ps - 08 - 2014

OPTIMIZE PUMPING SYSTEMSDiligent analysis, rigorous scrutinylead to longer system life

AUGUST 2014

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SEALS & BEARINGSTips for MaximizingPERFORMANCE

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August 2014 | Pumps & Systems

From the EditorThis month we introduce an exciting, fresh, modern look to our logo and design that has been thoughtfully crafted to make the magazine easier for

you to read and navigate. While the look has been

updated, the content remains the same high-quality

technical pumping information that you cant nd

anywhere but in the pages of Pumps & Systems.

It makes sense that we introduce this change with

a focus on the increasingly vital topic of pump system

optimization. Not long ago, the components of a

pumping system were designed separately, purchased

separately and maintained separately. anks to

advancements in technology and increased standards

and awareness and the Hydraulic Institutes devel-

opment of Pump Systems Matter, today the entire system is examined and modi ed to

decrease life-cycle costs and save energy.

On average, industrial pumps operate at less than 40 percent e ciency, and more than

10 percent of pumps run at less than 10 percent e ciency. is impacts the bottom line.

e cost to pump ine ciently is beyond your wildest imagination, says Mike Pember-

ton, ITT Performance Services Manager and Pumps & Systems Editorial Advisory Board

member. In the past several decades, pump e ciency has only increased 3 percent by

design. e biggest advantage in increasing e ciency is happening with automation and

controls. e infrastructure is in place, but the question remains, How do we optimize?

is year, Pumps & Systems published a three-part series from HI examining the Depart-

ment of Energys pump e ciency regulation changes (Jan.-March 2014, www.pump-zone.

com). e series describes how to reduce the burden on U.S. pump manufacturers and support

the DOEs e orts to achieve energy savings and e ciency improvements in the marketplace.

According to Pump Systems Matter, the most likely candidates for optimization are

large systems, systems with high operating hours, problem systems and production-crit-

ical systems. e most common red- ag symptoms are high energy costs, throttle valves

that are generally closed, bypass valves/recirculation lines that are generally open, fre-

quent failures or repair requirements, high operating noise levels (especially at the valve

or pump), vibrations in the system and/or pump assembly, systems with multiple parallel

pumps with the same number of pumps always operating, constant pump operation in a

batch environment or frequent cycle batch operation in a continuous process, and systems

that have undergone a change in function. Learn more by visiting www.pumps.org.

You can nd a wealth of solutions by reading this months cover series, which begins on

page 60. As always, pump e ciency will be a major topic at the 43rd Turbomachinery and

30th Pump Symposia in Houston, Sept. 23 25. Visit the Pumps & Systems team at Booth

514, and tell us about your pump optimization success stories.

EDITORIAL

EDITOR: Michelle [email protected] 205-314-8279

MANAGING EDITOR: Lori K. [email protected] 205-314-8269

SR. EDITOR, PRODUCTION & CONTENT MARKETING: Alecia [email protected] 205-314-3878

ASSOCIATE EDITOR: Michael [email protected] 205-314-8274

ASSOCIATE EDITOR: Savanna [email protected] 205-278-2839

CONTRIBUTING EDITORS: Laurel Donoho, Joe Evans, Lev Nelik, Ray Hardee

CREATIVE SERVICES

SENIOR ART DIRECTOR: Greg Ragsdale

ART DIRECTORS: Jaime DeArman, Melanie Magee

WEB CONTENT EDITOR & WEB ADVERTISING TRAFFIC: Robert Ring

PRINT ADVERTISING TRAFFIC: Lisa [email protected]

CIRCULATION

AUDIENCE DEVELOPMENT MANAGER:

Lori Masaoay [email protected] 205-278-2840

ADVERTISING

NATIONAL SALES MANAGER:

Derrell Moody [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

MARKETING ASSOCIATES:

Ashley Morris [email protected] 205-561-2600

Sonya [email protected] 205-314-8276

PUBLISHER: Walter B. Evans, Jr.

VP OF SALES: Greg Meineke

VP OF EDITORIAL: Michelle Segrest

CREATIVE DIRECTOR: Terri Jackson

CONTROLLER: Tim Moore

P.O. Box 530067Birmingham, AL 35253

EDITORIAL & PRODUCTION

1900 28th Avenue South, Suite 200Birmingham, AL 35209205-212-9402

ADVERTISING SALES

2126 McFarland Blvd. East,. Suite ATuscaloosa, AL 35404205-345-0784

Pumps & Systems is a member of the following organizations:

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. 2014 Cahaba Media Group, Inc. No part of this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any adver-tisements 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 submis-sion 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 22, Issue 8.

Michelle Segrest with ITTs Margaret Gan at the 2014 Offshore Technology Conference. The Pumps & Systems team returns to Houston for the Turbomachinery/Pump Symposia in September.

