Sie sind auf Seite 1von 76

The Magazine for Pump Users Worldwide January 2012

pump-zone.com

INSIDE: STATE OF THE INDUSTRY • INSTRUMENTATION, CONTROLS & MONITORING


Global
Manufacturing
Supported locally worldwide.
Manufactured in the
USA, India and China.

Reliable
Design
Rugged performance
based on nearly a century
of experience, with more
than 40,000 units installed.

The world turns to Elliott.


Technical
Excellence
Single and multistage
configurations built
to API standards Expert
or customized to
meet your needs.
Packaging
Complete system
packaging in Elliott’s
purpose-built facility.

Turn to Elliott.
The leader in mechanical drive steam turbines.
Reliable, economical Elliott steam turbines have been driving critical process
machinery for nearly 100 years. Single stage and multistage YR models are
available for API and industrial applications up to 10,000 HP. And Elliott’s
global service network provides responsive service and support to customers
everywhere in the world. Elliott YR steam turbines. Why turn anywhere else?

EBARA CORPORATION

Career opportunities around the world:


C O M P R E S S O R S p T U R B I N E S p G L O B A L S E R V I C E www.elliott-turbo.com

circle 102 on card or go to psfreeinfo.com


YOU CAN
HAVE IT ALL. E Q U I PPE D W I T H A

WITH THE GORMAN-RUPP


INFINITY LINE OF SOLIDS- TM

HANDLING VORTEX PUMPS.


OPTIMIZED PUMPING EFFICIENCY.
UÊ *>Ìi˜Ì‡«i˜`ˆ˜}Ê-Ì>}}iÀ܈˜}®Êˆ“«iiÀÃÊ>ÀiÊ̅iʓœÃÌÊ
ivwVˆi˜ÌÊۜÀÌiÝʈ“«iiÀÃʈ˜Ê̅iʈ˜`ÕÃÌÀÞ
UÊ Ê-Ê-iÀˆiîÊ6œÀÌiÝʫՓ«ÃÊÕÃiÊ Ê*Ài“ˆÕ“ÊÊ
vwVˆi˜VÞʓœÌœÀÃ

MAXIMIZED SOLIDS-HANDLING.
UÊ 6œÀÌiÝʈ“«iiÀÃÊ>ÀiʏiÃÃʏˆŽiÞÊ̜ÊVœ}Ê̅>˜ÊœÌ…iÀÊ
Vi˜ÌÀˆvÕ}>Êˆ“«iiÀÊ`iÈ}˜Ã
UÊ Ê-Ê-iÀˆiÃÊ6œÀÌiÝʫՓ«ÃÊ«>ÃÃÊλÊë…iÀˆV>Ê܏ˆ`Ã

MINIMIZED DOWNTIME.
UÊ *>Ìi˜Ì‡«i˜`ˆ˜}ʓœÌœÀʅœÕȘ}ÃÊ>ÀiÊ`iÈ}˜i`Ê̜ÊiÝÌi˜`ÊÊ
“œÌœÀʏˆvi
UÊ /iÀ“ˆ˜>Ê…œÕȘ}Ê>˜`ÊV>LiÊVœ˜˜iV̈œ˜ÃÊ>ÀiÊ`iÈ}˜i`Ê
vœÀÊi>ÃÞʈ˜‡Ì…i‡wi`ÊV>LiÊÀi«>Vi“i˜ÌÃ
UÊ Ê-Ê-iÀˆiÃÊ6œÀÌiÝʫՓ«ÃÊ>ÀiÊLՈÌÊ̜ʏi}i˜`>ÀÞÊÊ
œÀ“>˜‡,Õ««ÊµÕ>ˆÌÞÊÃÌ>˜`>À`Ã

THE GORMAN-RUPP COMPANY


P.O. BOX 1217 | MANSFIELD, OHIO 44901-1217 | USA
419.755.1011 | GRSALES@GORMANRUPP.COM | GRPUMPS.COM circle 104 on card or go to psfreeinfo.com
484 © Copyright, The Gorman-Rupp Company, 2011 Gorman-Rupp – Mansfield Division is an ISO 9001:2008 and an ISO 14001 Registered Company
PUBLISHER
Walter B. Evans, Jr.
Letter from the Editor
ASSOCIATE PUBLISHER
VP-SALES
George Lake
glake@pump-zone.com

T
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

is a member of the following organizations:


PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Pumps & Systems, a member of the Cahaba Media Group, 1900 28th Avenue So., Suite 110, 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 possessions $5, all other countries $15 US funds (via air mail). Call (630) 739-0900 inside
or outside the U.S. POSTMASTER: Send changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. ©2012 Cahaba Media
Group, Inc. No part of this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of
any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed
are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or
appropriateness of the advice or any 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.

2 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


circle 113 on card or go to psfreeinfo.com

From ITT comes Xylem. Learn more about the possibilities at xyleminc.com.
Table of Contents

The Magazine for Pump Users Worldwide January 2012

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.

shaped the evolution of the pump industry.

STATE OF THE INDUSTRY 2012 DEPARTMENTS

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

Centrifugal Pump Hydraulics by the Numbers . . . . 12


INSTRUMENTATION, CONTROLS & Terry Henshaw
MONITORING The Function of the Volute

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?

PRACTICE & OPERATIONS HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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

innovations. Pump Users Marketplace. . . . . . . . . . . . . . . . . . . . . . 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

4 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


HARDWORKING.
DEPENDABLE.
UNSTOPPABLE.

Count on U.S. MOTORS.


®

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.

yyy0pkfge/oqvqt0eqo"~"yyy0wuoqvqtu0eqo"
Pkfge"Oqvqt"Eqtrqtcvkqp."4233="Cnn"Tkijvu"Tgugtxgf0""
W0U0"OQVQTU ̶"ku"c"tgikuvgtgf"vtcfgoctm"qh"Pkfge"Oqvqt"Eqtrqtcvkqp0"Pkfge"Oqvqt"Eqtrqtcvkqp"
vtcfgoctmu"hqnnqygf"d{"vjg"̶"u{odqn"ctg"tgikuvgtgf"ykvj"vjg"W0U0"Rcvgpv"cpf"Vtcfgoctm"QhÝeg0

circle 107 on card or go to psfreeinfo.com


P&S News

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.

Off-BEP Energy Cost

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.

8 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


Another seminar example is shown in Figure 1. his
Joe Evans is responsible for customer and employee edu-
spreadsheet compares the same pump and motor when operat-
cation at PumpTech, Inc., a pump & packaged system
ing at and off BEP conditions. he example included shows a
manufacturer & distributor with branches throughout the
pump system that was designed for 5,000 gallons per minute
Pacific Northwest. He can be reached via his website www.
at 130 feet. Due to a design error, friction was miscalculated.
pumped101.com. If there are topics that you would like to
he actual flow is limited to a maximum of 4,000 gallons per
see discussed in future columns, drop him an email.
minute at 147 feet. To meet the required daily flow, the pump
must run two more hours each day. It P&S
also operates at a lower hydraulic effi-
ciency, and the head required is higher.
hese last two factors increase energy
consumption and result in an increased
ProSeries for All Systems ®

cost per 1,000 gallons pumped ($0.06


versus $0.049). All FLEX-PRO A2 ®

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
DOW
4
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

select a pump with a BEP flow that


reduces the system head to its original
calculated value—about 3,000 gallons
per minute at 130 feet, for example. FLEX-PRO A3 ®

Need More Volume?


Although the pump would run several Feed up to 33 gph. Built-in Tube Failure
hours longer than the one pumping 2,500:1 turndown. Detection.
4,000 gallons per minute, the energy Generous Warranty.

costs would be close to the original


5,000 gallons per minute estimates.

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

to water efficiency and head required.


An increased flow rate will increase the
horsepower required, but horsepower
is an indication of the work performed
SONIC-PRO
Ultrasonic Flowmeter
S3 ®

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
NEM
E MA 4X
For example, if a 500 gallon-per-minute WASH
WASH
WAS
WA
A DODOW
WN

pump and a 1,000-gallon-per-minute SEE OUR FULL LINE OF PUMPS & FLOWMETERS:
pump have the same wire to water effi- XXXCMVFXIJUFDPNtXXXNTFSJFTOFU
ciency and are pumping against the Built with Pride in the U.S.A.
same head, the energy required to pump
1,000 gallons will be the same. If the
head is increased or the efficiency is low- 5300 Business Drive, Huntington Beach, CA 92649 USA
ered, its energy consumption per given tTBMFT!CMVFXIJUFDPNtwww.blue-white.com
volume will increase.
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

Thermal Stress Affects Pipe


Forces on Pumps

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.

Minimize Pump Forces


he main objective of a good installation is to minimize the
forces that act on a pump. If a pipe bumps into a pump,
it will force the casing to deflect in relation to the rotor. A
stationary portion of a seal sits within the gland—essentially
a part of the casing—while the rotating portion of a seal sits Figure 1. Pump attached to cold water tank
on and rotates with the shaft.
A similar situation applies to the bearings when a
motor shaft is “forced” to align itself with the pump shaft. Case Study
herefore, any significant relative motion between the rotat- To illustrate, consider a simple example of a pump connected
ing shaft and the stationary casing boundary is likely to cause via a short pipe (2 feet long) to a storage tank with clean cold
their failure. water. See Figure 1.
API-610 specification has a table that contains the maxi- Let’s assume the water in the tank heats up from 60
mum allowable forces and movements as a function of pump degrees F in the morning to 90 degrees F in the summer
size. A bigger pump can withstand somewhat higher piping afternoon. With a pipe, cross-sectional area of roughly 10
force than a small pump. However, the intent of these tabu- in.2 (which is typical of an 8-inch pipe), the calculation below
lated allowable forces does not allow for sloppy installation. shows relative and absolute pipe elongation for carbon steel
Piping to casing nozzles must still be aligned with free-bolt pipe as it is heated by the water and the stress caused within
condition which means that bolts should not be forced but it by the elongation restricted by a pipe jammed by thermal
freely inserted between flanges. expansion strain between the tank and a pump:
herefore, there should be essentially zero force exerted
onto the pump by the piping. If this is not the case, then the
ΔL
= αΔT = (6.9 x 10-6 in/in°F) x 30°
piping needs to be cut and reconnected—an unfortunately L
expensive but necessary step if end users are interested in = 0.0002 in/in
reduced bearing and seal failures.
ΔL = LαΔT = (2' x 12") x 0.0002 = 0.005"
Thermal Forces
he allowable forces tabulated in API-610 and in similar
ANSI pipe loading criteria and other specs—such as PIP, for ΔL
example—are meant to apply to thermal changes, which are
stress σ = E = (30 x 106) x 0.0002
L
not within the control of the installing maintenance/mill- = 6000 psi
wrights crew.
his requires piping designers to make sure proper Force = 6,000 lb. x 10 in.2 = 60,000 lb.
expansion loops, hangers, supports and other factors are con-
sidered so that the incremental forces due to thermal changes L = Pipe length
are within the tabulated specified allowable forces and will not ΔL = Change in pipe length
damage the pump. Pump designers, therefore, ensure that the ΔT = Change in temperature
pump is designed robustly enough to withstand these forces.

10 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


Such “natural” thinking is not a good idea, as the anchors
created will result in high loads—as shown in the calculations
above. he only correct approach is not to use anchors.
Use sliding supports, and design the entire piping in such
a way that the expansion does not cause the movement of the
pipe ends—neither toward the pump or toward the tank. hat
is also not an easy task, but we will leave that challenge to the
piping designers and plant process engineers.
From the pump standpoint, all we ask is no forces on
pumps, please.

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
Technology
ShinMaywa (America), Ltd. offer the CNWX series
of heavy-duty, non-clog submersible pumps for the
industrial and municipal wastewater markets.
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
the single vane non-clog passage. And its design
vir tually eliminates clogging, plugging, and
entangling of fibrous materials resulting in reduced
maintenance costs and electrical power
consumption. CNWX already
solved long lasting clogging
problem in some area of
res i d ent ia l a n d muni c i pa l
application. Explosion Proof
M o d e l (F M A p p r ove d ) a r e
also avaialbe.
Highly Effective Passing
Non-Clog Scroll Submersible Pump

For more details, please contact the address of the right note.
ShinMaywa(America), Ltd.
6135 Park South Drive Charlotte, NC 28210 ■ Phone: 704-945-7112 ■ Fax: 704-945-7101
www.shinmaywa.co.jp/america/  ■ E-mail:pump@shinmaywaamerica.com

circle 129 on card or go to psfreeinfo.com


PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 11
Centrifugal Pump Hydraulics by the Numbers
Terry Henshaw

The Function of the Volute

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.

12 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


Weir Minerals
Floway Pumps...
Expertise where it counts. SM

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.

Floway® Pumps products are built around the versatility of the


vertical pump design. Depending upon exact job specifications, our
engineers select the best combination of pump components and Excellent
materials of construction to meet virtually any customers’ application. Minerals
Solutions
Weir Minerals Floway Pumps - built to last.

