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205-345-0477 ackling 4,000 years of pump expect this piece of pump history to
EDITOR/VP-EDITORIAL technology and evolution spark memories and encourage
Michelle Segrest in only eight pages of further research from you. We
msegrest@pump-zone.com
205-314-8279 magazine space has been like welcome your comments and
MANAGING EDITOR trying to summarize War insight, and we will publish
Lori K. Ditoro
lditoro@cahabamedia.com and Peace in one sentence. on the freshly redesigned
205-314-8269 It has been a challenging www.pump-zone.com a full
CONTRIBUTING EDITORS task at best, daunting to say version of our historical
Laurel Donoho
Joe Evans, Ph.D. the least. And although it is timeline that includes contri-
Terry Henshaw perhaps impossible to provide butions from our readers and
Dr. Lev Nelik, PE, APICS
SENIOR ART DIRECTOR
a completely comprehensive many amazing photos that we
Greg Ragsdale account in that space, we have did not have the space to use here.
PRODUCTION MANAGER tried. As we take this special journey
Lisa Freeman
lfreeman@pump-zone.com It has been an absolute blast! into the past, it is a Pumps & Systems tradi-
205-212-9402 A close look at this illustrious history tion to use the January issue to take a look at
CIRCULATION & MARKETING helps us appreciate the genius of innovators the future of our industry. We are also proud to
MANAGER
Jaime DeArman like Henry Worthington, Jens Nielsen, Seabury bring you our annual focus on the “State of the
jdearman@cahabamedia.com Gould, Milton Roy Sheen, Robert Blackmer, Industry.” See page 22 for insight from industry
CIRCULATION
Jeff Heine
Jim Wilden, J.C. Gorman, Herb Rupp, Frank executives, our yearly market recap and a waste-
jheine@cds1976.com Weis and so many others. he glorious old water industry outlook.
630-739-0900
photos bring the legendary pump stories to life. We look forward to hearing from you about
WEB EDITOR
Jane Longshore It is difficult to imagine that some of the the past, present and future of this great industry.
jlongshore@cahabamedia.com earliest pumps were made of wood, used leather
ACCOUNT EXECUTIVES seals and were powered by steam. hrough the
Derrell Moody Best Regards,
dmoody@pump-zone.com years, the pump community has found a way to
205-345-0784 unlock the physics behind each industry chal-
Mary-Kathryn Baker
mkbaker@pump-zone.com lenge. No matter the application or viscosity of
205-345-6036 fluid, today there is a pump that will move it.
Mark Goins With the greatest respect and humility, we Michelle Segrest
mgoins@pump-zone.com Editor
205-345-6414 are proud to present to you our version of “he
Addison Perkins History of Pumps” in this issue (page 14). We msegrest@pump-zone.com
aperkins@pump-zone.com
205-561-2603 Editorial Advisory Board
Vince Marino Thomas L. Angle, PE, Vice President Engineering, Joe Evans, Customer & Employee Education, PumpTech,
vince@pump-zone.com Hidrostal AG Inc.
205-561-2601
Robert K. Asdal, Executive Director, Hydraulic Institute Ralph P. Gabriel, Chief Engineer—Global, John Crane
ADMINISTRATIVE ASSISTANT
Ashley Morris Bryan S. Barrington, Machinery Engineer, Lyondell John Malinowski, Sr. Product Manager, AC Motors,
amorris@pump-zone.com Chemical Co. Baldor Electric Company, A Member of the ABB
205-561-2600 Kerry Baskins, Vice President, Grundfos Pumps Group
EDITORIAL INTERN Corporation William E. Neis, PE, President, NorthEast Industrial Sales
Jennifer Polzin Walter Bonnett, Vice President Global Marketing, Pump Dr. Lev Nelik, PE, Apics, President, Pumping Machinery,
Solutions Group LLC
R. Thomas Brown III, President, Advanced Sealing Henry Peck, President, Geiger Pumps & Equipment/
A Publication of
International (ASI) Smith-Koch, Inc.
Chris Caldwell, Director of Advanced Collection Mike Pemberton, Manager, ITT Performance Services
P.O. Box 530067 Technology, ABS, & President, SWPA
Birmingham, AL 35253 Bruce Stratton, Product Manager, KLOZURE®, Garlock
John Carter, President, Warren Rupp, Inc. Sealing Technologies
Editorial & Production Jack Creamer, Market Segment Manager, Schneider
1900 28th Avenue South, Suite 110 Kirk Wilson, Vice President/General Manager,
Electric Integrated Solutions Group, & Vice President
Birmingham, AL 35209
Phone: 205-212-9402 David A. Doty, North American Sales Manager, Moyno Marketing, Engineering & Technology, Flowserve
Advertising Sales Industrial Pumps Corporation
2126 McFarland Blvd. East,. Suite A
Tuscaloosa, AL 35404
Phone: 205-345-0477 or 205-561-2600
From ITT comes Xylem. Learn more about the possibilities at xyleminc.com.
Table of Contents
pump-zone.com
January 2012
THE HISTORY OF PUMPS Volume 20 • Number 1 INSIDE:45"5&0'5)&*/%6453:t*/4536.&/5"5*0/
$0/530-4.0/*503*/(
Clockwise from the top left corner: Xylem Dewatering Solutions (Godwin Pumps), GIW
p
14
The History of Pumps
Michelle Segrest
Design, vision, technology and a focus on efficiency have
Industries, American Marsh Pumps, Wilden, Peerless Pump Company (Grundfos), Baldor Electric
Company, Goulds Pumps, Viking Pump Company, Ruhrpumpen, Xylem Dewatering Solutions,
The Gorman-Rupp Company, Blackmer, Peerless Pump Company (Grundfos), Hydro, Inc.
p
22
Wastewater Industry Outlook 2012
Adam Stolberg, SWPA
Submersible pump industry survey provides a unique
P&S News. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
forecast.
Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Joe Evans, Ph.D.
p
24 Executive Insights
Off-BEP Energy Cost
p
26 Pump Market Recap Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 10
Lev Nelik, Contributing Editor, P&S Editorial Advisory Board
Thermal Stress Affects Pipe Forces on Pumps
p
32
Cutting-Edge Treatment
Alan Cone, Siemens
Cobb County, Ga., adds automation to improve
Maintenance Minders . . . . . . . . . . . . . . . . . . . 42
Ralph Gabriel and Ian Smith, John Crane
wastewater treatment operations.
Safe Equipment
p
37
Power Quality Basics
Wade Thompson, Fluke Corporation
The fundamentals of how power quality issues affect the plant, how to detect
Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
David Kirk
Eccentric Disc Pump Technology Used in Food Processing
them and how to make them go away.
FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Why do I need to complete an application questionnaire?
p
54
Pump Curve Accuracy
George Stephens, PUMP-FLO Solutions (An Engineered
Software Business)
When purchasing new rotodynamic pumps, what type of
acceptance testing is recommended? What is a string test, and
when should it be specified?
Exploring the digitization methods of pump power and efficiency curves
Second of Two Parts Product Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
p
60
Wastewater Infrastructure in Prefurbia
Bill Nestor
Design and construction of sewer systems can include environmentally-safe
Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . 69
p
64
Environmentally-Friendly HVAC Solution
Brad Hubbard, Cerus Industrial
Improved motor starters help Fabri-Kal achieve its green vision.
P&S Market. . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
An irrigation pump motor that fails spells trouble. That’s why, for over four generations, farmers
have preferred the U.S. MOTORS® brand. Built for performance, our motors are reliable and long
lasting, providing years of dependability. The next time you need a motor, turn to the brand you
can count on to work as hard as you do, U.S. MOTORS. Visit www.nidec-motor.com/farms or
call 877-532-8988.
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NEW HIRES, PROMOTIONS & solutions and services for industrial customers.
ww.usa.siemens.com/industry
RECOGNITIONS
PUMP SOLUTIONS GROUP—PSG—
(DOWNERS GROVE, ILL.), a business AROUND THE INDUSTRY
unit operating within the Dover Fluid
BENTLEY SYSTEMS, INCORPORATED,
Management Segment of Dover Corpora-
(AMSTERDAM, NETHERLANDS) has acquired
tion, announced the appointment of Karl
U.K.-based Pointools Ltd, a hardware-neutral
Buscher to the newly created position of
provider of point cloud software technology, to integrate
senior vice president, PSG Commercial. In Karl Buscher
point cloud processing in innovative ways throughout its
this position, Buscher will report directly
product portfolio.
to PSG President Dean Douglas.
Bentley provides architects, engineers, geospatial pro-
Also, PSG announces the acquisition of Tianjin
fessionals, constructors and owner-operators with software
RedScrew Pump Manufacturing Technology Co., Ltd. he
solutions for sustaining infrastructure. www.bentley.com
RedScrew Pump manufacturing facility is ISO 9001 certified
and is located in Tianjin, China, in the Hua Yuan Technology
BOSCH REXROTH AG (FOUNTAIN INN, S.C.), with the pur-
Park. he terms of the transaction have not been disclosed.
chase of an additional building, doubled the production area
Dover’s PSG delivers positive displace-
at the Fountain Inn plant. Overall, the company will invest
ment pump and supporting technologies. www.
