november 2013

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2 November 2013 www.pump-zone.com PUMPS & SYSTEMS

From the Editor

PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 200, 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 subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call (630) 739-0900 inside or outside the U.S. POSTMASTER: Send changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. ©2013 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 descrip-tions 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. Volume 21, Issue 11.

is a member of the following organizations:

Our favorite time of the year, trade show season, is in full force. h e

Pumps & Systems team recently returned from two of our biggest annual shows—Pump Users Sym-posium/Turbomachinery in Hous-ton and WEFTEC in Chicago. h is month, we will attend the SWPA Fall Meetings/Training in Atlanta and POWER-GEN Inter-national in Orlando. In Decem-ber, we travel to Nashville for the National Groundwater Association Exposition (NGWA) and then to New York for Chem Show.

h e buzz from the showroom l oors has been positive. Most industry professionals anticipated a strong i nish for 2013 and plenty of growth and optimism for 2014. We will explore more of this insight in our annual State of the Industry issue in January.

By the end of this year, our team will have trav-eled to 10 process industry trade shows and i ve upstream oil & gas shows. We will have visited more than 20 manufacturing facilities with our Pumps & Systems on Tour series (see this exclu-sive coverage at www.pump-zone.com). No other pump industry publication has witnessed this many distinctive processes, innovative technolo-gies and unique installations. We will continue to provide this truly special coverage in 2014.

Meanwhile, enjoy this issue which explores pumping processes in one of our most important industries—power generation. h e cover series (page 38) includes innovative motor and gear tech-nologies and future-ready asset monitoring. Our Instrumentation, Controls & Monitoring special section (page 22) discusses the implementation of pressure sensors, automation architecture for trans-continental pumping stations and key information about arc l ash and shock protection.

Best regards,

Michelle [email protected]

Thomas L. Angle, P.E., MSc, Vice President Engineering, HidrostalAG

Robert K. Asdal, Executive Director, Hydraulic Institute

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

Kerry Baskins, Vice President of Sales, Viking Pump

Walter Bonnett, Vice President Global Marketing, Pump Solutions Group

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

Chris Caldwell, Director of Advanced Collection Technology, Business Area Wastewater Solutions,Sulzer Pumps, ABS USA

Jack Creamer, Market Segment Manager-Pumping Equipment, Square D by Schneider Electric

Bob Domkowski, Business Development Manager – Transport Pumping and Amusement Markets / Engineering Consultant, Xylem, Inc., Water Solutions USA – Flygt

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

Walt Erndt, Director of Market Development SSB, Environment One Corporation

Joe Evans, Ph.D., Customer & Employee Education, PumpTech, Inc.

Ralph P. Gabriel, Chief Engineer—Global, John Crane

Bob Langton, Vice President, Industry Sales, Grundfos Pumps

Larry Lewis, President, Vanton Pump and Equipment Corp.

Todd Loudin, President/CEO North American Operations, Flowrox Inc.

John Malinowski, Sr. Product Manager, AC Motors, Baldor Electric Company, A Member of the ABB Group

William E. Neis, P.E., President, Northeast Industrial Sales

Lev Nelik, Ph.D, P.E., APICS, President, Pumping Machinery, LLC

Henry Peck, President, Geiger Pump & Equipment Company

Mike Pemberton, Manager, ITT Performance Services

Scott Sorensen, Oil & Gas Automation Consultant & Market Developer, Siemens Industry Sector

Adam Stolberg, Executive Director, Submersible Wastewater Pump Association (SWPA)

Bruce Stratton, Product Manager, KLOZURE®, Garlock Sealing Technologies

Kirk Wilson, President, Services & Solutions, Flowserve Corporation

PublisherWalter B. Evans, Jr.

VP of SalesGreg Meineke

VP of EditorialMichelle Segrest

Creative DirectorTerri Jackson

ControllerTim Moore

EDITORIAL

EditorMichelle Segrest

[email protected] • 205-314-8279

Managing EditorLori K. Ditoro


Associate EditorAmanda Perry


Contributing EditorsLaurel DonohoJoe Evans, Ph.D.

Lev Nelik, Ph.D., PE, APICS

CREATIVE SERVICES

Senior Art DirectorGreg Ragsdale

Art DirectorJaime DeArman

Web Content EditorRobert Ring

PRODUCTION

Print Advertising Traffi cLisa Freeman


Web Advertising Traffi cAshley Morris


CIRCULATION

Jeff [email protected] • 630-739-0900

ADVERTISING

Derrell [email protected] • 205-345-0784

Mary-Kathryn [email protected] • 205-345-6036

Mark [email protected] • 205-345-6414

Addison [email protected] • 205-561-2603

Vince [email protected] • 205-561-2601

P.O. Box 530067Birmingham, AL 35253

Editorial & Production1900 28th Avenue South, Suite 200

Birmingham, AL 35209Phone: 205-212-9402

Advertising Sales2126 McFarland Blvd. East,. Suite A

Tuscaloosa, AL 35404Phone: 205-345-0477 or 205-561-2600

Editorial Advisory Board

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Table of Contents November 2013Volume 21 • Number 11

2 From the Editor

6 Readers Respond

8 News

48 Trade Show Coverage

50 Effi ciency MattersBy Brent Ross, Armstrong Fluid TechnologyIntelligent Pumps in Masdar City

56 Maintenance MindersBy Andy Hoy, SKF USA Inc.Partnerships for Optimized Machine Reliability

60 Sealing SenseBy FSA members Dick Dudman and Thom JessupHistory, Advantages & Applicationsof Pressure Seals

62 HI Pump FAQsBy The Hydraulic InstituteAdverse Effects of Mechanical Processes, Pump Suction Recirculation & NPSH Requirements for Vertical Pumps

64 Business of the BusinessBy Anand MG, Frost & SullivanPump Services: An Increasing Revenue Stream in the Industry

80 Product Pipeline

83 Index of Advertisers

84 Pump Users Marketplace

88 Pump Market Analysis

Departments

22 Implement the Ideal Pressure SensorBy Kyle Horsman, TURCKConsider application and performance requirements to properly select a pressure sensor for any system.

28 TransCanada Keystone Pipeline PumpStation ControlBy Ted Fowler, Siemens Energy, Inc.Flexible design is important for the future growth of generic, multivari-able transcontinental pump stations.

33 Industrial GFCIs Can Save LivesBy Nehad El-Sherif, LittelfuseFor applications in which electricity, people and water meet, this equip-ment can prevent on-the-job injury and death.

39 Innovative Motor & GearingTechnologies for High-Capacity, Low-Head PumpsBy Aron Abel, Baldor Electric CompanyReduce high vibration and increase reliability with CST gear motor technology in power generation applications.

42 The Future of Asset Monitoring TechnologiesBy Roberto Piacentini, Preston Johnson & Theresa Woodiel, National InstrumentsSophisticated asset monitoring systems provide benefi ts including cost savings, longer equipment life span and production assurance.

Practice & Operations

Columns16 Pump Ed 101

By Joe Evans, Ph.D.

Suction Specifi c Speed & Wastewater Pumps

20 Pumping PrescriptionsBy Lev Nelik, Ph.D., P.E., Pumping Machinery, LLC

Simplify Pump Design

Instrumentation, Controls & Monitoring

Power Generation Operations

68 Understand European Pump StandardsOrganizations & ProcessesBy Tom Angle, Hidrostal AG, Frank Ennenbach, & Friedrich Klütsch,VDMANorth American pump manufacturers and specifi ers can benefi t from knowledge of European standards.

72 A Holistic Approach to Identify Cost ReductionOpportunities in Pump SystemsBy Darren Moscato, ITT PRO ServicesMany plants may have a fragmented view of the true factors at work in improving productivity.

76 Water-Lubricated Sealing Solution forChemical ProductionBy Peter Jap & Andries Tuk, IHC Sealing SolutionsHeavy, salty pumped fl uids can be sealed with a water and buffer system.

78 Advantages of WasteHeat DistillationBy Brian Hebert, Maxim WatermakersEnergy effi ciency and minimal replacement parts make waste heat desalination a cost-effective solution to potable water making needs.

SPECIAL

SECTION

COVER

SERIES

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C O M P R E S S O R S T U R B I N E S G L O B A L S E R V I C E

EBARA CORPORATION

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Customer:Petrochemical plant, Malaysia.

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READERS RESPOND


“Resonant Frequencies,” October 2013

After perusing the October Pumps & Systems, I noticed that four of

the exponents shown on page 18, of “Resonant Frequencies,” were

shown as “4” instead of the intended “2.” They are highlighted in

green below.

ωn2 = βn4 x E I / (m/L) [Equation 1]

The following is a modii cation of Equation 1 to approximately

account for the effect of added axial shaft tension:

ωn2 = βn4 x E I / (m/L), can be rewritten as:

ωn2 = (βn2 x E I) x βn2 / (m/L)

Now add additional axial loading, “F.” to the axial force (βn2 x E

I), and the revised Equation 1 becomes:

ωn2 = (βn2 x E I + F) x βn2 / (m/L)

This can then be written as:

ωn2 = ωn(o)2 + βn2 x F / (m/L)

Where:

ωn(o) is the frequency without axial loading

from the original Equation 1.

Lee Ruiz

Oceanside, Calif.

“Why Root Cause Analysis Fails at Problem Elimination,” October 2013

I would like to respond to this article. First, I would say that it is

nice to see the errors pointed out in the philosophy of root cause

analysis (RCA) versus continuous improvement programs. I would

like to point out, though, that I disagree with the author’s analysis

of troubleshooting. I have, in the past, run into this same thought,

and I can explain it. Troubleshooting is not “problem solving” or

RCA. It is the i rst series of steps taken to dei ne the problem.

Troubleshooting is not supposed to “solve problems” or dei ne the

problem’s cause. It is supposed to identify the actual problem.

The author correctly identii es that the skill of the troubleshooting

team contributes greatly to their success. He incorrectly identii es

that troubleshooting is not a systematic approach. Troubleshooting

is a skill set that must be correctly trained. It is a series of system-

atic steps used to rule out false problems and symptoms and cor-

rectly identify the problem. Properly conducted, it is not haphazard

nor trial and error. If that is how your troubleshooters are operating,

your results will be weak at best. In my opinion, I believe the steps

and systems should be used together.

• Step 1—Properly and systematically trouble shoot the system

to identify the problem.

• Step 2—Using all available

resources (such as SMEs, tech-

nical data, performance history

current and historical conditions,

data, and anomalies), solve the

problem.

• Step 3—Conduct a proper RCA

to verify that the problem has been properly solved and deter-

mine if it will be a recurring issue. If so, what further steps are

necessary to prevent recurrence?

Of course, I also believe that the last two steps can be done at

the same time if the people involved choose to do so. As to con-

tinuous improvements, I believe that is an entirely different subject,

but occasionally, the two cross paths.

Richard Nielsen

Technical Trainer

PPL Montana

Mark Latino responds:

h ank you for sharing your experiences. I don’t think we are on dif erent pages, just perhaps using a dif erent dictionary.

h e troubleshooter’s series of steps referred to in the comment are cognitive based on individual experience. h erefore, each person could use dif erent steps in a dif er-ent order (more like trial & error) than problem solving. However, problems can and are solved through trouble-shooting when the experience levels of the troubleshooter match the problem at hand. If a problem solving step-by-step document is created and used as a checklist of things to evaluate, then I would see it more as problem solving. I have seldom seen mechanics use checklists to problem solve. Most ot en, obviously failed components are replaced with little to no problem solving until they become repeti-tive. P&S

To have a letter considered for Readers Respond, please send it to Amanda

Perry, [email protected].

properly solved and deter

Lee Ruiz

See what readers are talking about

on our Pump Chat Forum.

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NEWS


NEW HIRES, PROMOTIONS & RECOGNITIONS

DUNCAN COOPER, Grundfos

DOWNERS GROVE, Ill.(Oct. 1, 2013) Grundfos appointed Duncan Cooper as president and chief executive oi cer of the company’s North American region. Cooper succceeds Jes Munk Hansen, who leaves the company to pursue other interests at er leading the region for the past i ve years. Cooper has 16 years of experience within the company, most recently as regional managing director of Grundfos Western Europe. In his new position, Cooper will oversee and direct all operations in the U.S., Canada and Mexico. Grundfos is a pump solution provider. www.grundfos.us

LUCILLE CORSINI,

BJM Pumps

OLD SAYBROOK, Conn. (Sept. 26, 2013) – In remembrance of long-time employee Lucille Corsini, BJM Pumps has dedicated a newly built employee patio to her. A special luncheon was held to honor her memory. At the event, BJM team members shared fond memories of Lucille. Lucille’s daugh-ter Laura and son-in-law Anthony were also in attendance.

A brass plaque was placed along the wall next to the patio naming the patio, “Lucille’s Patio” and states, “She will always be remembered for her devotion to our custom-ers and for the constant, positive support she gave to her BJM family.” White roses wrapped with purple ribbons were also given to those in attendance. In addition, Ron Woodward, BJM President, read a poem written to honor her. BJM Pumps provides l uid handling solutions for industrial and municipal services. www.bjmpumps.com

CHRIS HUNTSMAN, COOPER Valves

STAFFORD, Texas (Sept. 24, 2013) COOPER Valves added Chris Huntsman to its management team as operations manager. Huntsman will guide COOPER through its rapid growth path and develop cost-ef ective manufacturing processes. COOPER Valves manufactures exotic and nickel alloy valves. www.cooper-valves.com

METSO Voted Top Automation Supplier for the Pulp and

Paper Industry

HELSINKI (Sept. 19, 2013) – Metso’s automation busi-ness has been recognized by the Brazilian Pulp and Paper Technical Association (ABTCP) with the “top supplier of automation for the pulp and paper industry” award. h e awards have been organized by ABTCP for the past 12 years. h is is the eighth consecutive year that Metso has won the automation category. Metso supplies technology and services to the process industries. www.metso.com

BRUCE HAUK, Partnership for Safe Water

Steering Committee

DENVER (Sept. 17, 2013) – Bruce Hauk, a 17-year water industry professional, was appointed to the Partnership for Safe Water Steering Committee for a three-year term. Hauk, currently vice president of Operations at Indiana American Water, brings years of in-depth experience in the water and wastewater industry to the Partnership’s Steering Committee as the National Association of Water Companies representative.

Lucille Corsini Memorial

Chris Huntsman

Duncan Cooper

MERGERS & ACQUISITIONS

EMERSONacquires Enardo LLC Oct. 4, 2013

SOR CONTROLS GROUP, LTD.acquires Smart Sensors Incorporated Oct. 3, 2013

DANFOSSacquires Sauer-Danfoss Oct. 3, 2013

SEAL ANALYTICAL acquires h omas Cain Oct. 1, 2013

INVENSYS acquires InduSot Sept. 24, 2013

ACTEONcompletes acquisition of Probe Oil Tools Ltd. Sept. 9, 2013

FTL CAPITAL LLC acquires Process Controls International d.b.a Automation Service Sept. 9, 2013

GEannounces partnership with XD Electric Aug. 27, 2013

EDWARDS GROUPenters into dei nite agreement to be acquired by Atlas Copco Group Aug. 19, 2013

For details about industry M&A activity, subscribe to

Pump Industry Insider and visit www.pump-zone.com.

PUMPS & SYSTEMS www.pump-zone.com November 2013 9

Indiana American Water, a sub-sidiary of American Water, provides water and/or wastewater services to approximately 1.2 million people. www.amwater.com

h e Partnership for Safe Water is a voluntary self-assessment and optimi-zation program for water treatment plant and distribution system opera-tion. It is sponsored by the American Water Works Association, Association of Metropolitan Water Agencies, Association of State Drinking Water Administrators, United States Environmental Protection Agency, National Association of Water Companies and the Water Research Foundation. www.awwa.org

ALL CRANE RENTAL of Georgia Wins

Workplace Safety Award

ATLANTA (Sept. 10, 2013) – ALL Crane Rental of Georgia—includ-ing branches in Atlanta, and its sister location in Phenix City, Ala.—were presented with the 2012 Award of Excellence from the Georgia Department of Labor in recognition of Exceptional Workplace Safety. For the Atlanta branch, it was the eighth consecutive win, and for the new Phenix City, Ala., branch, the second in a row. ALL Crane Rental of Georgia, Inc., is a member of the ALL Family of Companies.

ALL Family of Companies of ers its l eet of cranes, aerial work plat-forms, boom trucks, material han-dlers and other lit equipment from strategic locations. www.allcrane.com

MARK BRETT, Wood Group Mustang

HOUSTON (Sept. 9, 2013) Wood Group Mustang appointed Mark Brett director of business development for its Process Plants & Industrial Business Unit for its Martinez, Calif., location. Brett will c

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oversee the company’s West Coast business development, expanding brand presence and strategic direction for the California and Pacii c Northwest regions.

Wood Group Mustang is a global project management, engineering, procurement and construction operations company. www.mustangeng.com

GARY SIEGEL, Continental Pump

WARRENTON, Mo. (Sept. 11, 2013) – Continental Pump announced that Gary Siegel has retired at er 17 years of service.

Continental Pump Company manufactures progressing cavity pumps. www.continentalultrpumps.com

STEVEN R. LORANGER, Xylem Inc.

WHITE PLAINS, N.Y. (Sept. 9, 2013) – Xylem Inc. appointed Steven R. Loranger as chief executive oi cer and president. Loranger was chair-man, president and CEO of ITT Corporation when it spun its water businesses of as Xylem in October 2011. He currently serves as a direc-tor of Xylem and succeeds Gretchen W. McClain.

Xylem is a global water technology provider. www.xyleminc.com

GERALD KARCH, Putzmeister

AICHTAL, Germany (Sept. 2, 2013) – Putzmeister appointed Dr. Gerald Karch as CEO and successor of Norbert Scheuch. Scheuch let the company in mutual agreement at er four years as CEO. In addition CEO, Karch will be appointed to the Board of Sany.

Putzmeister is a German manufac-turer of concrete pumps. www.putzmeister.com

AROUND THE INDUSTRY

IMAGINE H20 Launches Water

Business Competition

SAN FRANCISCO (Oct. 1, 2013) Imagine H2O launched its i t h annual competition for water busi-nesses. h is year’s program advances innovations that improve water use, supply and treatment in commercial agriculture and food processing. h e program is open to entries through November 15 and features tracks for early-stage and growth-stage water businesses.

