PumpsAndSystems Jun2016 PDF

J U N E 2 0 16
SYSTEMS
PUMPSANDSYSTEMS.COM
The Leading Magazine for Pump Users Worldwide
How DOE Research

Is Shaping the
MOTOR
MARKET
10 Q U I C K T I P S O N P U M P C U R V E S | 8 -Y E A R P U M P R E L I A B I L I T Y S T U D Y
Circle 101 on card or visit psfreeinfo.com.
2 FROM THE EDITOR
T he Pumps & Systems editorial team is

always learning more and more about
this exceptional industry. As we learn, we are
EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
aarchibald@cahabamedia.com • 205-278-2843
SENIOR TECHNICAL EDITOR: Mike Pemberton
delighted to share that information with you.
mpemberton@cahabamedia.com
In addition to the magazine, which is 205-314-8279
available in print and digital editions, MANAGING EDITOR: Amelia Messamore
we provide the industry’s top website, amessamore@cahabamedia.com
205-314-8264
pumpsandsystems.com. The site offers the
MANAGING EDITOR: Martin Reed
case studies and technical articles found in the
mreed@cahabamedia.com • 205-278-2826
magazine, as well as web-exclusive content,
MANAGING EDITOR: Savanna Gray
news updates and a revamped, easy-to-navigate sgray@cahabamedia.com • 205-278-2839
Manufacturers Directory. CONTRIBUTING EDITORS: Lev Nelik,
P&S also offers a weekly e-newsletter, Ray Hardee, Jim Elsey
Pump Users Digest, and a monthly product CREATIVE SERVICES
e-newsletter, Products for Pump Users. Both DIGITAL PROJECT MANAGER &
contain valuable, relevant content specially SENIOR ART DIRECTOR: Greg Ragsdale
P&S Managing Editor Savanna Gray tries
chosen to share with our readers. Eaton Electrical’s virtual tour at the recent ART DIRECTORS: Elizabeth Chick, Melanie Magee
Social media is an integral part of our Offshore Technology Conference (OTC) in WEB DEVELOPER: Greg Caudle
industry coverage, and you’ll find our editors Houston. DIGITAL COMMUNITY MANAGER: Amy Cash
active on various sites daily. PRINT ADVERTISING TRAFFIC: Lisa Freeman
Follow Pumps & Systems on Facebook at facebook.com/pumpsandsystemsmag and lfreeman@cahabamedia.com • 205-212-9402
on Twitter at PumpsSystemsMag. Our LinkedIn group is large—more than 21,000 CIRCULATION
members—and growing all the time. Join us there at Pumps & Systems. AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
Each editor is busy on Twitter, where we share news and articles of interest from lmasaoay@cahabamedia.com • 205-278-2840
industry leaders and from our own magazine pages. Here is where to fi nd us:
ADVERTISING
Alecia Archibald, Senior Editor: @AleciaArch
NATIONAL SALES MANAGER: Derrell Moody
Savanna Gray, Managing Editor: @SavannaLGray dmoody@pump-zone.com • 205-345-0784
Amelia Messamore, Managing Editor: @AmeliaMessamore ACCOUNT EXECUTIVES:
Martin Reed, Managing Editor: @Martin_J_Reed Mary-Kathryn Baker
And, of course, we continue to grow relationships with our readers. We’re always mkbaker@pump-zone.com • 205-345-6036
excited for the chance to talk to you about your challenges, concerns and achievements. Mark Goins
mgoins@pump-zone.com • 205-345-6414
Managing Editor Savanna Gray attended the Offshore Technology Conference (OTC) in
John Harris
Houston last month where she had the chance to meet and talk with some of you. We jharris@pump-zone.com • 205-561-2607
look forward to those events, where you can tell us face-to-face your ideas. When you Garrick Stone
are attending an industry trade show, please look for us and pick up an extra copy of the gstone@pump-zone.com • 205-212-9406
magazine while you are there. MARKETING ASSOCIATES:
If you would like to subscribe to the magazine or to our e-newsletters, visit Sonya Crocker
scrocker@cahabamedia.com • 205-314-8276
pumpsandsystems.com/subscribe.
As always, thanks for reading.
PUBLISHER: Walter B. Evans Jr.

VP OF SALES: Greg Meineke
Senior Editor Alecia Archibald CREATIVE DIRECTOR: Terri J. Gray
CONTROLLER: Brandon Whittemore
aarchibald@cahabamedia.com
P.O. Box 530067

Birmingham, AL 35253
EDITORIAL & PRODUCTION
Pumps & Systems 1900 28th Avenue South, Suite 200
is a member of the following organizations: Birmingham, AL 35209
205-212-9402
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 offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the
right to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and ADVERTISING SALES
possessions $5, all other countries $15 US funds (via air mail). Call 205-278-2840 inside or outside the U.S. POSTMASTER: Send changes of address and 2126 McFarland Blvd. East, Suite A
form 3579 to Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253. ©2016 Cahaba Media Group, Inc. No part of this publication may be reproduced Tuscaloosa, AL 35404
without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements,
articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The 205-345-0784
opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes
no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS:
We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media Group, Inc.,
permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free
to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 24, Issue 6.
J une 20 1 6 | Pumps & Sy st e m s

The Triton Screw Centrifugal Pump combines the benefits of Vaughan’s UNMATCHED
RELIABILITY with the advantages of highly efficient, non-clog performance. Triton’s screw
centrifugal impeller is ideal for handling thick sludges, large solids, shear sensitive fluids
and delicate or highly abrasive material.
- Steep performance curves

- Heavy-duty power frames
- Expedite pumps and parts availability
See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP

4
This issue JUNE
Volume 24 • Number 6
COLUMNS
COVER
SERIES MOTORS & DRIVES PUMPING PRESCRIPTIONS
14 By Lev Nelik, Ph.D., P.E.
Pumping Machinery LLC
Eight-Year Study Reveals Vital
Knowledge about Pump Reliability
PUMP SYSTEM IMPROVEMENT
22 By Ray Hardee
Engineered Software Inc.
More than One Way to Fix a System
COMMON PUMPING MISTAKES

26 By Jim Elsey
Summit Pump Inc.
Understanding Pump Curves
48 2 FROM THE EDITOR

8 NEWS
48 FOLLOW THESE TIPS TO GET THE MOST FROM VMS PUMPS 12 TRADE SHOW PREVIEW
By Steven Ulrich, Franklin Electric 92 ADVERTISERS INDEX
Evaluate the application before installation to ensure a long-lasting, productive 92 PUMP USERS MARKETPLACE
and efficient pump.
96 PUMP MARKET ANALYSIS
52 DOE-FUNDED MOTOR SYSTEM MARKET ASSESSMENT TO PROVIDE
VALUABLE INSIGHT
By Paul Sheaffer, Prakash Rao & Arian Aghajanzadeh,
Lawrence Berkeley National Laboratory
The study will give industry stakeholders a better understanding of the SPECIAL REPORT
marketplace and help them become more globally competitive.
56 VFD ENERGY ALGORITHMS OPTIMIZE PID-CONTROLLED 30 3 CYBERSECURITY BEST

APPLICATIONS PRACTICES
By Charles Tahara, Eaton By Dana Pasquali,
GE Oil & Gas Digital Solutions
Drives with active energy control can save energy and extend motor life for
pumping and HVAC loads. Understanding these strategies is
critical for building a solid foundation
60 THREE-LEVEL AC DRIVE ELIMINATES LONG MOTOR CABLE ISSUES for a secure and productive
By Todd Thompson, Yaskawa America Inc. enterprise.
This alternative technology is ideal for petrochemical applications.
62 UNDERSTANDING THE NEW DOE PUMP SYSTEM 30

TESTING PROCEDURES
By Tom Lowery & Jack Creamer, Schneider Electric
This is the first time the DOE has developed rules to determine the efficiency of
pump systems.

6
This issue DEPARTMENTS
JUNE
SSPECIAL
PECIAL
INSTRUMENTATION, CONTROLS
SECTION & MONITORING 66 EFFICIENCY MATTERS
4 Real-World Examples of
Eccentric Disc Pumps In
34 GOING BEYOND SWITCHES FOR PUMP HEALTH MONITORING
Chemical-Handling Applications
API Standard 682 recommends transmitters instead of switches to monitor pump
sealing systems. By Mike Solso
Mouvex
By Brian Atkinson, Emerson Process Management
70 MAINTENANCE MINDERS
38 ADVANCED DIAGNOSTICS HELP CENTRIFUGAL PUMPS REACH NEW LEVELS How Does Your Facility’s
OF EFFICIENCY Maintenance Program Rank?
A model-based control system provides complete machine protection using a
By Mark Jennings
minimum number of sensors.
ARES Corporation
By Massimiliano Di Febo, Pasquale Paganini & Giacinto Di Mango, IPC
74 SEALING SENSE
Analyzing Life-Cycle Costs to
42 NEW INSTRUMENTATION EFFECTIVELY MONITORS & MANAGES SCALE Select the Best Sealing Solution
Electrical capacitance tomography can provide real-time imagery of any pipeline. By Mark Savage
By Todd Loudin, Flowrox Inc. FSA Member
76 HI PUMP FAQS
44 CUSTOM UPS SOFTWARE IMPROVES SYSTEM CONTROL FOR PIPELINE USERS Allowable Operating Speeds for
Engineers identified and corrected problems with the shutdown sequence. VFDs & Motor Enclosures for
By William Fox, John Ely & David McKinnon, AMETEK Solid State Controls Wastewater Applications
By Hydraulic Institute
PRACTICE & OPERATIONS

78 WHERE DO YOU GET YOUR SYSTEMS
The Leading Magazine for Pump Users Worldwide
J U N E 2 0 16
PUMPSANDSYSTEMS.COM
REPLACEMENT PARTS? How DOE Research

Is Shaping the
MOTOR
By Richard E. Martinez, MARKET
Standard Alloys Inc.
82 CALIFORNIA HOSPITAL CUTS CLOGS

& MAINTENANCE COSTS USING 10 Q U I C K T I P S O N P U M P C U R V E S | 8 -Y E A R P U M P R E L I A B I L I T Y S T U D Y
SUBMERSIBLE SHREDDER PUMPS ON THE COVER

By Mike Bjorkman, BJM Corp. Complete pump system with
high-voltage, 2,000 kW Nidec
86 4 ADVANTAGES OF AODD PUMPS ASI motor (Cover photo courtesy
By David Rozee, Tri-Ark Pumps Ltd.
82 of DMW Pumps, Japan)
EDITORIAL ADVISORY BOARD

THOMAS L. ANGLE, P.E., MSC, Vice BOB DOMKOWSKI, Business TODD LOUDIN, President/CEO North SCOTT SORENSEN, Oil & Gas
President Engineering, Hidrostal AG Development Manager – Transport American Operations, Flowrox Inc. Automation Consultant & Market
BRYAN S. BARRINGTON, Machinery Pumping and Amusement Markets/ MICHAEL MICHAUD, Executive Developer, Siemens Industry Sector
Engineer, Lyondell Chemical Co. Engineering Consultant, Xylem, Inc., Director, Hydraulic Institute ADAM STOLBERG, Executive Director,
Water Solutions USA – Flygt Submersible Wastewater Pump
KERRY BASKINS, VP/GM, Milton Roy JOHN MALINOWSKI, Sr. Product
Americas WALT ERNDT, VP/GM, CRANE Pumps Manager, AC Motors, Baldor Electric Association (SWPA)
& Systems Company, A Member of the JERRY TURNER, Founder/Senior
R. THOMAS BROWN III, President,
Advanced Sealing International JOE EVANS, Ph.D., Customer & ABB Group Advisor, Pioneer Pump
(ASI) Employee Education, PumpTech, Inc. WILLIAM E. NEIS, P.E., President, DOUG VOLDEN, Global Engineering
CHRIS CALDWELL, Director of LARRY LEWIS, President, Vanton Northeast Industrial Sales Director, John Crane
Advanced Collection Technology, Pump and Equipment Corp. LEV NELIK, Ph.D., P.E., APICS, KIRK WILSON, President, Services &
Business Area Wastewater Solutions, WILLIAM LIVOTI, Business President, PumpingMachinery, LLC Solutions, Flowserve Corporation
Sulzer Pumps, ABS USA Development Manager/Energy HENRY PECK, President, Geiger Pump JAMES WONG, Associate Product
JACK CREAMER, Market Segment Efficiency Specialist, WEG Electric & Equipment Company Manager – Bearing Isolator, Garlock
Manager – Pumping Equipment, Corporation Sealing Technologies
MARIANNE SZCZECH, Director,
Square D by Schneider Electric Global Marketing and Product
Management, Pump Solutions Group

200 Years of Reliable
Performance
With more than 200 years of combined experience, ABB and Baldor
have developed, designed and manufactured millions of motors and
variable speed drives, installed in most applications across many
industries. Using our products together provides customers a unique
opportunity to gain the latest technology, process control and optimal
energy savings in one package. Together we offer:
ÝReliable performance
ÝImproved efficiency
ÝLocal sales and support
ÝLife cycle management services
From low voltage to medium voltage, ABB drives and Baldor-Reliance
motors are designed for a variety of challenging operations and
industry requirements. Let us know how we can provide a package that
meets your needs.
i%DOGRU(OHFWULF&RPSDQ\ http://esp.to/wKPdfn

8 NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
MIKE KNAPEK, YASKAWA AMERICA TROY HEIMERL, JWC ENVIRONMENTAL
WAUKEGAN, Ill – Yaskawa America Inc. has SANTA ANA, Calif. – JWC Environmental has
announced the promotion of Mike Knapek, announced that Troy Heimerl has been promoted
president and COO of the Drives & Motion Division, to director of North American municipal sales. This
to the position of CEO. Knapek takes over for newly created position will allow the company to
Masahiro Ogawa, who has led Yaskawa’s Drives, make further investments in serving its customers
Motion and Robotics business in the Americas while supporting the needs of its partner network.
for the past 5-1/2 years. Ogawa will return to Mike Knapek Heimerl has more than 20 years of wastewater Troy Heimerl
Kurosaki, Japan, to take on the role of corporate industry experience. jwce.com
vice president and general manager of Yaskawa’s global robotics
business. In his new role, Knapek will lead both the Drives & Motion and JOHN V. BALLUN, VAL-MATIC VALVE &
Motoman Robotics Divisions of Yaskawa America Inc. yaskawa.com MANUFACTURING CORP.
ELMHURST, Ill. – Val-Matic Valve & Manufacturing
NIGEL GASCOYNE, BRENDAN Corp. announced that John V. Ballun, executive vice
O’DOWD & CARL BAKER, president and chief operating officer, will succeed
HAM BAKER Ted J. Makowan as president and CEO. Ballun earned
UNITED KINGDOM – Ham Baker a Bachelor of Science in engineering from Illinois
Group has made three key Institute of Technology and a master’s degree in John V. Ballun
appointments. Nigel Gascoyne business administration from Northern Illinois
and Brendan O’Dowd have both University. Patricia Nuter will continue to serve as chairman of the
been recruited as new business Nigel Brendan board, executive chairman and treasurer of Val-Matic. valmatic.com
Gascoyne O’Dowd
development directors, seeking
opportunities for Ham Baker’s complete offering of innovative water JEFF BERGMAN & SEAN
and wastewater products, including valves, pipelines, screening FITZPATRICK, DANFOSS DRIVES
equipment and scraper bridges. Ham Baker is also promoting Carl NORDBORG, Denmark – Danfoss
Baker to become Midlands area sales manager. hambakergroup.com Drives has expanded the Global
Strategic Customer organization
CHAD BOWERS, VALVTECHNOLOGIES with the addition of Jeff Bergman
HOUSTON – ValvTechnologies Inc. announced the and Sean Fitzpatrick. As global
appointment of Chad Bowers as chief information key account managers, Bergman Jeff Sean
officer. Based in Houston, Bowers will have and Fitzpatrick will provide expert Bergman Fitzpatrick
executive responsibility for technology strategy, support to Danfoss customers
digital architecture, business systems, application around the world. For the past 15 years, Bergman has played a key role
development, data management and security, in supporting the Danfoss Drives water/wastewater sales team in the
and communication systems. Bowers graduated Chad Bowers positions of product manager and key account manager. Fitzpatrick
from the University of Phoenix with a Bachelor has spent the past eight years supporting the global OEM pumping
of Science in business administration and received his MBA from the market in the roles of application engineer, business development
University of Houston. valv.com manager and global account manager for drives and automation
equipment. drives.danfoss.us
ALAN HUDSON, TRIHEDRAL
TRUSSVILLE, Ala. – Trihedral announced that Alan LINDA MUROSKI,
Hudson has assumed the role of U.S. sales manager TRELLEBORG SEALING SOLUTIONS
for VTScada software. He will be based in Trussville, FORT WAYNE, Ind. & SCHAUMBERG, Ill. –
Alabama. Hudson brings an extensive background Trelleborg Sealing Solutions appointed Linda
in the monitoring and control industry with more Muroski president of marketing Americas,
than 25 years of experience with companies such headquartered in Fort Wayne, Indiana. Muroski
as Revere Control Systems, Bristol Babcock, Control Alan Hudson joins Trelleborg Sealing Solutions from BASF, where
Microsystems and various key positions within she most recently served as the director of water Linda Muroski
Schneider Electric over the last solutions, North America. Muroski holds an MBA
10 years. trihedral.com from Penn State University. tss.trelleborg.com

9
AROUND THE INDUSTRY

Grundfos Gulf Distribution Opens Studio
Miyah Showroom in Dubai
DUBAI – In an effort to reaffirm its sustainable innovation
and environment-friendly practices, Grundfos Gulf
Distribution opened its new showroom, Studio Miyah, in
Dubai’s Jebel Ali Freezone. The showroom is the company’s
latest initiative that takes visitors on an interactive journey
to discover pump manufacturing. Named “Miyah,” the Arabic
word for water, the new showroom resembles a laboratory,
with pump solutions displays exhibited against blue walls
decorated with piping motifs. grundfos.com
Drinking Water & Clean Water Funding Provides

Billions in Return on Investment, Report States
ALEXANDRIA, Va. – A new economic benefits analysis of
the impacts of increased funding for the Drinking Water
and Clean Water State Revolving Funds (SRF) has revealed
that a requested $34.7 billion of federal SRF spending will
generate $102.7 billion in total economic input and create
more than 500,000 U.S. jobs. The analysis was released May
3 by the Water Environment Federation and the WateReuse
Association. They conducted the analysis at the request of
the Senate Environment and Public Works Committee for
an April 7 hearing that examined the federal role in water/
wastewater infrastructure funding. wef.org / watereuse.org
Australian Water Treatment Plant Named

Industrial Water Project of the Year
TREVOSE, Penn. – QGC’s water treatment plant at its northern
coal seam gas fields near Wandoan in Queensland, Australia,
was named Industrial Water Project of the Year at the annual
Global Water Awards. The award represents one of the most
impressive technical or environmental achievements in the
field of industrial water. Commissioned in May 2015, QGC’s
Northern Water Treatment Plant purifies 100,000 cubic
meters per day of produced water from the coal seam gas
fields, and the treated water is beneficially reused by the
local communities and farmers. An alliance between GE
and Laing O’Rourke Australia designed and built the water
treatment plant. ge.com
WRDA Bill Passes Senate Committee with Key

Water Reuse Provisions
WASHINGTON – The federal Water Resources Development

Act of 2016, which is new legislation that provides critical
investment in water infrastructure and includes support for
water reuse, was introduced in the Senate on April 26 and
passed by the Environment and Public Works Committee on
April 28. The legislation cites a Water Environment Federation
and WateReuse Association sponsored economic study
that demonstrates the value of robust funding for State
Revolving Fund programs. The legislation is the main vehicle
for authorizing water projects to be studied, planned and
developed by the U.S. Army Corps of Engineers.
epw.senate.gov
p u mp s a n d s y s te m s . co m | J u ne 2016
10 NEWS
AROUND THE INDUSTRY

LUDECA Announces Alignment & advancements, encouraging the adoption public bodies, and education and science
Ultrasound Partnerships of UOTF principles (water reuse, watershed institutions in the water sector. The alliance
DORAL, Fla. – LUDECA has announced stewardship, beneficial biosolids reuse, is headed by Aarhus Vand and includes the
two new partnerships. In order to improve community partnering and engagement, following companies: Applied Biomimetec,
and diversify their product offerings, they energy efficiency, energy generation Danfoss, DHI, Grundfos, Kampstrup, Leif
developed an exclusive partnership with and recovery, and nutrient and materials Koch A/S, Ramboll, Skytem and Smith
Swedish manufacturer EASY-LASER to recovery) and enabling participants across a Innovation. The alliance will provide a
promote and sell the next generation of broad range of capacities and capabilities to formal means for participating companies
precise, easy-to-use laser systems. Second, collaborate, learn and continue to evolve as to exchange information, expertise and
they have partnered with global ultrasound a unified sector. nacwa.org ideas. danfoss.com
technology provider SDT Ultrasound
Solutions to provide another product line Water Planet Software Evaluates Water Reuse Gains Momentum in
for leak and fault detection and optimized Feasibility of Treating Produced U.S. Amid Drought, Water Scarcity
bearing lubrication. ludeca.com Water for Irrigation BOSTON, Mass. – Water scarcity and
BAKERSFIELD, Calif. – IntelliFlux artificial drought continue to reshape the water
Ghalilah Desalination Plant intelligence-based software, developed by landscape, as demonstrated by the recent
Honored at Global Water Awards Water Planet Inc., is being used in a pilot increase in wastewater reuse projects in
CANONSBURG, Penn. – The Ghalilah project in Wasco, California, to evaluate the the U.S. Four states—Florida, California,
desalination plant in the UAE has been performance and economics of treating Texas and Colorado—now account for
honored at the 2016 Global Water Awards produced water for agricultural reuse. 95 percent of the development pipeline
with a Distinction Award in the Desalination The project, which is being done with that has surpassed 480 planned projects,
Plant of the Year category, which recognizes Sweetwater Tech Resources, utilizes Water according to a new market update from
plants commissioned in 2015 that represent Planet’s IMS-5000 Integrated Produced Bluefield Research. More than 400 of these
the most impressive technical achievement Water Treatment Solution powered by systems are slated for completion by
in the industry. In partnership with The IntelliFlux. The IMS-5000 technology used 2030, accounting for more than 6.7 million
Federal Electricity and Water Authority in the pilot is an integrated mechanical m3/d of reuse capacity, or $13 billion in
(FEWA) of the UAE, Aquatech completed and membrane filtration system that infrastructure investment, according to
the design, construction and commission incorporates ceramic membranes to filter Bluefield’s latest analysis. Just in the last
of the 15-MIGD plant, which is in the the water. waterplanet.com six months, Bluefield has identified 42
Emirate of Ras Al Khaimah. It is FEWA’s newly commissioned reuse systems.
largest desalination plant to date. Danfoss Joins Strategic Alliance bluefieldresearch.com
aquatech.com Between Denmark & US to Help
Solve Water Crisis Zoeller Expands Headquarters
Water Sector Groups Launch NORDBORG, Denmark – On April 4, Danish to Enhance Education
Utility of the Future Today Minister for Higher Education and Science LOUISVILLE, Ky. – Zoeller Company
Recognition Program Ulla Tørnæs inaugurated a new cross- recently opened a $4 million expansion at
WASHINGTON – A partnership of water Atlantic partnership, the Water Technology its headquarters in Louisville, Kentucky.
sector organizations—the National Alliance (WTA) California, in San Francisco, This latest addition, called The Center for
Association of Clean Water Agencies, California. The aim of the cross-Atlantic Excellence, underscores the company’s
the Water Environment Federation, the partnership is to share knowledge and dedication to providing quality products
Water Environment Research Foundation to develop water technology solutions and services and a place for its employees
and WateReuse, with support from the targeting the current water crisis caused and customers to learn about the pump
U.S. Environmental Protection Agency— by climate change. A number of Danish industry. The 6,000-square-foot addition
announced a new Utility of the Future companies, including Danfoss, have formed houses a state-of-the-art training space
(UOTF) Today Recognition Program. The the California-based alliance, supported by with classroom and hands-on laboratory. In
program will celebrate the progress and The Danish Industry Foundation and the addition, Zoeller Company’s research and
exceptional performance of the nation’s Danish Trade Council in Chicago, to serve development department will expand to
wastewater utilities while supporting the as the foundation for a close partnership occupy about 5,000 square feet.
widespread adoption of the innovative between Danish and American companies, zoeller.com
UOTF business model. The UOTF concept
was introduced in 2013 to guide utilities
toward smarter, more efficient operations
and a progression to full resource recovery
MERGERS & ACQUISITIONS
with enhanced productivity, sustainability Halliburton & Baker Hughes terminate the ANA ANA IMEP S.A., a Romanian appliance
and resiliency. The UOTF Today Recognition merger agreement they entered into in motor manufacturer. April 22, 2016
Program will celebrate these November 2014. April 30, 2016
WEG announces acquisition of Bluffton Motor
Nidec to acquire 94.8 percent of the shares of Works. March 31, 2016
To have a news item considered, please send the information to Amelia Messamore, amessamore@cahabamedia.com.

