harm the

Motor & Increase Operational Costs
ast months column (Pumps

& Systems, February 2014)
reviewed the pump selection
process and described how many
users oversize pumps by adding
design margins to account for
unknown conditions present
during the pump specication
process. Design margins are similar
to insurance, providing protection
for unknown conditions expected
in the life of the plant. This column
will explore how oversizing a pump
aects the motor driving the pump.
It will also examine the adverse
eects that occur when a pump
is no longer operating at its best
eciency point (BEP) for extended
periods of time and situations in
which a design margin increases
cost of ownership.
Drive Operations
Induction motors used to drive
pumps are ecient in converting
electrical energy into mechanical
energy. A motor is 92 to 96
percent ecient depending on its
classication and frame size. The
eciency is relatively constant
from 50 to 100 percent of full load,
with only a slight drop o when
operating down to 25 percent of
full load. Figure 1 shows a typical
eciency graph for a totally
enclosed fan-cooled (TEFC) motor
at a range of sizes operating at
varying loads.
The problem associated with
lightly loaded alternating
current (AC) induction motors
is their eect on power factor.
To understand the way electrical
Figure 1. The motor efficiency for a variety of motor sizes and

percent of full load power (Graphics courtesy of the author)
energy is converted to uid energy

using motors to drive a pump,
consider the components and
operation of a motor.
An electric motor consists of a
stator and a rotor. The AC power
supplied to the stator generates a
rotating magnetic eld within the
motors stator windings. When
the rotors windings are exposed
to the stators rotating magnetic
eld, an electric current is
generated in the rotors windings.
Th is results in a magnetic eld
within the rotor. The interaction
between the stators rotating
magnetic eld and the rotors
magnetic eld causes the motor
shaft to rotate. The motor shaft
is connected to the pump shaft,
resulting in rotation of the
31
pumps impeller. Increasing the

ow rate through the pump
requires more power from the
motor. A rise in power requires
increased current to the motor
stator, resulting in a rise in the

motors electrical load.
The amount of electrical power
used in the motor to rotate the
pump can be determined by
measuring the voltage across the

stator and the electrical current
through the stator winding. The
amount of power supplied to the
motor is referred to as real power
Figure 2. The relationship between real, reactive and

apparent power along with the power factor
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32
An industrial customer with many lightly

loaded motors will either have a power factor surcharge
added to their utility bill or will need to purchase and install
hardware to correct the plants low power factor.
(P) and is measured in watts.
Because the source of electrical
power is alternating current and
the motors stator consists of a
conductor wound around a stator,
an induced load in the motor
develops. The result of the induced
load is referred to as reactive
power (Q) and is measured in
volt-amperes reactive (VAR).
The reactive power caused by the
stator coil lags in relation to the
real power by 90 degrees. Th is
reactive power produces no
useful work.
The reactive current simply
moves between the generator and
the motor across the electrical
grid. The product of the real
power and the reactive power is
called apparent power (S) and is
measured in volt-amperes.
The power factor of the motor

is de ned as the ratio of the real
power over the apparent power
and is expressed as the cosine of
the angle between the real power
and apparent power. Power factor
ranges between 1, all real power,
and 0, all reactive power. The value
is unitless. The power factor of a
fully loaded motor is indicated on
the motors nameplate.
The real power varies with
the load on the motor, but the
reactive power is based on the
construction of the motor. Figure
2 (page 31) shows that a reduction
in real power causes an increase
in the angle . As a result, a lightly
loaded induction motor has a
reduced power factor.
The real power is used to
drive the motor. The reactive
Figure 3. Motor power factor as a function of motor

loading for a range of motor sizes
power simply ows between the

motor and the generator supply
electricity from the utility. The
resulting apparent power ows
through the power grid.
The electric utility must design
the transmission lines depending
on the apparent power, but the
generator only measures the
real power. Figure 3 shows how
a motors power factor varies
depending on the motor frame
size and percent of full-load
horsepower.
Figure 3 shows that a lightly
loaded motor has a very low value
of power factor. An industrial
customer with many lightly
loaded motors will either have a
power factor surcharge added to
their utility bill or will need to
purchase and install hardware to
Full Service
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34
correct the plants low power

factor. An increased power
expense is one example of
the added costs of excessive
design margin.
Figure 4. The pump curve shows the relationship between the flow rate, head
and pump efficiency. The pump is designed to operate around its BEP.
Pump Operations
A pump is designed for a
specic range of ow rates and
head values to meet the needs
of the market. The pumps peak
performance and maximum
service life for ow rates will
occurr around the BEP. A
pump operating at maximum
eciency results in a uniform
ow of uid through the pump.
Figure 4 shows the pump curve
used in last months column.
The pumps BEP of 79 percent
occurs at 1,070 gallons per

35
minute (gpm). In addition, the

efficiency value quickly drops off
from the BEP to the minimum
and maximum recommended flow
values. Unlike a motor, the pump
operates away from its BEP. The
flow through the pump is no longer
uniform, resulting in recirculation
within the impeller. This nonuniform flow creates uneven
pressure distribution in the pump,
causing an increase in vibration
and hydraulic load as well as a
reduction in efficiency. The price
here results from a combination of
energy costs, mechanical wear and
operational inefficiencies.
In Figure 4, the process flow rate
through this pump for the fi rst
year is only 200 gpm, with the
flow rate increasing to 400 gpm in
This non-uniform flow creates uneven

pressure distribution in the pump, causing
an increase in vibration and hydraulic load
as well as a reduction in efficiency.
the second year and 800 gpm by
the fi fth year. The design flow rate
of 800 gpm is only 75 percent of
the pumps BEP flow.
A standard developed by the
Hydraulic Institute, the ANSI/
HI 9.6. Rotodynamic (Centrifugal
and Vertical) Pumps Guideline
for Allowable Operating Region,
provides recommendations on
pump operation. The standard
can identify a variety of potential
problems when a pump is not
working at its BEP.
The ANSI/HI 9.6. standard
defi nes the preferred operating
region (POR) as a range of flows

either side of the BEP in which
the hydraulic efficiency is not
degraded. The standard defi nes the
allowable operating region (AOR)
as 70 to 120 percent of the BEP
flow rate for pumps with specific
speeds less than 4,500 and from
80 to 120 percent of the BEP for
pumps with specific speeds greater
than 4,500. The pump displayed in
Figure 3 has a pump specific speed
of 870, resulting in a POR between
750 and 1,285 gpm.
The AOR represents a wide
range of flow rates outside the
rtners
a
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36
POR acceptable to the service life of

the pump. The pump manufacturer
de nes the AOR on requirements other
than energy eciency. The AOR is
used extensively in the pump selection
process. The pump manufacturer

should be consulted before the pump is
operated outside the AOR. In Figure 4,
the manufacturer specied the pumps
AOR to be between 350 and 1,650 gpm.
The standard outlines concerns that

the pump manufacturer considers
when specifying the AOR. Operating
outside the AOR could result in reduced
bearing life, reduced shaft seal life,
internal mechanical contact, shaft
fatigue, thrust reversal, excessive
temperature rise through the pump,
increased vibration and noise,
insucient net positive suction
head and suction recirculation. The
pump should operate within the AOR
specied by the manufacturer to avoid
potential long-term mechanical damage
to the pump. These issues lead to
maintenance and energy costs as well as
unscheduled shutdowns.
Evaluating the Pump

In Figure 4, the 200 gpm of ow rate for
the rst year of operation is well below
the minimum AOR ow rate of 350 gpm
recommended by the manufacturer. If
the pump were to operate at this ow
rate for an extended period, extensive
mechanical degradation would occur. To
achieve the manufacturers minimum
ow of 350 gpm, a recirculation line will
need to be installed to recirculate 150
gpm back to the supply tank.
When the preliminary sizing was
performed, design margins for pump
head were added. Unknown conditions
were factored into the preliminary
design including the elevation of the
tanks, tank levels and pressures, pipe
length, and number of valves and
ttings. Now that the system is built,
the conditions are known.
In Figure 4, the pump head at the
design ow rate of 800 gpm was
calculated at 211 feet, but the system
as built only requires 190 feet of head.
The additional 21 feet of head required
by the design margin is excess head.
Because the full value of design margin
is not needed and the pumps are already
in place, the additional head (the 21
feet) is absorbed across the control
valves to eliminate excess energy.
37
Assessing the Cost of the

Piping System
As demonstrated, assigning design
margins of head and ow are
an integral part of every pump
selection. They provide designers
and engineers with the required
exibility to select long lead items
early in the design process.
Just like any expense, the
amount of insurance and resulting
costs should be evaluated and
re-evaluated. Oversizing pumps
increases the systems operational,
maintenance and capital cost.
Without knowing the true cost of
owning and operating a pump, the
process cannot be improved.
The purpose of the pump
system assessment is to review
how the installed and operating
system is performing. The system

is reviewed, and margins are
adjusted for optimization. The
initial design phase can only
supply a best-case scenario.
Determining costs associated
with each component in a piping
system helps calculate actual
operating costs, and performing a
post assessment allows engineers
and operators to evaluate what
can be done to improve system
performance further in full
operation.
References
Welcome to the Hydraulic Institute. (2014,
January 1). Retrieved January 7, 2015, from
http://www.pumps.org/content_detail.
aspx?id=4330
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. Reach him at
ray.hardee@eng-software.com.
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38
SPECIAL SECTION
Discover the Untapped

Potential of the
Internet of Things
The value-added services that IoT technology provides
could transform the pump industry.
BY MIKE W. OTTEN
4 ESSENTIAL STEPS TO SUCCESSFUL IoT IMPLEMENTATION
or the last few centuries, pumping

systems and the pump industry
have been relatively uncomplicated.
Beginning in the 1950s, however,
pump manufacturers arose from machining
shops, and a stream of acquisitions across the
globe created a new and rigorous demand for
pumps. Newly engineered pumps designed
for an ever-increasing landscape of
applications, material variations, sizes and
customized solutions created a competitive
market focused on creating the most energy
ecient pump.
Today, the Internet has transformed the
realm of energy eciency, oering remote
access and sensing devicesincluding
alarms and video capabilities that visually
display and analyze rooms, pump status and
other real-time datato provide critical
information at the swipe of a nger. Internetenabled apps accessed from smartphones,
tablets or other handheld devices allow
even the pump industry to control diverse
devices more eciently than ever. These
apps, if streamlined, could create new value
by closing the loop of the entire pump
life cycle from research and development
(R&D), to application design, to startup and
1. Define your focus.

When you Google IoT, you will get more than 25 million results. IoT
technology will garner about 15 million hits. These search results alone
reveal the hype about the newest available technologies and services. The
best approach to building an IoT strategy is to begin by spending time
and resources to clearly define your customer problem, determine an IoTbased solution and develop a business case for the value-added services
these technologies would provide.
2. Choose a platform that fits your needs.

Because most plant management teams are not software developers,
consider selecting an IoT platform that provides standard widgets and
templates that allow users to drag and drop and copy and paste precoded materials that will reduce your time to market by 10 times. Several
of these platforms are already available on the market.
3. Keep development simple.

Engineers are used to developing, breaking down and rebuilding again.
The development of wireless sensors, however, is different. Selecting
the wrong standard is the No. 1 pitfall that wastes time and resources.
To avoid these challenges, develop sensors and apps using a basic IoT
solution development kit.
4. Build a strong IoT ecosystem.

Entering this new IoT space requires time and teamwork. Building an
Internet of Pumps solution is impossible without key partners that have
strong ecosystems of solutions to serve your plants particular needs
especially as your IoT network grows.
39
The Internet has transformed the realm of energy efficiency,

offering remote access and sensing devices to provide
critical information at the swipe of a finger.
commissioning, to upgrade and retrot processes.
These Internet-enabled apps and devices integrated
into value-added services is known as the Internet of
Things (IoT). The use of consumer technology is driving
the growth of the IoT sphere. In fact, some predictions
estimate that by 2020, 26 billion installed IoT units will
exist, and IoT suppliers will generate $263 billion in
incremental revenues, resulting in a $1.9 trillion global
economic value.
The Internet of Pumps

More than a decade ago, pump engineers and operators
experimented with wireless application protocol (WAP)enabled phones to communicate with pumps. Around
that time, the industry used machine-to-machine (M2M)
technology based on general packet radio service modems
to package equipment data and send it to supervisory
control and data acquisition (SCADA) systems and
Web-based extranet interfaces to monitor and control

pump systems.
Today, high-tech tools including variable speed drives
(VSDs), SCADA systems, condition monitoring equipment
and other automation devices, are widely accepted by the
pump industry. However, these systems can be costly,
complex, dicult to install and focused only on the
individual asset.
To solve the challenges of modern pumping technology,
many companies and niche industriesutilities, mining
$263 billion
The estimated amount of incremental revenue
generated by IoT product and service suppliers
by 2020. (Source: Gartner, November 2014)
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Organized by

SPECIAL SECTION
IoT
Internet of Pumps
Added Value
40
SMART
(Connected pump)
SOFTWARE
DEFINED
(BMS/SCADA)
INSTRUMENTED
(On-site audit)
CONVENTIONAL
(Consultancy)
No intelligence or
connectivity
Connected data
loggers
Provide external data
(paper report)
Some local
intelligence
(controller) to tune
pump
AUTONOMOUS
Internet of things by
2020*
26 billion installed
units, $263 billion
new revenue and $1.9
trillion value-added
services
Additional sensors
Real time
diagnostics
Active condition
monitoring
Embedded
execution
Self optimization
New business
models
Interact with
ecosystem
Enhanced
intelligence
Performance
guarantee
Customer loyalty
Connect
everything
Enhanced data feeds
Level of Maturity
*Source Gartner, Forecast The Internet of Things worldwide
Figure 1. The Internet of Pumps (Graphics courtesy of the author)
and manufacturing in particularare implementing

IoT solutions to reduce operational expenditure,
increase their return on investment and improve
customer satisfaction.
Several levels of IoT sophistication exist within the
pump industry. The higher the level, the more plants
and facilities are able to tap into this unprecedented
opportunity to transform their commodity-driven
business into a value-adding, service-based organization
(see Figure 1).
Instrumented
In the instrumented level, actual data loggers could
be installed on-site to measure and log critical pump
dataincluding energy consumption, ow, and inlet
and outlet pressureover a period of time. Plotting that
data using Excel into the original design curve would
give a more accurate view of pump performance over
the period the data is logged. The same benchmark used
in the conventional approach could be used to estimate
potential savings.
Conventional
The rst level of sophistication (see Figure 1), the
conventional method of selecting or reviewing pump
performance, starts at the basics.
Using some basic application data, a consultant or
engineer takes the information from the nameplate and
chooses equipment using a pump selection program. With
that information, he or she can benchmark the existing
pump eciency against that of a newly designed pump
and calculated running times. The consultant or engineer
can then provide educated estimates about the energy
consumption and potential cost savings of installing a
new pump.
Software Defined
If the pump is equipped with a controller, the pump
will operate against dened set points making use of
the best possible predened working conditions. These
automated systems could generate some data reports
with historical trend lines and even generate set alarms
when data thresholds are reached. However, this level
of IoT sophistication does not provide any further
information about the performance of the pump system.
The system only noties the user when it works outside
the programmed conditions.
These building management systems (BMS), SCADA
or M2M applications have evolved in a context in which
41
42
SPECIAL SECTION
IoT
applications such as remote monitoring and support

for equipment have been tied closely to equipment
services contracts. To date, remote services and M2M
systems have largely been focused on simple remote
diagnostics and simple tracking services, in large part
because of technical complexities and business model
challenges. Existing technology has proven cumbersome
and costly to apply with many con icting protocols and
incomplete component-based solutions. The challenges
and costs of developing applications and integrating
diverse devices onto networks in an interoperable manner
have been signicant adoption hurdles. For this reason,
many organizations settle at this level.
Smart & Autonomous

Moving to smart and autonomous applications (the last
levels) involves multiple collaborating systems with
signicant interactions between assets such as pumps,
heat exchangers, control systems and people. The focus
is no longer solely on the product suppliers ability to
eciently deliver support for its product. Instead, value
is brought to the customer through business process
automation and optimization.
Consider any of the larger pump systems in more
complex industries such as power generation or
industrial manufacturing. In such high-value and

critical businesses, major electric utility customers
have good reason to hate equipment failures. At the
least, any downtime creates huge opportunity costs for
these customers. It often means they have to pay hefty
regulatory compliance nes.
To reduce risk, monitoring and diagnostics of critical
assets such as large pump systems enable suppliers to
send a technician or engineer before a failure occurs
(preemptively) as opposed to doing so according to a
schedule based upon assumptions (proactively) or, even
worse, after the power has gone o (reactively).
Most pumps suppliers cannot charge more than
$75 to $120 per hour for their technical support because
of price and benet pressures from local competitors.
With ecient network-enabled services, however,
leading players could charge $250 to $350 per hour for
the same technician who has become a skilled subject
matter expert.
The Future of IoT