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HYDRO INC. Opens New Repair Facility in

United Arab Emirates

CHICAGO (Oct. 8, 2013) – Hydro Inc. announced the opening of its newest pump repair facility in Dubai Techno Park. h is 20,000-square-foot service center is purpose-built to of er the region’s oil and gas, petrochemical and power generation markets with customized solutions for pump, drilling and rotating equipment.

Hydro Inc. is an independent pump rebuilder with service centers throughout the world. www.hydroinc.com

WORLD ENERGY COUNCIL Reports

Sustainable Future Dependent on

Energy Industry Support

WASHINGTON (Sept. 24, 2013) h e global energy industry must play a greater role in the transition to sustainable energy systems if United Nations development goals are to be met, warns a report launched by the World Energy Council (WEC). It reports that the potential for billions of people benei ting from sustainable energy systems in future decades hangs in the balance without increased private sector support. h e WEC’s 2013 World Energy Trilemma report, “Time to Get

Real – h e Case for Sustainable Energy Investment,” was produced with global management consulting i rm Oliver Wyman. h e World Energy Council is an alliance of more than 90 countries that provides information on all aspects of energy. www.worldenergy.org

Hydro Inc.’s new facility in Dubai Techno Park

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NEWS


HARRINGTON INDUSTRIAL PLASTICS Opens Branch in Alaska

ANCHORAGE, Alaska (Sept. 23, 2013) – Harrington Industrial Plastics announced the opening of a branch location in Anchorage. For more than 30 years, h e facility will be equipped to make local deliveries from its fully stocked warehouse.

Harrington Industrial Plastics distributes industrial plastic piping. www.harringtonplastics.com

THOMPSON PUMP Announces

Branch Location Move

PORT ORANGE, Fla. (Sept. 17, 2013) – h ompson Pump & Manufacturing Co., Inc., announced the move of its Atlanta Area Branch in Conyers, Ga., to a larger facility at Sigman Industrial Court in Conyers. h e new branch location is situated on 3.17 acres and features a larger oi ce facility and a 5,500-square-foot warehouse.

h ompson Pump manufactures heavy-duty lines of high-performance pumps. www.thompsonpump.com

FRANKLIN ELECTRIC Relocates to

New World Headquarters

FORT WAYNE, Ind. (Sept. 9, 2013) Franklin Electric Co., Inc., relocated to its new World Headquarters and Engineering Center of Excellence. h e new facility is located in Fort Wayne, Ind., and will serve as its corporate headquarters and expand

its research, development, design and testing capacity.

Franklin Electric is a motor manu-facturing company and provider of complete water systems and fueling systems. www.franklin-electric.com

P&S

To have a news item considered, please send the

information to Amanda Perry,

[email protected].

Franklin Electric’s new headquarters

Harrington’s new Alaska branch

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NEWS


NOVEMBER

SWPA PUMPING SYSTEMS &

CONTROLS TRAININGNov. 6 – 7

Westin Atlanta Airport

Atlanta, Ga.

www.swpa.org

POWER-GEN INTERNATIONALNov. 12 – 14

Orange County Convention Center

Orlando, Fla.

888-299-8016 / www.power-gen.com

PUMPTEC-ISRAEL 2013Nov. 20 – 21

Haifa, Israel

+972-50-865-0451 (Israel)

or 770-310-0866 (U.S.)

www.pumpingmachinery.com

DECEMBERNATIONAL GROUNDWATER

ASSOCIATION EXPODec. 3 – 6

Nashville, Tenn.

800-551-7379 / www.ngwa.org

CHEM SHOWDec. 10 – 12

Javits Center

New York, N.Y.

203-221-9232 / www.chemshow.com

JANUARYAHR EXPOJan. 21 – 23, 2014

Javits Convention Center

New York, N.Y.

203-221-9232 / www.ahrexpo.com

IPPEJan. 28 – 30, 2014

Georgia World Congress Center

Atlanta, Ga.

678-514-1977 / www.ippexpo.org

MARCHCONEXPO-CON/AGGMarch 4 – 8, 2014

Las Vegas Convention Center

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PUMP ED 101


By Joe Evans, Ph.D.

PumpTech Inc.

P&S Editorial Advisory Board

Suction Specii c Speed & Wastewater Pumps

In the February 2010 issue of Pumps & Systems, Idiscussed my Suction Specii c Speed (S) Calculator and

its ability to predict the stable range of l ow for a particular centrifugal pump. In November 2011, I wrote a follow-up that addressed the S value of wastewater pumps. Recently, I have seen some engineering specii cations that limit S to a maximum of 11,000 for any wastewater pump. I disagree with this across-the-board limit for several reasons that I will address in this column.

SUCTION SPECIFIC SPEED

In case you did not read my previous columns, I will start with a brief overview of suction specii c speed. In the early 1960s, many pump users began to encourage their manufac-turers to provide pump designs that reduced the required net positive suction head (NPSHr).

h e NPSHr at the best ei ciency point (BEP) l ow is a function of the impeller design, and a major design charac-teristic is the ratio of the impeller eye diameter to its over-all diameter. As this ratio increases, the entrance velocity decreases, and NPSHr is reduced. h ese large-eye impellers allowed pumps to oper-ate satisfactorily in applications with low NPSH available (NPSHa).

h ere was, however, a down side. h e peripheral velocity of the large eye also increased, and at some capacity, l ow into the entrance was distorted because of the high peripheral speed.

h is caused some of the l ow to reverse direction and begin recirculation at the entrance of the eye (suction recirculation). h is recirculation can result in intense vortices that cause cavitation and pressure pulsations.

h e l ow at which suction recirculation begins depends on the impeller design, but as the eye-diameter ratio increases, so does the recirculation point as a percent of BEP l ow. h e calculation for suction specii c speed was developed to help predict the point at which suction recirculation could begin. As the value of S increases, the l ow

at which recirculation can begin moves closer to BEP l ow. Guidelines were established that suggested that S values should not exceed a range of 8,500 to 9,500 for pumps that could potentially operate at l ows that were signii cantly below BEP l ow. Lower l ows could be caused by dynamic changes in system conditions or by a throttle valve at the discharge.

Suction specii c speed is calculated using Equation 1.

S = N √Q / NPSHr0.75 [Equation 1]

S is directly proportional to the pump speed in rpm (N) and the square root of pump l ow in gallons per minute (Q). It is inversely proportional to NPSHr to the three quarter power. h erefore, S will increase with an increase in speed and/or l ow. It will also increase with a decrease in NPSHr.

WASTEWATER EXAMPLES

Wastewater pumps are not designed for low NPSHr, but the large eye that is required for solids’ passage can reduce

5000

7000

9000

11000

13000

15000

17000

19000

21000

40 50 60 70 80 90 100

Su

cti

on

Sp

ec

ific

Sp

ee

d (

S)

Percent BEP Flow

500 - 2,500 Ns

5,000 Ns

10,000 Ns

Figure 1. Suction specifi c speed versus percent of BEP fl ow


NPSHr and, therefore, increase the value of S in certain designs.

Let’s take a look at a couple examples. h e two pumps described below have a 6-inch suction and are designed for a BEP rate l ow of 1,500 gallons per minute at a total dynamic head of 60 feet:• Pump A – 6-inch suction,

10-inch impeller, 1,750 rpm,NPSHr = 9

• Pump B – 6-inch suction,14-inch impeller, 1,150 rpm,NPSHr = 8

NPSHr is very similar for both, but Pump A operates at 1,750 rpm, while Pump B operates at 1,150 rpm. Both have a specii c speed (Ns) of around 2,200. Pump A has a relatively high eye-diameter ratio (0.54) which accounts for its low NPSHr. Pump B has a lower eye-diameter ratio (0.38), but because it operates at a lower speed, its NPSHr is also low. h e cal-culations for S are 13,044 for Pump A and 9,363 for Pump B. Based on the engineering specii cation I mentioned earlier, (S max = 11,000) Pump A would not be an acceptable option.

Figure 1 compares the values of S with the percent of BEP l ow at which recirculation can begin. Since Ns is less than 2,500 for both examples, we can use the blue curve for the compar-isons. h e lower, red arrow shows that Pump B could begin recirculation at about 43 percent of BEP l ow. h e upper, red arrow shows that Pump A could begin recirculation at about 52 percent of BEP l ow.

h e reason I disagree with the suction specii c speed maximum of 11,000 is that no wastewater pump should ever be operated anywhere near the two recirculation points shown in Figure 1. h e reasons that they should not be considered have nothing to do with recirculation. h e i rst is the cost of pumping. Once the process drops below about 85 percent

of BEP l ow, the cost per 1,000 gallons pumped increases substantially for most pumps.

h e second reason is pump life. Once the process drops below 75 percent of BEP l ow, higher head wastewater pumps will generate increased radial forces that will cause vibration and shorten the life of seals, bearings and wear

Do you have flows up to 1,400 US GPM(320 m3/hr), heads upto 3,400 feet (1,000 m),pressures up to 1,500psig (100 bar),temperatures from 20˚F to300˚F (-30˚C to 149˚C), and speeds up to 3,500 RPM?Then you need Carver Pump RS Series muscle!

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PUMP ED 101


rings. Why debate this? Why not just follow the engineer’s recommendation, and select Pump B? Well, you certainly can if you want to. h e pump I used in my example is a high-quality unit, but so is Pump A.

h e reason Pump A should be allowed is that its cost is about 40 percent lower because it has a higher rotational

speed. In many applications, 1,750-rpm pumps will have a life span that is very similar to their lower speed cousins, making i rst cost a signii cant factor in the equation.

Let’s close with one more example. A higher head, higher l ow pump is designed for 12,000 gallons per minute at 140 feet of total dynamic head. It has a 16-inch suction and a

22-inch impeller that rotates at 1,170 rpm. h e Ns is 3,250 and the NPSHr is 21 feet. h e calculated suction spe-cii c speed is 13,065, which is about the same as Pump A in the previous example.

Although the curve for Ns = 3,500 is not shown in Figure 1, the S value of 13,065 would intersect the curve at about 60 percent of BEP l ow. Once again, this is well below where any wastewater pump should operate.

Remember also that NPSH margin plays a role in the suction specii c speed’s predicted point at which recir-culation can begin. Most wastewater applications are l ooded suction and can take advantage of 100 percent of atmospheric pressure.

Also, suction submergence is typi-cally high. At sea level, the pump in this example could experience an NPSHa to NPSHr margin of 2-to-1. In the previous examples, it could be almost 5-to-1.

In my opinion, there is nothing wrong with high S-value wastewater pumps as long as they are sized cor-rectly for the application. At er all, suction specii c speed was developed to identify pumps that could undergo recirculation at signii cantly reduced l ows when running at full speed. It should not be used as a fudge factor for poor pump selection or system design. P&S

Joe Evans is responsible for customer and employee

education at PumpTech Inc., a pump & pack-

aged system manufacturer and distributor with

branches throughout the Pacii 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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PUMPING PRESCRIPTIONS By Lev Nelik, Ph.D., P.E.Pumping Machinery, LLC

P&S Editorial Advisory Board

Simplify Pump Design

Pump designers know that designing a complex pump iseasier than designing a simple one. Having my own roots

in design, I know how tempting it is to add another feature and a tweak to a pump design. Despite the best engineering intentions, pump designs developed in the comfort of an air conditioned design oi ce ot en end up a disaster in the i eld.

Statistics reveal that reliability is an inverse function of the number of components in a machine—doubling the number of parts reduces reliability by half. When apply-ing this simple rule to pumps, a double mechanical seal, for example, makes the entire pump less reliable when com-pared to a unit equipped with a single mechanical seal.

Another example is adding a feature of external adjust-ment to the end clearance between the pump and casing. h is may be a good selling feature, but it makes a pump more complex and less reliable.

Once the realities of the i eld kick in, the much-praised double mechanical seals may be replaced by single mechani-cal seals or eliminated and replaced with packing—a much simpler and more reliable method of keeping most of the l uid out of the pump. As for i eld-adjustment of the end clearance, most end users reset the clearance during over-hauls and not in the i eld. Modifying the clearance is not pleasant or easy and unwise when surrounded by running machinery, hot pipes, dirty enclosures and poorly lit corners.

Some of these more complex technologies are justii ed in some applications. Clearly, an 800-degree hot oil pump would not be a good place to apply packings. A highly corrosive acid is not a good natural lubricant for a packed stui ng box, which needs to leak for the packing to remain lubri-cated. h ese cases exist but are rare.

For perhaps 80 percent to 90 percent of pumps, the added feature is more a sales ploy than requirement for reliability. h is is why mechanical seals are installed on verti-cal pumps that move clean, or nearly clean, water, when they are not needed. In this pro-cess, a $300 packing would work adequately, without the dii culties and the expense of a mechanical seal. Because conducting a i eld study to correlate the overall expense asso-ciated with maintaining pumps and their components is impractical, the result is that end users remain at the mercy of whatever

improvement features were included with or added to the pumps.

Because the person who approves a feature may not know how to change a simple packing, impractical add-ons some-times happen in the i eld.

AN EXAMPLE

Let’s try to approximately quantify reliability for a simple, end-suction centrifugal pump (see Figure 1).

Notice that the shat diameter is smaller as it transitions from the bearing area to the seal area. For simplicity, the shat is 3 feet long, of which a 1-foot span is between the bearings (assume a 4-inch diameter), and a 2-foot (3-inch diameter) section is an overhung length from the bearing to the impeller. Intuitively, would you not feel somewhat uncomfortable with such a skinny shat ? Well, says the sales-man, you need this length…how else can you i t a double mechanical seal? We will calculate the radial del ection of the shat at the impeller. h e basic cantilevered-beam del ec-tion (y) formula is:

y = F x L3 / (3 x E x I) [Equation 1]

Where: F = radial loadL = cantilevered length (24 inches)E = modulus of the elasticity of the material (30,000,000

for steel in our example)

Figure 1. A simple, end-suction centrifugal pump


I = moment of inertia

For a circular shat , I = 3.14 x D4 / 64 (3.98 inches4 in our example), and therefore, a del ection at a given force is proportional to:

y ~ L3 / D4, or abbreviated, it is ot en written as L3D4

[Equation 2]

h e lower that L3D4 is, the less is the shat del ection, which is better for the seals. If L3D4 becomes too large, a pump shat can snap, espe-cially if operated close to shutof , where hydraulic radial loads are exces-sive. American National Standard Institute (ANSI) pumps, for example, have L3D4 ratios range from 20 to 120.

h e value of the radial load depends on many variables—such as a type of volute, operating point (percent of best ei ciency point) and other fac-tors beyond the limits of this article—but for this design, a 2,000-pound load is a reasonable estimate for this example:

y = 2,000 x 243 / [3 x 30,000,000 x 3.98] = 0.078 inch

[Equation 3]

What would happen if we shorten the shat by half (see Equation 4)?

y = 2000 x 123 / [3 x 30,000,000 x 3.98] = 0.009 inch

[Equation 4]

Equation 4 results in an order of magnitude reduction in del ection. h e L3D4 factor went from 243 / 34 = 171 to 123 / 34 = 21.

How will a reduction in shat del ection af ect pump life?

Can/should the shat be shortened by half ? If this is done, at what com-promise and at what price? Tell us,

and the best answer will appear in a later issue of Pumps & Systems. P&S

Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machinery, LLC, an Atlanta-

based i rm specializing in pump consulting, training, equipment troubleshoot-

ing and pump repairs. Dr. Nelik has 30 years of experience in pumps and pump-

ing equipment. He can be contacted at www.pump-magazine.com.

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Without measurement, there is no control. As with anytype of measurement, results should be clearly dei ned

to allow for accurate interpretation and application of the results. Accurate measurements and good measurement practices are essential in industrial automation and process environments because they have a direct ef ect on the success of the desired outcome.

Pressure, the act of a force on a specii ed area, is a common measurement used in many industries. Pressure sensors are used to measure pressure. A pressure sensor measures the amount of movement, or del ection, on an area with spe-cialty devices. Many current pressure sensors use a strain gauge or diaphragm that creates a signal to be processed based on the amount of del ection to which the diaphragm is exposed. Other technologies may also be used to mea-sure pressure—such as checking the changes in capacitance

because of pressure l uctuation, the straightening of tubes or using optical i bers.

REFERENCING PRESSURE

Pressure can be referenced in multiple ways. To accurately identify and relay pressure measurements, the application must be considered. Pressure sensors may use gauge, abso-lute, dif erential or sealed pressure.

Gauge Pressure

Gauge pressure uses a reference to the atmosphere around the sensor. Because the sensing element has a del ection as a result of a pressure change, a reference point is needed to know exactly what pressure is being measured. Pressure sen-sors that use gauge pressure—typically indicated in psi(g), bar(g), kPa(g)—have some type vent. h is vent can be built

Implement the Ideal Pressure SensorConsider application and performance requirements to properly select a pressure sensor for any system.

By Kyle Horsman, TURCK


SPECIAL

SECTION

Above: SAE fi ttings are a straight thread that uses a gasket to produce a seal, and they are generally used in high-pressure applications.



into the sensor or even through a tube in the electrical con-nection. h e vent is in place to use atmospheric pressure as a reference point for the sensor to measure the media. A common reason for using gauge pressure is to ensure that at any location throughout the world, the sensor will always reference the location in which it is installed.

Absolute Pressure

Absolute pressure uses a reference to a perfect vacuum. h is type pressure reference is the gauge pressure of the medium, in addition to the pressure of the atmosphere. As locations are changed, especially when dealing with elevation varia-tions, the reference point can change because of atmospheric pressure dif erences. Using an absolute pressure sensor elim-inates the reference to a varying atmospheric pressure and relies on a specii c pressure range for reference.

Differential Pressure

Dif erential pressure can be a little more complex than gauge or absolute but simply measures the dif erence between two media. Although most gauge pressures are technically a dif erential pressure sensor—measuring the dif erence between the medium and atmospheric pressure—a true dif erential pressure sensor is used to identify the dif erence between the two separate physical areas. For example, dif-ferential pressure is used to check the pressure drop—or loss—from one side of an object to the other.

