5 pumps and systems - june 2010

The Magazine For Pump Users Worldwide June 2010

pump-zone.com

SHOW C

OVERAGE

AWW

A & E

ASA

The Magazine For Pump Users Worldwide

pump-zone.com

June 2010

Also Inside

46 VALVE & PIPING

SPECIAL SECTION

21 Holistic Pump System Designs

64 Effi ciency in Air Distribution Systems

Also Inside

46 VALVE & PIPING

SPECIAL SECTION


64 Effi ciency in Air Distribution Systems

Moves a higher percentageof solids longer distancesthan any other PC pump

• Lower Your Capital Investment and minimize maintenance costs

• Twin Screw Feeder (TSF) – most efficient feed system, self-cleaning,no extended augers needed

• VFD Control for both pump and TSF – fewer energy losses, lowerhorsepower needed, lower noise

• Closed Piping System – controls odor

• G4 Pump with Ultra-Drive® – non-pulsating flow equals lower operating pressures, shortest dewatered sludge handling PC pumpon the market

• (Optional) Slip Injection System – further reduces discharge pressure by 3 or 4 times

• Just 1/2 the Cost of hydraulically driven piston pump systems!

Moyno®

2000 HS System

1-877-4UMOYNO www.moyno.com

circle 112 on card or go to psfreeinfo.com

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EagleBurgmann’s innovative hnology. We give top priority

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2 JUNE 2010 www.pump-zone.com PUMPS & SYSTEMS

Letter from the Editor

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 offi ces. Subscriptions: Free of charge to qualifi ed industrial pump users. Publisher reserves the right to determine qualifi cations. Annual sub-scriptions: 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) 482-3050 inside or outside the U.S. POSTMASTER: send change of address to Pumps & Systems, PO BOX 9, Batavia, IL 60510-0009. ©2010 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.

is a member of the following organizations:

We recently attended the Offshore Technology Conference in Houston where, not surprisingly, the buzz

centered on the blown oil well aboard the drill rig Deepwater Horizon in the Gulf of Mexico. However, it was also not a surprise that most of the conversations and speculations were more focused on fi nding solutions and not overstat-ing the problem.

It became evident early on that a sub-standard blowout preventer was the cause of the explosion that has allowed millions of gallons of crude oil to pollute miles of gulf waters. As is customary in the industry, the focus quickly diverted to the exploration of new technology to try and fi x it.

One of the many things I have learned from talking with our readers and advertisers through the years is that pumps are not going to change much over time. They continue to pull stuff in and spit stuff back out. In our industry, it is the technology surrounding the pump that continues to transform and improve.

At the time of this writing, the blown well has been leaking for almost a month. The catastrophe presents threats to the commercial fi shing and tourist industries from Louisiana to Florida, as well as harm to sea life. Several attempts at stopping the leaks, using old and new technology, have failed. However, it is cer-tain that some sort of advanced technology will be implemented to resolve the issue.

Pumps & Systems has covered the oil & gas industry for many years, but primarily from the downstream end of the business. We feel a more direct connection to this news after releas-ing the premier issue of Upstream Pumping Solutions, which covers the oil & gas industry from the perspective of exploration, drilling, well completion and production, including onshore and offshore activities. Advancements in technology will continue to be a focus for both publications.

We continue our oil & gas industry cover-age this month with a trip to Calgary, Alberta, Canada for the Global Petroleum Show. We hope to return with a multitude of new techno-logical information to share with our readers . . . not only regarding the recent oil spill, but other breakthroughs affecting the entire industry. This month, we will also be in Chicago for AWWA’s annual ACE convention (Booth 2167), as well as the EASA convention in Orlando (Booth 208). Please stop by and tell us about new tech-nology affecting your business.

Best Regards,

Michelle [email protected]

PUBLISHERWalter B. Evans, Jr.

ASSOCIATE PUBLISHER VP-SALES

George [email protected]

205-345-0477

VP-EDITORIALTambra McKerley

EDITORMichelle Segrest

[email protected]

MANAGING EDITORAlexandra Ferretti

[email protected]

MANAGING EDITOR—ELECTRONIC MEDIA

Julie [email protected]

205-314-8265

CONTRIBUTING EDITORSLaurel DonohoJoe Evans, PhD

Dr. Lev Nelik, PE, APICS

INTERNCatherine Jones

SENIOR ART DIRECTORGreg Ragsdale

PRODUCTION MANAGERLisa Freeman

[email protected]

CIRCULATIONTom Cory

[email protected]

ACCOUNT EXECUTIVESCharli K. Matthews

[email protected]

Derrell [email protected]

205-345-0784

Mary-Kathryn [email protected]

205-345-6036

Mark [email protected]

205-345-6414

A Publication of

P.O. Box 530067Birmingham, AL 35253

Editorial & Production Offi ces1900 28th Avenue South, Suite 110

Birmingham, AL 35209Phone: 205-212-9402

Advertising Sales Offi ces2126 McFarland Blvd. East. Suite A

Tuscaloosa, AL 35404Phone: 205-345-0477 or 205-345-0784

Editorial Advisory Board William V. Adams, Director, New Business

Development/Corp. Mktg., Flowserve Corporation

Thomas L. Angle, PE, Vice President, Product Engineering, Weir Specialty Pumps

Robert K. Asdal, Executive Director, Hydraulic Institute

Bryan S. Barrington, Machinery Engineer, Lyondell Chemical Co.

Kerry Baskins, Vice President, Grundfos Pumps Corporation

R. Thomas Brown III, President, Advanced Sealing International (ASI)

John Carter, President, Warren Rupp, Inc.

David A. Doty, North American Sales Manager, Moyno Industrial Pumps

Ralph P. Gabriel, Director of Product Development, John Crane

William E. Neis, PE, President, NorthEast Industrial Sales

Dr. Lev Nelik, PE, Apics, President, Pumping Machinery, LLC

Henry Peck, President, Geiger Pumps & Equipment/Smith-Koch, Inc.

Mike Pemberton, Manager, ITT Performance Services

Earl Rogalski, Sr. Product Manager, KLOZURE®, Garlock Sealing Technologies

ITT, ITT Watermark, the Engineered Blocks symbol and “Engineered for life” are registered trademarks of ITT Manufacturing Enterprises, Inc. © 2010, ITT Corporation.

How we use and reuse water will help define the future of our planet. ITT is at work in more than 130 countries, providing the people and products that help move and treat water at every stage of the water cycle. We realize that our collective actions have an impact on people around the world. Whether it’s delivering sustainable water and wastewater solutions through our trusted brands, or providing drinking water to those in need through our philanthropic ITT Watermark program, we do it all with the planet in mind.

www.ittfluidbusiness.com

To learn more about ITT’s commitment to a more sustainable future, please visit us in Booth #501, at ACE 2010, June 20-23 in Chicago, IL.

To see how the ITT Watermark program is making a difference, please visit www.ittwatermark.com

Where there’s life, there’s water.

Think about ITT.



TECHNOLOGY CONVERGENCE: SMARTER MOTORS & DRIVES

Holistic Pump System DesignsMike Pemberton, ITT Industrial Process

Holistic pump system designs optimize system effi ciency and life cycle performance.

Electric Motor Effi ciency Regulations (Part One)Kitt Butler and David Berkowitz, Advanced Energy

What pump manufacturers and pump users need to know about the Energy Independence and Security Act of 2007.

Emergence of Intelligent PumpingGrant Van Hemert, Schneider Electric

Smart pumping makes troubleshooting less challenging.

New Advances in VFDsSteven B. Weston and Michael W. Owens, Eaton Corporation

New, sophisticated technologies are impacting effi ciency and yielding more effective and more fi nely-tuned VFDs.

Energy Management Considerations with Today’s Drive Systems

Michael Perlman, Siemens Industry Inc.Multiple drive factors contribute to system energy effi ciency.

EASA Convention 2010

VALVES & PIPING SPECIAL SECTION

Internal Joint Restraint for Municipal Applications

Douglas Glenn ClarkRotting ductile pipe at the Port of Tampa was replaced with PVC piping, which reduced costs and municipal concerns.

Energy Savings with the Correct Duty PointJens-Uwe Vogel, VSX-Vogel Software GmbH

Pipe calculation software helps users correctly determine a pump’s required duty point.

Improve Control Valve Performance for Greater Process Reliability

Ken Hall, Emerson Process Management, Fisher DivisionTips to ensure optimal control valve performance.

American Water Works Association Annual Conference & Exhibition

Table of Contents

21

39

46

52

56

60

32

44

42

28

PRACTICE & OPERATIONS

Decentralized/Distributed Systems as Alternative Treatment Options

Robert K. Rebori and Jennifer Cisneros, Bio-Microbics, Inc.Onsite treatment systems benefi t homeowners, developers and the environment.

Impeller Balancing: An Important Element of a Quality Repair

Eugene Vogel, Electrical Apparatus Service AssociationBalancing procedures, tolerances and tips for pump impellers.

Structural Resonance Problems on Vertical Pumps

Francisco Gaytan and Alejandro Pineda, Flowserve Flow Solutions GroupUnderstand the process used to resolve the high-vibration issues on a power generating station’s vertical circulating water pumps.

Wind and Water Take Center StageLisa Tryson, Danfoss

Intertwined with climate change, wind and water will signifi cantly impact global energy production and use.

DEPARTMENTS

P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pump Ed 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Joe Evans, Ph.D.AC Power (Part One): AC Versus DC

Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 18Dr. Lev Nelik, P.E., APICSVariable Speed or Impeller Trim?

Maintenance Minders . . . . . . . . . . . . . . . . . . . . . . . . 62Kelly Paffel, Swagelok Energy Advisors, Inc.Flash Steam Recovery Using Condensate Tank Vent Condensers

Effi ciency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Curtis DietzschImproving Effi ciency in Air Distribution Systems (ADS)

FSA Sealing Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . 68What gasket properties are most important, and how do I use them?

HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Balancing Pump Impellers; High Effi ciency Pumps; Bailer Feed Booster Pumps

P&S Stats and Interesting Facts. . . . . . . . . . . . . . . . 96

76

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83

88

June 2010Volume 18 • Number 6 Co

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The Magazine For Pump Users Worldwide June 2010

pump-zone.com

SHOW C

OVERAGE

AWW

A & E

ASA

The Magazine For Pump Users Worldwide

pump-zone.com

June 2010

Also Inside

46 VALVE & PIPING SPECIAL SECTION


64 Efficiency in Air Distribution Systems

Also Inside

46 VALVE & PIPING SPECIAL SECTION


64 Efficiency in Air Distribution Systems

Are you laying awake at night thinking about the recent changes in bearing isolator product

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P&S News

PEOPLEPUMP SOLUTIONS GROUP (REDLANDS, CA) announces that Walter Bonnett has been promoted to vice president of PSG marketing, a position from which he will report directly to PSG President Dean Douglas. Bonnett’s focus as leader of the Marketing Group will be to spearhead and support strategic sales and marketing activi-ties and implement programs that will aid PSG’s image in the market.

PSG is a conglomeration of six pump manufacturers and technologies: Blackmer®, Wilden®, Neptune™, Griswold™, Mouvex® and Almatec®. www.pumpsg.com

ITT INDUSTRIAL PROCESS (SENECA FALLS, NY) appoints Marc DeSilva as business development director for ITT Oil & Gas and Global Project Management. DeSilva will be responsible for leading ITT’s worldwide global product management, project man-agement for the oil and gas market, and business development and strategic account agreements. DeSilva’s team will also support worldwide sales and marketing operations. He will report to John Manna, vice president of Global Marketing for Indus-trial Process.

ITT Industrial Process provides pumps, valves, water-makers, controls, monitoring and a wide range of services to global oil and gas markets. www.itt.com

SJE-RHOMBUS (DETROIT LAKES, MN) has expanded its sales force by hiring Brett Wilfong as east-ern regional sales manager. Wilfong will direct sales in Florida, Georgia, Connecti-cut, Rhode Island, Massachusetts, New Hampshire, Vermont, Maine, North Caro-lina, South Carolina, Alabama, Mississippi, Ohio, Pennsylvania, Maryland, Virginia, Delaware, New Jersey, Washington DC, Indiana, Kentucky, Michigan, Tennessee and eastern upstate New York.

SJE-Rhombus manufactures water/wastewater control panels, pressure booster controls and fl oat switches for the residential, commercial and industrial markets. www.sjerhombus.com

EAGLEBURGMANN (HOUSTON, TX) announces that David Peschell has joined the fi rm as key account manager. Peschell will be involved in global OEM sales efforts.

EagleBurgmann manufactures mechan-ical seals, systems, packing and expansion joints. www.EagleBurgmann.com

ROBBINS & MYERS, INC. FLUID MANAGEMENT GROUP (WILLIS, TX) announces that Bob LePera has been appointed to the position of industrial products VP Sales, Americas. In this role, LePera will be responsible for sales, service and after-market initiatives of industrial products in the Americas.

Robbins & Myers FMG brands include R&M Energy Systems, Moyno, Tarby and Chemineer. www.robbinsmyers.com

AROUND THE INDUSTRY NSK CORPORATION (ANN ARBOR, MI) announces that NSK Americas Technical Center and India-napolis Distribution Center was recently awarded United Technologies Corporation’s (UTC) Supplier Gold status. This award recognizes NSK’s performance in quality, delivery, customer support, value, fl exibility and lean practices.

The UTC Supplier Gold award rec-ognizes companies that deliver superior world class performance. The criteria used to evaluate suppliers for this award focuses on best in class quality, 100 percent on-time product delivery, value, technical and busi-ness support services and superior lean & 6S practices throughout the organization.

NSK Americas, a member of the NSK Ltd. company group (Tokyo, Japan), manufactures bearings. www.us.nsk.com

ITT WATER & WASTEWATER U.S.A. (CHARLOTTE, NC) announces that a Flygt emergency response group from Mil-ford, Ohio, comprised of Ray Sizemore, John Gray and Scott Myers, responded rapidly to an emergency call from the Zanesville WWTP in Zanes-ville, Ohio, after a 2 in potable water line ruptured a ball valve, tripped the MCC and shut down four pump drives.

Myers had two trailer-mounted, 8 in, diesel-powered pumps dispatched to Zanesville. The mobile setup with the 150 hp diesel-powered pumps was kept in Milford for major dewa-tering assignments and offered the needed capacity to temporar-ily restore the plant fl ow back through secondary treatment.

The damages impacted the plant’s O&M budget of approximately $87,000. Without the prompt actions that were taken, the incident would have been more costly.

ITT Water & Wastewater is comprised of Flygt, Sanitaire, Wedeco, Leopold and PCI Membranes. www.ittwww.com

Walter Bonnett

Marc DeSilva

Brett Wilfong

David Peschell

UTC Supplier Gold award

Zanesville WWTP

PUMPS & SYSTEMS www.pump-zone.com JUNE 2010 7

GARLOCK SEALING TECHNOLOGIES (PALMYRA, NY) launches a revised MICRO-TEC® II website (www.microtec2.com). The website features an easy to use technology naviga-tor that allows users to explore the MICRO-TEC II bearing isolator.

Garlock Sealing Technologies, an EnPro Industries com-pany, designs, manufactures and sells fl uid sealing products worldwide. www.garlock.com

MEGGITT PLC (DORSET, UK) is making the transition to a new structure com-prising fi ve operating divisions: Meggitt Sensing Systems, Meggitt Aircraft Brak-ing Systems, Meggitt Control Systems, Meggitt Polymers & Composites and Meggitt Equipment Group. The transi-tion should be completed in 2010.

Operating units Endevco, Ferroperm, Vibro-Meter France (Sensorex), Vibro-Meter Inc, Vibro-Meter SA, Vibro-Meter UK and Wilcoxon Research have been combined into a single Meggitt Sensing Systems division.

Meggitt also passed annual audits to keep current the Germantown facil-ity’s AS9100 Aerospace Standard for Quality Systems, ISO 9001 Quality Management System and ISO 14001 Environmental Management System certifi cations.

Meggitt PLC is a global engineering group specializing in extreme environ-ment components and smart sub-sys-tems for aerospace, defense and energy markets. www.meggittsensingsystems.com

ADAMS VALVES, INC. (HOUSTON, TX) moves to a new location at 12303 Cutten Rd, Houston, Texas. It will celebrate the ownership of its new property in con-junction with the 50th anniversary of its parent company, Adams Armaturen GmbH. The newly constructed 23,000 sq ft facility includes offi ce, manufactur-ing and warehouse on 3.25 acres.

Adams Valves manufactures rotary, isolation, control and check valves. www.adamsvalves-usa.com

MIDLAND-ACS (WOLVERHAMPTON, UK) opens a new Fluid Power Solution Center in Houston, Texas. Midland-ACS, a subsidiary of ITT Corp., offers pneumatic and hydraulic fl uid power solutions. www.midland-acs.com

New location

714-893-8529www.bluwhite.com

[email protected]: 714.894.9492

5300 Business DriveHuntington Beach, CA 92649 USA

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P&S News

LEISTRITZ (ALLENDALE, NJ) announces that one of the largest twin-screw, multiphase pumps ever ordered successfully com-pleted factory acceptance tests at the Leistritz Pumpen GmbH factory in Nuremberg, Germany.

The pump was the fi rst of 16 ordered in August 2009 by Pemex, the national oil company of Mexico. Leistritz will supply these pumps as part of complete packages that include

piping, valves, E-buildings, controls and automation. The packages will be installed on three platforms—Ku-Maloob-B, Zaap-B and Zaap-D—in the Gulf of Mexico.

Each multiphase pump will simultaneously transport 12 MBPD of oil and 13MM SCFD of gas at a pressure of 245 psig. The pumps will be driven by 2,500 hp, 1,800 rpm electric motors.

Leistritz manufactures engineered products for the transportation, power generation and process industries. www.leistritzcorp.com

KSB GROUP (FRANKENTHAL, GER-MANY) received an order for fi ve giant main cooling water pumps in the mil-lion euro range. They will be supplied to the Saudi Arabian power station of Rabigh situated on the coast of the Red Sea a hundred kilometers north of Jiddah. The new installation is a 1,200 MW heavy oil fuelled steam power sta-tion. The pumps will be supplying the seawater needed for cooling the conden-sate circuit.

KSB produces pumps, valves and related systems. www.ksb.com

Ulf Mester, Leistritz project manager, with his customer, following successful testing of a multiphase pump.

SEZA pumps of the type that will be supplied to Rabigh power station in Saudi Arabia.

SENTRY Pulsation Dampeners & Surge

Suppressors remove hydraulic shock and

vibration, enhancing all-around performance

and reliability of fluid flow applications.

SENTINEL Diaphragm Seals protect and

isolate all forms of system instrumentation

from hazardous and corrosive process fluids.

More than just leak detection! The patented

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P&S News

REVERE CONTROL SYSTEMS (BIRMINGHAM, AL) has estab-lished an alliance with Motion Industries (Birmingham, Ala.). Motion Industries is a distributor of maintenance, repair and operation (MRO) replacement parts to a wide variety of indus-trial customers in North America. Under the terms of the alli-ance, Motion Industries sales offi ces will be able to offer their customers turnkey automation and control system integration services, to be provided by Revere.

Revere is an industrial control system integrator. www.rev-erecontrol.com

VERDER GROUP (VLEUTEN, THE NETHERLANDS) AND GPM PUMP COMPANY (MACON, GA) have embarked on a joint venture to strengthen their service and support for their positive displace-ment pumps to the North Ameri-can marketplace. Operating now as VerderGPM, this new business com-bines more than 51 years of fl uid handling experi-ence and technical

expertise. Prior to January, GPM Pumps operated as master distributor for the Verderfl ex hose and SSP rotary pump lines. VerderGPM now operates as the U.S. entity for the manufac-turers.

Verder Group is a diversifi ed manufacturer of fl uid han-dling, laboratory and process equipment as well as a global dis-tributor of process equipment for a range of specialized manu-facturers. GPM Pumps, a division of GPM Industries, has been the master distributor for the Verderfl ex peristaltic pump and Alfa Laval tri lobe pump. www.verdergpm.com

ZOELLER PUMP COMPANY (LOUISVILLE, KY) announces that Extreme Makeover: Home Edition has selected Zoeller Pump Company as a preferred vendor to work with on upcoming build projects for the ABC reality show. The Emmy Awardwinning reality series has selected to use a Pro Pak 53, sump pump and battery backup pump combination on a recent home built in Bloomington, Ill. Zoeller Pump Company is proud to donate products for a family in need and hopes to continue this affi liation in the future.