Tel: +1 559 442 4000


Fax: +1 559 442 3098
www.weirminerals.com
circle 112 on card or go to psfreeinfo.com
THE HISTORY
OF
By Michelle Segrest
B
PUMPS
T
he pump is one of civilization’s earliest inventions. Considering its use in
everyday life, it may be one of the most important.
Since the beginning of time, there has been a need to push, suck or lift
liquid
liq from one place to another. Pumps provide the solution, dating back to 2000
BC
BC when the Egyptians
gyyp
p invented the shadoof. he physics of this first known pump
wwas simple. A long suspended rod with a bucket on one end
aand n a weight on the other was used to draw water from wells.
hrough 4,000 years of evolution, the viscosity of the
lilliquid
i has varied and so has the direction that it flows. he mis-
sion
ssii remains the same—to move liquid from Point A to Point B.
hanks to the revolutionary innovation, creativity and vision
of
o the industry’s most forward-thinking people and companies,
it
it doesn’t matter whether the liquid is water, peanut butter or
oil—today
o there is a pump that will move it.
Monitors and digital controls now provide more efficiency.
Energy
E is saved through intelligent pumping with the onset of
variable
va
va speed and frequency drives. Globalization provides more
opportunities
op to expand the supply chain and reduce the costs of
Above left: An early 10 Series pump casting being machined manufacturing.
m A focus on engineering and design continues to
on a vertical lathe. Photo courtesy of Gorman-Rupp Co.
Bottom right: Large split case pump ready for delivery out- stregthen the industry’s development.
side Quincy, Ill. Peerless Pump photo courtesy of Grundfos All have contributed to the progression of pump technol-
ogy and society’s need for it.
While most of the industry’s key developments did not happen in recent years, veterans in the industry remember some of the
greatest moments that helped shape the course of pump history.
“Imagine a time when, to bypass a system, you had to excavate a temporary wet well and install submersible pumps,” says Ron
Askin, Director and VP of Sales for Xylem’s Dewatering Solutions Business. “Rental access to portable self-priming pumps revolu-
tionized infrastructure development and repair in the U.S. through faster, less intrusive and more economical solutions.”
hirty-three years ago, Lev Nelik (a.k.a. Dr. Pump), came to the U.S. from Russia with $50 in his pocket and a knowledge
of pump engineering. He remembers working as a pump designer for Ingersoll-Rand in the mid 1980s under Dr. Paul Cooper. “I
was involved in applying a so-called ‘bias-wedge’ impeller inlet
hydraulics that made significant advancements in improving the
cavitation characteristics of pumps,” says Nelik, who now runs
Pumping Machinery, a pump repair consulting company.
“his design was applied initially for U.S. Navy projects,
but also evolved into commercial applications, such as power
plants. It helped solve problems of measurable cavitation resis-
tance issues. It helped to further advance the work of such titans
as Igo Karassik, Warren Frazer and others. It was a true game
changer.”

THE ELECTRONICS AGE


Dennis Wierzbicki, president of Grundfos Pumps Corporation,
says electronic and digital advancements have created key inno-
vations for pump manufacturers, including, “From providing
tools to reduce quotations on large projects from weeks to hours/
s// Pumps on display for a product demonstration in 1960.
Photo courtesy of Blackmer

14 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


days, to industries that we can serve with process equipment for production,” he says. “But
most important, the electronics age has changed the technology shift in our products,
from mechanical variable speed of the 1960s and 1970s to variable speed electronically
integrated pump, motors and drives with integration to process management systems.”
In addition, Wierzbicki says, “Who would have thought a meticulously assembled
quote for a $5M capital project that took me as an application engineer a better part of a
week to do, can now be done in an afternoon?”
George Harris, president of Hydro, agrees. “Tools such as 3D modeling, CAD, CFD
and other powerful analysis tools enable companies to perform complex engineering anal-
ysis and to strengthen our value-added engineering services.
“In terms of the pump aftermarket, rapid prototyping can be an important technol- HydroAire mechanic Hank Deluca with a
ogy with the potential to bring pump Byron Jackson pump that Hydro repaired for
upgrades and rerates to market in a Inland Steel. Photo courtesy of Hydro, Inc.
Design, vision, technology much more responsive time frame
than the traditional pattern process.”
and a focus on efficiency have
shaped the evolution of the INTELLIGENT PUMPS, ENERGY
pump industry. EFFICIENT MOTORS & DRIVES
Mike Pemberton, manager of ITT
Performance Services remembers
when PumpSmart was introduced at the Chem Show in New York, N.Y., in November
1999. PumpSmart pump control systems provide real-time control and protection for
pumps while also providing process insight. “It is clear that this signaled the rapidly Photo courtesy of Freudenberg
expanding use of variable speed drive technologies for industrial pumping,” he says.
Pump system optimization became a key ingredient in all applications.
“I wonder if the idea of using adjustable speed drives and energy efficient motors to
drive pumps isn’t the major step for the pump industry,” says John Malinowski, senior
product manager for AC Motors at Baldor Electric Company. “Not only can pump
output be adjusted to control needed output, but this saves much electricity and the con-
trol can be based on a set point or process control built into the drive.”
Matt Lorenz, vice president and general manager of Eaton Corporation’s Industrial
Control Division, says accurate power control has been a revolutionary development. 52-year-old pump. Photo courtesy of GIW
“At the turn of the last century, the first automatic motor starter was developed, Industries
laying the foundation for the modern motor control industry,” Lorenz explains. “In the
following years, that technology was used to develop control equipment for the Panama
Canal.” Today, Eaton continues to provide sophisticated motor control equipment for
major Panama Canal upgrades.
A dramatic change happened during the past decade as the industry shifted from
thinking about just the pump to considering the entire pumping system, says Jack
Creamer, market segment manager for Schneider Electric.
“Sometimes advancements are seen as ‘leap frog’ technological advancements that lit-
erally change the game,” says Creamer. “In other cases, advancements are more evolution- Kalamazoo mechanical seal manufactur-
ary . . . that is, they provide incremental change opportunities that enhance and improve ing and research lab in the 1950s. Photo
the performance of systems. From a performance standpoint, the two primary drivers are courtesy of Flowserve
energy and intelligence.
“Intelligence includes the concept of a smart motor management approach that pro-
vides predictive and preventative maintenance along with remote alarming that allows
operators to better monitor and in turn, guarantee increased system performance and
availability. On the energy side, variable frequency drives reduce energy consumption for
an application. With the increasing application of ‘intelligence’ to VFDs, energy savings
potential expand beyond the affinity law explanation to cover such things as BEP match-
ing, load matching and other energy savings opportunities.”
Machine shop lathes department in Battle
Creek, Mich. Photo courtesy of American
SOME THINGS REMAIN THE SAME Marsh Pumps
As much as things have changed, many things have not, Wierzbicki says. “We are still an Image to left: Worthington Series Booster
industry that is a close network of people. We compete hard, but with high integrity and Pump. Circa 1915. Photo courtesy of
respect for each other. Even with all the advancements, it is still the people that make this Flowserve
a great industry.”
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 15
THROUGH
THE
YEARS
Editor’s Note: his timeline was developed through research, cred-
ible sources and the knowledge of friends in the industry.he history
of pumps is long and illustrious. his account represents highlights
of some of the major historical and technological developments. We
welcome your contributions and will include them with the full
version on www.pump-zone.com.

2000 BC Egyptians invent the shadoof to raise water. It


uses a long suspended rod with a bucket at one
end and a weight at the other.
Peerless
P
Pee
Peerle
rlee large split case design from the 1940s being installed in the fifiel
Peerless Pump photo courtesy of Grundfos
eld
eld.
d

200 BC Greek inventor and mathematician Ctesibius


invents the water organ, an air pump with valves
1687 French-born inventor Denis Papin develops the first
true centrifugal pump, one with straight vanes used
for local drainage.
on the bottom, a tank of water in between them and a row of
pipes on top. his is the principal design that is now known as
the reciprocating pump. 1738 In fluid dynamics, Bernoulli’s principle states that
for an inviscid flow, an increase in the speed of the
fluid occurs simultaneously with a decrease in pressure or a
200 BC Archimedean screw pump is designed by
Archimedes is considered one of the greatest
inventions of all time and is still in use today for pumping
decrease in the fluid’s potential energy. It is named after the
Dutch-Swiss mathematician Daniel Bernoulli, who published
it in a book “Hydrodynamica.” he principle is applied to
liquids and granulated solids in both the industrialized world
various types of fluid flow and is loosely known as Bernoulli’s
and in the third world—where it is a preferred way to irrigate
equation.
agricultural fields without electrical pumps.

1475 According to Reti, the Brazilian soldier and historian


of science, the first machine that could be character-
1782 James Watt—who invented the steam engine’s con-
necting rod crank mechanism, which made it pos-
sible to convert the piston’s reciprocating motion into rotary
ized as a centrifugal pump was a mud lifting machine that
motion—designs an oscillating piston machine in which a
appeared in a treatise by the Italian Renaissance engineer
wing-shaped rotary blade made a near complete revolution
Francesco di Giorgio Martini.
uncovering inlet ports in a chamber separated by a curved
1588 Sliding vane water pump technology is described
by Italian engineer Agostino Ramelli in his book
radial wall.
“he Diverse and Artifactitious Machines of Captain Agostino
Ramelli,” which also included other pump and engine designs.
1790 Briton homas Simpson harnesses steam power to
pumping engines for municipal water applications
and founds the London company Simpson and hompson
1593 Frenchman Nicolas Grollier de Servière creates an
early design for a gear pump.
Co. (predecessor to Worthington Simpson).

1636 Pappenheim, a German engineer, invents the


double deep-toothed rotary gear pump, which is
1830 Modern screw pump is invented by Revillion.

still used to lubricate engines. his gear pump made it possible


to dispense with the reciprocating slide valves used by Ramelli.
1845 Henry R. Worthington invents the first direct-act-
ing steam pumping engine. Worthington Pump
designed its first products to power canal boats and U.S. naval
Pappenheim drove his machine by an overshot water wheel
vessels. Worthington later pioneered pump designs for boiler
set in motion by a stream and was used to feed w water
ater
ate
feed
feed,, oil
ed
feed, oil pipeline
p and hydro-electric applications.
fountains. he emperor Ferdinand II granted him i a
im
“privilege”—the equivalent of a patent--in respect
of this invention.
c
ct
M
1848
Mynderse
In Seneca Falls, N.Y., Seabury S. Gould
purchases the interests of Edward
and H.C. Silsby in Downs, Mynderse
1650 Otto van Guericke invents the piston
vacuum pump, which used leather
washers to prevent leakage between the cylin-
n
& Co., forming Downs & Co., later known as
G
Goulds Manufacturing Company.
der and the piston.
1849 Goulds casts and assembles the
world’s first all-metal pump.
1675 Sir Samuel Moreland—an English
academic, diplomat, spy, inventor and
mathematician—patents the packed plunger 1851 British
duces
inventor John Appold intro-
the curved vane centrifugal
pump, capable of raising great quantities of p
pump.
water with far less proportion of strength than
a chain or other pump. he piston had a leather
seal. Moreland’s pump may have been the first
1851 John Gwynne files his first centrifugal
pump patent. His early pumps were
us primarily for land drainage, and many can
used
use of a piston rod and stuffing box (packed in a Seabury S. Gould, 1848. Photo still stii be seen today in pump house museums.
st
cylinder) to displace water. courtesy of Goulds Pumps hey were usually powered by Gwynnes’ steam

16 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


engines. By the end of the 19th century, Gwynne was produc-
ing pumps of all sizes to cover all industrial applications, from
small electric pumps to those rated at 1,000 tons per minute.
1869 Downs & Company changes its name to Goulds
Manufacturing Company.

His company had also begun to produce scientific pumps,


e.g., porcelain pumps for chemical works. In the 1930s they
1870 UK Professor Osborne Reynolds develops an origi-
nal design of a centrifugal pump.
were producing almost 1,000 different models.
1871 Johannes Klein receives a patent on his “boiler feed
apparatus.” With Friedrich Schanzlin and Jakob
1857 Worthington produces the first horizontal, duplex,
direct-acting steam pumps for boiler feed.
Becker, he founds the company “Frankenthaler Maschinen-
& Armatur-Fabrik Klein, Schanzlin & Becker” (now known

1859 Jacob Edson invents the diaphragm pump and


founds the Edson Corporation in Boston, Mass., to
as KSB) to manufacture boiler feed equipment and valves.

manufacture and sell his pump. 1874 Wilson-Snyder grows into the premier line of slurry,
pipeline and refinery pumps.

1860 Adam Cameron founds the Cameron Steam Pump


Works, and becomes another pioneer in reciprocat-
ing steam pump engines. Like Worthington, Cameron’s first
1886 Jens Nielsen, founder of Viking Pump Company,
invents the internal gear pumping principal while
designing a pump to remove excess water that was seeping
products were used to power merchant marine and U.S. naval into his limestone quarry from a nearby creek.
vessels. Cameron pumps were later applied in water resources,
oil pipeline and refining and boiler feed.
1886 United Centrifugal Pumps is incorporated. It
becomes the world’s foremost supplier of high-pres-
1868 Stork Pompen of Hengelo, Netherlands, pioneers
the concrete volute pump for water drainage.
sure crude oil and reined product pipeline pumps.

HOW MOTORS HAVE CHANGED THE PUMP INDUSTRY


By William C. Livoti, Senior Principal Engineer, Baldor Electric Company, A Member of the ABB Group

E lectric motors have had a huge


impact on the pump industry.
While it is not certain how
Steam turbine technology
ccould be used in a number of the
ppump applications listed above.
centrifugal pumps were powered in HHowever, in today’s energy-con-
the early days, it is assumed with scious society, steam is more costly
sc
reasonable certainty that the power aand less efficient than electricity.
source was not as efficient or reliable he electric motor has become the
as an electric motor. Can you imag- ddriver of choice in about 75 percent
ine running a pump with a belt and oof all pump systems, but it cannot
pulley configuration powered by a ccure the energy crisis. he focus is
steam engine? nnow on the total system looking
Michael Faraday devised a Quality assurance testing (0 Turing to rotor OD on a three-phase bbeyond component efficiency.
rotor) 1920-30s. Photo courtesy of Baldor Electric Company
machine that generated electricity
from rotary motion (the electric motor), but it took almost 50 HISTORY OF ENERGY EFFICIENT MOTORS
years for the technology to reach a commercially viable stage. 1983 Motor industry begins to offer “premium
In 1895, the first modern electric power plant went online efficient” motors but no standard exists
using Nikola Tesla’s alternating current (AC) motor (genera-
October 1992 Energy Policy Act of 1992 signed
tor). Until then, all other motors had used direct current.
he industry quickly saw the value of AC motor tech- October 1997 Energy Policy Act of 1992 goes into effect
nology, coupling motors to pumping applications.he pump 1998 Consortium for Energy Efficiency establishes
industry now had the ability to efficiently vary the speed of the premium efficiency standards
pump using a stand-alone power source. Here are examples of August 2001 NEMA Premium® Efficiency Motor Standard
how electric motors helped advance pump technology: Defined
• Speed/process control using motor pole count July 2005 Energy Policy Act of 2005
• Compact pump packages
December 2007 Energy Independence & Security Act of
• Vertical pumping technology was developed around electric
2007 signed
motors
• High speed pumping technology (steam turbines were the February 2010 Small Motor Rule made by DOE
driver of choice) December 2010 Energy Independence & Security Act of
• Improved pump/system efficiency 2007 takes effect
• Variable speed technology
• Eddy current drives Timeline compiled by Pumps & Systems Editorial Advisory
• Variable frequency drives Board member John Malinowski, Sr. Product Manager, AC
Motors, Baldor Electric Company, A Member of the ABB Group.

PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 17


1897
m
makes
Preston
K. Wood
the first deep
now occupied by the city of New Orleans. Some of Wood’s
pumps have been in continuous use for more than 80 years
without need of repairs. New ones continue to be built from
well
w turbine pump his designs.
in Los Angeles,
C
Calif. 1916 Aldrich produces the first direct motor-driven
reciprocating pump.

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.

A single and two stage pipeline pump assembly 1901 Byron


Jackson
in the 1960s at the Ruhrpumpen plant in Witten, develops the first
1917 Louis Bergeron invents the concrete volute pump
and founds Bergeron S.A.
Germany. Photo courtesy of Ruhrpumpen deep well vertical
turbine pump. 1918 Byron Jackson produces the first hot oil pumps for
the petroleum industry.

1902 Aldrich Pump Company begins manufacturing the


world’s first line of reciprocating positive displace- 1920 Viking builds its first domestic oil burner pump
using a mechanical seal.
ment pumps for steel mills and mine dewatering.
1921 Jeumont-Schneider begins manufacturing water
and slurry pumps in Jeumont, France. It later
1904 Jens Nielsen enlists George “Shorty” Mathes to
construct his gear pump design. develops solids-handling pumps and segmental ring section
multistage pumps.
1905 Multistage centrifugal pumps are developed.
1923 Byron Jackson demonstrates the first use of centrif-
ugal pumps for oil pipeline and the first automatic
1905 Two Goulds triplex pumps are installed in the New
York Times building, accomplishing the highest lift
booster station.
of water to date—387 feet, 6 inches.
1924 Durco Pump introduces the world’s first pump spe-
cifically designed for chemical processing. It would
1906 André Petit invents the eccentric disc pump and
starts his company, Mouvex, in Paris.
go on to establish undisputed global leadership in ANSI
pump design.
1908 Western Land Roller pioneers the design and
manufacture of irrigation pumps.
1926 Paciic Pump Company produces the first hot oil
double casing pump.
1911 Jens Nielsen builds the first internal gear pump,
founding the Viking Pump Company. he Viking
Rotary “Gear-Within-A-Gear” pump (the first of its kind) is
1926 O.H. Dorer receives a patent for the first inducer,
which reduces the required NPSH. Inducers did not
become incorporated into standard pump lines until
placed on the market.
the 1960s.
1912 Durion, a universally corrosion-resistant material, is
invented by the Duriron Castings Company (later
known as Durco Pump) and is applied to process equipment.
1927 Viking introduces a line of hazardous liquid pumps
for use in the fuel oil market.

1913 Inventor and engineer Albert Baldwin Wood invents


the Wood screw pump.

1915 Viking Pump Company wins the Panama Paciic


Award for internal gear design.
Photo collage courtesy of Viking Pump Co.

1915 Albert Baldwin Wood invents the Wood trash


pump. Wood spearheads the reclama-
tion from swamp and the efforts to
develop much of the land

18 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


1927 Aldrich produces the first variable stroke multi-
cylinder reciprocating pump. 1941 British Pump Manufacturers Association is
founded.

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

1930 While inventing a compressor for jet engines, avia-


tion pioneer René Moineau discovers that this prin-
ciple could also work as a pumping system. he University of
on mechanical seals).
1957 DuPont com-
mercializes the first
Paris awarded Moineau a doctorate of science for his thesis
fluoroelastomer
on “the new capsulism.” His pioneering dissertation laid the
(Viton A).
groundwork for the progressing cavity pump.
1957 Edge welded
1933 he original version of the Bush Pump is designed as
a closed-top cylinder pump. In 1960 the design was
modernized. he base of the well was from then on bolted to
metal bellows seal is
introduced.
the well casing and got its current name, he Zimbabwe Bush 1963 Tungsten carbide Special vibration control products: ultra
P
Pump, the National is used in mechanical bushes for mounting astronomic telescopes,
Milton Roy Sheen with
an early disc pump S
Standard for hand seals. 1979. Photo courtesy of Freudenberg
design. Photo courtesy p
pumps in Zimbabwe. 1965 Fluoroelastomer is used in elastomeric bellows seals.
of Milton Roy A Zimbabwe’s
After
in
independence in 1967 Alloy C-276 metal bellows seals are introduced.
1
1980, the govern- 1971 DuPont commercializes the first high temperature
m creates its own
ment Perfluoroelastomers.
m
modernized version 1972 Solid Reaction Bonded Silicon Carbide is used in
o the pump, B-type
of mechanical seals.
Z
Zimbabwe Bush
P
Pump. he pump is 1970s First standard for mechanical seals, European
to
today regarded as a Standard EN 12756 (formally DIN 24960) is developed.
n
national treasure. In 1976 Standard cartridge seals are introduced into
1
1997, it was pictured ANSI pumps.
o a postal stamp.
on
1976 Double balanced primary rings for inboard seals of
1933 J.C. Gorman and Herb Rupp introduce a pump
with a “non-clogging” feature. It outperforms any
other self-priming centrifugal pump previously invented.
double (dual) seals are introduced.
1984 Contacting containment face seals are introduced.
he company Gorman-Rupp is established. 1983 A true seal chamber for ANSI pumps is introduced.
1986 Split seals for pumps are introduced.
1936 Robert Sheen invents the metering pump. he core
of his invention was a method of controlled volume
that was inherent to the pump. he first pumps were assem-
1980s Sealless pump technology is introduced.
1990 Clean Air Act places limits on fugitive emissions
bled in the basement of his father, Milton Roy Sheen’s, home,
where the initial patterns for castings were made. from pumps.
1992 Dual gas seals are introduced for pumps.
1936 Robbins & Myers acquires the North American
license for the Moineau progressing cavity pump
and brands it with the name Moyno.
1994 API Standard 682 1st Edition is released.
1996 Modular cartridge seals for ANSI pumps are
1937 IDP produces the first radially split, pull-from-the-
rear process pump.
introduced.
1998 Non-contacting dual dry running mixer seals are
1937 Worthington produces the world’s first hydraulic
decoking systems.
introduced.
2007 Diamond coatings on seal faces are commercialized.
1939 Durco invents Alloy 20, which is the standard
industrial material for corrosive surfaces.
Compiled by Ralph P. Gabriel, Chief Engineer—Global, John Crane and
member of Pumps & Systems Editorial Advisory Board. Marcus Pillion,
President of EagleBurgmann, contributed to this report.

PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 19


In 1955, Jim Wilden invented air-
operated double-diaphragm pump
technology. It had the right air valve
1968 Gorman-Rupp produces the first
fiberglass, below-ground, factory-built
sewage pumping station.
and diaphragms needed and was
tough and versatile enough to meet
the stringent demands of the mining
and heavy-construction industries.
1968 he ownership of Stenberg-Flygt AB
is transferred to the American multina-
tional enterprise ITT (International Telephone
During the 1980s, Wilden introduced
plastic AODD pumps that have the
& Telegraph Corporation). Prior to this transfer,
ability to stand up to the harsh oper- Stenberg-Flygt AB, AB Flygts Pumpar and Flygt
ating conditions and corrosive media International AB are consolidated as a single
transferred throughout the global company.
chemical market. Photo courtesy of
Wilden
1969 Mouvex launches the first sealless rotary
pump not based on magnets.
earned the prestigious Army-Navy “E” Award that year for
outstanding production of war materials. 1970s
selling OEM pump.
Viking introduces spur gear line of
pumps, which is the company’s largest

1947 Flygt’s Sixten Englesson, a master of engineering,


develops a prototype for the first submersible drain-
age pump, which is later known as the “parrot cage,” or 1970s Gorman-Rupp invents the bellows-metering
pump and the oscillating pump, while the
B-pump, used in mining for construction. Mansfield Division acquires the Roto-Prime pump.

1949 HMD Pumps invents and engineers the world’s first


magnet drive pump. 1970 Smith & Loveless engineer Frank Weis designs the
first-ever above-grade sewage pump lift station.

1954 Blackmer invents and manufactures the first practi-


cal positive displacement pump for liqueied
petroleum gas (LPG).
1973 Frank Weis pioneers the first-ever vortex grit
removal system for wastewater treatment plants.

1954 Worthington produces the world’s first high speed


(9,000 rpm) boiler feed pumps.
1973 KSB launches the BOA-H, the first maintenance-
free, standard cast iron valve.

1955 Jim Wilden invents the air-operated double-dia-


phragm (AODD) pump technology.
1978 KSB puts the BOA-W line onto the valve market.
he first soft-seated standard valve is able to cope
with dirt in the fluid.

1956 Sixten Englesson develops for Stenberg-Flygt AB


the submersible sewage pump, called the C-pump,
with a discharge connection and level regulator.
1980s Viking introduces the Universal Seal and Viking
Mag Drive lines of internal gear pumps—both
the first of their kind in the industry.

1956
pump.
Smith & Loveless engineer Frank Weis develops the
water industry’s first true solids handling, non-clog

1957 Ruhrpumpen Gmbh begins the production of pro-


cess pumps under the license of Paciic.

1959 Viking Pump Company launches abrasive liquid


heavy-duty pumps and handles the printing ink for
more than half of the major U.S. newspapers.
Right: Blackmer
sliding vane
hand pumps
used for the
1960s New lines of industrial pumps are developed by
Goulds Pumps, including large double suction
pumps, higher pressure pumps and non-metallic pumps.
transfer of
solvents by Pan
Am in the 1950s.
In home water systems, the jet water system is improved and a Photo courtesy
complete line of submersible pumps is completed. of Blackmer

1960 Europump is established.

1962 Sundstrand develops the first Sundyne


high-speed centrifugal pump and sells it
to Shell Chemical.

1962 Grundfos places the first circulator pump


into the market with variable speed
regulation.
Left: Marvin and

1964 In cooperation with German chemical


companies, KSB develops the CPK stan-
dardized chemical pump series to satisfy a newly-
Kathryn Summerfield
founded Cascade Pump
Company in 1948. They
are pictured here at an
published standard. industry tradeshow in

1968 Durco produces the first fully-lined PTFE


chemical processing pump.
the early 1950s. Photo
courtesy of Cascade
Pump Company

20 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


THE PUMP SUPPLY CHAIN
By Henry Peck, President, Geiger Pumps & Equipment/Smith-
Koch, Inc., Pumps & Systems Editorial Advisory Board

T he distribution and sales of industrial pumps has


experienced great changes throughout the past
decades.
In the 1960s and 1970s, it was common for
pump manufacturers to have directly employed field
sales forces or to have independent sales agents and
representatives who engaged the onsite needs of cus-
tomers. he pump applications expertise of those sales
forces was often specialized in a narrow band of pump
products. hey had exceptional, even legendary, know-
how. Pump end users typically had complete installed
spares for each application—in addition to owning
uninstalled spare pumps and parts—and the in-house
In 1933, J.C. Gorman and Herb Rupp introduced a pump which had a resources to provide the labor needed for repairs.
“non-clogging” feature.Their competitors claimed the pump would not work With time, the pump business community has
in a savage public awareness campaign to discredit the new design, which progressed to a more efficient pump support model.
resulted in about $100,000 worth of “free advertising.” At least one cus-
tomer was willing to try it. National Ice Company purchased the first pump, Today’s pump distributor is typically independent and
and the company Gorman-Rupp was established. Photo courtesy of regionally based and has pumps for nearly every appli-
Gorman-Rupp Company. cation with expertise in variable speed, controls and
other related process equipment.

1980s Gorman-Rupp unveils the nutating pump, a special


purpose small pump used in health care applications;
additional energy-efficient, self-priming centrifugal pumps; a series
he average-size pump distributor has grown
along with the pump manufacturers they represent.
Consolidations have contributed to the increasing size
of lightweight portable pumps and high-pressure pumps with the of pump distribution companies, as it has for pump
first digital-control panels. manufacturers and end users.

1980s Electronic controls enter the industry to make pumps


more energy efficient.
End users con-
tinue to make gains
in reducing idle
1984 First Texas A&M Pump Users Symposium is held.
assets by standardiz-
ing pumps and out-
1984 Scienco produces the first specialized positive displace-
ment pumps specifically designed for agricultural
applications.
sourcing inventories
to the suppliers and
their distributors.
1989 Sier-Bath incorporates the first application of multiphase
pumps in paper stock. Distributors have
made productivity
1994 Two new major products are introduced by Goulds Pumps,
the Industrial Model 3298 Magnetic Drive Pump and the
Water Technologies Model GS “Global Submersible.”
gains through their
economies of scale, A Wilden distributor with one of the
including sourcing first AODD pumps. Photo courtesy of
1997 ITT Industries acquires Goulds Pumps, making ITT the
world’s largest pump company. through online
Wilden

inventories with manufacturers and other distributors.