Sealed Pressure

Sealed pressure is less common than the previous three but still has a place in pressure measurement. Sealed pres-sure uses a predetermined reference point, not necessarily vacuum. h is allows for pressure measurement in locations that will vary with atmospheric changes. Because of the predetermined reference point, no venting on the sensor is needed.

In many applications, absolute pressure is specii ed unnec-essarily. A common misconception is that all pressure mea-surement must be absolute. While a need for absolute pres-sure measurement exists, the majority of applications only need gauge pressure or another alternative. By understand-ing the application details, an appropriate pressure sensor can be easily selected. A correct pressure sensor allows for more precise processes and a proper outcome in the most ei cient and economical way.

TYPES OF PRESSURE SENSORS

All sensor types measure pressure using a similar method but express the results in dif erent ways.

Pressure Transducer

A pressure transducer measures the amount of force being applied and of ers an electrical signal—typically a resistance or very small voltage—as a representation for the pressure. h is type device is used for continuous pressure measure-ment and typically does not of er a visual display.

Pressure Transmitter

A pressure transmitter measures the same force being applied but of ers a common process signal—such as 0 to 10 volts, 0.5 to 4.5 volts or 4 to 20 (4-20) milliamperes—as a representation for the pressure. Similar to a pressure trans-ducer, a pressure transmitter is used for continuous pressure measurement but may of er a visual display.

Pressure Switch

A pressure switch measures the amount of force being applied and of ers an electrical signal—such as 24 volts direct current (DC) or 110 volts alternating current (AC) along with other variations—when certain conditions are met. h ese conditions can be predetermined or user-dei ned. A pressure switch is used for applications in which specii c pressures are a concern.

Pressure Gauge

A pressure gauge measures the amount of force being applied, but instead of an output, a visual representation of the pressure is given. Most pressure gauges use a needle on the face of a dial to indicate pressure. However, a digital rep-resentation may also be used.

SPECIFYING A PRESSURE SENSOR

h e right type of pressure sensor can vary signii cantly depending on the application. To ensure proper selection, end users should consider the following factors:

A pressure sensor measures the amount of movement,

or defl ection, on an area with the use of specialty devices.

SPECIAL SECTION


• What type sensor is required? h e i rst critical deci-sion is the sensor type. It should be determined whetherthe sensor needs to provide an output. h e answer tothis question can narrow the possibilities substantially.If no output is needed, the most economical choice is apressure gauge.

• If an output is needed, what type signal is needed, and what will interpret the signal? h is questiongenerally has a straightforward answer that is decidedby the individuals responsible for the application.Unfortunately, an output is commonly specii edwithout knowing the details of the input device that is

connected to the sensor. Available power and input/output (I/O) devices can all vary based on applications and the manufactur-ers of devices. Most manufacturers of I/O devices of er a wide variety of input types—such as 0 to 10 volts, 0.5 to 4.5 volts, 4-20 mil-liamperes and AC and DC switch signals—but the requirements for the devices can dif er because of multiple manufacturers of pres-sure sensors. In this case, end users must consider the electrical signal required, the operating voltage of the sensor and the input imped-ance of the I/O device.

• What is the pressure range tobe measured? h e majority ofapplications are simple and do notrequire much ef ort when select-ing a pressure range. However, acommon misconception is that asensor is only needed to measurethe typical pressure range. Ot en,variations occur in the system thatcan cause a dramatic rise or fallin pressure. A pressure spike—a sudden and sometimes veryshort burst of pressure—can beextremely damaging to the sens-ing device because the sensor isonly rated for a specii ed range. Insome instances, selecting a sensorwith extra pressure range is betterthan risking damage to the sensor.Pressure sensor manufacturersmust state the sensor’s range alongwith any type of overpressure orburst pressure ratings.

• How will the sensor be connected for measurement? Pressure sen-sors can seal the area that needs to

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SPECIAL SECTION


be measured in dif erent ways. h e type of application generally dictates which type i tting is needed. In the U.S., a tapered thread (NPT) is used for most common applications. An NPT connection seals as the tapered thread makes a connection when it is threaded into the i tting. However, this type connection still needs a seal-ant, such as polytetral uoroethylene tape, to keep the connection air/water tight. NPT connections are not rated for pressure more than 15,000 psi and are typi-cally not used in applications of more than 10,000 psi. Society of Automotive Engineers (SAE) i ttings are a straight thread that uses a gasket to produce a seal. SAE i ttings are generally used for higher pressure applica-tions but are not limited to them. British Standard Pipe Parallel (BSPP) threads, also known as gas (G) threads, are a straight thread typically used in Europe but are also seen in the U.S. Similar to SAE i ttings, BSPP/G threads are straight threads that use a gasket to seal the connection. BSPP/G threads can be used in general applications and higher pressure applications. For sanitary applications, a tri-clamp mount can be used. Tri-clamp i ttings have a gasket between the mounting

area and the sensor but do not require any threads. h is i tting is sealed by using a special clamp around the cir-cular connection. h is type connection allows for easy removal during cleaning processes. Many other process connections are available, and all have the proper seal for dif erent applications.

• What medium must be measured? h is can be criticalknowledge because of the sensor’s material of construc-tion. Chemical compatibility of the sensor materi-als that contact with the medium, known as wetted materials, can play a key factor in the sensor’s lifespan, along with any possible contamination of the medium. Ensuring that the sensor can withstand the application’s environmental conditions, such as a washdown applica-tion, is also critical. Another key piece of information is the medium’s temperature and composition. Because all sensors are electronic devices, they have temperature restrictions. Heating and cooling a sensor beyond the rated specii cations can cause irreparable damage. h is applies to the medium and ambient conditions.

• How will the sensor be connected to the input device? Like any type sensor, the way it is connected to


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a control system can impact the way it is oriented and the time required to install/replace it. Most pressure sensor manufacturers of er dif erent ways to connect the sensor to a controller—such as an integral cable or a quick disconnect. Knowing the application and understanding how the sensor will be used helps dictate which connection is needed.

• Are other external considerations needed? As previ-ously stated, knowing the conditions to which the sensor will be exposed can af ect the usefulness of the sensor. Considering the presence of electrical noise is also important. Noise is any electrical interference that can cause unexpected results from the sensor—in both the performance of the sensor and the signal sent from the sensor. Noise can be generated by variable frequency drives, wireless communications and voltages running in cables. h e chances of receiving successful signals

from the pressure sensor are greatly increased by taking the precautions against noise. In addition to electrical noise, external considerations such as sunlight, moisture and physical damage should be taken into account.

CONCLUSION

Before selecting a pressure sensor for any system, under-standing all the details of the application and performance requirements is essential. h is will ensure accurate pres-sure measurement and increase the lifespan of the pressure sensor—signii cantly impacting a company’s bottom line. P&S

Kyle Horsman is a product specialist in TURCK’s sensor divi-

sion. He has more than three years of experience at TURCK

and has a background in controls engineering with a focus

on pressure sensing in the food and beverage industry. He

can reached at [email protected] or 763-509-7703.

Many current pressure sensors use a strain gauge or diaphragm,

which creates a signal to be processed based on the amount of

del ection to which the diaphragm is exposed.

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SPECIAL SECTION


The Keystone Pipeline (see the blue linein Figure 1) is 2,150 miles long and

transports crude oil from Alberta, Canada, to Illinois and Oklahoma. h e pipeline runs from Alberta east through Manitoba where it crosses the border into North Dakota. From North Dakota, the pipeline runs south through South Dakota and Nebraska. At Steele City, Neb., one arm of the pipeline runs through Missouri for deliveries into Illinois while the other arm runs south through Oklahoma for deliveries in Oklahoma. Keystone is operating with deliveries to three U.S. sites with a capacity to deliver up to 590,000 barrels per day of Canadian crude oil to the North American rei ning markets.

Each station is coni gured for the pipe-line hydraulic requirements because of the surrounding geography. An instrumenta-tion and control solution provider sup-plied 4,000 and 5,000 horsepower pumps, motors, switchgear, variable frequency drives (VFDs), sot -starters (SS), contac-tors, power factor correction equipment and unit control systems for 35 pump sta-tions. Each pump station (see Figure 2) has:

• One to i ve units (motor, pump, valvesand instrumentation package)

• Common drive lineup for all units (aVFD, a sot -starter or both)

• Drive lineup isolation contactors(actual number depends on the type ofmotor drive lineup)

• Motor/drive contactors (actual numberdepends on the number of units)

• Motor bypass contactors for utilityoperation (actual number depends onthe number of units)

TransCanada Keystone Pipeline Pump Station ControlFlexible design is important for the future growth of generic, multivariable transcontinental pump stations.

By Ted Fowler, Siemens Energy, Inc.

Figure 1. Map of the TransCanada Keystone Pipeline



• Coni gurable power failure recovery• Coni gurable alarm and trip

thresholds

FLEXIBLE DESIGN FOR

FUTURE GROWTH

Current business culture demands shorter delivery schedules. To meet these demands, many i rms overlook the need for maintainability and modii ca-tion during future growth. h is culture provides faster returns for suppliers at the expense of the end customers who have systems that become increasingly dii cult to modify, enhance, test and operate. h e life cycle of the pipeline needed to be considered i rst. h en the design could be approached with an up-front l exible design growth specii -cation. h e design must support future equipment expansion for increases in capacity and control system sot ware changes to enhance operations, per-formance and safety throughout the pipeline life cycle. h e challenge was to design this l exible growth system within a compressed schedule. h is article discusses the rapid deployment and l exible growth design approach for the pump station electrical systems, motors, pumps and automation for the Keystone Pipeline focusing on the unit control system.

HARDWARE ELECTRICAL DESIGN

h e i rst step was to design the electrical system for the

maximum number of pumps, motors, switchgear, contac-tors and unit automation and instrumentation interfaces. Each station’s electrical shelter was built for the initial number of units with room to expand. h e same concept was applied to the automation architecture. A single pro-grammable logic controller (PLC) was used with six remote input/output (I/O) racks for instrumentation and control.

Every system has one I/O rack for inter-facing with common equipment (such as the incomer feeder breaker, uninter-ruptible power systems or VFD). h e other i ve I/O racks were installed as necessary with one rack per pump unit for control and instrumentation—such as valves and pressure transmitters.

AUTOMATION SOFTWARE

MANAGEMENT RULES FOR THE

PIPELINE LIFE CYCLE

Creating automation sot ware for high l exibility, future growth and life-cycle maintenance requires a solid

Figure 2. Unit control system block diagram

Figure 3. Station/unit confi guration matrix

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possible unit and any equipment and unit combination.

State Machines

h e master program was designed using state machines, state-based logic, motor/drive ownership routines and coni guration tables. State machines and state-based controls are ideal for systems that require a high level of con-i gurability and, when implemented properly, are easy to modify with mini-mum ef ort. Because state-based con-trols and transition logic are inherently compartmentalized, modii cations to logic are also compartmentalized. State machines are extremely l exible and can be programmed in any lan-guage—such as ladder, statement list or structured ext. Sequence logic exists inside each of the machines’ states. By combining function-specii c sequence logic—such as starting and valve alignment—a power, stable and l ex-ible control architecture was realized with minimal ef ort. Future changes are easily implemented with minimal impact.

A generic unit control state machine was programmed. An instance was cre-ated for each pump. A state machine was also created for selection, operation and ownership of the motor/drive equipment (VFD or SS). Figure 4 is a simplii ed version of the unit control state machine. h e circles represent the “state” of the unit, while the arrows indicate a transition from one state to another. A state transition is driven by logic based on operator commands, system conditions and process variables. h ey are priority-based so only the highest priority transition is made (such as a unit trip) even when other transitions are possible.

CONCLUSION

h e design practices used for the Keystone Pipeline yielded an extremely stable design. h e automation sot ware is easy to modify and maintain. With an in-house unit control panel, process simulator and rigorous automation test pro-cedures, the designers were able to commission all stations in a few days without any sot ware modii cations. h e same process and in-house test and simulation have facilitated

several operational, performance and safety enhancements to the unit control sot ware during operation of the pipeline.

h e solutions developed together with TransCanada were then implemented on the TransCanada Corporation Pipeline Cushing Extension and are planned for the pro-posed TransCanada Keystone XL Pipeline to create one of the world’s longest and safest pipelines. P&S

Ted Fowler is senior key expert, Systems Integration and

Controls Automation, for Siemens. He has worked in

several industries in different capacities from design,

test, commissioning, integration and R&D. He currently

works in the oil & gas industry on automation, VFD

and power generation applications for offshore drilling

and oil pipelines. He has a bachelor’s degree in electrical engineer-

ing (Lakehead University) and an Electronics Engineering Technology

Diploma (Humber College of Applied Arts and Technology). Fowler may

be reached at [email protected] or 281-656-7017.

This article was produced for publication in Pumps & Systems magazine

with permission from and in cooperation with TransCanada Pipelines.

Figure 4. Unit control state machine diagram

trical engineer



Between 1992 and 2002, 3,378 on-the-job fatalities caused by electricity occurred—most from electrocution. From

1992 to 2010, electricity caused the deaths of three U.S. workers every four days.

If a pump has an electrical ground fault, water can bring the current into contact with a worker. h e risk of shock is present anywhere that pumps are used, from municipal water plants and food processors to mines and amuse-ment parks.

Clearly, safety measures should be implemented. It is interesting that a device proven to save lives, the ground fault circuit interrupter (GFCI), is not required in industrial settings, but it has been required in water-prone areas of homes—such as bathrooms, laundry rooms, kitchens and outside outlets—since 1973. Since their introduction into the electrical code, GFCIs have been credited with reducing residential electrocutions by 50 percent.

Fortunately, Underwriters Laborato-ries (UL) has extended the same pro-tection to workers on the job that they have in their bathrooms by dei ning a standard for industrial GFCIs.

A GFCI’S FUNCTION

A GFCI (also called a residual current circuit breaker or RCCB) does one simple thing: it compares the current in hot (phase) and neutral (return) con-ductors of the circuit that it protects. For example, a three-phase unit com-pares the currents in all three hot phases. If these currents are equal, then nothing happens. However, if they dif er by even a small amount, the current is leaking to

ground somewhere—possibly through a person—and the GFCI quickly interrupts the power before that person can be injured.

Industrial GFCIs Can Save Lives

For applications in which electricity, people and water meet, this equipment can prevent on-the-job injury and death.

By Nehad El-Sherif, Littelfuse

Figure 1. How to choose the class of GFCI for a particular application

Figure 2. The effects of current on the body: currents in zone AC-1 are generally imperceptible;

currents in zone AC-2 up to curve B are perceptible but not harmful unless they continue too

long. Similarly, the higher zones show increasing danger, but danger correlates with time—the

longer the current continues the higher the danger risk.

SPECIAL SECTION


RESIDENTIAL VERSUS INDUSTRIAL GFCIS

Residential GFCIs (dei ned by UL 943 as Class A) found in bathrooms and kitchens are designed to trip at a leakage current of 6 milliamperes. h is is i ne in the home, but in an industrial setting, low-level ground leaks ot en present no danger but would cause a Class A GFCI to trip needlessly.

On top of that, Class A GFCIs are intended only for cir-cuits running at 240 volts or less, so they cannot be used on higher-voltage industrial equipment.

UL STANDARDS FOR INDUSTRIAL GFCIS

Reliable GFCIs suitable for industrial use did not exist until recently. Last year, UL published UL943C, Special Purpose Ground-Fault Circuit-Interrupters. It covers industrial GFCIs that operate on circuits up to 600 volts, will not trip until leakage current exceeds 20 milli-amperes (comparable to the European standard of 30 milliamperes), and are suitable for industrial installa-tions. GFCIs built to the new stan-dard will increase reliability as well as protection.

UL943C separates industrial GFCIs into Classes C, D and E: • Class A, under UL943, is for

residential applications, with volt-age of 120 or 240 in single-phaseinstallations, with a 6-milliamperetrip level (which is too low forindustrial use).

• Class C is for use in circuits withno conductor more than 300volts alternating current (AC) toground where reliable equipmentgrounding or double insulation isprovided.

• Class D is for use in circuits withone or more conductors morethan 300 volts to ground and withoversized grounding to preventthe voltage across the body fromexceeding 150 volts during a fault.

• Class E covers equipment similarto Class D but with high-speedtripping required. h erefore, theoversized ground of Class D is notrequired.

Figure 1 shows how to choose the class of GFCI for a particular application.

While UL 943C has been released, the National Electrical Code (NEC)


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does not yet require the use of industrial GFCIs. It does, however, require the use of GFCIs for specii c applications. As awareness of the new UL standard increases, acceptance will also increase, and some industry players expect the NEC to be updated to require GFCIs in more applications.

TIME RESPONSE OF A GFCI

h e time taken for a GFCI to trip depends on the level of leakage cur-rent. Figure 2 shows the ef ects of current on the body: currents in zone AC-1 are generally imperceptible, and currents in zone AC-2 up to curve B are perceptible but not harmful unless they continue for too long. Similarly, the higher zones show increasing danger, but danger correlates with time—the longer the current contin-ues, the greater the danger is.

All GFCIs follow a trip curve dei ned by UL943 and shown in Figure 3. At 300 milliamperes, the GFCI must trip within 20 millisec-onds, while smaller currents take longer. A current of 20 milliamperes corresponds to a trip time of about one second.

ALTERNATIVES TO

INDUSTRIAL GFCIS

For higher leakage currents up to 50 milliamperes, equipment ground-fault protection devices (EGFPDs) can be used. EGFPDs fall under a dif-ferent UL standard and are intended for equipment and not personnel pro-tection. In reality, EGFPDs also pro-vide some personnel protection when the industrial GFCIs cannot be used.

Another device may be confused with a GFCI but is dif erent and is used for dif erent purposes. h is is the ground fault relay (GFR—also called a ground fault monitor). GFRs are intended purely to protect equip-ment, not people.