Zoeller offers a line of sump/dewatering, effl uent, sewage and grinder pumps. www.zoeller.com

New joint venture

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UPCOMING EVENTSHI SPRING MEETINGJune 9-12Renaissance Worthington Hotel / Fort Worth, TexasPresented by the Hydraulic Institute 973-267-9700 / www.pumps.org

AMERICAN WATER WORKS CONFERENCE & EXHIBITION June 20-24McCormick Place, West Building / Chicago, IL Presented by the American Water Works Association 303-794-7711 / www.awwa.org/ACE10

EASAJune 27-29Gaylord Palms / Orlando, FLPresented by the Electrical Apparatus Service Association, Inc.314-993-1269 / www.easa.com

AMTA CONFERENCE & EXHIBITIONJuly 12-15Town & Country Hotel / San Diego, CAPresented by the American Membrane Technology Association772-463-0820 / www.membranes-amta.org

ENERGY SAVINGS METHODS FOR PUMPSJuly 15Mekarot Water Company / Ashkelon, IsraelPresented by Pumping Machinery, LLC770-310-0866 / www.pumpingmachinery.com

ENERGY SAVINGS VIA PUMPS EFFICIENCY OPTIMIZATIONJuly 18-19Israel Electric Company Training Center / Hadera, IsraelPresented by Pumping Machinery, LLC770-310-0866 / www.pumpingmachinery.com

CENTRIFUGAL AND POSITIVE DISPLACEMENT PUMPSJuly 21-22Pumping Machinery Middle East Training Center / Be’er Sheva, IsraelPresented by Pumping Machinery, LLC770-310-0866 / www.pumpingmachinery.com

CENTRIFUGAL AND POSITIVE DISPLACEMENT PUMPSAugust 19-20W.W. Grainger Facility / Norcross, GAPresented by Pumping Machinery, LLC770-310-0866 / www.pumpingmachinery.com

PUMPTECSeptember 20-21Holiday Inn Select / Norcross, GAPresented by Pumping Machinery, LLC770-310-0866 / www.pumpingmachinery.com

2010 CADWORX UNIVERSITYSeptember 27-29Woodlands Waterway Marriott Hotel / Houston, TexasPresented by COADEwww.cadworxuniversity.com

P&S News

P&S


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Pump Ed 101

This three part primer is a basic introduction to AC power for those in the pump industry who need a place to start. It will also provide several web refer-

ences to access if you would like to further your understand-ing of this interesting and essential topic.

What is Electricity?The dictionary defi nes electricity as “a fundamental property of matter caused by the presence of electrons and protons, and manifesting itself as attraction, repulsion, luminous & heating effects, and the like.” Did that peak your interest?

I think that my defi nition is more meaningful: “An elegantly simple yet incomprehensible entity that moves at the speed of light yet can remain trapped in wires destined only to bounce back and forth; weightless but still breaks the sound barrier as it plummets from the clouds; attractive yet repulsive; a taker of lives but also a restorer of life.” This sounds a little more interesting, but I have to admit that it is still a bit vague.

Like many other properties in physics, electricity is diffi cult to defi ne. It more easily lends itself to descriptions such as attraction and repulsion. It can fundamentally be described as a force just as gravity is force, or as a form of energy. It can be static or it can be moving. Since electricity is so diffi cult to defi ne, it is probably best that we just try to describe it and its effects.

AC Versus DC: A Little History“A chicken in every pot and an eagle in every pocket” was a slogan during the Great Depression. Had Thomas Edison won the battle over power distribution, we could have added “and a power plant on every corner.” Edison was a great proponent of DC power and fought the use of AC bitterly. He invented the incandescent lamp in 1879 and began to develop a power generating and distribution system to pro-mote it. He opened his fi rst power plant in New York City in 1882 and added several others during the next few years.

His plan was to build a power grid with generating sta-tions about four miles apart. Although Edison’s efforts were a limited fi nancial success, it was soon recognized that DC transmission systems suffered heavy power losses over any

signifi cant distance.Edison’s principal opponent at the time was George

Westinghouse. He and his partner, a Serbian-American engineer named Nikola Tesla, made long distance AC trans-mission practical. Tesla invented the transformer and induc-tion motor, made major improvements in the AC generator and was awarded more than 100 patents.

In the late 1880s, LL Nunn, a mine owner from Telluride, Colo., came to Westinghouse with a proposal to build a steam powered AC power plant for his mine. Westinghouse accepted the offer, and when it went online in 1891 it was the fi rst AC power plant in the world. It eventu-ally became part of Nunn’s Telluride Power Company, which is now part of Utah Power and Light.

In 1893, Westinghouse won a contract to construct a commercial AC hydroelectric plant at Niagara Falls. This plant convincingly demonstrated the fl exibility of AC power and relegated DC to a secondary role. If you want to learn more about the bitter battle between Edison and Westinghouse, go to http://en.wikipedia.org/wiki/War_of_Currents.

Common Electrical Terms (AC and DC)Volt: A unit of potential difference. It is the difference in electromotive force (or charge) between two points. A rea-sonable analogy for those familiar with pumping applica-tions is pressure. Voltage in an electrical circuit is similar to pressure in a pipeline.

Joe Evans, Ph.D.

AC Power (Part One): AC Versus DC

Pump Ed 101

Figure 1

First of Three Parts


Ampere (Amp): A unit of current or the amount of the current in a circuit. When compared to water in a pipeline, Amps or current is similar to fl ow in gallons.

Ohm: A unit of resistance that impedes the fl ow of current in a circuit. Again, when compared to our pipeline, it is analogous to friction.

Watt: In the English system, the Watt is a unit of power and, in its simplest form, is the product of volts times amps. It is similar to the energy possessed by water in a pipeline, which is the product of fl ow and pressure.

AC/DC Pros and ConsWhy was DC power so attractive to Edison and its other followers? DC power is extremely simple when com-pared to AC. Once a DC voltage is switched on, its intensity remains con-stant unless something in the system changes. It also follows Ohm’s law. Just about everything you need to know about a DC circuit is described by: I = E/R (or E = IR) where E is voltage, I is current and R is the resistance. If simplicity is not enough, it can even be stored by a battery.

One of the major advantages of AC power is that its voltage can be changed easily by the transformer, a device that operates on the principle of induction and takes advantage of the relationship between the volt and the ampere. That relationship states that power in watts is equal to volts times amps where volts and amps can be any quantity. One kilo-watt (kW) can be 100 volts at 10 amps or it can be 1,000 volts at 1 amp.

When transmitting power over long distances, the combination of higher voltage and lower amperage results in

One of the major advantages of AC power is that its voltage can be changed easily by the transformer, a device that

operates on the principle of induction and takes advantage of the relationship between the volt and the ampere.



Pump Ed 101

lower transmission losses because the energy expended (as heat) in maintaining current fl ow increases as the square of current intensity. In other words, if you reduce voltage by one half while leaving power constant, losses due to heat will increase by four.

DC voltage, on the other hand, is diffi cult to change and typically must be generated at the same voltage at which it will

be consumed. Therefore, DC current intensity will always be disproportionately high and energy losses will follow the rule I just stated.

Another advantage is that AC current can be generated as a single wave form (phase) or in multiple waves (phases). We will talk more about this advantage next month. Also, its fre-quency (cycles per second or hertz) can be varied easily during

generation or afterward. Finally, it is easy to convert AC to DC when DC is needed but more expensive to convert DC to AC.

On the downside, AC power is far more complex than DC. Fortunately, this is not a major factor as all of its complexities have been studied and understood by those before us. If we follow the known rules, we can use all of its benefi ts and avoid any pitfalls. We will take a look at this more complex power curve.

The AC Power CurveThe single phase, 120 V sine wave shown in Figure 1 has several important characteristics. As it progresses through one full cycle (one 360 deg rotation of a generator), it begins at 0 V, then peaks at 170 V a quarter of the way through the cycle. It returns to zero at the halfway point and then reaches negative 170 V at 270 deg. At the end of the cycle it returns to 0 V. In the United States, this occurs 60 times each second, so one full cycle takes about 16.67 milliseconds. A full cycle is also known as a Hertz (Hz). Three complete cycles are shown in the illustration.

You are probably wondering why we call this a 120 V sine wave if the actual peak is at 170 V. Could 120 V be the average? If you were to average all of the voltage values, the result would be approximately 108 V, so that must not be the answer. Why then is the value, as measured by a Volt/Ohm Meter (VOM), equal to 120 V? It has to do with something called effective voltage. It turns out that the area of the green rectangle, whose upper border is at 120 V, is equal to the sum of the actual areas under the upper and lower curves of a single AC cycle (blue areas). This area is known as the effective voltage of the

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sine wave. We will take a closer look at effective voltage.If you were to measure the heat produced by a DC cur-

rent fl owing through a resistance, you would fi nd it is greater than that produced by an equivalent AC current because AC does not maintain a constant value throughout its cycle. If you did this in the lab, under controlled conditions, and found that a particular DC current generated a heat rise of 100 deg, its AC equivalent would produce a rise of only 70.7 deg or 70.7 percent of the DC value. Therefore, the effective value of AC is 70.7 percent of DC. 0.707 times the peak voltage of 170 in Figure 1 equals 120 V.

Also, the effective value of an AC voltage is equal to the square root of the average of the squares of the volt-age values across the cycle (√v1

2+v22+

•••vn2/n). Thus, effective voltage is

known as the root mean square, or RMS voltage. A simplifi ed form of the RMS equation is vp/√2 where vp is the peak voltage. If the peak voltage were 1, the RMS calculation will also yield 0.707. It follows that the peak voltage will always be 1.414 that of the effective or RMS voltage. Remember that unless stated otherwise, all VOMs are calibrated to display RMS voltage.

Next month we will discuss the relationship between peak voltage and frequency and then move on to three phase power.

P&S

Joe Evans is responsible for customer and employee educa-tion at PumpTech Inc, a pumps and packaged systems manufacturer and distributor with branches throughout the Pacifi c Northwest. He can be reached via his website www.PumpEd101.com. If there are topics that you would like to see discussed in future columns, drop him an email.

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The simplest way to change pump fl ow is to throttle the discharge by the valve. Even in this situation, the impeller diameter cannot be

arbitrarily chosen. The diameter should be selected to ensure that the pressure (head) is not excessive, and the power consumed provides the required coverage for the anticipated fl ow range.

Impeller size selection is straightforward and can be easily found in manufacturer manuals (see Figure 1). Figure 1 shows pump performance curves at several impeller trims. Such representation is called a combined curve (versus a single line curve) and is intended to help the pump user select the appropriate impeller diameter for the rated point (and around it) and evaluate effi ciency, power and NPSHR.

Unfortunately, if the conditions of service change to require more fl ow and head than originally specifi ed, the trimmed impeller size would limit such fl exibility. Moving to 100 gpm and 120 ft of head for a rated point of 70 gpm at 100 ft (as shown in Figure 1) is impossible; the 5.12 in trimmed impeller would not allow it.

Changing the operating conditions by a variable speed drive can be a fl exible alternative (see Figure 2). Ineffi ciently throttling the valve to change the fl ow is unnecessary, and the entire range of fl ow and head expands dramatically.

The Affi nity Laws calculate the required pump’s speed if a fl ow range equivalent to that in Figure 1 is desired. Each operating fl ow-head point scales up or down by simply mul-tiplying the fl ow by the ratio of the diameter (or speed) and the head by the square of that ratio. This is how Figure 2 is constructed. In our example, several points on the H-Q curve shown in Figure 1 are picked—for example, 0, 40, 80

and 120 gpm, with heads at these points being 158, 150, 138 and 112 ft.

If we wanted to make the new speeds correspond to exactly the same impeller diameters given in Figure 1 (6, 5.5, 5.0, 4.5, 4.0 and 3.5 in), we simply calculate the speed ratios corresponding to the ratios of the impeller trim at a given curve to the impeller diameter at the maximum OD.

The main advantage of the VFD with regard to effi ciency and energy savings is that effi ciency essen-tially remains the same for a given “scale-down” of speed. Trimming the impeller diameter, while allowing the same modifi cation to the head-fl ow curve, can be ineffi cient (compare Figure 1 to Figure 2).

For example, BEP effi ciency at maximum diameter is 58 percent and drops to about 43 percent when the impeller is trimmed from 6 in to 3.5 in. With equiva-lent reduction of speed from 3,500 rpm to 2,014 rpm, effi ciency essentially remains the same. You can easily calculate the energy saved by this method.

Scaling down the H-Q curve by trimming the impeller follows the Affi nity Laws only approxi-mately, and certain correction factors must be applied.

Effi ciency decreases with a reduction in speed. However, this reduction in effi ciency with speed is small.

In general, the higher the power, the more money saved—as long as you properly account for all variables, including initial purchase cost of the VFD, installation, maintenance and effi ciency difference.

P&S

Dr. Lev Nelik, P.E., APICS

Variable Speed or Impeller Trim?

Pumping Prescriptions

Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machinery, LLC. He can be contacted at www.PumpingMachinery.com.

Figure 1. Pump performance curve at various impeller trims. (Courtesy of

ITT Goulds Pumps)

Figure 2. Hydraulic coverage similar to the impeller trim method can be easily estimated using the Affi nity Laws and applying a variable speed drive.

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Motor and valve performance helps make or break the bottom line for continuous process plants that employ hundreds of pump systems.

A pump system that is well-designed not only maximizes overall system effi ciency, it can also be adapted to changing process demands in the future. In the long run, it means low life cycle cost and high return on investment for end users. To achieve optimum system effi ciency and life cycle performance, we need to adopt a holistic approach in designing the pump system within the overall operation.

Thinking Beyond Traditional Process DesignWhen deciding to build a new facility or modernize an exist-ing one, initial design considerations are focused on sizing the major capital equipment items. Once mass balances are deter-mined, the reactors, vessels and other capital equipment items are selected. The next phase typically includes sizing the pipes and motor driven systems—like centrifugal pumps—to meet production targets.

In anticipation of future load growth, the end user, sup-plier and design engineers routinely add 10 to 50 percent “safety margins” to ensure the pump and motor can accom-modate capacity increases. Near the fi nal design phase, when the piping isometrics and pump sizing are completed, process control engineers select the instruments and valves needed to implement process control strategies. As each design phase progresses, the various engineering disciplines rarely collabo-rate on the subtleties associated with pump, pipe and valve sizing to consider their overall impact on operating stability. As a result, optimum process control is seldom achieved at plant start-up. Furthermore, as control loop performance is known to decay over time, the performance gap will continue to widen during the life of the plant unless it is addressed.

In 1996, a Finnish Technical Research Center report entitled “Expert Systems for Diagnosis and Performance of Centrifugal Pumps” revealed that the average pumping effi -ciency, across the 20 plants and 1,690 pumps studied, was less than 40 percent, with 10 percent of pumps operating below 10 percent. Pump over-sizing and throttled valves were identifi ed as the two major contributors to this sizeable effi ciency loss. Besides hindering overall plant effi ciency, poor pump perfor-mance results in lower product quality, lost production time, collateral damage to process equipment and inordinate main-tenance costs.

The majority of pumping systems run far from their best effi ciency point (BEP) for reasons ranging from a lack of accu-rate design data when the system was new to overly conserva-tive design as well as decades of incremental process change. As

Holistic Pump System DesignsMike Pemberton, ITT Industrial Process

Holistic pump system designs optimize system effi ciency and life cycle performance.

Industry PumpsPulp & Paper Mill 100 – 1000

Petroleum Refi nery 500 – 5000

Chemical Plant 100 - 8000

Industry Pump Energy(% of Total Motor Energy)

Petroleum 59%

Pulp & Paper 31%

Chemical 26%

Table 1. Typical pump populations in the process industries (Source: ITT Industrial Process)

Table 2. Pumping systems are energy intensive (Source: Bureau of Economic Analysis, 1997)

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a result, most pumps, pipes and control valves are incorrectly sized. Therefore, the pump system does not operate with the economy, reliability and control inherently available in the fi nely engi-neered individual components.

Design Considerations for Improved Pumping Effi ciency In the process industries, the purchase price of a centrifugal pump is often 5 to 10 percent of the total cost of ownership. Typically, considering current design practice, the life cycle cost (LCC) of a 100 hp pump system, including costs to install, operate, maintain and decom-mission, will be more than 20 times the initial purchase price. Centrifugal pumps consume between 25 and 60 percent of plant electrical motor energy depending on the industry (see Table 2).

Based on current design practice, energy accounts for about 40 percent of life cycle costs (LCC), with mainte-nance averaging around 25 percent. In poorly designed systems, maintenance may reach as high as 40 percent of LCC, even more.

Initial process design considerations help identify opportunities to improve pump system effi ciency. The following criteria offer the highest potential for effi ciency improvements:

Reduced load on the motor through • optimum process designBest match between component size • and load requirementUse of speed control instead of throt-• tling or bypass mechanisms

Among all rotating assets in a pro-cess plant, centrifugal pumps typically have the best overall potential for elec-trical energy savings. In addition, the excess energy in fi xed-speed systems, not used for moving fl uid, is often dis-sipated into the infrastructure and con-tributes to noise, vibration and lower equipment reliability, i.e., instruments, valves, pipes and pumps.

In the process industries, the purchase price of a centrifugal pump is often 5 to 10 percent of the total cost of

ownership.



In addition to energy cost reduction, a top priority is to solve and eliminate recurring operating problems experienced by plant production, maintenance and engineering departments. Typically, the asset group with the highest failure rate is centrifugal pumps, with seal leakage as the fault that causes the highest downtime and maintenance cost. Pumping system optimization helps minimize unscheduled downtime and contributes to productivity improvement.

Greenfi eld and Modernization Project Benefi ts In the future, pumps must be considered part of the automation architecture, along with the valves and instruments considered the fundamental elements of process control systems. Plant management often views process automation as a key to competitive advantage. During the past 30 years, with the advent of the information technology revolution, process automation has dramatically enhanced the operation of plant processes. Tighter monitoring and control has reduced cost while providing important productivity and quality gains.

The revolution is not complete, however. While process automation has pro-duced a wide range of benefi ts, integrating the pumping system—through the use of variable frequency drives, condition monitoring technology and embedded chips, among other information rich tools—offers quantum leaps in performance. To compete in a global economy, pump automation will provide the needed advances in technical and economic performance. While these enabling technolo-gies are readily available, they are not being readily adopted.

Plant management has often overlooked the need to invest in new automation strategies to improve asset effi ciency and productivity. Surveys suggest that plant management is not convinced that automation technology has fully delivered on past promises of large cost reductions. As a result, there has been a lack of spending on process automation, and many plants now have aged control systems that are technologically, if not functionally, obsolete. Future investment in process control systems must ensure the pump system as an integral component of the system when considering functional design enhancements.

To remain competitive in global markets, continuous process plants must become more innovative in pump system design and ensure these systems are part of process automation strategies. New plant designs must incorporate the latest process control and asset management technologies and strategies that will allow them to produce the highest value product and the absolute lowest possible operat-ing cost.

ConclusionAn important step in improving capital effectiveness is to rethink process design and the role of pumping systems. Optimal design provides major opportunities to

Energy Savings Method SavingsReplace throttling valves with speed controls 10 – 60%

Reduce speed for fi xed load 5 – 40%

Install parallel system for highly variable loads 10 – 30%

Equalize fl ows using surge vessels 10 – 20%

Replace motor with a more effi cient model 1 – 3%

Replace pump with a more effi cient model 1 – 2%

Table 3. Techniques for lower pump energy consumption (Source: DOE Offi ce of Industrial Technology, United States Motor Systems, Market Opportunities Assessment, 1998)

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integrate all the elements of pumping, control and asset management systems for improvements in operator effective-ness. The growing body of pump opti-mization knowledge will support effec-tive system design and operation.

Despite the fi nancial and operat-ing benefi ts of these design changes, process companies face many obstacles when implementing motor effi cient technologies. Among the major barri-ers is the lack of awareness among staffs, suppliers and design engineers of new technologies and strategies to improve pump and process performance.

The perceived risk from chang-ing long established operating prac-tices often delays decisions and project implementation. In addition, plants have reduced staffi ng levels in mainte-nance, operations and engineering that limit the time available for evaluating and commissioning new technologies.

Alternately, on the supplier side of the equation, there are confl icting incentives for promoting effi cient sys-tems and practices. For example, pump distributors may have greater incen-tive to sell additional pumps to meet demand growth, rather than advise cus-tomers on how to manage load growth through more effi cient pump operation. Interestingly, even when the distributor identifi es opportunities and quantifi es the potential benefi ts, many end users continue to make buying decisions based on initial cost rather than spend the incremental capital required for achieving long-term life cycle savings.