These instances, however, are still examples of
simple applications largely focused on the product
manufacturers own value chain. They are simple hub
and spoke remote support. While these models have
Figure 2. IoT solution cycle
43
Internet-enabled apps accessed from smartphones, tablets

or other handheld devices allow even the pump industry to
control diverse devices more efficiently than ever.
value, signicant untapped
opportunities are available to
provide new value for users and
customers.
Plant managers have many
options. Based on their IoT
expertise and resources, they can
either develop their own smart
devices and code their Internet of
Pumps platform or use plug and
play hardware kits and pre-coded
IoT software platforms to retrot
existing sensors.
For companies and plants
wanting to revamp their business
models and provide better valueadded services, implementing
an IoT strategy that connects
everything from a pump in the
eld to the corporate network
can transform not only those
companies but the entire
pump industry.
Sources
1. Blog Analyst, Andy Mulholland
2. Gartner forecast Internet of Th ings
worldwide
3. Mike W. Otten was employed by
Grundfos from 1997 2012
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Mike W. Otten works with leadingedge technology and manufacturing

industries. He has a
reputation for delivering
successful startups.
For more information,
visit Ottens site,
sense4things.com.
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44
SPECIAL SECTION
IoT
How to Protect Plants from

Invisible Threats
A solid cyber defense strategy can protect plant assetseven eld
devices and pumpsfrom dangerous and costly security breaches.
BY GARY WILLIAMS, MSC, IT SEC
SCHNEIDER ELECTRIC
plants industrial control system (ICS) is no

longer an island, and a eld deviceonce
ranked low in the risk and threat analysis
tableis no longer safe simply because it is
protected by its own control conguration. Today, a
cyberattack can be initiated at any point in a plants
interconnected industrial system. For this reason,
plant managers must consider cybersecurity at every
level of the plantfrom the business network to each
critical eld device and pump. Failure to do so could
have catastrophic eects on both human safety and
production.
System Complexity
Industrial systems consist of an array of devices, systems
and software that are used to control, monitor and report
vital data, making them a prime target for malicious
activity. Reports of rogue databases, such as Shodan,
show that these programs can openly report devices and
systems connected to the Internet. They reveal critical
system informationincluding location, purpose and
protocolthat a hacker can use to compromise a system,
cause damage and interrupt production.
The advent of wireless connectivity and the Internet
of Things presents a totally new threat vector that puts
even eld devices at risk. While much of the modern
wireless technology available today (including tools
that are compliant with WirelessHART and ISA100) is
fairly secure, wireless devices and programs can suer
interference from any Wi-Fi, Bluetooth or other wireless
device operating in the same frequency band. Even
10 STEPS TO A FORTIFIED CYBER

DEFENSE SYSTEM
1. Assess vulnerabilities of inventory-critical
assets.
2. Implement plans and systems to eliminate
vulnerabilities.
3. Manage electronic access to controls using
physical or logical network segmentation.
4. Manage user access to controls through user
privilege and password management.
5. Keep operating system and software patches
up-to-date.
6. Enable advanced antivirus software, and keep it
current.
7. Back up software regularly, and create an
incident-response plan.
8. Establish and enforce rigid policies for using
flash drives, CD-ROMs and the Internet.
9. Seek vendor assurance that servers,
workstations and other systems are hardened
and standards-compliant.
10. Stay current on industry standards such as
ISA99, IEC62443, ISA Secure, WIB and IEC62443,
and review operations accordingly.
45
wireless printers and scanners pose a threat, because

most wireless printers come with the wireless facility
switched on by default, which alone could compromise
an ICS.
Industrial specic protocols are no longer a defense
either. A new trend among hackers is to gain notoriety by
advertising vulnerabilities in legacy protocols, software
and systems. These range from supervisory control and
data acquisition (SCADA) to ICS control software.
The Standards
Despite the countless variables at play, plants can
employ an eective approach: Adopt an information
security management system, as dened by the
International Standards Organization (ISO27001), and
comply with standards put forth by the International
Society of Automation (ISA99) and the International
Electrotechnical Commission (IEC62443).
ISO27001 was designed as a methodology to address
security. It lists a number of controls companies can use
to employ policies and procedures that address system
condentiality, integrity and availability.
1.5 million
monitored cyberattacks occurred in the U.S.
in 2013 (Source: IBM Security Services 2014
Cyber Security Intelligence Index, April 2014,
accessed on ibm.com)
Concentrating more on a companys ICS, ISA99,

IEC62443, ISA Secure, WIB and ANSSI address security
and protection of industrial systems. IEC62443 could
eventually encompass all of these standards, providing
one standard that covers best practices, policies and
procedures (see Figure 1). It gives direction on network
design, protection, maintenance of the industrial
network, patching of operating systems and anti-virus
software. It will retain the ve ICS levelsfrom eld
instrumentation and safety instrumented systems (SIS)
to enterprise nancial systemsput forth originally in
ISA99 (see Figure 2, page 46).
Figure 1. This diagram shows a comprehensive cybersecurity standard set. One of the most important things a company can do
to prevent cyberattack is to follow best practices recommended by established standards bodies. ISA-62443 is one of the most
comprehensive standards and eventually could encompass all of the others. Diagram shows planned and published standards.
(Graphics courtesy of Schneider Electric. Source ISA-99 Standards Committee)
SPECIAL SECTION
IoT
Level 5
Level 5 - Enterprise
- Enterprise financial systems
Level 4
Level 4 - Site Business Planning

- Site production scheduling
- Site accounting
Level 3
Level 3 - Site Manufacturing Operations

- Production control
- Optimizing control
- Process history
- Windows domains
Level 2
Level 2 - Area Supervisory Control

- Supervisory controllers
- Primary operators interface
Level 1
Level 1 - Basic Process Control

- Batch controllers
- Continuous controllers
- Discrete controllers
- Process monitoring
Level 0
Level 0 - Field Instrumentation

- Sensors, transmitters, control valves
- Field networks (e.g. Foundation Fieldbus,
Profibus)
Safety-Critical
- Protective systems
- Safety instrumented systems
Level 5
46
Figure 2. This chart depicts enterprise cyber protection layers. A cybersecurity assessment begins with an identification of the areas that
need to be protected. The ISA-99 standard recommends six levels. (Source: ISA-99 Standards committee)
For the ICS, Levels 3 through 0 should be protected.

Most companies also have Level 3.5, which serves as a
demilitarized zone (DMZ) to provide a rewall against
outside threats that can compromise the system.
The Strategy
The rst step is to assess the risks and threats that might
be associated with each layer. To do this, managers must
consider their plants target levels and evaluate the
consequences of a cyberattack for each level. What are the
chances of this level being exploited and by whom? What
skillset and knowledge would be required to compromise
this element? Would a compromise at this level result in
loss of life or production? The results of this assessment
reveal what type of access or knowledge is needed to
compromise each level and indicate the most critical areas
that need protection.
Addressing ICS security by implementing safeguards
in this way is known as creating layers of defense. No one
exercise or handbook can dictate what security is needed
for each layer in a particular company.
field device
field bus module
field control processor
Figure 3. Example of communication between devices
Layers are dened by the security gaps within an

organization. Finding these holes requires a site-specic
gap analysis that identies a companys current situation
and the factors that are preventing it from achieving
maximum security.
To identify existing security gaps, analyze each level
and the communications to the
next level. The standards ISA99 and IEC62443 refer to
this process as identication of zones and conduits.
For example, if a plant started at Level 0 designating
all of their pumps in a zone, the conduit would be the
communication between the pump and the next device in
line (see Figure 3).
This step results in a list of current assets, protocols
and connectivity that would allow a plant manager
to determine strategies to protect them by applying
technologies such as rewalls, switch management
and virtual LANs.
This process is continued until Layer 3, although any
threat that cannot be mitigated at a low level can be
addressed at a higher level. If a eld device only accepts
software suite
operator console
47
Modbus signals, for example, but does

not have the necessary resources to
discriminate intelligently, a rewall
could protect it at the next level.
Modern rewalls are capable of deep
packet inspection. They can be
congured to ignore all but specic
protocols and can even discriminate
by packet length and content.
Once at Level 3, the number of
threats increases because higher
levels can include multiple protocols
and connectivity to a number of
smaller systems. Level 3 is also the
top layer before connectivity to the
corporate network or outside world,
which is why it needs a DMZ.
Many system engineers do not
possess the necessary skillset to
execute the actions required for
maximum cybersecurity. As the
demand for security increases,
however, plant managers, operators
and other personnel must have a
greater understanding of modern-day
threats and security. In fact, most
of the security exploits experienced
in the last few years have actually
been introduced by ICS engineers,
often via a USB key or a compromised
CD-ROM. For this reason, facility
management should provide up-todate operator awareness training
and push vendors to provide
secure products, services and
consultancy at every level of security
implementation.
Cyber threats are real, and the
consequences of a breach could be
dire. Plant managers should begin
assessments early, ensure that the
entire company is on board and
remember that cybersecurity is
continually evolving as new
threats develop.
Gary Williams, MSc, IT SEC, is senior director of cybersecurity

and communications technology at Schneider Electric. He brings
more than 30 years of experience in communications, design and
implementation for industrial, military and law enforcement,
and applications.
Read more
blog/5-reasons-you-shouldinvest-internet-things

48
SPECIAL SECTION
HARSH CONDITIONS
Submersible Pumps
Handle Corrosive Solids
at Ethanol Testing Plant
A caustic, high-temperature cleaning solution
puts excessive demand on equipment.
BY MIKE BJORKMAN
BJM CORP.
orn-based ethanol is a vital part of the total

global energy requirement. During the past
decade, the U.S. has become the largest
producer of ethanol in the world, with a 56.8
percent share totaling more than 13.7 billion gallons (52
billion liters) produced in 2013. Production has doubled
since 2007, and improvements in equipment, systems and
processes have contributed to this increase.
One Midwest-based research center is working to
improve the ethanol process. Located outside of St. Louis,
Missouri, this research center focuses on validation and
commercial testing of products, technologies and new
concepts. The center is fully equipped to meet all research
or technology validation needs, providing laboratory,
fermentation and pilot plant production process services
in an integrated setting.
Pilot Plant
Costs associated with the design and development
of products for the renewable fuel market represent
a tremendous investment. Knowing precisely how
these products will perform in a real plant before that
investment is made can make a significant difference in a
companys success or failure.
The 24,000-square-foot pilot plant, equivalent to a
50th scale ethanol production facility, operates at a 100
to 400 bushel per day capacity and offers continuous
or batch-run operation. The pilot plant ethanol process
begins with the whole corn kernel ground into meal. The
meal is then slurried with water to form a mash. Enzymes
are added to convert the starch to dextrose, a simple
sugar. Ammonia is added for pH control and as a nutrient
to the yeast.
The mash is processed in a high-temperature cooker
to reduce bacteria levels before fermentation. It is then
cooled and transferred to fermenters where yeast is
added, and the conversion of sugar to ethanol and carbon
dioxide begins. The fermentation process generally takes
about 40 to 50 hours. During this part of the process, the
mash is agitated and kept cool to facilitate the activity of
the yeast.
After fermentation, the resulting beer is transferred
to distillation columns where the ethanol is separated
from the remaining stillage. The ethanol is concentrated
to 190 proof using conventional distillation and then
dehydrated to approximately 200 proof. The ethanol is
blended with about 5 percent denaturant (such as natural
gasoline) to render it undrinkable and exempt from
beverage alcohol tax. It is then ready for shipment to
gasoline terminals or retailers.
The pilot plant is staffed with an experienced team of
engineers and operators. The ethanol plant operating
coordinator is a veteran of the industry. It is his job to
keep the pilot plant operating at optimum efficiency.
Finding the right equipment is critical to his mission.
Image 1. The U.S. has become the largest producer of ethanol in the world, with a
56.8 percent share totaling more than 13.7 billion gallons produced in 2013.
(Images courtesy of BJM Corp.)
Image 2. High-temperature, stainless-steel submersible pumps in the sump application

proved effective for a Midwest-based research center working to improve the ethanol
process.
Room for Improvement

One of the maintenance requirements of the
fermentation process is flushing the tank periodically
with a caustic hot water (160 to 180 degrees F) cleaning
solution. The blend of corn fines and corrosive water is
then flushed into a sump where the wastewater is held
before treatment. The cast-iron pumps responsible for
clearing the sump, however, experienced excessive wear
and short service life.
The operating coordinator consulted with a Midwest
industrial distributor with experience in ethanol
production. The distributor recommended hightemperature, stainless-steel submersible pumps for the
sump application.
The selected pumps are designed to handle hightemperature corrosives and provide solids handling for
the bottom-settling corn fines. Non-clog, single vane
impellers deliver the high volume and lift performance
that is required for the sump service. All of the wear and
wetted parts, such as the impellers and wear-plates, are
made of cast 316 stainless material. The elastomers
such as O-rings, lip seals and gasketsare made of
chemically resistant, high heat resistant flouroelastomers.
An additional life cycle enhancing feature provides
three-seal motor protection. The submersible motor is

protected by double mechanical seals. The lower seal is
made of silicon carbide/silicon carbide, and the upper
seal is made of carbon/ceramic. An additional lip seal
is installed above the impeller to prevent abrasives
such as corn fines from entering into the seal chamber.
Additional winding protection, National Electrical
Manufacturers Association Class R motor insulation and
a thermal cut-out switch that will allow the stator to
reach a winding temperature of up to 300 F are standard.
Conclusion
After more than two years of operation, the stainlesssteel submersible pumps have worked exceptionally
well, with no maintenance issues. Upgrading equipment
to improve mean time between failures is imperative
to ensure the best testing results for clients and lowest
operational costs for the research center.
Mike Bjorkman is vice president of BJM Corp. and has
more than 30 years of experience in the pump industry.
He serves as director of marketing and information
technology for BJM Pumps, LLC, and All Test Pro, LLC.
Both companies are subsidiaries of BJM Corp. He may be
reached at 860-399-5937.
49
50
SPECIAL SECTION
HARSH CONDITIONS
Mechanical Seal Design

Protects Submersible Pumps
from Abrasive Wastewater
Customized seals made from superior materials can help prevent
premature failure in heavy-duty applications.
BY SPENCER REYNOLDS
VULCAN SEALS INC.
ump manufacturing companies have made

strides in improving design, efficiency and energy
usage in recent years through developments in
impeller profi le and the use of optimized motors
and variable frequency drives. All of these changes
enhance end users bottom lines by reducing energy costs.
But operators have more options to improve efficiency
and reliability while reducing costs of fluid management.
They can, for example, extend the period between
necessary maintenance activities and minimize the cost
of spare parts required during maintenance.
One particular pump application that consistently
accrues a high maintenance bill is wastewater movement,
especially on a site that lacks pump operation experience.
The most convenient and commonly adopted design for
this demanding application is a waterproof pump
complete with an upper and lower set of mechanical
seals designed to protect the bearings and motorwith
a vertical shaft that is submerged in the pumped liquid.
Such submersible pumps can be lowered into sumps,
storage tanks, storm drains, cesspits, bilge and ballast
tanks, rivers, flooded foundations or workings of all kinds
to draw the fluid out and move it to an area where it can
be processed or disposed of as needed.
Two contributory factors have a negative influence on
the life of mechanical seals inside submersible pumps.
These pumps handle a typically contaminated aqueous

fluid that has a high solids content with a wide range
of particle sizes, from microns to large pieces of
masonry, all of which are potentially damaging to
mechanical seals.
The pumps are often neglected, either because they
are underwater and out of sight or are being operated
by contractors with little knowledge about or training
on the requirements of correct pump operation. The
pumps frequently run dry once the fluid level has
been reduced to the minimum and the impeller is no
longer submerged.
Submersible pumps are often regularly repaired. In the

case of rental companies, the pumps are repaired after
each user and are often recalled for repair during service
because of seal failure. Since these pumps have several
O-rings that ensure adequate water proofing as well as
upper and lower sets of mechanical seals, the inventory of
spares required each time one of these pumps is repaired
has a relatively high value.
The typical design of a submersible pump requires a
shorter than standard mechanical seal. This is because
this design of submersible pump has two sets of seals
mounted in close proximity on the vertical shaft. Because
no common design standard exists, each manufacturer
designs the sealing chambers according to its own
51
Because no common design standard exists, each manufacturer

designs the sealing chambers according to its own policies.
policies. As a result, each pump design has a unique

seal chamber that requires a custom mechanical seal
designed specifically to fit the space available.
This design methodology means that industry
standard mechanical seal designs cannot be fitted to
the vast majority of submersible pumps. This situation
has caused frustration for many pump users in the past.
Without the option of a standard, off-the-shelf seal from
a third-party manufacturer, repairers had to use the
standard original equipment manufacturer (OEM) part
instead of specifying an alternative replacement part.
A mechanical seal company can provide repair shops
with the seals that are needed, rather than producing a
range of industry standards and leaving the repair shop
to find what is required on its own. Many seal companies
offer parts that have a close visual similarity to the
original parts, as well as necessary O-rings and any
fitting tools.
ati
re
e
Wh
In
v
no
s
low
F
n
For example, an OEMs seals may come in two basic

types with upper and lower seal faces in one seal that is
easier to install. However, some of these wearing parts
may be composed of low-cost materials and will need
frequent replacement. A seal company, on the other
hand, could create several seal ranges that fit into the
seal chambers without modification to the equipment
and with parts made from higher-end materials chosen
for a specific application. These customized seals
characteristics could help prevent premature seal
failures, especially in an arduous application requiring
submersible pump service.
Spencer Reynolds is the business development manager
at Vulcan Seals Inc. He may be reached at spencer.
reynolds@vulcan-eng.com. For more information, visit
vulcanseals.com.
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52
SPECIAL SECTION
HARSH CONDITIONS
Harsh Liquids Require