$80 million in the site and is planning to hire approximately
pumpsg.com
160 additional associates in the next five years.
Bosch Rexroth AG produces drive and control technol-
GRUNDFOS PUMPS (OLATHE, KAN.)
ogies. www.boschrexroth-us.com
announced the promotion of Greg Bretz to
director of regional program management.
THE WATER ENVIRONMENT FEDERATION—WEF—
In this role, Bretz will be responsible for
(ALEXANDRIA, VA.) announced that a total of 16,961 water
continuing to develop the strategic direc-
professionals and 923 exhibiting companies from around the
tion for regional program management and
world attended WEFTEC 2011—the Water Environment
accelerating program management devel-
Greg Bretz Federation’s (WEF) 84th Annual Technical Exhibition and
opment across Grundfos’ North America
Conference—in Los Angeles, Calif.
organization.
WEF also announced that students from the University
Grundfos provides pump solutions in water technology.
of Wyoming and the University of Florida won the 2011
www.grundfos.us
Student Design Competition. he University of Wyoming
team’s project, “Preliminary Design for Upgrading the
MCCROMETER (HEMET, CALIF.) wel-
Littleton/Englewood Wastewater Treatment Plant for
comed Bruno Santos Pinton as regional
Phosphorus Removal” won in the wastewater design category,
sales manager, Brazil. Pinton will report
and the University of Florida team’s project, “Stormwater
directly to Carlos Souza, area sales man-
Cycling Design Options in an Urban Industrial Watershed”
ager, Latin America.
won in the environmental design category. his was the first
McCrometer provides liquid, steam
win for the University of Wyoming (a Student Chapter of
and gas flow measurement solutions for Bruno Santos the Rocky Mountain Water Environment Association) and
municipal/industrial water & wastewater, Pinton the sixth win for the University of Florida (a Student Chapter
oil & gas, process control &
of the Florida Water Environment Association) in 10 years.
plant, electric power generation, institutional
WEF is a not-for-profit technical and educational orga-
facilities and agriculture applications. www.
nization with 36,000 individual members and 75 affiliated
mccrometer.com
member associations representing water quality professionals
around the world. www.wef.org
SIEMENS INDUSTRY, INC. (ATLANTA, GA.) announced
that four of its water services facilities have been awarded
YASKAWA AMERICA, INC., (WAUKEGAN, ILL.) was one
ISO 14001 certifications by Intertek Testing Services for
of the companies featured on the show “World’s Greatest
outstanding commitment to environmental management.
TV” airing on the ION Network. he show will focus on
Siemens carbon reactivation facilities in Parker, Ariz., Red
Yaskawa as an innovative, company that has, via its parent
Bluff, Calif., and Darlington, Penn., as well as a waste and
company in Japan, been serving the world’s needs with
wastewater treatment facility in Roseville, Minn., received
products to improve global productivity through automa-
the esteemed recognition.
tion since 1915.
Siemens Industry Sector is the world’s leading sup-
Yaskawa America’s Drives & Motion Division manufac-
plier of innovative and environmentally friendly products,
tures industrial automation equipment. www.yaskawa.com.
6 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
circle 103 on card or go to psfreeinfo.com
Pump Ed 101
Joe Evans, Ph.D.
L
ast month, I discussed the Draw Down calculator
and its role in determining the actual operating point
of wastewater pumps. Like several of my previous
articles, it focused on off-BEP (best-efficiency-point) opera-
tion and the damage that can occur due to unbalanced radial
forces and recirculation. he premature failures that occur
in these pumps increase downtime, and repeated repairs
are costly. You will probably think that I am beating a dead
horse as this month’s article also addresses off-BEP operation.
However, this time it is from a different perspective. Instead
of the cost due to increased maintenance and repair, we will
review how it can affect electrical power costs.
Lev Nelik’s “Pumping Prescriptions” (July 2011 Pumps
& Systems) discussed the energy savings that can be achieved
by replacing a pump impeller with one designed to operate at
BEP. he example he used was a large pump (40,000 gallons
per minute) operating at 50 percent of BEP flow (20,000
gallons per minute). he energy wasted annually was 3.1 mil-
lion kWh. You may be surprised how much can be wasted by Figure 1. Screenshot of the Off-BEP Cost Calculator
much smaller pumps operating at 80 to 85 percent of BEP.
One of the seminars that I present at water and waste- manufactured after December 19, 2010, must meet the pre-
water conferences is “Determining the Long- & Short-Term mium efficiency standard. herefore, new installations will
Costs of Pump System Efficiency.” In it, I break down a take advantage of increased motor efficiency unless you have
pumping system (installed or proposed) into its components an old motor in your warehouse. EISA does not apply to
and evaluate their individual contribution to the overall motors purchased before its inception, and those motors can
system efficiency. Achieving higher efficiency in a pumping also be rewound and continue to be used. When evaluating
system usually increases the initial costs, but this can be offset existing pumping systems’ efficiency, the cost of replacing
by long-term savings. Breaking a system into individual com- older, lower efficiency motors should be evaluated.
ponents makes assessing short- and long-term costs easier.
The Piping System
Components That Affect Efficiency One example I use in my seminar is an Excel calculator that
Pump and motor efficiency are major contributors to overall compares the wire to water efficiency of two pump and motor
system efficiency. Higher efficiency pumps will typically have combinations. It was the subject of my March 2010 Pumps
a higher first cost because they are often designed and built to & Systems column. It provides a simple payback analysis for
a higher standard. One or two efficiency points may not have comparing the short- and long-term costs of two pump/
much affect in some applications, but when the difference is motor combinations with different operating efficiencies.
5 percent or more, the long-term return should be evaluated. Although the pump and motor affect the overall effi-
Installed pumps will lose efficiency over time due to ciency, piping systems can have a greater influence. Poorly
wear and corrosion. My 2010, two-part series on restora- designed piping systems often require increased head, which
tion and coating showed how the Monroe County Water translates into increased horsepower. Older piping is also
Authority in Rochester, N.Y., reduced electrical consump- problematic. Friction increases over time due to corrosion
tion substantially. Even though the procedures appeared and build up, and increased demand will over tax the origi-
expensive ($4,000 to $13,000), the payback period was often nal design capability. he starting point is always the system
less than one year. curve, which shows the required pump performance (head
With the Energy Independence and Security Act of 2007 and flow). When pumps run to the left of BEP, they will run
(EISA), all three-phase motors from 1 to 500 horsepower longer at a lower efficiency, and energy costs can increase.
N E W
What are the options? he most Smaller Systems Don’t have to Put
obvious fix would be to modify the Up with Noisy, Inefficient Solenoid
piping and get the pump to BEP flow. Pumps—Move up to Peristaltic
If this is not cost-effective, a smaller Performance!
pump with a better efficiency should Self priming.
be selected. An increase in efficiency IP6
P666 Smooth pumping action.
No expensive rebuild kits!
from 81 to 85 percent at 4,000 gallons NEM
EMM
WASH
WAS
WA
A
ASH DO
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WN
X
Generous Two Year Warranty.
per minute would reduce the cost per
1,000 gallons to $0.057 and save almost
$2,500 per year in electrical costs.
A more efficient fix would be to Standard 61
Energy Consumption
Energy consumption for a given volume
of pumped fluid can be a bit perplex-
ing. It has nothing to do with the flow IP6
P6
66 NEM
EM
MA 4X
WA
WASH
WAS
WA
ASH DO
DOWWN
rate of the pump. It involves the wire Standard 61
per unit of time. A higher flow rate does No Moving Parts. Clamp-on transducers.
No Wetted Materials. Works with clean or dirty fluids
more work in a shorter period of time.
NEM
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For example, if a 500 gallon-per-minute WASH
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circle 118 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 9
Pumping Prescriptions
Dr. Lev Nelik, P.E., P&S Editorial Advisory Board
T
wo major headaches for pump plant maintenance
are seals and bearings. While new bearings or seals
being faulty is always a possibility—although not
typical if purchased from a reputable manufacturer—this
is not the main reason for failures. A more likely reason
is either a bad installation or improper operation. In this
article, we will discuss installation.
January Quiz
Now, a parting quiz/question:
What is wrong with the calculated 60,000 lb. value
from the case study calculation? Can it be true?
Figure 2. Anchors are a bad idea because they will result in high
loads. A correct answer gets you a winning ticket to my next
hands-on Pump School training session: www.pumpingma-
his force far exceeds every possible API-610 allowable chinery.com/pump_school/pump_school.htm.
force or any similar specification. For a longer pipe, this situa- P&S
tion would obviously get even worse. Dr. Nelik (aka “Dr. Pump”) is president of Pumping
A “natural” inclination is to grab a pipe in front of a pump, Machinery, LLC, an Atlanta-based firm specializing in
isolating it from the rest of the pipe, essentially shortening the pump consulting, training, equipment troubleshooting and
effected growth in front of the pump. his would “seem” like pump repairs. Dr. Nelik has 30 years of experience in pumps
a good idea for hot processes in which temperature changes and pumping equipment. He can be contacted at www.
could be even greater than this example. PumpingMachinery.com.