11
EVENTS
Gas Power 2016
June 7 – 8, 2016
The Westin Galleria & Westin Oaks Houston
Houston, Texas
312-924-3730 / worldarena-corp.com/index.php/
gas-experts-2016-texas-programme
2016 EASA Convention

June 12 – 14, 2016
Metro Toronto Convention Centre
Toronto, Ontario
314-993-2220 / easa.com/convention
National Fire Protection Association (NFPA)

Conference & Expo
June 13 – 16, 2016
Mandalay Bay Convention Center
Las Vegas, Nevada
800-344-3555 / nfpa.org/training/conferences/
conference
Aquatech China 2016

June 15 – 17, 2016
National Exhibition & Convention Center
Shanghai, China
+86-21-332 313 00 / aquatechtrade.com/china
American Water Water Association Annual

Conference and Exhibition (AWWA-ACE)
June 19 – 22, 2016
McCormick Place
Chicago, Illinois
800-926-7337 / awwa.org/conferences-education/
conferences/annual-conference.aspx
World Nuclear Exhibition

June 28 – 30, 2016
Paris Expo - Le Bourget, Hall 2B
Paris, France
33 147 56 65 37 / world-nuclear-exhibition.com
INDOWATER 2016
July 20 – 22, 2016

Grand City Convex
Surabaya (East Java)
+49-40-3999905-0 / indowater.com
The Water Expo 2016 – 5th Edition

August 31 – September 1, 2016
Miami Airport Convention Center
Miami, Florida
305-412-3976 / thewaterexpo.com
12 TRADE SHOW PREVIEW
Preview: 2016 EASA Convention

June 12-14, 2016
Metro Toronto Convention Centre
Toronto, Ontario, Canada
T
he 2016 EASA Convention in Toronto will focus on its theme of E3: Educate, Experience and Engage. EASA Board
Chairman Mike Dupuis said the gathering’s goal involves educating attendees through many sessions at the
conference and offering them the chance to experience “what’s new in the industry” with more than 160 exhibitor
booths at the conference.
“Besides a terrific location, this year’s convention offers a host of outstanding sessions and speakers, the industry’s
largest display of products and services, and loads of opportunities to network with fellow members,” Dupuis said in a
letter to conference attendees.
EASA is the Electrical Apparatus Service Association Inc., an international trade organization representing more than
1,900 electromechanical sales and service firms in 62 countries. This year’s gathering offers pre-convention educational
sessions on June 11, but the conference’s full range of events and activities happen June 12-14.
About two dozen industry leaders are scheduled to speak at various conference events. This year’s keynote address will
be delivered by motivational speaker Sam Glenn at 11:45 a.m. on June 12.
Attendees are encouraged to visit the New Product Theater in the
exhibit hall to learn about the latest products and services from a select
group of exhibitors during 30-minute sessions at various times each day. Exhibition Hours
The 2016 EASA Convention takes place at Metro Toronto Convention Sunday, June 12 1 p.m. - 4:30 p.m.
Centre. For more information about the schedule of events, registration Monday, June 13 12 p.m. - 4 p.m.
and exhibitors, visit the event’s website at easa.com/convention. Tuesday, June 14 9 a.m. - 12 p.m.
Preview: 2016 NFPA

Conference & Expo
June 13-16, 2016
Mandalay Bay
Las Vegas, Nevada
L
abeled as the most comprehensive industry event for fire, electrical and building safety, the annual Conference
& Expo for the National Fire Protection Association (NFPA) is June 13-16 in Las Vegas, Nevada. The event draws
thousands of professionals ranging from building managers and contractors to public fire service and enforcement
agencies to share their knowledge and experience.
This year’s conference features nearly 140 education sessions and hundreds of product displays from the industry’s
leading suppliers. Attendees can learn from industry experts, earn continuing education units, evaluate products,
network with peers and stay current with technological advances.
A new feature at this year’s event is the Discovery District, which
offers attendees a chance to check out new and emerging technologies Exhibition Hours
impacting the world of fire safety and protection. Monday, June 13 4 p.m. - 8 p.m.
For more information about the conference including details about Tuesday, June 14 11 a.m. - 4 p.m.
the schedule of events and registration, visit nfpa.org/training/ Wednesday, June 15 10 a.m. - 2 p.m.
conferences/conference.

Another Vanton AdVantage
The Vanton Pump Technical Library

If you’re pumping corrosives, handling aggressive or ultrapure fluids,
need to eliminate product contamination, or ensure compliance with
environmental regulations, Vanton’s line of Thermoplastic Pumps
provides solutions to answer virtually every concern.
Most questions are addressed in our

Technical Library in scores of
articles on a wide range of
pumping issues. Just scan the
QR Code below and we’ll
transport you directly to
our archives. Of course
we’re always available
to discuss your specific situation.
Just call us at 908.688.4216

…and think of it as
another Vanton AdVantage.
vanton.com
PUMP & EQUIPMENT CORPORATION
Sump-Gard® Chem-Gard® Flex-I-Liner® Pump/Tank

Vertical Centrifugal Horizontal Centrifugal Rotary Peristaltic Non-metallic
Pumps Pumps Pumps Systems
14 PUMPING PRESCRIPTIONS
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
Eight-Year Study Reveals Vital Knowledge

about Pump Reliability
Figure 1. Working copy of a pump performance curve (Graphics courtesy of
Editor’s note: Reg Christmas of the authors)
Kemira Chemicals Inc. contributed
to this column.
T
his column discusses the
results of an eight-year
TOTAL HEAD IN FEET
reliability study conducted at

a chemical plant. The plant uses six
horizontal split-case cooling water
pumps to provide cooling water
to the production facility. These
six pumps operate in banks of two
units, taking suction from three
cooling towers and feeding cooling
water to three plant processes:
• Crystallizer condenser (Cooling

Tower A feeding Pumps A and B)
• Process 3040 (Tower B feeding
Pumps C and D) to 6,500 gpm, depending on the a wide range of flow, sometimes
• Process 5060 (Tower C feeding process demand. As the study substantially too far to the left
Pumps E and F) showed, Pumps A and B operated, of the BEP and sometimes too
on average, at a higher flow than far to the right. As a result,
Company management wanted Pumps C through F. both cavitation (high flow) and
to evaluate the operation of The main indicator of reliability recirculation (low flow) were
the pumps with regard to their degradation, which typically concerns. The system went online
reliability and energy consumption. indicates a need for repair or in the 1990s, and the present
The eight-year pump reliability overhaul, is a significantly management inherited the problem
study began in 2008 and includes increased level of vibrations. To and wanted to find the most
the best economic use of the assess this parameter, the overall economical and practical solution.
installed equipment. The pumps are level of vibrations was measured Both vibration data and flow
12x10x12XL model 8100 (11.4- at four locations: inboard and are plotted as a function of time,
inch impeller diameter), driven by outboard bearing housings of as recorded in Figures 2 through
150-horsepower (hp) motors at the pumps and motors as well 7. The time axis represents each
1,775 revolutions per minute (rpm). as at horizontal, vertical and monthly recording.
axial directions at each position, Pumps are sitting on the ground
Evaluating Performance equaling a total of 12 data points level, approximately 5 feet above
As shown in Figure 1, the best per monthly test. The highest value the water supply level, so net
efficiency point (BEP) is at 4,800 of the 12 is plotted on the charts positive suction head available
gallons per minute (gpm) for the shown in Figure 3 (page 16). (NPSH A) is approximately 29 feet.
11.4-inch impeller. The actual flow As shown by the performance The performance curve in Figure
varies from approximately 1,500 curve, the pumps operate within 1 indicates that the pumps would

CAN YOU RECOGNIZE
A GOOD DESIGN?
HIDRACAR S.A.’s pulsation dampeners are designed down to the smallest detail by our engineering team.
Temperature fuse Anti-corrosion valve

security system that that prevents the charging
releases the gas inside valve to be attacked by the
the dampener in case of corrosive fluid in case of
external fire bellow breakage
P0 P2
Our PTFE bellows Our dampener only has
dampener takes into two parts in contact with
account the entire fluid – the PTFE bellows
volume for dampening and the nozzle piece in
functions to more PTFE, PVDF,... to ensure
compact, affordable chemical compatibility in
and lighter solutions your application.
for you.
P2
#7&RQVWDQW
P0
We specially designed the dampener to If ANSI flanges are required, we can integrate
prevent any deformation when pre-charged that into the dampener to provide you with
gas pressure is applied. compact and stable equipment for your system.
You will discover our bladder and membrane

designs in the next ad. Or visit:
Designing and manufacturing dampeners since 1974 www.hidracar.com

vibs-Ɵme A
2.00
1.80
1.60
occasionally run out of net the existing installations, field- 1.40
vibs, in/sec
positive suction head required recorded values are somewhat 1.20
1.00
(NPSHR) when operated beyond more liberal, with 0.30 in/sec 0.80
approximately 5,500 gpm. being the warning level and 0.60
0.40
Among the suggestions for 0.50 in/sec being the alarm 0.20
improvement was replacing level. No known studies exist, 0.00
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70
these split-case pumps with however, to correlate vibration
Ňow, gpm
vertical turbine pumps in order to failures because of the time
to increase NPSH A to more such studies would require
Ňow-Ɵme A
than 40 feet, with an impeller/ to accumulate reasonable
7000
bell of the vertical pump statistical data to quantify the
6000
positioned about 6 feet below theory. The eight-year study
the water level. The cost of this discussed in this column is 5000
Ňow, gpm
change was evaluated against among the first of its kind 4000
present maintenance. and presents quantifiable, 3000
The following observations albeit perhaps limited, data 2000

can be made from analyzing on correlation between the 1000
the eight-year data shown in measured vibrations and 0
Figures 2 through 7: failure rate (MTBF or MTBR). 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70
Because of this lack of Ɵme
• Pumps A and B operate, information, a common plant

on average, (disregarding strategy was to replace the Figure 2. Vibrations and flow with time for Pump A
occasional abnormalities) rotors when a substantial
toward higher flow as change in vibrations was
compared with Pumps C observed. That level was
through F. Pumps A and significantly higher than the vibs-Ɵme B
B operate between 2,000 typically recommended values 2.00
of vibrations usually suggested 1.80
and 6,000 gpm. Pumps C
1.60
through F operate between by theoreticians. For example: 1.40
vibs, in/sec
2,000 and 4,000 gpm. 1.20

1.00
While far from perfect, • Pump A shows two
0.80
this data implies that substantial spikes in 0.60
Pumps A and B operate, on vibrations (near time 55 0.40
0.20
the average, closer to the and time 67) where the
0.00
BEP, so they are expected rotors were replaced, 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67
to have better reliability. resulting in a significant Ňow, gpm
• There seems to be no decrease in vibrations
clear correlation between until the next large spike, Ňow-Ɵme B
vibration and flow, resulting in another rotor 7000
meaning there is no replacement. 6000

correlation between failure • Pump B shows spikes at 5000
rates and flow. times near 22 and 46.
Ňow, gpm
4000
• Pump C shows spikes at
3000
The traditionally accepted times near 13, 43, 55
and 64. 2000
vibration levels for pumps are
well-known and, depending • Pump D shows spikes at 1000
on pump size and type, are times 43, 46 and 52. 0

1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67
roughly below 0.20 inches per • Pump E shows spikes at
Ɵme
second (in/sec) (rms values) times 43, 52 and 67.
and are usually understood to • Pump F shows spikes at Figure 3. Vibrations and flow with time for Pump B
apply to new installations. For times 27, 33 and 43.

vibs-Ɵme C
2.00
1.80
1.60
Based on this information, on bearings, causing eventual 1.40
vibs, in./sec
1.20
there were 17 rotor changes in failures. However, these forces
1.00
eight years, with an average are largely unnoticed because 0.80
of two changes for groups A vibration levels typically do 0.60
through B and three to four not change much as a function 0.40
0.20
changes for groups C through of flow.
0.00
D. Therefore, the pumps Additional studies on these 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64
operated at flows farther to the pumps (not reported in this Ɵme
left of the BEP and had more column) showed that throttling
frequent repairs, roughly 1.5 the discharge valve from BEP Ňow-Ɵme C
to 2 times more often. Thus, to zero (shut valve condition) 7000
there does appear to be a direct increased vibration by about 6000
correlation between the flow 10 to 15 percent (for example, 5000
and (measured/quantified) from 0.40 in/sec to 0.45 in/
Ňow, gpm
4000
reliability (not simply between sec). This is essentially within 3000
flow and vibrations). statistical error of month-to- 2000
The above statistics seem to month measurements. While 1000
support the following theory: not easily observed by vibration
0
Internal forces acting on a rotor spot testing, the internal forces 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64
increase substantially as flow do cause damage internally. Ɵme
moves farther to the left, away From an economic
from the BEP. These forces act standpoint, the cost of the Figure 4. Vibrations and flow with time for Pump C

19
vibs-Ɵme D vibs-Ɵme E
2.00 2.00
1.80 1.80
1.60 1.60
1.40 1.40
vibs, in/sec
1.20
vibs, in/sec
1.20
1.00 1.00
0.80 0.80
0.60
0.60
0.40
0.40
0.20
0.20
0.00
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 0.00
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67
Ɵme
Ɵme
Ňow-Ɵme D Ňow-Ɵme E
7000
7000
6000
6000
5000 5000
Ňow, gpm
Ňow, gpm
4000 4000
3000 3000
2000 2000
1000 1000
0 0
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67
Ɵme Ɵme
Figure 5. Vibrations and flow with time for Pump D Figure 6. Vibrations and flow with time for Pump E

vibs-Ɵme
vibs-Ɵme FF ŇŽǁ-Ɵme FF
2.00 7000
1.80
6000
1.60
1.40 5000
vibs, in/sec
Ňow, gpm
1.20 4000
1.00
0.80 3000
0.60 2000
0.40
1000
0.20
0.00 0
1 3 5 7 11 15 19 23 27 31 35 39 43 47 51 55 59 63 1 3 5 7 11 15 19 23 27 31 35 39 43 47 51 55 59 63
Ɵme Ɵme
Figure 7. Vibrations and flow with time for Pump F
rotor, including labor, is about As a result, the failure of the References

$119,000 ($7,000 x 17) for eight vertical turbine pumps would have 1. Nelik, L., “Energy/Efficiency Studies by
On-Line Efficiency Monitoring System
years, or $15,000 per year. been more frequent, and the cost (PREMS-2A), doctorpump.com
The cost of a typical double- of repair would have been greater 2. Nelik, L. and Moskovich, D., “Efficiency
suction pump of this size is roughly than that of a double-suction Evaluation for the Vertical Turbine
$15,000, while a similarly rated pump rotor. Pump, Clean Water Well”, Weizmann
vertical turbine is usually double An obvious culprit of this issue Institute reports
3. Pumping Machinery Technology
that, about $30,000. is a wide variation of flow. The total Program, PREMS-2A (Pumps Reliability
Because the new motors would maximum flow demand (assuming and Energy Monitoring System):
need to be used, the total unit 6,000 gpm as maximum) is pumpingmachinery.com/pump_school/
cost of the vertical turbine pump 36,000 gpm (6,000 x 6). If piping PVA/pva.htm (module #11 and #10)
would have been about $40,000, or could be modified, and perhaps
$240,000 for all six pumps. Adding variable frequency drives (VFDs)
to this installation cost, the total implemented, the flow could be
project would likely cost around controlled and maintained to
For more columns by
$350,000. always be at the BEP, with the VFD Dr. Lev Nelik, visit
If piping modifications are to varying the BEP. However, this pumpsandsystems.com/
be included (to even the flow), the setup would raise two concerns: tags/lev-nelik
grand total project cost would be cost and reliability because of a
nearing half a million dollars. Th at new need to maintain and service
would imply a payback time of 23 the controls.
years ($350,000/$15,000)— While such a system can, in
clearly not a good number, even theory, provide smoother operation
if the installed vertical pumps and fewer failures, the cost of Dr. Nelik (aka “Dr. Pump”)
never fail. implementation is substantial. is president of Pumping
However, by nature of the However, this setup cannot be Machinery LLC, an Atlanta-
design, vertical turbine pumps ruled out completely, because the based firm specializing in pump
are generally not more reliable cost analysis of alternatives must consulting, training, equipment
than double-suction split-case be considered. troubleshooting and pump
pumps, which have two bearings The authors would like to extend repairs. Dr. Nelik has 30 years
rigidly supporting the rotor on their appreciation to the company of experience in pumps and
two ends. Vertical pumps, having management for permission to pumping equipment. He may
a long cantilever design, have a publish this information, and they be reached at pump-magazine.
slender rotor, which is susceptible would be pleased to hear feedback, com. For more information, visit
to deflections and damage when questions and any comments from pumpingmachinery.com/pump_
operating at flow rates even slightly readers about the information in school/pump_school.htm.
off the BEP. this report.

22 PUMP SYSTEM IMPROVEMENT
A better understanding of complete system operation
By Ray Hardee
Engineered Software Inc.
More Than One Way to Fix a System
Figure 1. The example piping system

(Graphics courtesy of the author)
M
y longtime readers know
that a piping system is
made of three parts: the
pump elements, process elements
and control elements. The pump
elements add all the energy needed
to move the fluid through the
system; the process elements make
the product or provide the service;
and the control elements improve
the product or service quality. Table 1. Power cost balance sheet for the spray system prior to system
Understanding how these improvements
various elements work together Element Energy addition/use Power cost (existing
provides a clear picture of how the (feet of fluid) condition)
system works. Pump elements 213.3 $25,972
This month’s column will use this
Process elements 141.9 $17,280
approach to improve the operation
of a typical process system. The Static head 31 $3,775
system in this example consists Pipelines 87.6 $10,663
of a stock tank, spray pump, spray Spray nozzle 23.3 $2,842
control valves and a spray nozzle, Control elements 71.4 $8,692
as shown in Figure 1.
The purpose of the system is In this example, I was working the spray pump, powered by
to apply a stream of fluid onto with a paper mill plant utility a 75-horsepower (hp) motor,
a moving screen. The flow rate engineer to find ways to reduce operates continually, and it is
through the system is a function of energy consumption and improve an easy system to understand.
the speed of the traveling screen. operations within the facility’s In addition to reducing energy
At the current production rate, the pumped systems. Th is system set consumption, the user wanted to
flow rate through the system is 600 was the first project chosen for know the reason for cavitation in
gallons per minute (gpm). energy use evaluation because the spray control valve.
Table 2. Comparison costs of reducing impeller speed by incorporating a VSD and reducing impeller diameter
Element Head loss (feet) Reduce impeller speed Reduce impeller
with VSD diameter
Pump elements 175 $21,584 $20,952
Process elements 141.9 $17,503 $16,991
Static head 31 $3,823 $3,711
Pipelines 87.6 $10,801 $10,485
Spray nozzle 23.3 $2,879 $2,794
Control elements 33.01 $4,081 $3,961

24 PUMP SYSTEM IMPROVEMENT
The key to any system improvement savings for the proposed improvements. The power cost balance sheet for each
program is to first understand how In previous columns, I discussed the element in the sample system shows
much the system costs to operate. concept of the power cost balance the energy added or used by the various
Then, each item in the system can be sheet, which shows how much it costs elements, along with the annual cost
evaluated to determine available cost to operate each item in a piping system. of pumping power. The calculations
used to develop Table 1 (page 22) can be
found on the Pumps & Systems website
at pumpsandsystems.com/fi xasystem.
Table 1 shows the energy consumed
by each item in the system in feet
of fluid, along with the annual cost
of operation. At 600 gpm, the pump
produces 213.3 feet of fluid and costs
$25,972 per year to operate.
Of that total, the process elements
have a head loss of 141.9 feet of fluid
and an annual operating cost of
$17,280. The control elements have a
head loss of 71.4 feet of fluid and an
annual operating cost of $8,692. Based
on this information, we can see that the
energy supplied by the pump elements
equals the energy used by the process
and control elements.
We will use the items listed on
the power cost balance sheet to
determine ways to improve the system.
First, we will look at the price of the
control elements.
The head loss across the control
valve is 71.4 feet of fluid. The fact
that the control valve is a ball-style
valve is probably why the valve is
experiencing cavitation. The control
valve supplier suggested that the plant
reduce the differential pressure across
the control valve. A value of 15 pounds
per square inch differential (psid)
was recommended to reduce energy
consumption while eliminating the
problem with cavitation.
To reduce the excess pressure across
the spray control, the user must reduce
the amount of head developed by the
pump. This can be accomplished by
either reducing the diameter of the
spray pump impeller or by reducing the
rotational speed of the spray pump by
installing a variable speed drive (VSD).
Table 2 (page 22) shows the results for
each option.

25
We can see from the power cost

balance sheet that the pump with the To see the calculations used to
VSD costs slightly more per year to develop the power cost balance sheets
referenced in this column, visit
operate than the pump with the reduced pumpsandsystems.com/fixasystem.
impeller diameter. That is because the
pump with the VSD must account for
the additional losses of the VSD (which
is 97 percent). This higher pumping cost
that results from using the VSD is the
reason for the higher costs for both the
process and control elements.
At this point, you may wonder why
anyone would want to use a VSD when
trimming the impeller is the least
expensive option in this example.
The answer is that pump speed can be
easily varied, while an impeller, once
trimmed, cannot be varied.
In this system, the efficiency of the
pump operating at the slower speed
was less than 1 percent more efficient
than the reduced impeller trim. In most
cases, reducing the impeller diameter
and pump speed has a greater effect
on efficiency.
Minimizing the head loss across
the spray control valve by adjusting
the energy that the pump puts into
the system will reduce the power cost
in this system. The lower pressure
A World Class Provider of
drop across the spray control valve
eliminates cavitation within the valve,
Fluid Sealing Solutions
which reduces maintenance costs for
the control valve.
Next month’s column will look at
how the operating costs of the system
can be reduced with a VSD by making
modifications to the system.
Ray Hardee is a principal founder of

Engineered Software, creators of PIPE-FLO
and PUMP-FLO software. At Engineered
Software, he helped develop two training
courses and teaches these courses
internationally. He may be reached at ray.
hardee@eng-software.com.
26 COMMON PUMPING MISTAKES
Simple solutions for end users
By Jim Elsey
Summit Pump Inc.
Understanding Pump Curves
I
n my last column (“Tips for Proper Pump
Selection,” Pumps & Systems, May 2016), I 10 QUICK TIPS ON PUMP CURVES
briefly mentioned “drooping curves” and
stated that I would spend time in a future article
discussing the subject. 1 The curve shape for a given pump is mostly a function
of the impeller specific speed (Ns). In general, the
lower the specific speed of an impeller, the flatter
A drooping curve is a characteristic head-flow the curve will be. In other words, high-head, low-flow
performance pump curve that does not continually pumps will have flatter curves than high-capacity,
rise when moving from the best efficiency point low-head pumps.
(BEP) back to shutoff. In fact, the curve reaches
a high point prior to zero flow, then declines
as it approaches shutoff. Just as misinformed 2 Typically, the more vanes an impeller has, the flatter
the curve will be.
discussions have led to a notion that pumps with
suction specific speeds (Nss) above 11,000 should
be avoided, pumps with drooping curves have been
3 Adding an inducer (impeller suction side) has a similar
effect to lengthening the impeller vane leading edges
and can steepen the curve.
incorrectly outcast to the pump graveyard.
A pump with a drooping curve could rapidly
“hunt” or oscillate (fluctuations in pressure and
4 Adding a discharge orifice to the pump can steepen
the curve.
flow resulting in instability) when operated in

certain ranges—in other words, it is unstable.
Because there are now several operating points to
5 Over- or under-filing (removing existing material on
one side of the vane) on the impeller can change the
shape of the curve. Over-filing rarely has predictable
cover, the pump does not know where to operate, results, but under-filing is a commonly acceptable
technique in the industry.
and it tries to meet both conditions, usually failing
in the attempt.
Many industry standards and end-user
specifications require that the pump performance
6 Changing the cutwater location, usually removing
material, will affect the curve shape. The BEP will
move to the right, but efficiency will be compromised.
head curve continuously rise from the
rated condition point (or BEP) as the flow is
simultaneously reduced to zero. These are referred
7 Changing the impeller vane discharge angle or width
will affect curve shape.
to as “stable curves.” It is common to state the

minimum acceptable increase, which is usually
8 percent for a single pump and 10 percent for
8 Trimming the impeller outer diameter at a calculated
angle will change the curve shape. For example, for a
back pull-out or overhung pump, the impeller shroud
pumps in parallel operation. To put it another that is on the suction side will be a larger diameter
way, the curve has a negative slope as it moves to than the back shroud.
the right from the zero flow shutoff point to the
rated condition point, which should be in the best
operating range for the pump.
9 A pump with a drooping curve will probably be more
efficient than one of the same size with a constantly
rising curve.
In many cases, a continuously rising curve is a
good decision, but it is not always required.
A centrifugal pump is a simple machine and
10 Some pump curves may show a droop as the pump
approaches shutoff, but the phenomenon may
actually be the result of non-compensated changes
will operate on its performance curve at the in the fluid density overlooked by the manufacturer,
intersection of the system resistance curve, if it is rather than a function of impeller geometry.
possible for the pump to operate at that junction.

28 COMMON PUMPING MISTAKES
The intersection of system curve imposed often exceed the strengths If your system requires that the
and pump curve may not match the of the components. operating point cover a wide range,
manufacturer’s published curve for This scenario is compounded a continuously rising curve will
several reasons, including worn or when the system has an open be better. Many boiler feed pumps
incorrectly set clearances, a liquid design, in which the pump is operate with relatively fl at curves,
with viscous properties (fluids supplied by an open tank or other not drooping curves, with only a
other than water), or a different source and then pumps to an slight rise to shutoff. Part of the
speed or diameter. Another reason open system. When the pump is reason this is feasible with boiler
may be that the system resistance supplying a closed system, such as feed pumps is that the boiler is
curve was not correctly calculated. a pressurized tank or boiler, the not an open system and the boiler
A centrifugal pump will supply pressure from the closed portion pressure acts like a shock absorber,
the flow rate that corresponds to acts like a shock absorber and accumulator or dampener.
the system friction, also referred mitigates the harmful effects. If you operate centrifugal pumps
to as the resistance (resistance in parallel, then the pump curves
curve). A pump with a drooping Possible Catastrophe must continuously rise to shutoff.
curve will intersect the system Several decades ago, I saw a pump Industry practices recommend that
resistance curve (SRC) once, but with a 40-inch discharge and the rise be more than 10 percent,
that corresponding value of head drooping curve destroy itself and and I strongly advise that the
(pressure) may occur twice on the system piping in just a few rise for each pump be as close to
the pump curve—that is, once at minutes of operation. I estimate identical as possible.
the SRC intersection and again that the rated flow on that pump References
at another point where the curve was 50,000 gpm. Th is catastrophic Pump Users Handbook – Life Extension, Allan
droops to that same value. The effect was not caused by a drooping R. Budris and Heinz P. Bloch
The Pump Handbook, 4th edition. Paul Coo-
pump will valiantly attempt to curve but by improper design and
per, Charles C. Heald, et al
meet both points of flow for the operation. Note that this system Temperature Measurement at Low Flow on
same head requirement. There may was an open design; it was pulling Typical ANSI Chemical Process Pumps,
be a large flow difference between “makeup” water from a lake to an David W. Lawhon, et al. Proceedings
the two points. For example, open cooling pond. of the 17th International Pump Users
Symposium 2000
the pump head curve initially Globally, tens of thousands of
Centrifugal Pump User’s Guide, Sam Yedidiah
intersects the system curve at 340 centrifugal pumps operate reliably
gallons per minute (gpm), but the and efficiently with drooping
head (pressure) also corresponds curves. These perform well because Jim Elsey is a mechanical
to a point at 100 gpm. Note both the system curve and the operating engineer who has focused on
flow rates would have the same curve intersect at a condition point rotating equipment design and
total head (or pressure) point. The in a safe region, where oscillations applications for the military
difference in flow rates is 240 gpm. and fluctuations are not created and several large original
Assume the pumped fluid is by a pump trying to operate equipment manufacturers for
water with an approximate weight simultaneously at two points. 43 years in most industrial
of 8.33 pounds per gallon, which The head capacity curves of markets around the world. Elsey
yields a weight (mass) difference many vertical turbine pumps, is an active member of the
of 2,000 pounds, or 1 ton. While with specific speeds typically near American Society of Mechanical
trying to meet both flow rate 8,000, have small hairpins or dips Engineers, the National
conditions, the pump could at points away from the BEP. This Association of Corrosion
experience oscillations several characteristic shape is also known Engineers and the American
times a minute or even every few as discontinuous head. Society for Metals. He is the
seconds. Now imagine this ton of A resistance curve with mostly general manager for Summit
water speeding up and slowing friction components but little static Pump Inc. and the principal of
down and changing direction or pressure head will intersect the MaDDog Pump Consultants LLC.
every 5 seconds or less, and you pump curve at a higher angle than Elsey may be reached at jim@
understand why this is a condition a curve with mostly static head but summitpump.com.
you want to avoid. The forces little friction head.