1999 PumpSmart is introduced at the ChemShow in New York.
Servicing the pumps that a distributor sells is no longer
an option. It is a competitive requirement.
2001 Flowserve introduces its MSP (medium speed pump) with
variable frequency drive.
Not everything changes. he on-time performance
for the supply of pumps is still challenged. Pumps and
2001 KSB presents the first “intelligent” submersible motor
pump. Ama-Porter ICS is sensor-controlled and needs no
float switches.
parts travel by courier at roughly the same pace today
as many years ago. While reliability has increased dra-
matically, pumps are far from maintenance free.

2008 Dover Corporation creates he Pump Solutions Group, a


conglomeration of Wilden, Blackmer, Mouvex, Neptune,
Almatec and Griswold pump companies.
he biggest cost in the life cycle of pumps contin-
ues to be energy consumption, with excess resources
consumed, and nearly every pump installation

2011 ITT Corporation spins off into three separately traded


companies, creating Xylem, Inc., the world’s largest water
technology company.
having a more efficient alternative available. hese
are among the enduring reasons that we will find the
future pump supply chain more important than ever.
P&S

PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 21


State
of the
Industry
Wastewater Industry
Outlook 2012
Adam Stolberg, SWPA

Submersible pump industry survey provides a unique forecast.

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

Grinder Pumps Component Parts and Accessories


Respondents said that they expect grinder pump shipments to he outlook for component parts and accessory items (as per
increase 2 to 2.5 percent. With a continued lackluster hous- SWPA’s established product categories) according to the survey
ing market, many respondents cited aging infrastructure and respondents will increase 2 to 8 percent this year. Several of the
failing septic tanks as the main driver for these modest growth respondents said they were cautiously optimistic for 2012, but
projections. sales for component parts and accessories are still correlated to
pump sales, which are expected to show only modest gains in
Solids Handling Pumps 2012.
Respondents expect total solids handling pump shipments Demand for more intelligent controls and variable fre-
to increase 3 to 3.5 percent, with municipal installations quency drives (VFDs) are expected to outpace other component

22 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


parts and accessories, according to the Andy Stolberg is the executive director of SWPA. his year, primarily in response to
survey respondents. Other, more specific member input to its Industry Outlook Survey, SWPA expand its semiannual, two-day
comments on the outlook for compo- training programs to include an advanced program, on-line training and a SWPA
nent parts and accessory items include: Certification Program.he Charles G. Stolberg Memorial Scholarship Program for
• Spending will need to slowly but Engineering Students has been expanded to two scholarships, and the 4th Edition of
steadily increase to respond to aging the Submersible Sewage Pumping Systems (SWPA) Handbook has been updated and
infrastructure and updating of exist- scheduled to be released in the first quarter of 2012.
ing equipment.
• While large municipal spending is
slow, replacement and small projects
still exist.
• Winners will be those that differenti-
ate and supply value add solutions.
• Money must be available.

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

WEF Award Winner.


SCT – Smart Conveying Technology.
SCT was recently presented with the 2011 Innovative Tech-
nology Award for the Solids Handling/Disposal Category.

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

circle 128 on card or go to psfreeinfo.com


PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 25
State of the Industry 2012

Pump Market Recap


Source: U.S. Census Bureau, Summary of Pump Shipments (2010)
Note: NR = Not Reported Units Value of Change
Shipped Shipments in Value
Industry Summary in 2010 (in 1000s) from 2009
Industrial pumps (excluding hydraulic fluid power pumps) NR 4,014,796 129,937
Industrial pumps, value of drivers 1/ NR 544,502 -19,873
Domestic water systems, including drivers 1,483,354 261,864 6,321
Domestic sump pumps, 1 horsepower and under, including drivers 3,366,481 234,118 54,452
Oil-well and oil-field pumps (excluding boiler feed) NR 664,089 2,080
Other pumps, including drivers 2,651,172 381,270 -23,970
Parts and attachments for pumps and pumping equipment NR 1,536,740 280,830
Air and gas compressors NR 12,624 -2,035
Vacuum pumps, excluding laboratory NR 195,982 32,812
Parts and attachments for air and gas compressors and vacuum pumps NR 987,975 -175,117

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

Flexible, Rugged and Reliable...

Basler’s IEM-2020 is designed to make control, protection and monitoring of industrial


engines simple and reliable, offering flexibility and performance. The IEM is perfect for engine
driven pump applications and its rugged design can easily handle the harshest environments.

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

Worldwide Headquarters Singapore Suzhou, P.R. China Wasselonne France


Highland, Illinois USA Tel: +65 6844 6445 Tel: +86 512 8227 2888 Tel: +33 3 88 87 1010
Tel: +1 618 654 2341 singaporeinfo@basler.com info@basler.com chinainfo@basler.com franceinfo@basler.com
info@basler.com www.basler.com/pump
circle 116 on card or go to psfreeinfo.com
26 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
Units Value of Change
Shipped Shipments in Value
Centrifugal Pumps (cont.) in 2010 (in 1000s) from 2009
Single-stage, single-suction, frame- or foot-mounted, nonmetallic pumps, built 1,440 10,358 -1,033
to National or International Standards ANSI B73.1 or ISO 2858
Centrifugal single stage, single suction, frame or foot mounted, non-ANSI, non-ISO, 235,192 133,202 NR
with or without recessed impeller, all size discharge
Single-stage, single-suction, replaceable-elastomer-lined or hard metal, frame- or foot-mounted NR NR NR
Single-stage, single-suction, centerline-mounted NR NR NR
Single-stage, axially-split, double-suction, all size discharge 13,157 213,174 51,034
Multistage, single- or double-suction, diffuser design, radially-split case 14,519 NR NR
Axially split case 1,099 NR NR
Propeller and mixed flow, horizontal and vertical, all sizes 1,193 134,656 754
All other centrifugal pumps NR 467,499 46,334

Vertical Turbine Pumps


Including pumps with submersible motor, bowl assemblies, and can and pot type 29,438 175,159 -75,491

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.

NEW FLOWROX PROGRESSIVE CAVITY (PC) PROVEN PERFORMANCE with


PUMPS’ C-SERIES • Peristaltic Hose Pumps
• For the most demanding paste pumping and • Pinch Valves
industrial slurry applications • Knife Gate Valves
• Unique features and patented design: • Rotary Disc Valves
High efficiency + high pressure = All suitable for the toughest
Shorter construction applications including
• Less energy consumption, easy to install, powders, coarse substances,
less maintenance need = abrasive, corrosive, viscous
Low life cycle costs and/or crystallizing media.
FOR MORE INFORMATION: WWW.FLOWROX.COM

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

circle 121 on card or go to psfreeinfo.com


PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 27
State of the Industry 2012

Units Value of Change


Shipped Shipments in Value
Domestic Water Systems in 2010 (in 1000s) from 2009
Domestic water systems, including drivers 1,483,354 261,864 6,321
Nonsubmersible pump systems (jet and nonjet, including drivers) 954,699 149,289 337
Submersible pump systems including drivers, all horsepowers 508,567 110,771 5,924
Domestic hand and windmill pumps, pump jacks, and cylinders, sold separately, including drivers 20,088 1,804 60

Domestic Sump Pumps


1 horsepower and under, including drivers 3,366,481 234,118 54,452
1 horsepower and under, pedestal, including drivers 265,429 12,563 455
Submersible, including drivers, all horsepowers 3,101,052 221,555 53,997

Oil-Well and Oil-Field Pumps


Oil-well and oil-field pumps (excluding boiler feed) NR 664,089 2,080
Oil-well and oil-field pumps (excluding boiler feed), value of drivers 1/ NR 263,264 11,224
Subsurface pumps for oil-well pumping NR NR NR
Other oil-well and oil-field pumps, including mud pumps (slush pumps) NR NR NR

Parts and Attachments for Pumps and Pumping Equipment


Aftermarket (spare) parts for centrifugal pumps NR 658,818 -6,533
Aftermarket (spare) parts for vertical turbine pumps NR 132,123 59,654
Aftermarket (spare) parts for reciprocating pumps NR 243,868 89,591
Other pumps NR 501,931 138,118
P&S
1/ he value of drivers (electric motors, internal combustion engines, hydrostatic transmissions, steam turbines, etc.) is not included for most product categories but rather placed
in one of four separate “driver” categories within the product class. Drivers may be included in values for products in product classes without separate driver categories.

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
municipal, industrial and energy applications.
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

CONTROL SYSTEMS 888-473-9546 or 315-788-9500


105 Water Street
T 1.205.824.0004 // REVERECONTROL.COM New Model DFM 5.0 Massena, NY 13662
Doppler Flow Meter www.greyline.com

circle 148 on card or go to psfreeinfo.com circle 145 on card or go to psfreeinfo.com


28 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
circle 109 on card or go to psfreeinfo.com
For decades, ABB variable speed drives and Baldor • Local Sales & Support
motors have set the standard for quality, reliability and
energy savings. Now, industrial customers in the U.S.
can buy these products and receive expert support
• Energy Efficiency
from a single source. Call 479-646-4711 to locate the
district office nearest you.

Two trusted names. One local source for sales and • Industrial Motors & Drives
support. Only from ABB and Baldor.

baldor.com • Unmatched Customer Service

Scan with your smartphone to watch a


motor and drive energy efficiency video
©2011 Baldor Electric Company or go to http://bit.ly/mSM0JV.
circle 100 on card or go to psfreeinfo.com
Instrumentation, Controls & Monitoring
A Special Section of

January
January 2012
2012

Conducting a power and energy survey at primary


systems and large loads documents power con-
sumption and identifies sources of power quality
issues. Photo courtesy of Fluke Corporation
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 31
Special Section: Instrumentation, Controls & Monitoring

Cutting-Edge Treatment
Alan Cone, Siemens

Cobb County, Ga., adds automation to improve wastewater treatment operations.

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

32 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


The Solution “Before, we had to use a dedicated desktop unit and a lim-
he Technology Support Group (TSG) considered a new ited license pool to manually access the plant,” Brechbill explains.
release of the plant’s 12-year-old SCADA software. But after “Our new Web-based SCADA enables portable licensing that
months of research and brainstorming all the available options, allows us to log on at the plant or anywhere, use an online license
the team instead initiated a full blown replacement to leverage to see the plant, make the changes and log off. hat is a powerful
the full potential of the existing programmable logic controller solution that is saving us money and time and opens the door to
(PLC) platform that was in service across much of the CCWS tremendous capabilities we didn’t have before.
operation.
With a PLC platform already in
place throughout the system, the TSG
opted to standardize the upgrade on
the series of PLCs. “he synchroniza-
Mission SCADA Works Right Out Of
tion of our PLC and SCADA software
platforms was critical. We had to imple-
The Box, But Won’t Box You In
ment a system we knew would grow Mission Managed SCADA systems The flexibility of the Mission wireless
and expand together,” says Brechbill, are designed to get your pumps system allows you to expand as
who ultimately decided to replace the and systems monitored in hours, needed, and on your terms. Mix
not days. Our packages start and match any of our products
old SCADA with a web-based WinCC around $1000 with a maintenance one at a time or all at once, the
solution. fee of less than $1 a day. Mission choice is yours. That is why you
strives for ease in doing business. will find Mission SCADA monitoring
The Plant’s Full Potential Give us a try – no bureaucratic over 10,000 pumps and systems
“he S7 series is an extremely powerful red tape, no huge commitment – if throughout the U.S. and Canada.
you like it, buy it. If not, send it Learn more at www.123mc.com
PLC platform, fully capable of commu- back. It’s that simple. or call 877-993-1911.
nicating with different network layers
simultaneously. Most integration soft-
ware can’t do that,” Brechbill says. “By
marrying the Siemens PLC with the
WinCC SCADA, we can get the most
from our architecture and our plant far
into the future.”
Once the system-wide upgrade Managed SCADA
is complete in late 2012, all the plants
and pump stations will be operating on
WinCC and accessible through online
portals using Web Navigator. “We want
to ensure that everyone who’s authorized
to operate and maintain the facilities can
easily and quickly get as much informa-
tion and feedback from the plant as pos-
sible, but in a safe, secure and authorized
manner” says Brechbill. “WinCC and
Web Navigator put the whole system
at their fingertips. hat plant-wide view
just wasn’t possible before with our lim-
ited SCADA.”
Using built-in plant viewing sta-
tions or laptops at home or on the road,
operators, maintenance and engineering
crews can see the entire CCWS or drill
down to the device level in any facility to
monitor, program or troubleshoot. Web (877) 993- 1911 www.123mc.com
Navigator can be used for web access to
anything in the human-machine inter- Advanced Monitoring • Low Cost • Managed SCADA
face (HMI).
circle 125 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 33
Special Section: Instrumentation, Controls & Monitoring
The Noonday Creek facility was the first plant to be upgraded.