To capture the many benefi ts of pump optimization, the process indus-tries, their fl uid handling equipment suppliers and design engineers must work together to improve process design and capture the signifi cant capital and operating cost savings that are readily available.

P&S

Mike Pemberton is manager of energy performance services, ITT Industrial Process.

Typically, the asset group with the highest failure rate is

centrifugal pumps…


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Integral Hp AC motors Between 1-500 hp

The Energy Independence and Security Act of 2007 (EISA), which restates and broadens the defi nition of General Purpose Electric Motors, goes into effect on

December 19, 2010. Certain motors “manufactured (alone or as a component of another piece of equipment)” will be required to have nominal full load effi ciencies that meet the levels defi ned in NEMA MG-1 (2006) (see Table 12-12). Motors manufactured after December 19, 2010, must comply with the law.

For the fi rst time, OEMs will be held accountable for the effi ciency of motors in their equipment. With the dead-line quickly approaching, motor manufacturers should have an action plan for complying with the law. They should be con-ducting testing in accordance with the regulations and carefully recording the results. OEMs requiring design changes should be reviewing their options. End users should be paying close attention to the amount of energy their motors consume, while researching potential cost saving programs available.

This new legislation, while vast in scope, is designed to “move the United States toward greater energy independence and security, to increase the production of clean renewable fuels, to increase the effi ciency of products, buildings and vehi-cles, to promote research on and deploy greenhouse gas capture and storage options.” Specifi cally, the new legislation restates the defi nition of General Purpose Electric Motors as defi ned in 10 CFR 431 from the Energy Policy and Conservation Act of 1992 (EPCA) and classifi es these motors as Subtype I.

Additionally, the law also defi nes a new category of General Purpose Motors, Subtype II, as motors incorporating design elements of a general purpose motors (Subtype I) that are con-fi gured as:

U-Frame motors• Design C motors• Close coupled pump motors• Footless motors•

Vertical solid shaft normal thrust motor (tested in a hori-• zontal confi guration)Eight pole motors (900 rpm)• Poly-phase motors with voltage less than 600 volts (e.g., • 575 volts)

Subtype II motors between 1 and 200 hp manufactured alone or as part of another piece of equipment shall have a nominal full load effi ciency that is not less than as defi ned in NEMA MG-1 (2006) (see Table 12-12). Each fi re pump motor manufactured alone or as a piece of equipment must comply with Table 12-11. NEMA Design B motors with horsepower ratings above 200 hp and not greater than 500 hp are required to comply with NEMA MG-1 (see Table 12-11).

A signifi cant point is that close coupled and footless motors, used extensively in pumping applications, will now be regulated for the fi rst time ever under Subtype II. Whether a pump OEM purchases motors from vendors or manufactures them for his own products, the effi ciency level must be accept-able and a Certifi cate of Compliance from the Department of Energy (DOE) is required.

Electric Motor Effi ciency Regulations (Part One)Kitt Butler and David Berkowitz, Advanced Energy

What pump manufacturers and pump users need to know about the Energy Independence and Security Act of 2007. First of two parts.

Motor build inspection analysis



Table 12-11 (Continued)FULL-LOAD EFFICIENCIES OF ENERGY EFFICIENT MOTORS

Enclosed Motors

2 Pole 4 Pole 6 Pole 8 Pole

HP Nominal Efficiency Nominal Efficiency Nominal Efficiency Nominal Efficiency

1.0 75.5 82.5 80.0 74.0

1.5 82.5 84.0 85.5 77.0

2.0 84.0 84.0 86.5 82.5

3.0 85.5 87.5 87.5 84.0

5.0 87.5 87.5 87.5 85.5

7.5 88.5 89.5 89.5 85.5

10.0 89.5 89.5 89.5 88.5

15.0 90.2 91.0 90.2 88.5

20.0 90.2 91.0 90.2 89.5

25.0 91.0 92.4 91.7 89.5

30.0 91.0 92.4 91.7 91.0

40.0 91.7 93.0 93.0 91.0

50.0 92.4 93.0 93.0 91.7

60.0 93.0 93.6 93.6 91.7

75.0 93.0 94.1 93.6 93.0

100.0 93.6 94.5 94.1 93.0

125.0 94.5 94.5 94.1 93.6

150.0 94.5 95.0 95.0 93.6

200.0 95.0 95.0 95.0 94.1

250.0 95.4 95.0 95.0 94.5

300.0 95.4 95.4 95.0 …

350.0 95.4 95.4 95.0 …

400.0 95.4 95.4 … …

450.0 95.4 95.4 … …

500.0 95.4 96.8 … …

© The National Electrical Manufacturers Association

Table 12-12

Table 12-11

Table 12-12 (Continued)FULL-LOAD EFFICIENCIES FOR NEMA PREMIUM

™EFFICIENCY ELECTRIC

MOTORS RATED 600 VOLTS OR LESS (RANDOM WOUND)

Enclosed Motors

2 Pole 4 Pole 6 Pole

HP Nominal Efficiency Nominal Efficiency Nominal Efficiency

1 77.0 85.5 82.5

1.5 84.0 86.5 87.5

2 85.5 86.5 88.5

3 86.5 89.5 89.5

5 88.5 89.5 89.5

7.5 89.5 91.7 91.0

10 90.2 91.7 91.0

15 91.0 92.4 91.7

20 91.0 93.0 91.7

25 91.7 93.6 93.0

30 91.7 93.6 93.0

40 92.4 94.1 94.1

50 93.0 94.5 94.1

60 93.6 95.0 94.5

75 93.6 95.4 94.5

100 94.1 95.4 95.0

125 95.0 95.4 95.0

150 95.0 95.8 95.8

200 95.4 96.2 95.8

© The National Electrical Manufacturers Association

Subtype I Motors (1-200 hp) must be manufactured to these effi ciency levels beginning 12/19/2010.

Subtype II motors must be manufactured to these effi ciency levels beginning 12/19/2010.

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Impact on Pump Manufacturers (OEMs) Who Employ Motors in EquipmentElectric Motors (EISA)After December 19, 2010, covered motors cannot be manufactured alone or sold as a piece of new equipment below the prescribed levels of effi ciency. Many OEMs purchase motors from manufacturers and may only have a few specifi cs to consider. Some already offer motors in their equipment that meet the regulations and market them as high-effi ciency models in their product offerings. Some OEMs manufac-ture their own motors for equipment needs. No matter the circumstance, OEMs will most likely have to address the new regulations.

OEMs purchasing motors from manufacturers requiring increased effi ciencies to meet the regulation may have new design considerations to consider. Motors meeting higher effi ciencies tend to run faster than their less effi cient counterparts. Matching speeds to application need (pump fl ow, fan cfm) is important to consider. Drives may be required, which offer the opportunity to increase system effi ciency in applications with variable output requirements. In some cases, mounting dimen-sions for motor into machinery may be slightly different. If changes need to be made to meet the requirements, OEMs will have the opportunity to validate motors to fi nd the best fi t for their equipment needs based on performance and price.

OEMs manufacturing their own motors covered by EISA for their own equip-ment have more to consider. They must submit a Compliance Certifi cate (CC#) Application to the DOE to verify their motors are compliant. In this situation, the law views the OEM as the manufacturer and requires the same compliance as a motor manufacturer. Evidence must be presented, including test results from accredited labs or programs demonstrating motor designs meet requirements. The DOE will then issue a CC# that must be displayed on all covered motor nameplates. The OEM may choose to review motor suppliers selling covered products approved by DOE, or continue building motors. In either case, careful review is required by engineers and equipment designers. OEM purchasing departments are important in this process as motor suppliers need to be sourced and evaluated.

Impact on Pump UsersElectric Motors (EISA)Electric motors are the single largest electric technology deployed in terms of energy use, which is why the DOE creates Minimum Effi ciency Performance Standards

Motor reliability testing

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(MEPS) in regulations like EISA. Electric motors convert an estimated 40 to 60 percent of all electricity generated in the world into mechanical energy. Electric energy used by motors in industrial and commercial facilities can be 70 percent of the total used. Countries around the world are following the United States’ lead by creating MEPS programs.

The good news for end users at all levels is these regulations will result in reduced energy consumption if applied properly. End users have no direct com-pliance requirements with the DOE like motor manufacturers and OEMs. They do not need to concern themselves with equipment design issues related to motor changes nor do they need to submit compliance paperwork to the DOE.

The end users’ best approach to realizing savings is a Motor Management Plan. Organizations succeeding with active motor management programs have dedicated staff consisting of management, engineers, maintenance and purchasing profession-als focused on specifi c policies and goals. These organizations claim 5 to 8 percent reductions in their total electric energy use with increased process reliability as a result of their motor management programs.

Many resources are available to assist end users with realizing cost savings. At a minimum, end users should have a motor purchase specifi cation that includes buying NEMA Premium® motors and a motor repair specifi cation. With no regula-tion for effi ciency associated with motor repair, working with a motor service center that has a quality assurance program is critical.

Another resource for motor management information is the Motor Decisions Matter (MDM) campaign, administered by the Consortium for Energy Effi ciency, which includes motor manufacturers, utilities, the DOE and energy effi ciency advocates. Utility organizations across the country offer demand side management programs that include fi nancial incentives to upgrade motors and drives. A list of organizations with rebate programs can be found at the MDM.

Part Two of this article will address the Small Electric Motor laws being intro-duced later this year. The DOE estimates the Small Electric Motor laws will save 2.2 quads of cumulative energy during the 30 year period from 2015-2045.

P&SKitt Butler is the director of motors and drives and David Berkowitz is the director of OEM test services at Advanced Energy, 909 Capability Drive, Suite 2100, Raleigh, NC 27606, 919-857-9000, [email protected], [email protected], www.advancedenergy.org.

Dynamometer testing (effi ciency)

For info, go to: www.emersonct.com/smart

Our Pump Drive Solution takes a pre-programmed, intelligent Emerson variable frequency drive (VFD) and makes it even smarter with a LogicStick memory device. Preloaded with Pump-ing Solution software, the VFD is now a constant-pressure controller using diagnostic and detection informa-tion to protect the system, increase uptime and reduce maintenance costs. Because the drive runs the pump on an as-needed basis, the system can save up to 60% on energy costs.

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Traditional control techniques examine the “running” status and the “not ready” status of

the control circuit. While this method has served well for decades, it does have limitations. First, monitoring the contact of a starter does not detect if the wires have become discon-nected, or if the linkage between the pump and motor is intact. Likewise, the “not ready” status will indicate an electrical problem is present, but it will not identify the problem, or how it occurred.

Reasons to Obtain More DataTroubleshooting can be costly. In 1997, Kellogg Brown and Root stated that 85 percent of trouble-shooting time is spent on dead ends. Minimizing the time spent on dead ends minimizes troubleshooting time.

More information is needed to minimize the task. However, under traditional control schemes, each data point required a dedicated piece of equipment. For instance, if winding temperature was desired, a temperature switch, or sensor, would have to be purchased. Each piece of additional data added direct cost to the control system via the additional component, increased the labor times and impacted the panel size. The enclosure cost could be the single largest expense in a panel. Adding data points using traditional meth-ods was perceived as prohibitive on all but the largest motors.

Advances in semiconductor technology created new tech-niques to measure data points at a dramatically reduced price, often with a negligible impact on cost, labor or panel size. Furthermore, maintenance labor dramatically decreased.

The cost of maintenance depends on the industry. According to results released by the Meta Group in October 2000, if the pumping system is in energy, then the cost can be $3,000,000 for each hour. However, if the pump is in water and wastewater, then the cost is about $750,000 for each hour.

Emergence of Intelligent PumpingGrant Van Hemert, Schneider Electric

Smart pumping makes troubleshooting less challenging.

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What data will help reduce troubleshooting time? Figure 1 from Cooper Bussmann shows the causes of motor failures. This chart indicates that voltage conditions and overloads (which are related to torque) cause 44 percent of failures. The chart also shows that rotor failures, bearing failures, con-taminants and some miscellaneous failures can impact torque. Pump failures can also create shaft, bearing, contaminant

and other failures that impact torque. Torque changes will be refl ected in current or power draw. Monitoring power, current and if possible power can detect 81 to 90 percent of motor failures, and some pump failures.

Available Technologies for Enhancing DataVariable Frequency DrivesAC motors can have their speed changed if the frequency changes. Speed changes can modify pump capacity. A variable frequency drive (VFD) takes the stan-dard 60 hz signal and converts it to a desired frequency. Drives analyze per-formance and create a collection of parameters. Other parameters can be sent to the drive to modify the drive’s behavior. Electrical equipment suppli-ers design these drives to be used in a variety of industries. Some VFDs have as much as 858 parameters, but some of these parameters are not needed in pumping. Parameters for pumping include voltage, current, power, current at last fault, power at last fault, voltage at last fault and torque.

Motor StartersIf the system has constant speed motors, the solution is a motor management device. These devices perform data analysis and the function of an overload relay. They can be used where standard eutectic, bimetallic or solid state devices are used.

A motor management device will measure current and other factors. Like the VFD, these factors will then be converted to parameters that can be monitored. An expansion unit provides voltage measurement, and combines voltage with current to calculate power measurement.

Another method of constant speed control is to use a smart combined starter. These devices combine overcur-rent protection, starter contacts and overload in a single device. They gather data in a similar manner to a motor management device, but may vary in the parameters that can be monitored. Some of these devices can provide enhanced fault protection that can lead



to a limited number of restarts after an electrical fault without requiring a rebuild or replacement of the starter.

What To Do With the DataIn a traditional control method, two parameters (motor “run” status, and motor “not ready” status) were used per motor. In the new method, perhaps ten or more parameters are used. This is a mix of discrete and value-based (analog) parameters.

In a system with 100 motors using the traditional method, there would be 200 data points. The same system with the new method would have 1,000 data points (assuming 10 points per motor) or more. This fi ve-fold increase in data requires careful management to be useful.

Data management is where many intelligent-based pumping systems fall short of their full potential. There are three approaches to gathering pump data: local, remote and hybrid.

The local approach is applied in standalone pump systems. In this method, some means is provided to gather, monitor, trend and organize the data. The advantage is that the data is locally available to enhance mainte-nance. This includes not only instan-taneous data, but also historical data. Someone can see how the system per-formance has changed over time, and react accordingly.

To do this, a PC-based HMI can be placed into a panel. This terminal would run SCADA software. However, this might be cost prohibitive for small- to medium-sized systems. Another way is to use a web-enabled device. These gateways gather data from the drives and motor starters and present the informa-tion in webpage format. The webpages could include trend graphs, alarm tables and basic operational pages with instan-taneous readouts. Once these webpages are developed, they can be accessed with a standard browser. Browsers come stan-dard with new PCs. Using these brows-ers minimizes cost, and eliminates the compatibility issues that can be encoun-tered with some software as operating systems change over time.

Once the data is gathered into the

webpages, the system owner can decide whether to have the pump system isolated, or connected to the Internet. There is value to both approaches. However, that discussion is beyond the scope of this article.

The remote approach involves taking the data from the devices and transferring it to a central repository. The data is then typically managed via PC-based SCADA software. The

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benefi t is that the data from multiple systems can be displayed at a central site. This eliminates the need to travel to various pumping systems for per-formance data. This method has two drawbacks. The fi rst is that the data is not available for local diagnostics. The second is that the amount of data requires a high speed network such as Ethernet to function properly. If this is not already present, then the imple-mentation cost must be carefully considered.

The hybrid approach is a combina-tion of the two approaches described above. This provides data locally and remotely simultaneously. Within this approach, two sub-methods exist.

One sub-method is to have the web gateways locally, and only a bare minimum amount of data trans-mitted remotely. This method can take advantage of the slower serial networks that are still common, while providing the enhanced data

How Information Saves Maintenance CostsGiven: A motor has registered a “not ready” signal.

Case 1:Steps: A truck heads to the pump station, and a reset is engaged. This does not work. The motor circuit breaker is repeatedly re-engaged and trips immediately. This break-ing is too rapid for the instantaneous meter. A meter with Min and Max capability is used. The Max reading is well beyond the running limits. The pump is removed from the motor and the problem still exists. The starter is examined, and the wires to the motor are tested for conductance and insulation between phases. The results are normal. The wiring inside the pump is examined, and bad windings are found. Further testing also uncovers bad bearings.

Result: Ten hours of troubleshooting including reset and drive time. In a wastewater utility, this results in $7.5 million of maintenance time.

Case 2:Steps: A truck heads to the pump station and a browser is connected to the pump panels. A high voltage spike is recorded in the fault record. It is suspected that the insulation in the windings is bad. The motor is tested and shorted windings are found. While investigating the data, a small but continuous amp curve is noted. The bearings are repacked as a precaution.

Result: Troubleshooting takes three hours, at a cost of $2.25 million.



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collection locally. The drawback is that the remote location cannot see all the parameters, so a maintenance person dis-patched to handle an anomaly may not be fully prepared for the situation at the pump system.

The other sub-method is to have a high speed network installed, as well as local gateways. In this method, a mainte-nance person can have access to the latest data via a browser locally, but the same data is viewable remotely. This provides a seamless operational view, while minimizing software costs to only the main SCADA terminals. However, as stated before, the disadvantage is that a high speed network must exist to the remote SCADA system.

Once the method is determined, care must be taken to ensure that the data needed is gathered and analyzed properly. This, not the approach method, is where advanced informa-tion systems fall short. Pumping, especially in water and waste-water, is a bid-intensive fi eld. To remain competitive, many pump system suppliers must provide the minimum capability to meet their interpretation of the contract documents.

For example, if the specifi cation says, “Provisions will be made to display drive parameters in a local gateway, and remote SCADA,” a pump supplier may include the local gate-way and connection method to a remote station, but not pro-vide the programming or webpage development. The pump system supplier has met the specifi cation because the provision

has been made. However, if the designer wanted webpage development,

then this interpretation difference can cause debate during implementation. Make sure to specify exactly what data needs to be monitored and how. This will help ensure that the proper webpages are developed and delivered.

Traditional control technologies provided minimal infor-mation to be monitored, and more advanced data came with an added cost. Today’s technology offers added data at a neg-ligible cost. However, care must be taken to analyze how this data is gathered and displayed to obtain maximum impact while minimizing implementation cost. The result is a system whose maintenance can be signifi cantly minimized.

P&S

Grant Van Hemert, P.E., is a water wastewater appli-cations specialist for the Schneider Electric Water and Wastewater Competency Center. He has 15 years experi-ence in water and wastewater automation and another fi ve years in automation and control engineering. He is a reg-istered professional engineer in the state of North Carolina and is the chair for the American Water Works Association Instrumentation and Control Committee.

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Variable frequency drive technology is effi cient and accurate, which leads to increased energy savings. Advancements in capacitors and direct current (DC)

link reactors, IGBTs, heat management, processing power and measuring technology are all enabling the development of solutions to problems that were not even recognized ear-lier. Additionally, new and advanced algorithms affect energy effi ciency.

High Effi ciency Capacitors In the most advanced drives, the state-of-the-art capacitor uses a new type of plastic fi lm capacitor . This device stores energy from the rectifi er, and is part of a LC fi lter that reduces ripple on the DC bus and minimizes current surges. The advance-ments in capacitor technology are yielding net energy savings while limiting toxins.

Previous capacitor technology relied on electrolyte capaci-tors. Today, new capacitors use thin, metalized fi lm capacitors, which do not contain toxic electrolytes. Capacitors are non-toxic and do not leak electrolytes into landfi lls; they are fully Restriction of Hazardous Substances (RoHS) compliant. In addition, metalized fi lm capacitors are self healing—prevent-ing the occurrence of hot spots and extending the life of the product, while decreasing heat loss.

State-of-the-art capacitors do not require re-charging, even after years of sitting on the shelf.

Ultimately, these advances in technology allow the newest capacitors to offer 80 percent less power loss than older capaci-tor technology. As a result, there are less power losses, increased effi ciency and lower heat output within a drive package. Since heat is the greatest threat to the drive, these drives will have a longer life span.

DC ChokeIn the latest generation of adjustable frequency drives, the internal line reactor is replaced with a built-in DC link choke. In earlier drives the internal line reactor provided protection

for the AC diode and some amount of harmonic mitigation; the line reactor is most effective at the highest order of the harmonic spectrum.

The DC link choke performs a similar function as the AC line reactor; that is, it prevents harmonic distortion from get-ting back on the line and acts as a fi lter to smooth the ripple on a DC bus. While it reduces harmonics similarly to the AC line reactor, the DC link choke reduces harmonics across the entire harmonic spectrum. In turn, this allows users to meet the more rigid requirements of IEC 61800, which looks at individual harmonics, not just the total harmonics of the system.