30
SPECIAL REPORT
3 Cybersecurity
Best Practices
Understanding these strategies is critical for building a solid
foundation for a secure and productive enterprise.
BY DANA PASQUALI
GE OIL & GAS DIGITAL SOLUTIONS
connectivity and data transmission,
I
n the past year, sophisticated cybersecurity attacks
have demonstrated that a multitude of industries companies must not only manage the
and organizations are at risk. Given the increased input from various field networks but
connectivity and associated risks, companies and also maintain secure processes across
plants from all industries must be aware of how each remote connections.
of their assets and actions impacts the security of their Any organization operating with multiple
networks. Implementing advanced security technologies networks and various security requirements
and practices is essential to a secure operation. For should prioritize the top two concerns—
organizations with industrial control systems (ICSs), safety hazards and unplanned shutdowns—
including those in the power generation and oil and gas and determine best practices to prevent them,
industries, this is particularly critical. including assessing current posture, establishing
While the control network is a top operational priority, centralized management and visibility, and increasing
processes are tightly tied to many interactions with employee awareness.
other networks, which can be infi ltrated by a significant
breach in an external—or even internal—system. Field Threats to Safe, Reliable Operations
devices and pump systems, which are often distant Cybersecurity is primarily aimed at keeping process
from the central control systems, pose even more risks controls stable and preventing unanticipated changes.
by increasing the overall attack surface. Process control Cybersecurity incidents typically cause loss of view,
networks represent higher-risk technologies simply control, operation or production, with different levels
because they can be highly coupled. Being highly coupled, of consequence to an organization. The intersection of
or interconnected, increases the likelihood of a lower- operational technology (OT) and information technology
level incident cascading into a higher-level event. As a (IT) has improved efficiencies, but it has also posed
result, cybersecurity measures must be designed to break greater risks.
down the coupling dependence so negative events become In the IT world, hacking a computer is unlikely to
more manageable. cause physical harm to the recipient of the attack, but
In the past, pumps did not pose a threat to the control in the OT environment, manipulating industrial assets
network inside the plant because they interfaced with through digital channels can cause serious damage. When
the physical world at “Level 0.” Today, however, pipelines cyberattacks cause loss of view, loss of control, or denial
and pumps are just as digital as the computers within the or modification of control, operators are no longer able
plant. New portable field devices and sensors can monitor to manage their process control networks and their most
movement, corrosion and impact to pump systems, as critical assets effectively and safely. This could lead to an
well as transmit a large magnitude of data. With increased inability to turn pumps on or off or monitor the pressure,
31
Image 1. In addition to safety threats, security breaches can

lead to costly unplanned downtime. (Courtesy of GE)
flow rate or chemical composition of the pumped more vulnerable areas of entry into the system. Security
medium. As a result, those assets become a safety hazard practitioners are less concerned about the number of
to the surrounding environment. attacks that come their way than they are about the
Similarly, loss of control over turbines or process attacker’s persistence or the duration an attacker can stay
equipment could have detrimental effects. In 2014, cyber on the network undetected.
attackers hacked the process control network of a German The longer an attacker is on the network, the deeper
steel mill and caused an explosion in a blast furnace that he or she is able to infi ltrate, send back data or cause
resulted in massive damage. significant damage.
The world of OT security is foundationally different Furthermore, many process control networks were
from traditional IT detection systems in existence today. installed 10 or more years before current technologies
Securing connected machines in the industrial sector has and cybersecurity solutions existed. Outdated technology
a unique set of complexities that are much different from exposes known vulnerabilities that, if compromised,
protecting a business datacenter. could cause loss of view, control or operations. Most
While safety is the top priority when it comes to the organizations also have multiple pieces of equipment
most aggressive cyberthreats, another potential side from various manufacturers and generations, which
effect of cyberbreaches is costly unplanned downtime. makes a unified security program difficult to implement
An oil and gas company, for example, calculated that and operate.
the failure of one of its control system’s human machine Even the latest technology tends to focus on
interfaces (HMIs) and the resulting downtime of two days operational efficiency rather than security. With a wide
would cost the organization an estimated $12 million in range of systems operating across legacy hardware
lost production. from remote locations, it is challenging for operators to
Field devices and pump systems transmit data to manage secure connections and keep even the simplest
the organization through the control system network. things such as passwords, antivirus tools and software
Attackers bypass the most secure layers and identify updates current.
32
Cybersecurity Best Practices

As technology continues to advance, pump professionals
must know the industry risks and their potential effects.
1 Assess current posture. As the saying goes,
“You don’t know what you don’t know.” The first
step of assessment is understanding gaps in security
Considering the following three cybersecurity best and being prepared to institute policies and procedures
practices will help end users develop a much stronger pertaining to people, processes and technologies. If you
security posture to ward off growing threats and ensure do not know where to start, standards are available based
business continuity. on industry and/or region to help provide best practices
for companies to create a baseline
security reference architecture
that meets their needs. The SANS
Mission SCADA Works Right Out Institute critical security controls
guidelines are a widely accepted
Of The Box, But Won’t Box You In resource for best practices.
2
Mission managed SCADA systems are Mission flexibility allows you to expand
designed to get you up and running in your system as you are ready and on your Centralize management
hours, not days. Our packages start at terms. Mix and match any of our products and visibility.
around $1,000 with a maintenance fee of one at a time or all at once, the choice is
less than $1 a day. Mission strives for yours. That is why you will find Mission All organizations should have
ease in doing business. Give us a try – no SCADA monitoring over 2,000 municipal- centralized management
bureaucratic red tape, no huge commit- ities across the U.S. and Canada. systems configured to ensure
ment. If you like it, buy it. If not, send it
back. It’s that simple. all access points are protected
and continuously monitored.
By running regular tests and
documenting updates and
configurations, operators are better
able to evaluate vulnerabilities
and keep track of threats entering
their systems. Operators can
log potential threats and send
notifications to the proper contacts
through a centralized system. In
In Sewer Level Alarm Lift Station Tank and Well Control
addition, centralized management
enables security experts to collect
and store system components,
indexing them for quick and easy
retrieval. This approach provides
clear accountability for any
security incident, unlike when
information is fragmented.
Centralized management can
also help support strong password
management and enforce role-
based access control, which
requires every user to have a
unique username and password
associated to a role. Restricting
remote access to a small number of
security expert operators reduces
the risk of privileged user threats
and remote access breaches,
particularly when threats extend
Advanced Monitoring • Low Cost • Managed SCADA across multilevel networks in
(877) 993-1911 • www.123mc.com the organization.
33
3 Increase awareness with training.

The greatest threats to the process control are
people whose lack of knowledge can result in negligence,
Dana Pasquali is the cybersecurity
product manager for GE Oil & Gas
accidents or ineffective processes.
Digital Solutions. She may be reached
Without the availability and enforcement of
at controlsconnect@ge.com.
informative training, employees will not have a
strong foundation of security awareness to guard their
daily behaviors.
Employee training should
shed light on unusual machine
behaviors or signals so that end
users can identify potential threats
immediately.
This is particularly important
in the field where there is
significantly less exposure to
and awareness of cybersecurity.
Field operators and technicians
must follow protocols regarding
the use of the wireless networks
that support their devices and
smart assets.
Ports, CDs/DVDs and USB
access must be hardened or locked
down so no personal devices can
be connected. Strict protocols
pertaining to personal devices
and data sharing should be
established to prevent introducing
vulnerabilities into the secure
network. Fostering awareness
about cybersecurity will help
mitigate internal risks.
As more technology is
introduced in the field, there is
greater need to validate secure
configurations and implement
strong segmentation to maintain
a reliable control system network.
Industrial organizations must
further understand the challenges
of and differences between
IT and OT to execute a strong
cybersecurity strategy.
As industrial organizations
place greater emphasis on
cybersecurity, they should rely on
industry standard best practices
and lessons learned to build a
solid foundation for a secure and
productive enterprise.
34
SPECIAL SECTION
INSTRUMENTATION, CONTROLS & MONITORING
Going Beyond
Switches for Pump
Health Monitoring
API Standard 682 recommends transmitters instead
of switches to monitor pump sealing systems.
BY BRIAN ATKINSON
EMERSON PROCESS MANAGEMENT
A traditional mechanical switch is not as effective as
R
eleased in May 2014, the fourth edition of the
American Petroleum Institute (API) Standard a transmitter because it can only provide an on/off
682 provides guidance for monitoring the signal. Unlike a transmitter, a switch cannot indicate
sealing systems used on pumps deployed in the distance from an alarm or set-point, so it cannot be used
petroleum, natural gas, chemical and related industries. to predict problems. Most switches do not have onboard
Pertaining to pump operations and maintenance, some diagnostics, making it difficult to know if the switch is
important aspects of API Standard 682 describe changes operating properly.
in instrumentation used to monitor pump auxiliary seal Smart transmitters allow for calibration, remote
flush systems. The new edition indicates a preference configuration and diagnostics, providing additional value
for continuous measurements using pressure and level and ease of maintenance.
transmitters instead of the prior practice of using Many facilities have limited existing wiring for
pressure and level switches. additional instrumentation, and often implementing
a wired monitoring solution is not feasible, especially
Pump Problems considering the safety requirements of installing the
Because of the costs associated with monitoring pumps necessary wiring in an operating process plant. Wireless
using wired instruments, often only a small percentage sensors provide an economically viable option that can be
of a typical process facility’s pumps are monitored easy and relatively inexpensive to implement.
online. Many pumps are inspected only periodically by
operations or maintenance personnel on field rounds. Seal Flush Piping Plans
As a result, the majority of process pumps operate API Standard 682 defines piping plans and various types
without continuous monitoring, increasing the risk of of sensors and controls for pump auxiliary seal flush
unanticipated failures, leaks, fires and other potentially systems. Although the standard defines several plans, the
dangerous situations. most significant in this context are Plans 52 and 53 A, B
In addition, most pump auxiliary seal flush systems and C.
have limited online measurements. Their traditional These cover dual mechanical seals with a flush fluid for
inspection approach involves manual monthly checks in lubrication and cooling. In all plans, heat is removed by
the field and the use of switches to detect low level, high cooling water coils in the reservoir or by circulating the
pressure or high temperature. flush oil through finned tubes.

35
Figure 1 (left). API 682 recommends use of a pressure transmitter (A) and a hydrostatic level transmitter (B) for Plan 52 and 53 A systems.
Figure 2 (middle). For Plan 53 B, API 682 recommends pressure transmitters (A) and temperature transmitters (B) to monitor the
circulating flush fluid temperature.
Figure 3 (right). Plan 53 C instrumentation includes a differential level of the piston pressure transmitter (A), a differential pressure flow
transmitter to monitor circulating flush fluid (B) and a temperature transmitter (C). (Graphics courtesy of Emerson Process Management)
A
A B
B
A A
If an existing facility is upgrading its mechanical seals For the unpressurized system defined in Plan 52 (see
from single to dual, then it may select either Plan 52 Figure 1), API 682 recommends using pressure and level
(unpressurized) or one of the three pressurized plans—53 transmitters. The level transmitter provides a low-level
A, B or C—for the auxiliary seal flush system. All four alarm in all cases, and a high-level alarm is specified for
plans need instrumentation to monitor the level, pressure cases where the pumped fluid is still in the liquid phase at
or temperature in the seal flush reservoirs. atmospheric pressure (non-vaporizing).
For existing process units, there may be insufficient Plan 52 is designed to keep the buffer liquid at a
spare wires in the vicinity to deliver these measurements pressure less than the seal chamber pressure, which is
to a control room or other location, making wireless typically intended to be less than 40 pounds per square
sensors an attractive option. inch gauge (psig), or 276 kilopascal (kPa). The pressure
The objective of the API Standard 682 committee for signal has a high-level alarm that indicates when the
the fourth edition was to make recommendations for leakage rate of the vaporizing pumped fluid into the
continuous seal system operation for at least three years reservoir increases to the point where the pressure
(25,000 operating hours). Other objectives were increased accumulates to above the high-pressure alert setting.
availability and simplified maintenance. Vaporizing fluid will increase the reservoir pressure as
API Standard 682 gives users several options for more flow passes through the restriction orifice to the
selecting instrumentation to achieve these objectives. fl are or vapor-collection system.
The current edition gives preference to using indicating Plan 53 A defines a pressurized system using an
transmitters for pressure and level measurements rather external source of pressurization such as nitrogen. Plan
than on/off switches. 53 A recommends a pressure and a level transmitter
With indicating transmitters, wired instruments or instead of pressure and level switches, as it does for Plan
wireless sensors, field personnel can visually monitor 52. The level transmitter is specified with a low- and a
operating parameters at the equipment, and operators high-level alarm.
can view the same data in a control room. Data from The reservoir pressure must exceed the seal chamber
transmitters can be analyzed to predict problems before pressure by a minimum of 20 pounds per square inch
they occur—for example, watching a trend as a measured (psi), or 138 kPa. If the reservoir pressure is less than the
value approaching an alarm point. Predicting failures seal chamber, the normal leakage flow direction across
allows maintenance to happen prior to a breakdown. the inner seal will be reversed. The barrier liquid may
36 SPECIAL SECTION INSTRUMENTATION, CONTROLS & MONITORING
become contaminated with the process liquid, Figure 4: This example of a comprehensive pump health monitoring system uses a
possibly creating a hazardous barrier liquid and wireless pressure transmitter to check cavitation (A), as well as wireless vibration (B),
increasing the possibility of seal failure. strainer plugging (C), temperature (D), hydrocarbon leak (E) and seal fluid level (F)
transmitters.
A low-level alarm indicates that it is time to
refi ll the reservoir or that a leak has occurred in
the outboard seal on the atmospheric side. For A Cavitation
Plan 53 A, the pressure should be sufficiently B Vibration

high, while low pressure will be an alarm
C Strainer Plugging
condition, indicating loss of the external source of
pressurization gas. D Temperature
Plan 53 B defines systems with an accumulator
bladder that maintains pressure (see Figure 2, page E Hydrocarbon Leak
35). The reservoir is completely fi lled with barrier Seal Fluid Level
F
liquid, so no level measurement is required.
Leakage past the inner and outer seals results in
a decrease in flush system pressure. This requires
the barrier system to be pressurized to a higher can vary considerably from night to day and with seasonal
initial pressure and allowed to slowly depressurize to changes, a fi xed low-pressure alarm setting on a cold day
the minimum allowable system pressure. The system is can indicate that it is time to refi ll the reservoir before it
then refi lled to restore the maximum working barrier is really necessary.
liquid volume. On hot days, the accumulator pressure may still
The low-pressure alarm indicates that it is time to refi ll be above the low-level alarm setting, even when the
the reservoir or possibly that an outboard seal failure has inventory of flush fluid is depleted. As a result, the fourth
occurred. Because the ambient temperature in a refi nery edition specifies a low-pressure alarm set-point that is a
PROTECT PUMPS
$2925..).'s#A6)4!4)/.s"%!2).'&!),52%s/6%2,/!$
MONITOR PUMP POWER COMPACT EASY MOUNTING

s"EST3ENSITIVITY /NLYXX
s$IGITAL$ISPLAY s3TARTER$OOR s0ANEL
s2ACEWAY s7ALL
TWO ADJUSTABLE SET POINTS
s2ELAY/UTPUTS UNIQUE RANGE FINDER SENSOR
s!DJUSTABLE$ELAY4IMERS s7ORKSON7IDE RANGEOF-OTORS
s3IMPLIlES)NSTALLATION
4-20 MILLIAMP ANALOG OUTPUT
WHY MONITOR POWER INSTEAD OF JUST AMPS? PUMP POWER

VALVE CLOSING
POWER
PUMPING
AMPS
VALVE OPENING NO FLUID

No Sensitivity
Power is Linear-Equal Sensitivity For Low Loads
at Both Low and High Loads
NO LOAD FULL LOAD NO LOAD FULL LOAD
CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247

WWW.LOADCONTROLS.COM
37
function of the current ambient temperature and of the Once the pump seal flush system is equipped with
pressure and temperature the last time the bladder was wireless sensors and the accompanying wireless
charged with nitrogen. infrastructure, it is relatively easy to add other sensors to
Plan 53 C defines systems in which pressure in the a pumping system to measure cavitation, flow, vibration
reservoir is supplied by a spring-loaded piston (see Figure and other parameters such as temperature, strainer
3, page 35). Level measurement in the piston accumulator plugging, seal fluid level and hydrocarbon leaking (see
may be challenging for both differential pressure and Figure 4) to provide a comprehensive pump health
guided wave radar level sensors. In this case, level monitoring system.
switches may be the best option, but further examination When coupled with the appropriate control and
is often necessary to determine the best option. monitoring system software, this type of pump
monitoring system will comply with API Standard 682
Wireless Sensors and provide other benefits including increased uptime,
For many installations, the key to an economical pump lower maintenance costs and optimized operations.
seal instrumentation scheme is wireless sensors. Many
pumps are located in hazardous areas, difficult-to-reach
Brian Atkinson is a senior application development
places or in locations such as wellheads and offshore
consultant for Emerson Process Management. He is
platforms where electrical power is limited. In many
responsible for driving integrated product and technology
of these cases, using wired transmitters may be too
roadmaps and leading new product
expensive because of the cost to install and maintain
introduction efforts. He has more than
the wiring infrastructure.
15 years of experience in automation
The installation of wireless sensors can be
and control. He has a bachelor’s degree
straightforward. The sensor has to be plumbed into the
in chemical engineering from the
process to measure level, pressure or temperature—no
University of Delaware.
wiring is required.

Advanced Diagnostics Help

Centrifugal Pumps Reach
New Levels of Efficiency
A model-based control system provides complete machine
protection using a minimum number of sensors.
BY MASSIMILIANO DI FEBO,
PASQUALE PAGANINI & GIACINTO DI MANGO
IPC
• an optimal control action on the operational state of
C
entrifugal pumps are widely used in industrial
applications, and pumps absorb nearly a quarter the pumping system using a minimum number of field
of the electric energy of the European industry. transducers with a consequent reduction of installa-
Pumps driven by medium- to low-power motors tion costs
(70 kilowatts [kW]) represent almost all of the installed • continuous automatic complete pump protection from
machines in oil and gas process plants. Despite the high all possible failure causes through the implementation
cost of maintaining pumping systems, control, protection of a pump performance model
and diagnostic systems for medium- to low-power pumps
are not yet widely applied. This type of solution requires
external sensors to acquire process parameters, which While minimizing the number of sensors and
could have a considerable impact on initial costs. components reduces the possibility of relative
A centrifugal pump model-based control system can malfunctions, the system architecture of a model-based
solve these challenges by incorporating variable speed control system provides continuous machine monitoring
drive (VSD) techniques and using installed sensors. and diagnostics using an advanced diagnostic
Modern control systems change pump rotational speed algorithm that integrates field measurements and
using frequency converter VSD techniques. Facilities can performance predictions.
improve process output and reduce machinery-related The algorithm is based on field data and on the
production costs with accurate, precise and reliable real- determination of the pump operative expected
time information about how the machinery works and parameters from the implemented pump model.
through congruent control and protective actions. The system monitoring and diagnostic capabilities are
Recent literature discusses many sensorless control designed to increase machine availability and reliability
techniques, which have a considerable advantage in terms while reducing downtime and maintenance costs.
of energy and implementation costs. However, these The process-oriented control architecture also reduces
methods do not allow for simultaneous control of the costs for process surveillance, while the VSD technique
continuous monitoring system and diagnostics reduces energy consumption. These benefits are possible
for the equipment. A model-based control system, because the characterization model of centrifugal pump
however, provides the following features: performance is the central element of this system.

39
Figure 1. Typical pumping system structure (Graphics courtesy of IPC)

Pump Model
VSD systems are equipped
with powerful control units
that enable the monitoring
of inverter power output
and actual motor speed. The
relationship between these
variables and the pump
process parameters is defined
by pump performance curves:
flow-head (QH) and flow-
power (QP).
Both curves are essential
parts of the vendor pump
documentation.
Another relevant system
parameter is the net positive
suction energy (NPSE) or
the net positive suction head
(NPSH). The QH and QP
curves demonstrate the trend
State-of-the-Art Control Techniques of the head and the pump power consumption against
A typical pumping system consists of a driver, a the flow rate, respectively. These correlations are used to
centrifugal pump, valves and tanks. Advanced systems determine the flow rate without the need for sensors.
may include a VSD block and sensors that produce the For variable speed pumps, manufacturers present pump
process variable feedback (see Figure 1). performance maps as curves plotted for different speeds.
At any given moment, the overall process status can Even when only the nominal speed curve is available, it is
be described as the group of relevant process parameters always possible to determine the operational points at an
(flow rate, liquid level, process pressures, fluid properties, arbitrary speed using the affinity laws.
etc.) as well as pump operative parameters. The actual Further characterization is necessary to perform pump
value of the process parameters depends on the pump diagnostics. In particular, it is necessary to determine the
characteristics and the hydraulic load. When the load curves NPSHRQ (NPSHR, NPSH required; Q, volume flow),
changes, the operative state of the pump changes. ηQ (η, efficiency) and PHQ (PH, hydraulic power) that vary
Pump parameters susceptible to variation are flow rate, with the pump’s speed of rotation.
suction and discharge pressure, power, and efficiency.
Selection of the more suitable control system depends Model-Based Control & Diagnostics
on factors such as plant configuration, the required To develop additional diagnostic capabilities, a model-
operational process state and price. based control system includes a few elementary sensors.
Such systems can use four main techniques for pump Compared with the sensorless version, this choice
system control: throttle control, bypass control, on/off introduces modest installation costs.
control and VSD control. The first three are simple and The proposed model-based control system uses two
low-cost. But because these controls run the pump at a pressure transducers installed near the pump fl anges
fi xed speed, they are relatively inefficient, consume more and a vibration sensor to perform control tasks and to
energy, produce machine wear and incur operating costs. implement the pump diagnostic feature, respectively.
While the VSD control approach is more efficient, it The system also includes a frequency converter and a
has the disadvantage of higher implementation costs. programmable logic controller (PLC), as shown in Figure
But this type of control system adjusts the motor 2. The PLC provides multivariable control, executes
speed, permitting the pump to match user demand. sequencing tasks and provides computations for the
Furthermore, producing a centrifugal pump control pump model.
system that saves energy is possible using a VSD, as well The algorithm also allows calculation of the expected
as machine control, monitoring and diagnostic features. values for power, efficiency and NPSHR.
Figure 2. A model-based control system architecture
The diagnostic system is based on knowledge of the

hydraulic power (Phe) and the expected pump efficiency (ηe).
This information is used to determine the expected power
(Pwe= Phe/ ηe), which is then compared to the actual power
(Pw), measured by a frequency converter onboard sensor.
This model-based control system reduces energy costs and
eliminates the need for extra components. The result is an
increase in machine reliability and availability, particularly
for centrifugal pumps used in oil and gas applications.
Massimiliano Di Febo is operation manager for IPC S.r.l.

He has a master’s degree in mechanical engineering and
is a registered Professional Engineer in the province of
Bari. Pasquale Paganini is technical manager for IPC S.r.l.
Diagnostic Algorithm He has a master’s degree in mechanical engineering and
The algorithm is based on real-time monitoring of machine is specialized on thermodynamic and energetic systems.
and process parameters. It calculates the deviation between He is a registered Professional Engineer in the province of
expected and actual performance parameters in real time. Bari. Giacinto Di Mango is an engineer for IPC. He has a
Expected performance is obtained from reference and design master’s degree in electronic engineering and has extensive
characteristics, adjusted to actual operative conditions; experience with instrumentation devices and signals
actual performance is derived from field measurements in a conditioning, digitalization systems for process parameters
specific operative condition. The time trend of the amount of acquisition, monitoring, and numerical analysis. For more
deviation can give early indication of impending problems. information visit ipc-eng.com.