Prior to the upgrade, when a maintenance technician


signed on for a license to check a particular plant, the opera-
tor had to be hands off during the troubleshoot effort. hat
often meant operators went an hour or more without a view
into the plant while they waited for the manual license to
return to the pool.
he new plant architecture was planned from the
outset of the project. “We sat down
with Siemens and some of their solu-
tions consultants to make sure we set
a sound foundation for the long haul,”
says Brechbill.
he WinCC SCADA platform
unleashes the full potential of the
CCWS. Operators, engineers and main-
tenance teams at the Noonday Creek
plant are already reaping the benefits of
automated maintenance and manage-
ment tools.
Changing a pop up screen in the old
system, for example, required the pro-
grammer to make the change to every
pop up. “Now our pop ups are global, so
we make the change to one pop up and
every identical screen is updated auto-
matically,” Brechbill explained. “hat’s a
huge time and cost savings. What used
to take four hours or more is done in five
minutes.”
“Because plants like CCWS feature
objects and processes that require redun-
SENTRY Pulsation Dampeners & Surge
dant programming and setup, Siemens
Suppressors remove hydraulic shock and and iQuest (a solutions integrator) have
vibration, enhancing all-around performance helped us globalize everything we can
and reliability of fluid flow applications. possibly globalize,” says Brechbill. “he
biggest benefit is far more productive
SENTINEL Diaphragm Seals protect and plant maintenance and management,”
isolate all forms of system instrumentation he added.
from hazardous and corrosive process fluids. WinCC enables integrators to auto-
mate configuration.
More than just leak detection! The patented
SPILLSTOP Leak Containment System Building on Success
prevents costly and hazardous spills caused he first plant upgrade at the Noonday
by pump diaphragm failure. Creek facility in Kennesaw, Ga., creat-
ing a model for the technology refresh
at Cobb’s three other treatment plants.
Because the system standardized to the
PLC and WinCC SCADA, CCWS can
reuse all the screens and templates cre-
ated for the Noonday plant in upgrades
Don’t Pump Without Us at the other system facilities. he South
Cobb plant in the Austell community
is nearing completion, the Northwest
800.603.7867 ■ 951.342.3100 ■ www.BLACOH.com ■ Sales@Blacoh.com
treatment site in the town of Acworth is
circle 117 on card or go to psfreeinfo.com
34 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
on deck and the Sutton plant in Smyrna will be revamped by with a primary server, the upgraded PLC and SCADA platform
December 2012. None of the plants will need to be shut down delivers the same data at the same time to every server.
during the upgrade. “Network glitches used to cost our maintenance crews a
“he S7 PLC series design allows us to implement WinCC lot of time because they would have to remote in and manually
in parallel with our old SCADA system,” explains Brechbill. publish data to the servers. We don’t have to do that anymore,”
“As a result, we could beta test WinCC while running the old says Brechbill.
SCADA at Noonday. Once testing is completed at each plant, he TSG is rebuilding the networking infrastructure of the
the migration to WinCC will be
seamless and simple.”
he CCWS hit a wall with its
aging SCADA system and couldn’t
build on the investment made years VFD-Induced
ago. “Now we’re positioning ourselves
to take advantage of Siemens’ TIA Bearing Currents
(Totally Integrated Automation) plat-
form. hat will enable our operations
staff to easily integrate and leverage
Kill Motors!
new technologies and applications in
the future,” says Brechbill, who envi-
sions plant access on smart phone and
handheld devices fast approaching.
“he more portable and flexible the
access, the more our teams will know
what’s going on across the plant,” he
notes.
Universal Mounting Kit
One of the mission-critical
strengths of the PLC is its network-
ing capabilities and design to commu-
nicate simultaneously with multiple
Save energy with a VFD, Save your motor with
servers. While other software pack-
ages, including CCWS’s old SCADA SGR
system, rely on a fail-over platform BEARING PROTECTION RING

Proven in hundreds of thousands of


installations, the AEGIS™ SGR protects
motor bearings from damaging VFD-
induced currents and extends motor life.
It also dramatically reduces downtime
and improves the reliability of motor-
driven equipment and systems.
Garlock SGi™ Ring combines
U Safely channels harmful currents away AEGIS™ bearing protection
with a bearing isolation seal
from bearings to ground
U Maintenance-free, easy to install, lasts ®

for life of motor


U Standard sizes and universal mounting
kit for any motor

To download a free technical paper on bearing


protection technologies, visit our website:

1-866-738-1857 | sales @ est-aegis.com


www.est-aegis.com

The Noonday Creek plant feeds clean, New from BALDOR:


Super E® Motor with AEGIS™ SGR Installed
treated water into Noonday Creek
circle 120 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 35
Special Section: Instrumentation, Controls & Monitoring

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 ฀ ฀ ฀ ฀ ฀

MONITOR PUMP POWER COMPACT EASY MOUNTING


฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀฀ ฀ ฀
฀ ฀ ฀
TWO ADJUSTABLE SET POINTS
฀ ฀ UNIQUE RANGE FINDER SENSOR
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
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

circle 124 on card or go to psfreeinfo.com


36 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
Power Quality Basics
Wade Thompson, Fluke Corporation

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.

The Many Faces of Power


Quality Issues
he electrical power issues that most frequently
affect industrial plants include voltage sags and
swells, harmonics, transients and voltage and cur-
rent unbalance. he proper tools to correct these
issues include knowledge and electrical test instru-
ments ideally suited for each task.
Plant operators also need an accurate one-
line diagram of the facility. he one-line diagram Equipment is vulnerable to power quality issues and may contribute to them.
identifies the AC-power sources, the loads they
serve and their ratings—an operator’s electrical road map of because of careless human behavior.
the facility. Investigating power quality problems without it is Detecting sags can be quite challenging because predicting
nearly impossible. when they will occur is difficult. Operators can use the min/
Testing, measuring, troubleshooting, repairs or any other max function of a high-quality digital multi-meter (DMM)
work performed on any electrical system should be performed to detect single, worst-case sags of 100 milliseconds or more
only by qualified personnel who have been trained to perform while energizing the load. For suspected recurring sags, use the
these functions safely, using proper procedures and using test sags & swells trending feature on a high-quality power-quality
tools rated for the specific electrical system. analyzer.
If an operator needs to document power quality events for
Sags a longer duration, event recorders are available that can record
A sag is a reduction in voltage magnitude between 10 and sags, swells, outages, transients and frequency deviations for
90 percent of the normal root mean square (RMS) voltage several weeks.
for more than eight milliseconds (one half cycle at 60 Hz) and Correcting problems that cause sags usually comes down
less than one minute, according to the Institute of Electrical to electrical engineering best practices. For example, wiring
and Electronics Engineers (IEEE). Industrial equipment such should be adequate for the loads they feed. Minimize source
as programmable logic controllers (PLCs), robots and variable impedance by limiting the length of feeder runs to subpanels.
frequency drives (VFDs) are sensitive to voltage sags. Don’t cascade subpanels off other subpanels. Reduce the load
More than 50 percent of voltage sag events originate from on the panel if necessary and if possible. Transformers should
within the same building due to increases in current require- not be overloaded. Such overloading can also increase harmon-
ments, such as starting large inductive loads (typically motors) ics, which are discussed in the next section.
that create temporary inrush current conditions. However, Correct wiring and/or loading issues first. When the plant
voltage sags come from external events as well. Most external is in order, then other sag-mitigating solutions can be pursued,
events that result in voltage sags are nature related, but some are such as voltage regulators and constant voltage transformers.

PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 37


Special Section
Pump
Alignment Harmonics
Harmonics are multiples of a fundamental frequency. hey cause trouble when
& Machine Base combined with the fundamental electrical waveform. When harmonics mix with
Flatness the fundamental, they distort the sine wave. Devices that conduct current for less
than the entire voltage sine wave are non-linear loads, and generate harmonics.
his includes any device with a rectifier and pulse-generating devices such as VFDs,
electronic ballasts, electronic test equipment and switched- mode power supplies.
Since harmonic current flowing through system impedances generates har-
monic voltage distortion, it also creates voltage drops. In severe instances, this volt-
age distortion can cause thermal tripping of relays and protective devices and logic
faults in PLCs and VFDs. As voltage distortion increases, linear loads begin to draw
harmonic current. In motors, some of these harmonic currents—most notably the
fifth and eleventh harmonics—create counter-torque in the motor, causing it to
draw more current—which decreases motor efficiency, increases heating and short-
ens motor life.
Operators can measure harmonics at the point of common coupling using a
power quality analyzer or a harmonics analyzer. For simple snapshots, operators can
use a high-quality DMM for harmonic voltage or a high-quality clamp meter for
harmonic current. However, the DMM and clamp meter must be true rms because
Rotalign® ULTRA true-rms test tools are necessary for accurate measurements of distorted waveforms.
Many six-pulse VFDs generate fifth and seventh harmonics. However, 12- and

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.

& Balancing Transients


Transients are momentary excursions of voltage above the normal sine wave. heir
magnitudes can be more than five to 10 times the nominal system voltage. Transients
are different from surges. A surge is a high-energy transient, which is usually associ-
ated with lightning strikes.
Most transient-causing events happen inside the plant. hese include capacitor
switching, current interruptions, power electronics operation, arc welding, contact
and relay closures and loads starting up or disconnecting.
When transient voltages exceed electrical insulation ratings, the stress can lead
to gradual insulation dielectric breakdown or possibly abrupt failure. Transients also
deteriorate solid-state components. A single high-energy transient can puncture a
solid-state junction, and sometimes repetitive low-energy transients can have the
same effect.
Operators can detect lower-speed transients using the same tools and tech-
VIBXPERT® II niques that they would use to detect sags. Nearly all electronic equipment manu-
h
WatcOS factured within the last three decades includes some level of transient protection,
circle 137 on card or go to psfreeinfo.com

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.

Behind Closed Doors


Troubleshooting or testing for power
quality problems usually requires that
technicians take electrical measure-
ments while the equipment is energized.
his puts them at risk and requires that
they use appropriate personal protective
equipment (PPE). However, technicians
and electrical workers can find some
power quality and electrical reliability
issues without the associated risks—
thanks to thermal imaging. circle 140 on card or go to psfreeinfo.com
Experienced electrical workers use
infrared (IR) cameras or imagers to per-
form thermographic inspections, which
should be performed at least annually
according to NFPA 70B. Historically, IR
inspections required that equipment be
fully energized and running and panels
be open so that switchgear or panel
components were visible. Unfortunately,
open panel inspections expose workers
and equipment to hazards such as arc
flash, shock or electrocution.
IR windows installed in panel doors
eliminate the need for panel doors to
be open. hey allow thermographers
or trained electrical workers to acquire
images of energized and loaded electri-
cal components safely because the doors
are closed. Equipment and components
that technicians can inspect with ther-
mal imagers typically include:
• hree-phase power distribution and
switchgear
• Fuse boxes
• Cables and connections
• Relays and switches
• Insulators
• Capacitors
• Circuit breakers
circle 133 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 39
Special Section: Instrumentation, Controls & Monitoring

• Electric motors Common Causes of Voltage Unbalance


• Motor controllers • Unbalanced transformer bank supplying a three-phase
• Transformers load that is too large for the bank
• Battery banks • Unevenly distributed single-phase loads on the same
• Substations power system
• Unidentified single-phase to ground faults
Unbalances, Overloads and • An open circuit on the distribution system primary
Intermittent Connections Source: U.S. Department of Energy
Although IR thermography will not detect every power quality
overloaded. Heavily-loaded phases will appear warmer, while
problem, it is useful when performing preliminary checks for
a comparatively cooler circuit leg could indicate a failed com-
unbalances, overloads and intermittent connections. Most ther-
ponent. Since an unbalanced load, overload, bad connection
mal imaging is a comparative, qualitative process. Look for spots
and harmonics can create similar thermal patterns, follow up
that are unexpectedly hotter than similar equipment under the
with actual measurements using a digital multi-meter (DMM),
same load conditions. Hotspots could indicate unbalanced loads,
power quality analyzer or a harmonics analyzer to troubleshoot
triplen (third harmonic) current in neutrals, overload/excessive
and diagnose specific problems.
current, loose or corroded connections, insulation failure, compo-
When checking for connection and wiring problems,
nent failure, wiring mistakes or underspecified components.
look for connections with higher temperatures than similar
When looking for problems with a thermal imager, maxi-
connections under the same electrical and loading conditions.
mum electrical equipment loading conditions are ideal. If max-
Hotspots associated with connection problems typically appear
imum loading is not possible, the equipment should be under
warmer at the spot of high resistance and cooler as distance
at least 40 percent of nominal load.
from the spot increases.
When checking for three-phase unbalance, capture thermal
Eventually, every plant experiences electrical equipment
images of high-load connection points such as drives, discon-
failure and power quality problems. When equipment or
nects and controls. Compare the phases, checking for apparent
components deteriorate, often thermography can detect their
temperature differences. Hot conductors may be undersized or
warning signs before they fail. Using IR
windows enables experienced thermog-
raphers and electrical workers to locate
problems before they become major
downtime issues—safely.

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.

40 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


circle 110 on card or go to psfreeinfo.com
Maintenance Minders

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

We’re serious about seal safety


You depend on your seal system to keep your equipment up and running safely. John Crane’s
proven sealing technology and local support expertise provide solutions that protect your workers,
the environment, proitability and your peace of mind…

ENDtoEND Solutions circle 123 on card or go to psfreeinfo.com


In the past, a large percentage of component Tighten bolts, nuts and fasteners evenly to the torque levels specified
seals failed prematurely because they were incorrectly Risks of improper tightening are:
installed. he growing use of cartridge seals has elimi- • Excessive frictional heat
nated many of these failures. • Excessive face heat
he risks due to excessive seal leakage depend on
the pumped liquid’s properties, the leakage rate and Gland Plate
the surrounding environment. If the liquid is above its Stud nut or Bolt
auto-ignition temperature, it can catch fire spontane-
ously or explode. A fire or explosion can also occur if
the liquid or its vapors encounter an ignition source.
Hazards can also occur if seal faces are not lubri- Drive Collar
Set Screw
cated properly. Most pump mechanical seals are wet
designs, meaning that the radial face must be lubri-
cated and cooled by a liquid, which, depending on the
configureation, can be the pumped liquid or a separate
buffer/barrier liquid. Without lubrication, the seal’s
rubbing surface can overheat leading to a fire or an
explosion. Proper fastener tightening is the first step in successful installation.
crane, the seal should have a tapped hole in the gland plate
Selecting a Safe Seal for an eyebolt. he type, number and location of eyebolts
When selecting a seal system, pump users should ensure that
that are needed vary depending on whether the equipment
the system will work with the pumped liquid at the pump’s
has a vertical or horizontal shaft, so use the correct kind.
operating conditions. Conditions to consider include the oper-
• Tighten bolts, nuts and fasteners evenly to the specified
ating pressure, temperature, maximum shaft speed and the
torque levels, and fasten screws securely. Over-tightening
external supply of any cooling, heating, quench, flush, barrier
gland bolts can create gland plate distortion, resulting in
or buffer fluid. If any aspect of the pumping operation changes,
seal leakage.
review the seal system to ensure that it is still compatible.
• Align the shaft and gland plate correctly. If possible, check
Single and dual seal systems offer different types of safety
the drive shaft after assembly to make sure it can move
mechanisms to mitigate leakage. Pump operators can use con-
freely.
tainment bushings to manage leakage in single seal systems.
• Verify that each port on the seal’s cartridge is connected to
Dual seal configurations can include outer containment seals
the appropriate service. Refer to the specified API piping
or pressurized barrier liquid to control leaking, which are smart
plan for guidance. If ports on the seal are not used, plug
options for particularly hazardous process fluids.
them with metal plugs instead of plastic plugs, which have
Some seals and support systems also feature alarms to warn
lower temperature limits and can melt.
users if leakage-rate levels are unacceptable. Users should know
• Train your staff on how to respond to alarms.
what steps to take if an alarm occurs and act promptly.
• Ensure that interconnecting pipe work specifications mini-
mize flow resistance and follow venting advice.
Seal System Installation • Consult the seal’s vendor with questions.
Installing the seal system properly is crucial for safe operation.
Users should read all instruction manuals and keep these to-dos
Operating the Equipment
in mind:
Once the seal systems are installed, users should review the
• If the system includes a heavy cartridge seal that requires a

Packing Couplings Filtration Systems

Mechanical Seals Support Systems Bearings Gas Seals Production Solutions

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

For hot-running pumps, check the


torque on the drive collar set screws annu-
ally, since vibration can loosen the screws.