Editor, Michelle Segrest

2

Motors | Automation | Energy | Transmission & Distribution | Coatings

Features that make a difference:

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"Oversized diagonally split aluminum terminal box that exceeds IP55 requirements. (Ideal for easy installation and tough environments).

"Terminal box is rotatable in 90 degrees increments for easy installation

"AEGIS ring inside (optional) to extend bearing life when used with VFDs

"IP55 ingress protection is standard

"Suitable for VFD operation per NEMA MG1 part 31.4.4.2

"Color coded leads for easy installation

"Motor paint resistance exceeds 500 hours of salt spray test

Transforming Energy into Solutions www.weg.net/us

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A product line with superior features that make a big difference for our customers.



4 AUGUSTThis issue

60 STREAMLINED MOTOR MANAGEMENT SYSTEM BOOSTS BIOMASS POWER GENERATION

BY Matthias Borutta

Phoenix Contact

Trusted gateway connections allow for system growth, e ciency and consistent maintenance at Swedish paper mill.

64 INTELLIGENT MONITORING DELIVERS REAL-TIME PUMP PERFORMANCE DATA

By Mike Pemberton

ITT Pro Services

An energy e ciency and reliability study helped one plant save $1 million annually by avoiding downtime.

69 CLOSE INSPECTION SOLVES HIGH THRUST BEARING TEMPERATURE PROBLEM

By Gary Dyson

Hydro Inc.

Careful analysis identi ed the issue with this multistage oil transfer pump.

73 SYSTEM SELECTION CRUCIAL FOR LONG WASTEWATER

PUMP LIFE

By Lars Bo Andersen

Grundfos Wastewater

Driving down investment, energy and maintenance costs translates into big savings throughout an installations lifetime.

76 REDUCER FITTINGS DECREASE PIPE SIZE TO PREVENT FAILURE

By Ross Mahaffey, Aurecon and Stefanus Johannes van Vuuren, University of Pretoria

Design of the pump inlet piping can protect overall operation.

COVERS E R I E S

PUMP SYSTEM OPTIMIZATION

COLUMNS

PUMP ED 101

20 By Joe Evans, Ph.D. Pump Tech Inc.

ree-Phase Voltage Variation & Unbalance

PUMPING PRESCRIPTIONS

26 By Lev Nelik, Ph.D., P.E. Pumping Machinery, LLC

Simplify the Equipment Selection Process

PUMP SYSTEM IMPROVEMENT

28 By Ray Hardee Engineered Software, Inc.

System Validation & Troubleshooting

GUEST COLUMNS

36 By Heinz P. Bloch, P.E.

Pushing Fluid Machinery Leads to Failure

40 By Amin Almasi

Estimate Pump Installation Costs

DEPARTMENTS

84 EFFICIENCY MATTERS

Smart Air Distribution Systems Upgrade Traditional AODD Pump Technology

89 MAINTENANCE MINDERS

6 Re nery Pump Maintenance Tips

94 MOTORS & DRIVES

e Di erences Between Submersible & Immersible Motors

98 SEALING SENSE

Expansion Joint Selection Optimizes Piping Systems

102 HI PUMP FAQS

Understand Speci c Speed & Disc Diaphragm Pump Coupling

64

60

Volume 22 Number 8

Cover photo courtesy of Colfax Fluid Handling

2

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4 W

ea

the

rfo

rd.

All r

igh

ts r

ese

rve

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Your business cant run on a fabrication order.

PUMP AND FLUID SYSTEMS

Contact and collaborate with us at [email protected]

We deliver the pump you need without the wait.

0VSVJEQVNQTLFFQZPVSCVTJOFTTNPWJOH'SPNDBVTUJDTUPDSVEFPJMBOEGSPNDSZPHFOJDUPCPJMJOHPVSQMVOHFSQVNQTEFMJWFSQPXFSBOESFMJBCJMJUZJOUIFPJMFMEGPPETFSWJDFNVOJDJQBMBOEDIFNJDBMJOEVTUSJFTUPOBNFBGFX8IFOZPVPSEFSB8FBUIFSGPSEQSPEVDUJPOQVNQZPVHFUNPSFUIBOBGBCSJDBUJPOPSEFS0VSFYUFOTJWFTUPDLPGQVNQTsJODMVEJOHUIPTFNBEFGSPNQSFNJVNNBUFSJBMTTVDIBTEVQMFYTUBJOMFTTTUFFMOJDLFMBMVNJOVNCSPO[FBOEDBSCPOTUFFMsFOTVSFTUIBUZPVHFUUIFQVNQZPVOFFEOPUBGBCSJDBUJPOPSEFS

Pressure ratings from

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Flowrates from

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Power ratings from

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Formation Evaluation | Well Construction | Completion & Stimulation | Production



6 This issueSPECIALS P E C I A LS E C T I O N

THOMAS L. ANGLE, P.E., MSC, Vice President Engineering, Hidrostal AG

ROBERT K. ASDAL, Executive Director, Hydraulic Institute

BRYAN S. BARRINGTON, Machinery Engineer, Lyondell Chemical Co.