Innovative Pass-Through
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These pumps feature the revolutionary new single
vane non- clog scroll impeller design from
ShinMay wa Industries, Ltd.(Japan) The scroll
impeller design incorporates a helix formed
passage at the inlet which is smoothly connected to
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vir tually eliminates clogging, plugging, and
entangling of fibrous materials resulting in reduced
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I
t is a common mis-
conception in the
U.S. pump industry
that the function of the
volute is that of a diffuser:
to convert velocity into
pressure. I have recently
read and heard statements
to this effect by centrifugal
pump authorities. Igor
Karassik [3] said that the
“velocity is converted
into pressure energy by
means of a volute.” Walter
K. Jekat [4] said that the Figure 1. A single-volute casing maintains a
“most popular…diffusion constant velocity and uniform pressure around Figure 2. Hydraulic radial thrust for volute
system…for centrifugal the impeller only at BEP. casings
pumps is the volute.” he
McGraw-Hill scientific degrees downstream from the cutwater. As shown in Figure
dictionary [5] states that a volute is “a spiral casing for a 2, the maximum thrust occurs at shut-off.
centrifugal pump…designed so that speed will be converted
to pressure.” Performance with Excess Capacity
When the pump is allowed to operate at a capacity that
Function at BEP exceeds the BEP, the result is just the opposite. he veloc-
It is understandable that such a concept has been adopted ity around the impeller increases, from the cutwater to the
because the volute has an increasing flow area as it wraps throat, causing a drop in pressure. his results in a radial
around the impeller, similar to a diffuser, but it is not the thrust that pushes the impeller in the opposite direction,
purpose of the volute to be a diffuser. Its function—when approximately 270 degrees downstream from the cutwater,
the pump is operating at the best efficiency point (BEP)— as shown in Figures 1 and 2. A.J. Stepanoff [1] got it right.
is to keep the velocity constant around the impeller so that He talks about a constant-velocity volute.
mixing losses are minimized. To achieve that function, the P&S
area increases so as to accept the additional flow exiting the References
impeller, which exits the impeller all around the outside 1. Stepanoff, A. J., Centrifugal and Axial Flow Pumps, John Wiley & Sons,
diameter (OD)—360 degrees. he pressure surrounding the New York, 1948.
impeller is uniform, resulting in zero hydraulic radial thrust 2. Stepanoff, A. J., Pumps and Blowers – Two-Phase Flow, John Wiley &
on the impeller. Sons, New York, 1965.
3. Karassik, Igor J., “Centrifugal Pump Construction”, Section 2.2 of the
first edition of the Pump Handbook, edited by Karassik, Krutzsch, and
Performance with Restricted Flow Fraser, McGraw-Hill Book Co., New York, 1976.
When the flow from the pump is restricted, forcing the pump 4. Jekat, Walter K., “Centrifugal Pump heory”, Section 2.1 of the first
to operate at a reduced capacity, the flow from the impeller edition of the Pump Handbook, edited by Karassik, Krutzsch, and Fraser,
is reduced, and the volute does act as a diffuser, creating an McGraw-Hill Book Co., New York, 1976.
increasing pressure from the cutwater all the way around to 5. Dictionary of Scientific and Technical Terms, Fourth Edition, McGraw-
the casing throat. he maximum pressure rise occurs at shut- Hill Book Co., New York, 1989.
off (zero flow). As shown in Figure 1, this rise in pressure Terry Henshaw is a retired engineer living in Magnolia,
around the impeller creates a radial thrust on the impeller Texas. He worked 50 plus years in the pump industry. He
that pushes the impeller in a direction approximately 90 can be reached at pumprof@att.net.
Copyright © 2011, Weir Floway, Inc. All rights reserved. FLOWAY is a registered trademark of Weir Floway, Inc.
FLOWAY® PUMPS
Vertical Turbine Pumps
Weir Minerals Floway Pumps has more than 75 years experience
providing customers with the right product and the highest quality
for their specific process.
manufacture and sell his pump. 1874 Wilson-Snyder grows into the premier line of slurry,
pipeline and refinery pumps.
1899
in
invents
Robert
Blackmer
sliding vane
1916 While Armais Sergeevich Arutunof first invented
submersible pumps in Russia in 1916, their use in
the United States did not begin until the 1950s. Arutunoff
p
pump technology, first designed his pump for use in ships, water wells and
a vane-type pump mines. He altered the design to work in oil wells. hanks to
design
d that was an further refinements to Arutunoff’s design, there are more types
important
im
m departure of submersible pumps, allowing use in other applications such
from
f
fr the old gear as pumping drinking water, creating fountains and pumping
principle
p and pre- wastewater.
d
decessor of today’s
sliding
sl vane pumps.
1917 Hydraulic Institute is established.
1928
supply.
Worthington-Simpson produces the world’s largest
steam-driven pumping engine for municipal water 1942 he Gorman-Rupp team creates the first com-
mercially available solids-handling trash pump to
respond to the contractor’s need for a pump to withstand the
considerable rigors of pumping out trash-laden septic tanks,
1929 Pleuger incorporates in Berlin, Germany. Its
first offerings are submersible motor pumps for cesspools and outhouses.
dewatering in the construction of underground railways and
subways. Pleuger pioneers the first successful application of
submersible motor pumps in offshore service.
1944 During World War II, Goulds extra-quiet trim
pumps are installed in every U.S. Navy submarine.
hat year, 157 Goulds men went to war and 157 women
took their places on the Goulds manufacturing floor. Goulds
1929 Byron Jackson uses the first double casing feed
pump in a power plant.
HOW SEALS HAVE CHANGED
1929 Stork Pompen produces the first concrete volute
pump for drainage, integrating the pump housing
in the civil construction of the pumping station.
THE PUMP INDUSTRY
1954 API Standard 610 1st Edition is released (with section
1956
pump.
Smith & Loveless engineer Frank Weis develops the
water industry’s first true solids handling, non-clog
S
ince 1997, the Submersible Wastewater Pump Association accounting for about 70 percent of all shipments. Significant
(SWPA) has conducted an annual Industry Outlook comments on the solids handling pump market for 2012
Survey as a major component of its strategic initiative to included:
“forge the future of the submersible wastewater pump industry.” • New stations will remain minimal as funding stays tight
he primary purpose of the survey is to gain valuable insight • Pump sales will primarily consist of replacement and
and gauge the expectations of the industry’s performance and upgrade work
product trends for this year. • Slow, modest but steady growth
Members from all three SWPA membership categories • Economic conditions continue to impact the growth of this
(manufacturer, component and associate) participated in the market and not much growth or improvement is expected
survey. In addition, SWPA’s pump manufacturer members during the next 12 months
reported on quarterly pump shipments through the associa-
tion’s Pump Shipment Reporting Program. hese shipments Dry Pit Submersible Pumps
are estimated to represent more than 75 percent of the indus- Total dry pit shipments should be up 4.5 percent, with about
try’s total. 85 percent of those pumps going into municipal applications,
he 2012 outlook presents a unique industry forecast of according to respondents. Significant comments on the market
our members’ expectations of pump shipments; trends in the outlook for dry pit submersibles for this year included:
market for component parts and accessories; and the overall • he continued replacement of conventional dry-installed
condition, changes and influences affecting the marketplace in pumps
2012. Respondents projected modest increases in pump ship- • Very slow but steady growth
ments in all categories. • Demand is stronger in larger horsepower pumps
Additional Insights
he SWPA survey asked respondents
to address their expectations of product
trends that will continue in this year as
well as any emerging product changes.
Many respondents talked about the
continued movement to premium effi-
ciency submersible motors, more focus
on energy savings and greater use of
VFDs. Technological advances will also
lead to improved grinding and cutting
designs. Advances in controls technol-
ogy is always a factor, including smarter
technology that will allow increased
communication/monitoring of equip-
ment status over the Internet.
In this difficult economic climate,
the concept of “the systems approach,”
(the customer purchasing all accessories
with the pump as a total package instead
of purchasing pumps, components and
accessories piecemeal) should be consid-
ered as customers look for total value and
intelligent solutions. In looking ahead to
2012, the factors that will influence the
marketplace for submersible wastewater
pumps are:
• he U.S. and global economies
• Achieving the lowest costs of
operation
• Government regulations
• he availability of public funding for
municipal markets
• Residential and commercial new
construction
• Replacements/upgrades
• Pricing and quality product support
• Neglect of the retrofit market, as
preventative maintenance.