The built-in DC link choke complies with the C2 cat-egory both for radiated and conducted emissions specifi ed in EN/IEC 61800-3.2 for commercial and industry environ-ments. In other words, all drive manufacturers will need to use a DC link choke to meet this emissions standard in the next generation of drives.

Further, the DC link choke has the added benefi t of a lower voltage drop than the equivalent AC line reactor, trans-lating into overall increased effi ciency for the drive. Specifi cally, the AC line reactor typically resulted in a 2 to 4 percent voltage drop, whereas the DC link choke has a voltage drop of less than 1 percent; this translates into overall increased effi ciency of the drive.

Heat ManagementIn HVAC applications, drives are typically used to improve or increase energy savings while providing system effi ciency. VFD manufacturers are now taking their own advice and using the same technology on the drive.

All drives generate heat, and use fans to cool themselves. Typically, cooling fans used to run at full speed whenever the drive was energized. Newer drive technology monitors the heat-sink temperature, and the fans provide only as much cool-ing as is necessary (0 to 100 percent), based on the ambient temperature and the drive load. This makes the fans inside the drives another variable speed application. Essentially, drives in HVAC applications are used to make fans more effi cient; now,

New Advances in VFDsSteven B. Weston and Michael W. Owens, Eaton Corporation

New, sophisticated technologies are impacting effi ciency and yielding more effective and more fi nely-tuned VFDs.



drive manufacturers are making the inter-nal fans in the drives more effi cient.

Closely matching cooling require-ments to fans speed can net a 20 to 60 percent reduction of energy used to con-trol these fans. Less losses means increased energy savings for the drive users.

Less Power Loss from Semiconductors New generation power semiconduc-tors—insulated gate bipolar transistors (IGBTs)—are able to operate at higher switching frequencies, resulting in less power losses and reduced heat within the drive. As this is a core component of the drive technology, it has a huge impact on overall drive effi ciency.

Advanced Power Management Control (Sleep Functionality)In run mode, a drive consumes a tremendous amount of energy even if a zero speed reference is given. This is due to the

fact that most systems require a minimum speed (12 Hz for example) to keep the TEFC motor cooled.

Some drive manufacturers now offer an enhanced sleep function, which allows the drive to shut down (remove run

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command) when it is not needed. This is typically used in a fan or pump application with the drive’s internal PID loop con-trolling speed. A PID loop uses a set point and feedback from the system to determine the correct speed. When the feedback from a remote sensor indicates a low or zero speed is required, the drive is able to turn itself off, or remove the run command, but return to run mode when the system indicates a higher speed is required. This same function can be performed using a costly PLC with extensive programming.

Drives can now be better tuned to actual energy needs, tapering system requirements during off hours, weekends and holidays—allowing customers to see signifi cant cost savings in their energy bill.

Advanced Algorithms Deliver The product of intensive research, advanced algorithms pro-vide energy savings and stability over traditional variable fre-quency control methods. In response to load conditions, the algorithms dynamically adjust the operating point of the drive and motor system to reduce motor losses and save energy, thus reducing the users’ utility bill. By reducing losses in the motor, the algorithms are designed to make the motor as well as the entire system (motor, drive and load) more effi cient. Further, advanced algorithms facilitate protective system monitoring

and response, and as a result, are able to better able to help the drive operate in optimal boundaries, providing added stability.

For example, comparing one new algorithm to older tech-nology, a 50 hp motor setup could see additional savings of $10,000 to $28,000 through the lifetime of the drive in lightly loaded conditions, typical of pumping and HVAC applica-tions (see Figure 1). These advanced effi ciency algorithms allow users to save an additional .5 to 10 percent over the sav-ings they realize now, by applying the drive to a variable torque load.

ConclusionDrive technology has come a long way. By adding up the new technological advances built into a drive, users can save more than before. The last 10 years have created advances that allow drives to be more intelligent; they now control more than a motor—they control themselves.

P&S

Steve B. Weston is the aftermarket services manager for drives at Eaton Corporation. Michael W. Owens is the HVAC manager at Eaton Corporation.

seepex has taken a major step in the right direction. In using “Smart Stator Technology” we have introduced a fundamental improvement in PC Pump technology by dividing the stator into two parts. As a result mainte-nance time is reduced to an unprecedented minimum.

Ask our experts for an offer that will also convince you about the benefits of “Smart Stator Technology“.

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While it is valid to state that energy effi ciency is defi ned as the same level of production achieved at an overall lower energy cost, it is equally impor-

tant for today’s machine builders and automation engineers to remember an energy effi cient system can actually translate into higher productivity. This is achievable through a comprehen-sive approach to energy management.

Energy management is a process, rather than a product or series of products installed on a machine or inline to achieve a basic energy saving of kW hour consumption. This process must be ongoing and perpetual, meaning that any defi ned goal should be viewed as a momentary metric of achievement, rather than a fi nal end. While any manufacturer can supply the right products and support services to hit a target mark of energy savings, the user’s mindset is essential in keeping the process recurrent. This ensures a continual increase in the productiv-ity levels achieved, defi ned as a factor of the energy consumed. In many ways, it can be viewed in the same manner as an ongoing, effec-tive, but constantly evolving quality management system for a company.

Elements to Consider for an Energy Effi cient ProcessEnergy monitoring systems must be in place to effectively determine current consumption. These can include, but are certainly not limited to, energy consumption displays, infeed/supply monitoring devices, power factor meters and more. Next, the proper calculation tools are needed to properly evalu-ate the life cycle costs of any investment. These tools can be as

simple as a motor sizing chart or software programs used to parameterize drives.

Alternatively, a more formal mechatronics protocol may be benefi cial to an operation. In this scenario, a thorough evalua-tion of both mechanical and electrical/electronic infl uences on the system, whether a machine or a process line, is conducted. The results can often open the eyes of machine designers, pro-cess engineers and system integrators. To realize the benefi ts of this analysis, the proper products and system solutions must be implemented.

At this point, a competent supplier can be an effective partner for an operation. For example, a solution might involve

a vector drive that uses an energy optimization function to enhance motor effi ciency during partial load operations. In a system with multiple motors, energy savings might be real-ized to a substantial degree by the use of a drive unit with a common DC bus. The designer can also select the most appropriate infeed solution for

the machine, pump or process operation, given the particu-lars of performance and required output. This may include an appropriately sized infeed unit with regenerative capability and the ability to put unused or braking energy back on the incom-ing power line.

Some applications may allow the use of high effi ciency standard induction motors and, in the process, realize a poten-tial savings of 1 to 3 percent. The use of frequency converters (VFD) for speed control might raise this to an 8 to 10 percent savings.

Optimizing an entire system through mechatronic analysis of the machine or process design can result in a potential savings

Energy Management Considerations with Today’s Drive SystemsMichael Perlman, Siemens Industry Inc.

Multiple drive factors contribute to system energy effi ciency.

Energy Management Considerations with Today’s Drive Systems:

Energy Monitoring• Equipment Selection and Optimization • (Mechatronics/Parameterization)Hardware: Common DC Bus/Infeed/• Regeneration


of 15 to 20 percent by avoiding over dimensioning of motors, plus partial load optimization by means of energy-related fl ow control. This analysis may also point to the use of controlled energy infeed and recovery.

To determine the true effi ciency of any drive system, it is necessary to demonstrate the amount of energy required by its power components and a corresponding examination of how the system uses energy. The different drive concepts used on the same system under identical power load must also be considered. This latter exercise might look into partial load effi ciencies with various motor and drive combinations, straight comparisons betweens synchro-nous servo versus asynchronous induc-tion motors or direct drive versus motor/gearbox combinations, drives with brak-ing components versus regenerative drive technology, as well as solutions with single versus multi-drive, common DC bus solutions.

A corollary to this discussion should also include a review of poten-tial hydraulic/pneumatic component change outs in certain applications where replacement with an integrated package of motion control and PLC technology might better resolve closed loop pres-sure control of axes, for example. Fewer components and their related power consumption can lead to overall system productivity improvements, as well as ongoing enhanced energy effi ciencies. Reduced programming, diagnostic and commissioning times can also follow from such an approach, providing even more opportunities for overall machine or process improvements. Tracking the energy effi ciency of such a system may seem problematic at fi rst, but today’s sophisticated mechatronic and virtual production protocols can be used to val-idate the real-world performance charac-teristics of such designs, far in advance of their implementation.

As the emergence of new technolo-gies has impacted many of the products used in energy effi cient systems, it is equally important to take a more holis-tic look at operational sequences and the overall integration scheme when designing, retrofi tting or rebuilding for improved energy use.

P&S

Michael Perlman is the marketing pro-grams manager for the Motion Control business of Siemens Industry, Inc., 5300 Triangle Parkway, Norcross, GA 30092, [email protected], www.usa.siemens.com/motioncontrol.

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This year, the theme for the Electric Apparatus Service Association

(EASA)’s annual conference is “Meeting the Challenge Together.” Held at the Gaylord Palms Resort & Convention Center in Orlando, Fla., the conference promises to deliver on that theme with extensive educational sessions and an exhibit hall featuring more than 158 exhibiting companies (including 23 fi rst-time exhibitors) in motors, drives and related electrical and mechanical equipment.

Gene Vogel, EASA’s pump and vibration specialist, will present several educational sessions at this year’s con-ference, including: “Understanding Pump Curves for Troubleshooting Pump Performance,” “Repair Tips for Submersible Pumps,” “Field Service Vibration Analysis” and “Vibration Testing in the Service Center.” Other topics include “Pricing for Profi t in the New Economy,” “Diagnosing Motor Vibration Following Start-Up,” “Synchronous Machine Repair Tips,” “Recent Problems Experienced with Medium-Voltage Windings,” “Root Cause Failure Analysis: Stator Windings” and “AC Motor Assembly and Testing.”

Photo credit: Carl Fields, EASAP&S

EASA Convention 2010Exhibit Hours

Sunday, June 271 p.m. - 4:30 p.m.

Monday, June 2812 p.m. - 4 p.m.

Tuesday, June 299 a.m. - 12 p.m.

All events held at Gaylord Palms Resort & Convention Center in Orlando, Fla.


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Valves & Piping Special Section

Corrosive, aggressive soil had eaten through a 35 year old ductile iron pipeline in the Port of Tampa area,

causing a multitude of leaks that could not be repaired. Replacing the rotten pipe with more iron would have been costly and short-sighted. The radical environment required polyvinyl chloride (PVC) piping.

For Tampa water department engineers, an internal joint restraint that eliminated the need for external fi xtures on PVC pipe fi ttings was a promising solution for the problem. Careful research and deliberations led staff to a unanimous decision to use the progressive technology.

Engineers believe the conditions that so easily destroyed the iron water main expected to last 100 years may be typical of many American ports. In Tampa, contamination came from soil dredged from the bay, which likely contained residual chlorides—a deadly enemy of ductile iron pipe. It is also possible that the groundwater in the area suffers from salt-water intrusion. More than 13 unstop-pable leaks were found in a 200 ft section of the old iron water main.

The Tampa Water Department approved the purchase of 960 feet of PVC piping with an internal joint restraint system, which was used in a project that began in November 2009 and concluded in January 2010.

Contractor ApprovalInstallation of the PVC piping was the responsibility of

Dallas 1 Construction & Development. The contractor specializes in underground utilities, including storm drains, sanitary systems and roadwork. With 28 years of experience working with pipe ranging in size from 2 to 84 in, the con-tractor was familiar with local city and county needs. Steve Mitchell, production pipe foreman, says the port project was the fi rst time they had encountered an innovative internal

Internal Joint Restraint for Municipal ApplicationsDouglas Glenn Clark

Rotting ductile pipe at the Port of Tampa was replaced with PVC piping, which reduced costs and municipal concerns.


joint restraint system.“Once I read the instructions, away we went,” Mitchell

said. “After installing a few we thought, this is great, much easier than ductile iron. I like the lock system because you do not have to physically install a locking system or put a restraint on the pipe itself. This system saves time because the lock is already installed. I have been doing this for 35 years, and I think it would work well in any number of situations.”

According to Mitchell, the timesaving aspect of the inter-nal restraint joint was particularly helpful because digging in the port area was diffi cult. The combination of toxic soil and rotted ductile slowed the process considerably. The Dallas 1 Construction crew could lay more pipe per day than would have been expected with ductile or other products that require old-fashioned restraints.

“One particular day we laid 640 ft of pipe. If I used restraint joints, we probably would have gotten only 450 to 500 ft installed because it takes about 30 minutes per restraint. Not only do you put them on, you have to get into the hole and put the bolts through. On the 12 in pipe, which is what we were installing, usually you need two bolts per side of the joint, and then you have to snug them up.”

Saving time was not the only virtue of using PVC. The lightweight, indestructible piping meant Mitchell’s crew did not have to expend as much physical energy to complete the

job. Therefore, they were more productive each day.“It saves energy and physical abuse to the body. We do a

lot of deep, nasty big pipe, so we are used to a lot of loading and locking up of pipe. Using this product is different. There are virtually no man-hours needed for the restraints. Personally, I think the system is fantastic, and every one of the guys who worked the project said they liked it too.”

At Valve Concepts, Inc., we realize that quality can’t be inspected into a product. Instead, it starts in the factory, where we employ an ISO 9001:2000 Quality Assurance Program to ensure compliance to international standards.

Our commitment to engineering excellence also extends to our own state-of-the art, full-scale test facility, where we collect and analyze flow performance data. We’re comparing the results against our own standards — which are often higher than those stated in API requirements. It’s just one more way that “We simply make it right.”

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Cities See Future in PVC Before the port project, the largest PVC installed by the Tampa Water Department was 8 in diameter. Why was it slow to adapt to other PVC products?

According to local industry expert Roy Thames, president and CEO of Thames and Associates, Tampa is “similar to many municipalities, where engineers embrace new standards and products only after the technology has been thoroughly tested and proven. In this case, ductile iron had been the reigning standard material for many years.” Engineers were ready to rethink their approach after digging up the rotting ductile iron.

Mitchell concurred. “It is not that Tampa offi cials do not like PVC. Like many municipalities, the city is picky about trying new products. The corrosive soil gave them no choice. This port island was pumped in 50 years ago. They did not have a lot of regulations, so everything you can imagine probably got put in there. Every iron pipe we have dug up has been totally eaten.”

Soil corrosion was not the only problem engineers needed

PVC products to overcome. Another sensitive issue for Tampa offi cials was the many live loads that the water pipe would endure on a daily basis.

The intersection of Gatx Drive and Guy N Verger Boulevard, where PVC pipe was installed, leads to one of many docks in the Tampa Port Authority district. Large trailer

Diagram of internal joint restraint technology for PVC piping.


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trucks traverse the area at all hours of the day. Understandably, city engineers initially expressed concern about PVC’s abil-ity to handle the pressure and weight. Conclusive evidence of PVC’s suitability for the project came from an Army Corps of Engineers study.

“There is not a person who puts pipe in the ground who would not like this product,” says Mitchell. “As long as you

follow the manufacturer’s guidelines, you will not have any problems.”

The internal joint restraint also solved another dilemma that allowed Tampa to avoid a costly renovation. The port water main crosses underneath railroad tracks in three locations. Replacement pipes, plastic or iron, would need to fi t through existing protective underground sleeves. Engineers knew that

external restraints would typically make the replacement pipe too big to fi t. Since using ductile iron was not an option, and expanding the underground sleeves would cost time and labor, Tampa per-sonnel were in a bind until the internal joint restraint system.

PVC Benefi ts in Any EconomyInternal joint restraint technology is fi tted into the bell portion of PVC pipe when it is manufactured. During on-site installation, each set of connected pipe immediately locks as the joints are put together. To promote corrosion resistance, the internal joint restraint is encased within the PVC pipe, so it is never exposed to soil and fl owing fl uids.

Installation of iron typically cre-ates complications—and man-hour demands—not associated with the use of plastic pipe. For example, Mitchell calculated that the use of plastic pipe with internal joint restraint on the Port of Tampa job saved him a few days of labor.

Other costs include making a sepa-rate run to pick up restraint and joint fi xtures for ductile pipe. The product is stored in the open air for long dura-tions, perhaps rusting while it waits to be installed. Compare that scenario, says Mitchell, to internal joint restraint tech-nology. When the PVC is delivered, it is ready to go.

Great savings, convenience and durability await municipal offi cers who realize it is time to embrace new con-cepts and technologies.

P&S

Douglas Glenn Clark is a writer based in the Los Angeles area.JM Eagle, 5200 W Century Blvd., Los Angeles, CA 90045, 310-693-8200, www.jmeagle.com.

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With continuously increasing energy costs, pump manu-facturers must provide energy

effi cient solutions for fl uid transfer. Besides hydraulically optimizing current technology, manufacturers are launching a number of new, highly effi cient electri-cal drives and powerful control systems.

With the focus on optimizing cur-rent and new technology, the savings that can be generated with dimensioning a pipeline and specifying the right duty point for a pump in the planning phase are often underestimated.

Pump Power Requirements A sample calculation will help illustrate the savings potential. A pump’s duty point is usually defi ned by the required fl ow and the related pressure. The latter is often indicated as head. For turbulent fl ows of Newtonian fl uids, the correlation between pressure loss and head follows a quadratic relationship. Formula 1 applies to a closed pipe system with a static pressure of zero:

H ~ Q2

H = HeadQ = Flow

Formula 1. Dependency of head and fl ow in closed pipe systems

The power requirement of a centrifugal pump is defi ned in Formula 2.

P1 = Q • H • p • gηgesP1 = Power input

p = Density of the mediumg = Gravitational accelerationηges = Total effi ciency of the unit

Formula 2. Power requirement of a centrifugal pump

Formula 2 implies a fl ow increase increases the power requirement by a factor of three. In other words, over-sizing the fl ow by 5 percent results in an increase of the energy demand by more than 15 percent (at constant effi ciency). An increased fl ow of 10 percent raises the energy consumption to 30 percent.

Conversely, the infl uence of fl ow on the completion of the fl ow task depends in a high degree on the application. A heating system, for example, will reach more than 80 percent of its heating power

if only half of the fl ow is provided. In contrast, an undersized pump in the sewage or process technology can cause fatal consequences.

Planning ToolsPump manufacturers must support users in the planning phase to guarantee effective pump use. Support can be provided via consultation during the selection process. Various pump manu-facturers also offer planning tools in the form of software, par-ticularly web-based applications. While complex pipe systems require extensive calculations, applications for unbranched pipes are also available. Numerous pump manufacturers are offering free access to calculation software in combination with a pump selection program.

Web-based software in particular offers a centralized updating process directly on the server and avoids the need for installations on local PCs. In web-based software, the required fl ow rate has to be determined to size the pipeline and calculate the pressure loss in the second step.

Flow Rate DeterminationEach centrifugal pump application has a different calcula-tion for required fl ow rate. For heating pumps, for example,

Energy Savings with the Correct Duty PointJens-Uwe Vogel, VSX-Vogel Software GmbH

Pipe calculation software helps users correctly determine a pump’s required duty point.

Figure 1. Increase of power requirement follows increase of fl ow in closed systems.


the required fl ow results from the heat requirement calculation, but the fl ow rate in industrial applica-tions depends on the particular transport task and the process parameters. In many applications, inter-national engineering standards are available (which are typically integrated in pipe calculation software programs).

Domestic Wastewater According to EN 12056, the fl ow rate for domes-tic wastewater resulting from drainage can be cal-culated by adding the run-off coeffi cients of several sanitary fi ttings, depending on the building type (see Formula 3).

Qww = K • √∑DUQww = Wastewater drainageK = Drainage fi gure according to type of buildingDU = Outfl ow value of sanitary fi ttings

Formula 3. Calculation of wastewater drainage according to EN 12056

Pipe calculation software programs integrate this formula and the necessary coeffi cients (see Figure 2).

Alternatively, the fl ow rate can be determined by the

number of inhabitants of a settlement area and the specifi c peak fl ow.

Storm WaterFor planning and implementation of drainage systems, an updated version of DIN 1986-100, which has to be applied with EN 12056, was released in May 2008. The objective is to size the drainage system so that it offers suffi cient protection against fl ooding. The rain water outfl ow for a storm water area is calculated depending on the calculated storm water run-off,

Figure 2. Calculation of fl ow rate for domestic drainage water according to DIN EN 12056

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which is determined statistically (see Formula 4).