A GFR does not open the circuit directly but triggers an upstream circuit breaker to open. While the

GFR may react in about a millisecond, the circuit breaker takes much longer to open—enough time for an electrical shock to stop someone’s heart. In addition, the trip level of a GFR can be set anywhere from up to 3 amperes (a fatal level of current), and its time delay can be set to as much as one second. Clearly, this is not intended for personnel


SPECIAL SECTION


protection. While GFRs are not intended to protect people, they do so indirectly by mini-mizing electrical hazards and damage to equip-ment. Ninety percent of ground faults occur slowly because of insulation breakdown, and a GFR can identify such an incipient ground fault before it escalates into a full-blown short to ground.

In contrast to GFRs, GFCIs are intended to protect people. h ey are used on grounded systems and can be set to trip at ground cur-rent levels as low as 6 milliamperes for Class A and 20 milliamperes for Classes C, D, and E. A GFCI contains its own contactor to interrupt power much more quickly than a GFR.

HOW INDUSTRIAL GFCIS ARE INSTALLED

Installing an industrial GFCI is relatively simple. h ey are much larger than their residential cousins and are mounted inside an existing electrical cabinet or other piece of equip-ment. h ey may also be ordered with their own enclosures and mounted like an electrical panel (see Figure 4). For temporary applications, the industrial GFCI may be located on a wheeled cart to make it easy to move to temporary locations.

WHERE INDUSTRIAL GFCIS ARE USED

Industrial GFCIs may be used anywhere, but they are espe-cially valuable in situations with a combination of high volt-age, contact with people and a presence of water or process l uids. h is can include submersible pumps, wash-down areas, aerators, high-pressure washers and mixers.

Other candidate areas include pumps used for construc-tion/temporary equipment and maintenance activities in which workers may need to enter tanks for cleaning, and dewatering pumps may be used when cleaning tanks.

GFCIs are useful with pumps in services that require frequent contact with operators or people, such as in paint booths, fountains, pools, water parks and amusement parks.

Although the i rst place to apply GFCI protection is in high-voltage equipment, such as a 480- or 600-volt pump, the amount of ground fault current that can kill a person is small. h erefore, an industrial GFCI is appropriate for lower voltage pumps if it is located in equipment that sees frequent maintenance or frequent operator contact.

SUMMARY

h e danger of electric shock is present wherever people and electricity come together. h e risk is higher in equip-ment that contains pumps because if there is anything more dangerous than electricity and people, it is electricity and people plus water.

Considering how many people are killed or injured by electric shock in industrial facilities each year, there has long been a need for better of protection. At the same time, Occupational Safety & Health Administration has been increasing i nes for injuries to electrical workers, and the cost of medical bills and liability continue to rise. Moreover, a death or injury will be tragic and cause downtime that may be very expensive. Now that industrial GFCIs have i nally become available, it would be wise for managers to consider their use. P&S

Nehad El-Sherif, P.Eng., is technical product specialist for

Littelfuse. El-Sherif has software and hardware design expe-

rience and has been involved in the certii cation of products

with CSA and UL. He received his B.Sc. in electrical engi-

neering and a M.Sc. in electrical engineering, specializing

in power systems and machines from Ain-Shams University,

Cairo, Egypt. El-Sherif may be reached at

[email protected].

Figure 3. All GFCIs follow a trip curve defi ned by UL943. At 300 milliamperes, the unit

must trip within 20 milliseconds, while smaller currents take longer. A current of 20

milliamperes corresponds to a trip time of about one second.

Figure 4. Installation diagram for industrial GFCIs

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Power GenerationOperations



In a power plant, the condenser circulating water pumpsystem is typically a high l ow, low-head application. Two,

three or possibly four identical pumps usually operate in parallel with a common system. h is system may or may not have discharge throttle valves, and in such cases l ow control is achieved by taking a pump out of service. In a parallel designs such as this, the pumps must be carefully matched to the system and their individual capabilities.

All combinations and variations of the system head curve should be considered and the system curve’s uncertainty caused by variable pump operation must be handled. Of -design point operation driven by unforeseen plant opera-tion and/or maintenance issues will af ect the pumps’ reli-ability and ei ciency. However, a dif erent approach with new motor and gearing technology may mitigate these issues while simultaneously improving ei ciency, reliability and performance.

THE ISSUE

Current driver choices for large vertical pumps are usu-ally limited to high pole count induction or synchronous motors. However, induction motors have a low power factor, while synchronous motors are expensive and more complex. h e inescapable issue is that both motor types have only one operating speed, which ot en means cen-trifugal pumps do not operate at or near the manufacturer’s design-rated conditions of head and l ow, referred to as the best ei ciency point (BEP). Because only one BEP is avail-able for optimum pump operation, any pump operating at excess capacity will surge and vibrate, which can cause bear-ing and shat seal problems and require excessive power. When operation is at reduced capacity, the radial thrust on the rotor will increase, causing higher shat stresses, increased shat del ection, bearing problems, seal problems, vibration and axial shat movement. Continued operation in this mode will result in accelerated deterioration and pos-sible pump failure.

h e startup and shutdown sequence of any pumping system is harsh on the pump because it takes time for the

system to achieve hydraulic stability. Specii cally, in the case of a long discharge (to the destination) the hydraulic tran-sient can cause minutes or even hours of instability, reduc-ing pump life as much as 50 percent. Maintaining a closed or partially open discharge valve for longer periods of time may also cause damage to the pump, valves, piping and the structure. Additionally, if the motor operated discharge valve fails to open or opens too quickly or if the system is not properly vented, water hammer can occur and result in severe damage to the pump and system.

Innovative Motor & Gearing Technologies for High-Capacity, Low-Head PumpsReduce high vibration and increase reliability with CST gear motor technology in power generation applications.

By Aron Abel, Baldor Electric Company

Figure 1. A vertically mounted, four-pole design, large horsepower AC

motor sits on a planetary gear reducer.

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ALTERNATE SOLUTION

An alternative approach is a large horsepower, low-speed gear motor with a built-in hydro-viscous clutch. h e con-trolled start transmission (CST) gear motor is manufac-tured in a fabricated steel housing that is designed to i t on an existing pump l ange. h e shat s and gears are made

of high-alloy hardened and carburized steel to American Gear Manufacturers Association (AGMA) 2001 durability and strength. A vertically mounted, four-pole design, large horsepower alternating current (AC) motor sits on a plan-etary gear reducer (see Figure 1).

By using a four-pole induction motor, the ei ciency will be equal to or greater than a high-pole count design. h e reducer is a single-stage reduction (3:1 to 9:1) CST with concentric input and output shat s for controlled starts and shutdowns. h e reducer is l ange-mounted to the motor with the male register for the driven equipment side, allowing for alignment to the pump.

h e planetary gearing shown in Figure 2 has four major components. h e gears are double helical type for low noise and vibration.

h e sun gear (1) is the high-speed input to the gear box. Around the sun gear are three planetary gears (2) that are supported by the planet car-rier (3), which is also connected to the low-speed output.

h e entire planet gear carrier assem-bly with the planet carrier rotates inside the ring gear (4). Speed control

Figure 2. The planetary gearing

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is accomplished through the clutch pack, which transmits torque between friction plates (5). h is arrangement divides the power into three paths to reduce the load on individual gearing, af ording high-power density and an ei ciency in the range of 98.5 percent to 99 percent. h e unit rating is based on the minimum rating of the components—such as the gears, shat s and keys.

h e planet cylindrical roller bear-ings are robust for the application with a minimum unadjusted design L-10 life of 50,000 hours at motor rating horsepower. h rust loads are supported by a spherical roller thrust bearing with L-10 life of 100,000 at 36,000 pounds of external thrust.

h e drive is designed to accommo-date momentary peak loads up to 200 percent. h e unit is rated to a maxi-mum design operating temperature limited to 200 F per AGMA 6023.

FUNCTIONALITY

h e controlled start is facilitated by a hydro-viscous internal wet clutch that controls the pump speed and l ow to enhance pump system startup. h e integral clutch will allow the motor to achieve motor base speed under a no-load condition.

h e clutch can be engaged and con-trolled to gradually bring the pump to full speed. Because the i nal output speed of the drive is determined by the gear ratio selected in the reduc-tion gearbox, the drive’s speed can be exactly matched to the pump BEP requirements for ei cient operation.

At er the motor is started, the clutch is engaged slowly to accelerate the load under a tightly controlled accel-eration curve, minimizing the impact on the power system and allowing for extended acceleration and decelera-tion times. h e clutch functions as a mechanical sot start that allows the driven load to stop without stopping the motor. Another advantage is that multiple pump starts can occur with-out stopping the motor. P&S

Aron Abel is an industry engineer supporting the power gen-

eration and water/wastewater industries for Baldor Electric

Company, a member of the ABB group. Abel is a certii ed

maintenance and reliability professional with 25 years of

experience in the power generation and petrochemical

industries. He can be reached at [email protected].

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A ccording to the U.S. Energy Information Agency,growth in power generation is expected to increase 8

percent while demand for electricity is expected to grow 8 to 9 percent from 2011 through 2020.

Compounding this growth are aging plants with criti-cal equipment at the end of its life—increasing demands for reliability—and an aging workforce reaching retire-ment in the next few years. All these factors exponentially increase the need for ef ective and automatic knowledge transfer, training and new approaches to the maintenance of power generation assets. Today, the process of condition monitoring is largely conducted manually, meaning techni-cians and operators monitor equipment on their walking rounds or tours within a plant (see Image 1 and Figure 1). h is includes capturing data logs, inspections and assess-ments, performance testing, maintenance, and capturing history and events. In addition, this provides limited access to equipment condition monitoring.

h is article discusses how reliability and maintenance engi-neers can use technology to improve existing maintenance programs. Most ot en, equipment failures can make the

dif erence between generating a proi t or a loss. However, increased inspec-tion through online monitoring and data collection can miti-gate these risks.

ASSET MONITORING

To optimize machine maintenance and, therefore, machine reliability and use, monitoring health indicators such as mechanical vibration, temperature and power factor is a widely accepted practice. However, the cost of cabling the sensor and data acquisition hardware to the control room has impeded the use of monitoring for reliability and usage improvements. Today, with the use of wireless vibration and power monitoring devices, reliability engineers can over-come historical cost barriers.

Power generation providers are taking advantage of the cost ef ectiveness of wireless devices to add low-cost sensors to equipment. Without the need to connect wires to trans-fer data, reliability engineers can expand instrumentation beyond critical assets and communicate condition monitor-ing data for many assets across systems.

h e Electrical Power Research Institute (EPRI) has cal-culated comparative maintenance costs in U.S. dollars per horsepower for each maintenance strategy. According to the research, a scheduled maintenance strategy is the most expensive to conduct at $24 per horsepower. A reactive maintenance strategy is the second most costly at $17 per horsepower and includes the additional costs of safety being compromised. A predictive maintenance strategy is the most cost-ef ective at only $9 per horsepower, and it nearly eliminates the risks of secondary damage from catastrophic failures.

Conversely, one of the consequences of the development of advanced maintenance strategies, such as predictive

The Future of Asset Monitoring TechnologiesSophisticated asset monitoring systems provide benei ts including cost savings, longer equipment life span and production assurance.

First of Two Parts

By Roberto Piacentini, Preston Johnson & Theresa Woodiel, National Instruments

Image 1. The current manual leak

detection and localization practice

Image courtesy of National Oilwell Varco

Figure 1. The topology of a hex pump leak detection system

Image courtesy of National Oilwell Varco



maintenance, is the increased need for ei cient informa-tion/data management methods. As an example, advanced predictive maintenance strategies require signii cantly larger data sets to monitor assets and ef ectively determine the actual state of the asset being monitored. h ese data sets include machine parameters, measuring points, failure modes to be detected, the relationship between faults and symptoms, and real-time math calculations.

As a result, acquiring, analyzing and managing this mas-sive amount of data, ei ciently and timely and communi-cating operations knowledge throughout the organization becomes a complex task.

TYPES OF ASSET MONITORING

Each of the i ve main types of machine condition monitor-ing serves a dif erent role. h ese i ve are described below:

• Route-based monitoring involves a technician record-ing data intermittently with a handheld instrument.

• Portable machine diagnostics uses portable equipmentto monitor the health of machinery from sensors thatare typically permanently attached to a machine.

• Online machine monitoring monitors equipment asit runs. Data are acquired by an embedded device andare transmitted to a main server for data analysis andmaintenance scheduling.

• Online machine protection actively monitors equip-ment as it runs. Data are acquired and analyzed by anembedded device. Limit settings can then be used tocontrol turning the machinery on and of .

SENSORS AND SIGNALS

h e following types of sensors dominate machine condition monitoring:

• Accelerometers are used to monitor the vibrations of amachine.

• Proximity probes monitor the movement of a shat and

With the use of wireless vibration and power monitoring devices,

reliability engineers can overcome historical cost barriers.

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detect imperfections, such as faulty bearings or other external factors preventing perfect rotation.

• Tachometers determine the equipment’s rotationalspeed and phase information, so engineers can matchfrequency components to shat speed and position.

Most machine condition monitoring sensors require some form of signal conditioning to optimally function, such as excitation power to an accelerometer. Filtering on the signal to reduce line noise and unwanted frequency ranges is also common.

ASSET MONITORING BENEFITS

Implementing an asset monitoring system provides other advantages in addition to cost savings. For example, orga-nizations can plan replacement parts inventory to meet maintenance demands by ensuring that the correct parts

are available at the right location as needed, ensuring better l eet management. Also, with a longer maintenance cycle based on machine health, a longer equipment life span can be expected.

Another benei t is the production assurance that an asset monitoring system provides. h e system can identify devel-oping faults with enough lead time to properly schedule maintenance during planned downtimes, avoiding unneces-sary and expensive site shutdowns.

Most important, by monitoring the machine and its per-formance parameters, the condition monitoring system can signal a system shutdown before serious injury or other harm occurs.

FUTURE-READY ASSET MONITORING INSTRUMENTATION

With the advent of advanced maintenance methods, indus-trial machinery and asset monitoring systems continue to

become more sophisticated. As a result, the requirements for such sys-tems are constantly evolving, which creates new challenges for selecting the appropriate instrumentation for asset monitoring.

Stand-alone traditional instru-ments—such as temperature loggers, power quality meters, vibration ana-lyzers and bearing checkers—that are robust, standards-based and embed-ded are currently available. However, they are also expensive and designed to perform one or more specii c or i xed tasks dei ned by the vendor.

Alternatively, the rapid adoption of the PC during the last 30 years cata-lyzed a revolution in instrumentation for test, measurement and control/automation markets. Computers are powerful, open source, input/output, expandable and program-mable. Virtual instrumentation is the foundation for future-ready devices because it bridges traditional instru-mentation and computers to of er the

Most machine condition monitoring sensors require some form of

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POWER-GEN International is an annual event for power generationprofessionals. It provides comprehensive coverage of the trends,

technologies and issues facing the global power generation industry with a focus on new solutions and future innovations. Trade Show Executive magazine named the event one of the Elite Gold 100. More than 21,000 power professionals from more than 75 countries attend. h is year, POWER-GEN celebrates its 25th anniversary.

h e event features 1,400 exhibitors, more than 200 speakers and more than 50 educational conference sessions. It also of ers competitive power college courses, networking events, technical tours and opportunities for new business development. Attendees who are registered as full confer-ence delegates are eligible to receive 10 hours of professional develop-ment hour credits. Many dif erent power industries are represented at the event—such as electric utility, construction, OEMs, maintenance service providers and power plant designers.

POWER-GEN International’s exhibit l oor showcases the latest prod-ucts and services including boilers, turbines, engines, computer hardware

and sot ware, controls and instrumen-tation systems, pumps, valves and valve actuators. In addition to the exhibit, the conference sessions provide an opportunity for attendees to learn about new solutions and innovations. h e sessions are organized into tracks including industry trends/competi-tive power generation, environmental issues, emissions control, gas turbine technologies and plant performance.

h e 2013 event introduces Power Generation Week—featuring four events in i ve days in one location. POWER-GEN International will partner with NUCLEAR POWER International, Renewable Energy World Conference & Expo North America and POWER-GEN Financial Forum for full coverage of the power generation industry. Attendees can benei t from i ve days of pre-conference workshops, techni-cal tours, more than 70 conference sessions, panel discussions, three exhi-bition days and several networking events. P&S

POWER-GEN InternationalNov. 12 – 14, 2013Orange County Convention CenterOrlando, Fla.

Exhibition

Tuesday, Nov. 12 11:30 a.m. – 6 p.m.

Wednesday, Nov. 13 9 a.m. – 5 p.m.

Thursday, Nov. 14 9 a.m. – 2 p.m.

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EFFICIENCY MATTERS


In Masdar City—a celebrated, centrally planned com-munity in Abu Dhabi, UAE—temperatures recently

reached a record of more than 51 C. h e city is being built by the Abu Dhabi Future Energy Company with additional funding from the Abu Dhabi government. A long-term, truly sustainable view of capital investment is clear. At the moment, 100 percent of the electrical demand is provided by photovoltaic power generation. As the city population grows and demand for energy increases, it is expected that the existing 10-megawatt (MW) solar installation will pro-vide 20 percent of the city’s electricity, with the remaining 80 percent coming from alternate sustainable sources.

SUSTAINABLE INVESTMENTS

City planners began the project by focusing on minimiz-ing the total energy requirements through passive means,

carefully managing the orientation and form of buildings for maximum ei ciency (see Image 1). As a secondary step, planners looked for advanced solutions in building perfor-mance optimization and other active controls.

h e city has implemented stringent building ei ciency guidelines for insulation, lighting, window glazing, reliance on natural light and the installation of smart appliances. To help manage the electrical network and minimize electri-cal demand through informed decision-making, the city requires the installation of smart meters and building man-agement systems. It also relies on an integrated distribution management system to monitor and manage energy usage patterns.

Masdar’s perimeter wall is designed to block hot desert winds, and the minimal use of motor vehicles allows for narrow shaded streets that help funnel cooler breezes across

Intelligent Pumps in Masdar CityContemporary pump engineering principles help achieve optimum efi ciencies while cooling a city using renewable energy sources.

By Brent Ross, Armstrong Fluid Technology

Image 1. Masdar City’s layout


the city. An updated version of the cooling tower concept has been included and also contributes to this ef ect.