New Instrumentation
Effectively Monitors &
Manages Scale
Electrical capacitance tomography can provide
real-time imagery of any pipeline.
BY TODD LOUDIN
FLOWROX INC.
process down to perform mechanical cleaning. While
P
rocess scaling affects numerous industries,
causing varying degrees of unwanted costs and the oil and gas industry, for example, spends large
downtime. The oil industry, for instance, spends amounts of money on instrumentation to monitor and
up to 0.25 percent of the global gross domestic control its processes, many operations monitor scale
product (GDP) per year eradicating and treating paraffin deposits primarily by watching for pressure drops in the
wax deposits in piping systems. The mining industry piping system. Th is method, however, is imprecise because
can be negatively affected by scale in process water, many variables can affect pressure drop. For instance, as
cyanide leaching and tailings. Alumina and bauxite a pump begins to wear, the pressure output of the pump
refining operations face scale in digesters and transfer may decrease. This does not always indicate the presence
piping, which often creates a significant bottleneck in of a scale deposit; it could simply be a worn impeller.
production. The pulp and paper industry experiences
scaling in pulp digester screens and white, green and Detection Tools
black liquor processing. Other industries that are affected New scale-detecting instrumentation uses electrical
by scale include steelmaking, wastewater treatment, capacitance tomography (ECT) to create a visual display
chemical production and power generation. of pipeline scaling without having to physically open
In most cases, the scaling is calcium carbonate or the pipeline. This instrument can monitor hard and soft
similar culprits. A type of nontraditional scaling is zebra scaling in numerous industries and enables plants to
mussels in the Great Lakes region. While not generally reduce anti-scaling chemical usage and associated costs.
classified as scale, they can completely clog large- Typically, a plant adds more chemicals than necessary
diameter pipeline in a short amount of time. Struvite to prevent a production shutdown or slowdown. With this
scaling is a culprit often seen on exit lines of digesters in instrumentation, plants can know when scale is present
wastewater treatment facilities. and in what thickness so they can use chemicals only
Some remedies for scaling include mechanical cleaning, when necessary. They can also monitor the effectiveness
chemical cleaning or pigging pipelines. One of the keys of the chemicals they are using, and anti-scaling chemical
to proper treatment of scaling is knowing when to add manufacturers can fine-tune their anti-scaling chemicals
chemicals, when to run the pig or when to shut the and validate the success of new formulations.

43
ECT can provide a new level of intelligence regarding These instruments are similar to a spool piece that
what type of scaling is occurring as well as multiphase is inserted between two fl anges of a pipeline. The flow
flow visualization. In a piping system where a vortex will pass through the instrument as if the instrument
effect is present, the instrument can provide clear was another piece of the pipeline. In most cases, the
imagery of this phenomenon. instrument is manufactured from the same material as
A pipeline that has two or three different chemicals the mating piping to exactly mimic scaling that occurs in
or solids can be imaged to show a video of the flowing the remaining pipeline.
process. Even if there is a significant amount of scaling ECT for industrial piping and other industrial systems
on the inside of the instrument, it will not affect the is relatively new, and only a handful of companies employ
multiphase flow capabilities. this technology in this manner. The instrument is
The U.S. Department of Energy at the Morgantown connected to an electrical control box, which delivers low
Energy Technology Center in West Virginia and the voltage to the electrodes and then collects the capacitance
University of Manchester Institute of Science and measurements. The electrical control box contains an
Technology in the U.K. both performed extensive early industrial computer that performs algorithms to create
research and pioneering on the potential uses and the imagery. The control box delivers the imagery using a
applications of ECT technology. 4-20 mA signal to plant monitoring systems and control
Some types of instrumentation can monitor scaling panels. The electrical box can be located close to the
conditions but only on a basic level. For instance, instrument or up to 300 feet from the actual instrument
ultrasonic instruments can detect scaling conditions, in non-explosion-proof environments. In explosion-proof
but many of these instruments lose the ability to environments, the distance to the box can be cut in half.
see additional accumulation of scale after only a few
millimeters of scale buildup. New ECT instruments can Long-Term Investment
provide real-time imagery of any pipeline—from one that Scale is present in many industries but may not be enough
has less than 1 millimeter of scaling to one that is 95 or of a nuisance or capital drain to invest in this type of
even 100 percent built up with scale. technology. However, paper mills, mining operations,
chemical plants, steel mills and other producers that
How ECT Works spend $1 million or more per year on anti-scaling
ECT instruments do not require radiation and use very chemicals may find this new technology a significant
low levels of energy to generate pipeline visualizations. asset to reduce chemical consumption and overall
They are targeted at a point of interest and then measure operating costs. Most important, this new technology can
the results of the material properties within the target. prevent and alarm if scale conditions reach critical levels.
ECT applies excitation signals to the target point of One new solution using ECT technology that will
interest and measures the output signals that depend on become available in 2017 is a plug that can be inserted
the electrical properties of the medium and scale present. into a large-diameter pipeline or vessel to detect and
The instrument measures the conductivity as well as monitor scaling. The idea is to reduce the size and cost of
permittivity distribution. the instrument for insertion in a large-diameter pipeline
ECT instruments use a grouping of electrodes mounted or vessel. During this same time, the market may also
around the target of interest. As an electrode is excited, see a probe that can be inserted into a vessel to measure
the other electrodes are grounded and measure the the phase boundary of various substances as well as the
capacitance. The permittivity of the distribution of the emulsion layer. This will allow chemical manufacturers
medium is measured due to resistance of permittivity involved in a decantation process and similar processes
to the electrical field. The higher the permittivity found to reap the benefits of increased end-product recovery,
within the target of interest, the greater the resistance decreased wastewater treatment costs and improved
to electrical stimulus. The electrodes create an electrical product quality.
field, and grounded capacitance-measuring electrodes
measure this resistance. Very low levels of electrical Todd Loudin is president of Flowrox Inc.
current are supplied to the electrodes—as little as 3 volts in Linthicum, Maryland. Loudin may be
and sometimes up to only 12 volts alternating current reached at todd.loudin@flowrox.com. For
(AC). Each electrode is excited in turn, and algorithms more information visit flowrox.us.
create a 3-D image of the pipeline’s interior.
Custom UPS Software

Improves System Control
for Pipeline Users
Engineers identified and corrected problems with the
shutdown sequence.
BY WILLIAM FOX, JOHN ELY & DAVID MCKINNON

AMETEK SOLIDSTATE CONTROLS
protocols are conducted by various servers that monitor
R
egardless of the application, most
uninterruptible power supply (UPS) users and control the system parameters. Some users have
require some degree of customization. It might reported, however, that because of server errors, their
be as simple as adding an analog meter or two systems did not operate correctly even when following
for quick visual reference. Or they may need a full-on the predetermined powering-down protocols.
tailored system designed to match their unique electrical To remedy this problem, the manufacturer’s design
requirements. Customization is not new to most UPS engineers conducted a thorough analysis of the reported
manufacturers, but few companies go as far as developing unsafe network shutdown procedures. They noticed
an entire new line of products to meet the special needs that when the UPS approached the system design life of
of a user. the backup battery duration and eventual power loss,
One manufacturer designed solutions for a user’s many of the control systems deployed at a pumping
rigorous specifications and ended up with new hardware, station or pipeline control mechanism malfunctioned.
software and system design suitable for widespread They determined that the malfunction was caused
industry use. either by the servers not sending the proper shutdown
communications before the power loss or sending no
The Problem communications at all after the power was lost.
Many UPS users operate in unusual and challenging The engineers concluded that such a situation is
circumstances. Many of their applications are in remote, unacceptable because improper sequencing of pump valve
rugged environments, in hard-to-reach locations away shutdown protocols can lead to significant problems such
from the populous. While some UPS systems are designed as auto-shutdown valves not activating and, in the worst
to install in climate-controlled rooms that house case, ruptured lines.
electronics and other switchgear, other installations may
be exposed to wide temperature swings, humidity and The Solution
even corrosive environments, resulting in more frequent As a result of their analysis, the engineers determined
failures that can be extremely costly. that the UPS system could monitor the battery time
When a power outage or severe power quality remaining and control server shutdown protocols based
deterioration occurs, pipelines and pumping systems on true battery life. A lack of information regarding
must enter into safe network shutdown procedures. These estimated battery life, however, was responsible for

45
the system errors, causing the servers to lose power before The software’s time-out function is also critical. If the
commencing a shutdown of the pump systems. Calculating communication message sent from the MopUPS software
battery time remaining is essential for creating dynamic to the Network Adapter 2 is not received after 30 seconds, a
protocols for safe shutdown communications from control server time-out alarm is generated for that server, indicating
system servers. that communication has been lost with the MopUPS client
The new software package, which was designed based running on the server. Also, at a time interval specified by
on these discoveries, allows users to program battery the user, the network adapter sends a message to each server
specifications. The system then calculates
in real time the estimated battery time
remaining during the UPS backup
operation (battery discharge cycles). The
UPS communicates constantly with all
servers in the circuit. If a backup power
situation arises, the UPS will determine
when—and in what sequence—the
servers will power down. The new system
also will send shutdown messages to the
servers, allowing sufficient time for them
to commence safe shutdown procedures
and eliminating errors caused by servers
simply losing power.
In the fail-safe mode, the new UPS will
time out servers based on a predetermined
time interval, eliminating any chance of
premature server power failure.
Other features include network services
over two Ethernet ports and additional
functions for the UPS. One of the two
Ethernet ports, Network Adapter 1, is on
the UPS display board. Network Adapter 2
is mounted inside the UPS.
Network Adapter 1 provides viewing
and retrieval of data logs over Ethernet,
Modbus TCP messages, and viewing of
system parameters and status. The second
adapter is for shutting down servers,
“heartbeat” messaging from the client
running on the servers, testing shutdown
from the front panel, synchronization of
UPS time to Network Time Protocol (NTP)
server, and SNMP messaging.
Solving the Primary Problems

In power-loss situations, the primary
UPS function is server shutdown. With
the new system, this is facilitated by the
software running on Network Adapter 2
and additional software running in the
background on servers to be shut down.
The adapter software sends a shutdown
message to a server when the UPS is
running on batteries and the shutdown
time criteria have been met. Circle 131 on card or visit psfreeinfo.com.
expecting a response. If there is no response, the server time-out

William Fox is senior design engineer at AMETEK
occurs for the non-responding server.
Solidstate Controls. His industry experience
The new solution also synchronizes both the software on the
spans more than 30 years, including the past
Network Adapter 2 and the clock on the UPS display board to
eight years with AMETEK. He previously served
an NTP server. If communication fails with the NTP server and
in key engineering positions with Vanner
displays a drift of more than 5 seconds, the time on Network
Inc., Encore Networks (formerly Fastcomm
Adapter 2 will be synchronized to the DPP display board, which
Communications), Lockheed Martin and IBM.
includes a real-time clock. Once communication has been
reestablished with the NTP server, Network Adapter 2 will
John Ely is the marketing manager at AMETEK
resynchronize the clock on the display board.
Solidstate Controls. He has more than 18 years
The web page on Network Adapter 1 allows for monitoring of
of experience in industrial and consumer
the current UPS status and the ability to view and download the
marketing, along with a master’s degree in
event, battery history and battery test logs. The home page provides
marketing and communications, a bachelor’s
an overall status of UPS operations, an abbreviated alarm status,
degree in technical management and
percent output loading, and UPS manufacturer information. It also
an associate’s degree in electrical
provides buttons that will display separate pages for comprehensive
engineering.
measurements, detailed alarms, UPS log and other functions.
Values are displayed graphically as meters, along with the actual
David McKinnon is an applications engineer at
values for each measurement.
AMETEK Solidstate Controls, where he directs
A data log page also gives users the ability to view the data log,
development, technology integration and
battery history, battery test log and the datastore with all events
customer demand discovery. He has worked
and alarms recorded by the UPS during operation. Once the
for Sky Climber as an engineer, as well as at
maximum 2,000 entries have been recorded, the data log will wrap
Decision One in the lead technician position.
back and write over the oldest entry first.

47
SMART PUMPING
I N I R R I G AT I O N
D ATA P R O V I D E D B Y N E T I R R I G AT E
To feed the global population of 9.6 billion people expected by 2050, food production must increase by 70 percent,
according to Beecham Research. Maintaining sustainable water practices is one of the most vital aspects of
increasing food production. With thousands of pumps registered for agricultural irrigation in the U.S., the Internet of
Things (IoT) can make significant improvements in pumping efficiency and conservation. Here are some facts that
highlight the important relationship between IoT and farming.
More than 5,625 farms

in the U.S.
experienced diminished crop yields resulting There are 603,579 powered
from irrigation equipment failure. pumps used across 154,890 farms
According to USDA, National Agriculture in the U.S.
Statistics Service
According to the 2013 Farm and Ranch survey
IoT
These farms spend, on average,
per year on irrigation
2.7 million in the U.S.
According to the 2013 Farm and Ranch survey
Remote monitoring IoT technology can greatly reduce

those risks, though the technology faces barriers for
adoption such as increased management time and cost.
Investment
IN 2015, ONE IOT TECHNOLOGY SAVED
in IoT for
the farming
industry
was more than
5,000 180gallons
million $4.6 billion
pumping hours of in 2015 compared with
conserved water $2.4 billion in 2014.
According to AgFunder.com
p u m p s a n d s y s te ms . co m | J une 2016
48
MOTORS & DRIVES
Follow these Tips to Get

the Most from VMS Pumps
Evaluate the application before installation to ensure a long-lasting,
productive and efficient pump.
BY STEVEN ULRICH
FRANKLIN ELECTRIC
Figure 1. To properly size a pump, look toward the center of the VMS pump
performance curve to find the best efficiency point and range, and try to
operate within that area. (Graphic and image courtesy of Franklin Electric)
V
ertical multistage (VMS) pumps have become
popular because they provide increased
pumping efficiency along with energy savings.
With a variety of nominal flow ratings and
the benefit of multistaging, the technology features a
wide range of discharge pressures and pump horsepower
ratings to cover a multitude of hydraulic applications
such as water supply and pressure boosting; heating,
ventilation and air conditioning; light industrial;
irrigation and agriculture; and water treatment.
Combine one of these fi xed-speed pumps with a
variable frequency drive (VFD) controller, and the
affinity laws will provide even more pump versatility. (hp), 2-stage pumps with three-phase, standard-efficient,
There is, however, a misconception that a VFD allows open drip-proof motors with Class B insulation, capable
the VMS pump to function properly without having to of 25 gallons per minute (gpm).
appropriately size it according to the application. While The first question asked about these 460-volt VFDs
pump sizing is key, users should consider a few other tips was how far they were located from the motors they
to ensure proper safeguards. controlled and whether there was an output fi lter
included with each VFD. The response was that the pumps
Case History were about 50 to 60 feet away from their drives, and no
Examining a common example of how VMS pumps fi ltering was in place.
can be misused and overloaded helps demonstrate the An internet search of the VFD’s model number
specific effect pump sizing can have in the field. A series provided the owner’s manual, which stated that a VFD
of identical VMS pumps, each controlled by a separate supplying 460 volts to a motor needed output fi ltering
VFD and all installed at a single site, had experienced if more than 25 feet separated the device and the motor.
premature motor failures on a number of the pumps. Personnel insisted that the operation had many similar
None of the motors had been taken to a motor shop for installations but had not experienced multiple motor
evaluation. The units purchased were small, 1-horsepower failures after a few weeks of run time.

Image 1. Know the max flow and head requirements, and
then properly size the VMS pump according to the application
pre-installation.
The operation had replaced one of the failed motors By throttling the pump flow back with a valve, the amp
with an inverter duty motor, and it was still having draw was reduced to just below the motor nameplate
issues. Personnel also reported that the pumps had not max-amps value. No suction or discharge pressure
experienced any mechanical issues (tight turning gauges were installed in the system, making it difficult
pump/motor shaft, grinding of stages, etc.), so a field to know exactly where on the pump curve they normally
service engineer was dispatched to the site to gather operated without the artificial backpressure imposed by
more data. the throttling valve. The inspecting technician suspected
they were either on the far right side of the curve (high
Finding the Cause flow/low head pressure) or completely off it.
The pumps were taking water on a flooded-suction basis Further questions and answers led to the
from an open-to-atmosphere inlet vessel that collected understanding that this type of fi ltering system would
washdown from a manufacturing process. The pumps normally be outfitted with a 1.5-hp, 50-gpm pump—
transferred the water up into large, low-pressure media much different from the 1-hp, 25-gpm pumps used for
fi lters. The liquid-level transducer tied to the VFD this application. It was determined that the higher-head,
monitored the inlet vessel fluid height and adjusted the lower-flow VMS pumps placed into this application
pump speed to maintain a specific level in that vessel. were the root of the problem; this application called
On the pump’s discharge side, there was a small for low-head, higher-flow pumps. Even with a VFD
elevation change up to the fi lter inlet and no obvious controller, this setup led to numerous motor failures as
friction loss. The fi lters offered little backpressure to a result of overloading.
the pump flow, even when they were fully loaded just
before backwashing. Eliminating the Problem
For the units that remained operable, amp draw was With the transducer and proportional integral-derivative
high and the motors ran hot. The cable between each VFD (PID) controller loop set up on the suction side to keep
and its pump motor was 125 feet—double the initial the inlet vessel at a steady level, the pump could run at
estimate received—which further stressed the need for up to full speed to move the correct amount of water.
output fi ltering on each VFD. With little to no backpressure on the pump’s discharge
50 COVER SERIES MOTORS & DRIVES
9 TIPS TO AVOID VMS MOTOR FAILURE

It is important to look toward
1 Know your max flow and head
requirements, and then properly size your
VMS pump according to your application
the center of the VMS pump
pre-installation. curve to find the best efficiency
point and range and to try to
2 A VFD does not give your VMS pump
supernatural abilities. Overloading can
still occur if the pump is not sized properly. operate within that range.
Ensure your overloads are set properly
to take the pump offline should a
problem develop.
3 When setting up a pump system to

be controlled by a VFD, follow the VFD
manufacturer’s guidelines concerning the
side, the 25-gpm pump tried to output 50-plus gpm
and overloaded the motor in the process. Had the
need for output filtering to reduce damage throttling valve been properly set up at startup—which
to the motor insulation system from would have required an amp clamp measurement while
voltage spikes. Using a motor with a Class running the pump at full speed—these incorrectly sized
F or H insulation system would give the pumps could have operated on their curve.
motor a higher temperature rise rating and Another more “tamper-proof” throttling option
ensure the insulation holds up better under would be installing a fi xed orifice flow control valve on
warmer operating conditions.
the pump discharge line to prevent it from going beyond
4 Properly set up the throttling valve at

pump startup if the transducer and PID
feedback are not monitoring the pump’s
its recommended operating range. If the VFD was set
up to hold back or fold back the motor’s revolutions
per minute (rpm) when it detected slight prolonged
discharge side.
overloading, the amps could have been maintained
5 One option is to install a fixed orifice
flow control valve on the pump discharge
line to prevent it from going beyond its
below the motor nameplate rating so the motor would
run cooler and the windings last longer.
recommended operating range. Sizing the pump to properly fit an application is
critical to avoid problems. It is important to look toward
6 Follow the manufacturer owner’s manual
closely and test repeatedly.
the center of the VMS pump curve to find the best
efficiency point and range and to try to operate within
7 To achieve results backed by proper
testing, partner with one manufacturer
(for both the VMS pump and the VFD) that
that range. When possible, try to establish safeguards
against changing a system that has been designed. It
tests the products working together and is not uncommon for a new employee to open or close
can prove their performance. a valve, for example, so keep that in mind before the
installation to protect against motor failure.
8 When buying your VMS and VFD, choose
a manufacturer with a proven history of
on-site product support to ensure future
VMS pumps provide flexibility to meet pumping
requirements for many applications. Take the time
challenges or questions are quickly before installation to evaluate the previously noted
resolved and maximum performance details, and the result should be a successfully applied,
is continued. long-lasting, productive and efficient pump.
9 When using a VFD on any pump, including

a VMS pump, bearing failure from VFD-
induced shaft voltage and the resulting Steven Ulrich is the senior portfolio manager for
bearing currents can be prevented with large surface pumps at Franklin Electric.
the use of ground shaft rings, or it can be He has more than 40 years of experience
reduced significantly with the use of a with pumping systems. Ulrich’s expertise
dv/dt filter. includes pump sizing, selection and
performance. For more information, visit
franklinwater.com.

DOE-Funded Motor System

Market Assessment to
Provide Valuable Insight
The study will give industry stakeholders a better understanding of
the marketplace and help them become more globally competitive.
BY PAUL SHEAFFER, PRAKASH RAO & ARIAN AGHAJANZADEH

LAWRENCE BERKELEY NATIONAL LABORATORY
The study showed that motors are the largest single
T
he U.S. Department of Energy (DOE) Advanced
Manufacturing Office (AMO) is updating the Motor category of electricity end use in the American economy.
System Market Assessment (MSMA) that was Pump systems accounted for about 25 percent of the motor-
previously published in 1998. In the prior study, the system energy consumption and about 20 percent of the
DOE published an assessment of motors and motor-driven motor-system population in the industrial sector.
systems titled United States Industrial Electric Motor Systems Since this study was conducted, the energy efficiency
Market Opportunities Assessment. This study led to a greater of motor-driven systems has improved and markets have
understanding of the energy consumption and efficiency changed. For this reason, a new study is underway to help the
opportunities for motors and motor-driven systems in the industry better understand the additional opportunities for
manufacturing sector. It also shed light on the market uptake energy-efficiency enhancement.
of technologies designed to address these opportunities. Since 1998, motor-system energy efficiency has improved
Information from this landmark study has been cited in for several reasons. First, there is a greater awareness and
hundreds of publications on efficiency opportunities in the availability of energy-efficient options. Second, there are
industrial sector. It has guided motor systems policy decisions lower costs for energy efficiency solutions, such as variable
for the last 15 years and has led to a greater understanding of frequency drives (VFDs).
efficiency opportunities in motor-driven systems. Other factors impacting the market include motor
The 1998 U.S. industrial motor system assessment found: regulations, the emergence of advanced motor and drive
• In 1994, U.S. industrial motor systems consumed 747 technologies, manufacturers moving outside the U.S.,
billion kilowatt-hours (kWh). The electricity these motor- increased share of electric drives over steam drives, advances
driven systems consumed represented 25 percent of U.S. in and increased adoption of automation, and an expansion in
electricity sales. There was a 90/10 percent split between U.S. oil and gas extraction, which has led to new facilities in
process uses and heating, ventilation and air-conditioning the chemical industry with motor-intensive operations.
(HVAC) uses. This new MSMA will accomplish the following:
• There was 11 to 18 percent in energy savings potential • develop a detailed profi le of the stock of motors and
using the proven and cost-effective measures that were motor-driven systems in commercial and industrial
identified. More than half, about 62 percent, of the facilities in the U.S. (The new study is also covering
savings potential was from pumps, fans and compressed the commercial building sector, as well as water and
air systems. wastewater treatment.)

53
• develop a profi le of commercial and industrial motor energy consumption characteristics and evaluate savings
and motor-driven system purchase, operational and potential. This new assessment will employ staff interviews,
maintenance practices. visual observations and spot measurements. An assessment
• analyze opportunities by market segment for improved tool will be developed to ensure consistent information is
energy efficiency and cost savings from motors, control collected across all evaluations.
technologies, system optimization and
new/future advanced designs.
• evaluate the global supply chain (for
example, sources, availability and the
U.S. role in the supply of technologies
and materials) that support the
manufacture of motor and drive
technologies.
The DOE AMO is overseeing the

project and managing external project
communications. Lawrence Berkeley
National Laboratory (LBNL) is managing
the project under AMO direction,
managing all subcontractor relationships
and conducting the analysis of the
collected data.
Industry and other stakeholders are
consulting to provide technical assistance
and insight on strategy, content and
outcomes of assessment. Industry
representatives will also communicate
progress and status of assessment to their
respective stakeholders. Subcontractors
include the Cadmus Group, which will
be conducting the field assessments, and
DNV GL, which will assist in developing
the statistical components for the project.
The site visits will be conducted until 2017,
when an interim report will be produced.
The final report is slated to be complete
in 2018.
Motor systems to be considered in this
study include those driven by a polyphase
motor, 1 horsepower (hp) (0.75 kW) or
greater, and large (greater than 50 hp and
37 kW) direct-current motors. All types
will be considered, including pumping, fan,
compressed air and HVAC.
For these purposes, a system includes
drive and controller, motor, power
transmission, motor-driven equipment,
and distribution system.
The goal of field assessments is to
develop a quantitative and qualitative
understanding of a site’s motor-system
COVER s ERIE s MOTORS & DRIVES
Field assessments will evaluate facilities using a tiered The new MSMA will use a combination of field-collected
approach. General information collected at all sites will data, existing data and motor-system expert input to
include an understanding of the environment in which the accomplish the following:
motor system operates through collection of facility-level develop a series of profiles, segregated by U.S. industrial
information, as well as data for all systems greater than and commercial building subsectors, on energy use and
1 hp, including nameplate information, load profiles and consumption; operational and maintenance practices,
duty factors. including load variability and the use of adjustable speed
Other collected general information will include the drives; and purchasing practices.
system efficiency of large systems determined using energy identify opportunities to improve the energy efficiency of
efficiency checklists, which will include a description of motor-driven systems, including advanced technologies.
system components, evaluation of distribution systems, profile the market flows for motors and drives sold, used
estimate of motor load profile and maintenance history. in and exported from the U.S.
The statistical sampling methodology is currently being identify the U.S. global situation in motor and drive
developed. A representative, random sample for each three- manufacturing.
digit manufacturing North American Industry Classification
System code (for all of manufacturing and water/wastewater When completed, the MSMA will help U.S. manufacturers
treatment) and U.S. DOE Commercial Buildings Energy better understand the commercial marketplace and become
Consumption Survey commercial building types (e.g. more competitive globally. The assessment will also enable
hospitality, office building, education) will be used. policymakers to better understand the motor system
The field assessment methodology, which will incorporate efficiency opportunities in the industrial and commercial
a tablet-based collection system with a relational database, is building sectors, as well as inform future DOE research
also being developed. funding decisions.
Jordan, Knauff & Cotnpany NEW: Hydraulic lnstitute's Wastewater

INVESTMENT BANKERS Treatment Plant Pumps Guidebook
UNMATCHABLE EXPERIENCE
IN FLOW CONTROL This new guide provides the
TRANSACTIONS WASTEWATER TREATMENT
guidance necessary to select PLANT PUMPS
pump types, pump materials,
and auxiliary components so the
Jordan, Knauff & Company is a knowledgeable and wastewater pumping system
experienced provider of a comprehensive line of
investment banking services to the pump, valve and performs effectively, efficiently,
filtration industries ("Flow Control"). and reliably in various plant
operations. Find out what's
Our lines of business include: selling companies,
raising debt and equity capital, and assistance inside by visiting the link below.
on acquisitions.
To learn more about Jordan, Knauff & Company,

contact any member of our Flow Control
team. Access our Flow Control research at
www.jordanknauff.com/flowcontrol.
G. Cook Jordan, Jr. David A Kakareka

Managing Principal Senior Associate
cj@jordanknauff.com dkakareka@jordanknauff.com
312.254.590 I 312.254.5907
~Hydraulic
~ &-+I
Crtati11g Pump Srandards Si11a 1917
Circle 155 on card or visit psfreeinfo.com. Circle 154 on card or visit psfreeinfo.com.
June 20 16 I Pumps & Systems
55
Those interested in the pump market will gain information privately owned rights. Reference herein to any specific commercial product,
process, or service by its trade name, trademark, manufacturer, or otherwise,
on the installed base of pumping systems in U.S. commercial does not necessarily constitute or imply its endorsement, recommendation,
and industrial facilities, operational practices, and the or favoring by the United States Government or any agency thereof, or The
potential to improve the efficiency of pumping systems, Regents of the University of California. The views and opinions of authors
expressed herein do not necessarily state or reflect those of the United States
disaggregated at a detailed level (e.g. size range, opportunity Government or any agency thereof or The Regents of the University
and sector). of California.
Identified stakeholders include end users and their trade
Acknowledgement
associations; motor, drive and motor-driven equipment Th is work was supported by Advanced Manufacturing Office of the
manufacturers, distributors and their respective trade United States Department of Energy’s Office of Energy Efficiency and
associations; repair practitioners and their trade associations; Renewable Energy.
electric utilities and their member organizations; energy
efficiency program administrators and their member
organizations; energy efficiency service providers, Paul Sheaffer is a program manager in the Building and
consultants and purchasing agents; and governments at the Industrial Applications Department at Lawrence Berkeley
state, regional and national levels. National Laboratory. He has more than 20 years of experience
in commercial and industrial energy efficiency. Prakash Rao
Disclaimer is a principal scientific engineering associate in the Building
Th is document was prepared as an account of work sponsored by the United
and Industrial Applications Department at LBNL. Arian
States Government. While this document is believed to contain correct
information, neither the United States Government nor any agency thereof, Aghajanzadeh is a scientific engineering associate in the
nor The Regents of the University of California, nor any of their employees, Building and Industrial Applications Department at LBNL. For
makes any warranty, express or implied, or assumes any legal responsibility
more information about this research, contact Paul Sheaffer at
for the accuracy, completeness, or usefulness of any information, apparatus,
product, or process disclosed, or represents that its use would not infringe psheaffer@lbl.gov.