Q = r(D,T) • C • Ar(D,T) = Calculation storm water run-offC = Flow coeffi cientA = Effective storm water area

Formula 4. Determination of the rain water outfl ow according to EN 12056/DIN 1986

Pipe calculation software should contain the statistical values for the calculation as well as for the emergency drainage. Optionally, plot or roof areas for areas below the level of backed-up water can be calculated according to DIN 1986, 14.7.

Drinking WaterTo determine the fl ow rate for drinking water plants, DIN 1988 specifi es water sampling points and building types (see Figure 3).

Friction Loss CalculationIf the required fl ow rate is known, a pipeline can be sized, and the friction loss can be calculated. In many software programs, the system can be divided in several sections and multiple pumps operating in parallel can be considered.

For the friction loss in a straight pipe, Formula 5 applies.

pv = U • L4A

• p • v2

Di

• λ

pv = Friction lossA = Passed cross section areaU = Circumference related to AL = Pipe lengthp = Density of fl uidv = Average fl ow velocityλ = Friction factorDi = Inner diameter of the pipeline

Formula 5. Friction loss in straight pipes

The friction loss in straight pipes depends on the pipe friction coeffi cient, the cross section, the pipe length and the middle fl ow velocity. Subject to the Reynolds fi gure, the pipe

friction coeffi cient λ follows different principles depending on whether it is a laminar or turbulent fl ow. The pressure loss of valves and fi ttings is determined via the loss coeffi cient.

Many pipe calculation programs offer commonly used for-mulas like those from Colebrook and Darcy-Weisbach or the empiric method of Hazen-Williams.

Total HeadThe Bernoulli equation describes the equality of geodetic, static and dynamic energy. The total head consists of pressure losses and static head. The latter results from the geodetic height dif-ference between suction and discharge fl uid level and the static pressure difference. In closed cycles, the static part is zero.

Hges = pa - pe

p • g + (za - ze) + Hv(Q) + va

2 • ve2

2gpa - pe = Pressure difference between suction and discharge tankza - ze = Hgeo = geodetic heightHv(Q) = Pressure loss in dependancy of fl ow rateva, ve = Pipe length

Formula 6. Head of the plant

The term

va2 • ve

2

2g in Formula 6 can be disregarded if the basic cross section on suction-side and discharge-side is suf-fi cient, so the fl ow velocity is small. Furthermore, the pressure difference is not applicable in open tanks, which simplifi es the equation to Formula 7.

Hges = Hgeo + Hv(Q)Formula 7. Head of the plant with open tanks with a huge cross

section

Duty point calculations can be applied directly to pump selection. This is especially interesting for parallel pump opera-tion when different operating modes have to be analyzed.

Jens-Uwe Vogel is the managing director of VSX-Vogel Software GmbH, Hofmühlenstr. 4, Dresden, Germany 01187, [email protected], www.vsx.net.

Figure 3. Flow rate determination for the drink-ing water supply according to DIN 1988 Figure 4. Schematic demonstration of an unbranched pipe system


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Process control valves are commonly called “fi nal control elements” because they are the last link in loops control-ling fl uid pressures and fl ows through automated process

systems. As such, the performance of control valves is critical to the effi ciency and reliability of the process itself. The valve positioner directly infl uences control valve functionality.

A valve positioner positions the valve in response to input signals from the process control system (or programmable logic controller). Most systems currently use either analog 4-20 mA or digital bus-based communications to digital valve controllers, which are highly advanced digi-tal positioners with signifi cant capabilities beyond just positioning the valve.

Whether the signal is analog or digital, the controller converts that input to a pneumatic signal (I/P). This provides the force (air pressure) to move the valve to a new position and keep it there. If the air supply coming into the valve con-troller is dirty, the performance of the controller can be affected, resulting in poor valve operation.

Vibration is another major cause of valve and positioner related issues. High vibration applica-tions can cause damage to the valve controller feedback linkages, resulting in process instability.

Overcoming Dirty AirIt might seem that micron-sized particles in plant air supplies would not affect valve operation, but they do. Dirty air is prob-ably the number one contributor to control valve loop trip-ping and unplanned shutdowns. The incoming air must pass through small orifi ces in the I/P, a part of the unit that converts the input signal to the pressure needed to move a valve. Tiny

airborne particles can combine with moisture or oils droplets and build up inside an orifi ce, causing variations in the pneu-matic signal that can result in unreliable valve operation.

Since the quality of plant air varies signifi cantly, it is neces-sary to design the instrumentation to minimize the effects of dirty air at the control valve assembly. An additional tool is the diagnostics in HART® and fi eldbus communicating digital valve controllers to obtain advance information about the con-dition of valve (see below).

One design to mitigate effects of dirty air uses orifi ces made of sapphire, which is actually grown around a pin to the required size, instead of machined steel orifi ces (Figure 1). This material is perfectly smooth and essentially frictionless, so no machining is necessary. Standard steel machined orifi ces have small tooling grooving present to which the particulate can adhere. The walls at the air entry point offer another potential site for dirt buildup. That area was designed to create a much larger space for incoming air, signifi cantly reduc-ing the possibility of moisture-laden dirt collect-ing on the walls and altering the air fl ow.

More than a quarter million instruments are in use today with sapphire orifi ces with few reported failures worldwide due to dirt buildup in

the instrument since 2007.Better air fi ltration is another solution that should be

implemented where dirty plant air is a known problem. The ISA Standard 7.0.01 defi nes specifi cally how air should be fi ltered and dried. Unfortunately, most plants cannot meet these specifi cations consistently. Because digital valve control-lers provide much tighter control than standard positioners,

Improve Control Valve Performance for Greater Process ReliabilityKen Hall, Emerson Process Management, Fisher Division

Tips to ensure optimal control valve performance.

Figure 1


and reduced bleed is a major trend in the industry, orifi ces in the instruments in general have decreased in size. As a result, many DVC manufacturers are suggesting the use of fi lters with a greater fi ltration capability. It is common to see digital valve controllers installed with fi lters in the 2 to 5 micron range that also have the coalescing ability of removing moisture.

Counteracting VibrationHigh vibration caused by equipment operating near the control valve assem-bly can also be a problem, causing wear and damage to the linkage that provides feedback on the valve position. The control instrument needs to correctly sense the actual valve position to con-trol it accurately based on input sig-nals received from the process control system.

One solution making these link-ages less susceptible to vibration is a tough coating applied to the linkage. When cured, the surface can be hard and friction-free. Vibration will then minimally affect the linkage, reducing the risk of a process disturbance.

An even better solution is to remove that linkage altogether, replacing the mechanical connection with a linkage-less non-contact magnetic type of feed-back element. Wear is eliminated while valve position accuracy is retained. A substantial number of DVCs (Figure 2) are currently operating in the fi eld using this technology.

Predicting Valve IssuesIn addition to their primary position-ing function, digital valve controllers monitor and store a great deal of infor-mation about the control valve assem-blies on which they are mounted. This diagnostic information can be accessed in various ways, providing predictive intelligence that helps plant personnel determine what service may be needed and when it should be done to prevent unexpected malfunctions and possible unplanned downtime.

Diagnostic information can be retrieved from valve controllers in the fi eld by connecting to an instru-ment (point-to-point) and extracting the available data, depending on the type of controller. HART and fi eldbus

instruments yield a large amount of useful information, such as supply pressure diagnostics, which can indicate a problem with plant air.

In one plant, control valve setpoints could not be main-tained at certain times of day, and no one could fi gure out the cause. Finally, by observing daily dips in supply pressure to a HART instrument, technicians realized that other maintenance

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workers were tapping into plant air each afternoon at clean-up time, dragging down air pressures and reducing the ability of the valve to control the process.

DVCs provide an even larger volume of valuable information, frequently requiring less effort by technicians to access it. When the fi eld devices are integrated with a centrally located system, the fi eld-generated information can be gathered from the safety and comfort of the instrument shop or control room. The most advanced DVCs can be interrogated for valve performance diagnostics while the valve is in operation.

System AlertsHow often does a valve problem occur when someone is actu-ally checking out that device? Rarely, but valve controllers can be used to trigger a diagnostic, record the unusual event as it is taking place and provide a system alert. The result is an early warning of a developing problem, and the recorded profi le of the event can be useful in determining what happened and whether maintenance is warranted.

While dozens of alerts can play a role in the detection of problems, two high-value early indicators of potentially catastrophic problems are supply air pressure and valve travel deviation alerts. Maintaining suffi cient supply air pressure is critical for moving the valve assembly to all positions and in some cases maintaining the required seat load on the valve. However, inadequate supply air pressure can occur and go undetected until the valve is called on to change positions.

For example, if a valve typically throttles in the range of 30 to 50 percent open and damage has occurred to the air supply fi ttings, the issue may go undetected until the valve receives a set point of 60 percent, and there is not enough pressure to make it to the requested set point. A simple supply pressure alert provides early indication and enables corrective action before a process disturbance or travel deviation occurs.

A typical supply pressure alert point is 3 psi above the upper bench set for spring and diaphragm valves or 5 psi below nominal instrument supply for piston actuators. Whether due to inadequate supply pressure or other reasons, a travel devia-tion indicates the valve is not moving to its intended position. A valve travel deviation of 5 percent lasting more than three seconds is a typical alert point for a standard 2 to 6 in valve size that will provide the desired indication without having nuisance alerts. In addition to the alert itself, a travel devia-tion alert can trigger and save a diagnostic profi le of the valve during the event that can be used during troubleshooting.

Control valves are a critical part of the process loop and their performance and reliability often directly impact plant profi tability. Early indications of valve problems may enable plant personnel to recognize the existence of problems, so actions can be taken to prevent costly unscheduled stoppages.

This is the essence of predictive maintenance.Results include improved production reliability with

fewer unexpected shutdowns and lower maintenance costs, since proactive maintenance is far less expensive than reacting to equipment malfunctions. A good place to start is ensuring that dirty plant air and equipment vibration do not impede the functioning of critical control valves.

P&S

Ken Hall is with Emerson Process Management, Fisher Division, 641-754-3886, [email protected].

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With today’s energy prices and the need to reduce emissions, a plant cannot allow its steam/condensate

systems to vent fl ash steam to the atmosphere. The modulating steam system’s operational design requires that a gravity (0 psig) conden-sate system recover the condensate. A typical system will incorporate a condensate receiver, allowing the fl ash steam to vent to the atmo-sphere. The venting of the fl ash steam ensures the condensate receiver is never pressurized. To prevent the fl ash steam loss to the atmosphere, plants install devices such as fl ash steam vent condensers in the fl ash steam vent line.

Depending on the installation costs, plants will typically recover the cost of a fl ash steam vent condenser within 10 operational months. The cost-sav-ing benefi ts of a fl ash steam vent condenser include allowing a plant to recover the fl ash steam energy and use that energy to heat a fl uid for a process. It also reduces emissions since the boilers will have to produce less steam if the fl ash steam energy is recovered.

Flash Steam Recovery Systems (Modulating Steam Conditions)If the condensate/fl ash steam (two-phase fl ow) is discharged from a modulating steam/condensate process, the process application has a steam control valve modulating the steam to the process, and the control valve can operate from zero (closed) to 100 percent (full open) and anywhere in between (see Figure 1). The steam pressure after the steam control and before the process heat exchanger can vary (P2 reading) depending on the process conditions. The pressure at P2 can range from full line pressure that is delivered to the steam control valve (P1) all the way down to zero pressure.

In this case, the fl ash steam cannot be recovered in a pressurized fl ash tank or high-pressure condensate return system. Instead, the condensate fl ow from the process has to

Flash Steam Recovery Using Condensate Tank Vent CondensersKelly Paffel, Swagelok Energy Advisors, Inc.

First of Two Parts

P3

HEAT EXCHANGER

TEMPERATURETRANSMITTER

P2 P1

P4

P5

Figure 1. Steam control valve

FLASH STEAM

CONDENSATE

PUMPED CONDENSATE

VFD CONDENSATE CONTROL

Figure 2. Typical condensate receiver tank


be discharged into a condensate line pressure (P5) at 0 psig and delivered to a vented conden-sate receiver tank operating at or close to zero pressure.

Figure 2 depicts the typi-cal condensate receiver tank arrangement, where the fl ash steam is allowed to vent to the atmosphere. The energy loss and emission factors today do permit this loss in the system.

A fl ash steam vent con-denser is incorporated in the system to recover the fl ash steam by using an external heat exchanger (condenser) as seen in Figure 3. The vent condenser (heat exchanger) will consume the fl ash steam by heating air, water or some other process fl uids. The vent condenser is designed for the application to ensure proper operation. A stan-dard shell and tube heat exchanger functions in this application.

The process fl uid consumes the fl ash steam and allows the condensate to drain back into the condensate tank. Therefore, the fl ash steam is consumed and the condensate is recovered. In the case of a modulating steam process condition, the process steam system should use the lowest steam pressure, therefore producing the least amount of fl ash steam.

Kelly Paffel is technical manager for Swagelok Energy Advisors, Inc, Solon, Ohio, 239-289-3667, 888-615-3559, [email protected], www.swagelokenergy.com.

(continued on page 90)

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Air operated double diaphragm (AODD) pump tech-nology was invented and introduced to the market 55 years ago. That day in 1955 when the fi rst AODD

pump began operating remains a watershed moment in industrial pump history. AODD technology grew from humble beginnings, mainly as a way to pump wastewater in mining applications.

AODD pumps are reciprocating, positive displace-ment pumps. The wetted path (the area in which the pump-ing media is contained) consists of an inlet and discharge manifold and two liquid chambers. An air valve in the Air Distribution System (ADS) alternately directs compressed air behind the diaphragms in the air chambers. Fluid is drawn into one liquid chamber from the inlet manifold as fl uid is expelled from the other liquid chamber through the discharge manifold.

AODD pumps have many strengths. They do not require electricity, are self-priming, can pump fl uids with solids in suspension (rocks and debris), can run dry or be “dead headed” without damaging the pump. In addition, their performance can be tailored to specifi c needs by adjust-ing the inlet air pressure or restricting the discharge of the pump. AODD pumps were designed to operate in rugged applications. They were used in applications where most other pumps would fail and were designed to be an inexpen-sive, easy to maintain option for a variety of situations. They can transfer a wide range of media from wastewater to more viscous substances like slurries or even cement.

A decade of research and design innovations have led to refi nements and improvements to the air valve and wetted path. The pumps that have emerged are tough and versatile enough to meet the stringent demands of the mining and

heavy construction industries and the precise and sanitary requirements of the pharmaceutical and food processing industries.

The ChallengeThrough the years, energy costs have increased substantially. As energy costs have increased, manufacturers have become more concerned about reducing operating costs and have focused on improving the effi ciency of plant equipment.

Since their inception, one signifi cant challenge in designing and producing an effective AODD pump has been providing the end user with a good fl uid fl ow rate while at the same time minimizing air consumption (reducing energy costs).

Improving Effi ciency in Air Distribution Systems (ADS)Curtis Dietzsch

Advancements in ADS have drastically improved the overall effi ciencies of air operated double diaphragm (AODD) pumps, resulting in greater reliability and energy cost savings.

Effi ciency Matters


All AODD pumps have an ADS in their design. Part of the ADS’s job is to direct compressed air to one air chamber while exhausting air from the other air chamber. The air valve performs this task. This air valve can take many forms, but in many cases is a “spool” that slides back and forth in a cylindrical bore in the pump housing. It uncovers and blocks ports so that compressed air is supplied to the appropriate chamber and exhausted from the other. These original spools had a single diameter and air pressure was supplied to both sides of the spool. The pressure would momentarily be removed from one end of the spool to make it “shift.” The shift redirected the compressed air to the other chamber.

While this single-diameter spool in early AODD pump designs was innovative and effective, its shape meant that the ADS had a higher chance of stalling if the momentary signal did not completely shift the spool. This would lead to loss of production, ineffi cient operation and increased pump downtime.

The SolutionA number of improvements have been made to the AODD pump’s ADS to improve performance, reliability and effi ciency.

One improvement was the introduction of a new “unbalanced” air valve spool. This new design did not rely on a momentary signal to shift the spool. Rather, it relied on an unbalanced signal to control the shifting of the pump. The new spool

Cross-section of an air distribution system (ADS) that incorporates an unbalanced spool to prevent the pump from dead-heading.

AODD pumps with an Effi ciency Management System (EMS) into the ADS. The EMS allows the end user to adjust the size of the air inlet ports.

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Effi ciency Matters

had two different diameters. The smaller of the two ends was constantly supplied with air pressure. This air pressure would force the air valve in one direction. Alternately, the larger end of the spool would be pressurized. The larger area would produce a higher force (than the small end) and shift the spool in the other direction. The forces on the spool are always unbalanced and constantly force the spool in one direction or the other.

Another innovation resulting in increased effi ciency and energy savings was the incorporation of “advanced porting.” Advanced porting introduced larger air ports to the ADS that allow exhaust air to leave the pumping chamber with as little restriction as possible. At the same time the size of the inlet air ports was optimized to maximize the fl ow rate and increase effi ciency.

The latest generation of AODD pumps has added another level of adjustability to the ADS with the invention and incor-poration of an Effi ciency Management System (EMS). The EMS allows the end user to adjust the size of the air inlet ports. Decreasing the size of the inlet ports restricts the air fl ow rate into the air chamber. It allows some control over how much and how quickly the air chamber is fi lled and can prevent the chamber from “overcharging” with air.

This integrated feature allows the end user to optimize performance when operating the pump at their desired inlet air pressure by adjusting the air inlet passage size until the fl uid

fl ow requirement is met. This ensures that the pump is running in its most effi cient state while still meeting the user’s fl ow requirements, pumping only what is necessary while using the least amount of air to do so. (See sidebar for example of savings.)

Using the EMS to reduce the size of the inlet air ports and restrict air fl ow into the air chambers has the added ben-efi ts of increasing diaphragm life (reduc-ing maintenance costs) and increasing dry vacuum.

In addition to improvements to the ADS, advancements are being made to the wetted path to reduce friction losses. The reduced friction losses result in an increased fl uid fl ow rate without necessarily increasing air consumption. These improved wetted paths have been designed to “drop-in” to existing appli-cations by employing common mount-ing footprints and fl uid connections.

ConclusionIn these days of shrinking budgets and threatened bottom lines, fi nding the most effi cient way to run a manu-facturing operation is of the utmost importance. Savvy facility managers are

An exploded view of an Effi ciency Management System (EMS). The integrated feature of the EMS allows the user to optimize perfor-mance when operating the pump at the desired inlet air pressure by adjusting the air inlet passage size until the fl uid fl ow require-ment is met. This ensures that the pump is running in its most effi cient state while still meeting the user’s fl ow requirements, pumping only what is necessary while using the least amount of air to do so.



replacing older AODD technology with new pumps that feature advanced ADS systems and EMS technology.

Many manufacturers have evalu-ated their operations, isolated the areas of ineffi ciency and enhanced their return on investment through the introduction of pumping technologies that promise increased effi ciency and lower energy costs. AODD pumping technology that uses an EMS can reduce operating and energy costs, allow for more pumps in the same factory without adding compressor capacity and provide long-term benefi ts to the manufacturing operation.

P&S

Curtis Dietzsch is a development engi-neer for Wilden Pump & Engineering (www.wildenpump.com), LLC, Grand Terrace, CA. Dietzsch can be reached at 909-422-1730 or [email protected]. Wilden is a member of Dover Corporation’s Pump Solutions Group (PSG™), Redlands, CA. PSG (www.pumpsg.com) is comprised of six pump companies—Wilden®, Blackmer®, Griswold™, Neptune™, Almatec® and Mouvex®.

Example of EMS Effi ciencyA test was conducted involving a 2 in air operated double dia-phragm (AODD) pump that did not have an Effi ciency Management System (EMS) incorporated into its Air Distribution System (ADS) versus one that did. This test was conducted using water as the media.

The non-EMS AODD pump was run at 100 psig air inlet against a discharge pressure of 20 psig. At these conditions, the non-EMS AODD pump used 130 scfm to achieve a fl ow rate of 116 gpm.

When the same test was conducted using an AODD pump with an EMS ADS, the same fl ow rate of 116 gpm was able to be achieved while “dialing back” the air usage so that the pump was not running at maximum capacity. In this test, the AODD pump with an EMS ADS reduced the air consumption by 42 percent (or 54 scfm) at the desired fl ow rate of 116 gpm.



Material properties are typically reported on manu-facturers’ data sheets for each sheet-gasket type. These properties are determined through the use

of standardized tests, many of which are ASTM International Standards. The specifi c procedure used to obtain a given property is referenced on the data sheet to enable direct comparisons between gasket materials.