Careful Material Selection
Metallics and plastics oer advantages for dierent applications.
BY KEN COMERFORD
VANTON PUMP AND EQUIPMENT CORP.
hoosing the right pump material to handle

aggressive fluids is critical to the success of any
processing operation. Aggressive fluids are those
that either corrode or abrade the pumps used
to handle them, including acids, caustics, reagent grade
chemicals and unknown wastewater effluents. Selecting
the appropriate material for handling these aggressive
liquids requires careful analysis to avoid incurring the
cost of premature pump replacement and downtime.
Metal and plastic are the two major types of materials
used for pumping harsh liquids. Pump users must
consider multiple factors to select the optimal material
for their specific requirements.
When dealing with metals, users must be aware of the

four types of metallic corrosion.
1. General Corrosion - The formation of a passive fi lm on a

metals surface is what prevents it from degrading.
2. Galvanic Corrosion - This phenomenon occurs when
two or more disparate metals come in contact with one
another or when metals with the same analysis have
different surface conditions and an electrolyte is present,
which forms an electrolytic cell.
Table 1. A comparison of the performance of different materials of construction
MATERIALS OF CONSTRUCTION
PROPERTIES
Metallics
Historically, exotic metal alloy
Maximum
Specific
Abrasion
pumps were the tried and true
temperature
gravity
resistance
solution for the proper handling of
(mg) Taber,
harsh fluids. These materials were
F / C
1,000 cycles
so ubiquitous among processing
PP
polypropylene
185
85
0.94
15 20
professionals that corrosion-related
PVC
polyvinyl chloride
140
60
1.3
12 20
pump failure was considered both
chlorinated
polyvinyl
predictable and anticipated by
210
99
1.49
20
CPVC
chloride
independent sources. Examples
PE
polyethylene
200
93
0.92 0.94
5
of such sources are Compass and
Schweitzer, compendia that detail
PVDF polyvinylidene fluoride 275
135
1.75
5 10
the expected service life of materials
ethylene
300
149
1.75
5 10
ECTFE
in a given corrosive fluid. The
chlorotrifluorethylene
shortcoming of these measurements, PTFE polytetrafluorethylene 500
250 2.14 2.20 500 1000
however, is that they are taken
fiberglass reinforced
in a static condition. When these
300
121 3.40 5.00 388 520
FRP
plastic
materials must perform at high
stainless steel type
speeds, their life expectancy is
NA
NA
7.9
50
SS
304/316
curtailed even further.
Tensil
strength
PSI
4000-5000
6,000-7,500
7,500-11,000
3,500-5,600
5,500-8,250
6,500-7,500
2,000-5,000
10,000-13,000
65,000-77,000
53
Image 1. Assorted thermoplastic pump

components made of PVC, CPVC, PP, PVDF
and ECTFE ((Images and graphics courtesy
of Vanton Pump and Equipment Corp.)
3. Stress Corrosion Cracking - Since all

metals have residual or applied stress,
they are prone to stress corrosion
cracking, which is affected by extreme
thermal changes, excessive vibrations,
and expansion or contraction.
4. Intergranular Corrosion - This type

occurs only at the grain boundaries of
carbon-containing austenitic stainless
steels. If the steel is heated above 1,000
F, the carbon is released at the grain
boundaries, causing the area to become
more susceptible to corrosive attack.
While the shortened service life of
a metallic pump caused by corrosion
is problematic, corrosion may also
contaminate the pumped liquid and
compromise the fluids composition.
A properly selected plastic material,
however, would be inert to the most
harsh or caustic fluids because plastics
are compatible with such liquids and
would not react on contact. The correct
plastic for a particular application will
solve most fluid transfer, dosing and
collection problems.
54
SPECIAL SECTION
HARSH CONDITIONS
Plastics
How does a user select the right plastic for handling a
specific harsh liquid? The first step is to recognize that
choosing the ideal plastic pump is not a cure-all for every
pumping application. In high-temperature or highpressure applications, metallic pumps perform better
(see Table 1, page 52). In applications in which chemical
compatibility is a primary consideration, however,
plastics are considered the material of choice.
The two major non-metallic groupings are thermosets
and thermoplastics.
Thermosets
Thermosetting plastics are composites, not homogeneous
materials. Commonly referred to as fiber reinforced
plastics (FRP) or glass reinforced plastics (GRP) materials,
thermosets are constructed of vinyl ester or epoxy resin
reinforced by glass fibers.
The strength of FRP and GRP materials is influenced
by variations in its composition.For this reason FRP/GRP
pumps are commonly referred to by their trade names,
which provide specific analyses of the materials made
by their manufacturer. FRP/GRPs rigid properties (their
tensile strength, for example) more closely match those

of metallics than thermoplastics. Their resistance to
corrosives increases as vinyl is added to their formulation,
while their resistance to solvents is enhanced by their
epoxy content.
Thermosets can be custom-formulated to meet specific
service conditions, because different formulations of
their components (glass fiber/epoxy) can impart different
values to the composite material. For this reason,
standard corrosion charts are not always helpful. Instead,
performance characteristics should be determined by the
manufacturers and the users prior experience. Because
of the specificity of this type of material, users should
employ careful consideration when selecting thermoset
pumps for applications in which the fluid is unknown.
Thermoset pumps will resist most chemicals and can
reliably be used in applications in which the fluid reaches
300 F or higher.
Users should be cautious, however, when using
thermoset pumps to handle solids-containing liquids.
In these applications, the pumps resin surface may be
abraded, exposing the reinforcing fibers. This may expose
glass fibers beneath the surface, which could result in
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55
Advantages of Thermoplastic
Pumps over Fiberglass Reinforced
Plastic (FRP) Pumps
severe damage and even pump
failure. Since FRP/GRP pumps
are formulated to handle a
narrow and specific type of
caustic liquid, they are limited
in the range of harsh liquids
they can handle effectively.
No interbatch product
contamination
Solid homogeneous
thermoplastics do not wick or
absorb by capillary action
Superior resistance to abrasion
compared with thermoset
composites
Greater chemical resistance
coverage over the full pH range
Thermoplastics
Thermosets and thermoplastics
are much lighter than metallics,
providing ease of installation
and maintenance. Unlike
thermosets, thermoplastics are engineered materials,
giving them unique properties including a broad range
of chemical compatibility and resistance to impact,
abrasion and heat.
Typical thermoplastic materials used in pumps for
handling harsh liquids include:
Polypropylene (PP)
Polyvinyl chloride (PVC)
Chlorinated polyvinyl chloride (CPVC)
Polyethylene (PE)
Advantages of Thermoplastic
Pumps over Metal Pumps
No galvanic corrosion or rusting
Superior resistance to abrasion
Greater chemical resistance over
the full pH range compared with
metals
No ionization/metallic
contamination of the uid
No galling problems
Signicantly lighter in weight,
facilitating installation and
maintenance
Polyvinylidene fluoride (PVDF)

Ethylene chlorotrifluoroethylene (ECTFE)
Polytetrrafluoroetheylene (PTFE)
Homogeneous in structure, these plastics are inert

to most chemicals throughout the entire pH range.
Even when the material is nicked or abraded, the harsh
liquid that is being pumped remains in contact with the
same material, so the pumps corrosion and abrasion
resistance is not affected. According to Taber abrasion

56
SPECIAL SECTION
HARSH CONDITIONS
testing, thermoplastics show one-tenth of the weight

loss of stainless steel, affirming that, unlike metallic and
thermosets, they provide superior resistance to wear and
abrasion without degradation of the pump material.
While published corrosion-resistance charts for
thermoplastics can be used as guides, users should
provide their pump manufacturers with conditions of
service to arrive at the ideal performance parameters.
Temperatures can play a significant role in pump material
selection. As an example, according to published data, a
pump handling fluids with a temperature of 275 F should
use fluoropolymer material, while equipment that will
pump fluids reaching 140 F should use PVC to ensure
ideal performance.
Conclusion
Selecting the ideal material for pumping harsh liquids is
a matter of weighing performance and cost. The pumps
purchase price should not be the sole determining factor.
Users should also consider the cost of replacement parts
and downtime.
When planning a new system or replacing an existing

pump, thorough analysis is necessary for selecting
the most favorable material and ensuring long-term,
dependable performance. When selecting the basic
construction material for a pump that will handle
aggressive fluids, users should first take into account the
fluid being pumped, the operating temperature of the
fluid and the pressure of the application.
If the temperature is 300 F or higher, a metallic pump
is probably the ideal solution. When the fluid being
pumped is 250-300 F, materials such as fluoropolymers
(PVDF, ECTFE or PTFE) will prove most effective. If
the temperature of the pumped liquid is below 250
F, however, an FRP and a thermoplastic should be
considered. If product purity is paramount, natural,
unpigmented PP or PVDF will perform best.
Ken Comerford is the vice president of

Vanton Pump and Equipment Corp. He
has been with the company for 32 years.
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How Gear Motor

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Group. He is responsible for ABBs global large gearing and specialty gearing
business. Myers holds a B.S. in mineral engineering from the University of
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FRE E
58
SPECIAL SECTION
HARSH CONDITIONS
Customized Compounding
Boosts Resilience in
Harsh Conditions
Reinforcing additives combined with a carefully selected base resin
can create a high-performance compound for any application.
BY DR. JOEL BELL & WILL TABER
RTP COMPANY
ump manufacturers have a long, successful

history of working with metals and are familiar
with the beneficial properties they deliver in a
variety of pumping applications. Similarly, the
pump industry has been using thermoplastics in pump
designs for several decades because of their low cost, light
weight, superior chemical resistance, manufacturability
and other valuableand profitableadvantages.
While unmodified thermoplastic resins have many
inherent benefits, they also pose many limitations for
pump applications if used in an unmodified form. Chief
among these limitations are strength, impact, wear
resistance and fl ame-retardant properties that can often
fall short of those same properties in metals.
Despite these setbacks, manufacturers have a broad
range of options for enhancing the properties of
unmodified resins. Compounders can add combinations
of reinforcing fibers, fi llers and additives to a carefully
selected base resin to create a high-performance
compound with a host of distinct properties instilled
into a single material. Many manufacturers are
frequently surprised at the diversity of properties
that can be readily built into a compoundincluding
fl ame retardancy, impact resistance, strength, wear
and friction resistance, conductivity, temperature
resistance, chemical resistance, corrosion resistance and
colorabilityto deliver the exact performance criteria
that they have specified.
Developing the Right Formulation

The job of the compounder is to first understand the
pump application and its challenges and then consider
the wide variety of base resins, reinforcing fibers, fi llers
and additives in its portfolio to develop the optimum
formulation. Experienced compounders can begin with
lower cost base resins such as polypropylene for less
demanding applications, higher-temperature resins such
as polyphenylene sulfide (PPS) and polyetheretherketone
(PEEK) for more demanding thermal and wear
requirements, or fluoropolymers such as polyvinylidene
fluoride (PVDF) and ethylene tetrafluoroethylene (ETFE)
for extreme chemical resistance.
From this base resin, the compounder works to
create the composite using a combination of reinforcing
fibers, fi llers and additives such as long glass fiber to
increase mechanical properties or the internal lubricant
polytetrafluoroethylene (PTFE) for reduced wear and
friction. Other options include aramid fibers, graphite
or ceramic powders for improved wear resistance,
halogenated or non-halogenated fl ame-retardant
additives, conductive carbon fiber, and pigments and
dyes for custom color options.
Depending on the challenges presented by the
application, some of these formulations may be created
from scratch with no base resin in mind, while others
may begin with previously developed resin/additive
combinations.
59
During the development stage, manufacturers often

continually request additional properties. For example,
they may begin by requesting that strength be added to
the compound. Later, they may ask for a flame retardant
and finish off by requesting that the compound be
made the companys corporate color. An experienced
compounder is often able to accommodate these
requests, but compounding technology
requires balance and compromise of
ingredients and properties. Sometimes,
when one performance criteria is
added, issues may arise with others.
For example, imparting conductive
properties may result in reduction of
overall strength or impact resistance for
which the formulation must compensate.
A skilled compounder understands how
different constituents of the formulation
interact, as well as their advantages and
limitations.
izod impact strength that met all structural and impact

requirements of the application. The long glass fiber
reinforcement, with its unique balance of strength and
impact properties, allowed the manufacturer to benefit
from the use of a thermoplastic compound, a scenario
that otherwise would have been impossible because of
the inherent strength deficit of the polypropylene alone.
Maximizing Compound Strength

Compounders use a variety of reinforcing
fibers, including short glass fiber, carbon
fiber and very long glass fiber, to achieve
maximum strength and other specific
properties. The manner in which these
fibers are introduced into the melt
stream and the sizing chemistry used
on the fiber are key considerations when
striving to maximize material strength.
As an example, a manufacturer was
looking to convert components of a
fluid-handling pump that moves waste
products at up to 155 gallons per minute
(gpm) from metal to a thermoplastic.
Polypropylene was considered because
its weight savings were projected at 20
to 50 percent and the manufacturing
process was relatively quick and easy.
Because of the inherent properties
of polypropylene, the manufacturer
achieved excellent chemical resistance
but was unable to obtain the required
level of tensile strength.
After carefully analyzing the
application, the compounder selected
a 40 percent long glass fiber reinforced
polypropylene, with a 17,500 pounds
per square inch (121 megapascal)
tensile strength and 5.0 foot-pounds
per inch (267 joule/meter) notched
60
SPECIAL SECTION
HARSH CONDITIONS
Incorporating Superior Wear Resistance

Another property of enormous consequence to pump
manufacturers is wear and abrasion resistance. Despite
the large number of moving parts, pumps must provide
a long useful life with minimal downtime while
maintaining effective operation in corrosive, hightemperature and other inhospitable environments.
To incorporate wear resistance, the compounder
can select an additive technology, such as PTFE,
perfluoropolyether (PFPE), silicone, carbon and
aramid fibers, graphite and molybdenum disulfide. As
illustrated in Figure 1, wear resistance (per American
Society for Testing and Materials D3702) can be
improved in inherently wear-resistant materials such as
nylon 6/6 and acetal (POM) by incorporating PTFE alone
or in combination with PFPE.
Another common scenario for pumps used in corrosive
environments is selecting PPSa highly chemically
resistant thermoplastic with excellent thermal
stabilityand building in required wear resistance with
the addition of carbon fibers used in conjunction with
PTFE. Th is particular type of compound has been highly
successful in pump vane applications.
All fiber reinforcement, fi llers and additives have some
considerations, and the compounder must understand
them. For example, mating surfaces, applied loads and
speeds, and operating temperatures influence wear and
friction along with the wear package used.
Compounding: A Key to ATEX Success
ATEX is a legal guideline based on two European
Union directives that describe what equipment and
protective systems are allowed in an environment with
a potentially explosive atmosphere. Derived from the
French title of the 94/9/EC directive Appareils destins
tre utiliss en ATmosphres Explosives, ATEX is a
concern for thousands of manufacturers worldwide.
Often, it is a race to meet stringent conductivity
standards so that products can continue to be used in
mines and other potentially explosive environments.
Ironically, these are many of the same environments
where the light weighting, strength and corrosion
resistance provided by thermoplastic compounds have
become so valuable (see Figure 2).
To maintain the use of thermoplastics in these
applications, manufacturers can work with compounders
to fi nd the appropriate conductive technology from
possibilities such as carbon fibers, carbon nanotubes,
inherently conductive polymers and carbon black. Some
of these impact the strength of thermoplastics, so the
compounder must create the right formula to maintain
all the properties required by the application. The
Figure 1. Wear resistance of unmodified vs. modified materials

(Graphics courtesy of RTP Company).
Figure 2. Centrifugal pump impeller utilizing PPS with carbon

fiber and PTFE for maximum strength and wear resistance
compounder also needs to understand that ATEX

compliance might require a combination of several other
properties, such as fl ame retardancy, impact resistance
and thermal resistancemost of which are well within
reach of compounded thermoplastics.
Dr. Joel Bell is the international technology

manager for RTP Company in Winona,
Minnesota. He holds a Doctor of Philosophy
in materials science engineering from the
University of Minnesota-Twin Cities. He
may be reached at jbell@rtpcompany.com
or 507-454-6900.
Will Taber is industrial market manager for RTP
Company in Winona, Minnesota. He holds a
bachelors in plastics engineering technology
from Pittsburg State University and an
MBA in finance from the University of
Kansas. He may be reached at wtaber@
rtpcompany.com or 507-454-6900.
61
Another Vanton AdVantage
The Vanton Pump Technical Library