• Unemployment
P&S circle 126 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 23
Stateof the
Industry Executive Insights
A
positive turn in the economy in 2011 has directly Fenton Challgren, General Manager,
affected attitudes supporting potential growth for the Viking Pump
pump industry in 2012. Effective management, energy “Viking Pump has seen consistent, solid growth
efficiency, speed of production and customer service continue in all market sectors in recent years. With 100
to be common themes in the industry’s outlook. years of experience, we are confident that our
Financial and political instability in Europe could directly installed base business and global growth initia-
affect the global economy, resulting in reduced demand for tives will continue to drive growth.”
imports. Debt levels have reached dramatic proportions while
political instability worsens the already negative impacts. Dean Douglas, President
A weak Euro will make products exported from the U.S. to Pump Solutions Group
Europe more expensive, directly affecting U.S. manufacturers. “PSG will continue to expand its worldwide
Even with global economic threats and increased environ- footprint within emerging markets, key eco-
mental regulations, industry executives look toward 2012 with nomic clusters and wherever we can add value
guarded optimism and a focus on solutions, which include a to our customers. Asia and Latin America will
continued investment in new technologies. be critical growth regions in 2012 as we acceler-
ate our regional manufacturing for the continued globalization
Tom Angle, P.E., VP Engineering, Hidrostal and localization of our brands. M&A activity will continue to
AG, Pumps & Systems Editorial Advisory be a major trend. Our M&A strategies are critical this year and
Board beyond and will shape our product portfolio to be the pump
“I believe that in 2012 the European currency company of choice within our key vertical markets of oil & gas,
issues will begin to affect U.S. pump manufac- chemical, hygienic, water/wastewater and transport.”
turers more and more. As this crisis leads to a
relatively stronger dollar in relation to the Euro, George Harris, President, Hydro, Inc.
it also leads to economic turmoil in Europe that will result in “he sovereign debt issue in Europe and the
reduced demand for imports. For U.S. manufacturers export- U.S. is certainly a concern for businesses and
ing outside Europe, the effect of the crisis will likely be that investors. In such an uncertain economic envi-
global economic growth will be slower. ” ronment, most businesses will be conservative in
their outlook and planning. However, we have
Ron Askin, Director and VP of Sales seen an upturn in orders in the last quarter, and
Xylem’s Dewatering Solutions Business we expect to show modest growth in 2012 overall. Energy and
“Availability and cost of tier IV compliant environmental concerns continue to be a focus and older, less-
engines and the diesel fuel to power them will efficient plants will be closed. With fewer plants, many compa-
have the greatest impact on the pump industry nies will invest in upgrading and maintaining those plants that
(rental and sales) in 2012. Electric drive pumps remain, which is positive for our industry. Although unemploy-
will gain favor, particularly when showing ment is high, there remains a shortage of people in technical
system efficiency and low life-cycle costs.” fields and skilled crafts, which are critical to our industry.”
Marcus Pillion, President, EagleBurgmann Matt Lorenz, Vice President and General
“It is key that companies have an active and Manager of Eaton Corporation’s Industrial
robust R&D department to predict and imple- Control Division
ment market needs instead of the former model “As energy becomes more costly, the impor-
of reacting at the time of crisis. End users and tance of effective power management becomes
OEM customers will look to their suppler base increasingly apparent. Eaton pumping industry
to become more than a “hardware” supplier but experts are providing accurate power control
a valued team member. It is crucial that we continue to invest to reduce energy costs and extend system life, while advancing
in new technologies, our processes and our people. It is also energy efficiency and sustainability.”
crucial that our industry works together to ensure we improve
our environmental footprint.”
24 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
Ed Harvie, President, KSB, Inc. Dennis Wierzbicki, President, Grundfos
“2012 will be a year of moderate growth for Pumps Corporation
the industry. Due to surplus production capac- “2010 and 2011 have proved to be a challenge
ity for most pump companies, customers will in our economy, but opportunity has existed
benefit from better prices and can expect better for companies to grow, and 2012 is anticipated
service from their chosen suppliers.” to be no different. he impact of the eco-
nomic issues in the EU and the upcoming U.S.
elections will provide an uncertain economic picture again.
Gregg Morasca, VP – OEM Sales, Manufacturers have done well to be cash positive with nowhere
Schneider Electric North America to invest. Acquisitions and consolidation will be active in 2012,
“While some might argue that the pump indus- continuing to change the landscape of our industry.”
try is fairly mature, the future should provide
many exciting opportunities. he key to growth Kirk Wilson, VP/GM Integrated Solutions
will be three factors: Group, VP Marketing, Engineering &
Technology, Flowserve Corporation,
1) Focus—Focus on those pump industry subsegments that Pumps & Systems Editorial Advisory
offer global growth opportunities. Board
2) Market Trends—Address market trend opportunities that “Key trends include: 1) increasing focus on
will drive growth potential, even amidst what might be system optimization rather than simply equip-
considered slow-to-no-growth subsegments. ment performance; 2) an accelerating conversion from “reac-
3) Technology Trends—here will be technology trends for tive” to “proactive” to “predictive” customer maintenance strat-
both pumps and pump systems that will drive incremental egies; 3) growing customer demand for more OEM aftermarket
opportunity in 2012 and beyond.” services; and 4) increased interest in performance-based con-
tracts, including identifying key financial metrics like return
on investment.” P&S
With SCT, repair times have never been faster. Parts replace-
ment has never been easier and life cycle costs have never
been lower. The stator and rotor of the SCT pump is removed
in a few easy steps without dismantling the pump or pipe.
Stator segments can be tightened over time to in crease the
service life up to 30%.
Ask our experts for an offer with the new “Smart Conveying
Technology.
seepex Inc.
511 Speedway Drive sales@seepex.net
Enon, Ohio 45323 www.seepex.com
Centrifugal Pumps
Centrifugal sewage type (nonsubmersible), vertical or horizontal with non-clog impeller, all sizes 20,062 243,496 NR
Centrifugal submersible effluent pumps, less than 1-inch solids handling capacity, all horspowers 287,046 46,912 5,831
Solids 1-inch to 2-inch inclusive, all horsepowers 479,240 100,714 10,091
Greater than 2-inch solids handling capacity, all size discharge 13,875 57,996 160
Submersible grinder pumps, all horsepowers 93,888 103,051 8,800
Single- and two-stage, single- and end-suction, close-coupled with driver 1,300,972 190,745 22,820
Single- and two-stage, single-suction, in-line, close-coupled with driver NR NR NR
Single stage, single suction, vertical, in-line frame 28,975 29,475 10,108
Single-stage, single-suction, frame- or foot-mounted, metallic pumps, built 40,605 166,149 -13,718
to National or International Standards ANSI B73.1 or ISO 2858
IEM-2020
Industrial Engine Module
• Extremely rugged, fully potted design in an • FREE BESTCOMSPlus setup and monitoring software
affordable package is intuitive and powerful
• Fully operational at a temperature range of • Fast and simple programming with preconfigured
-40 to +70°C logic schemes
• SAE J1939 engine ECU communications • 16 programmable contact inputs and 7 contact outputs
Reciprocating Pumps
Reciprocating pumps, driven by electric motor, engine, or steam turbine, including reciprocating 603,698 310,913 47,955
piston, plunger, power-pumps for water flooding or diaphragm (not air-operated) pumps
Diaphragm Pumps
Air-operated 300,312 233,789 49,034
Rotary Pumps
100 psi and under, designed pressure, all gallons per minute, designed capacity 470,159 147,517 -9,302
101 to 249 psi, designed pressure, all gallons per minute, designed capacity 193,482 119,164 31,672
250 psi and over, designed pressure 166,077 116,555 16,296
Proven Performance
Larox Flowsys is now Flowrox
FLOWROX VALVES AND PUMPS with over 30 years of experience and
more than 100 000 installed products.
Flowrox Inc.
808 Barkwood Court Tel. +1 410 636 2250
Suite N Fax +1 410 636 9062
Linthicum info@flowrox.com
MD 21090 www.flowrox.us
The United States
ENGINEERED TO SERVE
Non-Contacting
PUMPING APPLICATIONS Flowmeter
At Revere, we engineer controls for an incredible range of
pumping applications. From control panels for original Measure Flow
equipment manufacturers to complex conigurations for
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from Outside a Pipe
Control your pumping systems. Designed for “difficult liquids” like
wastewater, slurries, sludge and
Control your business. liquids with bubbles or solids
! Works on metal or plastic pipes
½” diameter or larger
! Simple 5-key calibration
system
! Measures and totalizes
forward and reverse flow
! Isolated 4-20mA output
! 2 programmable control relays
! Optional data logger
! Optional Intrinsic Safety
Two trusted names. One local source for sales and • Industrial Motors & Drives
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January
January 2012
2012
Cutting-Edge Treatment
Alan Cone, Siemens
C
obb is one of metropolitan
Atlanta’s most populated counties.