Ralph Gabriel is the


global chief engineer
for John Crane, Inc.,
and has more than
39 years of experi-
ence in the mechani-
Clear as water,
cal seal industry. He WEG can provide the complete solution.
can be reached at 847-967-3744 or
From sales support through project management and service,
rpgabriel@johncrane.com. WEG can provide complete solutions for all your pumping needs!
Ian Smith is the From sales support through project
global training management and service, WEG can
MGP Line
manager for John provide complete solutions for all up to 65,000HP and 13.8kV
your water needs! Our experienced
Crane and is based U.S. based Application Engineers can LV and MV Variable Frequency
Drives
in Manchester, provide a quote for a quality, reliable, 0.25 to 8000HP
England. He has efficient solution to meet your
application requirements all over the
more than 40 years world. We can offer a solution of
of experience in the mechanical seal motors, starters, drives, control
industry. Smith can be reached at panels, and transformers all in one
44 161 886 5992 or ian.smith@ quotation, requiring only one P.O. and
one line of responsibility. We also
johncrane.co.uk. specialize in drop in replacements. To
learn more about WEG’s Solutions for
John Crane is a provider of engi- the Water industry or to request a
reference list, please contact
neered products and services for 1-800-ASK-4WEG. Visit us online at W22 LV and MV Soft Starters
Motors with higher effiency and 0.75 to 4,500 HP
process industries, including oil and www.weg.net/us. lower total cost of ownership
gas extraction and refining, power Medium Voltage Drives and Soft Starters
generation, chemical production, Transforming energy into solutions. are proudly assembled in the U.S.A.

pharmaceutical manufacturing, pulp www.weg.net


and paper production and mining. ©2011 WEG Electric Corp.

For more information, visit www.


johncrane.com.
circle 131 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 45
Efficiency Matters

Eccentric Disc Pump


Technology Used in
Food Processing
David Kirk

Leak-free operation optimizes waste-reduced food production capabilities.

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

46 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


Eccentric Disc, Sliding Vane & Peristaltic Pumps
ZI Plaine des Isles, rue des Caillottes
Auxerre, France 89000
33-3-86-49-86-30
mouvex.com

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

PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 47


Efficiency Matters

to seal and prone to crystallization—such as corn syrup, liquid


sugar and glucose—can adhere and cause damage, which elimi-
nates a maintenance concern.
Speaking of maintenance, eccentric disc pumps also fea-
ture clean-in-place operation that does not require the vertical
drain porting that robs lobe and circumferential-piston-style
pumps of a good portion of their efficiency. When cleaning
an eccentric disc pump, pressure is introduced to the back of
the disc through a pumping chamber. When the flush pres-
sure overcomes the spring, the disc moves away from the cyl-
inder, and the cleaning solution passes through the pumping
chamber. his allows a large amount of cleaning solution to
travel through the pump, resulting in thorough cleaning and
the elimination of the need for bypass piping.
All these features combine to make eccentric disc pumps
as much as 30 percent more efficient than their lobe/circum- This eccentric disc pump in a hygienic application provides consis-
ferential-piston-style counterparts, resulting in increased pro- tent performance that does not change over time.
ductivity and reliability and reduced cost for the food-plant a way to provide malnourished children with the dairy protein
operator. they need to help their brains function, mental and physical
growth and organ development.
From The Field In an application as important as filling the Challenge
Recently, a large, private-label food processor and packager Dairy Product pouches, waste cannot be tolerated at any level.
located on the west coast of the U.S. came to the conclusion By introducing the eccentric pump to its packaging operation,
that the lobe-style pumps being used to fill sauces, dressings and the facility has also optimized the packet weight in this crucial
marinades into 6- and 9-ounce plastic pouches were becoming operation.
increasingly unable to meet the strict weight requirements of
the packaging operation. Specifically, the rejected packets were Conclusion
as much as 24 grams over or underweight, a difference of more As the world’s population continues to grow, the only way
than ⁄ of an ounce above or below the required volume. it will be sustained is if the capabilities to meet humanity’s
his meant that as much as 400 pounds of barbecue expanding food needs are delivered by global food producers.
sauce, for example, were being rejected in a single eight-hour hat puts the burden on them to develop and implement food-
shift, which is enough to fill a 55-gallon drum. he result was production systems that minimize food waste in their opera-
thousands of dollars a day in wasted product. tions. One way that food producers, processors and packagers
“We were experiencing a loss of around 15 to 20 percent, can do that is by introducing the most efficient, reliable and
depending on the product, due to the cavitation of the lobe energy-conscious pumping technology into their plants.
pumps,” says the facility’s production manager. “here was just In many cases, this means turning to positive-displace-
too much variation in the pumps, and they weren’t able to ment eccentric disc pump technology. For more than a cen-
consistently inject the proper amount into the packages.” tury, this technology is capable of handling a unique array of
he solution to this costly situation was the installation liquids and semi-solids in food production and will continue
of an eccentric disc pump for use in the plant’s packet-filling to set the standard in consistent, leak-free operation that will
operation. Improved results were noticed immediately. help result in optimized, waste-reduced food-production capa-
“As soon as we installed the Mouvex, we were down to bilities around the globe.
under 2 or 3 percent of product loss for over and underweight P&S
pouches during an eight-hour shift. We simply don’t need to
throw away packets anymore,” said the production manager. David Kirk is the hygienic market manager for Dover
“Besides saving money, saving time and reducing the amount Corporation’s Pump Solutions Group (PSG), Downers Grove,
of wasted product, I can say I highly recommend the Mouvex Ill. He can be reached at 707-484-9023 or david.kirk@
C-Series pump. It is better than any other pump we’ve ever pumpsg.com. Headquartered in Auxerre, France, Mouvex
used.” was incorporated in 1906 and is a manufacturer of positive
In addition to the sauces, dressings and marinades that displacement pumps and compressors for the transfer of liquids
the west coast food processor specializes in, the company also or dry bulk products. Mouvex is a member of PSG, which
proudly packages what are known as Challenge Dairy Product is comprised of several pump companies including Almatec,
pouches. hese pouches are filled with highly viscous dairy- Wilden, Blackmer, EnviroGear, Griswold, Mouvex, Neptune
based products that are used in humanitarian-aid programs, and RedScrew. You can find more information on Mouvex at
such as those offered by UNICEF and USAID, specifically as www.mouvex.com.

48 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


circle 111 on card or go to psfreeinfo.com
From the voice of the fluid sealing industry

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

50 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


separately and with caution. on FSA publications. Please direct your questions to: sealingsense-
Flange Condition: Some imperfections on the sealing sur- questions@fluidsealing.com.
face can be sealed with certain materials but not others and P&S
have to be identified. Allowable imperfections, flatness irregu-
larities and misalignment are detailed in ASME PCC-1-2010 he following members of the Gasket division sponsored this
Appendices C, D, and E. ASME PCC-1-2010 is the accepted “Sealing Sense” series:
guideline for pressure boundary bolted flange joint assembly. American Falcon, Inc.
John Crane
III. Fastener Information—hese components—usually A.W. Chesterton
comprised of bolts, nuts and washers—and their installation Lamons Daikin America, Inc.
procedures are responsible for most leaking flanges. All gaskets Nippon Pillar Corp. of America
require even and sufficient compression, and this is the job of Donit Tesnit d.d.
the fasteners, along with proper installation techniques. Under SGL Technic Polycarbon Division
certain operating conditions, several grades of bolts cannot EGC Enterprises, Inc.
produce enough stress to achieve a tight gasket seal. Because Slade, Inc.
of the relationship between gasket performance and fasteners, Empak Spirotallic Mexicana SA de CV
most gasket manufacturers are knowledgeable about bolting Teadit International
and understand that no gasket recommendation can be made he Flexitallic Group
without this information. hermoseal Inc.
An often-overlooked consideration is the importance of Garlock Sealing Technologies
fastener lubrication. As much as 50 percent or more of the Triangle Fluid Controls, Ltd.
perceived torque value can be lost due to friction between fas- W.L. Gore & Associates, Inc.
tener components. Many of these guidelines are also in PCC- Teijin Aramid USA, Inc.
1-2010—including fastener selection, the importance of using GrafTech International Holdings, Inc.
hardened washers, proper lubrication and accepted tightening YMT/Inertech, Inc.
procedures and patterns.
he FSA has developed a pocket-
size Gasket Installation Procedures pam-
phlet that addresses the basics of proper
gasket installation. In most circum-
stances, an end user will ask the gasket
manufacturer for the proper bolt torque
specifications, too, once a suitable mate-
rial and design have been selected.

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.

Next Month: Why do PTFE gaskets leak Contact Graco today!


in FRP, plastic or other light load flanges? 1-877-844-7226
We invite your questions on sealing issues www.graco.com/hosepumps
and will provide best effort answers based
circle 135 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 51
PUMPFAQs ®

Q. When purchasing new rotodynamic pumps, what type of Recommended Test Specification Matrix

acceptance testing is recommended? Service Test Type Performance Hydrostatic NPSH Mechanical

Standard Up to 50 kW (67 hp) NO NO NO NO


Pumps
Greater than 50 kW (67 hp) YES NO NO NO
A. Purchasers of rotodynamic pumps should specify accep- Additional New/Unique Design YES YES NO YES
tance testing that will verify the rate of flow, head produced and Considerations
Critical Service or Application YES YES NO YES
power required. he costs of acceptance tests and special tests
NPSH Cr itical YE S NO YES NO
should be clearly stated in the contract. Specifying tighter accep-
tance tolerances can lead to higher testing costs and increased Figure 1. Recommended tests for different pumps and services
lead times. When NPSH testing is specified, test costs will be a torque transducer and a tachometer. hese values are used
higher because the tested pump must undergo a different and when calculating the power input to the pump.
more time-consuming test, often performed with a different A less accurate method, but one that may be specified, is
test set-up requiring additional assembly and tear-down time. a string test using the complete assembly—the motor, pump
For reduced tolerance bandwidth, tighter manufacturing and drive (for example, gearbox, belt drive, etc.). he accuracy
tolerances are required, which adds cost and increases deliv- of this test will be lower than when the pump alone is tested.
ery time. Sand-cast molds are the least expensive but have the In this instance, the power measured is the input power to the
greatest tolerance. Investment casting techniques will provide motor. he input power to the pump shaft is calculated by
superior surface finish and most consistent dimensions. using the published motor and drive efficiencies. Since these
Molding equipment expense for an investment casting may efficiencies are not known precisely, this method is less accurate.
be two to four times greater than a sand casting mold. A high When a VFD is used as part of the string, it becomes dif-
production volume is needed to justify the additional expense ficult to obtain an accurate value of input power to the pump
of this equipment. Many hours of hand labor may be required shaft. A wattmeter cannot accurately measure the power from
to produce sand castings to tight, repeatable tolerances. the VFD to the motor because of the VFD’s nonsinusoidal
Machining parts to closer tolerances can increase the labor waveform. A wattmeter can measure the input power to the
cost by 50 percent and increase the time to manufacture the VFD. However when the input power to the VFD is measured,
part to the required tolerances. Reduced tolerances increases the efficiency of the VFD must be known to calculate VFD
costs because of the additional care required during produc- output power to the motor. his information may be available,
tion and the potential of an increased scrap rate. he impel- but it adds another degree of error since the motor efficiency
ler may need to be hand-worked to obtain the required per- will change due to the nonsinusoidal waveform of the output
formance. Impellers must be axially positioned for optimum power from the VFD. (Although many VFDs provide a mea-
alignment with the casing to produce the required head and surement of output power, the value of this measurement is
high efficiency. only approximate and not accurate enough for acceptance test-
Figure 1 should be used as a guideline. For normally man- ing. his reading does not consider the reduction in motor effi-
ufactured pumps, users may consider a certificate of compli- ciency when operated on VFD power.)
ance instead of actual testing. A string test with a VFD may be required if the customer
specifies that the VFD be used for the string test. It may also be
Q. What is a string test, and when should it be specified? required when the customer wishes to have curves at a number
of speeds. In both cases, the suggested procedure is to conduct
A. Generating a pump curve requires measuring the rate of one test without the VFD, running the motor directly across
flow, head and power. From this information, the pump effi- the line. his allows a complete head-capacity-efficiency curve
ciency can be calculated. he pump curve efficiency is typi- to be produced at nominal speed. he VFD can then be con-
cally related to the shaft input power. he published efficiency nected to the motor, and head-capacity curves can be produced
is the hydraulic power produced by the pump divided by the at the required speeds without any power data measurement.
mechanical input power to the pump shaft. he efficiency Figure 2 contains the factors needed to calculate pump
published is only that of the pump. From a testing standpoint, efficiency for different configurations. A string test cannot mea-
the most accurate way to obtain the power data is by direct sure the efficiency of an engine-driven pump. In this case, the
measurement of the shaft torque and rpm. his is done using pump would need to be tested separately if accurate shaft power
measurements are required. he pump manufacturer’s curves
52 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
Pump often only provide the end user with the required power at the
Power RPM Efficiency
Configuration Drive Measurement Measurement Influencing Factors Accuracy pump input shaft. Further investigation may reveal that this
Pump only Mechanical Torque Tachometer None Highest information is provided with the pump being sealed by pack-
transducer
ing, not mechanical seals, which may absorb additional power.
Pump and Line power Wattmeter Tachometer (1) Motor efficiency
motor, direct From an energy consumption standpoint, these data do not
connected
provide the user with the true cost to operate the pump.
Pump and Line power Wattmeter Tachometer (1) Motor efficiency
motor, belt or (2) Transmission Wire-to-water efficiency and power consumption curves
gear driven efficiency
are more useful but are rarely requested. Wire-to-water perfor-
Pump and Line power Wattmeter From motor or (1) Motor efficiency
submersible vibration data (2) Seal power mance can be measured with all the configurations in Figure 2
motor consumption
(3) Cooling system by placing a wattmeter at the input to the motor or VFD. hese
power consumption
data will allow the end user to know the true power consump-
Pump and Motor + Wattmeter Tachometer (1) Motor efficiency
motor, direct VFD input to VFD (2) VFD efficiency tion of the pump system and evaluate the true operating cost.
connected (3) Motor efficiency
correction for VFD
power
P&S
Pump and Motor + Wattmeter Tachometer (1) Motor efficiency Pump FAQs® is produced by the Hydraulic Institute as
motor, belt or VFD input to VFD (2) Mechanical drive
gear driven efficiency
(3) VFD efficiency
a service to pump users, contractors, distributors, reps and
OEMs as a means of ensuring a healthy dialogue on subjects
(4) Motor efficiency
correction for VFD
power
of common technical concern.
Pump and Motor + Wattmeter From motor or (1) Motor efficiency
submersible VFD input to VFD vibration data (2) Seal power HI standards are adopted in the public interest and are
motor consumption
(3) Cooling system
power consumption
designed to help eliminate misunderstandings between the
(4) VFD efficiency
(5) Motor efficiency manufacturer, the purchaser and/or the user and to assist the
correction for VFD
power Lowest purchaser in selecting and obtaining the proper product for
Figure 2. Influencing factors for calculating pump efficiency for differ- a particular need. For more information about HI, go to
ent configurations www.pumplearning.org.