If youre pumping corrosives, handling aggressive or ultrapure fluids,
need to eliminate product contamination, or ensure compliance with
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62
AFTERMARKET
New 3-D Casting Methods

Produce Spare Parts Faster
Additive manufacturing also improves geometric tolerances.
BY JESSE STINSON HYDRO PARTS SOLUTIONS
& WERNER BARNARD HYDRO INC.
n increasing number of industrial plants are

reducing the spare parts inventories stored
at their facilities. At the same time, they are
replacing fewer pumps because of capital
constraints and have determined that remanufacturing
existing equipment is the best path forward. Many of
the pumps within these facilities have exceeded 50
years of service. This drives the need for replacement
parts and, in some cases, emergency replacement parts.
Considering the age of these pumps, the replacement
parts from the manufacturer are likely obsolete and may
not be easily available. Further complicating the situation
is the location of manufacture. Many cast parts are
manufactured outside the U.S and have long lead times.
To address these challenges, many companies are
developing technologies to meet the specific and growing
Image 1. New bronze impeller casting (Images

and graphics courtesy of Hydro Inc.)
demands of the industry. Many of these advanced

tools, including coordinate measure machine (CMM)
technology, allow for quicker emergency repairs, faster
deliveries and higher quality pump parts.
Emergency equipment repairs are common throughout
the industry. Having fewer spare parts makes this
classification of repair more challenging. Standard
equipment repairs typically take six to eight weeks, while
emergency repairs must be completed within one day to
three weeks, depending on the severity of the situation.
This type of repair often drives the need for rapidly
supplied cast parts, which traditionally require long lead
times because of the use of wooden tooling to create the
mold to manufacture the casting.
Recent advancements in 3-D technology, known
as additive manufacturing, allow the cast parts
Figure 1. Reverse engineering raw scan data
63
Figure 2. Temperature change during the pouring of casting

Image 2. An engineer verifies casting
geometry to hydraulic design specifications.
manufacturer to meet customer demands by

eliminating the need to create traditional tooling.
While most users are familiar with subtractive
manufacturing (the process of starting with a
piece of metal and removing chips to produce the
desired shape), additive manufacturing starts with a
parametric model and ends with the desired shape.
Many materials are used during this process,
but the most interesting and appropriate for rapid
casting manufacturing is sand. With sand, casting
tooling (molds and cores) can be created virtually
overnight. This allows users to eliminate the delay
involved in making wooden tooling for castings.
Using additive manufacturing, a computercontrolled process, companies can create cast parts
faster and with improved geometric tolerances than
they can with the traditional casting processes.
Once the geometry is defined, performing
material solidification simulation of the casting
is critical. The solidification software is designed
around computational fluid dynamics, which allows
engineers to simulate the velocities and temperature
gradients of the metal throughout the pour cycle.
In the past, performing such analysis on every

cast part was not common. Foundries typically had
several experienced individuals who developed their
casting pouring methods based on past experience.
With advancements in both software and
equipment technology, engineers are now able to
analyze the casting method design in more detail
than ever before. Engineers can consider each
casting with minimal delay in manufacturing.
This is critical for pump parts, because most vane
passage and volute areas have variable section
thicknesses that can result in variable shrinkage.
Variable shrinkage has been a problem in the
foundry industry for many years. Institutes have
developed casting tolerances to manage such
variance. Technology is now allowing the industry to
64
COVER
SERIES
AFTERMARKET
minimize the variance, which helps deliver

castings within the design parameters set by
hydraulic engineers.
When reverse engineering is required, new
CMM technology, coupled with advanced software,
captures geometrical data that allows companies
to provide faster deliveries and high standards
of quality demanded by the market. While CMM
is used to capture the geometrical data to create
the 3-D model, it can also provide continual
improvement with dimensional accuracy. Hydraulic
performance depends on how accurately the vane
passages are produced during casting manufacture.
In a centrifugal pump, the impellers and diff users
are the pump parts that have complex threedimensional vane passages. For manufacturers, the
challenge is to meet the dimensional accuracy. In
doing so, they can ensure the hydraulic performance
required by design engineers.
To meet vane dimensional accuracy, the
challenge is to predict and control shrinkage
inside the mold. During the manufacturing of
a casting, three types of shrinkage can occur:
shrinkage of the liquid, solidification shrinkage
and patternmakers shrinkage. The problem of the
shrinkage of the liquid can be ignored, since liquid
metal is continuously supplied into the mold. The
solidification shrinkage, which occurs because
metals are less dense as a liquid than a solid, can be
addressed with directional solidification design.
Figure 3. Vane hydraulic analysis
3 BENEFITS OF NEW SPARE PARTS

MANUFACTURING PROCESSES
1. New technologies are now available
that can significantly benefit the
procurement process. They can
drastically cut spare parts lead times,
making it possible to return critical
pumps to service more rapidly.
2. Studying how metal solidifies during
the cooling process means that
castings consistently meet the vane
geometry specified by hydraulic
engineers. This, in return, will
save the end user money by
operating the pumps within the
optimum parameters.
3. Scientific developments in additive
manufacturing are allowing foundry
engineers to make significant
process changes in the way tooling is
developed and castings are created.
Since most major pump parts come
from castings, pump users will
continue to see improvements in
critical areas such as price, delivery
and quality of their spare parts.
65
Figure 4. An image
of drag mold with
casting
One pump repair company has been studying

these shrinkage factors to improve the vane
hydraulic accuracy. The companys approach has
been to measure and analyze each casting. The part
dimensions are collected with a CMM, and the results
are then analyzed and compared with a database of
previous measurements. Because the company has
designed and manufactured impellers of many sizes
and material construction, this database is extensive.
The results are then calibrated against the developed
model and the industry standard shrinkages,
taking into consideration material, geometry and
manufacturing methods.
This approach has enabled the company to correct
and predict the effect of variable shrinkage in
impellers while improving hydraulic accuracy of the
impeller and obtaining better-than-standard casting
tolerances on the vane passages. As a bonus to better
hydraulic accuracy, this approach achieves a reduction
in dynamic balancing costs as well as an improvement
in the consistency of pump performance tests.
Jesse Stinson joined Hydros service

network in 2012. He is the vice president
of operations for Hydro Parts Solutions
Inc., a Hydro Inc. company created to
support the pump aftermarket with
high-quality parts. Stinson has spent his
entire career specializing in castings,
specifically for pumps.
Werner Barnard joined Hydros service
network in 2010. With a Bachelor of
Science with honors in metallurgical
engineering, Barnard plays a
major role in supporting Hydros
reverse engineering processes and
pump parts program.
66
COVER
SERIES
AFTERMARKET
New Detection Technology

Reduces Leak Risk
Block and bleed isolation capabilities improve safety and prots.
BY YVETTE SCHMIZ
INTEGRA TECHNOLOGIES
ompanies across the globe encounter

an increasing number of regulatory and
environmental pressures that call for new
and specialized services. Technological
advancements are constantly evolving to meet the high
expectations of the industry and the individuals who
power it. To ensure safety and maintain high levels of
productivity, qualied and sustainable resources are
necessary. Safety is always the primary goal followed
closely by schedule and, of course, cost.
A leak-free start-up promotes a zero-incident work
environment. Planning for zero leaks is a completely
attainable goal that improves safety and reduces cost and
unforeseen downtime. One company oers products that
drastically reduce the risk of leaks and provide immediate
results for critical complications.
New Technology
A specialized method of double block and bleed isolation
allows for welds to be hydrostatically tested rather than
testing an entire line. This procedure reduces time and
costly restraints while increasing accuracy and eciency
in overall asset performance. A modern hydrostatic,
high-pressure system safely and completely isolates the
environment from residual product to provide a setting to
identify leaks and structural aws in eld welds.
This technology and tooling provide the ability
to monitor any backpressure that may have been
accidentally introduced after the line was isolated. Users
can also monitor upstream vapors to ensure the isolation
will not fail and consequently become a potentially
hazardous projectile. Hydrostatic testing services have
been successfully performed up to 2,250 pounds per

square inch (psi) and can accommodate testing slip on,
socket weld and weld neck anges in a full range of sizes
from 0.75 to 30 inches. Using these test plugs reduces test
time and requires less than one gallon of liquid.
In addition to testing, incorporating leak-detection
technology is the most eective method of nding and
controlling joint-connection leaks. One leak detection
product can identify leaks during normal operations,
startups and at low pressure, which makes it ideal for
preventive maintenance procedures. With ultrasonic
technology, early warning signs and defects can be
detected to prevent costly repairs, safety-related injuries
and unscheduled downtime. Operations are always costly
to execute, but expenses increase during prolonged
periods of production suspension.
This quick and accurate method for determining
equipment conditional analysis and leak detection can be
used regardless of the type of gas being processed or lowpressure variables. Leak detection services are eective
in compressed air or gas systems pressurized to less than
6 psi. High sensitivity, selectivity and a high signalto-noise ratio distinguish leaks in even the harshest
environments and enable a leak-detection service to
provide maintenance diagnostics, ensure safety and
protect quality control.
An ultrasonic leak detection service was chosen by
NASA for use on the International Space Station and all
of the space shuttles. The U.S. military also used this
technology for predictive and preventive maintenance
opportunities. This service can detect leaks in a diverse
range of applications including equipment condition
67
monitoring and analysis, non-pressurized vessel integrity

testing, and pressure and vacuum leak detection.
Obstacles such as residual inuences and physical
distance or obstructions that have previously impeded
the quality of alternative detection services have been
overcome in this leak detection service. Media include
compressed air, hydrogen, oxygen, helium, Freon,
ethylene oxide, nitrogen and argon.
Proximity requirements, precision
and armation are all improved
features. This is also an acceptable
method of leading detection during
tightness testing and eliminates the
need for pressure test taping.
Yvette Schmiz is the Gulf Coast sales and marketing

coordinator for INTEGRA Technologies
and can be reached at yschmiz@
integratechnologies.com. She works closely
with the senior engineer of BlackHawk
Engineered Products, a division of INTEGRA
Technologies. Visit integratechnologies.com.
Case Study
Leak detection technology can
be used as a routine maintenance
procedure to check for leaks on
any piping, including pumps. This
process does not involve vibration
or barring tests but rather includes
all the pipelines, pumps, valves,
exchangers and reactors. One user
employed this technology as a
routine maintenance check on 10
heaters with 100 valves per heater.
These valves are made of 1-inch
pipe and operate at 80 psi. The
technology revealed that 35 of the
1,000 valves were leaking nitrogen
on the gas lines feeding into the
heaters. After completing a full walk
and agging the units that were
leaking at 80 psi, the leak detection
service provider compiled and
generated a full report noting each
problem area. These valves were
replaced completely to eliminate
the potential hazard and save
underlying costs.
All of the leak-detection service
providers test tools are nondestructive so they do not damage
the interior walls of the pipes
or pressure vessels. These
technologies are non-invasive and
provide instantaneous results
so end users can access all the
necessary information to maintain
regulatory compliance and up-todate operations.
68
COVER
SERIES
AFTERMARKET
4 Engineering
Strategies That Can
Save Millions
Advanced test analysis tools, remanufacturing
and training help end users solve problems.
BY STEVEN HUNSCHE
SKF USA INC.
nce a machine or system is up and running,

monitoring the assets operation and
performance and deploying proper solutions
when problems develop can pay big dividends.
With the increasingly demanding needs in the marketplace
to more eectively manage and support assets, various
aftermarket tools, technologies and services have emerged
to help operations successfully do the job.
Specialized tools collect data regarding machinery
health and detect system abnormalities. Similarly,
remanufacturing (rather than replacing) components to
full working specications, as well as maintaining spare
parts inventory and management services, can be quick
Portable data collectors enable all tasks needed to perform

on-the-spot analysis of the condition of rotating machinery.
(Images courtesy of SKF USA Inc.)
and cost-eective ways to minimize downtime.

Expert on-site or online training programs are available
to educate and equip sta in the context of best practices.
For example, one North American coal-red plant
wanted to verify if a submerged circulating water pump was
about to fail. An asset reliability company used advanced
analysis tools to test the electric motors on site. The results
lead to a timely x for the pump that saved $3.5 million
in possible downtime and lost production. This was the
case when a shaft unexpectedly broke on a second pump
without warning, requiring ve weeks of repairs and
associated costs.
Strategic and tactical asset management tools and
services, like those that aided the power plant, can
help maintain, monitor, repair and optimize assets
throughout their operating life.
Evaluating Machinery Health

Owning and operating equipment is one of the biggest
costs for a plant. Global competitive pressures have
increased demands to keep operations running better,
longer and more cost-eectively by reducing unscheduled
downtime and increasing uptime for machinery assets.
The maintenance sta carries the responsibility of
achieving optimized asset eciency, but equipment
maintenance is now more complicated. Environmental
and safety laws have grown increasingly strict. Despite
these challenges, machine uptime must be maximized.
These scenarios have prompted sustained interest in
69
A worker files a bearing as part of
a remanufacturing process as an
alternative to bearing replacement.
conditions and detect early stages of component degradation so that remedial

action can be taken to prevent failures and reduce unanticipated downtime.
The following are among the categories of aftermarket tools and
technologies that deliver or analyze performance data on operating
machinery:
proactive maintenance programs to

help achieve equipment reliability
objectives. Among them, condition
monitoring oers a practical
approach by determining the
condition of machinery through
non-invasive methods during
normal operation.
Condition monitoring is a
strategy that measures physical
parameters (such as vibration,
noise, lubrication properties and
temperature) regularly to help
ascertain machinery health. Th is
process allows personnel to detect
machine and component problems
before they result in unexpected
downtime and the high costs
associated with interruptions in
production.
Condition monitoring can serve
as a platform for implementing
a condition-based maintenance
program, through which
maintenance, inspection and
overhaul of plant machinery are
scheduled on the basis of machine
condition instead of the calendar.
The goal is to trend and analyze
data to identify troublesome
Provided to Our Customers For Over 125 Years

Condition Monitoring Systems
Vibration Analysis Equipment
Spin Test Systems
Moment Weighing Scales
High Speed Facilities
Dynamic Balancing Machines
Its a relationship that begins when the negotiations end.
Its balancing equipment that goes beyond specications and
exceeds expectations.
Its a higher level of service that is responsive and maximizes
performance.
Its comprehensive support to guide you through the
challenges, elevate your capabilities and train your experts of
the future.
The Difference is Quality.