Buildings in Masdar must also have energy-ei cient cool-ing systems, given that the city’s raison d’être is to serve as a model of environmental responsibility. h e original goal was to rely entirely on renewable energy with a sustainable, zero-carbon, zero-waste ecology and to become a world-leading hub for companies in the clean technology sector. Masdar City is already home to the headquarters of the International Renewable Energy Agency (IRENA), several international ecology confer-ences, one of the world’s largest solar farms and the Masdar Institute of Science & Technology. h e commu-nity puts a strong emphasis on tech-nology-driven energy ei ciency, and this priority is rel ected in the design of its pumping systems.

h e contemporary pump technol-ogy, design principles and installation approaches used in Masdar contrib-ute to improved energy performance, easier maintenance a more stable operation than is of ered by conven-tional set-point-feedback control systems.

If someone needs a big truck for 15 days each year and a small car for the other 350 days of the year, it is not an optimal solution to buy a big truck. So the pump company responsible for the Masdar system employed only intelligent, pre-packaged l uid man-agement equipment and worked with engineers to initiate design planning for the use of demand-based control in Masdar. Demand-based control is a system optimization method for HVAC systems.

SENSORLESS DEMAND-BASED

CONTROL

A pump company’s design-envelope technology plant’s packages and con-trols use the Equal Marginal Perfor-mance Principle (EMPP) established

several years ago as a way to realize ei ciency improvements of 25 to 50 percent more than equivalent conventional set-point methods for operating HVAC systems.1

h e EMPP states that the energy performance of any system that operates with multiple modulating components is optimized when the marginal system output, per unit

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EFFICIENCY MATTERS


energy input, is the same for all indi-vidual components in the system.

h e embedded control technol-ogy manages equipment according to optimized, system-wide power rela-tionships, rather than meeting inter-mediate temperature or pressure set-points. Design envelope technology also of ers sensorless demand-based control, which reduces the costs for equipment purchase, installation and commissioning.

On the more than 30 pumps in the university buildings at Masdar City, no external sensors are installed. h e cooling systems rely on prefabri-cated, integrated pump stations called design envelope intelligent l uid man-agement systems (IFMS). IFMS sta-tions consist of a number of precisely matched, vertical in-line pumps with integrated controls, plus an intelli-gent pump control unit. h e control unit calculates the head and l ow requirements in real time, enabling pump speed adjustments based on the immediate demand for cooling.

EFFICIENCY ENVELOPE

Design envelope technology pro-vides very high ei ciency levels across a wide design/performance range, regardless of the operating point. h is ensures that pumping systems consume as little energy as pos-sible. It also allows installations to exceed American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) 90.1 guide-lines for 2010, mandating 70 percent energy savings at 50 percent of peak load, with resulting carbon emissions well below the current legal require-ments. It lets owners buy a small car rather than a big truck, while enjoy-ing both the performance of the truck and the energy and cost advantages of the small car.

Image 2. Downtown Masdar City


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EFFICIENCY MATTERS


A WIDE RANGE OF HIGH EFFICIENCY OPERATION

h e choice of intelligent, integrated pump stations also optimizes energy ei cient pumping capabilities over a wide operational range. h is allows building designers to future proof HVAC systems by designing in the l exibility to accommodate additional cooling load. h is operating l exibility, combined with high ei ciency across the perfor-mance range, can also reduce iterations of pump selection, control risk, and protect capital and operating budgets.

Changes to specii cations are common during the plan-ning phase of a major project. h ese changes may involve consultants and other engineers in costly redesigns, which points to another part of the value of design envelope tech-nology. h e broader range of operating ei ciency means that a given selection of design envelope pumps can accom-modate changes in cooling load.

In many instances, although building specii cations might change, redesign or re-selection of the design enve-lope pumps will not be required. Even at er installation, the wider performance capabilities of integrated, design enve-lope technology can accommodate variations in cooling requirements. New or revised requirements may stem from

increased occupant density, changes to building use or modii cations in the shade conditions because of changes in the building’s surroundings—such as the construction of new buildings adjacent to the existing site. h is oper-ating l exibility is signii cant on large projects such as Masdar City, which is expected to require an additional 50,000 tons of district cooling during the next i ve years. For the city’s proj-ect managers, the broader operat-ing range of the pump systems will provide greater adaptability without costly HVAC refurbishment, while ensuring continued optimization of pump ei ciency.

h e imperatives that have driven the industry in recent years are in tune with the requirements of the city and its leadership goals. Although some of the systems used were the i rst of their kind in the region, the installation at Masdar City has led to three similar projects in Qatar and another in Abu Dhabi.

Image 3. The pumps are suspended vertically, one above the other.


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PUMP STATIONS PRE-BUILT OFF-SITE

Each pump package for Masdar was designed, built and tested of -site at a U.K. plant. Manufacturing of systems of -site ensures energy ei ciency performance, reduces installa-tion costs and eliminates project risks during installation. Where many large installations of cooling systems expe-rience delays related to the coordination of labor and the sourcing of components, of -site manufacturing removes all these issues from the project plan.

Project managers can stay abreast of the assembly process but do not have to worry about sourcing and labor issues. h e integrated cooling systems for Masdar City were deliv-ered to the site fully assembled and ready to be lit ed into place by a crane.

SUSPENDED VERTICALLY

One factor that af ected cost ei -ciency was the way contemporary pumps are installed. In the days of noisy, vibrating equipment, engineers took comfort in mounting pumps squarely and horizontally on a con-crete platform on the l oor. At Masdar City, the pumps are suspended verti-cally, sometimes one above another (see Image 3). h is saves space in the mechanical room, which leads to reduced capital cost.

h e cooling ei ciencies achieved in one of the world’s hottest places are truly impressive. h e integrated chilled water plant will consume 0.55 kilowatts per ton (kW/ton) (6.4 coei cient of performance—COP) or better on an annual average basis, which signii cantly exceeds today’s best-in-class levels of 0.75 kW/ton (4.7 COP) for water-cooled systems. Even in the more than 51 C peak heat

of summer, the readings are between 0.73 to 0.85 kW/ton for the full plant.

h anks in part to advances in HVAC technology, inside the renewables mecca of the desert, it remains cool. P&S

References

1. http://www.automatedbuildings.com/news/jul05/interviews/hartman.htm

2. ASHRAE Journal, (Vol. 47, No. 7, July 2005). American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc., (www.ashrae.org).

Brent Ross is the director of Coni gured Building Equipment with Armstrong

Fluid Technology. He can be reached at 416-755-2291. For more information,

visit www.armstrongl uidtechnology.com.

The contemporary pump technology, design principles and

installation approaches used in Masdar contribute to improved

energy performance, easier maintenance and a more stable operation

than is offered by conventional set-point-feedback control systems.



MAINTENANCE MINDERS

More than 30 years of machinery studies have reinforcedthat almost 90 percent of all machinery failure modes

occur randomly—making failures of pumps, motors, compressors, gearboxes, fans and other equipment essentially unpredictable. However, warning l ags of a failure in progress can ot en be detected by changes in the operating conditions of equipment. If the warnings are detected and addressed quickly, the problems may be i xed before the failure occurs. h is is the fundamental principle behind predictive maintenance.

Predictive maintenance is a proactive strategy to identify and repair machinery problems before they escalate to full-failure modes. Supported by diagnostic tools, sot ware and remote monitoring technologies, the strategy has largely replaced time-based maintenance and run-to-failure approaches. Some bottom-line reasons for this replacement are:

• h e direct cost of machineryrepairs because of break-downs can be at least three times greater than the cost of planned repairs

• h e production outage timeneeded to complete an emer-gency repair can be up to i ve times more time than required for a planned repair.

h e upshot is that predictive maintenance as an anticipatory initiative can help reduce the costs of machinery maintenance, pre-vent breakdowns and unplanned downtime, increase the availability of machinery, improve productiv-ity and limit production losses.

Despite the potential benei ts, however, the successful roll-out and implementation of a predictive maintenance pro-gram can sometimes be thwarted by economics, logistics and/or many other factors.

Especially for small- to mid-sized operations, the invest-ment for the startup equipment, training, initial support, and the time and costs associated with ongoing analysis and reporting may be more than they can manage. h ese costs can exceed $100,000 for the startup alone when run entirely in-house. Even if a predictive maintenance program is ulti-mately outsourced to a third-party provider, issues typically arise when timely visits must be coordinated around pro-duction schedules and special in-plant safety precautions must be established, among many other onsite challenges.

Partnerships for Optimized Machine ReliabilityA relationship with a service provider that will remotely monitor equipment can minimize downtime and equipment failure.

By Andy Hoy, SKF USA Inc.

Technicians check a critical electric motor as part of the MHRP.

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MAINTENANCE MINDERS


One maintenance service provider closely surveyed the manufacturing landscape and coni rmed that small- to mid-sized operations have historically been at a disadvan-tage when attempting to establish and run an ef ective and af ordable predictive maintenance program. h e result was that this provider leveraged its expertise to develop a machine health reporting program (MHRP).

An MHRP introduces a practical approach to deliver the benei ts of predictive maintenance and minimize the impacts—i nancial and otherwise—on an operation. h e risk-management program involves existing labor force in partnership with the service provider (of ering enabling technologies and expertise) to collect data about the health of machinery and deliver reliable analysis, reporting and remedial recommendations.

h is all-encompassing portfolio of interrelated technol-ogy and services of ers a cost-conscious proactive mainte-nance alternative for plant operations to reduce the risk of unplanned production stoppages and minimize machine breakdowns.

INITIATING AN MHRP

An MHRP as a vibration-based maintenance service pro-gram is engaged through the provider’s authorized distri-bution network and designed to build on the strengths of each partner—the service provider’s expertise

in maintenance strategies and predictive maintenance and a distributor’s inherent knowledge about the customer’s operations and onsite logistics.

h e service provider contributes the technologies and expertise to collect data regarding the health of machinery at the facility and delivers reliable analysis, reporting and remedial recommendations. Equipped with ample warning, operators can be aware of problems in advance and take pro-active measures to prevent catastrophic machinery failure, which is the purpose of predictive maintenance programs.

h is type program is especially well suited for operations with established goals of:

• Reducing maintenance costs• Production requirements that must be achieved• Up to 500 critical and interdependent rotating produc-

tion machines• Equipment for which high repair or replacement costs

can be expected

Some MHRPs are structured similarly to a cell phone subscription, in which the facility or plant signs up for the “service plan” and the maintenance service provider deliv-ers vibration data collectors as part of the “contract” and instructs the facility’s front-line workers on their proper use.

Hand-held portable data collectors/fast Fourier trans-form (FFT) analyzers are designed to capture full feature dynamic (vibration) and static (process) measurements from many sources and for any rotating equipment. Signals from connected sensors are digitally recorded, stored and uploaded for post-processing purposes, including analysis

and reporting. A facility learns what is wrong with a machine, the extent of the problem and

what to do about it.While analysis and reporting of data typically

would necessitate purchasing expensive sot ware, installing it on servers maintained by an IT support

group and preserving data integrity, the MHRP allows these actions to be performed remotely by taking advantage of a cloud-based sot ware infrastructure, supplied sot ware and analysis/reporting protocols.

In ef ect, machinery information and measurement data are uploaded to the cloud server, where it is stored and is available for viewing anytime and anywhere using Internet access. Incoming data are reviewed continuously by the ser-vice provider’s support team, which automatically compares the new data against known (and good) baseline measure-ments for possible deviations.

h e sot ware l ags problems and alerts a designated ser-vice provider engineer, who reviews the data and decides on

An operator with a

microlog portable

data collector


the best course of remedial action(s). A report follows with recommendations.

THE MHRP IN ACTION

h e intrinsic MHRP partnership can position plant opera-tions solidly on the road to realizing i rsthand how a com-prehensive predictive maintenance program can make a substantial dif erence, especially when supported by part-ners equipped with the knowledge that allows them to deliver optimized uptime and savings.

In one application, a manufacturer initially tried to imple-ment a predictive maintenance program on its own, but the busy in-house plant maintenance team could not keep up with the program. Inexperience with vibration analysis made converting the data into actions dii cult, and frustrations grew. Management was in a quandary, but machine reliabil-ity was a top priority, so they turned to an MHRP.

h e service provider’s experience and results were well-documented. Previous failures of a mission-critical com-pressor at a plant cost more than $30,000 in repair parts alone and unplanned production downtime was measured in days, not hours. With the MHRP in full swing, it was determined that a failing bearing was at fault and, by proactively replac-ing the bearing, the plant saved tens of thousands of dollars in the direct cost of repair parts. All work was completed during a regularly sched-uled production stoppage with no additional interruptions, and no shut-downs for additional repairs or analy-sis were required.

Other machinery was probed, too, including a critical pump and blower, with a mean time between failures that was too early and too ot en. h e MHRP approach was applied. In just the i rst six months of program implementation, the plant was able to eliminate more than 25 hours of unplanned downtime and gain tens of thousands of dollars that had pre-viously added up in lost productivity and repairs.

MHRP IMPLEMENTATION

Implementation begins in the i rst month when a facility supplies a list

of critical machines for analysis. h en the service provider instructs the facility’s staf on predictive maintenance fun-damentals, collects machine information and builds a measurement database. In the second (or launch) month, microlog data collectors are delivered, instruction is pro-vided, communication sot ware is installed, baseline data is collected and the i rst in a series of machine health reports is published. Once up and running, the program collects data and delivers machine health reports monthly with quarterly on-site analysis meetings and on-demand “spot” checks included.

A predictive maintenance program’s goal is to continually impart cost-ef ective reliability improvements. An MHRP can of er a viable and practical way for facilities to diagnose the health of critical machinery assets and minimize all the risks of unplanned downtime. P&S

Andy Hoy is director, North American Machine Health

Reporting Program, for SKF USA Inc., headquartered in

Lansdale, Pa. Hoy may be reached at [email protected] or

267-436-6780. For more information about SKF USA Inc. and

its Machine Health Reporting Program, visit www.skf.com.


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SEALING SENSE

A pressure seal is a valve design concept that of ers distinct advantages when compared to a conventional bolted

body-to-bonnet sealing mechanism. It uses the valve system pressure to provide sui cient forces against the valve body’s internal diameter (ID) and the bonnet surfaces. As the system pressure increases, the force on the pressure seal gasket also increases.

Although the only working part of the gasket is the apex or toe, the pressure seal conforms to the inside diameter of the valve. When the system pressure is activated, the toe forms a seal that can maintain thousands of pounds of pressure and keep the system media contained within the valve.

Most ot en, it is used for high pressure in power genera-tion, pulp and paper, rei neries and even chemical plants. Because of the reliance on system pressure to maintain a seal, these valves are best applied in systems in which the minimum operating pressure is more than 500 psi.

IS THE PRESSURE SEAL NEW?

h e pressure seal valve design can be traced back to as early as the 1900s. Its usage increased signii cantly in the late 1940s to early 1950s as war technology began to be applied for consumer appli-cations. h e pressure seal was further developed to remove weight from large ships. At the time, all ships used a steam engine for propulsion, and the removal of weight improved the vessels’ operation and maneuverability.

Because many valves were necessary for steam generation, reducing the weight of these valves resulted in a signii cant over-all weight reduction. Within a high-pres-sure system, shut-of valves, control valves and a host of boilers with blow-down and

shock-valves operate. Also included was the plumbing that held it together. If the weight in each valve is reduced by 100 pounds, which is multiplied by a thousand valves, a huge amount of weight is removed.

Prior to the development of the pressure seal valve, all valves used bolted bonnets to keep the pressurized media within the valves. h e bonnet was extremely heavy. h eir removal was viewed as a way to lose a signii cant amount of weight. h e new design incorporated a metallic pressure seal and eliminated the need for the bolted bonnets. h is worked extremely well, saving a great deal of weight and changed valve design forever.

A pressure seal is a valve design that offers distinct advantages when compared to a

conventional bolted body-to-bonnet sealing mechanism. It uses valve system pressure to

keep thousands of pounds of pressure and system media contained within the valve.

History, Advantages & Applicationsof Pressure SealsWhat are pressure seals, and how do they work?

By FSA members Dick Dudman and Thom Jessup


HOW DOES THE PRESSURE

SEAL WORK?

h e pressure seal gasket must conform to the ID of the valve body and the clear-ance between the seal, and the body has to be small. h e pressure seal gasket is typically made of a malleable iron and then treated with silver to aid in conformance. h e structure of the seal con-sists of a wider top, an angle consisting of 45 degrees or 30 degrees, and a wire-thin toe at the bottom.

h e pressure seal gasket is placed just below the keeper ring. With enough force, the metal will move into its cor-rect position and force the toe between the body ID and the bonnet surface. When the system pressure is turned on, the seal becomes a permanent part of the valve until it requires replacement.

h e pressure on the gasket in pounds per square inch is enormous. It can be calculated by taking the system pres-sure times the area of the bonnet, which equals the amount of force generated by the system. For example, for 2,000 pounds per square inch times a 10-inch pipe the load is 157,000 pounds. Considering that the Space Shuttle weighs 292,000 pounds, not much more, in terms of load, would be needed to launch it.

CYCLING

Temperature cycling impacts metal pressure seals. h ermo-cycling is when a temperature oscillates. With a metal gasket, during a temperature increase the gasket heats and expands. When the temperature decreases, the gasket con-tracts. Pressure cycling occurs when operators modulate the system or turn the system on or of . When the system is shut down, the metal gasket starts to contract. When the system is on and begins to pressurize once again, the gasket expands. If both types of cycling occur at the same time, the metal gasket will weld itself into position. As any service guys who work in the power industry can attest, bonnet removal at er this occurs is the pits.

GRAPHITE

Carbon steel, brass, stainless and aluminum have been can-didates for use instead of malleable iron, but most were deemed unsatisfactory. h ey either cracked or could not

tolerate the enormous temperature, pressure and chemistry parameters.

Arguably, the best alternative to metal is a l exible graphite or graphitic pressure seal gasket. It can be used as a replace-ment for the metal at ermarket and, in many cases, as an orig-inal equipment manufacturer (OEM) pressure seal gasket.

From a valve manufacturer’s perspective, thermo and/or pressure cycling is a big problem. Metal seals do not respond well to cycling because of their high coei cient of expansion (CTE). But little or no ef ect is experienced with a graphitic gasket. Graphite works with every startup, and it rebounds at er every cycle regardless of the number of times the cycle is stopped and started.