Nearly one million people call it
home. Millions more work, play and visit
inside the borders of this suburban stretch
of neighborhoods, businesses and parks.
he infrastructure is among the area’s best
and getting better. he Cobb County
Water System (CCWS) is a strong case in
point.
he CCWS is capable of handling
three to five times more than the combined
80 million gallons of sewage and runoff it
processed daily through four regional treat-
ment plants. he aging SCADA system
that monitored and managed the facili-
ties, however, was due for a major upgrade,
as the county was experiencing the costs
that come with lost productivity and
inefficiencies.
Process control analyst Walt Rittenhouse gets a bird’s eye view of the Noonday Creek plant
with WinCC.
The Challenges plants and 42 pump stations, which direct wastewater from
he biggest challenge facing technicians charged with upgrad- neighborhoods and developments throughout the 345-square-
ing the operation was identifying and implementing a solu- mile county, had been deployed over time by an assortment of
tion that could seamlessly unify the CCWS. he four primary integrators.
“Our old architecture was disjointed and
aging,” explains Pat Brechbill, technology support
manager for the CCWS who heads up a team of
seven process control analysts and six instrumenta-
tion technicians. “So, we focused on implementing
a future-proof plant upgrade capable of providing
our staff with a clear view into the whole wastewater
treatment system. he main goal is to give our engi-
neers, maintenance teams and operators real-time,
anytime plant access from virtually anywhere.”
Plant unification was the top priority, but other
lofty objectives loomed. he elimination of cumber-
some and complicated license management proce-
dures was high on the punch list. Time-consuming
programming and troubleshooting requirements
had to go too, along with outdated graphics and
screens.
Plant overview screen shot
CCWS in part based on the innovative work done at Orlando’s “here’s a huge cost savings that comes with self sufficiency
Iron Bridge wastewater treatment plant. Brechbill and his core in engineering and plant set up,” Brechbill says. “he intuitive
team toured the facility that underwent its own system-wide nature of WinCC allows us to do much of the work ourselves,
upgrade built on the WinCC and PLC platforms. to the tune of at least $150,000 in just engineering cost savings
at the Northwest facility,” he projects.
Self-Sufficient Solution Putting a price, however, on what Brechbill considers one
When Brechbill first joined the CCWS as a programmer five of the biggest benefits of the upgrade—a new level of confi-
years ago, he was new to upgraded PLCs. “I quickly realized dence in the operation and the clean water it’s putting back
how powerful the Siemens PLC platform truly is and how it into the area’s rivers and streams—is difficult. “We’ve always
enables you to innovate on the architecture side,” Brechbill says. produced reusable water at our plants, but our system upgrade
Now that the Noonday Creek plant upgrade is complete will no doubt enable us to further enhance our processes and
and the learning curve is a thing of the past, operators and sup- the quality of water destined for the Chattahoochee River,
port teams “are more confident than ever in their plant man- Noonday Creek and other waterways,” explains Brechbill.
agement capabilities,” says Brechbill. “Now that we’ve got the
exposure of two upgrades under our belt and a real comfort P&S
level with the intuitive SCADA software, our plan is to be self
sufficient with the next two plant upgrades and ongoing man- Alan Cone has been with Siemens for 16
agement,” he noted. years. he last 11 years he has been in
Should CCWS hit any hurdles, it has support in place industrial automation as product market-
that has the expertise to help. CCWS now has a standardized, ing for SIMATIC HMI currently respon-
revamped and efficient wastewater treatment system that the sible for SIMATIC WinCC.
staff can easily manage and maintain. he self sufficiency could
lead to an estimated triple-digit savings at the Northwest plant
alone.
PROTECT PUMPS
A
PUMPING
AMPS
The fundamentals of how power quality issues affect the plant, how to detect them
and how to make them go away
I
f the quality of the electricity that a plant con-
sumes is not what it should be, it costs the
company more than is necessary. Poor power
quality shortens the life of equipment, trips auto-
mated equipment and produces extraneous heat
that must be removed. Ironically, many of these
issues originate inside the plant.
Vibration 18-pulse drives help reduce harmonics because as the number of pulses increase,
their amplitudes decrease. Other solutions for mitigating drive-generated harmon-
Analysis ics include passive front-end chokes/filters, harmonic trap filters and active filters.
IDE
V ine typically a metal oxide varistor. Transient voltage surge suppression (TVSS) pro-
Onl vides additional transient protection. Operators can apply TVSS protection at sev-
eral points throughout the facility depending on protection equipment type. Apply
Quick and easy Category C equipment at the service entrance. Apply Category B equipment at
solutions for your distribution panels, and apply Category A equipment at the individual circuit level.
maintenance needs! Voltage Unbalance and Current Unbalance
Sales • Rentals • Services Voltage unbalance is the measure of voltage differences between the phases of a
three-phase system. It degrades the performance and shortens the life of three-
phase motors. Voltage unbalance at the motor stator terminals causes high cur-
rent unbalance, which can be six to 10 times as large as the voltage unbalance.
Unbalanced currents lead to torque pulsation, increased vibration and mechanical
305-591-8935 • www.ludeca.com stress, increased losses and motor overheating. hese unbalances may also indicate
maintenance issues, such as loose connections or worn contacts.
38 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
Operators can make some basic
phase-to-phase voltage unbalance mea-
surements using a high-quality DMM
and phase-to-phase current unbalance
measurements using a high-quality
clamp meter. Accurate, real-time unbal-
ance measurements need a three-phase
power quality analyzer to pinpoint
unbalance problems. Open circuits and
single-phase to ground faults are easier
to correct than load balancing, which
typically requires corrective, system-level
design changes.
Conclusion
Power quality issues are frequently inter-
related. Address them from an entire
plant approach without losing focus
on how they affect individual loads.
Sometimes, fixing one power quality
problem can make another problem
worse. Looking at the big picture by
using a three-phase power quality ana-
lyzer enables operators to correct the
causes of power quality issues and not
just doctor the symptoms.
P&S
Wade hompson is
a Fluke Corporation
power quality
specialist. hompson
specializes in
troubleshooting power
quality problems at
data centers, large embedded systems,
utilities and industrial facilities. He
can be reached at wade.thompson@
circle 134 on card or go to psfreeinfo.com fluke.com.
Safe Equipment
Ralph Gabriel and Ian Smith, John Crane
Proper safety precautions for selecting, installing and maintaining seal systems
W
hen it comes to operating Seal Type
mechanical seal systems in
pumps, safety is a prime Seal Materials Seal Arrangement
concern. he potential hazards asso- Adaptive Hardware Rotating or Stationary Mating Ring
ciated with operating and maintain-
ing pumps’ seal systems improperly Seal System Seal Configuration
Seal Face Technology
include fire, explosion, contamination Dual Seal Relative Orientation
and adverse health and environmental
Leakage Containment Design
effects. he results can be catastrophic.
By understanding seal systems and
Dual Seal Interconnecting Pipe Work
operating them correctly, users can mini-
Seal Accessories
mize safety hazards. Keeping things run- Seal Auxiliary System
ning smoothly will extend the life of the
Sealing system components
seal system and pumping equipment,
saving the end user significant costs. seal systems help keep pumping equipment operating safely.
Users should follow plant and local emergency response
The Seal System system rules when selecting a suitable seal system. Fluid can
he term “seal system” refers to all aspects of the seal and its also leak from flange seals, gaskets or piping connections
use in the pump, including: mounted to the casing directly or indirectly, so users should
• he type of seal, seal materials and any adaptive hardware monitor those potential safety hazards as well.
• he seal’s configuration, including whether mating rings
are rotating or stationary; the seal face technology; the Seal Safety Issues
relative orientation of any dual seals to each other, such as Mechanical seals include parts that wear out over time. Seals
face-to-back, back-to-back or face-to-face; and the seal’s generally operate with a low rate of acceptable controlled leak-
leakage containment design age, but if the seal is approaching the end of its life or fails pre-
• he seal’s accessories, including interconnecting pipe maturely, that leakage rate can climb to unacceptable levels.
work between any dual seals and the seal’s support system Causes of premature seal failure include:
• Incorrect seal system assembly
he seal system’s role in a pump is to minimize leakage • Incorrect pump installation
of the pumped liquid from the area in the pump where the • Incorrect pump operation
drive shaft enters or exits the casing. Depending on the type of • Failure of another pump component
pumped liquid, leaking fluid can be extremely dangerous, so • Changes in process conditions
1.800.SEALING | www.johncrane.com
Maintenance Minders
entire pump assembly to ensure that everything works correctly. • If the support system includes a heat exchanger and the
• Check the pump at the coupling to make sure the driver or coolant supply includes isolating valves, install a pressure
motor is aligned properly. relief valve between the isolating valves to avoid the risk of
• Make sure that the motor is rotating in the correct explosion.
direction.