Bredel hose pumps -


the best choice for
gritty sludge
• Ideal for centrifuge and press feed
• No costly rotors, stators or joints to replace
• Low maintenance – a quick hose change
• Easy operation – eliminate ancillary equipment
• Run dry without damage

Environmental Division wmpg.com


Bredel Watson-Marlow
800-282-8823
circle 119 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 53
Practice & Operations

Pump Curve Accuracy


George Stephens, PUMP-FLO Solutions (An Engineered Software Business)

Exploring the digitization methods of pump power and efficiency curves

Second of Two Parts

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)

lic analysis software packages.


(METERS)

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

meet their needs. Part One of this 8 60%


article detailed the digitization of 7.25"

pump performance curves and 20


the accuracy ramifications from 15
HP
different digitization methods. 4
7.2 10
8.3
10 NPSH NPSH HP
In Part Two, the digitization of 10
7.5
HP
NPSH
the pump power and efficiency 15
NPSH 20 3 5
HP
HP
curves will be explored. NPSH
200 400 600 800 1000 1200 1400 1600 1800
To recap Part One, the main U.S. L/S
GPM
15 30 45 60 75 90 105
function of a pump selection M /HR 3
50 100 150 200 250 300 350 400
program is the ability to digitally Figure 1. A manufacturer’s published curve
reproduce the manufacturer’s
pump performance data accu-
an application. Part One revealed the shortcomings of using
rately and to create a selection list of pumps that meet the
a simple polynomial regression analysis to store and display
customer’s criteria.
the manufacturer’s performance curves. Areas occur in which
Figure 1 shows a detailed manufacturer’s pump curve.
the digitized curve deviated significantly from the manufac-
his is an example of what the manufacturer might have
turer’s curve. It was also shown that a cubic spline regression
available in a paper catalog or in pdf format. It includes the
analysis rendered a much more precise curve.
flow versus head performance curves as well as isometric
curves for efficiency, power and NPSHr. hese curves accu-
rately represent the performance of the indicated pump in Power and Efficiency Curves
accordance with the ANSI/HI 1.6-2000 Centrifugal Pump In addition to the standard flow versus head performance
Tests standard. curves, many manufacturers also include curves for pump
For a software program to understand and use this power and pump efficiency. It must be stressed that pump
pump performance data, the data must first be converted effi ciency and pump power are functions of each other. he
into a form that can be read by the program. his digitization formulas relating power and efficiency are:
process must accurately reflect the manufacturer’s published QxHxρ QxHxρ
pump curve to aid the customer in evaluating the pump for bhp = and ηP =
247000 x ηP 247000 x bhp

54 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


Where: percentages clearly do not match up with the published curve.
bhp = brake horsepower he pump’s overall efficiency is overstated by up to 3 percent.
ηP = pump efficiency (expressed as a decimal) If a customer were to download these performance curves
Q = flow rate (gpm) (Figure 4a in black) from the pump manufacturer’s technical
H = total head (ft.) literature and then pulled up the performance curves (Figure
ρ = fluid density (lb./ft.3) 4a in pink) from this pump selection software, it is virtually
impossible to tell that these curves are from the same pump.
Power is calculated with efficiency
as a parameter and vice versa. To repro-
duce accurate and trustworthy results,
one set of data must be gathered from
the pump manufacturer, and the other
set of data must be calculated. When
generating curves, it is not accurate for
a software program to try to collect and
reproduce both sets of data from the
manufacturer. his would leave open
the possibility of errors. An end user
might select a flow, head and efficiency
from the graph and then perform a hand
calculation of the corresponding power
to find that the calculated power does
not match up with the power shown on
the graph.
For this reason, only one set of
empirical data, efficiency or power,
should be taken from the manufac-
turer. he other should be calculated.
Also, the efficiency data reported by
most pump manufacturers typically has
much more granularity than the power
data. hat is to say, there is typically a
wider range of efficiency values over
the range of pump operation than the
range of power values. For this reason,
it is usually more accurate to digitize the
manufacturer’s efficiency data and then
calculate the power data, than the other
way around.

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
circle 127 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 55
Practice & Operations

his introduces con-


fusion and a lack of Manufacturer’s Curves
Software Rendered Curves
Manufacturer’s Power Curves
Improperly Digitized Power Curves
confidence in the
software’s pump per-
formance data to the
customer.
In Figure 4b,
the manufacturer’s
performance and
power curves are
overlaid with the
pump selection soft-
ware’s curves. he
power curves start
off tracking fairly
well at lower flow
rates. However, the
range of displayed
power has been
severely limited on
the 30-horsepower Figure 4a. Performance and efficiency curves Figure 4b. Performance and power curves
and 50-horsepower
curves at higher flow much like the poorly rendered efficiency curves.
rates. hey do not extend to run out flow rates as they should. Two serious engineering issues can arise due to the inac-
his is a case of missing data and can also introduce confusion curacies of these curves. he first relates to the efficiency errors.
For example, consider if this pump were
operated with an 11-inch impeller at its
best efficiency flow rate of 1,800 gallons
per minute for one year, and assume
TARBY… that utility costs are $0.15 per kWh.
Overstating the efficiency by only two
a Step Above the Rest! percentage points will, over the course
of a year, increase the operating costs
Tarby has more than 30 years’
®
of this pump by almost $1,500. With
experience manufacturing high the increase in energy audits throughout
quality replacement parts to fit the industry, particularly within govern-
nearly any brand of progressing ment agencies and municipalities, this
cavity pump. type of inaccuracy is bound to come to
light and cast doubt on the validity of
Tarby replacement parts are the manufacturer’s pump performance
a step above other parts replicators. data.
A second issue lies with respect to
s All parts constructed using high quality materials, the power curves. he truncated power
machined to precise tolerances and checked for perfect curves shown in the Figure 4b do not
fit and function every time extend to run out flow rates. his is
important because pump motors are
s Experienced customer service agents are available most often sized to the non-overloading
to identify the correct replacement parts power on the design curve, which is fre-
quently at run out flow rates. If custom-
s All parts are readily available to minimize ers cannot decipher what the power is at
your downtime run out flow rates, then they will not be
able to properly size and select a motor.
800-854-1879 www.tarby.com

circle 141 on card or go to psfreeinfo.com


56 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
FIELD-TESTED PUMPS.
CUSTOMER-FOCUSED
PEOPLE.
A pump is only as good as the people behind it. Godwin Pumps proudly offers:
Godwin Pumps is an industry leader in the design, sale and rental of » Dry-running, automatic self-priming Dri-Prime
dewatering systems. With immediate availability of over 6,000 automatic pumps with excellent solids handling capability
self-priming Dri-Prime pumps for rent, parts inventory and a proven » Technical application support for pump
history of reliable equipment supported by responsive people, Godwin system design

is the preferred provider of engineered dewatering systems solutions for » Comprehensive product knowledge from
conception, design and manufacturing through
construction, mining and quarrying applications.
circle 106 on card or go to psfreeinfo.com

sales and rental


» New access to ITT’s expanding water and
wastewater capabilities

For more information, call 856.467.3636


Dri-Prime Critically Silenced Pump or visit godwinpumps.com.
Practice & Operations
A Powerful
Solution for Example Two
Now consider the curves in Manufacturer’s Curves
Properly Digitized Curves

Demanding Figures 5a and 5b. In this


case, the pump selection
Pumping software properly digitized
the efficiency curves from
Applications the manufacturer using
a cubic spline regression
analysis. he isometric effi-
ciency curves are dead accu-
rate at every point in the
graph, and the efficiency is
never overstated. In figure
5b, the power curves also
track extremely well with
the manufacturer’s, given
that they are calculated
power curves, and more
importantly, the endpoints
at the run out flow rates are
Figure 5a. Performance and efficiency curves from
accurate.
cubic spline regression analysis

Conclusion Manufacturer’s Power Curves


Using a pump selection Properly Calculated Power Curves

program that accurately


represents the manufac-
Hitachi offers a suite turer’s pump performance
of products for is a necessity. Inaccuracies
pumping and irrigation in curve digitization and
rendering can lead to
" Æ Inverter models with all critical improper pump and motor
functions built in
selections as well as faulty
" Æ Flexibility and expandability for
operating cost calculations.
a variety of applications
Users should be aware of
" Æ NEMA3R/12 Pre-Engineered
the digitization techniques
Panels with popular options
to choose from, all with employed by their pump
quick delivery selection software, and the
" Æ Pump Sleep Mode Option adds information in these articles
powerful sleep mode functionality should aid them in making
for energy savings and pump an informed decision when
longevity choosing a software package.
circle 136 on card or go to psfreeinfo.com

Figure 5b. Performance and power curves from cubic


P&S spline regression analysis

George Stephens is an application engineer and trainer for


PUMP-FLO Solutions(An Engineered Software Business).
Hitachi America Ltd. He has more than 18 years of process engineering experience
Tel: 262.787.4975 and has been with Engineered Software, Inc., for more than
www.hitachi-america.us/pumpVFD eight years. He earned his Bachelor of Science in Electronic
inverterinfo@hal.hitachi.com
Engineering from Central Washington University, in
Ellensburg, Wash. Stephens can be reached at george.stephens@
eng-software.com or 360-412-0702.

58 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


circle 114 on card or go to psfreeinfo.com
Practice & Operations

Wastewater
Infrastructure
in Prefurbia
Bill Nestor

Design and construction of sewer systems can include


environmentally-safe innovations.