The Difference is
1-800-873-2352
www.schenck-usa.com
sales@schenck-usa.com
70
COVER
SERIES
AFTERMARKET
Basic handheld condition monitoring tools place

the benets of condition-based maintenance within
reach for experts and novices alike. Examples include
thermal cameras, vibration measurement tools,
stroboscopes, tachometers, sound pressure
meters, ultrasonic instruments and electrical
discharge detectors.
Portable data collectors and analyzers supported
by enabling software can handle all tasks needed to
perform on-the-spot analysis of rotating machinery.
Online surveillance and protection systems
integrate permanently installed sensors for machine
monitoring to alert plant personnel of deteriorating
machine condition changes. Data are transmitted
to a host computer running applicable software. The
technology is especially suited for unsafe or hard-toreach locations where accessibility is limited.
Electric motor test equipment encompasses a wide
range of product solutions oering capabilities for
static testing and dynamic motor monitoring to help
plants avoid unexpected electric motor failures.
Remanufacturing vs. Replacing

When good components go bad, replacing them can be
expensive, both in terms of cost and delayed availability.
Remanufacturing can be an alternative way to save time
and money without compromising performance
or productivity.
In one case, a 1,000-megawatt coal- red power station
identied six pulverizer roll wheel bearings requiring
overhaul before the pulverizer could return to service.
The stations pulverizer was critical to maintaining peak
power and, in the absence of a backup, the pulverizer
had to be restored to its original specications for the
station to keep running without interruption until
its next scheduled outage. A seven-month lead-time
for new bearings meant that the scheduled timeline
requirements could not be met.
A bearing company completed an inspection and failure
analysis and determined that the bearings, although
damaged, could be restored. The bearing company was
able to remanufacture the bearings in only six weeks. The
plant saved almost $10,000 in new bearing purchases and
avoided ve months of reduced power production that
would have resulted in an estimated $1.2 million in lost
revenue while awaiting new bearing sets.
Before any work begins, remanufacturing experts
should inspect the bearings, ascertain whether
remanufacturing is possible and issue a comprehensive
bearing analysis report. If remanufacture is viable (and
An instructor conducts a course as part of an extensive training program.
larger-size bearings are typically prime candidates),

bearings can be restored or upgraded in a fraction
of the time required for new bearings and often at a
reduced cost. When remanufactured components can
be produced and delivered in a timely manner with
minimal disruption to operations, increased eciency,
uptime and productivity can follow.
Managing Spare Parts Inventory

While reducing the costs of purchasing, supply and
inventory is an integral part of increasing protability,
maintaining the proper spare parts inventory is essential
for optimal production. Managing inventories translates
to balancing supply and demand to achieve minimum
asset ownership and minimum risk, which reduces the
overall cost of inventory. Consultation and structured
programs from inventory control specialists can help
deliver consistent analysis, appropriate inventory levels
and an auditable reference trail.
As examples, a spare parts alignment, rationalization
and optimization program can identify and evaluate
inventory by using a comprehensive assessment. The
optimal level of spare parts can be determined with a
spare parts optimization tool. Spares analysis software
can be applied using a risk-based approach to document
economic justication for stocking levels.
71
IQV"UNWTT[A
These types of initiatives allow
operations to realize reduced inventory
costs and reduce the probability of
running out of stock.
Online & On-Site Training

A growing portfolio of courses from
qualied service providers can equip
upper management, engineering
sta and maintenance personnel
with the knowledge to help eliminate
machinery problems and achieve
maximum reliability and productivity.
Training venues can be located at
plants and regional sites or conducted
at an experts facilities, and course
categories can range from introductory
to advanced levels of training. In
addition, e-learning courses use selflearning modules to enable individual
instruction at an individuals own pace
and timetable.
Aftermarket solutions have
broadened to encompass evolving
issues and concerns, such as energy
consumption and operational
sustainability. Th is type of training
equips sta to make routine
measurements with the objective to
monitor pump energy eciency and
pave the way for improvements.
The success of any initiative for
optimizing operations can make
signicant headway by turning to
an established and experienced
provider of relevant technologies
and services. The resulting working
partnership can open a wider window
into the possibilities for achieving
positive outcomes.
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Steven Hunsche is director of services
for SKF USA Inc. and has been with the
company for four years. He has more
than 30 years of experience assisting
customers with operation and
maintenance of their assets. Contact
him at steven.hunsche@skf.com or
513-702-6871. For more information,
visit skfusa.com.
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COVER
SERIES
AFTERMARKET
Renery Revamps
1947 Vintage Pumps
An Indiana renery used reverse engineering to
solve multiple challenges with one custom pump.
BY BASIL S. ELKURD
BP OIL WHITING REFINERY
renery in Northwest Indiana is home to an

internal power plant, which includes three
high-pressure service water pumps. These
pumps provide cooling water to the bearings
for the forced-draft fans on top of the boiler house. They
also cool two other pieces of equipment throughout the
power plant. The pumps are 1947 vintage Ingersoll-Rand,
3BEV, two-stage horizontally split pumps (see Image 1).
Packing is used for sealing instead of mechanical seals.
In addition, the pumps use greased bearings and are
designed to provide a ow of 500 gallons per minute
(gpm) at 250 feet of total dynamic head (TDH). The
pumps have been reliable with low vibrations. The main
maintenance tasks are monitoring and replacing the
packing and changing the bearings in the eld.
After many years in service, the pumps began to
degrade internally and stopped meeting the designed
service requirements. Considering the critical nature
of these pumps, the power plant unit determined that
returning them to the designed performance levels was
imperative. The units maintenance and engineering team
developed a set of options and scheduled maintenance at
the next available opportunity.
Considering the high cost of repairs (because of the
pumps size) and the fact that the existing pumps had a
cast-iron body, opportunities for upgrades were scarce.
Knowing that the pumps had not been repaired in more
than 20 years, the team anticipated an extensive scope
with signicant costly internal and external weld repair
(see Images 2 and 3). The team had a choice: They
could either spend a signicant amount of money
on repairs to an
obsolete pump or seek
alternatives.
Since this work would
be conducted under the
routine maintenance
budget, the scope had
to be limited. It would not have the resources of a capital
project, restricting what improvements could be made.
Option One
The rst option to consider was the purchase of a new
pump. How much would a new, in-kind pump cost?
The thinking was, if the price of a new pump were
Image 1. The 3BEV, two-stage horizontally split

pumps (Courtesy of BP Whiting Refinery)
73
Image 2 and 3. The pumps had not been repaired in more than 20 years, so the team anticipated an extensive scope with
significant internal and external weld repair. (Courtesy of BP Whiting Refinery)
comparable to the repair, a business argument could be

made for the purchase. Unfortunately, the cost of a new
pump was more than twice the predicted cost of a repair.
Option Two
The second option was to reverse engineer the pump case
at a third-party facility. However, the pump would still
have the obsolete design with packing unless additional
engineering was carried out. The additional engineering
would add cost and lead time. The drawback of this
option was the high cost of reverse engineering and the
need to pull the pump for the duration of the project
(reverse engineering, casting, manufacturing, assembly
and testing). Th is choice was not ideal but seemed more
feasible than the rst option or the repair option.
Option Three
The third option considered was to evaluate several
original equipment manufacturers (OEM) product
lines for a modern design pump that meets the
hydraulic requirements and motor horsepower. Many
were available in dierent designs that met these
requirements and that provided metallurgy and design
upgrades that were in line with the cost of the repair
option. However, this change required foundation and
piping modication which would add to the overall cost.

Th is third option was considered acceptable in spite
of its expanded scope and higher cost because of the
advantages these upgrades provide.
Option Four
While these options were being considered, another
project was in the works at one of the renerys cooling
towers, which became the fourth option for this project.
This option was discovered by chance.
A fellow pump engineer was working with a
company that reverse engineers impellers. For that
specic application the renery needed several
impellers in a short period of time, and all the
traditional avenues (OEM or reverse engineering)
could not meet the deadline. Based on the positive
experience of another engineer dealing with a similar
challenge, he recommended contacting Sims Pump
Company (Sims). This company reverse engineers
impellers like other companies. However, it uses its own
material, which is Simsite. The material is a graphitecombination-ber, continuously interwoven, reinforced
composite with phenolic/epoxy thermoset resin. The
company was able to reverse engineer these impellers
faster than any of the other options. The material oered
74
COVER
SERIES
AFTERMARKET
its own advantages that included

corrosion resistance and
light weight.
During the discussions about
the impellers, the units team
wanted to learn more about the
capabilities of reverse engineering
and manufacturing pump casings
using this material. The sales
person provided the engineering
team with information including
the curve, outline drawing and
Figure 1. The 3-D model of the new pump prior to manufacturing
service conditions for review.
(Courtesy of Sims Pump Company)
During these discussions
The reverse engineers analyzed the current pump
and with full understanding of
design, an axial-split, two-stage, double-suction impeller
this new approach, the unit team had to agree on a list
pump. Knowing that centrifugal impellers with higher
of requirements, goals and potential drawbacks. Based
specic speed will have a higher hydraulic eciency, the
on these discussions, the renerys power plant team
engineering companys team created a suction specic
developed the following list:
speed window to work within.
That was the rst design change implemented, moving
Meet the same hydraulic specications.
from a two-stage, double-suction impeller design (with
Maintain the same motor specications (speed and
a specic speed of 1,680) to a two-stage, single-suction
power) to avoid motor replacement.
impeller (with a specic speed of 2,376) to increase
Maintain the same footprint to avoid foundation work
eciency based on the net positive suction head
and changes.
available. Once the impeller design was nalized, Sims
Maintain the same piping size.
began the next stage of mechanical design and modeling
Maintain the same outline and ange-to-ange
(see Figure 1).
spacing and orientation to avoid piping alterations.
The new pump should include mechanical seals instead
of packing.
Maintain the same coupling location to avoid motor
relocation. This was not a major issue, but the team
preferred this as part of the solution.
The cost of the pump (engineering/manufacturing)
must be comparable to the repair option, which
was the lowest cost option of the other three under
consideration.
Even though the list of requirements could not be
achieved by the previous options without the drawbacks,
the items became a requirement to be able to sell the idea
of an unconventional pump. The reverse engineering
company performed an in-depth analysis of the existing
equipment and a compilation of the list of requirements.
The engineering company responded that it was able to
and would like the opportunity to complete this project
according to the goals.
Upon agreement, the team sent the reverse engineers
the pump curve, the rst- and second-stage impellers
from the warehouse and the information provided earlier.
At the nal stages of the project, the team was able to
send the pump to verify the dimensions.
Image 4. The new high-pressure service water pump

(Courtesy of BP Whiting Refinery)
75
The end result was a new high-pressure service water

pump (see Image 4) that oered:
Near identical hydraulic capabilities

The same motor specications (rpm and speed)
The same footprint with no change in the foundation
or baseplate
The same suction and discharge
piping
The same ange-to-ange spacing
Mechanical seals
No motor relocation requirement
Comparable cost to repair option
In addition to the specied

goals, the pump delivered some
additional advantages because of the
engineering work. These include:
Pump case, impeller and bushings

made from a material that does
not corrode
A bearing housing made of 304
stainless steel, which protects
from corrosion if the seal leaks
A 360 degree bearing housing
designed for additional stability
and ease of maintenance. The back
covers can be removed to remove
the bearings and the seals without
pulling the bearing bracket.
410 stainless steel shaft for
corrosion resistance
More eciency because of its
single suction design
During the pumps installation, as

with every scope, additions required
further attention that would have
been required regardless of the pump
options considered. Because of the
water damage from the leaking
packing, the baseplate and pump
foot pads were badly corroded and
required repair and eld machining.
The motor foot pedestals were not
level and also required repair. After
these improvements, the pump was
commissioned successfully with low
vibration and bearing temperature.
It delivered the performance that the
renerys power plant unit needed.
Basil Elkurd is a rotating equipment pump engineer for BP Oil

Whiting Refinery. Elkurd has been at BP for 12 years. He has
bachelors and masters degrees in mechanical engineering
and is responsible for rotating equipment reliability in the
Hydroprocessing & Utilities sections of the refinery. He may be
reached at 219-398-1823 or basil.elkurd@bp.com.
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76
TRADE SHOW PREVIEW
WQA Aquatech USA

April 21 24, 2015
Exhibition Hours

Las Vegas, Nev.
Wednesday, April 22
Thursday, April 23
quatech USA, the Water Quality Associations annual

convention and exposition, is an event for water
professionals from a variety of industries, including the
process and drinking water markets. Attendees beneit from a
broad range of education, training, networking and business
opportunities. he New Product Showcase provides attendees
with the opportunity to see products and services that have
11:30 a.m. 5 p.m.

10 a.m. 5 p.m.
been released within the past year. his years exhibitors feature
water quality testing, iltration and water softener products.
Participants will be able to network with other industry
professionals and hear from water industry experts. Topics
covered during the event include commercial applications, water
treatment basics and business management.
For more information or to register, visit wqa.org.
INTERPHEX
March 21 23, 2015
Javits Center
New York, N.Y.
he International Pharmaceutical
Expo (INTERPHEX) is an event
for professionals from the
pharmaceutical and biopharmaceutical
manufacturing industries. Attendees
will have the opportunity to learn about
manufacturing solutions for processing
all dosage forms of life-enhancing drugs
through educational sessions, workshops,
exhibitions and networking. More than
12,000 industry professionals are expected
to attend.
INTERPHEX 2015 will be 30 percent
larger than last years event to accommodate
more technology, products and value-added
services. On the exhibition loor, more
than 600 vendors will feature the latest
pharmaceutical and biopharmaceutical
manufacturing technologies. New to the
2015 show, the PDA Learning Center will
feature industry experts providing technical
education focused on manufacturing for
aging facilities.
For more information or to register,
visit interphex.com.
Exhibition Hours
Tuesday, April 21
Wednesday, April 22
Thursday, April 23
9 a.m. 5 p.m.
9 a.m. 5 p.m.
9 a.m. 2 p.m.
77
Circle 111 on card or visit psfreeinfo.com.p u mpsa ndsyst ems.c om | Ma rc h 2015
78
EFFICIENCY MATTERS
5 Maintenance Factors that Help

Achieve Optimum Efficiency
Correct equipment selection and application
saved an aluminum producer $36,000.
By Mike Winkler
Motion Industries
he major focus of any

industrial distributor
should be maintenance. The
distributors personnel work daily
with maintenance mechanics,
plant engineers, maintenance
managers and all those working
to keep plants running. The work
of these key people aects the
overall eciency, reliability and
longevity of their liquid transfer
process equipment and systems.
These employees have often
inherited the equipment, and their
responsibility is to keep it working
day in and day out. While this may
seem simple, maintenance must be
approached from the perspective
of the plant oornot just from
the chair of the design engineer.
The best designs are a combination
of thoughts from the technician to
the senior engineer.
The equipment must

be correct for the
application. In the middle of
the night during the stress of a
breakdown, the maintenance
employee will do what he must to
get the equipment operational
including using something other
than the original part. Changes
of this nature are surprisingly
common. Even though changes are
made daily, they are not always
recorded, and best paperwork
practices are not always followed.
Distributors must rely on a users
information to supply the correct
product. If accurate records are not
kept, the possibility of receiving
the wrong product increases. For
these reasons, keeping accurate
records is critical.
Many pumps are on their
second or third application. They
may be from a closed plant or a
discontinued process, and they
Getting Started
The rst step to achieving optimum nd their way to the boneyard to
eciency is to dene it. Is it simply be used at a later time for another
application. Repurposed pumps
energy savings? Or is it reliability,
uptime, product longevity, reduced are used primarily because of their
convenience; they are paid for and
maintenance time and costs, and
product standardization? Eciency readily available. Before reusing
a pump in this manner, however,
consists of all of these elements
users should question if it is, in
and more.
fact, the correct product for that
To realize optimal performance
specic application. Misapplied
from the plant oor, all personnel
pumps typically require a
must understand ve key factors
signicant amount of replacement
aecting eciency.
parts and related labor, time and

costs and may result in downtime.
To avoid this pitfall, users
should nd out if the requirements
have changed since the initial
installation. They can check
items such as viscosity, pH
factor, temperature, product
being conveyed, available net
positive suction head (NPSH),
type of supply, discharge pressure
requirements and piping changes.
The efficiency of the

pumping system is
impacted by the piping design
layout. Answers to the following
questions and subsequent
corrective action will help ensure
maximum eciency from the unit.
Does the piping schematic allow

for the best eciency?
Are the velocities within the
recommended standards?
Has the number of Ls (elbows),
Ts, Ys and miscellaneous
ttings been minimized?
79
Image 1. An example of an inlet eccentric reducer with

the taper to the bottom and a discharge concentric
reducer (Images courtesy of Motion Industries)

80
EFFICIENCY MATTERS
Are the valves correctly applied

and kept to a minimum?
Are the correct ttings being
used (e.g., eccentric versus
concentric reducers)?
Is the piping in good condition?
Buildup of corrosion and wear can
result in higher resistance to ow.
Are the ttings, valves, etc.,

mounted no closer than the
minimum distance from the
pump as required?
Is the pump located in the best
location to minimize the runs
and all twists and turns?
Are valves being used to control
ow instead of sizing the pump

for the duty points?
For example, for the last
question, machining the diameter
of the impeller or controlling the
motor speed is the best solution in
most cases.
HOW ONE PLANT SAVED THOUSANDS IN REPAIRS & REPLACEMENT
Correct equipment selection and application can provide an efficient and reliable pump and
system. In the following case, a distributors pump specialist assisted a user, a major producer of
extruded aluminum, with a solution that led to $36,000 in savings.
The Root of the Problem

The aluminum producer needed to solve the problem of shortened life of their 6x6 vertical pumps.
The pumps, used for an acid wash on their paint line, were lasting only six to eight months.
After that, volute and impeller failure would occur. A quick observation showed the problem. The
pump was not mounted deep enough in the tank to keep the liquid from vortexing and causing
cavitation to the pump.
Because of this, the 1 percent sulfuric acid the user was pumping was at a velocity far too high
for the depth of the bell housing of the pump. The fluid should have been moving at about 3.25
feet per second but was moving more than four times as fast at 14.76 feet per second. The lower
velocity would prevent the pump from vortexing at the pumps immersion depth. Immersing the
pump lower would have stopped the vortex and prevented inevitable failure immediately.
Lowering the pump, however, posed a problem. At the current velocity, the pump would need to be
immersed to 13.5 feet. The tank was only 44 inches deep.
Luckily, immersion depth was not the only way to correct the problem and prevent constant
maintenance issues. The pump was also incorrectly mounted, which was quickly corrected.
The distributors pump specialist determined a simple fix by placing a stainless steel plate
above the bell housing of the pump to act as a vortex breaker. This plate would correct both the
vortexing and the entire system. The specialist calculated the required size of the plate, the user
made it to his specifications, and the plate was immediately attached.
A Long-Lasting Solution
At one time, this plants $10,000 pumps needed repairs costing at least $2,000 every 30 to 45
days, with a complete replacement of the pump every six to eight months costing $10,000 to
$12,000. Since the problem was corrected with the distributors help, the pump has operated for
two years without further maintenance or repairsresulting in approximately $36,000 in savings
since implementation.
81
The pump must be in top

condition for maximum
efficiency. Many factors aect
the eciency of the pump, such
as imbalance of the impeller,
incorrect size of impeller, coupling
misalignment, incorrect parts or
lubrication, and worn parts, which
could include bearings, casings,
wear rings, impellers and rotors.
One of the best ways to avoid
problems is to catch them early with
scheduled, preventive maintenance.
Mike Winkler is the director of Mi Process Pumps for Motion Industries. His extensive
experience includes 20 years with Motion Industries and more than 30
years in industrial distribution, which included many years promoting
liquid transfer products and troubleshooting applications. Motion
Industries is a wholly owned subsidiary of Genuine Parts Company.
For more information, visit motionindustries.com.
A properly sized motor in

new condition is essential.
Could the motor have been replaced
with a dierent one during a
breakdown? Has the motor lost
eciency? This is another example
of the importance of using the
correct equipment. Too much
horsepower or too little horsepower
will result in ineciency.
Monitoring the pump and

system is vital for longterm success. Inlet and discharge
pressure gauges are inexpensive and
can give a good indication of how
the system is performing. Users
should set the pointer on the inlet
gauge for the required NPSH and
on the outlet gauge for required
discharge pressure. Vibration
analysis is another great tool to
track pump operation and eciency.
A good distributors specialist
looks beyond the symptom to dene
the problems root cause instead of
oering a quick x. When looking
out for the users welfare, the
specialists focus should not be on
selling but on troubleshooting and
providing corrective measures. This
approach will bring value to the
plant oor by reducing their overall
cost of ownership, suggesting
methods or designs to improve
eciency and helping to ensure
productivity.
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82
MAINTENANCE MINDERS
Turbine Error Identification Prevents Costly