What Do These Properties Reveal?The application for which the gasket is considered deter-mines the importance of a specifi c property and what value might be considered good or acceptable. Many gasket properties are interrelated and often have to be considered together. A gasket with high compressibility might be desir-able, but high compressibility might come with a material that has limited load capability. Considering this fact, some compromises might be required.

This article will review properties from two basic tests, how they are determined and what value they have in selec-tion of sheet-gasket material for an application. Also under consideration are the limitations of the information insofar as a particular application is concerned.

ASTM F36: Test Method for Compressibility and Recovery of Gasket MaterialsThis test method determines two important, related gasket properties. The short duration test is performed at room temperature. The major load is applied for 60 seconds before taking the measurement for compressibility and the measurement of recovery is taken 60 seconds after removal of the major load.

Specifi c loads are applied to preconditioned speci-mens depending on the material type. This load is applied over an area defi ned by a penetrator to a gasket stress of 5,000 psi. The average of a minimum of three

samples constitutes a test. The results are calculated as follows:

Compressibility (%) = [(P – M)/P] x 100Recovery (%) = [(R –M)/ (P – M)] x 100

Where: P = Thickness under preloadM = Thickness under total loadR = Recovered thickness

How to Use the Results This test provides some basic guidance for selection of a sheet-gasket material. The internal pressure, type, condition and load capability of the fl anges are all factors that affect the amount of compressibility and recovery required.

Recovery is related to compressibility. The percent recovery is based on the amount the sample has been com-pressed under full load (P - M). This has to be considered in light of the percent compressibility. A low percent recovery value may have a higher absolute recovery than a material with a higher percent recovery, but a lower compressibility.

For example, consider one material, .062 in thick, which has 10 percent compressibility (.0062 in) and 20 per-cent recovery (.00124 in), and another material, also .062 in thick, which has 50 percent compressibility (.031 in) and 10 percent recovery (.0031 in). The material with 10

What gasket properties are most important, and how do I use them?

This month’s Sealing Sense was prepared by FSA Member Brian Hasha

Figure 1. Compressibility and Recovery

From the voice of the fl uid sealing industry

SEALING SENSE


percent recovery will actually have a larger absolute recovery due to the differences in compressibility. Recovery measures the ability of a material with a specifi c com-pressibility to maintain a seal during the fl ange transitions encountered in service.

Since this test is conducted at room temperature and only measures short-time compressibility and recovery, it is not intended to measure these properties under application of prolonged stress at elevated temperature. It should be used in conjunction with the full range of proper-ties relevant to a service application.

ASTM F38: Test Methods for Creep Relaxation of a Gasket MaterialThis test has two basic methods. The two terms, creep and relaxation, can be considered separately and in conjunction. Separately, they can be defi ned as follows. Creep is the loss of gasket thickness under constant load. If a compressive load were applied to a gasket sample of a given size, thickness would decrease. As the thickness decreases, the load would be allowed to remain against the gasket surface. The load would remain constant. This decrease in gasket thickness over time is defi ned as creep.

Relaxation is the measure of the loss in compressive stress under constant defl ection. If a gasket were compressed to a defi ned thickness and the movement of the device applying the load fi xed so that its position could not change, the change in the load over time would be a measure of the gasket’s relaxation.

Creep relaxation is a combination of these two properties. A defi ned compres-sive load is applied to a sample material and the defl ection or change in thickness is allowed to vary, while the applied load is allowed to decrease at the same time. Creep relaxation keeps the relationship between the change in gasket thickness and resulting change in load in a sort of equilibrium, much like one would see

between the gasket and fl ange/bolt assembly in a bolted joint. As the gasket thickness decreases over time, there is a resulting decrease in bolt load.

Two test methods are described in ASTM F38, Method A and Method B.

Method AThis procedure is normally run at room temperature. The test device uses a calibrated strain gauged bolt (see Figure 2).

Sealing Sense is produced by the Fluid Sealing Association as part of our commitment to industry consensus technical education for pump users, contractors, distributors, OEMs and reps. As a source of technical information on sealing systems and devices, and in coopera-tion with the European Sealing Association, the FSA also supports development of harmonized standards in all areas of fl uid sealing technology. The education is provided in the public interest to enable a balanced assessment of the most effective solutions to pump systems technology issues on rational Total Life Cycle Cost (LCC) principles.

The Gasket Division of the FSA is one of six with a specifi c product technology focus. As part of their mission they develop pub-lications such as the Metallic Gasketing Technical Handbook as well as joint publications such as the newly revised ESA/FSA Flange Gaskets – Glossary of terms, Guidelines for safe seal usage - Flanges and Gasketsas well as the FSA/ESA Gasket Installation Procedures, which are available in eight languages. These are intended to complement the more detailed manufacturers’ documents produced by the member companies.

The following members of the Gasket Division sponsor this Sealing Sense series:

American Falcon, Inc.Daikin America, Inc.Donit Tesnit d.d.Empak Spirotallic Mexicana SA de CVThe Flexitallic GroupGarlock Sealing TechnologiesW.L. Gore & Associates, Inc.GrafTech International Holdings, Inc.John CraneLamons Gasket Co.Latty International S.A.Nippon Pillar Corp. of AmericaSGL Technic Polycarbon DivisionSlade, Inc.Teadit InternationalThermoseal Inc.Triangle Fluid Controls, Ltd.YMT/Inertech, Inc.

Figure 2. ASTM F38 Method A Relaxometer


FSA Sealing Sense

During a controlled application of load applied at a uniform rate, strain read-ings are taken at defi ned intervals of time. These readings are then converted to a percentage of initial stress and plotted on a semi-log plot with the percent-age of initial stress plotted against the log of time.

Method BThis more common procedure also records loss of load over time, but uses a different relaxometer (see Figure 3) and can be performed at elevated tempera-tures. The device contains a removable precision dial indicator. The sample material is fi rst compressed and then the dial indicator is removed and the loaded specimen placed in an oven at 212 deg F for 22 hours.

The specimen with the device is then removed from the oven and allowed to cool to room temperature. The dial indicator assembly is then reattached, and a reading taken. The difference in this reading and the initial reading is used to calculate the percentage relaxation as follows:

Relaxation (%) = [(D0 - Df)/D0] x 100

Where: D0 = Initial dial readingDf = Final dial reading

This basic test allows for a relative comparison of a gasket material’s abil-ity to maintain a compressive stress over time. A portion of torque loss on a

Figure 3. ASTM F38 Method B Relaxometer

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bolted fl ange is the result of creep relaxation. Torque can also be lost by any number of other factors including bolt elon-gation, fl ange distortion and vibration. Elevated temperature also can intensify creep relaxation. When comparing values for creep relaxation for specifi c gasket materials, it is important to note which method was used.

ConclusionThe values obtained by these test procedures enable relative comparisons of the properties important to gasket perfor-mance. They are not intended to accurately represent results under actual operating conditions. The data give the end user guidance on these material characteristics to compare with other products subjected to the same standardized tests. They also provide some degree of insight as to material suitability for a given application.

When reviewing test data for different materials, the con-ditions under which the data were generated should be related to a specifi c application. How do the operating temperature range and bolt load requirements for an application compare with the conditions of the standardized tests? What gasket thickness was used in the standardized test, and what thickness is considered in the application?

These tests do not cover the wide range of operating and

load conditions a particular product might see in the fi eld. These tests, with others related to an application, provide a starting point for selection of gasket materials for a specifi c application. The gasket manufacturer can best provide the col-lective set of test data needed to make that selection.

Adapted, with permission from F36 Test Method for Compressibility and Recovery of Gasket Materials and F38 Test Method for Creep Relaxation of a Gasket Material, copyright ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428.

Next Month: What fastener should I use for my bolted fl ange connection?

We invite your questions on sealing issues and will provide best efforts answers based on FSA publications. Please direct your ques-tions to: sealingsensequestions@fl uidsealing.com.

P&S


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Q. How carefully must pump impellers be balanced to avoid unacceptable vibration levels when the pump is running?

A. Pump impellers are typically balanced in accordance with ISO 1940 balance quality grade G6.3 or better (see Figure B.2). This fi gure indicates the center of gravity displacement or resid-ual unbalance acceptable for balance grade 6.3.

Depending on component geometry, it may be satisfactory to perform a single-plane spin balance. Components are typically single-plane balanced if the ratio of diam-eter to width D/b is 6.0 or greater. The width b is mea-sured between the outside of the shrouds at the impel-ler OD.

Two-plane (or dynamic) balancing is typically performed otherwise.

Figure B.2 is used by entering the graph at the maximum expected service speed, such as 3,600 rpm, and reading the acceptable residual unbalance as 0.7 oz–in/oz. Multiply this number by the impeller weight in oz and the result is the allowable unbalance of the impeller in oz–in.

Balancing machine sensitivity shall be adequate for the part to be balanced. This means the machine is capable of measuring unbalanced levels to one tenth of the maximum residual unbalance allowed by the bal-ance quality grade selected for the component being balanced.

Balancing machines are capable of measuring unbalance independent of its speed. When the value for allowable unbalance is determined from Figure B.2, it is not necessary to operate the balancing machine at the same speed as the pump speed.

The practice of component balancing is appropri-ate for a large proportion of rotodynamic pump types that can be proven to meet the specifi ed vibration per-formance criteria while using clearance fi ts between the rotating component parts and the shaft. Residual unbalance grades are then determined to meet vibra-tion performance acceptance levels while also consid-ering the mass eccentricity effects caused by clearance fi ts and the resulting component runout. Clearance fi ts are preferred and used whenever possible to facilitate pump assembly and disassembly.

In many pump types and applications, however,

it is necessary to use shrink fi ts and perform a supplementary two-plane (dynamic) balance on the complete rotating assem-bly to meet the specifi ed vibration performance criteria. In these instances, the manufacturer and the purchaser should agree on the appropriate residual unbalance grade.

For additional detail on this subject, see the recently pub-lished HI Standard ANSI/HI 9.6.4 Rotodynamic Pumps for Vibration Measurements and Allowable Values.

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Q. When purchasing rotodynamic pumps, how can we be assured of selecting pumps with the highest effi ciency?

A. The major infl uences on rotodynamic pump effi ciency are pump size, specifi c speed ns (Ns), and the type of pump selected to meet the service conditions.

The following can infl uence effi ciency deviations: a) Pump Types: There are many different types of rotodynamic

pumps with unique confi gurations and features to meet spe-cifi c service conditions, e.g., stock, sewage, slurries, etc., all of which by virtue of their specifi c speed and design have less than optimum attainable effi ciency.

b) Surface Roughness: Effi ciency increase due to improvements in waterway surface fi nish is dependent on pump specifi c speed and size. Typically, surface fi nish improvements are economi-cally justifi able for small and low specifi c speed pumps.

c) Internal Clearances: Pump wear ring clearances can have a major infl uence on effi ciency, particularly for low specifi c speed pumps [ns < 29 (Ns < 1500)]. Internal clearances are determined by:Design compromise for manufacturability• Galling properties of the materials of construction•

d) Mechanical Losses: Bearings, lip seals, mechanical shaft seals, packing, etc., all consume power and reduce the pump effi ciency. Small pumps [less than 11 kW (15 hp)] are par-ticularly sensitive to these mechanical losses.

e) Pumpage:Viscosity: Liquids with a viscosity higher than water have • a detrimental effect on effi ciency. Refer to ANSI/HI 9.6.7 Effects of Liquid Viscosity on Rotodynamic (Centrifugal and Vertical) Pump Performance for viscosity correction.Solids size: Low concentrations (below 10 percent by • weight) of random-sized solids and tramp material in the liquid will not detrimentally affect effi ciency. Slurries: Larger concentrations (above 10 percent by weight) • of solids in liquids cause reductions in pump effi ciency. The pump supplier should be consulted when making effi -ciency corrections for slurries (refer to ANSI/HI 12.1-12.6 Rotodynamic (Centrifugal) Slurry Pumps for Nomenclature, Defi nitions, Applications, and Operation).

f ) Special Impeller Designs:High suction specifi c speed, • S (Nss) > 215 (11,000), could reduce the attainable effi ciency by upwards of three points (the effect is lessened as specifi c speed is reduced) Desired curve shape, such as head rise to shutoff or steep-• ness of head curve, can reduce the attainable effi ciency

g) Impeller Diameter Trim: Reduction in effi ciency due to impeller diameter trim must be expected. Effi ciency reduc-tions can range from one to six points by trimming to the minimum diameter. High specifi c speed pumps usually have greater reductions in effi ciency due to trim than low specifi c speed pumps.

h) Thrust Balance: Pumps often use varying methods of hydraulic thrust balance, which may reduce the pump effi ciency.

i) Specifi c speed: The specifi c speed at which optimum effi -ciency occurs varies with the pump type. For example, the specifi c speed ns (Ns) for opti-mum effi ciency for a volute-type pump is in the vicinity of 50 (2,500). With a vertical turbine diffuser type pump, the specifi c speed ns (Ns) for opti-mum effi ciency is about 100 (5,000). Volute pumps selected for services with ns (Ns) values that are not in the vicinity of 50 (2,500) will probably have lower effi ciencies. The relation-ship between the arithmetic effi -ciency correction and ns (Ns) is shown on Figure 20.3d

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Figure 20.3d. Effi ciency reduction due to specifi c speed (U.S. customary units)


HI Pump FAQs

The curve labeled “V” is for vertical turbine pumps, and the curve labeled “All but V” is for all other rotodynamic pump types.

To ensure high effi ciency, the design specifi c speed must be close to optimum indicated by the curves.

For more detail on this subject, see the soon to be pub-lished guideline, HI 20.3 Rotodynamic (Centrifugal and Vertical) Pumps. Effi ciency Prediction Method.

Q. What are “boiler feed booster pumps,” and why are they necessary?

A. The following answer is taken from a soon to be published Hydraulic Institute Application Guideline for Power Plant Pumps.

Boiler feed booster pumps are used to provide pressure to the feed pumps to meet their NPSH requirements and avoid cavitation. As the size and speed of boiler feed pumps have increased, the NPSH requirements have increased as well. It is not practical to install the direct-contact heaters from which feed pumps take their suction at suffi cient elevation to provide

adequate NPSHA without “boosting” the suction pressure to the feed pumps. Using low-speed booster pumps ahead of the feed pumps increases suction pressure.

Boiler feed booster pumps are generally of the single-stage, double suction design. See Figure A.3, pump type BB1 for axi-ally split case, and Figure A.4, pump type BB2 for radially

Figure A.3. Impeller between bearings—fl exibly coupled, single stage, axial (horizontal) split case [BB1]



split case versions of this design confi guration. They operate at lower speeds than the feed pumps, typically at four-pole motor speeds. The NPSH required by the booster pumps is much lower than that required by the feed pump it supplies. It is not unusual for the NPSH requirements of large, high-speed boiler feed pumps to be in excess of 60 m (200 ft). Such a requirement is much more than could be economi-cally provided by elevation differences from feedwater heater placement to the feedwater pump.

P&S

Pump FAQs® is produced by the Hydraulic Institute as a service to pump users, contractors, distributors, reps and OEMs as a means of ensuring a healthy dialogue on subjects of common technical concern.

HI standards are adopted in the public interest and are designed to help eliminate misunderstandings between the manufacturer, the purchaser and/or the user and to assist the purchaser in selecting and obtaining the proper product for a particular need.

As an ANSI approved standards developing organiza-tion, the Hydraulic Institute process of developing new stan-dards or updating current standards requires balanced input from all members of the pump community.

We invite questions and will endeavor to provide answers based on existing HI standards and technical guidelines. Please direct your inquiries to: [email protected].

For more information about HI, its publications, Pump LCC Guide, Energy Saving Video-based education program and standards please visit: www.pumps.org. Also visit the new e-learning portal with a comprehensive course on “Centrifugal Pumps: Fundamentals, Design and Applications,” which can be found at: www.pumplearning.org.

Figure A.4. Impeller between bearings—fl exibly coupled, single stage, radial split case [BB2]

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Practice & Operations

A city’s wastewater treat-ment infrastructure is part of the groundwork

of an entire community’s orga-nization and is one of a com-munity’s most costly endeav-ors. Using a centralized system often does not have environ-mental benefi ts since conclusive evidence shows that centralized sewer collection systems are leaking and causing treatment plant overfl ows during strong wet weather events. Leakage into streams and ground water commonly occurs in many places and is a signifi cant prob-lem in many communities across the United States.

A study in Albuquerque, N.M., concluded that leakage of wastewater from sewer pipes amounted to 10 percent of aver-age daily wastewater fl ow at its treatment plant, or fi ve million gallons per day. Due to cost and these types of overfl ow issues, alternative ways of providing wastewater service in suburban areas are gaining increasing attention.

In many situations, a decen-tralized/distributed system may be an option. Often seen as suitable only in low-density, rural situations and then only as temporary solutions, decentral-ized wastewater treatment sys-tems are not usually thought of as an option for more than one home. However, with proper design, installation and opera-tion, decentralized systems have many advantages. By collecting, treating, and reusing or dispos-ing of wastewater from indi-vidual homes, buildings and/or cluster systems near the point of generation, decentralized/distributed systems can reduce the time, water amount and energy involved with treating wastewater with a higher pol-lutant removal rate.

Benefi ts for DevelopersDevelopers who consider alternatives to sewer or center-collection systems actually see many reasons to choose

Decentralized/Distributed Systems as Alternative Treatment OptionsRobert K. Rebori and Jennifer Cisneros, Bio-Microbics, Incorporated

Onsite treatment systems benefi t homeowners, developers and the environment.

Temporary community system in Louisiana


decentralized/distributed systems for their homes. For example, a developer looking to build 50 suburban homes can have his project delayed up to fi ve years while the city extends the exist-ing sewer lines to the homes. Plus, the developer is likely going to pay signifi cant sewer tap fees and substantial fees for the cost of extending sewer lines so cur-rent sewer customers will not see rate increases. If the developer is charged more, chances are the developer will charge the residents more. Additionally, especially in places like coastal areas, small lots and heavy regulation can tie the developer’s hands if he is trying to put in a sewer. The fi ve year or longer timeline is likely to stretch farther.

Because these decentralized/distributed systems are typically composed of modular, intercon-nected and easily replaceable parts, installation and maintenance is simple. It only takes a few days or weeks to install and start-up a decentralized system. The savvy developer does not have to plan as extensively in com-parison to building a neighborhood with a sewer. The devel-oper may also decide to use these systems instead of building out from the central infrastructure because they require less time and money to obtain permits. One of the major benefi ts of these systems is the developer can build out slowly and add to the treatment system as needed to maintain treatment, so the initial costs are signifi cantly lower.

As an example, small, quick-to-install, wastewater treat-ment units are available. Modular units can typically treat 500 gallons per day or signifi cantly more using a cluster system treating from 3,000 up to 160,000-plus gallons/day—enough to accommodate an entire community. Fixed activated sludge treatment units are easily upgradable, scalable and fi ll consid-erably less space than centralized treatment options. Moreover, these advanced treatment systems offer a water reuse oppor-tunity for community parks, schools, golf courses and other common areas. The developer also has more options in terms of the topography and/or type of land available, which not only increases property value but can lead to a decrease in urban sprawl.

Benefi ts for ResidentsHomeowners generally do not like to think about sewage treat-ment. Frequently, residents who live near a large treatment

plant will be irritated by its smell, noise or appearance. Residents will be happy to know that odor is usually less of a concern with decentralized/distributed systems, and they are typically almost unseen because they can be installed below ground.

Since the size of land nor-mally reserved for the drain fi eld on a given property can be reduced by using individual onsite systems or eliminated by using cluster sys-tems, the residual land can be used for other structures like a pool or common areas like parks or green space. Another benefi t is that the treated water can be reused for drip tube irrigation of the lawn or other landscaped areas.

Whenever a community has a centralized wastewater system and developments are proposed, questions are likely to arise over how the costs and benefi ts of the system are to be distributed,

which can be avoided when all the costs and benefi ts go to single homes or clustered developments. It is also important to consider that property values near large centralized systems understandably decrease. Houses with individual or distrib-uted systems have a more equal distribution of value. In addi-tion, distributed/decentralized systems are often much more economical for smaller communities than sewers. In 1995, for instance, Columbus, N.M., had a choice between paying $4.21 million for sewers with aerated wetlands and ponds, or paying $1.19 million for new single home treatment systems.