• Ensure that all alarms and transmitters are operating. Proper pressures throughout the system are particularly
• Make sure that all valve positions are set correctly. important for safe operation. If the system includes a barrier
system, the system’s pressure should
not fall below the seal chamber’s pres-
sure. he seal supplier may recommend
a buffer/barrier fluid pressure based on
the original operating conditions, but
end users must verify compatibility. he
barrier pressure rises and falls with the
surrounding environment’s temperature,
particularly in piping API Plan 53B sys-
tems, so monitor the outside tempera-
ture while running the equipment.
he seal system can also climb
above its maximum allowable work-
ing pressure while it is being filled, so
pump operators should use the correct
topping-up system and avoid releasing
the barrier system’s pressure while top-
ping up. Based on the type of system, it
may need to be topped up automatically
or manually with a hand pump.
In addition, users should avoid
running pumping equipment without
liquid or with liquid that has high gas
Sometimes less is more... content. Doing so can overheat the seal’s
radial face and cause an explosion. If the
system makes a squealing noise, it may
indicate that the seal’s radial face is not
Especially when it comes to water usage lubricated properly.
Chesterton® mechanical packing and seals can
dramatically reduce your water consumption on
Preventative Maintenance
rotating equipment. With over a century of experience
Regular plant tours and system mainte-
in providing sealing solutions in a wide variety of nance allow operators to identify poten-
applications and industries, Chesterton can deliver tial problems before they lead to a fail-
solutions that are right for your plant and equipment. ure. Before performing maintenance on
Our local specialists have the ability to analyze the seal system, make sure the machine
applications and implement programs as a single is stationary, secured from unforeseen
point solution provider. start-ups and blocked from the pumped
liquid. Drain the pump completely,
Run long, run dry with... including any liquid in the seal chamber
Chesterton’s Water Management Programs. and auxiliary system. Users may need
For more information go to www.chesterton.com/water to purge the system with an inert gas to
clear the pump of liquid.
During maintenance checkups,
users should confirm that all seal system
21885 © A.W. Chesterton Company, connections are leak-free and check the
2011. All rights reserved.
seal’s leakage rate. An increasingly steady
leakage rate normally indicates that the
seal is failing.
circle 115 on card or go to psfreeinfo.com
44 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
Users also should measure the pump’s vibration level, Pump operators who need to transport used seal parts for
which can be a good indication of the machine’s condition. repair should clean and decontaminate them using the manu-
In addition to posing safety hazards, high vibration levels can facturer’s instructions and attach appropriate safe handling
shorten the seal system’s life, so correcting issues will preserve instructions to the package. Users should also dispose of buffer/
equipment life. Causes of high vibration include: barrier liquids properly, since they may be contaminated.
• Operating beyond the pump’s allowable operating range Following proper safety measures can do more than help
• Excessive pipe strain, which can distort the casing pump operators avoid disaster.
P&S
• Inadequate coupling alignment
• Damaged, corroded or eroded pump
components, especially those that
control the radial location of the
Motors | Automation | Energy | Transmission & Distribution | Coatings
shaft to the casing
• Incorrect impeller adjustment for
some pumps
• Inadequate tightening of hold-down
bolts
• Worn bearings, which can develop
into catastrophic seal and machine
failure
M
ankind reached its latest population milestone of which force the pumped material to flow around the inte-
on October 31, 2011, when the United Nations rior of the pump’s casing—has often been a top choice of
Population Fund estimated that a baby boy born plant operators. he popularity of lobe/circumferential-pis-
in the Russian city of Kaliningrad became Earth’s seven bil- ton pumps in these types of operations stems from their con-
lionth resident. hat meant that only 11 years were needed tinuous-flow and dry-run capabilities, which affords them
to add another billion people to the world’s population since the ability to handle the wide range of solids, slurries, pastes
the six-billion threshold was reached in 2000, while the and liquids that are found in sanitary food production and
population has doubled from 3.5 billion in the early 1970s. packaging operations.
Even with fertility rates declining, the U.N. predicts that the he plant operators who rely on these pumps are, how-
world’s population will continue to grow and reach eight bil- ever, forced to live with a series of operational inefficiencies
lion in 2025 and 9.2 billion by 2050. that are inherent to the pump. hese inefficiencies come not
Any way you look at it, that is a lot of mouths to feed. only in the form of decreased reliability over time, but an
he challenge, then, for food producers around the globe is increase in energy consumption and cost, which is becoming
to put into place systems that not only grow, raise or fab- a more crucial consideration for production-plant operations
ricate enough food to meet the needs of the worldwide worldwide as “green” energy initiatives take hold.
population but to do so in the most efficient, cost-effective Because of their method of operation, from day one,
manner and with the smallest amount of spoilage or waste lobe/circumferential-piston pumps will wear constantly. his
possible. Because of this, a 2008 report commissioned by the wear means that the internal clearances in the pump’s housing
Stockholm (Sweden) International Water Institute should will become greater, resulting in reduced flow capacity and
have been an eye-opener for food producers everywhere. volumetric consistency over time, along with the increased
In the report, titled “Saving Water: From Field to Fork— possibility that product “slip” will occur. hese conditions
Curbing Losses and Wastage in the Food Chain,” the authors will combine to produce an overall reduction in the pump’s
noted that the most often quoted estimate on global food efficiency and a corresponding increase in the cost of operat-
waste is that “as much as half of all food grown is lost or ing it due to the increased speeds required to maintain the
wasted before and after it reaches the consumer.” desired volumetric consistency.
his article will show how an innovative pump technol- Other shortcomings of lobe/circumferential-pump
ogy can help food producers, processors and packagers opti- operation that food processors must be aware of include:
mize operations on the front end. his will result in waste • he need to seal two shafts, which doubles both seal
reduction that will benefit the growing world population and expenses and the potential for leakage
the production company’s bottom line. • Chronic seal failures that can cause products to solidify
inside the pump
The Challenge • Self-draining that requires vertical porting, which can
When it comes to sanitary food-processing applications, decrease volumetric efficiency by 20 percent or more
lobe/circumferential-piston pump technologies—the designs • Greatly reduced speeds required to handle
This new type of eccentric disc pump is sealless and uses a unique stainless steel bel-
lows that results in increased performance.
high-viscosity liquids
• Diminished performance when handling
low-viscosity liquids
The Solution
Eccentric disc pump technology is becoming a growing option for food production.
When looking for an acceptable alternative to lobe/circumferential-piston-style
pumps regarding optimized performance, highest volumetric consistency, lowest
life-cycle costs and the best energy efficiency, eccentric pumps are the solution.
he versatility, reliability and sanitary operation of this technology make it ideal
for an array of food-production applications—including the handling of yogurts;
ice cream; custards and chocolate; beverages such as fruit juices and milk; confec-
tionary items like glucose and aromas; sauce-type liquids such as tomato sauce,
mayonnaise, mustard and baby food; and many semi-abrasives.
he eccentric disc (or movement) principle was invented by French engineer
André Petit more than a century ago. Basically, the eccentric disc pumping prin-
ciple has produced a family of pumps that does not need mechanical or dynamic
seals to operate. his makes eccentric disc pumps perfectly suitable for the sanitary/
hygienic operating conditions that are the hallmark of food production, processing
and packaging.
Eccentric disc pumps do not require mechanical seals because, even though
they are driven by a standard rotating drive, the disc is rotated by an off-center shaft
that produces its eccentric movement and allows each point of the disc to move at
circle 139 on card or go to psfreeinfo.com
the same speed. his means that the drive end of the pump’s shaft is located on a
different plane than the tip end of the shaft that actually drives the pumping mecha-
nism. Attached to the shaft are bearings that are enclosed in a hermetically sealed
metal bellows or rubber boot. So, when the shaft rotates, the bellows or rubber boot
does not rotate, but, rather, flexes in an eccentric circle.
his gives the eccentric disc pump an operation that is similar to that of a
peristaltic pump, but without the need for any hoses, which can often fall victim to
their own inefficiencies. During operation, the pump’s disc is driven by the eccentric Highland Oaks I,
movement of the shaft allowing product to flow through both the pump’s inner 1100 W 31st Street, Suite 120
Downers Grove, IL 60515
and outer chambers. his style of operation eliminates any possibility of pulsation Tel: 909-512-1257
within the pumped liquid, and since the pump does not depend on clearances to Fax: 909-512-1209
Info@pumpsg.com
facilitate product flow, any slip is negligible. Additionally, with the pump needing pumpsg.com
no mechanical seals, there are no surfaces present where products that are difficult
SEALING SENSE
Why do I need to complete an application questionnaire?
This month’s “Sealing Sense” was prepared by FSA member Larry Sheffield.
E
very day, gasket manufacturers are asked to make
recommendations to distributors and end users for
sealing applications. he FSA has developed question-
naires that help gather most of the information necessary for
gasket manufacturers to make the best possible recommen-
dation. One form is specific to standard flanges while the
other covers custom flanges. Both are available for comple-
tion and submission on the FSA website, www.fluidsealing.
com. See Figure 1 for the standard flanges questionnaire.
Application Information
When the manufacturer or distributor is involved in the
gasket selection process, it is most often to help solve an exist-
ing sealing problem or to seal a specific piece of equipment.
In both these situations, specific information is required.