Outages for Power Plants
An advanced software solution saved one user $350,000 in lost power production revenue.
By Brandon Perkins
urbine failure can result

in unwanted downtime
and costly repairs. Early
detection is key to keeping
the plant running at optimum
eciency. Software monitoring
solutions provide the opportunity
to schedule repairs during
planned plant outages. This type
of technology allows end users
to monitor turbine and overall
plant performance and proactively
handle required maintenance.
Combustion Problem Solved at

a Combined Cycle Power Plant
On March 6, a software monitoring
solution detected an issue
with three combustion turbine
exhaust thermocouples during
a steady state run that was the
turbines rst run after a hot
gas path inspection. As this
combustion turbine varied load
between 100 and 155 megawatts,
intermittent deviations appeared
in thermocouples 3, 4 and 6.
The exhaust thermocouples
were expected to have values
between 1,100 and 1,200 F. Actual
temperature measurements varied
as much as 100 degrees below
expected values.
Since this hardware was
recently replaced, the end user was
interested in further evaluating
this combustion issue with the
original equipment manufacturer
(OEM). The OEM investigated
and eventually replaced
combustion nozzles 12 and 13
during a subsequent planned
maintenance outage.
Finding this issue early helped
to ensure the end user did not
take a forced outage during its
summer run season. Th is end
user is under a long-term service
agreement so it was not liable
for the replacement costs of the
combustion nozzles. The end
user estimated that, by detecting
Figure 1. Increases in actual (blue) versus expected (green)

power for combustion turbine power (top), actual exhaust
temperatures (second from top) and actual (blue) and
expected (green) values for exhaust temperatures (bottom
three) (Graphics courtesy of GE Intelligent Platforms)
83
The notification of this issue from the provider allowed the site to
take preventive action to clean the system before further increases
in the backpressure of the condenser occurred.
this issue early and preventing

a problem in the summer peak
season, it was able to avoid more
than $350,000 in lost power
production revenue.
Sediment Identified on a
Steam Turbine Condenser
In the end of December, a software
detected an increase in steam
turbine condenser backpressure,
from a normal operational pressure
of approximately 3 inches
of mercury (inHg) (or 10.1
kilopascals (kPa)) to values
as high as 6 inHg (or 20.3
kPa). The software provider
notied the end user and
began tracking the issue on
regularly scheduled calls.
The plant discovered
that the cooling tower had
a chemistry upset. The
upset deposited a light
lm of sediment on the
condenser tubes. After
a cleaning solution was
introduced into the cooling
system in mid-January, the
condenser back pressure
returned to normal.
Figure 2. These charts include the condenser vacuum measurements,
Increases in the
which changed from about 22.7 inHg (or 76.9 kPa) to as low as
condenser backpressure
about 6 inHg (or 66.8 kPa). The bottom chart shows the condenser
backpressure averages. Unusual readings started in late December and reduced eciency in
returned to normal after cleaning in January.
the condenser, leading
to a loss in revenue. The
notication of this issue from the

provider allowed the site to take
preventive action to clean the
system before further increases in
the backpressure of the condenser
occurred. The backpressure
returned to model predictions
after maintenance was performed.
If this preventive measure had
not been taken, backpressure
could have continued to increase,
resulting in a need to shut down
the unit. Th is could cause a loss
of production and increased
maintenance costs.
Brandon Perkins is the product
marketing manager for Industrial
Data Intelligence at GE Intelligent
Platforms. He believes that data
is the fuel of the 21st century and
that the Industrial Internet will
transform industries and economies
by improving productivity,
environmental
stewardship and
worker safety around
the globe. He may be
reached at
brandon.perkins@ge.com.
124
on card
or visit
pCircle
u mpsa
ndsyst
ems.c
om psfreeinfo.com.
| Ma rc h 2015
84
MOTORS & DRIVES
Prepare for the New DOE Electric Motor Efficiency Rule

The Integral Horsepower Motor Rule will take effect June 1, 2016.
By John Malinowski
Baldor Electric Company
he U.S. Department of
Energy (DOE) is empowered
by congress to review
eciency regulations for covered
products every ve years. Electric
motor manufacturers are currently
operating under the Energy
Independence and Security Act
of 2007, which went into eect
in December 2010. Around this
time, the DOE started to review
the regulation to see if raising the
levels above premium eciency
was warranted.
Motor manufacturers that are
members of the National Electrical
Manufacturers Association
(NEMA) discussed the potential
rulemaking and decided to
collaborate with energy eciency
advocacy groups and form a
coalition to make a proposal to
the DOE that might be easily
adopted as a direct and nal rule.

The Motor Coalition proposed at
the rst DOE meeting that the
eciency levels be maintained at
premium eciency level (NEMA
Standard MG 1-2011, Table
12-12, 20A and 20B) for 1- to
500-horsepower (HP) motors
rather than raising the level
above premium eciency. Th is
12-12 level is equivalent to IE3
(premium eciency) as de ned
in International Electrotechnical
Commission (IEC) Standard
60034-30. Furthermore, the
proposal recommended that
most de nite-purpose and
special-purpose motors would be
included along with options that
previously exempted motors from
coverage. During this process,
some loopholes from the previous
Energy Policy Act of 2005 and
Extended Industry Standard

Architecture (EISA) rules were
also closed.
To accept the expanded scope,
the DOE was required to issue a
nal rule on how all these motor
congurations could be tested.
Th is rule was released in late
2013. The nal rule for integral
HP motors was published in the
Federal Register on May 29, 2014,
and will take eect June 1, 2016.
Rule Comparison
The voltage range now includes all
three-phase, 60-hertz (Hz) designs,
600 volts and less. Additionally,
motors with special shafts and
mountings along with 56-frame
enclosed motors will now be covered
at premium eciency levels. Partial
motors built without a drive endplate
are also covered. Both NEMA and
Table 1. Differences between EISA and the new Integral Horsepower Motor Rule (Courtesy of the author)
Motor Type
EISA
Integral Horsepower Motor Rule
1 to 200 HP Subtype I
Premium Efficient
NEMA MG 1, Table 12-12
Premium Efficient
1 to 200 HP Subtype II
Energy Efficient
Premium Efficient
201 to 500 HP
Energy Efficient
Premium Efficient
NEMA MG 1, Table 12-12,
20-A & 20-B
56-Frame Enclosed
Exempt
Premium Efficient
Custom Configurations
Exempt
Premium Efficient
1 to 200 HP Fire Pump Motors
Energy Efficient
Energy Efficient
85
IEC motor designs are included, as are motors mounted

to equipment imported to the U.S. for use here.
For the pump industry, close-coupled pump
motors are categorized in the 1 to 200 HP Subpart
II category. In the new rule, they change from an
energy ecient level (NEMA MG 1-2011, Table
12-11) to premium eciency (Table 12-12). Hollowshaft pump motors and medium- and high-thrust
vertical pump motors are now included at the
premium eciency level as well.
More ecient premium motors use additional
active material (copper and electrical steel) and
higher grade electrical steel. These materials may
mean a price increase over energy-ecient motors.
Table 1 shows the dierences between the EISA
and the new Integral Horsepower Motor Rule.
Motor Specifications
The DOE dened a motor covered under the new rule
by nine attributes:
Is a single speed motor
Is rated for continuous duty (MG 1) operation or

for duty-type S1 (IEC)
Contains a squirrel-cage (MG 1) or cage (IEC) rotor
Operates on polyphase alternating current (AC)
60-Hz sinusoidal line power
Has two-, four-, six- or eight-pole conguration
Is rated 600 volts or less
Has a three- or four-digit NEMA frame size (or
IEC metric equivalent), including those designs
between two consecutive NEMA frame sizes (or
IEC metric equivalent) or an enclosed 56 NEMA
frame size (or IEC metric equivalent)
Has no more than 500 HP but greater than or
equal to 1 HP (or kilowatt equivalent)
Meets all the performance requirements of a
NEMA design A, B or C electric motor or an IEC
design N or H electric motor
With the new Integral Horsepower Rule, many motor

congurations were upgraded to premium eciency.
These include:
86
MOTORS & DRIVES
NEMA Design A motors from 201 to 500 HP

Electric motors with moisture-resistant windings,
sealed or encapsulated windings
Partial electric motors
Totally-enclosed non-ventilated (TENV) electric
motors
Immersible electric motors
Integral or non-integral brake electric
U-frame motors
Design C motors
IEC 100 frame, NEMA 66 frame
Electric motors with non-standard endplates or
anges
Electric motors with non-standard base or
mounting feet
Footless motors (C-face or D-ange less base)
Electric motors with special shafts
Close-coupled pump motors
56J Jet pump motors (enclosed)
Vertical, hollow-shaft electric motors
Vertical, medium- and high-thrust, solid-shaft
electric motors
Electric motors with sleeve bearings
Electric motors with thrust bearings
Pre-NEMA frame motors
Arbor saw motors
Even with these added motor congurations, many

motors are not covered under this rule. Some that
include only general purpose NEMA frames 42, 48
and 56 with open drip-proof (ODP) enclosures are
covered by the 2010 Small Motor Rule. Single-phase
capacitor-start/induction-run and capacitor-start/

capacitor-run along with three-phase induction
motors are included at specic DOE average eciency
levels. However, the following congurations are not
included:
Single-phase ODP motors (may be covered by Small
Motor Rule)
Single-phase enclosed motors
Direct current motors
Two digit frames (42 48) (may be covered by
Small Motor Rule)
56 frame ODP (may be covered by Small Motor
Rule)
Multi-speed motors
Medium voltage motors
Totally enclosed, air over or open air-over motors
Submersible motors
Water-cooled motors
Intermittent duty motors (S2-S8)
Stator-rotor sets
Design-D motors
Motors designed for inverter power (MG 1, Part
31) with no line start
Synchronous AC motors
Permanent-magnet rotor AC motors
Servo motors
These DOE integral HP motor regulations apply to
motors manufactured for use in the U.S. Motors built
before June 1, 2016, may still be used. No restrictions
were set limiting the repair or rewind of older motors
below these eciency levels.
SMALL MOTOR RULE EFFECTIVE MARCH 2015

In 2010, the U.S. DOE published a final rule covering small electric motors. By definition,
these are motors in the - to 3-HP range in NEMA frames 42, 48 and 56. Single-phase capacitor-start/induction-run and capacitor-start/capacitor-run designs and three-phase AC induction motors are covered, but only in ODP enclosures. Only general purpose designs are covered.
Equivalent frame IEC motors are also included, but ODP IEC motor designs in these sizes are not
commonly available.
For the pump industry, this means only ODP base-mounted motors, with and without C-face or
flange or footless C-face or flange motors, are covered. Motors designed for specific applications
as defined in NEMA MG 1, Part 18 covering definite-purpose and special-purpose motors are not
covered by the rule. This means 56J style pump motors are exempt.
Efficiencies are defined by the DOE as average efficiency, not the usual NEMA nominal levels.
The rule mandates that motor manufacturers may not produce non-compliant motors after March
9, 2015. This also applies to motors installed on equipment being imported to the U.S.
87
OEMs 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. Note that 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.
References
1. 10 CFR Part 431 Energy Conservation Program: Energy
Conservation Standards for Commercial and Industrial Electric
Motors; Final Rule, Federal Register, Vol. 79, No. 103, Thursday,
May 29, 2014
2. NEMA Standards Publication MG1-2014, Motors and
Generators, National Electrical Manufacturers Association, 1300
N 17th Street, Suite
For more information on motor
1752, Roslyn, VA,
and pump efficiency, visit
December 2014
pumpsandsystems.com
John Malinowski is the senior manager of industry affairs at Baldor Electric Company, a member of the ABB Group, in
Fort Smith, Arkansas. He is past chairman of NEMA 1MG Motor & Generator Section and familiar with collaborating with
CEMEP and ABB IEC colleagues on global motor standards. Malinowski is a senior member of the Institute of Electrical
and Electronics Engineers (IEEE) and a member at large on the IEEE Industry Application Society Executive Board.
He serves on the IEEE Pulp & Paper Industry Committee and is active with IEEE Petroleum and Chemical Industry
Committee having recently rotated out of the chair of the Chemical Subcommittee. He has served on several IEEE
standards working groups, including several revisions of IEEE 841 and IEEE 303. He also served on the
American Petroleum Institute (API) 541 and API 547 working groups. Malinowski has published several
IEEE papers on efficiency standards, motor and drive efficiency, maintenance, and other applications. He
acts as company advocate with government agencies, professional associations and industry standards
committees. He also serves as a member of the Pumps & Systems Editorial Advisory Board.
Malinowski may be reached at john.malinowski@baldor.abb.com.
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88
SEALING SENSE
Updates to Industry Standards Offer New

Options for Fugitive Emissions Testing
End users should be aware of the latest standards revisions to employ the most up-to-date
valve sealing practices.
By Philip Mahoney
FSA member
tandards groups in the

U.S. and abroad have been
actively advocating for
compression packing used in valve
stem sealing. Some of the more
relevant provisions and changes
are outlined in this article.
The working group (WG 10)
for International Organization
for Standardizations (ISO)
ISO/TC 153/SC 1, which covers
industrial valvesincluding
design, materials, manufacturing,
testing and inspectionhas been
working on the second edition of
ISO 15848-1 (Industrial valves
Measurement, test and qualification
procedures for fugitive emissions
Part 1: Classification system and
qualification procedures for type

testing of valves). The second edition
has reportedly been approved and
is expected to be released in the
rst quarter of 2015.
Industrial Valve Standard

The standard has undergone
notable changes and updates,
including:
The ushing method has been

removed from the standard and
replaced with two new methods
for use with helium test gas.
Accumulation (based
on EN13185) is a bagging
method with two specic
times at which measurements
Image 1. Helium mass spectrometer