Septic Systems Have Had a Negative ReputationFrequent system failures are associated with the various types of conventional septic systems. When developers contract with a company or individual to install onsite systems, they are look-ing to minimize costs by adhering to the minimum standards instead of looking to protect the environment. Sometimes they are simply unaware that other options exist. Usually, the fail-ures are characterized by unpleasant events affecting an entire development of homes where the systems were not designed or installed properly. Events include untreated wastewater surfac-ing on the ground or backing up into the houses. Many assume that onsite systems simply cannot be reliable. However, look-ing deeper into the situation, the problems of onsite systems diminish considerably when a system using proven technology is designed, installed and maintained correctly, and given no

Community units with drainfi eld Iin Virginia



harsh chemicals to treat.Homeowners can help take

care of the system and extend its life. Reading the owner’s manual of any treatment system is a must. In it, homeowners are reminded that paint thinners, medicines and even liquid fabric softeners can be harmful to a septic system. Regular inspection and pump out of septic tanks also goes a long way in reducing failures. A pro-fessional should always perform any maintenance to a system. The good news is that decentral-ized systems require less operation and maintenance than central-ized wastewater treatment plants, and therefore can be less costly to maintain overall.

Environmentally ConsciousProperly designed, installed and

operated decentralized/distributed wastewater systems have signifi -cantly cleaner effl uent than cen-tralized systems. Untreated water is sometimes disposed to the envi-ronment with centralized systems due to aging infrastructure, water main breaks, fl ooding or poor operation. Often, minimal energy is needed to create this superior effl uent. Using again the example of a modular unit, the blower can be cycled on and off for two reasons: reduced operating cost (up to 45 percent) and improved nitrogen reduction performance (in specifi c situations).

A great concern of the EPA is the amount of nitrates a system releases into the environment. These nitrates can enter ground-water and under the right condi-tions are implicit in causing cer-tain birth defects and are thought to cause other disorders like

Commerical unit in steel tank in Mexico

Residential system in Latvia



hyperthyroidism. If too many nitrates enter a pond or lake, they create algae, which destroy oxygen in the water and subse-quently kill fi sh. Many centralized systems remove hardly any nitrates, while some distributed/decentralized systems remove an impressive amount of nitrates.

Water table levels and stream base fl ows can be harmed by the use of centralized systems and are improved or preserved

by the use of decentralized/distributed systems. Centralized systems do not discharge effl uent anywhere near where homes or businesses use and/or obtain water. Many streams lose water to these systems, but with decentralized systems, the water goes to the nearby leach fi eld and possibly back into the stream. In addition, riparian zones (the area between land and a stream) are less frequently disturbed by the installation and operation of onsite systems than they are by sewer systems.

Conclusion It is important for developers and residents to decide what type of wastewater system is most feasible to implement—economically, politically and environmentally. It is not always a clear choice, but substantial evidence shows decentralized systems are frequently a solution. They are less labor intensive for responsible builders and homeowners, and they are a more environmentally friendly.

P&S

Robert K. Rebori is a staff writer and Jennifer Cisneros is the marketing communications coordinator for Bio-Microbics, 913-422-0707, Fax: 913-422-0808, [email protected], [email protected], www.biomicrobics.com.

Multiple units to accommodate a large project




It has new bearings and seals. It has been cleaned, coated and aligned. Your overhauled pump should be perfect, but your “fi nger vibrometer” tells you that it is just okay.

It could be that some residual unbalance is at work, exerting damaging dynamic forces on those new bearings, seals and foundation every hour, every day.

Impeller balancing or, more correctly, pump rotor bal-ancing is an important element in any quality pump over-haul. Balancing pump impellers and assembled rotors is a straightforward process, but a few “gotchas” can result in poor fi nal balance quality. The step is too often skipped because it is assumed that the impellers were balanced at the factory. Whether you are a pump end user, service technician or rebuilder, this discussion of balancing procedures, toler-ances and tips may help you get that perfect pump instead of one that is just “okay.”

Balancing MethodsBalancing a pump rotor starts with the impeller. With the various impeller sizes and shapes there is no single best way to approach the task. The impeller may be mounted on a balancing mandrel and spun in a low-speed dynamic balanc-ing machine. It may be mounted on the pump shaft and balanced in a dynamic balancing machine. If it is a close-coupled pump (integral pump and motor), the impeller may be mounted on the motor shaft without the pump assembly and balanced at operating speed.

For some high-speed rotors with multiple impellers, a high-speed spin pit may be needed to achieve good bal-ance quality at operating speed. At the other extreme, for some low speed, narrow impellers, a static balance may be adequate, although a dynamic balance is always preferred.

Balance QualityBalance quality is not just a function of weight distribution.

The fi t of the impeller to the pump shaft and the condition of the shaft also play critical roles in fi nal balance quality. To appreciate this, it is helpful to review some dynamic balance quality requirements for rigid rotors in ISO Standard 1940/1. While not all pump rotors are “rigid” from a dynamic per-spective, this document is a good starting point for under-standing rotor balancing. It provides formulas and charts for determining the “Permissible Residual Unbalance (eper).”

eper can represent gm-mm/kg (lb-in/lb) of rotor weight residual unbalance, or it can represent µm (inches) displace-ment of the center of gravity. The fi rst interpretation of eper is the common understanding of unbalance–i.e., an amount of weight at some distance from the center and relative to the rotor’s weight.

The second interpretation of eper relates to the fi t of the impeller on the shaft and can be explained best by an exam-ple. If a 1 kg impeller was mounted eccentric on the shaft by 5 µm, that would be equivalent to 5 gm-mm of unbal-ance. In the foot-pound-second (FPS) system, a 1 lb impeller that is 0.005 in eccentric on a shaft equates to 0.08 oz-in of unbalance.

Transitional fi ts. Many pump impellers have a tran-sitional fi t to the pump shaft, which leaves some potential for error in mounting. If an impeller is balanced on the pump shaft, then removed for pump assembly and fi nally reinstalled, it may mount slightly eccentric from its balanced location. This could result in some additional residual unbal-ance. Likewise, if an impeller is balanced on a mandrel and then installed on the pump shaft, some additional residual unbalance may result. The good news is that as long as the impeller’s actual fi t to the pump shaft is not excessive (0.0005 in or 0.0127 µm clearance fi t for most pumps), the potential for additional residual unbalance is small.

Balance grade numbers. Any discussion of ISO Standard 1940/1 should include the balance grade “G” numbers. These numbers, which derive from the dynamic

Impeller Balancing: An Important Element of a Quality RepairEugene Vogel, Electrical Apparatus Service Association

Balancing procedures, tolerances and tips for pump impellers.


characteristics of pure unbalance, represent an assessment of balance quality independent of speed and rotor weight. (That is why speed and rotor weight must be known to convert “G” numbers to actual unbalance amounts.)

Although the standard specifi cally lists pump impellers in the G6.3 category, most pump manufacturers, knowledgeable end users and quality rebuilders will not accept greater than G2.5 for any mission-critical pump. While G1.0 may be chal-lenging to achieve for multistage pump rotors, getting as close as possible to G1.0 will pay dividends in pump reliability. As mentioned earlier, balance quality grade numbers are indepen-dent of rotor weight and speed, so do not believe that G6.3 or greater is okay for a big, slow rotor. It does not work that way.

Two-plane unbalance. ISO Standard 1940/1 also provides a good basis for understanding the two-plane nature of pump impellers. The allowable residual unbalance for the rotor must be split between two correction planes, based on the rotor’s rel-ative dimensions. Special rules apply to narrow rotors where the distance between correction planes is less than one-third of the distance between bearings. Under these provisions, all rotors require balancing in at least two planes. Finding two available correction planes on pump impellers can be challenging (more about this in the discussion of weight addition/removal).

As an example of “unexpected” two-plane unbalance, con-sider the case of a 720 rpm axial fl ow impeller with a diameter of 8 ft (2.44 m) and a width of about 16 in (40.6 cm). When fi rst mounted on a balance mandrel in a low-speed dynamic balanc-ing machine, its couple unbalance was 12 lb at 44 in radius (5.4 kg at 111.76 cm). That calculates to more than 8,000 oz-in (6,083 g-m) of unbalance. Needless to say, this unit had a his-tory of rough operation. This narrow impeller was thought to likely require only a single-plane, static balance.

Note that couple unbalance is a two-plane unbalance con-dition where equal weights in either plane are 180 deg apart.

The result is a rotor that is statically balanced but dynamically unbalanced. Couple unbalance exerts axial torque on the shaft, potentially causing dynamic shaft defl ection.

Just as the fi t of the impeller to the shaft can cause static unbalance, the fi t of the impeller against the shaft shoulder or spacer can cause couple unbalance. A shoulder that is not square to the rotating axis, or that has a ding or other anomaly, can cock the impeller on the shaft, causing couple unbalance. Couple unbalance can also occur if the bore of the impeller is not true to the face. In either case, turning the shaft slowly will make the impeller’s edge appear to wave back and forth.

Multiple impellers. When a pump shaft has multiple impellers, as with multistage pumps, the desired result is a balanced rotor assembly. If the rotor were truly rigid, any two correction planes would suffi ce. The geometry of a multistage pump dictates that the shaft be long and slender, and thus sus-ceptible to fl exure.

Even multistage pumps that operate well below their fi rst rotor critical frequency can experience shaft fl exure from the dynamic forces of individual impellers. These impellers are usu-ally mounted between bearings, so the shaft passes through the suction eye, which limits impeller capacity. To compensate for this, shaft diameter is kept to a minimum, making the shaft more fl exible. If one impeller is pulling left when another is pulling right, some amount of shaft fl exure will likely result in a slight S-shape. The implication for smooth operation of the pump is obvious.

To avoid this condition, each impeller must be dynami-cally balanced before installation. During assembly, rotor bal-ance must also be tested after each impeller is added. A rotor with four impellers would therefore require four individual impeller balances, and four successive balances of the stage-assembled rotor.

If the rotor exceeds the balance quality tolerance at any

Correctionplanes

Shaftaxis

Journalsurface

Shading denotes heavy spot.

CG plane

Shaftaxis

Journalsurface Principle interia

axis

Centerof gravity

A B

UL

UR

Shading denotes heavy spot.

Figure 1. Couple unbalance Figure 2. Static unbalance



stage of assembly, the cause must be investigated. It is possible that the combined residual unbalance of the individual impel-lers adds up vectorially to exceed the tolerance. It is also possible that the face of an impeller or spacer is not true, and resulting axial tension in the assembly is causing a rotor bow. Another possibility is excessive clearance on the fi t of an impeller bore to the shaft. Under ideal conditions, it should be possible to disas-semble and reassemble the rotor without signifi cantly affecting the balance quality.

Physical Issues for Balancing Impellers/RotorsSince we have looked at balancing theory, what are some of the physical issues that can affect the balancing procedure for an impeller/rotor?

Mounting the impeller. With dynamic balancing machines, mounting the impeller so that it spins true and smooth is of primary importance. The balancing mandrel should fi t the impeller snuggly—i.e., not a shrink fi t but defi -nitely not loose. Even if the pump shaft has clearance to the impeller, the mandrel should not.

As noted earlier in regard to couple unbalance, the impel-ler faces must run true. If a face appears to waver as the impeller turns slowly in the balance machine, it is not true to the bore, and couple unbalance will result. (Note: The rotating speed of different types of balancers can sometimes be an issue. A full discussion of balancing machines is beyond the scope of this article.)

Pump shaft bearing journals. Dynamic balancing machines usually support the shaft on rollers, which present a wear factor for pump shaft bearing journals. This is a critical issue for sleeve bearing journals, where scoring cannot be toler-ated. Supporting the shaft on the shoulder next to the journal will only produce good results if the supporting surface is per-fectly true to the journal. A supply of CLEAN lubricating oil on the shaft and rollers will help prevent shaft damage.

Removing weight. Removing weight from an impeller can be quite a challenge. Most experienced balancing techni-cians will fi rst balance by adding temporary weight like putty

and then grind off equivalent weight at the 180 deg location. Grinding on the impeller shrouds is preferred over drilling, because it does not leave sharp edges that create turbulence.

When weight must be removed from the impeller vanes, it should be taken from the leading edge, near (but not at) the tip; avoid chamfering the tip. Removing weight from the back of the vane (under-fi ling) can affect impeller performance and should be avoided (Figure 3). Of course, no weight should be removed from the wear ring, but smooth grinding on the inside of the suction eye is acceptable for some impellers. Note that weight is not usually added to balance impellers, so an impeller with balance weights should raise suspicion.

Special challenges. Many impellers and rotors present special challenges with regard to balancing. The single-vane impeller is worth mentioning. This design, which maximizes the size of solids that can be passed, cannot be dynamically bal-anced. The liquid discharge is asymmetric and creates a hydrau-lic unbalance that is compensated for with mass unbalance. When this type of impeller runs dry, vibration will be severe; operation will be much smoother while it is pumping liquid.

ConclusionA basic understanding of quality balance requirements for impellers/rotors can help develop repair specifi cations that will ensure the rebuilt pump is “perfect”—not just “okay.” Remember, proper pump rotor balancing procedures will pay dividends in pump reliability, whereas failing to address this critical quality issue invites premature failure and associated costs.

P&S

Eugene Vogel is a pump and vibration specialist at the Electrical Apparatus Service Association (EASA), St. Louis, MO, 314-993-2220, Fax: 314-993-1269. EASA is an international trade association of more than 1,900 fi rms in 56 countries that sell and service electrical, electronic and mechanical apparatus.

Figure 3. Shaft supported on rollers

Figure 4. Removing weight from impeller vanes


Introduction

Mechanical resonance is the tendency of a mechani-cal system to absorb more energy when the fre-quency of its oscillations (external excitation

source) matches the system’s natural frequency of vibration than it does at other frequencies. Mechanical resonance may cause violent swaying motions (large vibrational displace-ments) and even catastrophic failure (1).

External items in large vertical pumps that could excite a natural frequency are:

Rotational unbalance • Impeller exit pressure pulsations• Gear couplings misalignment•

Natural frequencies of a vertical pump and motor are calculated by performing a modal analysis using the Finite Element Method (FEM). The common name to refer to this kind of analysis is Finite Element Analysis (FEA). Typical software tools used at the Flowserve Santa Clara business unit for the analysis are ANSYS and Pro/ENGINEER. The primary reason for conducting an FEA is to obtain an accept-able separation margin between the unit operating speed and the individual structural natural frequencies.

FEA is based on a numerical method that some authors defi ne as Galerkin’s Method [Reddy, 1984]. A domain is divided into n number of subdomains, the elements, and equa-tions of n grade are used to approximate the solutions of each subdomain. The accuracy of this numeric method depends on the number of subdomains into which the domain has been divided and the boundary conditions.

As associated with solving a differential equation, the

accuracy of the FEA performed on a vertical pump and motor depends on the nature of the elements (in FEA soft-ware a considerable number of options are available for the analyst to select from depending on the purpose) and the boundary conditions applied to the model.

The element selection is not complex for an analyst with knowledge of the FEA software. Software like ANSYS, the one used by the Flowserve Santa Clara business unit, describes each element by the degrees of freedom, its particu-lar properties, and its behavior and outputs.

On the other hand, the proper application of boundary conditions for a model requires knowledge and experience by the analyst. The analyst must not only possess the skills and knowledge about how to run the FEA software, but must also understand the behavior of the system modeled. In addi-tion, an analyst must understand the signifi cance of various actions and decisions that must be taken while modeling and running the analysis.

BackgroundDuring the spring of 2009, two large vertical pumps installed in a power generating plant experienced mechanical vibra-tion problems associated with structural resonance.

The initial vibration amplitude of the pumps was found to be above the user’s allowable vibration level. Preliminary solutions to the vibration problem affected the natural fre-quency values of the pump system, and a mechanical reso-nance condition appeared.

When the pumps were initially installed at the site, vibration readings were taken and a discrepancy was reported between the contractual limit of 0.157 in/s peak-to-peak and

Structural Resonance Problems on Vertical PumpsFrancisco Gaytan and Alejandro Pineda, Flowserve Flow Solutions Group

Understand the process used to resolve the high-vibration issues on a power generating station’s vertical circulating water pumps.




the measured vibration amplitude.Before evaluating possible solutions to the problem,

the pumps were bump tested to determine their struc-tural natural frequency. Without water in the suction pit, the fi rst structural natural frequency was 5.5 Hz, and the second natural frequency was 10.5 Hz. The second natural frequency is 23 percent higher than the operating speed of 514 rpm (8.5 Hz). As the suction pit was fi lled with water, the natural frequency values were reduced, since the water adds mass to the system. With the suction pit fi lled with water, a subsequent bump test showed a natu-ral frequency at 8.5 Hz, which indicated that structural resonance was a contributing factor to the high mechani-cal vibration recorded when the pumps were operated.

The manufacturer proposed several different alternatives to shift the structural resonance and reduce the amplitude of the operating vibration. Since the second natural frequency coincided with the operating speed, a possible solution involved increasing the fl exibility of the pump discharge head. Two

methods to accomplish this task were evaluated—removing the external ribs from the discharge head or adding an external mass at the top of the motor.

The fi rst step in the problem-solving process was to modify the FEA so that it agreed with the site bump test results. Cutting the external ribs would reduce the stiffness of the discharge head to mounting plate connection, which would lower the natural

frequency value. The model was updated to simulate removal of the external ribs, and the analytical results showed that the natural frequency value decreased. Unfortunately, the reduction was not suffi cient to provide the desired separation margin between the pump operating speed and the pump system natural frequency.

The next step was to model adding an external mass at the top of the motor. The pump manufactur-er’s standard is to procure motors capable of having external weight added to the top of the motor that is equal to 20 percent of the motor weight without affecting the structural integrity of the mechanical operation of the motor.

The pump motor’s manufacturer was aware of this requirement and approved the installation of a 2,000-lb weight at the top of the motor.

Figure 1. Discharge head with external ribs available on orig-inal design. Cutting the external ribs was a proposed solution for increasing fl exibility of the discharge head.

Figure 2. 3-D model of the pump.

Pump A

ConditionParallel Direction

Separation Margin (%)

Perpendicular Direction


Data- Baseline with original ribs

7.75 -9.50% 8.50 -0.80%

Data after cutting ribs. Not operating

(dry pit)10.00 16.70% 10.25 19.60%

2,000 lbm top motor during operation. (Unit A operating

alone) with high pit level

7.70 -10.10% 8.00 -6.60%

2,000 lbm top motor during operation.

(Unit A & Unit B operating) with high

pit level

7.38 -13.90% 7.70 -10.10%

Structural Natural Frequency (Hz)

Figure 3. Natural frequency values of pump A.


Figures 3 and 4 show the bump test results of these two modifi cations.

Figures 3 and 4 show that the resonant condition still exists with the addition of mass at the top of the motor and the cut external ribs. Although the pumps and motors are identical,

the bump test results show differences attributed to foundation differences.

Figures 5 and 6 provide the operational vibration ampli-tudes associated with the two modifi cations for the A and B pumps.

Pump B

ConditionParallel Direction


Perpendicular Direction


Data- Baseline with original ribs 8.00 -6.60% 8.75 2.10%

Data Baseline with original ribs.

Uncoupled. Low pit level.

11.50 34.20% 11.50 34.20%

Data after cutting ribs. Not operating. Dry pit. 10.25 19.60% 10.25 19.60%

Data-not operating after cutting ribs. High

pit level.8.67 1.20% 8.78 2.50%

2,000 lbm top motor during operation. (Unit B operating alone) with

high pit level

7.60 -11.30% 8.20 -4.30%

2,000 lbm top motor during operation. (Unit

B & Unit A operating) with high pit level

7.60 -11.30% 8.20 -4.30%

Structural Natural Frequency (Hz)

Pump A

Condition Parallel DirectionPerpendicular

Direction

Baseline N/A N/A

Data after cutting ribs 0.15 0.50

2,000 lbm top motor (Unit A operating


0.05 0.11

2,000 lbm top motor (Unit A & Unit B

operating) with high pit level

0.05 0.12

Forced Response Vibration Amplitude at 1x rpm (in/s pk)

Figure 4. Natural frequency values of pump B. Figure 5. Vibration amplitude values of pump A.

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After cutting the external ribs and adding the extra weight, the operational vibration amplitude readings for pump A are within the contractual limits; however, pump B was not within the con-tractual limits.

Figures 7 and 8 show the defl ected mode shapes from the FEA for the modes closest to the operat-ing speed. These defl ected mode shapes show that the major defl ection is occurring in the portion of the pump below the pump baseplate. Consequently, the initial modifi cations to the portions of the pump above the pump baseplate were not as effective as expected.