KERRY BASKINS, VP/GM, Milton Roy Americas

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, VP/GM, Crane Pumps & Systems

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, PumpingMachinery, 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)

JERRY TURNER, Founder/Senior Advisor, Pioneer Pump

KIRK WILSON, President, Services & Solutions, Flowserve Corporation

JAMES WONG, Associate Product Manager Bearing Isolator, Garlock Sealing Technologies

EDITORIAL ADVISORY BOARD

2 FROM THE EDITOR

8 READERS RESPOND

10 NEWS

80 TRADE SHOW COVERAGE

118 PRODUCT PIPELINE

124 PUMP USERS MARKETPLACE

128 PUMP MARKET ANALYSIS

SEALS & BEARINGS

42 CANNED MAGNETIC BEARINGS MINIMIZE CORROSION IN OIL & GAS PROCESSING

By Richard R. Shultz

Waukesha Magnetic Bearings

Safely immerse motor compressorsin process gas without risking costly damage.

45 THE RIGHT SEAL & LUBRICANT COMBINATION CAN PREVENT BEARING CONTAMINATION

By James Wong

Garlock Sealing Technologies

Lip and labyrinth seals provide protection in harsh oil and gas applications.

PRACTICE & OPERATIONS

106 ENERGY EFFICIENT VERTICAL TURBINE PUMPS PROMOTE SUSTAINABLE MINING EFFORTS

By Petar Ostojic

Neptuno Pumps

e computational uid dynamics process advances highly e cient pump designs for di cult applications.

110 SPECIFIC PUMP & VALVE FEATURES SERVE LIQUEFIED NATURAL GAS APPLICATIONS

By Gobind Khiani

Fluor Canada Ltd.

LNG bene ts have increased the demand for this cleaner burning fuel and associated production and distribution equipment.

114 DEWATERING PUMPS HANDLE SAND SLURRIES IN POST-HURRICANE RECOVERY

By Mike Bjorkman

BJM Pumps

Reconstruction and infrastructure upgrades require pumps from durable materials.

50 SELECT SEALS THAT MEET THE CHEMICAL CHALLENGES OF HPLC PUMPS

By Jerry Zawada

Trelleborg Sealing Solutions

Abrasive processing and wide temperature range are some of the pumping di culties for high-performance liquid chromatography.

54 TREATED CARBIDE SURFACES ENHANCE RUNNING PERFORMANCE

By Mark Slivinski

Carbide Derivative Technologies Inc.

is technology self-lubricates, reduces friction, and performs in wet or dry operating conditions.

AUGUST

Borets Equipment is a HPS horizontal

multistage pump manufacturer that

provides pumping solutions with

exceptional customer service.

HORIZONTAL PUMPING SYSTEMS

SERVICESERVICEReliable. Quality. Modular.

Horizontal Pumping System (HPS) by Borets Equipment.

Cost-competitive and customizable for your specific application, the HPS equipment

requires less inventory and delivery time than traditional API 610 multistage, vertical

turbine can and reciprocating pump equipment.

Engineered for reliability, modularity, and quick replacement of components, the HPS

pump has a lower life cycle cost, thanks to minimized downtime and low maintenance

requirement. The result is a reliable, flexible and innovative pumping system.

You provide the application, well provide the Pump Power and Service.

RELIABLE FLEXIBLE INNOVATIVE

w w w . b o r e t s . c o m / H P S

Low Pro Design



8 READERS RESPOND

A Salute to

Frank Weis,

From the Editor

MARCH 2014

I was sent your article

while I was at the

American Water

Works Association

conference in Boston. ank you so

much for writing this and sharing some

of your thoughts on Frank.

I just wanted to share more with

someone, so I decided to give you more

background. Frank was my rst boss

when I joined Smith and Loveless in

1983, fresh out of graduate school. I

wont go into all the engineering details

I learned from just watching him but

wanted to share the personal side.

I worked for, with and shared lunch

with Frank many days over my next

six years of employment. He treated

everyone the same, from the janitor to

the president of the company. He was

friendly to all, had a great sense of hu-

mor, enjoyed pulling pranks on select

employees, and I never, ever saw him be

upset or have a bad day!

We were both alumni of the Univer-

sity of Missouri, and he loved sports,

had coached his kids baseball and bas-

ketball teams and loved to talk sports

of all kinds. He shared his knowledge

with any that asked, but he was the

most humble guy I have ever known.