(Images and graphics courtesy of FSA)
are taken, and the bag has a

dened/conrmed volume.
The suck-through method
essentially bags the valve with
a vent of a prescribed length
to allow outside air into the
bag to prevent collapse. Flow
rates of the probe are known,
and the external air helium
levels can be determined prior
to the test.
Units for leakage rates at the
packing dened in Table 1 of
the standard have been revised
to include a mass ow or
volumetric ow per millimeter
of stem diameter, making it
more convenient to match the
typical units displayed by the
helium mass spectrometers
used for this test.
Class AH (A for the highest
sealing level and H for helium
testing gas) leakage has
been revised to be 1 x 10 -5
rather than 1 x 10 -6 (using
the informational rate of
milligrams per second per
meter of stem perimeter). At
least one test laboratory has
indicated that the 1 x 10 -6
leakage class has never been
achieved with compression
packing in rising stem valves,
though some could meet the
new revised Class A criteria.
Class AH is typically achieved
with bellows seals or equivalent
89
Figure 1. API 622 Emission capturing set-up
stem packing sealing systems

for quarter-turn valves.
Methane is now included as
a test gas, and the leakage
limits are specied in parts per
million (ppm): Class AM 50
ppm, Class BM 100 ppm and
Class CM 500 ppm (A, B and C
are for the sealing level, and M
is for methane test gas).
It was clearly noted that no
correlation exists between
ppm/methane leakage classes
and mass leak rates of helium
leakage classes. For this
reason, a packing meeting
class BH is not necessarily the
same as a packing meeting
class BM. The requestor
species using this test
method prior to the test.
In the on-o valve test, the
CO1 cycles have been reduced
from 500 stem cycles and three
thermal cycles to 205 stem
cycles and two thermal cycles.
The two new methods give test

facilities and end users other
options to better suit their needs.
These methods also may be easier
to set up and run with dierent
valve types. With the addition of
methane and sning detection
methods, some end users will
likely consider the ISO standard
as an acceptable test method per
the Environmental Protection
Agencys denition of good
engineering practice for fugitive
emissions testing of valves. This is
particularly the case with control
valves for which there is no current
American Petroleum Institute
(API) test method.
API 622
API 622, Type Testing Of Process
Valve Packing For Fugitive Emissions,
Second Edition, expires in October
2016, but the working group has
convened to get a head start on this
revision. First, the addition of a
test xture for inch cross section
packing to simulate packing sizes
typical for forged valves is under
review. The current edition of the
standard denes a test xture for
inch packing, which is typical
of cast valves. This change would
ensure that functionality of the
packing being tested extends to
multiple valve and packing sizes.
Also, the corrosion test portion of
the standard is being reviewed for
potential changes that would make
the test xture less complicated
and reduce the cycle time.
Currently, the test can take six to
eight weeks.
API 641
API 641, Type Testing of Quarterturn Valves for Fugitive Emissions,
is a new standard currently in
development. This standard
will dene a valve type test
similar to API 624, Type Testing
of Rising Stem Valves Equipped
with Graphite Packing for Fugitive
Emissions, First Edition. The 641
Updates to Other Standards
standard will likely include both
In the U.S., API standards
polytetrauoroethylene and
committees are actively working on graphite-based packing materials.
standards (new or existing) related Exact details of the test conditions
to fugitive emissions in valves.
are still being developed.
API RP-621
API RP-621- Reconditioning of
Metallic Gate, Globe and Check
Valves, Third Edition, is actively
being revised. This standard
denes guidelines for the
reconditioning of valve types that
are being serviced for continued
use in an end users facility. The
new revision will have a complete
addendum that denes the
requirements for low emissions
service, noting that valves in these
services are more dicult to seal
and, therefore, have more stringent
requirements than those for other
services (i.e. steam).
In addition to these updates, API
589 Fire Test for Evaluation of Valve
Stem Packing, Second Edition was
last updated on July 1, 1998. The
standard is no longer active in API,
so no active committee regularly
reviews it. Though the standard can
still be found for sale online, it is
considered withdrawn.
Next Month: What are the
important considerations relating
to installation tolerances when
using rubber expansion joints?
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 suggestions and questions to
sealingsensequestions@fluidsealing.com.
90
HI PUMP FAQS
Recommendations for Rotary Pumps,

Diaphragm Pumps and VFDs
By Hydraulic Institute
Can rotary type pumps

be used to pump slurries?
If so, should users be
aware of any special
precautions?
Rotary pumps may be used
to transfer slurries when the
application dictates. Hard-particle
slurries can cause abrasive wear
to eciency-critical components
in rotary pumps, which reduces
volumetric and mechanical
eciency. Users must carefully
select and apply rotary-type pumps
in slurry service.
The concentration of solids
usually has the greatest eect on
uid characteristics of the mixture.
A uid containing only a trace to
3 percent by weight of ne sand
content in crude oil, for example,
would not be considered a slurry. A
range of 5 to 15 percent by weight
slurry of paper stock, however, goes
through three stages of uidity or
shear characteristics, while high
concentrations of ner solids can
change watery carrier liquid to
viscouseven thixotropicuid.
The size and shape of the solids
in a slurry normally determine
whether a particular rotary pump
conguration and/or cavity, or
chamber size, can be used for
the slurry in question. Typically,
the cavity must be greater than
particle size.
In some pumps, the rotor
conguration will accept larger
particles as long as the size,
distribution and shape are
controlled. The size must be related

to porting, rotor cavity size,
conguration and interaction, and
operating clearance.
The hardness of solids greatly
inuences the wear rate of the
rotary pump because of close
relative motion of surfaces at the
rotor tip or ank. The range of
hardness is from soft solids, such
as polymer chains of lubricating
quality, to brous products that
are usually soft but may carry
hard particles, to very hard,
irregular particles such as sand and
carbon. Carbon is primarily soft,
but the aggregate carries lumps
with hardness approaching that
of silicon carbide. A qualitative
scale listing the hardness of
several materials is often useful

to compare solids and select pump
materials (see Figure 3.3.16.1.4).
Critical factors governing a
system handling a watery slurry,
in which the solids have a much
higher specic gravity than the
carrier liquid, are the settling
rate and characteristics. The
settling rate measures how quickly
solids will fall out of suspension in
a slurry.
Coarse solids with high settling
rates that are carried in a rotary
pump require precautions
to prevent bridging, draining
and squeeze-out.
Because speed directly aects
product shear and the relative
velocity of solids to the housing
Figure 3.3.16.1.4. Materials hardness (Courtesy of Hydraulic Institute)
91
delayed check valve seating and

reverse liquid ow.
End users should carefully
determine the nature of the liquid
being pumped. Non-Newtonian
or shear-sensitive liquids may
have pumping characteristics
unrelated to those of Newtonian
liquids with similar quiescent
viscosity. Apparent viscosity
for an application using a nonNewtonian liquid can be adjusted
based on ow rate conditions for
the application by consulting the
material manufacturers shear rate
versus shear stress diagram for the
specic material.
For more information on airoperated pumps, see the Hydraulic
Institute Standard ANSI/HI
10.1-10.5 Air-Operated Pumps
for Nomenclature, Definitions,
Application and Operation.
the torque decreases with the

square of the speed, and the power
decreases by the cube of the speed.
When selecting a VFD for a
rotodynamic pump application,
many manufacturers recommend
a variable torque or standardduty-rated VFD. This labeling
is commonly referenced for the
overload capacity of the drive. As
always, discuss the application,
installation and its nuances with
the drive representative, as the
How is the performance of
installation or application may
air-operated diaphragm
require a drive outside the
pumps affected by the
typical one utilized in variable
viscosity and specific
torque service.
gravity of the liquid?
With a constant torque
A pump manufacturers
application, the torque is not
published data is normally based
dependent on speed. Constant
on testing with water. The supplied
torque applications include positive
air pressure, pump ow rate, net
displacement pumps, conveyors,
positive inlet pressure (NPIP)/
belt presses, screws and augers.
net positive suction head (NPSH)
Although the torque remains
and the pumping system determine
constant as the speed increases, the
the discharge pressure for a given
Can I use the same type of power changes linearly with speed.
air-operated diaphragm/
When selecting a VFD for a
variable frequency drive
bellows pump.
constant torque application, VFD
(VFD) for a rotodynamic
Liquids with viscosity below 500
manufacturers will recommend a
pump and a positive
centipoise do not usually aect
drive specic to that application.
displacement pump?
manufacturers published pump
Contact your drive representative
performance data. As viscosity
Rotodynamic pumps and
with the specics of your constant
increases above this value, the
positive displacement pumps have
torque application.
possibility of liquid cavitation
dierent torque characteristics as
For more information on
increases, and drops in pressure
speed is varied. The VFD selected
variable frequency drives, see the
across pump components
must supply sucient current to
Hydraulic Institute Guidebook
particularly the suction check
the motor so the motor can produce Variable Frequency Drives: Guidelines
valvesraise the required NPIP/
the required torque throughout its for Application, Installation and
NPSH signicantly.
operating range.
Troubleshooting.
Specic gravity can also aect
With a variable torque load,
pump suction performance. A
the torque loading is a function
liquid with a high specic gravity
of speed. This type of load
HI Pump FAQs is produced by the
will reduce the manufacturers
requires less torque at lower
Hydraulic Institute as a service to
published data on suction-lift
speeds than constant torque
pump users, contractors, distributors,
reps and OEMs. For more information,
capabilities.
loads. Rotodynamic pumps, fans
visit pumps.org.
Viscous liquids tend to impede
and certain blowers (consult the
ecient check valve operation,
blower manufacturer) are common
which can result in a reduced ow
applications that have a variable
rate. This condition is caused by
torque load. As the speed decreases,
and rotor, pump speeds should
always be reduced well below those
for nonabrasive uid applications,
regardless of the type of rotary
pump used for abrasive slurries.
For more information on this
subject, see the Hydraulic Institute
Standard ANSI/HI 3.1-3.5 Rotary
Pumps for Nomenclature, Definitions,
Application and Operation.
92
PRACTICE & OPERATIONS
Tips for Using Pulsation Dampeners

in Dosing or Volumetric Pump Systems
Understanding the equipments operation capabilities and how to calculate the
required size is critical.
Second of Three Parts
By Manuel Carcar-Gimeno
HIDRACAR, S.A.
umps with one, two or three

pistons and crankshaft
movement are the most
common types of pumps. These
are also the pump types that most
need pulsation dampeners. Figure
1 shows the instantaneous ow
during a complete crankshaft
revolution for each type of piston
pump. Each type of pump has the
same piston dimension (diameter
x stroke).
Figure 1 shows how a pulsation
dampener works. The rst curve
represents a single-piston pump.
The use of a dampener is important
for this type of pump, otherwise
no liquid ow is delivered during
half of the revolution of the pump
crankshaft. If the pump does not
include a dampener, the diameter
of the pipe must be calculated for
the maximum instantaneous ow,
which occurs in the middle of the
piston stroke when the piston
speed is also at its maximum. The
ow curve is a sinusoid.
From the point where a
dampener is mounted, the
maximum ow supplied to the
circuit is close to the mean ow of
the pump. This makes it possible
to reduce the pipe diameter by
approximately 40 percent, because
the maximum instantaneous ow

of the pump is 2.8 times more than
its medium ow. In some cases,
the reduction of the pipe diameter
alone compensates for the cost of
the dampener. The main advantage
of a dampener is the stabilization
of the circuits pressure, which

provides a variety of associated
improvements. Pressure in a
hydraulic circuit is basically a
function of the ow. As the ow
varies, the pressure varies.
The rst curve in Figure 1 also
Figure 1. Pulsation dampeners store excess volume over the mean flow line of the total piston head
during the piston impulse stroke. (Graphics courtesy of Hidracar, S.A.)
93
demonstrates that the

Figure 2. The flow and pressure fluctiuation of a circuit with a dampener installed
dampener stores excess
volume over the mean ow
line of the total piston head
during the piston impulse
stroke. The dampener then
returns this volume (1) back
into the circuit during the
piston suction stroke. In this
type of pump, the volume
stored by the dampener is
half of the pump head or
capacity per revolution.
Analyzing all three curves
shows that as the number
of pistons increases, the
mean ow gets closer to
the maximum ow, and the
liquid volume 1 stored by
When a gas is compressed, its
y-axis (time) represents a volume
the dampener is correspondingly
pressure increases; when its volume that, in the case of a single-piston
reduced. As a result, the required
pump, is equal to the pump
expands, its pressure decreases.
size of the dampener also
capacity per stroke or revolution.
When a dampener is installed by
decreases. This is easy to see when
the outlet of a piston pump, the
all the pistons in the three pumps
pressure of the liquid in the circuit
Flow x Time = Volume
have the same diameter, stroke and
will uctuate according to the
number of revolutions per minute.
In all hydraulic circuits, the
volume of gas inside the dampener.
The more pistons a pump has,
This pressure variability, a +/pressure at the pump outlet port
the lower the dampener size
percentage of pressure, will be
is a function of the ow, pipe
required and the smaller both
dened by the technical designer
length and diameter, viscosity
the pipe section and the port
of the circuit or by nal end user
of the pumped liquid, internal
connection between the dampener
requirements.
pipe surface roughness and
and the circuit can be, assuming
geometric height. If the ow
The lower curve in Figure 2
the pumps provide the same ow
shows the pressure uctuation of a remains constant, the pressure
independently of the number of
needed to pump the liquid will
circuit with a dampener installed.
cylinders. Equations 1, 2 and 3
also be constant as long as no
This curve relates to the pump
show the relationship between v
change occurs in ow resistance.
ow variation curve. A dampener
and the capacity per head (C) for a
This type of change can be caused
stores the volume of liquid above
one-, two- and three-piston pump,
by sedimentation on lters, for
the pump mean ow. For this
respectively. These are practical
example. This constant working
reason, the minimum value of the
values for the calculation of
pressure is known as Pt. When
pressure curve (P1) must coincide
dampener size.
designing a circuit, the mean ow
with the rst crossing point of the
and the opposing resistances are
instantaneous ow curve with
C
v =
Equation 1 the line of the mean ow. The
needed to calculate Pt.
2
maximum value of the pressure
On one side, the dampener
curve (P2) must coincide with the
appears to stabilize the ow and
C
v =
Equation 2 second crossing point, the moment pressure, but the pressure actually
6
moves from P1 to P2. To stabilize
when all v has been introduced
inside the dampener.
the ow, the dampener needs to
C
v =
Equation 3
The area between the
compress and expand a volume of
15
instantaneous ow curve and the
gas. These pressure variations in
94
PRACTICE & OPERATIONS
+/- percentage of Pt regulate the

values accepted in the circuit.
This pressure uctuation can
be reduced to very small values
by increasing the volume of the
dampener. P1 and P2 are the
percentage values of Pt, which
are pressure variations that
the end user must determine.
Manufacturers recommend that
these variations are at least +/- 2
percent, because the environmental
temperature conditions will likely
modify the theoretical calculation.
Mounting Suggestions
for Maximum Dampener
Efficiency
The single-piston pump has the
highest maximum instantaneous
ow/mean ow ratio and the
highest value for v, which is the
liquid entering and exiting the
dampener each cycle. The following
examples and recommendations
will focus on single-piston pumps.
Figure 3 shows the proper
mounting of a pulsation dampener.
The following recommendations
should be observed:
The dampener must be mounted
with its axis aligned with the
axis of the pump outlet.
The distance between the pump
outlet port and the dampener
port connection must be as
short as possible.
The pipe section between
the pump and the dampener

connection must be calculated
for the pump maximum
instantaneous ow.
The remaining pipe section of
the circuit must be calculated
for the mean ow.
Figure 4 illustrates many of the

principles discussed in this article.
: Pipe section for the mean ow
: Small length of pipe section for
the maximum instantaneous
ow
Q: Maximum instantaneous ow
q: Mean ow
L: Distance between pump and
dampener, as short as possible
Fluid mechanics principles
can show the dierence between
in-line and derivation mounting to
a circuit and the higher eciency
of in-line mounting. The ow
of a liquid inside a pipe follows
dierent speed lines. The velocity
is higher in the center of the pump,
while it is nearly zero close to the
pipe inner wall (see Figure 5). If the
mean liquid velocity increases, the
dierence between the dynamic
pressure (measured in the liquid
movement direction) and the static
pressure (measured perpendicular
to the liquid movement direction)
also increases.
Figure 5 reects this concept.
In-line mounting corresponds to
Figure 3. Proper mounting of a pulsation dampener
the dynamic pressure reading.