VFD Energy Algorithms

Optimize PID-Controlled
Applications
Drives with active energy control can save energy and
extend motor life for pumping and HVAC loads.
BY CHARLES TAHARA
EATON
N
ASA Tech Briefs describes proportional control loops require proportional and integral methods,
integral derivative (PID) controllers as “the while motion control responds best to derivative
modern industrial workhorse” because methods. Temperature regulation often requires a mix
of their distinct role in automating the of all three. The following descriptions highlight the
regulation tasks of today’s advanced process control differences between each type of control.
systems. PID controllers are well-suited for many speed,
temperature, flow and pressure processes. In industrial • Proportional control simply matches output action to
and commercial settings where these elements are error proportionally.
sometimes matched with processes that are nonlinear, • In integral control, the controller reduces errors
that exhibit high inertia or that require multiple complex through incremental or decremental outputs that
calculations, PID control can add significant value, gradually improve or refine the overall process. The
automating many operations that would otherwise need speed with which this occurs can be fast or slow
to be performed manually. depending on whether the error is large or small,
Yet, for many hydronics and heating, ventilating and respectively. But the integral timing must be precise to
air-conditioning (HVAC) applications that use induction avoid problems in the loop, such as sluggishness
motors to power pumps and fans, the torque needed to or instability.
drive the motor loads varies based on the shaft speed • Derivative control provides faster, more responsive
of the motor, which can be controlled by a variable output action, but it is also highly sensitive to
frequency drive (VFD). measurement noise. For this reason, it is used
Leveraging advanced VFD algorithms for PID- more selectively. Derivative controllers measure an
controlled applications in industrial and commercial adjustable time setting in minutes and seconds and
building settings is a unique approach that can improve derive the amount of output action to be produced
the longevity of electric motors and reduce energy based on that measurement. In other words, the
consumption for systems. controller reduces errors by calculating outputs
against an observed rate of change. As the rate of
Tuning into Control Modes change increases, more or less control is exerted.
PID controllers regulate output through the sum of Instability can result if the derivative time is set
their proportional, integral and derivative actions. Most too long.

When reliable performance
cannot be compromised …
… that’s Chemistry At Work.

Installing valuable, mission-critical equipment and
anchoring it securely is no easy task, and certainly no
place to cut corners. MasterFlow grouting products are
designed for a variety of uses, giving you application
flexibility and unparalleled performance for use in even the
most demanding environments. We can help you identify
the right solutions and back you up with complete system
support to help accomplish your critical mission.
Master-Builders-Solutions.basf.us
Master Builders Solutions and MasterFlow are registered trademarks of BASF.

© 2016 BASF Corporation. All rights reserved. Circle 103 on card or visit psfreeinfo.com.
Timing and tuning are paramount to achieving both reference frequency, successfully automating reduced voltage
optimal efficiency and high performance with PID controllers. while maintaining the optimal torque and speed performance
This is why VFDs can often provide important support for of the motor. No manual tuning is required. Instead, the
process controls. algorithm dynamically adjusts the motor’s operating point
In the example of pumping and HVAC applications, the based on its load conditions, providing power savings and
relationship between the shaft speed and the other key improving energy efficiency.
parameters for a pump or fan is expressed in the affinity Both linear and square/quadratic V/Hz curves are static
laws: Flow is proportional to shaft speed, head/pressure is V/Hz control methods, which means that the voltage
proportional to the square of the shaft speed, and power is output depends only on the reference frequency without
proportional to the cube of the shaft speed. Based on these any considerations based on the actual motor load. If the
affinity laws, the torque needed to power a fan or pump at a motor load is low, the static voltage generated by either curve
lower reference frequency is lower than that required for a may be more than adequate to power the load, generating
higher reference frequency. unnecessary core losses. However, if the motor load is higher
The main benefit of reducing the input voltage to an than what the static voltage can handle, the squared V/Hz
induction motor is the consequent reduction in motor core control method may endanger the motor’s stability and cause
losses, which are typically proportional to the square of the it to overheat or stall.
input voltage. Applying unnecessarily high voltage to the These concerns are the major motivation for the design
motor generates excessive motor core of dynamic V/Hz control methods.
losses in the form of heat and noise. The active energy control method
In fact, noise and variability are takes into account the motor’s real-
the primary challenges for PID One specialized energy time operating parameters when
controllers. If the controller creates control algorithm optimizes determining the output voltage
volatility in the process, efficiency of the VFD. The control algorithm
will suffer and unnecessary wear and energy usage to produce 2 monitors the motor load and motor
tear is likely to occur. to 10 percent energy savings current, as well as other parameters,
Most PID controllers require to find an operating point that both
tuning to time the speed of the over standard drives. optimizes energy usage and ensures
output action properly. Some tuning motor stability.
rules, such as Cohen-Coon, work well This algorithm is built into the
on almost all control loops that require a rapid response. But logic of the drive. Upon drive startup, the algorithm begins to
even with this approach, additional methods are still needed analyze the demand using the factory default setting for
to address concurrent impacts on oscillation. In addition, V/Hz mode.
tuning rules do not always work well with self-regulating Once the drive is given a run command, it outputs a given
processes that stabilize at a point of equilibrium. reference frequency and voltage level, which is determined
To meet the specific objectives for each aspect of PID based on the initialized V/Hz relationship. If that reference
control, hundreds of controller-tuning methods have evolved. frequency is steady, the drive will start to back down
Two examples of PID-control designs include noninteractive the output voltage in 5 volts alternating-current (VAC)
and parallel algorithms. increments to determine if the motor can still provide the
same torque output required at a lower voltage.
Active Energy Control To ensure the stability of the motor, the algorithm initially
One specialized energy control algorithm optimizes sets the drive output voltage at the same level as the voltage
energy usage to produce 2 to 10 percent energy savings over based on the linear V/Hz method for the same reference
standard drives. frequency. It then begins to reduce the voltage incrementally
A standard drive controls a motor based on a linear to optimize energy usage. Meanwhile, the algorithm
volts-per-hertz (V/Hz) relationship. The output voltage monitors several real-time parameters to prevent the motor
waveform of a standard VFD is typically based on pulse-width from conditions that may lead to instability. When the
modulation (PWM). The amplitude, duty cycle and periodicity motor enters the optimal zone of operation, the drive output
of the PWM waveform decide the effective voltage and voltage stays the same until commands to the drive trigger
frequency of the VFD output. a change. After the output voltage stabilizes, the drive
In contrast, a VFD using the active energy control continues to monitor the real-time parameters of the motor
algorithm dynamically adjusts the voltage down at a given to prevent instability.

59
If the motor output frequency remains constant, the

drive will continue to reduce the motor voltage until the
output frequency becomes unstable. Once the drive hits
the unstable region, it will bump the voltage up 10 VAC
to let the torque stabilize and maintain that level.
If the reference frequency or the stability of the load
changes, the voltage will dynamically adjust back to
following the linear V/Hz scale. The process repeats itself
automatically each time the frequency is changed. With
the load held at a constant speed, the voltage reduced
and the current increased during this process, the
system can capture significant power savings because of
the reduction in motor core losses.
Efficiency & Cost Savings

In a comparison of this active energy control algorithm
over linear V/Hz control, an unloaded, low-horsepower
rated motor with an output frequency of 30.00 Hz, 885
revolutions per minute (rpm), motor current of 0.16
Amperes (A) and a steady state/motor startup voltage
of 229.9 VAC achieved the lowest possible motor voltage
of 96.6 VAC while lowering the motor current to 0.05
A. This represents a reduction in output voltage by 133
volts and motor current by 104 percent.
Reducing the voltage output to the motor reduces
motor core losses, but excessive reduction in the supplied
voltage may cause the motor current to rise, which
leads to potential motor instability and an increase in
other losses, such as motor copper loss. The algorithm
monitors motor slip and motor current to ensure the
voltage is not reduced to an excessively low level.
Energy savings achieved through this method are
typically reached more quickly in motor applications
with load. At scale, these savings add up significantly for
motors that run eight hours a day, five days a week, most
weeks of the year.
Motor instability is affected by load. A slower change
in motor load causes motor slip and motor current to
change, and the algorithm will adjust the voltage output
based on these changes. An abrupt increase in the motor

load is the most challenging for motor stability. If the
algorithm detects a rapid increase in motor current or
motor slip, it quickly increases the output voltage to
ensure motor stability.
Charles Tahara is global product manager

for industrial drives with Eaton. He has 11
years of experience with industrial control
products. For more information, please
visit eaton.com/drives.
Three-Level AC Drive
Eliminates Long
Motor Cable Issues
This alternative technology is ideal for petrochemical applications.
BY TODD THOMPSON
YASKAWA AMERICA INC.
Figure 1 (top). Conventional two-level PWM output.
Figure 2 (center). Voltage overshoot due to long cables.
Figure 3 (bottom). NPC three-level control PWM output
(Courtesy of Yaskawa America Inc.)
I
n certain applications, alternating-current (AC)
variable speed drives (VSDs) can offer several
advantages over traditional methods of process
control, including energy savings, reliability and
process improvement. Petrochemical drive applications,
however, often require the motor to be located long
distances from the drive. In some cases, this distance
can lead to premature motor failure and negate
these advantages.
Conventional 480-volt (V) pulse width modulated
(PWM) AC drives switch 650V direct-current (DC) power
to make a variable voltage, variable frequency AC output.
The resulting output is a two-level waveform.
Two-level PWM is acceptable when output lead length is
small. But when distance begins to increase, peak output
voltage will also increase because of voltage overshoot.
This overshoot is caused by capacitive coupling in the
motor cables and reflective waves. Peak voltages up to
three times the original DC switching voltage have been
observed in some applications. If this peak output voltage
exceeds the motor’s insulation withstand capability,
motor winding insulation damage will result.
Over the years, many solutions to this problem have
been created and used. While the most common solution
is to specify inverter-duty motors, use of this equipment
does not guarantee a problem-free application. National This means that 460V motors must be able to
Electrical Manufacturers Association (NEMA) MG1 withstand 1,426V. As previously stated, conventional
Part 31 specifies that “definite purpose inverter-fed” PWM drives can deliver two to three times the DC
motors should be capable of withstanding 3.1 times the switching voltage, or up to 1,950V peak in long-
rated voltage. cable applications.

61
The elimination of output filters reduces the

total system space significantly and reduces
installation costs, especially for applications
where installation space is limited.
Reactors, long lead fi lters or sine wave fi lters can be electrical rooms separate from the driven motor. Often
added to the drive output. When used correctly, these the distance between the drives and motors is 800 feet
devices can reduce the peak output voltage to within the or more. Three-level drives can reliably power motors at
motor’s insulation capability. However, they often occupy these distances with no degradation of motor insulation.
valuable real estate, decrease reliability and increase
power losses.
Todd Thompson is a sales engineer with Yaskawa
An alternative 480V drive topology that addresses
America Inc. He has a Bachelor of Science
these challenges is the neutral-point clamp (NPC) three-
degree in electronic engineering technology
level control PWM drive. This drive topology switches
from Texas A&M University. He has 25 years
325V DC instead of 650V DC like in conventional PWM
of AC drive experience in a variety of roles
drives, resulting in a more sinusoidal waveform with
including application engineering, product
lower peak voltages.
management and field sales.
The three-level drive never exceeds the insulation
limits of NEMA MG1 Part 31 motors, regardless of
output lead distance.
In petrochemical plants, drives
are generally located inside
electrical equipment rooms, and
motors are located in the process
area. For applications where the
drive and motor are separated
by distances of up to 2,000 feet,
some drives can eliminate the
need for additional equipment
such as output fi lters and keep
the total voltage level at the
motor terminals well within the
range of standard inverter-duty
motor insulation. The elimination
of output fi lters reduces the
total system space significantly
and reduces installation costs,
especially for applications where
installation space is limited.
Petrochemical plants use AC
drives for energy savings and
process control improvements.
When applied correctly, AC drives
are more reliable than the process
control devices they replace.
However, typical installations
require the drives to be located in
Understanding the
New DOE Pump System
Testing Procedures
This is the first time the DOE has developed rules to
determine the efficiency of pump systems.
BY TOM LOWERY & JACK CREAMER

SCHNEIDER ELECTRIC ADDITIONAL VFD BENEFITS
With a variable frequency drive, pumping

systems can also benefit from:
A
fter many years of study, analysis and • Smart pump control
discussion, the U.S. Department of Energy
• Remote access and monitoring
(DOE) has released new rulemaking
that defines a pump system efficiency • Predictive maintenance
test procedure, 10 CFR Parts 429 and 431 – Energy
Conservation Program: Test Procedure for Pumps.
Energy conservation has been a focus for both the the resultant laws governing minimum allowable motor
private and public sectors for years, but this is the first energy use as detailed in 10 CFR Part 31 of the 2010
time the DOE has developed rules to determine the Energy Conservation Standard for small electric motors.
efficiency of pump systems. The process started with the Energy Policy Act of
Pumps represent more than 50 percent of all potential 1992, which required that certain types of motors sold
energy savings of motor-driven loads. Furthermore, in the U.S. after October 1997 meet or exceed minimum
energy costs associated with pumping applications efficiency standards.
represent approximately 40 percent of the total cost of Efficiency guidelines continued to expand with the
ownership for the life of that pump. Energy Independence and Security Act, setting the
Because pumps are a major consumer of electric energy, minimum efficiency for motors above 1 horsepower (hp)
the DOE pump system guidelines have been the topic of (signed in December 2007), followed by the DOE Small
discussion for several years. Th is is the first time that the Motor Rule that set minimum efficiency requirements for
government has taken steps to address energy usage in certain electric motors between 0.25 and 3 hp in 2015.
the previously unregulated pump industry.
This rule does not include information on any action Measuring Pump System Efficiency
that the DOE will take against inefficient systems; Pump system efficiency typically has been measured
however, it lays the groundwork for future rules detailing only when a system is operating at 100 percent capacity
efficiency level requirements and subsequent penalties (speed, flow and head pressure).
for noncompliance. Many pump users remember the This full load and speed point of operation, while
process that the DOE and the Environmental Protection important, did not represent where most installed
Agency (EPA) underwent to develop minimum efficiency pump systems ran for long periods of time. Even
standards for electric motors nearly a decade ago and if throttle valves or other mechanical bypass

63
This new efficiency test procedure requires that measurements be

taken at different key load points, gauging the system’s
efficiency at varying loads to provide a more holistic understanding
of the pump system’s overall energy use.
means were used to vary system flow any updates to installed pumps. The modern variable frequency drives
and pressure, the overall system rarely regulations underscore the importance (VFDs), devices designed to
ran at 100 percent capacity. of energy efficiency for all pumping electronically vary a motor’s speed to
This new efficiency test procedure systems across all industries—both to match demand within a given process.
requires that measurements be taken reduce environmental impact and to VFDs have become an important
at different key load points, gauging improve the bottom line. contributor to overall pump system
the system’s efficiency at varying Fortunately, most pumping systems efficiency gains without sacrificing
loads to provide a more holistic can be adapted to increase system system performance.
understanding of the pump system’s efficiencies without incurring high In addition to the motor control
overall energy use. installation costs associated with functions, VFDs can offer greater
replacing mechanical equipment. insight into the level of efficiency for
Addressing Pump Technologies designed to increase their respective processes. With that
System Efficiency process efficiency and provide detailed knowledge, the process owner can
This rulemaking will be applied to new information on energy use have been make changes to run the system
pump systems and will not mandate evolving. One such technology is more efficiently.

Table 1. Load profiles based on pump configuration

Pump Configuration Load Profile Load Points
Pumps sold without continuous or non- Constant load profile 75 percent, 100 percent and 110 percent
continuous controls (i.e. bare pumps and of BEP flow
pumps sold with motors)
Pumps sold with continuous or non- Variable load profile 25 percent, 50 percent, 75 percent and
continuous controls 100 percent of BEP flow
Federal Register (Vol. 81, No. 15) Monday, January 25, 2016, “Rules and Regulations” p. 4105; “10 CFR Parts 429 and 431 – Energy Conservation Program: Test Procedure
for Pumps,” Dept. of Energy.
Figure 1. For energy savings opportunities on motor-driven loads,

2. Total harmonic current distortion at drive input
pumping applications account for slightly more than 50 percent of terminals
all savings. (Courtesy of Schneider Electric) 3. The rate of voltage change over time (Dv/Dt) of drive
output waveform measured at motor input terminals
with 6-, 15- and 30-meter cable lengths
The first of these three criteria seeks to reach the

same goals as the new DOE testing method—measuring
efficiency at different defined load points. Th is is a critical
point because the DOE guideline states that “AHRI
1210–2011 specifies appropriate power supply tolerances
so that both pump manufacturers and DOE enforcement
testing can be confident with the establishment and
verification of ratings of VFDs sold with pumps.” Th is
means that, when the DOE begins to require system
efficiency verification, those with AHRI-certified VFDs in
their systems will be able to reference the independently
Contributing to the Guidelines verified AHRI data from the certification process to show
As with the majority of federal guidelines, this rule was that their systems meet the DOE requirements.
developed through years of study and with the input The option available for those not using AHRI-certified
of independent industry groups. The Air-Conditioning, systems is to test and verify compliance using the new
Heating and Refrigeration Institute (AHRI) is one group method of test, which can be costly, time-consuming
prominently referenced in the legislation. Th is rule comes and cumbersome for multiple sizes and types of each
on the heels of that organization’s recently published component: the VFD, motor and pump.
VFD standard, AHRI Standard 1210 (IP) and 1211 (SI)
References
Performance Rating of Variable Frequency Drives, which 1. ASHRAE Journal, Feb. 2016; p.58-59
addresses system efficiency by focusing on the drives.
By adding a VFD, it is possible to reduce a pumping
system’s electrical consumption by at least 30 percent. Thomas Lowery is the drives marketing
However, it was difficult to understand which drives operations manager for Schneider
provide greater process efficiency. Electric’s industry business. He has
The AHRI standard represented the first independent, more than 25 years of experience in the
nationally recognized performance standard in the application of variable speed electric drives.
industry for VFDs, allowing users and consulting
engineers to better specify VFDs based on published Jack Creamer is Schneider Electric’s market segment
performance data verified by credible third- marketing manager —pumping equipment. Creamer
party testing. To achieve the Standard 1210/1211 serves on the Editorial Advisory Board of Pumps
Certification, manufacturers must complete a detailed & Systems magazine. For more information
process, including independent testing of three VFD about AHRI certification, visit ahrinet.org/
measurements: site/847/Certification/AHRI-Certification-
1. Combination drive/motor efficiency at defined speed Programs/Variable-Frequency-Drives.
and load points

DISCFLO DISC PUMPS
PROVIDING RELIABLE SOLUTIONS FOR THE DIFFICULT TO PUMP APPLICATIONS
In-Line Close-Coupled Side-by-Side
HORIZONTAL PUMPS GLASS LINED PUMPS

+DQGOHVDZLGHYDULHW\RIGLIƓFXOWŴXLGVHIƓFLHQWO\DQGHIIHFWLYHO\ZLWKRXWEUHDNLQJGRZQLQVHUYLFH $VSHFLDOW\OLQHRISXPSVRIIHULQJVXSHULRU
7KHVDPHSXPSPRGHOFDQKDQGOHŴXFWXDWLRQVLQWHPSHUDWXUHSUHVVXUHVROLGVFRQWHQWDQGHYHQ DEUDVLRQDQGFRUURVLRQUHVLVWDQFHDYDLODEOH
SURGXFWZLWKRXWEUHDNGRZQ+RUL]RQWDOSXPSOLQHLQFOXGHVLQOLQHFORVHFRXSOHGVLGHE\VLGHRYHU on all standard Disc Pump models. Extends
XQGHUDQGVHOISULPLQJFRQƓJXUDWLRQVIRUKDUGWRSXPSDSSOLFDWLRQV WKHZHDUOLIHRIDSXPSRYHUDQ\RWKHUW\SH
RISXPSLQWKHLQGXVWU\
SANITARY PUMPS SUBMERSIBLE PUMPS CANTILEVER DISC PUMPS SUMP & DRY PIT PUMPS
2IIHUVXQLTXHSURGXFWLYLW\DQG ,GHDOIRUPXQLFLSDOZDVWHZDWHU2LO Utilized in tank or sump environments. &RPELQHVKHDY\GXW\FRQVWUXFWLRQ
FRVWVDYLQJVEHQHƓWVIRUXVHUV 3HWURFKHPLFDOLQGXVWULHVDQGHVSHFLDOO\ Fluctuations in temperature, pressure ZLWKFORJIUHHRSHUDWLRQIRUKDUGWR
in specialized application areas HIƓFLHQWLQKLJKYLVFRXVKLJKVROLGV and solids content are handled pump industrial applications.
ZKHUHVDQLWDU\SXPSVDUHUHTXLUHG VOXGJHDQGVOXUU\DSSOLFDWLRQV1R HIƓFLHQWO\ZLWKRXWEUHDNGRZQ,GHDO
Compliant to 3A standards, BS EN FORVHWROHUDQFHVSXOVDWLRQIUHH VROXWLRQVIRUUHOLDEOHORZPDLQWHQDQFH
6WDQGDUGV ŴRZDQGLVEDVHGRQDQRQFRQWDFW operation in the harshest applications.
SXPSLQJDFWLRQ
API PUMPS
2IIHUH[FHSWLRQDOSURGXFWLYLW\DQGFRVWVDYLQJVEHQHƓWV8VLQJWKHLQQRYDWLYH'LVFSDFWHFKQRORJ\WKHVHSXPSVRIIHU
DVXSHULRUDOWHUQDWLYHWRFHQWULIXJDOSURJUHVVLYHFDYLW\OREHDQGJHDUSXPSVIRUYLVFRXVDEUDVLYHKLJKVROLGVDQGJDV
HQWUDLQHGŴXLGVDVZHOODVKDQGOLQJVKHDUVHQVLWLYHDQGGHOLFDWHFKHPLFDOVDQGHPXOVLRQV7HVWVKDYHSURYHQWKDW'LVF
SXPSVFDQSXPSRLOZDWHUŴXLGVZLWKRXWHPXOVLI\LQJWKHP%XLOWWR$3,6WDQGDUGVIRUWKH2LO 1DWXUDO*DVLQGXVWU\
For more information, please contact Sonia Ruiz: sales@discflo.com