REPLACEMENT

A shared problem for the at ermarket providers and OEMs is the replacement of a metal pressure seal gasket. Metal can become galled or welded to the valve body, which requires a jackhammer for removal. h en, once it is removed, the valve body must be re-machined to restore its ultra-smooth i nish so that another metal seal can take its place.

Not so with a graphite gasket. First, it takes no more ef ort to remove a graphite gasket than it does to install it, and most damaged areas related to a metallic gasket operation and removal are accommodated by the graphitic gasket. When servicing a pressure seal valve, the valve surfaces rarely need to be re-machined when using a l exible graphite gasket. P&S

NEXT MONTH:

Do I really need to use a torque wrench?

We invite your suggestions for article

topics as well as questions on sealing

issues so we can better respond to the

needs of the industry. Please direct your

suggestions and questions to sealing-

sensequestions@l uidsealing.com.

The structure of a metal seal consists of a wider top, an angle consisting of 45 degrees or 30 degrees and

a wire-thin toe at the bottom.


BUSINESS OF THE BUSINESS

Servicing is an integral part of the pump industry. At er motors, pumps are the second largest machinery

component used in the world. Given this large installed base, servicing this equipment has always been a lucrative industry, but several factors are currently driving further growth of the pump servicing industry.

During periods of economic recession, the pump servicing market typically gains signii cant momentum. As end users curtail investments in new projects and postpone the pur-chase of new pumps, they are forced to use pumps for longer periods than originally intended, resulting in a greater need for services than in an economic growth scenario.

Normally, seals are replaced every two years and preven-tive maintenance happens every six months to two years. When pumps are used for longer periods, mean time between failure (MTBF) decreases, and the pumps are ser-viced at a much shorter interval.

Another factor driving the pump servicing industry is a decline of skilled workforce. h e U.S. Bureau of Labor Statistics’ current population survey reports that in 2008, 53 percent of the utilities industry workforce was 45 or older, and 18.1 percent was older than 55. h erefore, the industry is faced with an aging workforce at the same time that new capac-ity is needed, which places signif-icant pressure on the industry to i nd and train the next generation of operations and maintenance personnel. In its employment outlook for the utilities industry, the Bureau of Labor Statistics reports that, for many utilities industry occupations, on-the-job training is intensive, so preparing the upcoming workforce will be one of the industry’s highest pri-orities during the next decade.

PUMP SERVICING INDUSTRY ANALYSIS

Data is readily available in the utilities industry because it is heavily regulated. h is industry’s general trend is mirrored in most industry verticals across the manufacturing and pro-cess spaces. In the near future, a larger number of employees are likely to retire within a short time span and the need to i nd qualii ed employees to replace them will become a priority. Pump manufacturers and distributors can benei t because it provides an opportunity to act as the extended servicing arm for customers that no longer i eld full internal service departments.

End-User Analysis

h e oil and gas industry is the largest and most demanding end user of pump services because of the hostile operating conditions, as well as the aggressive and dangerous media that is handled. Subsea application and submersible appli-cation in of shore processes have the highest pump failure rate. Oil rei neries and petrochemical industries are also large consumers of services.

In the chemical industry, value added services (VAS) such as asset management and condition monitoring are essential

Pump Services: An Increasing Revenue Stream in the IndustryThe economic recession and a decline of skilled workforce drives the pump servicing industry.

By Anand MG, Frost & Sullivan

- sector with highest growth potential

End User growth potential (% CAGR, 2013-2018)

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Others include marine, pulp & paper, agriculture, and automotive. Source: Frost & Sullivan

Low

High

Low High

Oil & Gas

Commercial

Chemicals

Water & wastewater

Food, beverage and Pharma

Power Generation

Mining

Others

- sectors with high growth potential

- sectors with low growth potential

Pump servicing market—end user opportunity matrix

BUSINESS OF THE BUSINESS


for increasing performance and the safety levels of the entire plant. h e lack of interchangeability of spares among pumps makes repair, maintenance and having spare parts inventory crucial.

Because of its large installed base of pumps, the rev-enue generated by the water and wastewater industry for the pump services market has been high. Most of the core assets—such as water pipelines and sewers—are old and

frail, which augurs well for ser-vice providers. End users face several issues—such as cavitation, frequent damage to mechanical seals, bearing misalignment and corrosion of internal parts.

h e food and beverage industry places high priority on quality with hygiene and, therefore, has a high demand for spares to ensure non-contamination of food and a leak-free environment. Centrifugal, ro-tary lobe, air-operated diaphragm and peristaltic pumps are used in applications for producing or pro-cessing dairy products, meat, bak-ery products, confectionery, beer, wine, syrups and juices.

CM – Condition Monitoring

AM – Asset Management

MRO – Maintenance, Repair & Overhaul

I&C – Installation & Commissioning

Cons – Consulting

Dec – Decommissioning

End User growth potential (% CAGR, 2013-2018)

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Low

High

Low High

Smart

Pump

I&C

CM

MRO Cons

Parts

Dec

AM

- sector with highest growth potential

- sectors with high growth potential

- sectors with low growth potential

Pump servicing market—service type opportunity matrix



Service Analysis

Because of the global economic slowdown that resulted in new projects being delayed and shelved, pump services for maintenance, repair and overhaul (MRO) have assumed greater signii cance. MRO services improve the overall condition of the pump, facilitate checks of the critical parts and help determine the suitability for reuse. Moreover, the time taken to conduct these services is reduced compared to new pump installations. Apart from cost savings, the other advantage of using MRO services is having consultants and specialized technical personnel analyze the entire process.

Because of new projects being delayed or shelved, the market revenue stream from new pump installations and subsequent commissioning services has gradually reduced. High purity applications in the pharmaceuticals industry, subsea applications in the oil and gas industry, and submers-ible pump installations in the water and wastewater indus-try account for the major portion of the installation services revenue. Decommissioning of pumps in the chemical pro-cess, pharmaceuticals, and oil and gas industries handling aggressive and volatile media is cost intensive.

VAS has constantly evolved throughout the last decade, resulting in the development of new technologies. Certain conservative, end-user industries have been slow to adopt new technologies, but this trend is expected to change in the long term. As the cost of technology is expected to decrease over the long term, the opportunities for VAS seem copious.

CONTINUED GROWTH

Frost & Sullivan industry research has shown a consistent trend of annual growth rates exceeding pump unit growth rates for several years, and this trend is expected to continue. h is indicates some interesting dynamics in the industry, as both manufacturers and distributors position themselves to capture this growth revenue stream by adding expertise and capabilities across diverse and new areas—including intelli-gent pumps/systems, enterprise asset management and life-cycle cost reductions. P&S

Anand MG is program manager for Frost & Sullivan. The

author may be reached at [email protected]. For more

information about Frost & Sullivan, visit www.frost.com.

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Pump specii ers and manufacturers in the U.S. are generally familiar with American pump standards, and,

to a lesser degree, the processes by which those standards are created. However, entry into the European market brings a far more complex set of processes and organizations that can be bewildering. h e purpose of this article is to explain the European pump standards and processes and to familiarize American readers with the dif erent groups and associations that are involved.

In North America, pump companies directly become members of the Hydraulic Institute (HI). h is is not the case with European pump companies. In Europe, pump companies become members of a national association—such as Verband Deutscher Maschinen und Anlagenbau – German Association of Machinery and Plant Engineering (VDMA), British Pump Manufacturer’s Association (BPMA) and Prol uid—on a voluntary basis. h e national pump associations may become members of EUROPUMP. For example, the U.K. member of EUROPUMP is the BPMA, and in Denmark it is Association of Danish Pump Manufacturers (DK Pumps). In both cases, the groups rep-resent only the national pump manufacturers.

However, in some instances, a EUROPUMP member is the pump sector of a general umbrella association that represents a wide span of companies in the indus-try. In Germany, this is the pump section of the VDMA. In Switzerland, it is the pump section of Verband der Schweizerischen Maschinen, Elektro, und Metallindustrie – Swiss Association of Mechanical and Electrical Engineering Industries (SWISSMEM).

h ese economic associations are independent of the national standardization bodies—such as British Standards Institute (BSI), Deutsches Institut für Normung – German Institute for Standardization (DIN), Schweizerische Normen-Vereinigung – Swiss Standards Organization (SNV), or Association Française de Normalisation – French Association for Standardization (AFNOR).

THE STANDARDS

h e primary standards organizations dealing with pumps in the U.S., Europe and the world are discussed in this section.

U.S.—ANSI

American National Standards Institute (ANSI) is a private non-proi t organization that oversees the development of voluntary consensus standards for the U.S. ANSI also coordinates U.S. standards with international standards. In general, pump standards in the U.S. are written by HI and published as HI/ANSI documents.

Europe—CEN

European Committee for Standardization (CEN) is a non-proi t organization that encompasses two major aspects. First, it is the organization for the many European stan-dards organizations that are responsible for European Norm (EN) standards. h e national standardization bodies of European Union (EU) member states have to be a member of CEN. National standards that cover a given subject must be withdrawn when a CEN standard cover-ing the same subject becomes available. h e second is that CEN supports the European Commission by preparing so-called harmonized EN standards. Applying those har-monized standards enables a manufacturer to claim the ful-i llment of the EU (formerly European Community—EC) directives or EU regulations.

Non-EU member states cannot become members of CEN. Membership is only allowed for EU and EFTA members.

Pump standards are published via CEN/TC 197, which secretariat is held by AFNOR (France). By means of the “Vienna Agreement,” a parallel standards procedure for CEN and ISO has been established.

h e section of CEN that relates directly to pumps is Technical Committee (TC) 197. TC 197 is currently divided into working groups. At the present time, three

Understand European Pump Standards Organizations & ProcessesNorth American pump manufacturers and specii ers can benei t from knowledge of European standards.

By Tom Angle, Hidrostal AG, Frank Ennenbach, & Friedrich Klütsch,VDMA


working groups are active. h ese are:• WG1 – Circulators (Secretariat: Danish Standards

Foundation, Denmark)• WG2 – Water Pumps (Secretariat: DIN, Germany)• WG3 – Packings (Secretariat: DIN, Germany)

Worldwide—ISO

h e International Organization for Standardization (ISO) is an international standard setting body. Its membership is composed of representatives from national standards orga-nizations. Headquartered in Geneva, Switzerland, ISO was founded in 1947 and promotes worldwide proprietary industrial and commercial standards. Note that other stan-dards organizations develop and issue standards of interna-tional signii cance in specii c sectors—such as the HI and the American Petroleum Institute (API).

h e section of ISO that relates directly to pumps is TC 115. TC 115 is presently divided into three subcommit-tees, each of which deals with a dif erent aspect, similar to CEN. h ese are:

• SC1 – Dimensions and Technical Specii cations of Pumps (Secretariat: BSI, U.K.)

• SC2 – Methods of Testing (Secretariat: DIN, Germany)

• SC3 – Installation and Special Application (Secretariat: ANSI/HI, U.S.)

h e standards writing process for CEN consists of nine steps, and for ISO it consists of i ve steps. h e maximum allowable time is 36 months, but in practice, this goal is rarely met, and standards take a considerably longer period of time.

Besides the oi cial standardization body—such as BSI, DIN or AFNOR—each European country has one or more national standard setting organizations that gener-ally do not belong to either ISO or CEN. Standards issued by those organizations are usually applied in the country in which they have been developed. Standards by the oi -cial national standard organizations will only be published if no CEN or ISO standard exists. In all cases, CEN/ISO standards supersede national standards regarding the same subject.

THE DEVELOPMENT PROCESS

h e standards development process is signii cantly dif er-ent in Europe than in the U.S. One of the key dif erences between the U.S. and Europe that is not well understood by the U.S. pump industry relates to the pump associations themselves. In the U.S., the organization that writes (and publishes) pump standards is HI. Some of the standards (or guidelines) may be published as ANSI documents or some as strictly HI documents. On the European side, it is very important to note that EUROPUMP is not a stan-dards writing or publishing organization. h e entire pump standards writing process in Europe is performed by CEN or ISO, not by EUROPUMP.

Standards that af ect technical specii cations are the responsibility of the TCs of CEN and/or ISO. For any case in which i ve member organizations request techni-cal support, a CEN or ISO standard will be written by the nominated stakeholders and later voted on by the member organizations of CEN or ISO.

In the case of so-called harmonized standards, the i nal document is the result of a slightly dif erent process. Regulatory standards legislation is instituted on general terms by the European parliament, equivalent to the U.S. Congress. Depending on the subject, the EC (equivalent to one of the U.S. cabinet departments and divided into sev-eral Directorates General—DG) will dei ne the mandate for the standard. h e writing of the standard itself will be under the directive of CEN.

h e actual work involved in writing the standard is com-pleted by one of the TCs (for pumps, TC 197). In contrast to the development of common technical standards, one of the stakeholders in this process is mainly the EC assisted by non-governmental organizations (NGOs) or other interested parties. Dif erent EUROPUMP members will be involved via national standardization bodies in which representatives from manufacturer companies are active in parallel to their participation within EUROPUMP and its member associations.

When the drat standard is completed, it will be sent to CEN for evaluation. In the case of harmonized standards, CEN needs then to determine if the drat standard fuli lls the mandate of the EC.

Besides the ofi cial standardization body—such as BSI, DIN or

AFNOR—each European country has one or more national standard

setting organizations that generally do not belong to either ISO or CEN.



Nominated CEN consultants who CEN hires for this task makes this determination. h ese consultants are familiar with the processes and procedures but not nec-essarily with the product itself. A signii cant amount of time and ef ort can be expended to bring the standard to a level that satisi es the EC mandate and is generally accept-able to all parties and stakeholders. In parallel with this ef ort, the normal voting procedure takes place.

Once the standard has been written and approved, CEN will publish a document (EN standard or CEN report). h is document will then be a national standard (individual language) by the national standardization organizations (for example, DIN EN for the German language version).

h e ISO process is similar to the CEN process, although consultants are not used. However, one addi-tional specii c process must be mentioned. Under the Vienna Agreement, CEN and ISO can develop standards in parallel. h ese standards are technically identical and are published as ISO and EN ISO, whereby the EN ISO will also be published as a national standard (for example, as a DIN EN ISO for the German translation).

EU DIRECTIVES AND REGULATIONS

h e harmonized standards published by CEN are a tool used to implement the requirements of the EU directives and regulations. h e EU directives and regulations have the status of a European law.

EU directives/regulations automatically become appli-cable throughout the EU when they are completed, but a transition period is allowed. h e directive/regulation becomes applicable in a particular country when the gov-ernment of that country formally adopts it. However, if a member state does not meet this date, a penalty may be issued by the EC. Because of this, formal adoption by individual governments is routine in most instances.

A somewhat dif erent procedure is followed when dealing with the Eco Design directive, which relates to product ei ciency. h is directive is a called a Frame Directive, which only specii es the targets. In this case, the target is “the saving of energy.” h e realization of this legal requirement is met through implementing measures that are legally issued as EU regulations. EU regulations become applicable on the day they are published in the oi cial journal. At this time, they will be applied in all EU member states.

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in the process of being implemented and/or developed and will be featured in depth in a future article in Pumps & Systems:

• Lot 11—h is standard af ects water pumps (in commercial buildings), drinking water pumping, food industry, agriculture and circulators (stand alone or integrated into products). h e i rst set of energy ei -ciency requirements went into ef ect in January 2013 and the second (more stringent) energy requirements will go into ef ect in 2015.

• Lot 28—h is standard regards pumps (extended product approach including motors, variable speed drives (VSDs) and controls, where appropriate) for private and public wastewater (including all stages and also includes buildings, networks and treatment facilities) and for l uids with high solids content. h e planned completion is in 2015 with the i rst set of energy ei ciency requirements going into ef ect in 2017.

• Lot 29—h is standard af ects pumps (extended product approach including motors, VSD and controls, where appropriate) for private and public swimming pools, ponds, fountains and aquariums. It also includes clean water pumps larger than those regulated under lot 11. h e planned completion is in 2015 with the i rst set of energy ei ciency requirements going into ef ect in 2017. P&S

Tom Angle is vice president, Engineering, for Hidrostal AG in Neunkirch, Switzerland.

He is also a member of the Pumps & Systems Editorial Advisory Board. He may be

reached at [email protected] or 41 52687068.

Frank Ennenbach is chairman of the EUROPUMP Standards Commission. He may be

reached at [email protected] or 49 2246900333.

Friedrich Klütsch is technical manager for technical and standard affairs on pumps

at VDMA in Frankfürt am Main, Germany. He may be reached at friedrich.kluetsch@

vdma.org or 49 6966031286.

The authors would like to express their appreciation to Mr. Steve Scoi eld of BPMA for providing valuable

background information for this article.

On the European side, it is very important

to note that EUROPUMP is not a standards

writing or publishing organization. The entire

pump standards writing process in Europe is

performed by CEN or ISO, not by EUROPUMP.

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For every complex problem, there is a simple solution…and it is wrong,”

said the author H.L. Mencken. Although he was not referring to cost reduction opportunities in pump systems, the concept still applies.

During the last several years, manufac-turing executives and plant managers have focused on reducing operating costs to stay competitive in the global industrial marketplace. Many plant managers have adopted lean initiatives to optimize assets and streamline work processes with the hope of lowering operational expenses. Others have chosen to lower their costs by outsourcing for less expensive, non original equipment manufacturer (OEM) products and parts that may not of er the same quality or ei ciency as the OEM equipment. While these solutions can lower initial costs, many “quick i xes” may lead to increased cost of ownership and lower institutional knowledge.

What options remain for executives and managers who want to reduce opera-tional costs without sacrii cing critical plant equity? Fortunately, a fruitful area has been largely overlooked by plant personnel and consulting companies. Life-cycle optimization of pump systems, including supporting infrastructure, can signii cantly decrease the total cost of ownership. Life-cycle cost reductions far outweigh initial cost considerations, ot en by 10-to-1 or more.

A HOLISTIC & EFFECTIVE PATH TO

COST REDUCTION

To achieve the most substantial and

A Holistic Approach to Identify Cost Reduction Opportunities in Pump SystemsMany plants may have a fragmented view of the true factors at work in improving productivity.