Derivation mounting corresponds
to the static pressure. This assumes
that the uid circulates in a
laminar regime.
If the dampener is mounted
in derivation and far from the
pump outlet, its eciency will
be signicantly reduced. If it is
also installed in a pipe section
with a smaller diameter than the
main circuit pipe, the eect of the
dampener will be negligible.
The pulsation dampener
admission duct must be wider than
its connection port. Any reduction
in the diameter when attached to
low pressure circuits will greatly
reduce the performance and
eciency of the dampener.
Figure 4. A visual of the recommended system
95
Figure 5. The velocity is higher in the center of the pump but nearly zero near the pipes inner wall.
Manuel Carcar-Gimeno graduated

in mechanical technical engineering
at the Tarrasa Industrial School and
the Anderlecht Technical School
(Brussels). In 1974, after working as a
technical salesperson for the MercierGreer Group, he founded HIDRACAR,
S.A., initially as an importer of oleopneumatic accumulators. Years later,
the company began the design and
manufacturing of oleo-pneumatic
accumulators and other derived
products, such as oleo-hydraulic
starters, oleo-pneumatic shock
absorbers and suspension cylinders,
and various pulsation
dampeners. For more
information, visit
pulsation-dampershidracar.com.
REGISTER TODAY!
APRIL 21-23, 2015 | JAVITS CENTER, NYC
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96
PRODUCTS
Solids
PumpMeasurement
Control & Alarm Panel
See Water Inc.s SIM-A pump
control and alarm panels will
warn of high liquid levels
and control a 120/208/240V
single phase pump or a
208/240/2\480V three phase
pump in dewatering, sewage
and wastewater pumping
applications. The simplex
panels include integrated
electronic pump control and
alarm circuitry, an IEC motor contactor and three
floats: pump on, pump off and high liquid alarm.
Circle 205 on card or visit psfreeinfo.com
Grinder Pump
Couplings
Kurt Hydraulics announces its
new Push-On Hose and Push-Loc
Hose Couplings for low pressure
applications. The hose operates
in temperature ranges from -20 F
to +180 F. Designed to integrate
with Kurt Hydraulic hose, the Push-Loc couplings are
precision machined of corrosion resistant brass. Kurt
Hydraulics Push-Loc hose couplings are available in
22 different types and sizes. Applications for Kurt
Hydraulics new Push-On hose and Push-Loc couplings
include paint spraying systems and similar industrial
equipment and maintenance systems requiring fast,
push-on hose assembly.
Corrosion-Resistant Butterfly Valves
Zoeller offers the Shark Model

840, a 2-horsepower grinder pump
for residential and commercial
wastewater applications. The units
stainless steel cutter works with
a rotational shearing action that
changes direction each time the
pump activates. The pump is castiron and includes a powder-coated
epoxy finish. The Shark Model 840
contains an oil-fi lled, hermetically
sealed motor with Class F
insulation. Preassembled systems are available.
Intelligent Pump Drive

Yaskawa America, Inc.,
released the iQpump Micro
intelligent pump drive, which
serves as an extension of the
iQpump1000 drive technology.
The iQpump Micro drive provides
microdrive control for variabletorque pump loads through 25
horsepower. iQpump Micro is available in National
Electrical Manufacturers Association (NEMA) 1 and
NEMA-4X rated models. NEMA 3R Configured Packages
are also available. Yaskawas integrated pump-specific
software allows for a wide range of pumping applications.
As a complement to its
complete line of fiberglass
centrifugal pumps, Fybroc
offers a new line of nonmetallic, corrosion-resistant
butterfly valves. Ideal
for handling corrosives,
seawater, solvents and other
difficult liquids, the standard
model valve (1.5 inches to 12
inches/40 millimeters to 300 millimeters) has a black
polypropylene body, a polyvinylidene fluoride disc
and a fluorocarbon (Viton) seat for superior chemical
resistance and temperature capability.
Submersible Explosion-Proof Pumps

BJM Pumps now offers the new XPKZN heavy-duty submersible explosion
proof pumps. The XP-KZN pumps
are specifically designed for tough
conditions where explosion-proof,
factory mutual, (Class I, Division 1,
Group C & D) materials are needed.
The XP-KZN features a top discharge,
slim-line design with agitator to
suspend heavy slurries containing
coal, ash, sand, gravel or other abrasive materials. The
XP-KZN is protected by Class H motor insulation and built
in amperage and temperature overload protection. It has
flows up to 665 gpm and head up to 61 feet.
THE GIFT OF
C L E A N WAT E R
COMING IN MAY TO
This year, Pumps & Systems proudly continues to tell the

stories of companies that help bring clean water to those
who need it around the world.
Pumps & Systems will be on the ground reporting from
Malawi, Africa, with exclusive coverage of innovative
deep-well pumping technology.
Follow the story on Twitter @PumpsSystemsMag and
@AmeliaMessamore and on Facebook (/pumpssystems).
LEARN HOW YOU CAN HELP

pumpsandsystems.com/giftofcleanwater
HAVE A STORY TO TELL
about providing clean water to those who need it?
Email Amelia at amessamore@cahabamedia.com
98
PRODUCTS
Shaft Alignment
Medium-Voltage Drives
Ludeca now ofers the Rotalign

Ultra, an intelligent system
for machinery alignment.
It features Sensalign, an
intelligent sensor for precision
and accuracy. Rotalign Ultra
provides a wireless laser shaft
alignment in three steps: enter
machine dimensions, sweep
shafts less than a quarter turn
from any starting position,
and view results for coupling and feet graphically.
he Rotalign Ultra ofers machine train aligment
of up to 14 machines in the advanced system and 6
machines in the lite system. he Rotalign Ultra Move
Simulator allows the user to simulate and experiment
with diferent corrective solutions when the suggested
corrections are impractical or impossible. A display
software for training large groups is included.
Eaton now ofers the new

Eaton SC9000TM EP mediumvoltage drives. hese drives
are engineered for global
oil and gas, mining, utility
and water, and wastewater
applications. he power
pole inverter with heat pipe
technology provides a high
power density in a compact
footprint, while enabling the
SC9000 EP drive to withstand
harsh environmental conditions. he SC9000 EP
drives meet the Institute of Electrical and Electronics
Engineers (IEEE) 519 guideline for harmonic control
and reactive compensation of static power converters,
Underwriters Laboratories (UL) 347 for mediumvoltage power conversion equipment and Canadian
Underwriters Laboratories (cUL) standards.
To have a product considered for our Products section, please send the information to Amy Cash, acash@cahabamedia.com.
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.
NEW: Rotodynamic Pumps

- Guidelines for Dynamics of
Pumping Machinery
Available now in the new
Hydraulic Institute eStore
This new standard:
Describes (3) types and levels of dynamic analysis for
pumps and pump trains.
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rotor lateral, rotor torsional, and structural read critical
frequencies within Level 1 analysis.
Helps the end user avoid costly reliability problems
related to resonance of the rotor system and structure.
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For more information, contact Liz Clark
at 210.477.8483 or liz.clark@ frost.com
99
TAKE THE SURVEY
THE EFFECT
OF GLOBAL
FORCES ON
PUMP USERS
ATTITUDES
S
Expenditure
(CAPEX)
plans for 2015
Emerging technology
and equipment
upgrades
F
of global trends
Frost & Sullivan and Pumps & Systems magazine are partnering to discover how pump users
I
will be published as a series in Pumps & Systems, authored by the research analysts at global
F
S
A
bit.ly/pumpsurvey
Connect with Frost & Sullivan and Pumps & Systems
J
100
Advertisers
Advertiser Name
Page RS#
Advertiser Name
Meltric Corporation . . . . . . . . . . . . . .102
163
All-Flo Pump Co. . . . . . . . . . . . . . . . . . .10
118
NETZCH Group . . . . . . . . . . . . . . . . . .103
164
Almatec, Part of
Pump Solutions Group . . . . . . . . . .15
Pinnacle-Flo, Inc.. . . . . . . . . . . . . . . . . .53
149
119
PPC Mechanical Seals. . . . . . . . . . . . . .13
132
Automationdirect.com . . . . . . . . . . . . .19
101
Ruthman Companies . . . . . . . . . . . . . .53
150
Badger Meter, Inc. . . . . . . . . . . . . . . . . . 17
102
Scenic Precise Element, Inc. . . . . . . .102
165
Bal Seal Engineering, Inc. . . . . . . . . .103
159
Schenck Trebel Corp . . . . . . . . . . . . . . .69 134
Baldor Electric Company . . . . . . . . . . .33
103
SEEPEX. . . . . . . . . . . . . . . . . . . . . . . . . . .31
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Best Pumpworks/Pumpworks 610 . .56
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SEPCO . . . . . . . . . . . . . . . . . . . . . . . . . . .43
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BJM Pumps. . . . . . . . . . . . . . . . . . . . . . .71
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Sero . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
178
BLACOH Fluid Control, Inc. . . . . . . . BC
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Sims Pump Co. . . . . . . . . . . . . . . . . . . . .77
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Blue-White Industries . . . . . . . . . . . . . . 9
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Sims Pump Co. . . . . . . . . . . . . . . . . . . . .47
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Cat Pumps . . . . . . . . . . . . . . . . . . . . . . . .29
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Sims Pump Co. . . . . . . . . . . . . . . . . . . .101
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Conhagen. . . . . . . . . . . . . . . . . . . . . . . . .67
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Sims Pump Co. . . . . . . . . . . . . . . . . . . .102
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Dan Bolen & Associates, LLC . . . . . .103
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Singer Valve. . . . . . . . . . . . . . . . . . . . . . .71
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Denmar Pump Services . . . . . . . . . . . .41
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SJE Rhombus . . . . . . . . . . . . . . . . . . . . .79
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Dickow Pump Company. . . . . . . . . . . .59 122
Skinner Power Systems . . . . . . . . . . . .36
140
DP Pumps-USA . . . . . . . . . . . . . . . . . . .35
Smith & Loveless . . . . . . . . . . . . . . . . . . . 3
112
St. Marys Foundry, Inc. . . . . . . . . . . .102
168
125
123
Frost & Sullivan . . . . . . . . . . . . . . . . . . .98
152
GE Intelligent Platforms . . . . . . . 82/83
124
Gorman-Rupp Company . . . . . . . . . . .21
Streamlight, Inc. . . . . . . . . . . . . . . . . . .28
139
Summit Pump, Inc. . . . . . . . . . . . . . . .101
169
107
Submersible Wastewater Pump

Association (SWPA) . . . . . . . . . . . . .81
147
Graphite Metallizing Corp. . . . . . . . . .65
126
Titan Flow Control, Inc. . . . . . . . . . . . .85
157
Hayward Flow Control . . . . . . . . . . . . .37
127
Titan Manufacturing, Inc.. . . . . . . . .101
170
Heinrichs USA LLC . . . . . . . . . . . . . . . .87
153
Topog-E Gasket Co . . . . . . . . . . . . . . .102
171
HIDRACAR S.A.. . . . . . . . . . . . . . . . . . .27
108
Trachte, USA . . . . . . . . . . . . . . . . . . . . .101
172
Hydraulic Institute . . . . . . . . . . . . . . . .98
154
Tuf-Lok International. . . . . . . . . . . . .101
173
Hydro, Inc.. . . . . . . . . . . . . . . . . . . . .IFC/1
100
Vanton Pump & Equipment Corp . . .61
113
Hyundai Heavy Industries . . . . . . . . .11
109
Varisco USA, Inc. . . . . . . . . . . . . . . . . .101
174
IDEX Viking . . . . . . . . . . . . . . . . . . . . . .75
146
Vaughan Company . . . . . . . . . . . . . . . . . 5
114
IDEX Sandpiper . . . . . . . . . . . . . . . . . . .55
145
Vertiflo Pump Company. . . . . . . . . . .101
175
International Products Corporation 34
128
Vesco Plastics Sales . . . . . . . . . . . . . . 100
176
INTERPHEX, Reed Exhibitions . . . . .95
129
Watson-Marlow Pumps Group. . . . . .22
141
JDA Global . . . . . . . . . . . . . . . . . . . . . . .25
130
WEG Electric Corp. . . . . . . . . . . . . . . . .23
115
Jordan, Knauff & Company . . . . . . . .87
155
Wilden . . . . . . . . . . . . . . . . . . . . . . . . . . .51
144
KSB, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . 7
110
WorldWide Electric Corp . . . . . . . . . . .16
142
Load Controls, Inc . . . . . . . . . . . . . . . . .20
131
143
116
LobePro . . . . . . . . . . . . . . . . . . . . . . . . .103
161
Water Quality Association (WQA)

Aqautech . . . . . . . . . . . . . . . . . . . . . . .39
Magnatex Pumps, Inc. . . . . . . . . . . . . .85
156
Xylem, Inc.. . . . . . . . . . . . . . . . . . . . . . .IBC
Master Bond, Inc. . . . . . . . . . . . . . . . .103
162
Visit www.psfreeinfo.com to request more

information from these advertisers.
Page RS#
Advanced Engineered Pump, Inc. .100 158
Electrical Apparatus Service

Asssociation (EASA) . . . . . . . . . . . .54
FREE PRODUCT INFORMATION
he Index of Advertisers is furnished as a courtesy, and no

responsibility is assumed for incorrect information.
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101
REPS WANTED
Sims Pump, a fast growing structural
composite pump, pump parts, and
mechanical seals manufacturer is
seeking ambitious, aggressive, and
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both the marine and industrial
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Your Best Value in

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Please fax your resume to

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x*-
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>i`
UV
U}i`
/vi>>
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102
PUMP
PLUGS
QUICKLY CONNECT
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Button
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Rated up to 200A, 75hp

Connector + Switch in 1 device
Maximizes Arc Flash Protection
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meltric.com
800.433.7642


103
Knowledge is
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104
PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

By Jordan, Knauff & Company
Figure 1. Stock Indices from February 1, 2014, to January 31, 2015
he Jordan, Knauf &

Company (JKC) Valve Stock
Index was down 15.2 percent
over the last 12 months, while the
broader S&P 500 Index was up 14.5
percent. he JKC Pump Stock Index
decreased 12.1 percent for the
same time period.1
he Institute for Supply
Managements Purchasing
Managers Index (PMI) decreased
1.6 percentage points in January
to 53.5 percent, even as comments
from the survey indicated that
most industries are experiencing
strong demand. he New Orders
Index registered 52.9 percent,
down 4.9 percentage points
compared with December,
while growth was reported in
10 industries. he Export Index
fell below 50 percent, indicating
contraction and highlighting
concerns about global growth.
Declining for the ifth straight
month, the Census Bureau reported
that new factory orders fell 3.4
percent in December. Both durable
and nondurable goods were down.
he transportation equipment
sector fell 9.1 percent because
of a decline in aircraft spending.
Other declining sectors included
machinery, primary metals,
and computers and electronics.
Sectors showing growth included
furniture, fabricated metal
and electronic
equipment.
Manufactured
goods orders
averaged $498.8
billion per month
in 2014, 2.8 percent
higher than the
monthly average
in 2013.
U.S. gross
Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates.
domestic product
he JKC Pump and Valve Stock Indices include a select list of publicly traded companies involved in
(GDP) grew at
the pump and valve industries weighted by market capitalization.
an annual rate
than at the same time last year and
of 2.6 percent in
Reference
is the highest level for this time of
the fourth quarter of last year
1. he S&P Return
year in the last 80 years. Driven
according to the irst estimate by
igures are provided
the Commerce Department. Lower by supply from non-Organization
by Capital IQ.
of Petroleum Exporting Countries
gasoline and energy prices have
sources, the EIA estimates that
increased household purchasing
global oil inventories increased
power as consumer spending
Jordan, Knauff
& Company is an
by almost 0.8 million barrels per
increased 4.3 percent during the
investment bank
quarter. Spending on durable goods day last year and will continue to
based in Chicago,
grow by 0.9 million barrels per
increased 7.4 percent because of
Illinois, that
day
during
the
irst
half
of
2015,
healthy motor vehicle sales, and
provides merger and
keeping downward pressure on
acquisition advisory
nondurable goods spending rose
services to the
4.4 percent. In 2014, GDP increased oil prices. Inventory growth is
pump, valve and
expected to taper of by the end
2.4 percent, the strongest annual
filtration industries.
of the year as lower oil prices
rate in four years and up from 2.2
Please visit
cause supply growth to weaken,
percent in 2013.
jordanknauff.com for
further information.
especially in the U.S.
According to the Energy
Jordan Knauff &
On Wall Street, the Dow Jones
Information Administration
Company is a member
Industrial Average fell 3.7 percent,
(EIA), U.S. commercial crude
of FINRA.
the S&P 500 Index dropped
oil inventories (excluding the
3.1 percent, and the NASDAQ
Strategic Petroleum Reserve) were
Composite lost 2.1 percent for the
413.1 million barrels at the end of
These materials were
prepared for informational
month of January.
January. his is 15 percent higher
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.
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The Leading Magazine for Pump Users Worldwide

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From the Editor

PUBLISHER: Walter B. Evans Jr.

Editor, Michelle Segrest

P.O. Box 530067

Pumps & Systems

M a rc h 2 015 | Pum ps & S ys t e m s

1900 28th Avenue South, Suite 200

2126 McFarland Blvd. East, Suite A

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66 NEW DETECTION TECHNOLOGY REDUCES

68 4 ENGINEERING STRATEGIES THAT CAN

72 REFINERY REVAMPS 1947 VINTAGE PUMPS

An Indiana refinery used reverse engineering to solve multiple challenges

PUMP SYSTEM IMPROVEMENT

44 By Gary Williams, MSc, IT SEC

STATE OF THE INDUSTRY

FROM THE EDITOR

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

48 SUBMERSIBLE PUMPS HANDLE

A caustic, high-temperature cleaning solution

50 MECHANICAL SEAL DESIGN PROTECTS

Customized seals made from superior

52 HARSH LIQUIDS REQUIRE CAREFUL MATERIAL SELECTION

Metallics and plastics offer advantages for different applications.

58 CUSTOMIZED COMPOUNDING BOOSTS RESILIENCE IN HARSH CONDITIONS

5 Maintenance Factors that

84 MOTORS & DRIVES

By Dr. Joel Bell & Will Taber, RTP Company

92 TIPS FOR USING PULSATION DAMPENERS IN

EDITORIAL ADVISORY BOARD

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DOSING OR VOLUMETRIC PUMP SYSTEMS

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

LEV NELIK, Ph.D., P.E., APICS, President,

DAVID A. DOTY, North American Sales Manager,

MIKE PEMBERTON, Manager, ITT Performance

WALT ERNDT, VP/GM, CRANE Pumps & Systems

SCOTT SORENSEN, Oil & Gas Automation

JOE EVANS, Ph.D., Customer & Employee

ADAM STOLBERG, Executive Director,

LARRY LEWIS, President, Vanton Pump and

JERRY TURNER, Founder/Senior Advisor,

TODD LOUDIN, President/CEO North American

KIRK WILSON, President, Services & Solutions,

JOHN MALINOWSKI, Sr. Product Manager, AC

JAMES WONG, Associate Product Manager

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