DISCFLO CORP. SANTEE, CA 619-596-3181 DISCFLO.COM

66 EFFICIENCY MATTERS
4 Real-World Examples of Eccentric Disc

Pumps In Chemical-Handling Applications
By Mike Solso
Mouvex
I
n the 110 years since its sealed metal bellows or rubber boot chemicals are not
invention by French engineer in which the bearings are contained properly contained.
Andre Petit, the eccentric flexes in an eccentric circle. This Many chemicals and
disc pump has been used in a mechanism is similar to that of their raw components
wide variety of fluid-handling a peristaltic pump, but without have unique handling
applications. the need for hoses. Th is method characteristics that must
Driven by what Petit termed of operation prevents leaks and be observed, so operators
the “eccentric movement principle,” enables the fluid to flow through must employ a pump
the eccentric disc pump design both the pump’s inner and outer technology that can
features a disc placed inside a pump chambers without any pulsation or successfully check all of
cylinder with an eccentric bearing product slip. the operational boxes.
on the pump shaft driving the disc. The eccentric disc pump’s seal- Handling high-value and
This setup creates four distinct free design and volumetrically specialty chemicals is a daily fact
pumping chambers that increase consistent operation are ideal for of life for chemical manufacturers.
and decrease in volume as the distributors of raw feedstocks Their operations, however, only
disc rotates, producing suction and the manufacturers of end achieve the highest level of cost-
and discharge pressures as the products in the chemical industry. effectiveness and safety when they
chambers move in pairs 180 Both the raw materials used and incorporate pumping technology
As the shaft rotates, a hermetically sealed metal bellows

or rubber boot in which the bearings are contained flexes in
an eccentric circle. This mechanism is similar to that of a
peristaltic pump, but without the need for hoses.
degrees apart. Th is method of the finished products created in that can properly contain uniquely
operation ensures that the fluid chemical manufacturing can be expensive or hazardous feedstocks
passes through the pump at a expensive, so the loss of high-value and finished products.
constant and regular flow rate. commodities through product leaks After experimenting with other
The design also means that or spills can be detrimental to the types of technology, many global
eccentric disc pumps do not require operation’s bottom line. manufacturers in a wide range of
mechanical or dynamic seals. As Safety risks also increase industries that rely on or produce
the shaft rotates, a hermetically when dangerous or hazardous chemicals have discovered that

67
Image 1. Eccentric disc pumps can reliably transfer commodities as diverse as ethanol,
pharmaceuticals, isocyanates and paints. (Courtesy of Mouvex)
the eccentric disc pump is an ideal

choice when searching for sealless,
low-shear and volumetrically
consistent operation with
optimized product recovery in
liquid-transfer applications.
Outlined on Page 68 are a
handful of real-world examples
of companies that use or produce
specialty chemicals and have
benefited from the use of eccentric
disc pumps in their fluid-handling
operations.
See 4 real-world examples

on page 68.
Mike Solso is director business

development – Americas for
Mouvex and PSG. He may be
reached at 909-422-
1733 or mike.solso@
psgdover.com. For
more information,
visit mouvex.com or
psgdover.com.
68 EFFICIENCY MATTERS
4 Real-World Examples of Eccentric Disc Pumps in Chemical-Handling Applications

Below are four examples of companies that use or produce specialty chemicals and have benefited from the use of eccentric
disc pumps in their fluid-handling operations, continued from page 67.
Table 1. Example 1
Company Fluid The Challenge The Solution
Global leader in Tall oil fatty The application requires a pump to pull fatty acids from After considering a variety of pump
the distribution of acids a railcar and transfer them to a holding tank. The pump technologies including progressive cavity
chemicals and related is required to run dry for brief periods to ensure that the and peristaltic, the operator chose an
products railcar is completely emptied and as much fluid as possible eccentric disc pump because of its ability
is cleared from the discharge line. By clearing the discharge to run dry and, more important, the
line, the operator can minimize waste and disposal costs while capability to evacuate up to 80 percent of
removing weight from the line, which makes it easier and safer the liquid in the discharge line.
for plant technicians to handle.
Table 2. Example 2
Global producer of 50 percent The application requires the pump to be mounted on a Facility technicians tried several
medicines, vaccines, caustic platform 15 feet above the storage tank, meaning the pump traditional pump technologies, but the
biologic therapies and solution at 60 must have dry-suction-lift capability of 18 feet. Because equipment could not meet the sealless
animal health products F to 80 F (16 C dangerous chemicals are being transferred, the pump needs and suction-lift requirements, so the
to 27 C) to be sealless so the liquids can be fully contained with no operators turned to eccentric disc
possibility of leakage through mechanical seals or packing. The technology. The sealless design contains
actual fluid-transfer operation requires constant recirculation the dangerous chemicals, and the pump
at 50 gallons per minute (gpm) with minimal head for 24/7/365. is capable of producing suction lift in
Additionally, for two hours each day, the pump transfers a excess of the 18 feet required for the
caustic solution at a maximum flow rate of 100 gpm with total fluid-transfer application. The pump,
dynamic head (TDH) of 92 feet. For these two hours, the 100- which has been operating for two years
gpm flow rate consists of 50 gpm of heating recirculation plus without incident, is also equipped with a
50 gpm of caustic transfer to specific locations in the plant, variable speed drive in order to meet the
with a return to the 50-gpm recirculation flow at the conclusion varying gpm requirements.
of the two-hour period.
Table 3. Example 3
Leader in expansion- Polyol and The operator needed a portable system The company chose an eccentric disc pump for this
control systems for the isocyanate that would allow construction crews to in-line blending application because it provides low-shear
construction industry dispense a predetermined blend of polyol and virtually pulseless flow. As other technologies wear,
and isocyanate through a discharge line the fluid will slip back past the impeller or rotor, requiring
to a dispensing nozzle at jobsite locations. constant adjustment to maintain desired flow rates.
This required a pump technology that could Eccentric disc technology eliminates fluid slip because
provide consistent, low-shear, pulseless flow of its unique self-compensating disc and cylinder design,
over time, even as the pump begins to wear. resulting in consistent flow over the entire service life of
the pump.
Table 4. Example 4
Global paint Mill-based The operator began experiencing seal failure and run-dry The internal gear pumps were not able to
manufacturer paint damage in internal gear pumps that were used to transfer satisfy all of the operational requirements,
pigment abrasive paint pigment from a bead mill to a process so the manufacturer replaced them with
tank. Bead mills are porcelain-lined rotating vessels that a sealless eccentric disc pump, which can
contain 3-millimeter (0.12-inch) diameter ceramic beads contain the abrasive material while operating
that aid in pigment dispersion during paint manufacture. in a run-dry condition when needed. The
The pumps are next to the bead mills and have a strainer original eccentric disc pump that was
at the suction end that captures any beads that escape purchased was placed in service more than five
should the bead mill’s screen develop a rip or tear. When years ago and continues to provide leak- and
the suction strainer becomes clogged, fluid supply to the maintenance-free operation, with all of the
pump shuts off, causing a run-dry condition. Additionally, plant’s gear pumps subsequently having been
sealless technology is preferred in order to contain the replaced with eccentric disc models.
abrasive liquids that are being pumped, with no chance of
leaks at the mechanical seals or packing.

45 TH TURBOMACHINERY & 32 ND PUMP SYMPOSIA
HOUSTON, TEXAS | SEPTEMBER 12 - 15 2016
GEORGE R. BROWN CONVENTION CENTER
REGISTER
45 TH TURBOMACHINERY & 32 ND PUMP SYMPOSIA
The premier conference for Turbomachinery and Pump professionals.

DEVELOPED FOR THE INDUSTRY, BY THE INDUSTRY.
TPS.TAMU.EDU
FOR MORE INFORMATION

EMAIL: info@turbo-lab.tamu.edu
OR VISIT: TPS.TAMU.EDU

How Does Your Facility’s Maintenance

Program Rank?
Pump users must think outside the box to ensure their equipment will avoid
impending failure.
By Mark Jennings
ARES Corporation
P
erformance criteria is one of criteria are globally understood and that of this chart is packaged with just about
the most—if not the most— consistent and coherent data is collected every vibration meter, vibration analyzer
important aspects of a successful for analysis. and vibration data collector on the
preventive maintenance (PM) and Ask yourself: Has your facility made market today. It is still referenced 20
condition-based maintenance (CBM) this level of investment in its PM and years after ISO 2372 was withdrawn.
program. The asset owner must refine CBM programs? After 40 years of presentation, you
and accept all performance criteria would think that most would understand
for it to be meaningful, and the Low-Frequency that this chart is not an absolute—it
criteria must be documented to ensure Vibration Monitoring provides guidance only. It offers a place to
consistent application. Specifically, when The following discussion focuses on start when developing a CBM process.
referencing national and international broadband, fi lter-out, low-frequency This chart was also referenced in the
consensus standards as a basis for a vibration monitoring (less than 2 original ISO 10816 (ISO 10816-3, to be
facility’s performance criteria, personnel kilohertz [KHz]). The discussion also specific) as an appendix. In more recent
must evaluate the criteria to ensure it is deals with International Organization revisions of ISO 10816, the appendix has
representative of the normal operating for Standardization (ISO) consensus been removed and the severity chart has
characteristics of the asset. standards associated with general been rewritten. However, no matter what
In all of the CBM (and predictive equipment vibration. The notions and color you paint it, the severity chart is
maintenance [PdM]) courses I have concepts presented in this article are still there. ISO 10816 (the original and
developed over the years, I have always also applicable to those consensus the latest iteration) also contains the
shared the following: “It is the facility standards that directly apply to in-situ following statement: “The ISO does not
owner’s responsibility to establish pumps and fans, Hydraulic Institute and provide pass or fail criteria. It provides
performance standards (objective Air Movement and Control Association reasonable guidance ensuring that gross
criteria). Any defined performance (AMCA) International. deficiencies (read as unsafe) or unrealistic
standards should provide alarm values In the days before ISO 10816, requirements (read as too limiting)
and shutdown values.” Mechanical Vibration – Evaluation of are avoided.”
If consensus standards or even machine vibration by measurements on For whatever reason, few people notice
original equipment manufacturer non-rotating parts, Parts 1 through 6, this statement. Many technicians and
(OEM) recommendations are used as there was ISO 2372, Mechanical vibration engineers see the charts and tables and
a basis for specific asset performance of machines with operating speeds 10 to jump to the conclusion that these are
standards, those recommendations must 200 rev/s – Basis for specifying evaluation absolutes. Figure 1 (page 72) shows a
be evaluated and, in most cases, adjusted standards. ISO 2372 was replaced by ISO variation of the old 2372 severity chart.
to fit a specific set of asset operating 10816 in 1995. Several things are important to note:
conditions. The facility owner’s engineer One example of performance criteria • The severity chart is no longer
is typically responsible for that decision. that must be evaluated and adjusted specifically referenced in a consensus
Documenting the criteria and to fit a specific set of asset operating standard.
providing training are also necessary conditions is the old—from 1974—ISO • The chart is not used as pass or fail
to ensure that the defined performance 2372 Vibration Severity Chart. A version criteria but as general guidance.

Figure 1. A variation of the ISO 2372 severity chart (Courtesy of ARES Corporation)
• It is the facility owner’s
Overall
responsibility—not a third-
RMS
party committee’s—to establish Class I Class II Class III Class IV
Velocity
performance standards (objective
criteria). IPS (mm/s)
.01 (.25)
Case Study
As an example, a global manufacturer .017 (.4) A
A
with a fleet of facilities in the U.S., .028 (.7) A
Taiwan, China, Japan and Korea that A
has been in business for more than 100 .044 (1)
years drank the ISO 2372 Kool-Aid. B
.07 (1.7)
During initial visits to each facility when
the technicians walked through their
B
.11 (2.8)
vibration monitoring program(s) for C B
small-frame pumps, they showed their .18 (4.6)
latest manual data collection and on-line C B
.28 (7)
monitoring schemes.
Not surprisingly, none of the programs
C
.44 (10)
was consistent or even similar in terms C
of data collection and analysis. That was .7 (17) D
the first fi x: to establish a consistent and D
coherent program. However, one thing
1.1 (28) D
was consistent: a devout following of
D
1.8 (46)
the ISO 2372 severity chart. The alarm
points in all of the monitoring schemes
were always in line with the severity
chart. A red line at 7 millimeters per • “The commercial vibration training down to 2.5 mm/s RMS. For a shutdown
second (mm/s) root mean squared (RMS) course I attended referenced these value, the facility chose 3 mm/s RMS.
was drawn across all of the trending data alarm values.” Once the facility set these limits, assets
for their small-frame pumps—a solid D • “These are ISO alarm values.” that performed in a range greater than
according to the ISO severity chart. the alarm value but had not reached the
Despite this diligent effort to establish When asked to show a copy of the shutdown value were put on a watch list.
a limit, the mean value of all vibration ISO, they pulled out the old ISO 2372 Assets with readings in the shutdown
data collected on the facility’s small- severity chart that came in the box with range were, of course, shut down.
frame pumps was less than 2 mm/s the monitoring equipment or device—no Shutdown assets became a priority,
RMS. The alarm value was established standard, just the severity chart. When prompting personnel to correct
at 300 percent of any actual monitored asked why they allowed a vendor (a third deficiencies and at least get vibration
condition. In effect, the equipment party) to define what was or was not performance below the shutdown
could fail—and actually had a history of acceptable criteria for their equipment, values in order to place the equipment
failure—before the condition that would the management looked astonished. They back in service. Watch-list equipment was
cause a failure was identified. Based on invested heavily in a program (training, considered a secondary priority,
the alarm value, the program could not equipment and software) and had not and personnel aimed to bring
provide a return on investment. This was seen any real return. performance in line with similar assets
the No. 2 fi x: to establish meaningful Did this facility’s maintenance team with better performance.
performance criteria. change course? Yes, they did. ISO 10816 Most performance issues associated
Common explanations for how the includes a caveat that states that changes with the company’s small-frame pumps
alarm value was derived included: in vibration amplitude greater than 25 at all of its facilities were coupling and
• “The vendor that sold us the percent warrant investigation. So with alignment issues. This challenges the idea
monitoring equipment set the a mean value of 2 mm/s RMS for all that balance is the most common cause of
alarm values.” readings, they adjusted the alarm value vibration issues.

73
This is what CBM is all about: finding

Partial discharges in
indications of potential failure, and
prioritizing, planning and correcting the
motors are telling.
cause before actual failure occurs. Facilities
will see return on investment and asset Reliably detect early-stage winding
performance improvement.
insulation weaknesses with
25 Percent Baker DX Surge PD
In the discussion above, you probably noted
that I used a value listed in a consensus The SKF Static Motor Analyzer – Baker DX Surge PD
identifies early problems with coil and winding
standard (in this case, ISO 10816, Part insulation with an innovative partial discharge (PD)
1) to establish an alarm value. However, resistive measurement approach. There is no quirky
past experience and how I incorporate radio-frequency antenna to adjust, and it produces
consistently reliable high-resolution PD waveforms
that experience into training on vibration that identify insulation defects and weaknesses.
acceptance is a bit different. For common
equipment types, I have the end user Visit www.skf.com/emcm to learn more, or email
salesEMCM@skf.com for more information.
collect data on all bearings in all plains
to establish a baseline. Then I have the
individual use a spreadsheet to list the
equipment on the rows and the data The Power of Knowledge Engineering
collected at each bearing position in the
columns. We look at the mean value of data
from each column and the mean value of all Circle 147 on card or visit psfreeinfo.com.
of the means. The first standard deviation
from the mean of the means is the alarm,
and the second standard deviation is the
shutdown. Then I round the values up to
the next whole number (of half value). It is
a fairly simple process. What is particularly
interesting is that the alarm value generally
comes in at 25 percent.
We are establishing performance
criteria based on the equipment’s
operating characteristics in a specific set of
circumstances. We are using the consensus
standard as guidance and reference to
ensure the decision is reasonable—not too
high and not too low. Using this method,
facility owners are taking responsibility
for establishing performance criteria to
evaluate the condition of their equipment.
Mark Jennings is a senior engineering

consultant with ARES Corporation. Jennings
provides PdM program training, PdM
technology application, commissioning-
related PdM and consensus standard
interpretation related to PdM. He may be
reached at mjennings@arescorporation.
com or 509-936-8800. Celebrating Over 32 Years
74 SEALING SENSE
Analyzing Life-Cycle Costs to

Select the Best Sealing Solution
By Mark Savage
FSA Member
C
hoosing the sealing solution Seal maintenance and repair costs. packing. It is also the pump heat
that will be the most These costs are associated with soak, energy removed from the
cost-effective option for reconditioning the mechanical pump to reliably operate the shaft
a particular application is not as seal or replacing the packing rings, sealing solution. It also takes
simple as selecting the one that has lantern ring and sleeve. into account energy consumed in
the lowest one-time cost. Downtime and loss of production additional downstream processing.
To assist users in choosing costs. This is the cost of lost
the best seals, the Fluid Sealing production from the unexpected Combining one-time costs with
Association (FSA) created a life- failure of the sealing solution, total annual operating costs,
cycle costs (LCC) calculation tool which affects the operation of an the LCC tool can determine an
that enables end users to compare entire production unit. expected total LCC based on the
solutions to determine which Environmental costs. This projected life expectancy of a
offers the lowest cost over the life is the cost of complying with particular pumping asset. It also
of the pump. environmental regulations for the provides an output of the energy
The FSA’s LCC calculation tool particular sealing solution. An that a particular sealing system
allows users to compare additional example includes monthly organic consumes with a carbon footprint
considerations, including the vapor analyzer sniffing of single in the form of “equivalent carbon
annual operating cost of each seals. It could also include penalties dioxide emissions per year.”
sealing solution. The tool calculates and fines for fugitive emissions. As an example, consider a
the traditional elements, such as Energy costs. This is the frictional typical service encountered at an
spare parts and labor, plus parasitic power consumed by the seal or oil refinery that is pumping a hot
losses that are often overlooked.
The LCC tool can determine these
Figure 1. Summary of energy and life cycle costs (Graphics courtesy of FSA)
losses using standard engineering
calculations and data from the
user’s inputs. Annual component Initial Purchase Cost (Investment)
considerations can be grouped as:
Total Power Consumption KW
Operating costs. These costs are
items needed to support the sealing CO2 Equivalent Emissions
metric tons per year
system such as cooling water,
flush and quench fluids, buffer and
barrier fluids, barrier gas, and/or
effluent treatment.
Equipment maintenance and repair
costs. These are associated with the
need to perform repairs and replace
parts on the pump because of
failure of the sealing solution.

75
Figure 2. Detailed cost breakdown The purchase

costs for the seal
support systems
are added. Scenario
1 requires a heat
exchanger, stand and
1) Annual Operating Calculations
Operating Cost interconnecting piping.
Based on consumption/treatment of: Scenario 2 requires
Flush $ / year
Quench $ / year interconnecting piping,
(IÀXHQW \HDU
Cooling Water $ / year instrumentation, as
Nitrogen $ / year
Product Loss $ / year well as pressure and
Barrier Fluid $ / year flow-controlling valves.
Additional $ / year
Equipment Maintenance and Repair Cost A closed-loop barrier
Based on labor for: Remove/Repair/Replace $ / year
Based on materials for: Equipment Parts $ / year fluid circulating skid is
Seal Maintenance and Repair Cost
Based on materials for: Seal Repair $ / year selected for Scenario
Packing replacement $ / year 3 with a significant
Seal Support System Maintence and Repair Cost
Based on labor for: Remove/Repair/Replace $ / year initial investment of
Based on materials for: Support System Parts $ / year
Downtime and Lost Production Cost $ / year $50,000.
Environmental Cost $ / year
Energy Cost Direct Power Consumption $ / year The results give a
Heat Soak $ / year detailed breakdown of
Flush Cooling $ / year
Removal of Flush-to-Process Dilution $ / year the annual operating
Miscellaneous Energy Costs $ / year
costs, including the
costs of parasitic
losses. In this example,
there is a significant
difference in the
one-time costs of the
sealing solutions (see
Figure 1). That
hydrocarbon fluid at 650 F (343 C). the seal support system will require difference is considered along
For this, three potential candidate water. Kerosene is selected for the with the operating costs over
sealing solutions can be compared: Plan 32 injection fluid for Scenario the projected life expectancy of
Scenario 1: Single seal with 2, and the injection fluid value is a particular pumping asset. The
American Petroleum Institute increased. The value of the pumped resulting total estimated LCC
(API) Plan 23 (heat exchanger fluid is also increased. Because this suggests a different selection. The
cooling the seal chamber). pump is considered critical, $5,000 scenario with the highest initial
Scenario 2: Single seal with API per failure is selected to represent cost turns out to be the one with
Plan 32 (external injection of a the impact to production in the the lowest LCC. The tool also
clean fluid into the seal chamber). event of a seal or system failure. provides a summary of the energy
Scenario 3: Dual pressurized The pumping conditions and requirements and the carbon
seal with API Plan 54 (closed-loop the expected mean time between footprint of each solution.
barrier fluid circulating system). failure (MTBF) are then added. A
Using the default values in reduced MTBF for Scenario 1 is Next Month: Why should the
the LCC calculation tool and selected because the performance practice of hot re-torque end?
making some minor adjustments of the heat exchanger is expected We invite your suggestions for article topics as
for this example, we can make to deteriorate over time as a result well as questions on sealing issues so we can
better respond to the needs of the industry.
a quick comparison of the three of the large heat load placed on it. Please direct your suggestions and questions to
available scenarios. The MTBF for the heat exchanger sealingsensequestions@fluidsealing.com.
The heat exchangers used in is also modified to match that of
Scenario 1 and 3 are changed to the seal, assuming the cooling coils
water-cooled heat exchangers, so require cleaning on a regular basis.
76 HI PUMP FAQS
Allowable Operating Speeds for VFDs & Motor

Enclosures for Wastewater Applications
By Hydraulic Institute
What is the allowable up to 10 percent above base What type of motor

pump/motor operating speed without adverse effect, but and motor enclosures
speed range when a operators should first consult the are recommended for
variable frequency drive OEM to evaluate electrical and wastewater application
(VFD) is used? mechanical design considerations. pumps?
In rotodynamic pump
VFDs are used to vary the applications, the load is governed In wastewater applications,
speed of the pump in order to by the pump affinity laws, which the pump driver can be a motor-
optimize system efficiency and/ state that a change in torque is or engine-driven unit. The
or process control. Adjusting the proportional to the square of the most common pump driver in a
frequency applied to the motor speed change and that change in wastewater treatment plant is
allows the speed of the motor horsepower is proportional to the an electric-powered induction
and pump to be changed, usually cube of the speed change. Th is motor. Engine-driven pumps are
to a lower speed than the base type of load is known as a variable typically used in emergency or
revolutions per minute (rpm) torque load (VT). Most motors standby service when electrical
stated on the motor nameplate or are capable of operating 10 times power supply is not available.
lower than the speed the pump slower than the nameplate rpm of Synchronous motors can also
would operate with utility power. the motor (10-to-1 speed range, be used, but they are normally
Operating a pump at reduced or turndown) when driving a provided for kilowatt requirements
speeds is usually acceptable within rotodynamic pump. above 750 (horsepower
a specified range, but operators Positive displacement pumps requirements above 1,000).
must consider certain mechanical present higher relative loads at The selection of a type of motor,
design features such as bearing reduced speeds, which will have the method used to start the motor
lubrication and natural frequency a more significant impact on the and considerations for operating
interactions. Anyone considering motor and drive. Most motors can the motor are based on many
reduced-speed operation should operate with a 2-to-1 turndown factors. These include location,
consult the pump original speed range with this type of load, atmospheric designation of the
equipment manufacturer (OEM). which is commonly considered a location, operational conditions,
Operating the motor at lower constant torque (CT) load. size of the motor to be used,
speeds usually results in a For best results, define the load number of motor starts required
reduction of the motor cooling type and operating speed range in and power availability.
system capability, because motor advance. Provide this information The options for motor enclosures
cooling fans produce less airflow to the pump, motor and drive include open drip-proof (ODP),
over the motor at reduced speeds. manufacturers and discuss it with totally enclosed fan-cooled (TEFC)
Operators must ensure that the them to ensure the motor and and totally enclosed non ventilated
motor can withstand the added drive selection is the best fit for the (TENV). When choosing the
heat that is created by operating pumping application. enclosure, consider the application
below base speed. The operating For more information on VFDs, and the area of use.
speed range should be defined refer to HI’s guidebook Variable ODP motors are suitable
and applied to motor capability Frequency Drives: Guidelines for for general industrial use in
requirements. In many cases, Application, Installation, and outdoor or indoor locations with
the pump and motor can be sped Troubleshooting. relatively clean atmospheres and

77
nonexcessive ambient temperatures. The

ventilation openings of an ODP motor
CHEM-PRO
SUPERIOR DIAPHRAGM METERING PUMP
Precise Chemical Metering
®
prevent interference with motor operation

when liquid or solid particles less than 50
millimeters (mm) (1.97 inches) strike or
enter the enclosure at an angle up to 15
degrees downward from vertical. In an
open motor, air circulates freely through
the motor for cooling. Openings are
limited in size to prevent contact with
IP6
P6
66
hazardous internal parts. Th is provides
NEM
EM
MA 4 X
some protection from drip, splash and WASH DOW
WAS
WA OW
WN
falling objects. The motor is susceptible to
moisture and contamination.
A TEFC motor is enclosed to prevent PVDF DIAPHRAGM: PATENT PENDING
• Single piece injection molded design
the free exchange of air between the with zero breakdown or delamination,
inside and outside of the case, but it is reducing field maintenance requirements and down time.
• Manufactured 100% in-house exclusively for
not airtight. The exterior surface is cooled use on Chem-Pro® Diaphragm
Metering Pumps.
by an external guarded fan attached to
the motor shaft, which circulates air over 5300 Business Dr., Huntington Beach, CA 92649 USA
the frame housing. A finned cast-iron 714-893-8529 • sales@blue-white.com • www.blue-white.com
framed motor or a steel motor on a smaller
motor frame is usually suitable for this Circle 140 on card or visit psfreeinfo.com.
type of enclosure. Because air does not
pass freely through the motor, the TEFC
enclosure protects the motor from harsh
environments. They can be operated
indoors or outdoors.
A TENV motor is a frame surface-cooled
unit that is cooled by free convection. It
is enclosed enough to prevent the free
exchange of air between the inside and
outside of the case, but it is not airtight.
The motor is cooled by free convection and
radiation only. A TENV motor is suitable
for use in dusty, humid environments. In
general, it is limited to low horsepower
ratings or limited-time, duty-rated motors.
For more information, refer to HI’s
guidebook Wastewater Treatment Plant
Pumps: Guidelines for Selection, Application,
and Operation.
HI Pump FAQs® is produced by the Hydraulic

Institute as a service to pump users, contractors,
distributors, reps and OEMs. For more
information, visit pumps.org.
78 PRACTICE & OPERATIONS
Where Do You Get Your

Replacement Parts?
End users in need of replacement parts should understand the
capabilities and offerings of different suppliers to obtain optimal
system components.
By Richard E. Martinez
Standard Alloys Inc., a KSB Company
T
he aftermarket business The process of finding and
continues to be in a state of selecting an alternate source has
flux. For many years, pump become more complicated with the
users and original equipment advent of new portable coordinate
manufacturers (OEMs) have referred measurement machines (PCMM).
to non-OEM parts as pirate or Just because a parts supplier uses
replicator parts. these devices does not mean it will
Recently, several companies be able to provide an optimal part; a the data collected using the PCMM
have evolved into a new category of quality parts supplier does more than based on their understanding of
solution providers. Parts supplied by purchase equipment. pump design. They rationalize
these companies go beyond simple PCMM machines are highly the data and have the technical
parts replacement. accurate devices that take thousands expertise to identify manufacturing
A solution provider focuses on the of measurement points or scan deviations, in-service part wear and
total cost of ownership to provide complete surfaces to measure a manufacturing flaws. From there,
quality parts using state-of-the-art part’s physical characteristics. The they reverse engineer a product
manufacturing. These companies supplier must have the technical that meets the original fit, form and
engineer upgrades that improve ability to analyze the data collected. function. Assuming the replicator
runtime and use dedicated or job- Even if the part being copied is a has the in-house expertise to
shop manufacturing processes to new part, it is likely to have some rationalize the data as described, the
provide quick deliveries. manufacturing deviations that can parts supplied will work and often
These unique solutions can resolve hinder the performance of the part be adequate to restore the original
aftermarket supply chain problems being supplied. The OEM can clearly operating performance.
and improve a plant’s operational evaluate and even categorize these
bottom line. deviations for disposition and use, Solution Providers
but a pirate cannot. Subsequent Albert Einstein has been quoted as
Pirates & Replicators deviations can occur that prevent saying, “The definition of insanity is
While many users would prefer to the pump from meeting the original doing the same thing over and over
purchase from the OEM, they often operating conditions, and this and expecting different results.”
look for alternate sources for their problem could worsen if the pirate is Based on the discussion above, a
parts because some OEMs may working with a worn sample. The pirate may produce an unfavorable
lack the flexibility to meet delivery part will simply be a brand-new, result, which can jeopardize the
requirements or because the OEM worn-out part. pump’s operation. A replicator
has closed. For this reason, pirate Replicators take the process one can produce the desired results
and replicator companies have existed step further: They reverse engineer but typically does not optimize
for decades. the part. This means they evaluate performance of the part. In other

79
Image 1. Pump repair is available for all

API designations. (Images and graphics
courtesy of Standard Alloys Inc.)
words, if a user had poor design

performance and reliability before the
part is replaced and the supplier or
replicator simply provides the same part
again and again, the user cannot expect
the pump’s performance and reliability to
become acceptable.
Solution providers do not simply
repair or replace parts; they offer
value-added engineering from hydraulic
and mechanical design, metallurgical
expertise and manufacturing know-how.
They partner with the end user to look at
the total pump system and offer solutions Simple, Reliable
with tangible reliability improvements
and measureable cost savings.
Solution providers have become even
Efficient
Vapor Recovery? LPG Transfer? Natural Gas Boosting?
more critical in today’s global energy- The answer is the FLSmidth® Ful-Vane™ rotary vane compressor!
conscious environment. Plant operations Built robustly for long service life, it has only three moving parts. Combined with low operating speeds
and maintenance personnel are pressed which minimizes wear and vibration, it is designed to not only outlast other compressors, but save you
money on power and maintenance costs.
to minimize their plants’ carbon
• Suitable for natural gas, flare gas, bio gases, LPG vapor, and ammonia refrigeration
footprints while increasing profitability.
• Carbon fiber vanes last longer than traditional blades
This is difficult to do when many pumps • Variable flows with VFD and/or bypass
in service today are operating off their • Single stage to 3000 SCFM, two-stage to 1800 SCFM
• Discharge pressures to 250 PSIG
design point because they were not
• Made in the USA for over 80 years
properly sized during the design phase
or because the operating conditions have Find out more at www.flsmidth.com/compressors
changed since startup.