By Darren Moscato, ITT PRO Services

“

An engineer gathers fi eld data that is used for analyzing an operation’s effi ciency and reliability

and to identify opportunities for improvement.


lasting cost reductions, end users must i rst recognize the primacy of ongoing, recurring costs versus the initial purchase price of pump systems and parts. h e equipment’s purchase price represents only about 10 percent of an industrial pump’s cost of ownership. When plant operators i rst recognize that a pump system’s total cost of ownership (TCO) is the higher impact metric than initial purchase price, they are well on their way to managing their costs, but they are by no means i nished.

Second and equally critical is the recogni-tion, measurement and coordination of the factors that af ect ongoing ownership costs. Some industry experts have begun to focus on energy and maintenance when evaluating life-cycle costs. While these two elements are cer-tainly important, a plant manager must avoid taking too narrow an approach when evalu-ating a system. A holistic approach ensures that the big picture is not missed and that all potential opportunities for cost savings are identii ed.

Taking a comprehensive approach when evaluating a pumping system is important. h e process and tools can vary depending on the operator’s objectives. Four critical areas that should be evaluated in a plant environment are energy ei ciency, reliability, training and asset management.

h e scope of cost-reduction projects should not be dei ned too narrowly, or substantial cost savings may be missed. Taking too narrow a view with any one of these areas will cost a plant money, time and ef ort in the long run.

Energy ei ciency is so important that some plants now have an energy specialist on staf . h ese energy experts may be too limited in their thinking and not consider other factors that af ect TCO. For example, energy studies usu-ally produce both energy and reliability benei ts. In many plants, an energy expert may only look at energy savings, not considering the longer term savings gained by reliabil-ity improvements to a pump system. h is may result in rejections of improvement projects because the return on investment calculations only consider part of the savings potential.

A SOUTH AMERICAN COPPER MINE ELEVATES

EFFICIENCIES AND SAVES MILLIONS

A great example of the need to evaluate both energy ei -ciency and reliability improvements occurred in a large

copper mine operation in South America. h e mine was using seven vertical-turbine pumps to move rei no, an acid used in the extraction process. In this reclaimed water system, these critical pumps were not reliable. h e plant approached a local pump repair shop to evaluate and modify these pumps with a request that the repairs improve reliability.

h e non-OEM supplier missed a key opportunity to fully evaluate the situation by deciding to focus solely on the reli-ability issue. Its solution was to increase critical tolerances, which in turn improved the mean time between failure (MTBF). However, these adjustments delivered a much lower ei ciency and decreased throughput. Performance faltered, and plant operators saw l ow reductions of more than 20 percent, while the pump head diminished more than 15 percent. Solving only a portion of the problem did not address the plant’s overall objectives. h is adjustment to operations was counterproductive.

Another repair service team evaluated the entire system and ultimately uncovered the root cause of the problem. h e team worked with the mine operators and soon realized that the pumps were operating at an ei ciency of only 64 to 68 percent, with a much higher potential. During the anal-ysis, the team learned that the modii cations by the local,

The capability of a partner organization to analyze equipment trends can have a material

impact on plant asset management.



non-OEM supplier, intended to improve performance, cost the plant millions of dollars per year in lost production. Furthermore, the parts and repairs did not meet specii -cations and created additional inei ciencies that cost the plant more than $500,000 per year in excess energy costs.

To test theories on the plant’s problem, the repair service team built a precise pipe-l ow model. h ey used identical parallel pumps and corresponding elevations, pipe i ttings, valve l ow coei cients, and pipe relative roughness and mea-surements showed that the model was 99.8 percent accu-rate. h e repair service experts also advised the plant on how changing distribution nozzles at dif erent elevations would af ect l ow. h ese changes allowed the team to increase and rei ne l ow by almost 1,000 cubic meters per hour. With this approach, the result was a synergistic combination of increased ei ciency, reliability and throughput for the plant’s pump system.

h e repair service team’s holistic approach convinced the mine operators to restore their pumps to OEM speci-i cations and make other system changes to solve the origi-nal reliability problem. h e elevated ei ciency delivered substantial bottom-line benei ts. Increased ei ciency and higher l ow rates increased mine production revenues by $10 million and delivered energy cost savings of $500,000 annually, demonstrating the pay-back of a thorough, multifaceted approach to cost reduction and productivity.

MAINTENANCE & TRAINING

While critically important, cor-recting reliability and ei ciency problems alone is not sui cient if a plant is to fully realize its cost-saving opportunities. Once the systems are optimized, changes must be institutionalized through ef ective training programs. Without education, unreliability and inei ciency will return.

A lack of awareness and educa-tion can create adverse impacts even before pump installation, when a decision is made to buy an oversized pump. Putting the increased purchase costs aside, the life-cycle costs—while small day-to-day—add up to a substantial

cost throughout many years. Over-sizing can lead to 20 per-cent higher energy costs, excessive vibration, heat and wear that lower service life, and the spread of other inei ciencies throughout the pump system.

Another factor procurement personnel must be aware of is the impact of the quality and ei ciency of parts that are used during scheduled maintenance and repairs. h e exam-ple of the mining operation’s decision to buy non-OEM parts is unfortunately a common mistake that may result in signii cant losses for a plant. Typical life-cycle costs in rotating equipment grow more substantial as inei ciencies emerge, resulting in increased maintenance, hydraulic inef-i ciency and emergency repairs because of unplanned down-time and lowered MTBF. h e links between ei ciency and maintenance are numerous.

So, too, are the links between ef ective equipment opera-tion and maintenance and training. Many times, a lack of skills on the plant l oor is an issue. Long-term savings can be gained by providing technicians with the knowledge to properly repair pumps and other rotating equipment. Sometimes plant executives decide to reduce costs through staf reductions and, in some cases, the elimination of train-ing organizations. h is may mean that operators and main-tenance personnel are not properly trained, contributing to

Training services, such as this hands-on session with monitoring and control equipment on a pump

simulation system, help operations personnel in a plant sustain the savings they seek in their pump

systems after installation.


operating errors and improperly maintained equipment. Operator errors can result in equipment damage, loss of performance and ultimately costly unplanned repairs. High quality training can address these issues and be one of the best investments that a plant can make to ensure that pump-ing systems continue to run ei ciently and reliably for the maximum life cycle.

PROBLEM-SOLVING IN A PULP & PAPER MILL

Evaluating energy ei ciency and reliability together is a comprehensive approach to identify problem areas. A repair and ei ciency service company evaluated a large North American pulp and paper mill to i nd ways to reduce its energy and maintenance costs. h e operators had previ-ously attempted to reduce costs by implementing a repair program through a non-OEM shop. h e OEM team con-ducted a plant-wide optimization assessment with targeted energy and reliability studies. h e team worked with the operators to evaluate a system of more than 50 pumps and identify maintenance practices, pump coni gurations and energy savings opportunities.

h e result was that the team found numerous opportuni-ties for energy reduction and reliability improvement, net-ting more than $750,000 in annual savings across the plant. h e consultative and holistic approach to evaluating the mill’s reliability problems avoided a limited focus of only looking at energy. By evaluating the whole spectrum of oper-ating costs, the team delivered a trifecta of reduced energy and maintenance costs with higher runtimes, saving the plant thousands of dollars annually in energy and reliability.

EFFECTIVELY MANAGING ASSETS

Large cost reductions can also be achieved through proper management of assets. Poor record keeping or a lack of any record keeping can cause plant managers to make costly, uninformed decisions. Ot en the i nancial implications of these decisions can ripple through a plant and add up to substantial losses.

For example, the night shit crew in one plant did not complete work orders on some of the work they performed. A particular pump failed four times in one month at an average cost of $4,500 for each occurrence and resulted in signii cant losses in production. h ese failures went largely undetected for several weeks. When the details of these fail-ures i nally surfaced, they were attributed to a blockage in the suction line of the pump, which caused it to fail cata-strophically. Most of the failures could have been avoided if emergency work orders had been completed and reviewed by the reliability engineering group.

Without accurate and complete equipment history, ef ec-tive analysis to eliminate the cause of the failure is impos-sible. Accurate work order information should be com-pleted for all maintenance activities. h e work order should include:

• A description of the work requested• A description of the actual work completed• h e number of hours required to complete the work• h e parts used• h e total cost• All failure codes and causes• Recommended follow-up actions

Amassing that historical data and putting it to use will sig-nii cantly lessen failures and reduce costs.

Another common issue is a lack of a formal data review process that continuously analyzes historical data to i nd similar failure patterns, repeat or like failures, average MTBF, TCO, labor use, and parts use. h is begins with having work processes and automated systems in place that allow for accurate data collection throughout the equip-ment’s life cycle. If the maintenance manager is not ensur-ing that all work is covered by a work order in a formal work order system, then establishing accurate maintenance records is not possible. Using multiple vendors for replace-ment parts and repairs will complicate documentation and data collection and make assembling a complete picture of equipment history dii cult.

Plants should partner with a shop that returns equipment to OEM or better condition and works collaboratively with the plant to meet TCO goals. h is includes capturing and reporting key reliability metrics. h is will help managers identify opportunities for cost reductions.

EVALUATE ALL FOUR OPERATING AREAS

It is never too late to take a holistic and comprehensive approach by evaluating the four important operating areas of a pump system. h is complete evaluation approach will uncover the true source of any potential problems as well as deliver long term cost savings and optimal returns on any future investment in a pump system. P&S

Darren Moscato is the director of PPS Americas, part of ITT

PRO Services, which includes Plant Performance Services

(PPS), a consulting services business that helps customers

reduce their total cost of equipment ownership. Moscato

has a B.S. in engineering and management from Clarkson

University. Before joining ITT, Moscato held service manage-

ment positions with Rockwell Automation, and he owned a

consulting services business.



For a process pump in which liquids with chemical contents are pumped, damage to the seal can occur. h e

chemicals may cause damage on a standard seal. In many of these applications, a water-lubricated lip seal may eliminate this kind of damage.

BASIC FUNCTIONS WITHIN A LIP SEAL

Initially designed for heavy-duty dredging pumps, the lip seal is a water-lubricated shat seal, which is best suited for pumps that process l uids containing abrasive particles or particles that are larger than 100 micrometers. h is lip seal is designed to be lubricated with an external l ushing water supply (up to 40 bar) that is reduced to almost atmospheric pressure by the seal itself.

h is lip seal is made of independently operating modules, each fuli lling a function. h e basic functions are:

• Sealing• Dirt retaining• Pressure reduction

h e sealing module prevents undesired leakage into the atmosphere and performs at optimal conditions. h e dirt retaining module keeps sand and/or dirt in the stui ng box (water chamber) from entering the water-lubricated lip seal.

h e pressure reducing module lowers the l ushing water pressure (P

f) to approximately that of the atmospheric level

(Pa). In this module, the lip seal runs over helical grooves.

h ese grooves transport water from the l ush inlet to the sealing module. h is ensures that the heavily loaded run-ning surface of the pressure reducing lip seal is continuously cooled and lubricated. h e water lubricated lip seal is suit-able for l ushing water pressures up to 40 bar(g).

h e l ow of the l ushing water discharge serves as an indicator of the condition of the seal. With time, the heli-cal grooves on the bush gradually wear. h is way, a smaller amount of water will l ow through the seal and the water discharge l ow gradually decreases. When the discharge l ow reaches 20 percent of the initial l ow, maintenance should take place.

By plotting the decrease of the discharge l ow, main-tenance can be planned ei ciently. h is way, mean time between maintenance (MTBM) can be optimized. Monitoring this l ow and scheduling maintenance activities helps avoid sudden pump failure. Emergency maintenance will no longer be needed.

CASE STUDY: PAINT & COATINGS COMPANY

A European paints and coatings company encountered continuous major problems with packing seals on its salt production, circulation axial-l ow pumps. h ey wanted to maintain a MTBM of six years, because that would coincide with the main maintenance interval of the pumps. h e fric-tion caused by the salt and water resulted in damage to the pump seal that was installed on these pumps.

h e company needed to increase the availability of its process system and increase reliability. An employee of the paints and coatings company had previously worked with a seal company that developed a plan to solve this kind of problem. h is seal company’s team decided to remove and replace the gland packing with a water-lubricated lip seal that included a buf er system.

Water-Lubricated Sealing Solution for Chemical ProductionHeavy, salty pumped l uids can be sealed with a water and buffer system.

By Peter Jap & Andries Tuk, IHC Sealing Solutions

A section of an engineered design of the

water-lubricated process pump sealing solution


h is new seal arrangement used an additional buf er system with retaining rings (dust lips) combined with a throttle bush function (buf er system). h ese additional

buf er systems prevented the pumped medium from reach-ing the water-lubricated lip seal. h e water-lubricated seal l ushes the seal module and the buf er system with the

external l ush.h e company was more than

satisi ed with extended MTBM, which is beyond the set maximum required period and contributes to the optimal reliability of the sealing system. P&S

Peter Jap is sales man-

ager and Andries Tuk is

project engineer for IHC

Sealing Solutions. Jap can

be reached at info.seals@

ihcmerwede.com or +31

(0)78-6921846.

For more information,

visit www.ihcsealingsolu-

tions.com.

v

The water-lubricated lip seal

Peter Jap

Andries Tuk

Publication Title:Pumps and Systems Magazine

Publication Number: 1065-1084

Filing Date: 9/2013

Frequency: Monthly

Number of Issues Published Annually: 12

Annual Subscription Rate $48.00

Complete Mailing Address of Known Office of Publication

1900 28th Avenue South Ste 200

Birmingham, Alabama 35209

Complete Mailing Address of Headquarters or General Business Office of Publisher


Birmingham, Alabama 35209

Full Names and Complete Mailing Address of Publishers, Editor and Managing Editor

Walter B. Evans, Jr.


Birmingham,Alabama 35209

Editor: Michelle Segrest



Managing Editor: Lori Ditoro



Owner: Cahaba Media Group

P.O.Box 530067 Birmingham,AL 35253

Stockholder: Walter B. Evans Jr

P.O.Box 530067 Birmingham,AL 35253 Average No. of

Copies Each Issue

During Proceeding

12 Months

No. Copies of

Single Issue

Published Nearest

to the filing date.Issue Date of Circulation Below: September, 2013

Total Number of Copies (Net Press Run) 38413 39950

Paid/Requested Outside County Mail Subscriptions Stated on form 3541

(Include advertisers proof and exchange copies) 23753 23019

Total Paid and/or Requested Circulation 23753 23019

Free Distribution Outside County as stated on 3541 13280 13684

Free Districution Outside mail 508 1001

Total Free Distribution 13788 14685

Total Distribution 37541 37704

Copies Not Included 872 2246

Total: 38413 39950

Percentage Paid and/or Requested Circulation 63.27 61.05

Walter B. Evans, Jr. Publisher 9/2013

Statement of Ownership, Management and Circulation

I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes

false or misleading information on the form or who omits material or information requested on the form may be

subject to criminial sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties)


U N M AT C H A B L E E X P E R I E N C E

I N P R I VAT E C O M PA N Y

T R A N S A C T I O N S

MEMBER FINRA, SIPC

Jordan, Knauff & Company is a knowledgeable and experienced provider of a comprehensive line of investment banking services to the pump, valve and filtration industries (“Flow Control”).

Our lines of business include: selling companies, raising debt and equity capital, and assistance on acquisitions.

To learn more about Jordan, Knauff & Company, contact any member of our Flow Control team. Access our Flow Control research at www.jordanknauff.com/flowcontrol.

G. Cook Jordan, Jr.Managing Principal

[email protected]

David A. KakarekaAssociate

[email protected]



The combination of vacuum enhanced distillation and waste heat recovery is a proven concept that has been

used for more than 60 years. h is tried-and-true method of desalination is making a comeback. Advances in technology have resulted in evaporators that:

• Are more energy ei cient• Of er a reduction in weight and installed spare

requirements• Are more reliable • Of er a clear green advantage

HOW HEAT RECOVERY EVAPORATORS WORK

Waste heat evaporators use waste heat from engine jacket water, engine exhaust, steam or other heat sources to transform seawater, brackish water or contaminated feed water into pure potable water that is suitable for human consumption, industrial processes, agriculture and many other applications. Operational ei ciency can be further enhanced by adding additional evaporation stages and/or ef ects to increase the amount of fresh water produced using a reduced amount of heat.

Properly designed heat recovery evaporators provide thermal stability in rough seas, consistency of clean water across all types of feed water and can handle wide ranges of feed water temperatures. Evaporators can function well in river water, brackish bay water or sea water, yielding the same high quality water.

APPLICATIONS

Heat recovery evaporators/watermakers extract high-quality salt free water from seawater using waste heat. Watermakers are used in the com-mercial shipping industry on oceangoing tankers and cargo vessels. h e military has applications on

aircrat carriers, destroyers and submarines in which highly reliable water production is critical for the mission. h e oil industry also uses this technology on of shore oil and gas drilling rigs, production platforms and supply vessels.

ADVANTAGES

Compared to other desalination technologies, heat recov-ery evaporators are advantageous for a multitude of rea-sons. Heat recovery evaporation is the most energy ei cient desalination technology. Waste heat, normally discharged

Advantages of Waste Heat DistillationEnergy efi ciency and minimal replacement parts make waste heat desalination a cost-effective solution to potable water making needs.

By Brian Hebert, Maxim Watermakers

Heat recovery evaporators such as this one offer a reduction in weight

and installed spare requirements.

This heat recovery evaporator has a

water production capacity of 3,000

gallons per day.


to the surrounding atmosphere, is used, which provides the bulk of the process’ energy requirements. Fuel ei ciency on vessels is enhanced because the transportation of large tanks of potable water or bottled water is not required. More cargo space is also available when large amounts of water do not need to be stored.

h e water produced is high quality, containing less than 4 parts per million (ppm) of total dissolved solids, compared to other desalination technologies that contain 300 to 500 ppm of total dissolved solids of which at least 50 percent is salt. Heat recovery evaporators operate under vacuum con-ditions at low boiling temperatures, which minimizes the scaling of the heat transfer surfaces and the maintenance associated with cleaning. h ere are no high-pressure (700 to 1,000 psi) hydraulic components. Low-pressure systems, fewer moving parts and simple designs make these systems reliable. A heat recovery evaporator requires less mainte-nance than other technologies.