Since most leaking flanges have little to do with the
gasket material itself, answering these questions may provide
insight into where the problem lies. Generally, gasket manu-
facturers understand how their materials work under certain
conditions and are dedicated to solving the problem, not just
selling a gasket. Even though gathering this information may
be somewhat tedious, this questionnaire is an invaluable tool Figure 1. Questionnaire for standard flanges
in the decision making/recommendation process.
information on the actual leak may be required. As stated
earlier, a leaking flange may have little to do with the gasket
Recommendation Requirements itself, but the incumbent gasket always gets the blame. See
hree components must be considered to make a proper
January 2008 “Sealing Sense: Was it really the gasket?”
gasket recommendation: flanges, fasteners and application
or operating conditions. Each component must be identified
II. Flange Information—Knowing the size and shape
because each has a direct effect on the others. After deciding
of the flanges to be sealed allows the gasket manufacturer
between a custom or standard flange design, the user com-
to narrow the choices. In general, this information provides
pletes the questionnaire. he information below is requested:
the amount and type of surface area to be sealed, which has
a direct bearing on calculating gasket stress or the amount
I. Application Information—his section identi-
of required load to achieve a seal. Some flange designs and
fies information that will narrow the gasket material choices.
materials are more or less robust than others, and this can
Conditions such as temperature, pressure, media (chemical
limit choices. he hydrostatic end force (flanges being forced
compatibility) and cycling will eliminate the use of certain
apart) and internal pressure (gasket being pushed out) must
materials and reinforce the use of others. If the gasket recom-
be considered. Some tongue and groove designs produce
mendation request is based on an existing leak, additional
extremely high compressive loads and must be considered
Conclusion We Pump
he purpose of developing this ques-
tionnaire and asking for the information Circles Around
is to allow gasket material manufactur-
ers to provide the best possible recom- The Competition
mendation. Gathering the information
on a convenient, concise form on the
front end prevents any misinterpreta- Introducing
tion of the facts and eliminates the
chance of any surprises. After all, every- Graco EP Series
one involved in this exercise wants the Hose Pumps
same result—leak-free, bolted flange
connection.
Q. When purchasing new rotodynamic pumps, what type of Recommended Test Specification Matrix
acceptance testing is recommended? Service Test Type Performance Hydrostatic NPSH Mechanical
M
ore than 150 pump SIZE : 6x8x11 IMPELLER : Enclosed R. P. M. : 1180
manufacturers present
their pump perfor- 20
11" 40%
mance data via electronic means. 60 50%
60%
hese digital pump catalogs can 70%
be found online, within stand- 16
75% 80%
alone pump selection software 50 10"
85%
and through select hydrau- 85%
HEAD (FEET)
40 9" 80%
housands of engineers world- 12
75%
wide use these catalogs to evalu- 25
70%
ate and select the pumps that best 30 8"
NPSH
Example One
To see the effect that digitizing can have
on power and efficiency curve genera-
tion, consider the curves in Figures 4a
and 4b. In this example, the pump
selection program attempted to digitize
the isometric power curves and then cal-
culate isometric efficiency curves from
the power. Notice that the software ren-
dered efficiency curves in Figure 4a are
well off the mark, particularly in and
around the 70-percent-and-up operat-
ing range. Not only are the isometric
efficiency curves misaligned, but the
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PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 55
Practice & Operations
is the preferred provider of engineered dewatering systems solutions for » Comprehensive product knowledge from
conception, design and manufacturing through
construction, mining and quarrying applications.
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Wastewater
Infrastructure
in Prefurbia
Bill Nestor
M
ost homeowners would
choose to live within
neighborhoods that pro-
vide unique streetscapes, people-
oriented walkways and interesting
architecture. Instead, many devel-
opments offer little privacy, green
space or landscape sculpting. Rick
Harrison, the author of Prefurbia:
Reinventing the Suburbs from
Disdainable to Sustainable, and his
team have spent 30 years designing
more than 700 innovative neigh-
borhoods in 46 states and 14 coun-
tries. More communities across the
U.S. are becoming aware of Rick
Harrison’s vision and expertise and
are actively taking part in planning A sanitary and storm water sewer system with homes that include basements
committees and discussions about
Prefurbia. Prefurbia incorporates specific relevance to pump system professionals and the
Harrison’s green neighborhood design thoughts, innovative design and construction of sewage systems.
ideas, techniques and methods.
“Prefurbia is a balance of design elements that address
economic, environmental and existence—the human desire Sustainability and Sanitary Sewers
for self-worth, and space. [hese are] the three Es of sustain- Sanitation is one of the world’s largest problems, especially as
ability,” states Rick Harrison, president of Rick Harrison populations grow faster than economies. A popular method
Site Design Studio, a planning firm, and Neighborhood to remove of human waste has been gravity through sewer
Innovations, LLC, a technology and educational firm. “It’s pipes. Pump and system professionals can create the most
about designing every home location to enhance the quality economical and efficient design by understanding gravity
of life through new design methods made possible by the systems.
advanced technology in today’s digital age.” Sewer pipe is expensive, anything that can be done to
Harrison’s suggestions, initiatives and experience have lessen the sewer length while designing a neighborhood
municipal system will be a savings, but a lot more makes up
Need a better pump? sewage elevated to a higher point so it can continue a downhill
path, a costly lift station, essentially a sewage elevator, may be
We can help you design one! required. hey need to be extremely reliable and also have an
energy source. Plans and designs featuring gravity that reduces
Concepts NREC offers complete solutions for Design or eliminates lifting sewage dramatically lower costs.
pumps. By using our extensive experience in Homes are connected to the sewer system by a lateral,
pump engineering, proven methodologies and which is typically a smaller (around A 4-inch diameter) and
advanced technologies, we can help you:
lower-cost pipe connecting directly to the main sewer pipe
t Design, manufacture, and test custom using a tee connection or directly into a nearby manhole. he
""rworu"vq"oggv"tgswktgf"urgekÞecvkqpu0 deeper the pipe, the more complex and expensive the entire
system becomes. If the homes are slab on grade, the system
t"Vtqwdngujqqv"cpf"tguqnxg"kuuwgu"nkmg"àqy Manufacture
""ecrcekv{."ecxkvcvkqp."ghÞekgpe{."gtqukqp." should not require excessive depths.
""cpf"xkdtcvkqp0 If basements are introduced, the entire system becomes
about 10 feet deeper and the cost to construct the sewers rises,
t Get timely delivery of high-value designs
""ykvjqwv"iqkpi"vjtqwij"pqtocn"equvn{"rtq/
particularly for areas in which tough soil conditions and/or
""vqv{rkpi"kvgtcvkqpu0 rock needs blasting for construction.
Original Pump (l)
Redesigned by CN (r) It gets even more expensive if large storm sewer pipes
t"Ceswktg"qwt"uqhvyctg"vqqnu"cpf"igv" each with manholes and inlets need to be constructed. Pump
Test
""vtckpgf"hqt"kp/jqwug"fgukip"qh"rworu0
and system professionals serve as valuable resources in keep-
Contact us today to SAVE ing down costs by paying attention to details and components
proposed in the planning stage to create feasible and afford-
ENERGY, TIME and MONEY!
able sewer system designs that follow nature’s patterns of sur-
802.296.2321 face flow.
A Total Turbomachinery Resource sales@ConceptsNREC.com
Low-Pressure Sewers
circle 142 on card or go to psfreeinfo.com A pressurized sewer can be a viable option, especially when
difficult soils, slopes and/or a plan introduce a lot of interest-
ing geometry. Pressurized systems need no manholes or lift
stations. he pipe can be shallow and can bend easily.
Some pressure sewer systems are powered by grinder
pumps. he system uses small-diameter pipes and grinder
pumps, often installed at each home. he grinder pump sta-
tion collects all the wastewater from the home and grinds it
into a slurry. he wastewater is then pumped to a larger sewer
main or directly to a wastewater treatment plant.
While gravity sewer systems often use large mains that
are installed in deep trenches, pressure sewer pipes may be
as small as 1¼ inches in diameter and follow the contour of
the land. hese small trenches can mean huge savings because
they greatly diminish excavation and piping costs.
Pressure sewer systems are used in areas where a con-
ventional gravity sewer system cannot be installed or is too
on
@PumpsSystemsMag
and at
www.pump-zone.com
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PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 63
Practice & Operations
Environmentally-
Friendly HVAC Solution
Brad Hubbard, Cerus Industrial
F
abri-Kal’s 400,000-square-foot
plant in Kalamazoo, Mich., was
formerly a vacant brownfield
site that was transformed during the
last two years into a state-of-the-art
design and manufacturing facility.
In continuous operation as a com-
pany since 1950, Fabri-Kal produces
custom packaging products in the
foodservice markets.
As with many American manu-
facturers, Fabri-Kal’s management
wanted to upgrade its facilities to meet
the company’s long-term sustainabil-
ity goals. When they renovated the
Kalamazoo plant, they insisted on
meeting Leadership in Energy and
Environmental Design (LEED) Silver
certification requirements.