Centrifugal pumps have a

Figure 1. Original design showing cavitation (top) and solution provider design showing no
wide operating range that helps cavitation (bottom)
plants through unit upsets or
short durations of non-standard
operation. However, each pump
has a specific design point
referred to as the best efficiency
point (BEP). OEMs will identify
the preferred operating region
and allowable operating region on
the performance curve. Th is is all
done to help end users understand
where they should apply and
operate the centrifugal pump.
At the end of the day, the pump
is going to operate where the
system curve intersects the pump
curve, and this point may be far
from the theoretical design point
listed on the pump data sheet and
performance test curve.
These off-design operations will
lead to maintenance headaches
with a high rate of bearing failures
or—even worse—mechanical
seal failures.
Pumps that have been oversized
from initial startup and plants
that are being forced to double-
pump to meet new system head
curves have many pumps running
far to the left of the BEP. Less
common but still an issue are
pumps that operate far to the
right of the BEP.
A solution provider can develop
a long-term solution when these the user the most cost-effective needs, and mechanical upgrades
pumps are down for maintenance way to eliminate operations and are employed to ensure that the
and the end user is asking “repair maintenance headaches. These seal chamber, rotor stability and
or replace?” These solutions can pumps are engineered with the casing designs are within the latest
go far beyond a simple hydraulic proper hydraulic fit where the BEP American Petroleum Institute
re-rate where a donor hydraulic and the standard operating point (API) requirements.
is applied to an existing design. are a sound match. While these design elements are
Sometimes the best solution is This means that even as the important, the real value is that the
a complete drop-in replacement plant goes through normal load drop-in replacement pumps meet
pump. A solution provider can swings, the pump operates within all of the current pump’s existing
deliver these products quickly the preferred operating region, connection points. Th is means that
with dedicated or job-shop offering peak efficiency, low the drive, piping and foundation
manufacturing capability. vibration and optimum reliability. do not have to be reworked or
Solution providers offering The materials of construction replaced. This, in turn, saves huge
drop-in replacement pumps give are upgraded to meet particular capital project dollars.

81
Image 2. Typical pump impeller being machined
The Difference equipment, the OEM or potentially

The need to secure an engineered a quality replicator might be the
replacement part or a complete best fit for a direct replacement.
drop-in replacement pump will A solution provider, however, can
be even more important as U.S. help take the reliability of critical
industrial infrastructure continues pumps to a new level.
to age. By understanding the complete
A real solution provider must pump system as well as the design
have integrated engineering and and manufacturing processes,
manufacturing resources to be able end users can adequately evaluate
to generate these high-value offers. available solutions that will
They must have specialized design further their continuous
and manufacturing knowledge and improvement programs and take
must be able to apply this know- their reliability to levels that were
how to help the user look beyond a previously not achievable.

direct replacement part.
Pirates and replicators often can
offer a direct replacement with
a more attractive delivery time Richard E. Martinez is president
and lower price than the OEM. of Standard Alloys Inc.,
But for end users who need full- a KSB Company. He
service optimized parts, a solution may be reached
provider may be the best choice. at richardm@
If your reliability is already standardalloys.com
acceptable for a specific piece of or 409-983-3201.
California Hospital Cuts Clogs & Maintenance

Costs Using Submersible Shredder Pumps
The Pomona Valley Hospital Medical Center was spending between $4,500 and $8,500 per
incident to remove solids from its sewage ejection pits.
By Mike Bjorkman
BJM Corp.
B
ecause they clog pumps,
non-dispersible wipes have
become a source of anguish
for many maintenance teams.
When pumps that run in critical
applications become clogged, the
cost to repair or replace those
pumps escalates.
These excessive maintenance
expenses have been shouldered by
many hospitals across the U.S. that
have experienced a rapid increase
in non-dispersible materials
entering their sewage systems.
A nationally recognized, not-
for-profit hospital serving eastern
Los Angeles and western San
Bernardino counties contacted
Cortech Engineering in April 2014,
determined to address a persistent
clogging problem to save on
maintenance costs.
Pomona Valley Hospital Medical
Center (PVHMC), which is staffed
by about 800 physicians and twice Image 1. Between 2008 and 2014, the Pomona Valley Hospital Medical Center’s
as many nurses, is a 437-bed sewage ejection pumps needed to be rebuilt and replaced several times. (Images
courtesy of BJM Pumps)
hospital that relies on seven sewage
ejection pits to collect waste from consistently becoming clogged Year’s Eve. When the pumps get
the hospital complex. These sewage with wipes and other materials not clogged, the maintenance team has
ejection pits are responsible for designed to be flushed through a to act quickly to keep the system
pumping waste material out of the sewage system. working,” said Karen Deshler,
buildings and into the municipal Between 2008 and 2014, the outside sales engineer for Cortech
sewer system. hospital’s sewage ejection pumps Engineering. “When the pumps
Like many other hospitals needed to be rebuilt and replaced become clogged, the hospital has
across the U.S., PVHMC was several times. to bring in extra maintenance staff
having problems with disposable “Clogs happen at all times of the and incur higher expenses during
wipes. The pumps operating in the year—they don’t care whether it’s off-shifts and holidays. They were
facility’s sewage ejection pits were Thanksgiving, Christmas or New spending between $4,500 and

83
$8,500 each time they had to bring

in a super-sucker vacuum truck to
remove the solids from the sewage
ejection pits. Over time, and with
repeated incidents, this became
quite costly.”
Looking for a Solution

Peter Kersten, stationary engineer
for PVHMC, began researching
grinder and shredder pumps that
were available on the market and
decided on a submersible shredder
pump designed to shred almost
everything—from rubber chickens
to running shoes. He presented the
pump to his bosses and explained
how a submersible shredder would
meet their critical requirements:
• The pumps needed to be able
to shred the disposable wipes
and rags that were pushed into
the sewage ejection pits. The Circle 149 on card or visit psfreeinfo.com.
sewage ejection pits needed to
stay clear of fibrous, floating
debris to prevent clogs and avoid
emergency situations.
• The pumps needed to be able to
operate reliably to avoid extra
maintenance expenses.
The selected submersible shredder

pump can handle up to 3.5-inch
MURPHY POWERCORE ®
Murphy’s PowerCore family just got bigger with the TEC-10.
solids at 570 gallons per minute This turnkey electronic controller is ready to work out of the
with a maximum of 59 feet of head. box and is the perfect fit for your industrial needs.
Engineered to shred solids, the
pump uses a cutting impeller with a
tungsten carbide tip to continuously
rip apart solids against a tooth-
edged, spiral-shaped diff user plate.
With 360-degree shredding action
and non-clog, single-vane impellers,
the pump can shred the disposable
wipes and rags that are pushed
through the sewage ejection pits.
The pump is constructed of
hardened cast iron to withstand
rough handling and a 304 stainless
steel motor housing, which offers CHOOSE YOUR CONTROL WITH MURPHY.
abrasion-resistance that is superior WWW.FWMURPHY.COM/3XCONTROLLER 918-317-2642
to aluminum motor housings.
With 15 months of successful operation, the

submersible shredding pumps are successfully handling
the disposable wipes and keeping the 16-foot-deep
sewage ejection pit operating smoothly.
The pump motor is protected lip seal is installed above the Manufacturers Association Class
with double mechanical seals, impeller to prevent unwanted F motor insulation, the pump can
which are comprised of a lower materials from entering the withstand motor temperatures
seal made of silicon carbide/silicon seal chamber. up to 230 F. An automatic switch
carbide and upper seal faces made Incorporating winding turns the pump motor off if the
of carbon/ceramic. An additional protection and National Electrical temperature and/or amp draw
gets too high. When the motor
cools, the switch is designed to
automatically reset, and the pump
will once again begin operating.
The pump is also equipped
with a seal moisture detection
system, which features a sensor
probe inside the oil chamber that
can provide an early warning to
protect the pump motor. When
the seal failure circuit, or moisture
detection circuit, is properly
connected to a control panel, it
informs the pump operator that
moisture is within the oil chamber.
This early warning can allow
the operator to schedule pump
inspection and repair.
Results
Once the PVHMC decision makers
were on board with the selection,
two of the submersible shredder
pumps were installed in a duplex
arrangement inside the 16-foot-
deep sewage ejection pit. During
installation, under the direction
of Cortech Service Manager Mark
Fox, Cortech’s on-site technicians
installed a lifting chain, electrical
wiring to a 15-amp breaker for the
duplex control panel and the seal
Image 2. The pumps operating in the Pomona Valley Hospital Medical Center’s
sewage ejection pits were consistently becoming clogged with wipes and other moisture-detection relay, and new
materials not designed to be flushed through a sewage system. stainless steel check valves.

85
PINNACLE-FLO
QUALITY•VALUE•ENGINEERING
“The lifting chain makes it INDUSTRIES:
easier for us to hoist the pumps • Chemical Process
for inspection and maintenance,” • Refinery
• Oil & Gas Municipal
Kersten said. “The … control panel • Food Process Markets
alerts the staff in case there is a • Water/Wastewater
problem, which will help to prevent PRODUCTS:
a burnout. The stainless steel check • ANSI Process
valves are an added bonus. Cortech • API 610
• Centrifugal
recommended the new valves for Solids-handling
increased reliability because they Self-prime Introducing Pinnacle-Flo, Inc.
will last much longer than the • Centrifugal MUD Fully Synthetic Oil
• Air Operated Double Pinnacle-Flo, Inc. and Royal Purple have
previous cast-iron valves.” Diaphragm Pumps teamed together to create a fully synthetic
With 15 months of successful oil called MicroSyn 88. This is a
Clean, Dry, Long Life, High Film Strength,
operation, the submersible Energy Efficient, Synthetic Lubricant that
shredding pumps are successfully Significantly Increases Bearing Life and
Equipment Reliability.
handling the disposable wipes and MicroSyn 88 is shipped with every
keeping the 16-foot-deep sewage one of our ANSI 8896 pumps as well as
our line of Self-Prime centrifugal pumps.
ejection pit operating smoothly. Contact Pinnacle-Flo, Inc. for the nearest
“The maintenance staff stocking distributor.
Our on-sight engineers and professionally trained
appreciates the decrease in calls for sales staff support our network of distributors.
middle-of-the-night and holiday
emergencies, and those managing Pinnacle-Flo.com • Houston, Texas • 832-303-1245 • sales@Pinnacle-Flo.com
the maintenance budget are Circle 145 on card or visit psfreeinfo.com.
happy to save money they’d been
spending on the vacuum truck,”
Deshler said.
Kersten added, “Last Christmas
was the first one I’ve had off in over
three years. No more calls at 2 a.m. An engineering design firm helping pump manufacturers
to unclog a pump.” accelerate organic growth
The hospital is in the process of
purchasing four more submersible
through product and process
shredder pumps for use in two innovation
other sewer ejector pits.
We serve as a dynamic extension of your R & D:
• Create differentiated product lines
Read more about • Supplement your R & D resources
shredder pumps at • Speed time to market
pumpsandsystems.com. • Cut production cost up to 50%
• Utilize our Pump Innovation Lab
Products in the pipeline for sale or license:

Mike Bjorkman is vice president • ANSI sealless centrifugal: Breakthroughs in efficiency, NPSH,
run-dry and cost plus aftermarket interchangeability.
of BJM Corp. and has more than 30
• New sealless hygienic lobe: Simple design that is affordable
years of experience in the pump and fully interchangeable with leading manufacturers.
industry. He serves as director of • New generation electric double diaphragm: Game-changing
marketing and IT for BJM Pumps efficiency, weight, size and affordability.
LLC and All Test Pro LLC. Both
companies are subsidiaries of BJM
Corp. Bjorkman may be reached at Contact Bill Taylor: wtaylor@peopleflo.com, 714-856-7222
860-399-5937. www.peopleflo.com
4 Advantages of AODD Pumps

These pumps can provide versatility and reliability within a variety of applications.
By David Rozee
Tri-Ark Pumps Ltd.
A
ir-operated double- The AODD pumps are able to mediums as diverse as water, harsh
diaphragm pumps (AODD) run dry without damaging costly chemicals, effluent, animal entrails
have been through many internal wear parts or destroying and naphtha. They can efficiently
innovations in technology and an expensive motor. Also, the handle anything from water to
design since their introduction to pumps do not use oil or other 90 percent solids. The ability to
the market more than six decades lubricants, which means they do customize the pump also ensures
ago. They are now a key player in not stall or get clogged because of costs are kept to a minimum
the pump selection process. lack of lubrication. because users are not forced to
AODD pumps offer a sealless, A useful feature is that they can purchase a pump that is too large
positive displacement alternative be deadheaded without damage for the application.
to centrifugal pumps. They are used to the pump. Also, if a system is The type and composition of
for a number of applications across programmed to shut down the the pumped fluid will influence
a wide range of industries including pump when certain pressures the material of the pump, and the
oil and gas, food processing, have been reached (a fi lter press desired flow rate and potential
chemicals, paints, electronics and application, for example), it can do pressure conditions will determine
pharmaceuticals. this safely without incurring huge the size of the pump. For example,
By considering these four repair bills for broken pumps. a small metal pump used to pump
advantages of AODD pumps, Another advantage of an AODD water would be unsuitable for
end users can decide if this type pump is that they are lightweight pumping acids because it would
of pump is the right choice for and portable, making them ideal dissolve. In this case, a plastic
their application. for use in multiple locations. They construction would be better.
are also easy to dismantle, repair, In some industries, diaphragm
1 Simple Construction
A key selling point of AODD
pumps is that they are easy to use.
clean and maintain compared with
other types of pumps with a more
complex construction that have
pumps must be certified and
comply with national and
international safety guidelines and
The simple design combined with multiple electrical components and standards. For example, selecting
the ability to pump most materials parts. This simplicity ensures the appropriate construction materials
makes them a popular option. production line continues to run is crucial in the food and beverage
AODD pumps do not have any smoothly, provided that regular industry where pumps are used for
close-fit, sliding or rotating parts pump maintenance is scheduled. hygienic applications for products
and, as a result, require minimal such as beer, wine, milk, vegetables
assembly. Many refer to these
pumps as “plug-and-play” items 2 Versatility
Various levels of customization
and other foods.
because, once they are connected

to a compressed air line, they are
ready to use immediately. Once in
are available for diaphragm
pumps, and the size and material
of construction depend on the
3 Safe Design
AODD pumps do not require
electricity or any fuel other than
place, the pumps can effectively intended purpose. This means compressed air. Th is intrinsically
run with little maintenance. AODD pumps can be used for safe design means that no harmful

87
fumes are exhausted, eliminating

the risk to the workers and
product. Furthermore, they are
4 Flexibility & Discharge
AODD pump sizes range from
0.25 to 4 inches, with flow rates
pressure of more than 125 pounds
per square inch (psi) is required,
users can opt for a 2-to-1—or even
fully sealed units, meaning they ranging between 19 and 1,100 a 3-to-1—ratio pump unit which
can be partially or completely liters per minute. can exceed pressures of 300 psi.
submerged in a liquid. This Today, manufacturers offer a
minimal risk of contamination range of flexible sizes, enabling
provides an added benefit to the users to buy a pump that will give
food and beverage industry. them a balanced system. David Rozee is the managing
Diaphragm pumps are driven AODD pumps are capable of director of UK-based company Tri-
by air, eradicating the risk of a pumping as slow as 1 gallon Ark Pumps Limited, which supplies
short circuit or liquid penetrating per minute. Of course, a 3-inch industrial pumps and spares
through the wiring to cause a spark pump will carry a higher capital worldwide for all popular pump
or produce fl ashing. In addition investment, but the returns can brands. These include Sandpiper
to this built-in safety advantage, be exponential when it comes to pumps and the
these diaphragm pumps are productivity gains from using a Blagdon and Graco
available ATEX (ATmosphères larger pump. ranges. For more
EXplosibles) certified for use in Another benefit of AODD pumps information, visit
applications where it is unsafe or is that standard units are 1-to-1 tri-ark.com.
not possible to use electricity. ratio pumps. When a discharge
When splines or keys fail

prematurely, Polygons
are your Solution
Polygon Systems
The Ultimate Shaft-To-Hub Connection
• Transmit nearly twice the torque of involute splines in the same
shaft diameter.
• Minimum backlash, even Zero BacklashZLWKWDSHUSRO\JRQVRUSUHVVƓW
connections.
• Excellent concentricity, provide balance at high speeds.
• Polygons are self centeringHYHQRQVOLGLQJƓWV
• Can be ground after hardening, avoiding heat treatment distortion.
• Polygons high strength makes it possible to reduce connection size when
space limitation is required.
• Increase connection life on violent torque reversals.
• Easy to assemble, easy to clean.
• Peak Stress, half as high as in a spline, thus fatigue life is 10x greater
Stoffel Polygon Systems, Inc.

199 Marbledale Road, Tuckahoe, NY 10707
Tel. (914) 961-2000 Fax (914) 961-7231
www.stoffelpolygon.com
88 PRODUCTS
1
New & Notable Technology
Products selected by the Pumps & Systems editors:
1 COUPLINGS
In an effort to address increased demand for
its SERVOMAX elastomer couplings in high-
speed spindle applications, R+W COUPLING
TECHNOLOGY has released its new ultra-
3
precision model SP6. Made with improved
concentricity and perpendicularity, as well as
higher-grade materials, the hubs are capable
of handling circumferential speeds of up to
80 meters per second and higher torque levels
per size. The SP series also has an increased
bore diameter capacity per body size and
adjustable positioning of the outer clamping 6
4
ring, allowing users to fi ne tune the location
during installation.
2 DIAPHRAGM METERING
INJECTOR PUMP
BLUE-WHITE INDUSTRIES is offering its
5
Chem-Pro M diaphragm metering injector
pump designed for use in municipal water
and wastewater treatment systems. Able to
handle injection of aggressive and/or viscous
chemicals, the Chem-Pro M is equipped with 6
a variable speed DC motor and offers smooth,
quiet chemical dosing with no hard pulses.
A full stroke every time prevents vapor lock.
Intelligent electronics permit connection
to SCADA systems (Modbus TCP, Profi Net,
Modbus, Profibus) and other remote
controllers for dosing control.
beverage, pharmaceutical, and home and personal NEMA standard JM or JP motor for mechanical seal or
3 SUBMERSIBLE PUMPS care industries. The control unit offers an affordable packing gland configurations, both of which include a
BJM PUMPS has introduced its SKGF Series and cost-effective alternative to conventional valve 416 stainless steel shaft sleeve for durability and ease
submersible pumps that are designed to monitoring and control solutions. It detects loss of air of service.
pump clear or solids-laden liquids up to 200 pressure, which is one of the most common types of Circle 205 on card or visit psfreeinfo.com.
F (93 C). The cast-iron F-Series submersible process failures. Th inkTop D30 is watertight and IP66/
pumps perform in sumps where liquids are IP67-compliant, so it prevents condensation as well as 6 DOSING SKID SYSTEM
too hot for some other submersible pumps. stops dust, water and other particles from penetrating The GRUNDFOS Dosing Skid System (DSS) is a pre-
They include patent-pending RAD-AX Dual into the control head. engineered floor or panel dosing system package that
Shredding Technology, featuring radial Circle 204 on card or visit psfreeinfo.com. offers integrated controls and one-, two- or three-pump
and axial shredding elements, to help configurations designed to accurately meter liquid
obliterate difficult solids in high-temperature chemicals for a variety of water supply/treatment
installations. Motor winding protection 5 CENTRIFUGAL CLOSE-COUPLED PUMPS systems, as well as industrial and manufacturing
and (NEMA) Class R motor insulation allow FRANKLIN ELECTRIC CO. INC. has expanded its line applications. The Grundfos DSS uses an intelligent
motor temperatures to rise to 428 F of AG Series centrifugal close-coupled pumps designed drive and microprocessor controller to ensure that each
without damage. for optimal performance in challenging water transfer dose is performed precisely and with low pulsation,
Circle 203 on card or visit psfreeinfo.com. applications that demand efficiency in industrial, even with chemicals of high-viscosity or off -gassing
commercial and agricultural markets. The expanded properties. The packaged skid systems are available for
series includes 10 pump families covering the most all models of Grundfos hydraulically and mechanically
4 VALVE CONTROL popular hydraulic performance ranges with models actuated metering pumps, including SMART Digital
ALFA LAVAL has released its Th inkTop D30 from 3 through 75 horsepower, flow ratings from 50 Dosing pumps with stepper motor technology offering
easy-to-install integrated control unit for through 2,000 gallons per minute, and heads up to 300 up to 3,000:1 flow turndown.
hygienic applications in the food, dairy, feet. Each AG Series Pump is equipped with either a Circle 206 on card or visit psfreeinfo.com.
To have a product considered for this section, please send the information to Martin Reed, mreed@cahabamedia.com.