Several other alternatives were evaluated such as increasing the size of the coupling access holes in the pump discharge head, adding mass to the pump’s lower portion, adding a lateral restraint to the lower portion of the pump, and adding a spring plate between the pump and motor. Each of these alternatives was evaluated through FEA, and the practicality of its application was dis-cussed with the user. A decision was made to pursue the spring plate alternative.

Spring plates are mechanical devices consisting of two cir-cular plates with an engineered gap in the area between them. One plate is attached to the pump discharge head, and the other is attached to the motor mounting fl ange.

The design of the spring plates is performed using propri-etary software developed by the pump manufacturer.

To ensure that the spring plates provided the expected results, one set of plates was manufactured and installed on pump A as shown in Figure 9.

The spring plate modifi cation was performed. The pump was bump tested to determine the actual natural frequency values, and the operational vibration values were recorded.

Pump B, which exhibited the higher operational vibration values, decreased to 0.11 in/s peak-to-peak for perpendicular direction and 0.10 in/s peak-to-peak for parallel direction mea-sured at the top of the motor. In addition, the natural frequency separation ratio was increased to more than 15 percent, which was accepted by the end user.

SolutionFor this case, the objective was to decrease the stiffness of the mechanical system.

The fi rst step was to fi ne-tune the FEA model to match the on-site bump test results for the pumps. When this was completed, proposed changes could be evaluated with the FEA model. Removing external ribs and adding extra weight at the top of the motor were preliminary solutions, but when it was determined that a signifi cant weight was needed, this option was abandoned.

Spring plates were the best solution, considering that the

Pump B

Condition Parallel DirectionPerpendicular

Direction

Baseline N/A N/A

Data after cutting ribs 0.20 0.85

2,000 lbm top motor (Unit B operating


0.10 0.24

2,000 lbm top motor (Unit B & Unit A

operating) with high pit level

0.09 0.22

Forced Response Vibration Amplitude at 1x rpm (in/s pk)

Figure 6. Vibration amplitude values of pump B.

Figure 7. Third mode (8.23 Hz parallel) close to pump operating speed.

Figure 8. Fourth mode (8.60 Hz perpendicular) close to pump operating speed.


solution was designed to reduce the discharge head stiffness, and only the above-ground parts of the pump system need modifi cation.

The ease of design and manufacture of spring plates are important advantages of these devices when a mechanical reso-nance exists in pumps already installed at the user’s site. The incorporation of spring plates into installed pump systems affects only assemblies of the motor and motor support inter-face and the motor-to-pump coupling. Piping and foundation work need not be disturbed.

ConclusionThe fi nite element modeling and analysis techniques provide an understanding of the mechanical system behavior, including the natural frequency values during design phase.

Understanding the predicted natural frequency values allows an evaluation of the expected separation between the pump natural frequency and excitation frequencies, such as pump operation speed. The separation is established by the pump manufacturer to avoid mechanical resonance.

The boundary conditions assumed during FEA are essen-tial to the accuracy of predicted results. In some cases, the fi nal as-built conditions (such as foundation stiffness) signifi cantly affect the analysis accuracy if they differ from those conditions assumed during the analysis.

When this happens, it is necessary to perform a bump test to know the actual natural frequencies of the pump systems after they are installed on site. Using the results of the bump tests, the fi nite element model must be tuned to match the results obtained on site. Proposed solutions can then be simu-lated and analyzed.

It is important to know the type of acceptable solution that will provide the best pump operation. In some cases, results from the bump test indicated that increasing the natural fre-quency of the system was the best solution. The increase in natural frequency could be accomplished by modifying two of the pump system’s physical characteristics, reducing mass or increasing stiffness of the system.

In this example, increasing the separation between the pump system natural frequency and the excitation frequency (pump rotational speed) required that the pump system natural frequency be reduced. Spring plates were installed to increase the fl exibility of the upper pump structure, thus reducing the natural frequency.

Spring plates are optimized solutions when the pumps are installed on site and the user requires a fast and effective solu-tion without removing the pumps or modifying the site infra-structure. Finite element analysis and design tools, combined with simple materials and manufacturing methods, provide the customer with a quick, effective solution.

P&SReferences

1. Singiresu, S. Rao, Mechanical Vibrations, Addison Wesley, 2003.

2. Reddy, J.N., An Introduction to Finite Element Method, McGraw Hill, 1984.

Francisco Gaytan is the manager of engi-neering in Santa Clara for the Flowserve Flow Solutions Group.

Alejandro Pineda is a design engineer and FEA specialist in Santa Clara for the Flowserve Flow Solutions Group.

Figure 9. Spring plates design and assembly installed on the pumps.

Figure 10. Spring plates installed on motor support. Note the exis-tence of the gap between both plates.



The 15th Conference of the Parties under the United Nations Framework Convention on Climate Change (COP 15) recently brought new attention to how

global climate change is rapidly reshaping the environment, people’s health and the world’s precious natural resources.

While climate change is certainly a large issue with no easy solutions, two other issues—wind and water—are growing in importance and closely intertwined with climate change. In fact, both wind and water are natural power sources and will likely signifi cantly affect global energy pro-duction and use.

Wind in Their SailsFor decades, Europe had been the global leader in harness-ing wind power, but the United States is now emerging as a lead player out of necessity (less dependence on foreign oil), economic opportunity and environmental concerns. At the end of 2008, with wind power plants generating a total of 25,369 MW of electricity, the U.S. pulled ahead of long-time leader Germany (23,902 MW), according to the American Wind Energy Association (AWEA). The U.S. is now the world’s largest market for new wind power instal-lations (8,545 MW added in 2008), ahead of China (6,300 MW added in 2008).

“The fact that wind power is now mainstream is good news for our economy, our environment and our energy security,” AWEA noted in Windpower Outlook 2009.

AWEA points out the benefi ts of wind power, “one of the cleanest and most environmentally benign energy sources in the world today.” Among the advantages of this endless resource are a more stable climate (wind power gen-erates electricity without emitting gases that cause global warming), cleaner air (wind power does not emit pollutants that contribute to acid rain and smog), cleaner water (wind

power does not contaminate water with pollutants like mer-cury or require water for cooling or steam to drive turbines) and a light footprint (wind projects do not cause extraction and transportation of fuels or production of hazardous or toxic solid wastes, ash or slurry).

In fact, if wind power provided just 20 percent of America’s electricity needs by 2030, the electricity sector’s water use would decrease by 17 percent in that year, accord-ing to a U.S. Department of Energy report, 20 Percent Wind Energy by 2030.

Growth Provides OpportunitiesThe U.S. wind power market is providing new business opportunities for manufacturers. In 2008, there were 14 util-ity-scale, wind turbine manufacturers in the U.S.—up from eight in 2007 and six in 2005, according to AWEA. The key players include GE Wind Energy, Vestas and Siemens. These manufacturers rely on sub-suppliers for critical subas-semblies and components.

“Today, when selling a wind turbine to wind farm owners or power-supplying companies, wind turbine manu-facturers are faced with a demand for maximum produc-tion and limited downtime,” says Per Sonderriis, global sales manager, wind energy, of Danfoss A/S.

“All major wind turbine manufacturers have established their own control centers to follow the different wind tur-bines in wind farms around the world. The different systems and major components are followed closely in these control centers to deliver the promised production hours and to carry through service whenever needed.”

As the wind power market gains momentum, so has the need for components that help ensure maximum production and limited downtime. According to Sonderriis, the number of sensors in a wind turbine has increased dramatically in the

Wind and Water Take Center StageLisa Tryson, Danfoss

Intertwined with climate change, wind and water will signifi cantly impact global energy production and use.


last fi ve years. Temperature and pressure sensors indicate the condition of different systems or vital components within the turbine, such as pitch cylinders, oil brake, gearbox, mechanical disk brake, rotor lock system, hydraulic unit, yaw gears and air cooler for the generator.

“A vital component is the bearing,” Sonderriis says, “and measuring the temperature of the bearing indicates the bear-ing’s condition. If the temperature increases slowly over time, it can indicate that an overhaul of the bearing is needed. Or, if the temperature increase is sudden, it can signal that the bear-ing is failing.”

Bearing sensors meet the wind market’s demand for accurate and timely measurement of the bearing’s condition. Sensors typically feature a solid metallic contact between the sensor and bearing, ensuring that any temperature change is quickly transferred to the sensor. In addition, sensors are fl ex-ible on insertion length, which makes the accuracy of the bore in the bearing housing less critical.

Water, Water. . . Everywhere?Bearing sensors are just one example of technological inno-vation in the wind power market. Technology is also helping address the challenges facing the worldwide water market.

On a global scale, factors such as drought, long over-dense population zones, long-term natural climatic variation and other natural forces are reshaping the water equation.

“Water is the oil of the 21st century,” said Betsy Otto, vice president of strategic partnerships for American Rivers, speaking at the ninth Danfoss EnVisioneering symposium, “At Water’s Edge: The 21st Century Agenda in Water Strategy and Technology.” American Rivers is a Washington, D.C.-based, non-profi t association that strives to protect and promote U.S. rivers as valuable assets for health, safety and quality of life.

The population explosion, both in the U.S. and abroad, will put tremendous stress on global water supplies—99.23 percent of which are unusable for most humans, says Mark Shannon, director of the National Science Foundation’s Center of Advanced Materials for the Purifi cation of Water with Systems. By 2030, he predicts that many U.S. cities—Atlanta, Chicago and Denver are prime examples—will see “massive increases in water usage.” In fact, water consumption increases twice as fast as the rate of population growth.

According to the U.S. Environmental Protection Agency (EPA), water quality will also become an issue as the changing climate mixes with the greater demand for water supplies. An increasing number of conversations on better water manage-ment, strategy and technology are happening nationwide to ensure the sustainability of the U.S. population, infrastructure and industry.

Fortunately, one of America’s most water-challenged states, California, is taking a fresh approach. With a growing popula-tion, reduced water supplies and an aging infrastructure, the state faces a crisis to secure future water supplies, but it also

boasts the most advanced thinking on macro-water strategy.The California Department of Water Resources has

developed a comprehensive strategy that focuses on three main areas:

Regional strategies include fully implementing Integrated • Regional Water Management and aggressively increasing water use effi ciency.Statewide strategies include practicing and promoting • integrated fl ood management, enhancing and sustaining ecosystems, advancing and expanding conjunctive manage-ment of surface and groundwater resources, and fi xing the Delta region.In addition, the department seeks to improve management • and decision-making capacity. This involves preserving, upgrading and increasing monitoring, data analysis and management; planning for and adapting to rising sea levels; and identifying and funding climate change impacts as well as adaptation research and analysis.

While California implements its strategy for addressing climate change, water management and energy effi ciency, industry partners are doing their part to develop innovative, cost-effective technology solutions. These advanced technolo-gies will play a key role in solving California’s—as well as the world’s—water challenges, says John Masters, director of sales, Water and Wastewater, Danfoss Drives.

“Technology is the central element in every meaningful response to the water crises the world is facing,” Masters says. “Part of the challenge is behavior-based and cultural, but tech-nology offers an avenue to a water-secure world.”

Relevant technologies range from point-source water heat-ers—74 percent of water energy is used after the water passes the meter at its point of use—to “smart” metering, which can give water departments greater control over usages and con-sumers a clearer standard of appropriate water usage to meet.

“The dialogue on water strategy and technology is just beginning,” Masters emphasizes. “We’re convinced that an enlarged dialogue between the worlds of engineering and policy will be critical.”

The same could be said for the wind power market. If world economies desire to fully tap into the tremendous resource of wind, it will take cooperation from governments, industry, regulatory bodies and end users.

P&S

Lisa Tryson is the director of communications at Danfoss, [email protected].


Poly-Ceramic Pump BasesPrecision Polymer Casting introduces CASTINITE HCR poly-baseplates. They are produced using the latest polymer casting technology, consisting of high chemical resistance polymers mixed with precisely blended ceramic aggregates. They are cast so fl at that little or no shaft alignment adjustment is needed. This new design features a no drip top edge, a threaded grout hole and cast in place tapped holes for easy stilting. These highly chemical resistant baseplates are cast in accordance with in ANSI standard sizes and can be ordered in most basic colors. Virtually any custom design can be produced quickly and economically using composite tooling. Their factory direct pricing is comparable to plain steel.Circle 201 or go to psfreeinfo.com

Polymer Mixing SystemProMinent Fluid Controls, Inc. offers the ProMix-S, a pre-engineered polymer mixing system made for the water

and wastewater markets. Applications include emulsion or dispersion poly-mer activation, coagulant or solution polymer feed, water and wastewater treatment, clarifi cation and sludge treatment. Visit the ProMix display at AWWA Booth Number 555.Circle 202 or go to psfreeinfo.com

Explosion Proof PumpsUsing technology unique to the industry, Zoeller Pump Company’s new Automatic Explosion Proof pumps are high head pumps for submersible sewage or dewatering applica-tions. Features include motors FM listed for Class 1, Division 1, Group C & D environ-ments plus durable cast iron cover, motor adapter and pump housing with stainless steel parts that will not rust or corrode. Available in 2 or 3 in NPT Flange discharge.Circle 204 or go to psfreeinfo.com

CondenserThe shell and tube heat exchanger designed for a condenser application is the typical heat transfer design used in fl ash steam condensers. Other heat exchanger units that can be used are spiral, plate and frame, and fi n coil units (heating units for air or process gases). Materials and installation considerations will vary depending on the application. All vented condensers are engineered for the application.

Fluid for the CondenserTo condense the fl ash steam, the condenser requires a fl uid temperature of less than 160 deg F (general consideration). The fl uid can be a liquid or vapor, depending on the application. If an insuffi cient quantity of cooling fl uid for the fl ash steam is in a liquid cooling system, then the plant should consider using a fl ash steam bypass or some other method to prevent the cooling liquid from absorbing too much energy and changing from a liquid to a vapor, causing water hammer.

Heating air is another application for a vent condenser. Figure 4 shows the air passed over a tube fi n confi guration with the fl ash steam inside the tube. The lower temperature air con-denses the fl ash steam and the condensate is allowed to drain back into the condensate tank.

Pressure on the Condensate TankIn choosing the design of the vent condenser, the plant must

ensure it chooses a design that does not create signifi cant pres-sure for the condensate receiver tank. The fl ash steam vent line from the condensate tank to the condensing unit velocities should not exceed 900 feet per minute.

Required InformationTo purchase, install and operate a vent condenser successfully, the plant should know whether the following parameters are maximum, minimum or normal: 1. Condensate fl ow rate2. Flash steam fl ow rate3. Cooling fl uid fl ow rate

Checklist 1. Find and document the different fl ash steam vent lines

discharging to the atmosphere.2. Determine the fl ash steam loss to the atmosphere.3. Calculate the projected energy loss and emissions

reduction.4. Determine what types of cooling fl uids are available.5. Install a condensate tank with a vent condenser.

Next month we will look at fl ash steam recovery from non-modulating steam applications.

P&S

(continued from page 63)

Maintenance Minders

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Asset management of urban water and wastewater networks

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INDEX OF ADVERTISERS

A.W. Chesterton Co. 122 35ABB Discrete Automation 123 15Advanced Diamond Technologies 153 79Alignment Supplies 154 78All Prime Pumps 165 95Applied Industrial Technologies 100 25Applied Industrial Technologies 101 45ASI 124 36ATC Diversifi ed Electronics 125 12Baldor Electric Co. 102 13Benshaw, Inc. 126 23Benton Foundry, Inc. 127 34Blacoh Fluid Control, Inc. 128 8Blue-White Industries 129 7Cashco, Inc. 130 47Chemicals Direct 166 94Control Microsystems 131 10Dan Bolen & Associates 167 94Danfoss 142 24EagleBurgmann 103 1Emerson Industrial Automation 143 31Equipump, Inc. 183 92Fairbanks Morse 144 66Flexitallic 104 33Flowserve 132 16Fluke 105 55Frost & Sullivan 155 93Fuji Electric 106 37Garlock Sealing Technologies 107 5

GE Energy 108 22Global Pump 111 61Graphite Metallizing Corp. 156 70Griffco Valve, Inc. 133 57Heinrichs USA LLC 157 78Hydraulic Institute 158 93Hydromatic 134 43Inpro Seal 109 BCITT Corporation 113 3ITT Goulds 145 63Junty Industries, Ltd. 168 95Larox Flowsys 110 59Load Controls, Inc. 135 40Load Controls, Inc. 182 92Ludeca 146 30Maintenance Troubleshooting 169 95Megator Corporation 159 79Meltric Corporation 170 94Metal Masters, Inc. 171 94Moyno, Inc. 112 IFCMSE of Canada Ltd. 172 93Myers 136 26National Pump Co. 137 17NOC 185 92Onyx Valve Co. 138 50Orival 147 74Perifl o 114 9Precise Castings, Inc. 173 95Proco Products, Inc. 148 71

ProMinent Fluid Control, Inc. 115 19Pump Solutions Group 149 65Pumping Machinery 184 92Revere Control Systems 160 38Salem Republic Rubber Co. 139 48seepex, Inc. 140 41Serfi lco 161 85Shanley Pump & Equipment, Inc. 162 38ShinMaywa 163 85Sims Pump Co. 116 51Sims Pump Co. 116 95Summit Pump 175 93Synchrony, Inc. 117 11Tamer Industries 176 94Teco Westinghouse 118 20The Fulfl o Specialties Co. 150 67Toshiba 174 27Trachte, Inc. 177 95Trask-Decrow 178 93Tuf-Lok International 179 94Val-Matic Valve & Mfg. Corp. 151 75Valve & Filter Corp. 141 53Vaughan 119 IBCVerder 164 70Vertifl o 180 95Vesco Plastics Sales 181 94WEFTEC 120 91Zoeller 121 49* Ad index is furnished as a courtesy and no responsibility is

assumed for incorrect information.

Advertiser Name R.S. # Page Advertiser Name R.S. # Page Advertiser Name R.S. # Page


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P&S Stats and Interesting Facts


P&S Stats and Interesting Facts

1150

1200

1250

1300

1350

1400

1450

1500

1550

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

-0.40%

-0.20%

0.00%

0.20%

0.40%

0.60%

0.80%

Apr-09 May-09 Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10

Pump and Pumping Equipment Manufacturing

Air and Gas Compresor Manufacturing

Pump and Compressor Manufacturing

65.00%

70.00%

75.00%

80.00%

85.00%

90.00%

95.00%

Apr-09 May-09 Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10

Chemical

Food, Beverage and Tobacco

Petroleum and Coal Products

Mining

Paper

$1.50

$1.70

$1.90

$2.10

$2.30

$2.50

$2.70

$2.90

$3.10

$3.30

Apr-09 May-09 Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10

Average Price of Gasoline

Average Price of Diesel Fuel

Rig Count (U.S.): Jan. 7 - May 7, 2010

Num

ber

of R

igs

Run

ning

Week

Month-to-Month Percentage Price Change in Pumps and Compressors

Plant Capacity Utilization by Industry

Average Fuel Prices (United States)

Source: Baker-Hughes Inc.

Source: Federal Reserve Statistical Release

Source: Energy Information Administration

The Producer Price Index program of the U.S. Department of Labor measures the average change over time in the selling prices received by domestic producers for their output. These charts detail the month-to-month percentage change in selling prices. Source: U.S. Department of Labor

The Inpro/Seal Company has been in the business of bearing protection for rotating equipment for 32 years and counting. We have been supplying bearing protection for the IEEE-841 motors since they were first introduced to industry. It is only logical that we would expand into the field of motor shaft current mitigation to protect motor bearings. The CDR is:

Machined entirely out of solid corrosion resistant and highly conductive bronze, the CDR/MGS is capable of carrying 12+ continuous amps. They are made exclusively by the Inpro/Seal Company in Rock Island, IL, to ensure consistent quality and same-day shipments when required.

The CDR and MGS (Motor Grounding Seal) products were developed in our own Research and Experimentation Laboratory and then extensively tested and evaluated by professional motor manufacturing personnel. Our standard guarantee of unconditional customer satisfaction of product performance applies. We stand behind our products.

When you order a CDR or MGS from Inpro/Seal, you are assured of the complete responsibility for technology and performance from a single source. We want to earn the right to be your first choice for complete bearing protection.

ROBUST

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For more information visit www.inpro-seal.com/CDR or contact800-447-0524 for your Inpro/Seal Representative.


5 pumps and systems - june 2010

Documents

correct duty pointjens

metalized lm capacitors

air inlet ports

external heat exchanger

swagelok energy advisors

highest failure rate

dc link choke

ac line reactor