A Fabri-Kal employee packages products.
LEED Certification
LEED refers to the green building certification system devel- Motor Starter Selection
oped by the U.S. Green Building Council. It is the foremost In selecting motor controls for the building upgrade, Pleune’s
program for the design, construction and operation of green engineer Kevin Jones wanted to design and construct a
buildings. system that used the latest, most efficient technologies, as
Achieving certification requires that facilities be rated well as simplified and reduced the cost of future upgrades.
according to different metrics for factors including efficient Jones consulted with Rob Born from Michigan Air Products
use of energy, water consumption, CO2 emissions reduction, of Grand Rapids, Mich.
improved indoor environmental quality and stewardship of he selection of the starters was made to fulfill a series
area resources and sensitivity to their impacts. of detailed requirements. For example, Jones wanted motor
Fabri-Kal’s management team worked hand-in-hand starters for the exhaust and supply fans that were easy
with Kalamazoo-based architecture, engineering and interior to integrate into the building’s automation systems. he
design firm, Eckert Wordell, to comply with LEED certifica- plant will ultimately be controlled with BACnet, and he
tion requirements when designing the upgrade of the facility. wanted the starters to be upgradable in the field when the
he selection of components for the building’s environmen- BACnet system’s installation is complete. Using BACnet,
tal controls was conducted by Pleune Service Company of an ISO and ANSI standard data communication protocol
Grand Rapids, Mich. for building automation and control networks, building
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CALL 913.888.5201
Smith & Loveless Inc.
VISIT SmithandLoveless.com
Above all others. TM
he chosen starter was designed from the ground up to the compressor room off the low-voltage terminal inputs of the
meet the needs of any automated building system. In addition starter without any interposing relays installed. he system also
to being the only starter to support a BACnet interface and used the 24-volt inputs to the controller to provide time and
integrated controls for dampers, this starter also provides an temperature information to activate seasonal settings for con-
integrated power meter. trolling each starter.
he ability to meter power usage allows for detecting prob- “Selecting EMS starters from Cerus was an easy decision,”
lems such as belt loss, but the internal meter can also be inter- says Jones. “Not only did I get the best solution for controlling
rogated by a remote building control system to enable active and protecting my fans, I also got a set of system components
monitoring and control of building energy consumption. that will allow for integration of systems to support Fabri-Kal’s
One could add separate BACnet communications and future sustainable objectives.”
power metering units to a conventional motor starter, but
doing this would be more costly and time consuming to design P&S
and install, and it would invite errors and safety risks. he safety
risks occur when technicians encounter a mix of low-voltage
and high-voltage contacts while installing discrete power sen-
sors and control modules within the same panel. Brad Hubbard has been an application
In contrast, EMS starters are safer and much more effi- consultant for Cerus Industrial for the
cient, allowing for interfacing, control and monitoring of all last three years. He received his bachelor’s
starter functions and motor power consumption externally, degree from Oregon State University and
without opening the unit’s enclosure (see Figure 1). is currently pursuing the USGBC LEED
In addition to traditional, high-voltage motor controls, Green Associate Credential. Hubbard can
these starters also provide low-voltage (24-volt) control capabil- be reached at brad.hubbard@cerusindus-
ity. Jones used this to enable the connection of a starter directly trial.com or 800-962-3787.
to a four-channel controller. he controller runs four fans in
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EPOXIES
FOR
Pump Applications
Stainless Steel, Aluminum
and Ceramic Filled Systems
www.masterbond.com
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INDEX OF ADVERTISERS
Advertiser Name R.S. # Page Advertiser Name R.S. # Page Advertiser Name R.S. # Page
A. W. Chesterton Company 115 44 Houston Dynamic Service, Inc. 122 61 seepex, Inc. 128 25
Advanced Engineered Pump, Inc. 150 70 Hydraulic Institute 146 68 SEPCO 159 70
Advanced Sealing International John Crane 123 42-43 ShinMaywa (America) Ltd. 129 11
(ASI) 133 39 Jordan, Knauff & Company 147 66 Sims Pump Co. 110 41
Baldor Electric Company 100 30 Junty Industries, Ltd. 152 71 Sims Pump Co. 110 69
Basler Electric 116 26 Load Controls, Inc. 124 36 SJE-Rhombus 140 39
Blacoh Fluid Control, Inc. 117 34 LobePro 153 71 Smith & Loveless 130 65
Blue-White Industries 118 9 LUDECA Inc. 137 38 St. Marys Carbon Company 149 62
Bredel Hose Pumps 119 53 Magnatex Pumps, Inc. 154 69 Tarby, Inc. 141 56
Concepts NREC 142 62 MasterBond 155 69 TAW 161 70
Dan Bolen & Associates, LLC 151 70 Meltric Corporation 156 71 TAW 162 70
DiscFlo 143 66 Milton Roy 103 7 Trachte, USA 163 71
EagleBurgmann 101 IBC Mission Communications 125 33 Tuf-Lok International 164 71
Electro Static Technology 120 35 Nidec Motor Corporation 107 5 Vaughan 111 49
Elliott Group 102 IFC NK Technologies 138 63 VERTIFLO 165 70
FlowRox Inc. 121 27 Orival 160 63 Vesco 166 70
Frost & Sullivan 144 68 Pump Pros 126 23 WEG 131 45
Fullo Specialties Co. 134 40 Pump Solutions Group 139 47 Weir Minerals 112 13
Gorman-Rupp Company 104 1 Pumping Machinery 157 71 Xylem Dewatering Solutions
Graco, Inc. 135 51 Revere Controls Systems 148 28 (Godwin Pumps) 106 57
Greyline Instruments Inc. 145 28 Ruhrpumpen 109 29 Xylem, Inc. 113 3
Grundfos 105 BC Scenic Precise Element Inc. 158 71 Zoeller Company 114 59
Hitachi America Ltd. 136 58 SCHENCK 127 55 * Ad index is furnished as a courtesy and no responsibility
is assumed for incorrect information.
Employment
EXECUTIVE SEARCH/RECRUITING Searching for:
GULF COAST
Regional
“Serving the Pump & Rotating
Equipment, Valve, and Industrial
Manager
Equipment Industry since 1969”
Domestic & International
Specializing in placing:
• General Management
• Engineering Solutions
• Sales & Marketing
• Manufacturing
DAN BOLEN • JASON SWANSON
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CHRIS OSBORN • DAN MARSHALL
9741 North 90th Place, Suite 200 www.sepcoUSA.com
Scottsdale, Arizona 85258-5065 Vesconite Hilube
(480) 767-9000 • Fax (480) 767-0100
Email: danbolen@mindspring.com Pump Bearings
www.danbolenassoc.com G Can run dry
circle 151 on card or go to psfreeinfo.com G Increase MTBR
circle 159 on card or go to psfreeinfo.com
G Avoid shaft
seizures
www.meltric.com • 800.433.7642
liable for claims relating to these materials and makes no warranties, express or implied, or representations as to their accuracy or completeness or for errors or omissions contained herein. his information is not intended to
Jordan, Knauff & Company Figure 1. Stock Indices from January 1 to November 30, 2011
hese materials were prepared for informational purposes from sources that are believed to be reliable but which could change without notice. Jordan, Knauff & Company and Pumps & Systems shall not in any way be
T
he Jordan, Knauff & Company (JKC) Valve
Stock Index was down 6.4 percent during the
first 11 months of 2011, below the broader
S&P 500 Index, down 1.9 percent. he JKC Pump
be construed as tax, legal or investment advice. hese materials do not constitute an offer to buy or sell any financial security or participate in any investment offering or deployment of capital.
Stock Index was down 13.7 percent in the same time
period.
Looking back at the U.S. economy in 2011, the
fears about a double-dip recession became the realiza-
tion that economic growth will remain sluggish for Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates. he
JKC Pump and Valve Stock Indices include a select list of publicly-traded companies involved in the pump
awhile. Moderate growth is the theme. and valve industries weighted by market capitalization.
he U.S. GDP grew slowly in 2011. According to
the Commerce Department, the economy expanded for more than two years. However, during the last few months
in the third quarter at a 2.0 percent growth rate. his is up of 2011, the PMI was near its lowest levels since mid-2009, after
from the 1.3 percent second quarter growth and the 0.4 first higher levels in early 2011. he Index rose in November to 52.7
quarter percent growth. he gains in the third quarter reflected from 50.8 in October. Growth in energy exploration and related
improved consumer spending, net exports and business invest- inputs of steel and fabricated metals appear to be the cause.
According to the U.S. Energy Information Administration,
Figure 2. U.S. Energy Consumption and Rig Counts the U.S. exported 753.4 million barrels of petroleum products
made from crude oil in the first nine months of 2011, while it
imported 689.4 million barrels, putting the nation on track to
Figure 3. U.S. PMI Index and Manufacturing Shipments
THINKING AHEAD
MAKES IT POSSIBLE
INNOVATION
IS THE ESSENCE
www.grundfos.com
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