-
Iii
....
ALL-TEST PRO 5
81111
•••
•'111
m ~ EAr,
10 10 PLUG VALVES
FLOMATIC CORPORATION has released its
new Model 5400 Flo-E-Centric plug valves.
The valves are round-port eccentric plug
valves designed in compliance with ANSI/
AWWA C517-09. The body, bonnet and plug
(NBR encapsulated) are constructed of
ASTM A536 grade 65-45-12 ductile iron,
and flanges are rated ANSI class 150#. All
fasteners and washers are stainless steel. The
valves are designed primarily for the water
and wastewater markets. Other applications
include handling a variety of liquids, slurries
12 and gasses including air and some chemicals.
11
11 BEARING PROTECTION RING

By diverting harmful shaft voltages induced
by variable frequency drives (VFDs) safely to
ground, the AEGIS PRO Series Rings protect
large AC and DC motors from bearing damage,
costly repairs, unplanned downtime and
lost revenue. Available for motor shafts up
to 30 inches in diameter, AEGIS PRO Series
Rings are specially designed for high-current
applications such as generators, turbines
and medium-voltage motors. Six rows of
7 SWITCHBOARD conductive microfibers completely surround
SCHNEIDER ELECTRIC has announced the U.S. three probe (rod, coaxial or cable) configurations the motor shaft, providing millions of
availability and manufacturing of its Okken up to 3 meters (9.8 feet) for the rod and coaxial and discharge points for harmful shaft currents
Intelligent Switchboard solution for low-voltage 5.5 meters (18 feet) for the cable design. The contact and diverting these currents away from
power distribution and motor control for !EC liquid level sensor is intended for low-corrosive bearings to ground.
(International Electrotechnical Commission) chemical, waste, oil or water storage applications in Circle 211 on card or visit psfreeinfo.com.
projects. Contractors and original equipment above-grade metal or reinforced concrete tanks or
manufacturers doing business overseas can source below-grade tanks of any material.
the solution in North America to serve customers Circle 208 on card or visit psfreeinfo.com. 12 CIRCULATORS Er
in regions where !EC is the applicable standard. The SEAL BEARING ASSEMBLIES
Okken switchboards provide enhanced efficiency 9 MOTOR CIRCUIT ANALYZER ARMSTRONG FLUID TECHNOLOGY offers
and safety for large industrial and critical process ALL-TEST PRO LLC is offering its ALL-TEST PRO 5 its line of Maintenance-Free (MF) S&H
sites and marine applications. The switchboards motor circuit analyzer that tests all types of motors, Circulators and the Seal Bearing Assemblies
combine high modularity with total insulation including induction, synchronous, AC, DC, brushless (SBA) used to service them. Armstrong MF
to enable complete electrical installation and DC, servo and wound rotors, as well as single-phase S&H Circulators eliminate the need for oiling,
operational safety. motors. The health of all motor components is saving time and cost for building operators.
Circle 207 on card or visit psfreeinfo.com. evaluated, including induction windings and rotors, The company's SBAs are compatible with many
DC field windings and armatures, and field and competing circulator models that require
8 GUIDED WAVE RADAR LEVEL TRANSMITTER rotor coils in synchronous motors. Single and three- maintenance. This allows building owners
OMEGA has released the LVRDlO Series of general phase transformers, pole and pad mounted, are also to upgrade those installed circulators by
purpose guided wave radar level transmitters that ideal candidates for evaluation with the ALL-TEST replacing the SBAs with the maintenance-free
provide continuous level measurement with a 4- to PROS. Armstrong versions.
20-milliamp signal output. The series is offered in Circle 209 on card or visit psfreeinfo.com. Circle 212 on card or visit psfreeinfo.com.
pumpsandsystems.com I Jun e 2016

90 PRODUCTS
13 DIAPHRAGM PUMPS
QUATTROFLOW, part of PSG, a Dover company, has 13
introduced its new single- and multi-use sealless
pumps specifically designed for biopharmaceutical
applications. The new QF20KSU single-use pump
features replaceable polypropylene wetted pump
chambers, which can be easily and quickly replaced
as a complete unit between batches to eliminate
sterilization, lower cross-product contamination risk
and reduce downtime. The new QF1200-HT single-
and multi-use pumps feature a high turndown ratio
for extremely precise accuracy in controlling flow 14
rates. Their versatile compact design with integrated
controller can provide a high-performance plug-and-
play solution for applications requiring precision flow 15 PERISTALTIC CASED PUMP
control, quick batch changes and a small footprint. WATSON-MARLOW FLUID TECHNOLOGY
Circle 213 on card or visit psfreeinfo.com. GROUP has introduced its 530 peristaltic
cased pump for metering and transfer
applications such as surface coating, printing
14 RADAR LEVEL SENSOR and lime addition. The new 530 models meet
ENDRESS+HAUSER has released one of the world’s the demands of rugged and often remote
fi rst radars with a transmission frequency of 79 environments and are built to operate 24/7 15
GHz for level measurement in liquids. The new without interruption. They feature integrated
Micropilot NMR81 for high-accuracy custody transfer PROFIBUS networking capabilities. With
applications is certified by independent test authorities two-way, real-time communications, the
to an accuracy of up to ±0.5mm. The sharply focused 530 range offers increased diagnostic
microwave beam angle ensures safe and reliable capability and faster response. It offers four
measurements without any interfering signals even drive options and nine pumphead variants.
in narrow tanks with baffles. Installation relatively Th is enables users to choose from manual
close to the tank wall is possible with the narrow beam operation to fully automated control,
angle. The technology permits long measuring ranges including the ability to link up to 16 pumps
of up to 70 meters. and provide real-time communication.
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
innovation by experience !
• Custom Research
• White Papers
Heinrichs: A reliable partner in business for more than Frost & Sullivan evaluates and implements
80 years, ISO/TS 16949 and ISO 14001 certified. Serving effective growth strategies. We employ 50
years of experience in partnering with Global
the drives and controls industries with smart solutions for
1000 companies, emerging businesses and
sealing, venting and gauging at highly competitive prices, the investment community from more than
including metric, BSP and UNF threads. Let us be your 40 offices on six continents.
global partner for high precision turned parts.
Visit us at www.frost.com
Heinrichs USA LLC | mail@heinrichs-usa.com
For more information, contact Liz Clark
www.heinrichs-usa.com It’s our turn! at 210.477.8483 or liz.clark@ frost.com

91
17 MACHINE LUBRICATION PUMP

VARNA PRODUCTS has introduced a new pump
17 series optimized for machine lubrication. Built on
the same “Whisper Vane” pump technology as the
16 XD line, the ML series pumps offer a solid option
for closed-loop lubrication systems. The ML-4 can
make up to 4 gallons per minute, while ML-2 makes
up to 2.6 gallons per minute. Both are the same
physical size and configuration, making it easy for
installers to integrate the pump into their systems
with interchangeable flow rates. The quiet-running
vane pumps are intended to be a part of a lube-
distribution system with delivery branches leading
to multiple lube points within a machine.
16 MONITORING DEVICE
The SENSAPHONE CELL682 cellular-
based system provides 24/7 monitoring of 18 SUBMERSIBLE PUMP
environmental conditions and unattended PENTAIR FLOW & FILTRATION SOLUTIONS
equipment at remote locations where has announced the expansion of its TMH series
telephone and Ethernet connectivity are of submersible pumps with the launch of the
unavailable. The CELL682 system provides 7TMH submersible pump. It provides agricultural
simplex or duplex alternating pump control irrigation users with higher head per stage and
using a level transducer or float switches. The efficiency improvements. Impellers and diff users
unit can perform machine-to-machine control were designed together to provide maximum
among multiple CELL682 devices. It can hydraulic performance. The pump’s new motor
monitor up to 14 critical conditions including coupling contains sand boots to help protect from
18
tank levels, turbidity, pump status, flow rates, sand intrusion. New ductile iron discharges and
security, power failure and equipment failure. motor adapters were designed for greater strength
If the system detects a potential problem, it while reducing intake restriction losses, and the full
sends alarm notifications to up to 24 voice, contact collet design ensures that impellers are held
text or email destinations. tightly onto the shaft.
Your Premier Manufacturer of

ANSI Pumps &
Centrifugal Mud
Pumps
• In stock, ready to ship
• Numerous makes and
models
• Service and repair on
existing pumps
1113 Howard Avenue | Houston, TX 77536 | 281-479-5000

curflo.com
92 PUMP USERS MARKETPLACE
Advertisers
Advertiser Name Page RS# Advertiser Name Page RS#
AE Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 158 Meltric Corporation . . . . . . . . . . . . . . . . . . . . . . 95 169
Albin Pump USA . . . . . . . . . . . . . . . . . . . . . . . . . 95 160 Mission Communications. . . . . . . . . . . . . . . . . 32 128
ALL-TEST Pro, LLC. . . . . . . . . . . . . . . . . . . . . . . 81 138 Murphy By Enovation Controls. . . . . . . . . . . . 83 142
Allied Reliability . . . . . . . . . . . . . . . . . . . . . . . . . 55 136 NOC Ningbo Ocean Fine Ceramic
Apex Engineering Products Corporation . . . 93 161 Technology Co., Ltd. . . . . . . . . . . . . . . . . . . . 93 170
AutomationDirect.com . . . . . . . . . . . . . . . . . . IFC 101 PeopleFlo Manufacturing . . . . . . . . . . . . . . . . . 85 144
Baldor Electric Company. . . . . . . . . . . . . . . . . . . 7 102 Pinnacle-Flo, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 85 145
Bartlett Bearing Company . . . . . . . . . . . . . . . . . 9 121 PSG, A Dover Company . . . . . . . . . . . . . . . . . . . 67 146
BASF The Chemical Company . . . . . . . . . . . . . 57 103 PumpWorks Industrial . . . . . . . . . . . . . . . . . . . 51 111
BBA Pumps Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 93 162 R+W America . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 135
BJM Pumps, LLC. . . . . . . . . . . . . . . . . . . . . . . . . 77 139 Rotech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 171
Blue-White Industries . . . . . . . . . . . . . . . . . . . . 77 140 RuhRPumpen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 129
CD-adapco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 150 Salem-Republic . . . . . . . . . . . . . . . . . . . . . . . . . . 18 130
CURFLO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 151 Schaeffler Group USA Inc.. . . . . . . . . . . . . . . . . . 5 112
Dan Bolen & Associates, LLC . . . . . . . . . . . . . . 95 163 Schenck Trebel Corporation . . . . . . . . . . . . . . . 45 131
Dickow Pump Company . . . . . . . . . . . . . . . . . . 24 122 See Water Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 132
Discflo Corporation . . . . . . . . . . . . . . . . . . . . . . 65 119 SEPCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 133
Dynamatic/Drive Source International . . . . 23 105 SERO Pump Systems . . . . . . . . . . . . . . . . . . . . . 93 172
Electro Static Technology . . . . . . . . . . . . . . . . . 53 123 Sims Pump Valve Company, Inc. . . . . . . . . . . . 17 118
Flowrox Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 124 Sims Pump Valve Company, Inc. . . . . . . . . . . . 92 175
FLSmidth Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 141 SKF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 147
Friendly Acquirer . . . . . . . . . . . . . . . . . . . . . . . . 95 159 Skinner Power Systems . . . . . . . . . . . . . . . . . . . 33 134
Frost & Sullivan. . . . . . . . . . . . . . . . . . . . . . . . . . 90 152 St. Marys Foundry . . . . . . . . . . . . . . . . . . . . . . . 93 176
GE Power Conversion. . . . . . . . . . . . . . . . . . . . . 41 106 Stoffel Polygon Systems. . . . . . . . . . . . . . . . . . . 87 157
General Rubber Corp.. . . . . . . . . . . . . . . . . . . . . 95 164 Sulzer Management Ltd Rotating
Greyline Instruments Inc.. . . . . . . . . . . . . . . . . 46 137 Equipment Services . . . . . . . . . . . . . . . . . . . BC 113
Grundfos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 107 Summit Pump, Inc. . . . . . . . . . . . . . . . . . . . . . . . 73 148
Hatz Diesel of America, Inc. . . . . . . . . . . . . . . . 27 108 Summit Pump, Inc. . . . . . . . . . . . . . . . . . . . . . . . 83 149
Hayward Flow Control. . . . . . . . . . . . . . . . . . . . 40 125 Titan Manufacturing Inc. . . . . . . . . . . . . . . . . . 94 177
Heinrichs USA LLC . . . . . . . . . . . . . . . . . . . . . . . 90 153 Tuf-Lok International . . . . . . . . . . . . . . . . . . . . 95 178
Helwig Carbon Products . . . . . . . . . . . . . . . . . . 87 156 TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 120
Hidracar S.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 109 Universal Flow Monitors, Inc. . . . . . . . . . . . . . 94 179
Horner Industrial Group. . . . . . . . . . . . . . . . . . 11 126 Vanton Pump & Equipment Corp. . . . . . . . . . 13 117
Hydraulic Institute . . . . . . . . . . . . . . . . . . . . . . . 54 154 Vaughan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 114
Hyundai Heavy Industries . . . . . . . . . . . . . . . . 29 110 Vertiflo Pump Company . . . . . . . . . . . . . . . . . . 92 180 Circle 175 on card or visit psfreeinfo.com.
International Procurement & Distribution . 93 165 Vesco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 181
Jordan, Knauff & Company . . . . . . . . . . . . . . . 54 155 Xylem Water Solutions. . . . . . . . . . . . . . . . . . . . . 1 115
Load Controls, Inc. . . . . . . . . . . . . . . . . . . . . . . . 36 127 Yaskawa America, Inc. . . . . . . . . . . . . . . . . . . . . 21 116
Load Controls, Inc. . . . . . . . . . . . . . . . . . . . . . . . 94 166
The Index of Advertisers is furnished as a courtesy, and no
LobePro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 167
responsibility is assumed for incorrect information.
Magnatex Pumps, Inc. . . . . . . . . . . . . . . . . . . . . 61 143
Master Bond Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 94 168
FREE PRODUCT INFORMATION

Visit psfreeinfo.com to request more information from these advertisers.
Circle 158 on card or visit psfreeinfo.com. Circle 171 on card or visit psfreeinfo.com. Circle 180 on card or visit psfreeinfo.com.

93
Water Scale Can Be Costing

You Thousands of Dollars
• Fast & Effective Circle 172 on card or visit psfreeinfo.com.

• Biodegradable
• Clean In Place
• Non-Hazardous
• Non-Corrosive
Start saving money today.
Contact us at 630-820-8888
www.ApexEngineeringProducts.com
OEM New Machined Engineered

Pump Castings, Forgings High Quality Guaranteed
Lower Acquisition Cost
& Machined Parts
INTERNATIONAL PROCUREMENT
& DISTRIBUTION, INC.
870-586-0147
tshort@ipdworld.com
www. IPDWORLD.com
94 PUMP USERS MARKETPLACE
MONITOR PUMP PERFORMANCE

s&,/72!4% 5.)6%23!,0/7%2#%,,
s/NE3IZE!DJUSTSFOR
s05-0#/.$)4)/. !LL-OTORS&ROM3MALL
UPTO(0
s$2925..).' s7ORKSON6ARIABLE&REQUENCY
$RIVES0HASE$#AND
s#!6)4!4)/. 3INGLE0HASE
sTIMESMORESENSITIVETHAN
s"%!2).'&!),52% JUSTSENSINGAMPS
s -ILLIAMP 6OLT
#!,,./7&/29/52&2%% $!942!),

Monitor
Water/Oil
Flow
for cooling or lube
Solve
dry start
problems with
Vesconite Hilube
bushings
G Increase MTBR
Adhesive compounds withstand: G No swell
• Acids • Bases • Organic Solvents G Low friction = reduced
electricity costs
G Quick supply.
No quantity too small
888-569-3090 Tollfree 1-866-635-7596
Universal Flow Monitors, Inc. main@masterbond.com ∙ +1.201.343.8983 vesconite@vesconite.com
www.flowmeters.com www.masterbond.com www.vesconite.com

95
EXECUTIVE SEARCH/RECRUITING
PUMP CONNECTORS
Simplify Service Work
From the Simple to the Simply Amazing
Better the Switch-Rated

Management Plugs & Receptacles
“Serving the Pump &
Rotating Equipment, Valve, of Rubber Quickly connect
& disconnect
Expansion Joints power to motors
and Industrial Equipment in Piping Systems
Rated up
to 75hp
Industry since 1969” with Our
Simplifies
NFPA 70E
Domestic & International MRO-Focused compliance
Specializing in placing: Plant Reliability

• General Management • Engineering & Efficiency
OFF
• Sales & Marketing • Manufacturing Program Button
DAN BOLEN • JASON SWANSON (PREP)
CHRIS OSBORN • JULIAN MUELLER FREE SAMPLES
ISO 9001 and 14001 VISIT MELTRIC.COM/FREE
9741 North 90th Place, Suite 200 CERTIFIED
Scottsdale, Arizona 85258-5065
(480) 767-9000 • Fax (480) 767-0100 800-233-6294
Email: dan@danbolenassoc.com A company of MARECHAL ELECTRIC GROUP
www.danbolenassoc.com general-rubber.com 800 433 7642 • meltric.com
Distributors of Mechanical Seals and other Rotating Equipment

A growing, cash rich international manufacturer seeks acquisitions
UÊ-iv>}}ÊEÊÃivÊÊ
of distributors / resellers active in the mechanical seal market. }ÀÕ`}
UÊ}Ê«ÀiÃÃÕÀiÊÊ
The “ultimate friendly acquirer”, its integrations process is deliberately À>Ìi`
slow and based around employee and customer retention. Ultimately, any UÊ-Ì>iÃÃÊÀÊÊ
acquired business will form a part of a national sales network. Acquirer `ÊÃÌii
values continuity, is a great home for loyal staff and is a succession UÊÜÊVÃÌ
planning solution that leaves in place what you have created. UÊ}Êi`Ê«Õ
Please contact
Tuf-Lok InternationalÊ
Discretion and confidentiality assured. FriendlyAcquirer@gmail.com *i\Ê Èän°ÓÇä°{ÇnÊ UÊ www.tuflok.com
SEAL-LESS
ESSSS SIM
SSIMPLICITY TAKE THE ROAD
Roller & Shoe Design Peristaltic Pumps
• SELF-PRIMING and
to ALL THINGS PUMPS
DRY-RUNNING Pumping what FIND
others cannot! IT HERE
• LOCAL STOCK in Ohio
• ACCURATE and REPEATABLE the Manufacturers
dosing and metering
• LONG LIFE and GREATER
Directory
RELIABILITY albinpumpusa.com pumpsandsystems.com/manufacturers
888-425-9494
96 PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

By Jordan, Knauff & Company Figure 1. Stock indices from May 1, 2015, to April 30, 2016
20%
10%
T he Jordan, Knauff &

Company (JKC) Valve Stock
Index was down 12.2 percent
over the last 12 months, while the
broader S&P 500 Index was down
(54,000). Government
jobs fell by 11,000, mining
by 8,000 and retail by
3,000. Manufacturing and
construction jobs increased
0%
-10%
-20%
-2.0%
-12.2%
-19.2%
-30%
2.0 percent. The JKC Pump Stock by 4,000 and 1,000,
Index also decreased 19.2 percent respectively. -40%
May-15 Jul-15 Sep-15 Nov-15 Jan-16 Mar-16 May-16
for the same time period. According to the Bureau
S&P 500 Index JKC Valve Stock Index JKC Pump Stock Index
Manufacturing activity of Economic Analysis’ first
improved for the second month estimate, U.S. gross domestic Source: Capital IQ and JKC research. Local currency converted to USD using
historical spot rates. The JKC Pump and Valve Stock Indices include a select list of
in a row with the Institute for product grew at an annual publicly traded companies involved in the pump and valve industries weighted by
Supply Management’s Purchasing rate of 0.5 percent in the first market capitalization.
Managers’ Index (PMI) registering quarter of 2016. Business fi xed
50.8 percent in April. Expansion investment, which includes the residential and commercial Reference
continued in new orders, spending on equipment, structures sectors declining by 9 percent 1. The S&P Return
production and backlogs. For the and intellectual property, fell by a and 6 percent, respectively, due figures are provided
by Capital IQ.
month, 15 of the 18 industries 5.9 percent annual rate, the largest to milder winter weather during
reported an increase in new decline since the second quarter of the year. Transportation sector
orders (up from 13 in March) and 2009. Led by services, consumer consumption rose by 2 percent.
production (up from 12 in March). spending increased at a 1.9 percent On Wall Street, the Dow Jones
Jordan, Knauff
For the second consecutive month, annual pace. Showing continued Industrial Average gained 0.3 & Company is an
the export orders index was momentum in housing recovery, percent, the S&P 500 Index gained investment bank
above 50, reaching 52.5 in April, residential investment was up 14.8 0.5 percent and the NASDAQ based in Chicago,
its highest level since November percent, the second consecutive Composite fell 1.9 percent. It was Illinois, that
provides merger and
2014. Although the employment month of double-digit gains. the first three-month positive acquisition advisory
index rose 1.1 percentage points For the sixth consecutive year, stretch for the Dow Jones services to the
to 49.2 percent over last month, it U.S. total energy production Industrial Average since January pump, valve and
remained at contraction levels. increased in 2015, according 2014, while for the first time this filtration industries.
Please visit
The Bureau of Labor to the U.S. Energy Information year, the S&P 500 Index gained
jordanknauff.com for
Statistics reported that the U.S. Administration. Crude oil for a second straight month. First further information.
economy added 160,000 jobs production increased by 8 percent, quarter corporate earnings results Jordan Knauff &
in April, a seven-month low. natural gas plant liquids increased were mixed and had a negative Company is a member
The unemployment rate was by 9 percent, and natural gas effect on the indices. of FINRA.
unchanged at 5 percent. The production increased by 5 percent The largest gainers for the
largest employment gains were for the year. Coal production month included energy stocks,
seen in professional and business declined by 10 percent. U.S. due to higher oil prices, while These materials were
services (65,000), as well as primary energy consumption technology and health care stocks prepared for informational
purposes from sources that
education and health services declined 1 percent in 2015, with were the biggest laggards. are believed to be reliable
but which could change
without notice. Jordan,
Figure 2. U.S. energy consumption and rig counts Figure 3. U.S. PMI and manufacturing shipments Knauff & Company and
Pumps & Systems shall not
4,000 20.0 $525,000 70.0 in any way be liable for
claims relating to these
materials and makes no
3,000 15.0 $450,000 60.0 warranties, express or
Quadrillion Btu
implied, or representations
Monthly Shipments
Rig Counts
(US$ in Millions)
PMI Index
as to their accuracy or com-

2,000 10.0 $375,000 50.0 pleteness or for errors or
omissions contained herein.
1,000 5.0
This information is not
$300,000 40.0
intended to be construed
as tax, legal or investment
0 0.0 $225,000 30.0
advice. These materials do
Apr-06 Apr-08 Apr-10 Apr-12 Apr-14 Apr-16 Apr-98 Apr-01 Apr-04 Apr-07 Apr-10 Apr-13 Apr-16 not constitute an offer to
U.S. Energy Consumption U.S. Rig Counts Worldwide Rig Counts
buy or sell any financial
U.S. Manufacturers' Monthly Shipments U.S. PMI Index
security or participate in
any investment offering or
Source: U.S. Energy Information Administration and Source: Institute for Supply Management Manufacturing deployment of capital.
Baker Hughes Inc. Report on Business and U.S. Census Bureau

Dosing Basics
THE 5 TH IN A 6-PART WEBINAR SERIES FOR 2016
Dosing pumps, also known as metering pumps, provide accurate liquid chemical
JUNE 22, 2016 feed into a fluid that is to be treated. This webinar will introduce you to the basic
concepts that lead to improved process control, high flow accuracy, and effective
1 P.M. EASTERN handling of hazardous and expensive chemicals in an almost endless variety of
markets and applications.
Jim Swetye holds a bachelor of arts from Hiram College, Ohio

and a master of science in education/curriculum leadership
from Emporia State University. He is a former VP of Knowledge
and Education for the Hydraulic Institute and is a certified trainer
for Pump Systems Matter.
Certificate to submit for CEU credits available!
Sign up today for this webinar

FREE
and the rest of the series!
pumpsandsystems.com/2016/grundfos
JANUARY 28, 2016 How to Read a Pump Curve*
FEBRUARY 24, 2016 Efficient Pump Selection and Control*
MARCH 23, 2016 Introduction to Boiler Feed Systems*
APRIL 27, 2016 Choose the Right Pump for the Application*
JUNE 22, 2016 Dosing Basics
JULY 20, 2016 Vertical Turbine Pumps - Wire-to-Water* (New Date)
(*Previous dates available online)

Sponsored by

PumpsAndSystems Jun2016 PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

PumpsAndSystems Jun2016 PDF

Hochgeladen von

Copyright:

Verfügbare Formate

J U N E 2 0 16

The Leading Magazine for Pump Users Worldwide

How DOE Research

T he Pumps & Systems editorial team is

PUBLISHER: Walter B. Evans Jr.

P.O. Box 530067

J une 20 1 6 | Pumps & Sy st e m s

- Steep performance curves

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

Circle 114 on card or visit psfreeinfo.com.

COMMON PUMPING MISTAKES

48 2 FROM THE EDITOR

56 VFD ENERGY ALGORITHMS OPTIMIZE PID-CONTROLLED 30 3 CYBERSECURITY BEST

62 UNDERSTANDING THE NEW DOE PUMP SYSTEM 30

J une 20 1 6 | Pumps & Sy st e m s

PRACTICE & OPERATIONS

REPLACEMENT PARTS? How DOE Research

82 CALIFORNIA HOSPITAL CUTS CLOGS

SUBMERSIBLE SHREDDER PUMPS ON THE COVER

EDITORIAL ADVISORY BOARD

J une 20 1 6 | Pumps & Sy st e m s

Circle 102 on card or visit psfreeinfo.com.

J une 20 1 6 | Pumps & Sy st e m s

AROUND THE INDUSTRY

Drinking Water & Clean Water Funding Provides

Australian Water Treatment Plant Named

WRDA Bill Passes Senate Committee with Key

WASHINGTON – The federal Water Resources Development

AROUND THE INDUSTRY

J une 20 1 6 | Pumps & Sy st e m s

2016 EASA Convention

National Fire Protection Association (NFPA)

Aquatech China 2016

American Water Water Association Annual

World Nuclear Exhibition

July 20 – 22, 2016

The Water Expo 2016 – 5th Edition

Preview: 2016 EASA Convention

Preview: 2016 NFPA

J une 20 1 6 | Pumps & Sy st e m s

The Vanton Pump Technical Library

Most questions are addressed in our

Just call us at 908.688.4216

PUMP & EQUIPMENT CORPORATION

Sump-Gard® Chem-Gard® Flex-I-Liner® Pump/Tank

Eight-Year Study Reveals Vital Knowledge

reliability study conducted at

• Crystallizer condenser (Cooling

J une 20 1 6 | Pumps & Sy st e m s

Temperature fuse Anti-corrosion valve

You will discover our bladder and membrane

Designing and manufacturing dampeners since 1974 www.hidracar.com

present maintenance. and presents quantiﬁable, 3000

The following observations albeit perhaps limited, data 2000

Because of this lack of Ɵme

• Pumps A and B operate, information, a common plant

2,000 and 4,000 gpm. 1.20

meaning there is no replacement. 6000

on pump size and type, are times 43, 46 and 52. 0

J une 20 1 6 | Pumps & Sy st e m s

Based on this information, on bearings, causing eventual 1.40

Circle 130 on card or visit psfreeinfo.com.

Circle 124 on card or visit psfreeinfo.com.