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

60 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


sanitary sewer construction costs than
the pipe installed. he type of soils on
the site (sand, clay, rock), the depth of
these substrates and slope of the land
further influence the cost.
Conventional sanitary sewers are
most often placed on an exact slope
and in a straight line. To make a bend
or change in direction, they will typi-
cally use a manhole. Manholes are
expensive, and to access the sewer line
underground, it is most practical if the
pipe is perfectly straight between two
manholes.
Storm sewer systems and conven- Low-pressure sewer system with grinder pumps at each home
tional sanitary sewers share some com-
ponents. Both require manholes and pipes. Both use gravity, premature wear if allowed to rush through the system. he
but storm sewers are designed to flow quickly to make sure regulations for sanitary sewers restrict the pipes to a fairly low
that the development does not flood. Storm sewer design is slope, as a steep slope would cause it to flow too fast.
also unpredictable with unknown volumes of water, so they are It is more cost-effective to create a sustainable design
typically over-engineered. around the physical limitations of the land during the plan-
Sanitary (gravity flow) systems are much different. he ning stage than to make changes that cut into profits or cause
volume of sewage going through the pipe can be more accu- undue increases to homebuyers’ costs later. In some situations,
rately estimated, and the sewage must flow at a steady but slow the depth of the sewer may need to be lower than the destina-
rate. Sewage can contain material that can be abrasive causing tion elevation or the land may be blocked by a hill. To get the

circle 122 on card or go to psfreeinfo.com


PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 61
Practice & Operations

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

S ince 1994, Rick Harrison Site Design Studio has been


an industry leader in land development innovation.
With a career that spans more than 43 years with experience
in land planning, civil engineering, land surveying, land
development and computer software development, he has
developed many successful communities throughout the
U.S. Harrison is a regular contributor to New Geography,
a leading blog related to building and planning issues. For
more information on Prefurbia land development planning,
go to www.rhsdplanning.com.

circle 149 on card or go to psfreeinfo.com


62 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
expensive to be installed. he land may
be too flat, rocky, hilly, or wet.
A low-pressure system can employ
sophisticated technology that is known
for its minimal maintenance, low upfront
costs, reduced operating expenses and its
ability to be installed at any site, regard-
less of landscape challenges.
“here are many advantages a
Prefurbia neighborhood provides over
conventional development planning,”
Harrison notes. “Less street lengths,
larger lots, greater open space, better
connectivity, safety and curb appeal all
while maintaining density result in less
cookie-cutter developments.”
For the past five years, Harrison’s
team has worked to develop intelligent
software that communicates precise spa-
tial data and reports efficiency, packag-
ing it with education on how to design.
“When we harness and master technol-
ogy, we can create wonderful, exciting,
efficient and affordable neighborhoods
that are also environmentally friendly,”
affirms Harrison. Low-pressure sewer circle 138 on card or go to psfreeinfo.com
systems use technology to improve and
simplify neighborhood sewer systems.
P&S
Bill Nestor, is a freelance writer
based in Brattleboro, Vt. He can be
reached at nestor@sovernet.net. For
more information on the E-One
low-pressure system and grinder
pumps, go to www.eone.com.

Stay Connected With

on

@PumpsSystemsMag
and at
www.pump-zone.com
circle 160 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 63
Practice & Operations

Environmentally-
Friendly HVAC Solution
Brad Hubbard, Cerus Industrial

Improved motor starters help Fabri-Kal achieve its green vision.

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

64 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


subsystems—such as HVAC units, alarm systems and power
trending software can—communicate status and control infor-
mation with a central building automation system.
High functional integration was also important in the
selection of electrical components for the Fabri-Kal upgrade to
reduce the need for mounting and interfacing discrete control
modules such as damper controls. If the motor starters also
power and control the dampers, this would save interfacing cost
and complexity.
However, network compatibility and cost savings were not
the only considerations that drove the selection for the proj-
ect. Jones also looked for a starter that had the intelligence to
protect the building’s electrical systems and simplify mainte-
nance. An important requirement for the Kalamazoo site was
power phase protection. Since the power supplied to the Fabri-
Kal plant is not always consistent, the Pleune engineer wanted
starters that would detect power phase failures and initiate an
orderly shutdown before the chance of damage to the motors
occurred. Figure 1. The external and internal views of the starter with the
“It only takes one incident of power fluctuation such as components labeled
this to kill a motor,” says Jones. “Phase loss protection is very
important.” energy and keep the motors from overheating,” says Jones, “but
It is also important to detect motor overloads and belt loss remote detection of motor status is also important because
on all belt-driven motors in every area of the building. many of Fabri-Kal’s systems are located in hard-to-inspect areas
“Not only does this metering capability allow us to save in the plant.”

Vds"Vdkk"Lntmsdc"Otlo"Rs`shnm

Vgdm"xnt&ud"fns"sgd" mdrs,dmfhmddqdc+"lnrs"bnrs,de bhdms"


otlo"rs`shnm"nm"sgd"ok`mds+"hs&r"g`qc"mns"sn"f`yd"hm"`clhq`shnm-"
'Sqx"cnhmf"sg`s"vhsg"`"rtaldqrhakd-("Vhsg"R%K"Mnm,Bknf"Otlor"
tmcdq"sgd"gnnc"`mc"`anud"sgd"vds"vdkk+"rtodqhnq"odqenql`mbd+"
bnmudmhdmbd"`mc"4/$"bnrs"r`uhmfr"`qd"xntqr"xd`q"`esdq"xd`q-"
Rn"sgd"eddkhmf"mdudq"fdsr"nkc-"S`jd"oqhcd"hm"xntq"otlo"rs`shnm-

Rg`qd"R%K"oqhcd"`s"E`bdannj-bnl.Rlhsg`mcKnudkdrr-

CALL 913.888.5201
Smith & Loveless Inc.
VISIT SmithandLoveless.com
Above all others. TM

circle 130 on card or go to psfreeinfo.com


PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 65
Practice & Operations

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

X Q P DW F K D E O H " H [ S H U L H Q F H
L Q " S U L YDW H " F R P S D Q ¥"
WUDQVDFWLRQV

Mrugdq/"Nqdxii")"Frpsdq|"lv"d"nqrzohgjhdeoh"dqg"
h{shulhqfhg" surylghu" ri" d" frpsuhkhqvlyh" olqh" ri"
lqyhvwphqw"edqnlqj"vhuylfhv"wr"wkh"sxps/"ydoyh"dqg"
Ûowudwlrq"lqgxvwulhv"+ÎIorz"FrqwuroÏ,1"
Rxu" olqhv" ri" exvlqhvv" lqfoxgh=" vhoolqj" frpsdqlhv/"
udlvlqj" ghew" dqg" htxlw|" fdslwdo/" dqg" dvvlvwdqfh""
rq"dftxlvlwlrqv1"
Wr" ohduq" pruh" derxw" Mrugdq/" Nqdxii" )" Frpsdq|/""
frqwdfw" dq|" phpehu" ri" rxu" Iorz" Frqwuro""
whdp1" Dffhvv" rxu" Iorz" Frqwuro" uhvhdufk" dw""
zzz1mrugdqnqdxii1frp2Ürzfrqwuro1"
J1"Frrn"Mrugdq/"Mu1 Mdfn"F1"Jrqghu
Pdqdjlqj"Sulqflsdo Ylfh"Suhvlghqw
fmCmrugdqnqdxii1frp mjrqghuCmrugdqnqdxii1frp
645158718<34 645158718<4;

Gdylg"D1"Ndnduhnd
Dvvrfldwh
gndnduhndCmrugdqnqdxii1frp
645158718<3:

PHPEHU"ILQUD/"VLSF

circle 143 on card or go to psfreeinfo.com circle 147 on card or go to psfreeinfo.com


66 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
Product Pipeline
New Wafer Check Valve Meets Critical Communication Protocol Software
Demands of Water Applications Dwyer Instruments, Inc.,
Asahi/America, Inc., introduces announces the release of its
10-inch and 12-inch PVC wafer DEVCOM2000 HART
check valves. Wafer check valves Communication Protocol Software.
are installed on the discharge side he software turns a PC into a full
of pumps in applications such featured HART communicator
as aquariums, water attractions, making it possible to configure transmitters and control
water treatment and municipali- valves at the desktop or in the field. DevCom2000 uses
ties to prevent back-flow flooding that could seriously device descriptions (DDs) to retrieve data that is stored in
damage pump systems. he valve’s body, disc and stopper the memory of smart field devices.
assembly are machined from solid PVC plate stock, which Circle 203 or go to psfreeinfo.com
conforms to ASTM D1784 Cell Classification 12454A.
Circle 201 or go to psfreeinfo.com Washdown Pumps
Jabsco announces the new
Shark Grinders Hotshot Series washdown
With models available from 1 to 7½ horse- pumps—the choice for fish
power, Zoeller Engineered Products offers a box, scaling, boat and anchor
broad line of grinder pumps. Cool run design n chain cleaning, and ideal for the harshest
technology effectively disperses heat, promot- marine environments. hese washdown pumps have a five-
le
ing longer life. hey are available with multiple chamber design, patented co-injected molded diaphragm,
discharge configurations and wet end designs, and larger, heavier duty motor brushes that significantly
and some models feature the Zoeller reversing extend pump life up to 50 percent longer than existing Par-
cutter design, preventing cutter jams. Models Max models.
are available with standard or explosion proof motors. Circle 204 or go to psfreeinfo.com
Circle 202 or go to psfreeinfo.com
P&S

ANSI/HI Standards Update:


Version 3.0 — All 30 Standards on one CD

Version 3.0 is here and ready for inclusion in your


standards library. The complete set of all 30 current ANSI/
HI Standards on a single CD. Convenient to use, store and
transport. Exceptionally cost-effective! Just some of the
important features:
t Twelve new/updated standards including:
— ANSI/HI 14.6 – Rotodynamic Pump
Tests NEW!
— ANSI/HI 12.1-12.6 – Rotodynamic
Slurry Pumps
— ANSI/HI 20.3 – Rotodynamic Pumps –
Pump Efficiency Prediction
— HI 50.7 – Electronic Data Exchange for
Pumping Equipment
t Simple, easy-to-use Adobe PDF format
t Annotation and printing enabled
t Master Index plus seperate index for each Standard
t Single-user license entitles two installations; use on desktop/laptop

A TRUE VALUE: $1,100 (+S/H)


Users Of 2.2: Upgrade to 3.0 – Only $150!

Order now at: eStore.Pumps.org

circle 144 on card or go to psfreeinfo.com circle 146 on card or go to psfreeinfo.com


68 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
PUMP USERS MARKETPLACE

EPOXIES
FOR
Pump Applications
Stainless Steel, Aluminum
and Ceramic Filled Systems

For repair and protection against:


ì Corrosion ì Abrasion
ì High/low temperatures

Hackensack, NJ 07601 USA


+1.201.343.8983 ì main@masterbond.com

www.masterbond.com
circle 110 on card or go to psfreeinfo.com circle 155 on card or go to psfreeinfo.com circle 154 on card or go to psfreeinfo.com

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.

PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 69


PUMP USERS MARKETPLACE

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
฀ ฀ ฀ ฀ circle 150 on card or go to psfreeinfo.com
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

Tollfree 1 866 635 7596


vesconite@vesconite.com
www.vesconite.com

circle 166 on card or go to psfreeinfo.com

circle 165 on card or go to psfreeinfo.com

circle 161 on card or go to psfreeinfo.com circle 162 on card or go to psfreeinfo.com

70 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


PUMP USERS MARKETPLACE

circle 158 on card or go to psfreeinfo.com

ROTARY LOBE 316 STAINLESS


NLESS STEEL PUMPS
Stainless Steel 316
cartridge seals
standard.

Helical four wing lobes


Stainless Steel wet end
with Viton elastomer
standard (wear plates, bolts
standard provide smooth
and housing segments) for
nqy"ujgct"Þqy"cpf"
corrosive resistance.
corrosive resistance.
912-466-0304 www.LOBEPRO.com Made in USA circle 152 on card or go to psfreeinfo.com
circle 153 on card or go to psfreeinfo.com

Theory Hands-On Live Performance Testing OFF


Button
Next Pump School Session
)HEUXDU\‡$WODQWD*$
EVERYTHING YOU EVER WANTED TO KNOW ABOUT PUMPS
Easy
)RUPRUHLQIRUPDWLRQJRWR Lockout
Dead
Front
ZZZ3XPSLQJ0DFKLQHU\FRP‡770-310-0866
circle 157 on card or go to psfreeinfo.com

 Protects from electrical hazards

 Simplifies NFPA 70E compliance


Qualified technicians can quickly
disconnect and connect power OFF
Button
up to 200A, 60hp, 600V.
FREE Samples Available

www.meltric.com • 800.433.7642

circle 156 on card or go to psfreeinfo.com


circle 163 on card or go to psfreeinfo.com circle 164 on card or go to psfreeinfo.com

PUMPS & SYSTEMS www.pump-zone.com JANUARY 2012 71


P&S Market

Wall Street Pump and


Valve Industry Watch

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

Source: U.S. Energy Information Administration and Baker Hughes Inc.

ment. Government spending provided a negative contribution


to growth, due to reduced federal, nondefense expenditures and
Source: Institute for Supply Management Manufacturing Report on Business® and U.S.
continued declines in state and local spending. Many econo- Census Bureau.
mists forecast a growth rate of between 2.5 and 3.0 percent for
the last quarter of 2011. Data on consumption, business spend- be a net exporter of gasoline, diesel and other oil-based fuels
ing and residential investment point to growth, but still below for the first time in 62 years. Booming demand from emerg-
the almost 4 percent late 2009 and the first half of 2010 growth. ing markets and faltering domestic activity caused the U.S. to
he labor market struggled to gain back even a fraction of export more fuel than it imported. As recently as 2005, the U.S.
the jobs lost in the recession. Monthly gains averaged 130,000 imported nearly 900 million barrels more of petroleum prod-
jobs, much less than the 200,000 monthly average considered ucts than it exported. P&S
needed for robust economic growth. End-of-the-year hiring Jordan, Knauff & Company is an investment bank based
accelerated with the unemployment rate unexpectedly falling to in Chicago, Ill., that provides merger and acquisition advi-
8.6 percent in November, its lowest rate in nearly three years, . sory services to the pump, valve and filtration industries.
he Institute for Supply Management’s Purchasing Please visit www.jordanknauff.com or email jgonder@jor-
Managers Index (PMI) has shown consecutive monthly growth danknauff.com for further information on the firm.

72 JANUARY 2012 www.pump-zone.com PUMPS & SYSTEMS


circle 101 on card or go to psfreeinfo.com
BEING RESPONSIBLE
IS OUR FOUNDATION

THINKING AHEAD
MAKES IT POSSIBLE

INNOVATION
IS THE ESSENCE

Grundfos is a company that changes as the world changes, but our


fundamental values of Be responsible – Think ahead – Innovate remain
constant. They are the cornerstones on which all our actions are based.
They inspire us to provide our customers, employees, and partners
with unparalleled excellence, and have made us a global leader in
advanced pump solutions and a trend-setter in water technology.

www.grundfos.com
circle 105 on card or go to psfreeinfo.com

Das könnte Ihnen auch gefallen