Heat recovery evaporators do not use membranes or i lters, which can scale in the presence of certain types of

feed water and do not react well to changes in the feed water quality or temperature. Heat recovery evaporators, depending upon the size of the unit, use two pumps—a sea-water pump and a fresh water pump. Both pumps are close-coupled, centrifugal pumps. h e seawater pump ranges from 2 to 7½ horsepower while the fresh water pump averages ¾ horsepower and depends on the capacity of the watermaker. h e seawater pump is used to pump seawater or other liquid feed source into a chamber at the base of the evaporator. h e fresh water pump is used to pump the distillate into a clean water holding tank.

h e footprint for a heat recovery unit is small, and storage space for replacement membranes and i lters is not required since heat recovery evaporators require no replacement parts.

Heat recovery evaporators do not use membranes or i l-ters requiring disposal. More than 10,000 tons of i lters and membranes are sent to landi lls annually.1 h is fact makes them a good choice for companies with the goal of environ-mental responsibility.

CONCLUSION

Heat recovery evaporators of er a better return on invest-ment. h e up-front capital costs of an evaporator are comparable to other desalination technologies. However, throughout the lifetime of the unit, the cost to operate and maintain it is signii cantly lower. Heat recovery evapora-tors average a lifespan of more than 30 years.

Heat recovery evaporators of er an energy ei cient and reliable solution to water-making needs. Companies that are cost conscience and good stewards of the environment will i nd that this green technology will meet their expecta-tions. P&S

References

1. “New Coalition to Coordinate Research on Membrane Disposal.” Desalination & Water Reuse, July 2012.

Brian Hebert is president of Maxim Watermakers. He may be

reached at [email protected] or 318-629-2460. For

more information, visit www.maximwater.com.Units such as this one, with a water production capacity of 7,500 gal-

lons per day, do not use membranes or fi lters.

Heat recovery evaporators operate under vacuum conditions at low

boiling temperatures, which minimizes the scaling of the heat transfer

surfaces and the maintenance associated with cleaning.


PRODUCT PIPELINE

CouplingsTuf-Lok ring grip pipe and tube couplings are low cost, heavy-duty, self-aligning couplings for either high-pressure—up to 150 psi(g)—or full-vacuum rated applications. Used in all industries in which pipe and tube ends need to be connected, they are used for pneumatic conveying systems and gas and liquid applications. h ese couplings install quickly and easily, reducing installation costs. Circle 200 on card or go to psfreeinfo.com

Safety Monitoring SystemSchenck Trebel VIBROCONTROL 6000 safety monitoring system is a reliable machinery protection system. It of ers a more modern design and easy expansion to the plant-wide machine condition monitoring system—the COMPASS 6000. Features include l exible monitoring modules, redundant power supply with universal connectivity, LAN interface/OPC communication, parallel MODBUS and Windows-based coni guration and visualization sot ware.Circle 201 on card or go to psfreeinfo.com

Flow MetersNoncontact Meters Inc., in ai liation with Instruments

Direct, introduced its line por-table l ow meters. h e NCMP-603 Handheld Portable Transit Time Flow Meter is a cost-ei cient meter for water, wastewater, HVAC and energy management needs. h e NCMP-603 is a clamp-on, non-invasive handheld meter that uses transit time technology to measure liquid l ow from outside the pipe. Circle 202 on card or go to psfreeinfo.com

InvertersHitachi America, Ltd., Industrial Components & Equipment Division announced the addition of 400-volt class inverters to the NE-S1 series. h e economical and simple-to-use inverters in the popular range of ½ to 3 horsepower of er an ultra-compact design. h e new 400-volt class NE-S1, like the 200-volt class, of ers options that can be used to coni gure the control for specii c applications. Circle 203 on card or go to psfreeinfo.com

Float SwitchesSquare D brand l oat switches, by Schneider Electric, are designed for automatic control of liquid level in open tanks, handling small motor loads directly or through alternating- or direct-current magnetic starters. h ree separate enclosure options meet the requirements of general-purpose, water-tight, dust-tight and explosion proof applications.Circle 206 on card or go to psfreeinfo.com

Box Mounting BracketEaton’s B-Line business introduced its re-engineered BB8-16 box mount-ing bracket. h e new design of ers an improved speed of installation and increased rigidity. It is ideal for pre-fab applications, allow-ing for complete compatibility with the B-Line’s Rapid Ring Self-Adjusting Pre-Fab Ring. Suited for conventional new construction, the bracket uses a pre-measured l oor stand to ensure that products are consistently mounted at a height of 18 inches. Circle 204 on card or go to psfreeinfo.com

Drivesh e Drives & Motion Division of Yaskawa

America introduced its MV1000 medium-voltage AC drive family. Designed for energy savings and improved process control, MV1000 drives combine compact modular design, high ei ciency, low harmonics and industry leading mean time between failure into a medium-voltage drive solution. Yaskawa’s Smart Harmonics Technology reduces input total harmonic distortion to less than 2.5 percent without i lters. Circle 205 on card or go to psfreeinfo.com

all industries in

pplications allow

l d l ibl i i

nt meter for water

igure the control

h i l h


PRODUCT PIPELINE

Pressure Switchh e Ashcrot A-Series min-iature pressure switch is now available in a safety-integrity-level-capable, explosion-proof coni guration for hazardous areas. With 316 stainless steel construction, an IP67-rated enclosure and an operating temperature range from -40 C to 89 C (-40 F to 192 F), the dual-seal rated, A-Series, explosion-proof pressure switch stands up to extreme environmental conditions. Circle 211 on card or go to psfreeinfo.com

Turbine OilChevron introduced its GST Premium 32 turbine oil, designed for power generation applications in markets like petrochemical production, utilities and heavy indus-try. h e new oil has exceptional thermal and oxidative stability and meets the strict requirements of a wide vari-ety of turbine original equipment manufacturers. GST Premium turbine oil is specii cally formulated for use in turbines in which extreme temperatures are experienced. Circle 213 on card or go to psfreeinfo.com

Air-Operated Diaphragm PumpIngersoll Rand released an ARO air-operated diaphragm pump with a ¼-inch port size. h e PD01 series pump is designed for dosing appli-cations in wastewater treatment and other applications in which accurate and repeatable dosing is integral. h e pump comes with a solenoid-actuated valve option to electronically control the volume of l uid dispensed, which allows the pump to operate accurately.Circle 212 on card or go to psfreeinfo.com

Bearing MaterialVesconite’s Hilube is best for pump steady bushings and wear rings and bushings for applications in pumps, dam gates, hydro equipment, valves, aerators and ships.Vesconite Hilube provides improved performance when compared with many traditional bearing materials and features lower friction, no water swell and low wear bush-ings. It is ideal for use in salt water.Circle 217 on card or go to psfreeinfo.com

losure and an operating

www.ippexpo.org

ONE SHOW

INDUSTRIESMEATFEEDPOULTRY

THREE

The World’s Largest Annual Poultry, Feed, and Meat Technology Exposition

January 28 - 30, 2014



To have a product considered for “Product Pipeline,” please send the information

to Amanda Perry, [email protected].

Calibration PumpBeamex introduced its new calibration pump. h e PGHP pump is a pneumatic, high-pressure generator with air as the pressure medium. h is pump is a practical, high-quality solution in calibrations in which using liquids is prohibited, such as the gas industry. h e pump is ei cient in generating pressure up to 140 bar (2,000 psi) in less than a minute.Circle 207 on card or go to psfreeinfo.com

Process PumpSulzer Pumps launched its AHLSTAR end suction single-stage, close-coupled process pump series. It of ers low life-cycle costs and a lighter environmental footprint. Based on the design features of the AHLSTAR range, this pump series was developed for demanding pumping applications in oil and gas, hydrocarbon processing, chemical, pulp and paper, general industry, power generation, and water and wastewater. Circle 208 on card or go to psfreeinfo.com PTFE Compound

Freudenberg Sealing Technologies introduced its polytetral uoroethylene (PTFE) compound Y005. Developed especially for use in guide bands on valves that come into contact with food, the material com-plies with the regulations of the U.S. Food and Drug Administration and European Union and also prolongs service life. h e main reasons for developing the special PTFE compound Y005 were to achieve a targeted bal-ance between pressure resistance and l exibility, authori-zation for contact with food, and resistance to cleaning-in-place and sterilization-in-place cleaning products.Circle 209 on card or go to psfreeinfo.com

Sealless Drive PumpsMouvex introduced its SLS4 and SLS8 models of its sealless drive eccen-tric pumps. h ese pumps are designed for use in pumping applications in the food, cosmetic and pharmaceutical industries—all of which require extremely hygienic operations. h e major technological advancement in the pumps is the incor-poration of double-wall bellows and monitoring that is performed by pressure switch. Circle 210 on card or go to psfreeinfo.com

hi i i l hi hli ht n i n nt l f tp int

maceutical industries all of

INDEX OF ADVERTISERS

A. W. Chesterton Company . . . . . . . . . . . . .40 121

Advanced Engineered Pump, Inc.. . . . . . . .84 160

All-Flo Pump.. . . . . . . . . . . . . . . . . . . . . . . . . 10 122

Baldor Electric Company . . . . . . . . . . . . . . . 13 101

Bartlett Bearing Company . . . . . . . . . . . . . .87 161

Blue-White Industries. . . . . . . . . . . . . . . . . . 21 123

Carver Pump Company . . . . . . . . . . . . . . . . 17 124

Check-All Valve Mfg. Co. . . . . . . . . . . . . . . .43 125

Continental Pump Company . . . . . . . . . . . .86 162

Dan Bolen & Associates, LLC.. . . . . . . . . . .84 163

Egger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 140

Elliott Group . . . . . . . . . . . . . . . . . . . . . . . . . . 5 103

ExOne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 120

Federal Pump . . . . . . . . . . . . . . . . . . . . . . . . 12 126

Flowrox Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .27 127

Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . . .70 149

Full o Specialties Co. . . . . . . . . . . . . . . . . . .55 141

GE Power Conversion . . . . . . . . . . . . . . . . . 47 104

Graphite Metallizing Corporation . . . . . . . .67 154

Greene Tweed & Company . . . . . . . . . . . . . 37 105

Helwig Carbon Products, Inc. . . . . . . . . . . .87 164

Houston Dynamic Service, Inc. . . . . . . . . . .86 166

Hydraulic Institute. . . . . . . . . . . . . . . . . . . . .70 150

Hydro, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . IFC 100

Inpro/Seal . . . . . . . . . . . . . . . . . . . . . . . . . . .53 106

International Production & Processing Expo . . . . . . . . . . . . . . . . . . .82 129

JDA Global . . . . . . . . . . . . . . . . . . . . . . . . . .84 167

John Crane.. . . . . . . . . . . . . . . . . . . . . . . . . . 19 107

Jordan, Knauff & Company . . . . . . . . . . . . .77 151

Junty International LLC . . . . . . . . . . . . . . . .87 168

KB Electronics, Inc. . . . . . . . . . . . . . . . . . . .59 147

KSB, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 119

KTR Corporation. . . . . . . . . . . . . . . . . . . . . . 71 148

Load Controls, Inc. . . . . . . . . . . . . . . . . . . . .26 130

Load Controls, Inc. . . . . . . . . . . . . . . . . . . . .87 169

LobePro. . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 166

LUDECA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 31 108

Magnatex Pumps, Inc. . . . . . . . . . . . . . . . . .86 170

Master Bond Inc.. . . . . . . . . . . . . . . . . . . . . .87 171

Mazdak . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 185

Meltric Corporation. . . . . . . . . . . . . . . . . . . .86 172

Mission Communications . . . . . . . . . . . . . . 24 138

Mission Communications . . . . . . . . . . . . . . 51 139

Murphy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 128

Pentair Flow Technologies . . . . . . . . . . . . . . . 3 109

Pentair Flow Technologies . . . . . . . . . . . . . .49 110

Precision Digital . . . . . . . . . . . . . . . . . . . . . .30 131

Reason Technology Co. Ltd. . . . . . . . . . . . .48 142

Revere Control Systems. . . . . . . . . . . . . . . .67 153

Rexnord Corporation . . . . . . . . . . . . . . . . . .57 111

Ruthman Companies . . . . . . . . . . . . . . . . . .45 112

Scenic Precise Element Inc. . . . . . . . . . . . .87 173

Schenck Trebel Corp.. . . . . . . . . . . . . . . . . .35 132

SEPCO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 133

SEPCO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 174

Sims Pump Company. . . . . . . . . . . . . . . . . .65 117

Sims Pump Company. . . . . . . . . . . . . . . . . .85 183

SJE-Rhombus. . . . . . . . . . . . . . . . . . . . . . . .52 143

Skinner Power Systems, LLC . . . . . . . . . . .34 134

Sulzer Pumps. . . . . . . . . . . . . . . . . . . . . . . . . 15 113

Summit Pump, Inc. . . . . . . . . . . . . . . . . . . . .85 175

Superbolt. . . . . . . . . . . . . . . . . . . . . . . . . . . .44 144

ThinQk Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . .84 176

Thomas Products, Ltd.. . . . . . . . . . . . . . . . . 18 135

Titan Pump Manufacturing/O’Drill MCM . .66 152

Topog-E Gasket . . . . . . . . . . . . . . . . . . . . . .85 177

Trachte, USA . . . . . . . . . . . . . . . . . . . . . . . . .84 178

Tuf-Lok International. . . . . . . . . . . . . . . . . . .84 179

UniqueFlo . . . . . . . . . . . . . . . . . . . . . . . . . . .85 180

United Rentals. . . . . . . . . . . . . . . . . . . . . . . . . 7 114

Varisco USA Inc. . . . . . . . . . . . . . . . . . . . . . .85 181

Vaughan. . . . . . . . . . . . . . . . . . . . . . . . . . . .IBC 115

Vertil o Pump Company . . . . . . . . . . . . . . . .84 182

Vesco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 184

Vulcan Pump. . . . . . . . . . . . . . . . . . . . . . . . . 14 136

Xylem USA. . . . . . . . . . . . . . . . . . . . . . . . . . BC 116

* The Index of Advertisers is furnished as a courtesy, and no responsibility is assumed for incorrect information.

Advertiser Name Page RS# Advertiser Name Page RS# Advertiser Name Page RS#


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Compatible with food environments.

Resistant to chemicals, corrosion, and wear.

Compatible with a widevariety of materials.

High Performance Carbon & Graphite Seals

Helwig Carbon Products, Inc., 8900 W. Tower Ave., Milwaukee, WI 53224-2849, Toll Free: 800.962.4851

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Resistance to cyclic fatigue



PUMP MARKET ANALYSIS

Wall Street Pump & Valve Industry WatchBy Jordan, Knauff & Company

The Jordan, Knauf & Company ( JKC) Valve Stock Index was up 27.8 percent during the last 12 months,

above the broader S&P 500 Index which was up 16.4 percent. h e JKC Pump Stock Index was up 28.7 percent for the same time period.1

h e Institute for Supply Management’s Purchasing Managers’ Index (PMI) registered 56.2 percent in September, its highest reading since April 2011. For the month, the New Orders Index decreased by 2.7 percent-age points to 60.5 and the Production Index rose slightly to 62.6 percent. h e Employment Index registered its highest reading of the year at 55.4 percent.

Because of relatively strong growth in production and new orders, manufacturing activity accelerated during the last four months. h e New Orders Index increased to 60.5 percent in September, while the Production Index increased from 53.4 percent to 62.6 percent. During the last four months, the PMI averaged 54.5 percent, and new orders reached an average of 58.5 percent. h e Exports Index fell from 55.5 percent in August to 52.0 percent in September.

U.S. rei ners exported a record 3.8 million barrels of petroleum products per day in July, almost 65 percent above export levels in 2010, according to the U.S. Energy Information Administration (EIA). Exports to Asia have grown by 31 percent over the i rst seven months of 2013 with greater demand from China and India. North African countries have increased their imports from the U.S. by more than 52 percent. New markets have also opened in West Africa, where U.S. imports rose 60 percent during the same time period.

U.S. diesel exports have doubled since the beginning of the year surpassing one million barrels per day (bpd) for the i rst time this summer. In 2010, diesel exports averaged 300,000 bpd. Low-sulfur diesel that meets the stringent air quality standards being put into place in South and Central America is in high demand.

h e EIA estimates that the U.S. will overtake Russia and Saudi Arabia to become the world’s top producer of petro-leum and natural gas hydrocarbons in 2013. For the past i ve years, U.S. petroleum production has increased by 7 quadril-lion Btu, while natural gas production has increased by 3 quadrillion Btu. Russia and Saudi Arabia each increased their combined petroleum and natural gas output by only one quadrillion Btu. On Wall Street stocks performed strongly in the third quarter led by the NASDAQ Composite Index which was up 11 percent, while the S&P 500 Index rose 4.7 percent and the Dow Jones Industrial Average was up 1.5 percent for the quarter. P&S

Reference1 h e S&P Return i gures are provided by Capital IQ.

Jordan, Knauff & Co. is an investment bank based in Chicago, Ill., that provides

merger and acquisition advisory services to the pump, valve and i ltration indus-

tries. Please visit www.jordanknauff.com for further information on the i rm.

Jordan Knauff & Co. is a member of FINRA.

Figure 2. U.S. energy consumption and rig counts

Figure 3. U.S. PMI index and manufacturing shipments

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

Source: Institute for Supply Management Manufacturing Report on Business® and U.S. Census Bureau.

Figure 1. Stock indices from Oct. 1, 2012, to Sept. 30, 2013

Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates. h e JKC Pump and Valve Stock Indices include a select list of publicly-traded companies involved in the pump and valve industries weighted by market capitalization.

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®

www.chopperpumps.com

®


TotalCare servicesFor secure, optimal operations

Xylem TotalCare is a comprehensive, integrated portfolio of

services that ensures your business keeps running at its best.

Our portfolio comes backed by deep systems knowledge

and expertise in water and wastewater applications. Which

gives you the operational security and more time to focus

on your core business.

What can Xylem do for you?

Call 1 704 409–9700 or visit

www.xylemtotalcare.com


november 2013

Documents

opinions of cahaba media

monthly cahaba media

e pumps systems team

industry issue

us funds

pumps systemsfrom

editor pumps systems

pump industry publication