He went about his work with

a quiet determination and knew

exactly what he was trying to

achieve, even if it didnt t with

the views of management at the

moment! He had an amazing

in uence on my professional

and personal life, and I tell sto-

ries related to him almost every

week. I left the company in

1989 and moved to Degremont

in Virginia, but his in uence

had more impact on me than

anyone I have worked with since

that time.

I am now back in Kansas City

and was fortunate enough to

attend the 50th anniversary of

Franks work at Smith and Love-

less in 2004. As was typical for Frank,

he didnt want it to be a big deal, so the

ceremony was held on the shop oor.

Several former employees attended,

many who had long since retired!

I knew then how unique Frank was

but have understood this even more

in the years that have passed. As great

a man as he was from the engineer-

ing and invention side, he was an even

better man overall. e world was a

better place for the time he was here

and for all the individuals that got to

know him.

Andy Mitchell

Director, Business Development

Metawater USA, Inc.

Pumps & Systems Editor Michelle

Segrest responds:

ank you for reading my column about Frank Weis (www.pump-zone.com/blog/salute-frank-weis) and for responding with these nice comments. e additional insight into the life of this legendary pump innovator is greatly appreciated. Frank Weis was well respected in the pump industry and will be missed by all who knew him.

READERS responD

To have a letter considered for Readers

Respond, please send it to Michael Lambert,

[email protected].

Frank Weis


10 NEWS

NEW HIRES, PROMOTIONS & RECOGNITIONS

LARRY LEWIS, VANTON PUMP

HILLSIDE, N.J. (July 10, 2014) The Board of

Directors of the Vanton Pump and Equipment

Corp. voted to name Larry Lewis as the companys

president and chief executive offi cer. Lewis has

served as Vantons president since 2010. Vanton Pump and Equipment Corp. supplies chemically

inert, thermoplastic pumps and systems that

solve fl uid containment, dosing and transfer

problems. www.vanton.com

DAVID BOEZI, DANFOSS

BALTIMORE (June 24, 2014) Danfoss hired

David Boezi as senior director, strategy and global

platforms. In this role, Boezi will help Danfoss

tailor its high-effi ciency compressor portfolio

to respond to changing customer needs that

are being infl uenced by new refrigerant and

energy-effi ciency regulations. Danfoss supplies technologies that meet the growing need for food

supply, energy effi ciency, climate-friendly solutions and modern

infrastructure. www.danfoss.com

DICK SHEAR, MULTI W SYSTEMS

EL MONTE, Calif. (June 20, 2014) Multi W

Systems Inc. announced the appointment of

Dick Shear as general sales manager. Multi W Systems manufactures and distributes

pump systems, electrical controls and related

engineered machinery. www.multiwsystems.com

PAMELA HENRY, WEF

ALEXANDRIA, Va. (June 19, 2014) The Water

Environment Federation (WEF) promoted Pamela

Henry to the position of deputy executive

director. Having been with WEF for more than

25 years, Henry is a seasoned leader who will

oversee a number of key organizational programs

including WEFTEC operations and exhibitions,

advertising and sponsorships, marketing,

communications and creative services, human

resources, and facilities management. WEF is a not-for-profi t technical and educational organization of 36,000 individual members

and 75 affi liated Member Associations representing water quality

professionals around the world. www.wef.org

CHUCK HULL, 3D SYSTEMS

ROCK HILL, S.C. (June 17, 2014) 3D Systems announced that Chuck

Hull received the 2014 European Inventor Award in the non-European

countries category in recognition of his invention of the three-

dimensional (3-D) printing technology Stereolithography. Presented

annually by the European Patent Offi ce, the award honors inventors

who made signifi cant contributions to technological progress and

the advancement of society. 3D Systems provides 3-D printing centric design-to-manufacturing solutions including 3-D printers,

print materials and cloud-sourced on-demand custom parts for

professionals and consumers in materials including plastics, metals,

ceramics and edibles. www.3dsystems.com

EDWARD CRANER, HOLT CAT

SAN ANTONIO, Texas (June 16, 2014) HOLT

CAT named Edward Craner senior vice president,

strategy and marketing. In his new role, Craner

will continue to lead and develop corporate

strategy, marketing and customer experience

initiatives to support sales growth. HOLT CAT sells, rents and services Caterpillar machines,

engines, generator sets and trucks.

www.holtcat.com

Edward Craner

Larry Lewis

David Boezi

Dick Shear

Pamela Henry

SPOTLIGHT

PUMPS & SYSTEMS LAUNCHES

MIDDLE EAST/NORTH AFRICA MAGAZINE

BIRMINGHAM, Ala. (July 2, 2014) Pumps & Systems, the leading

magazine for pump users worldwide for more than 20 years, expands its

international coverage of powerful technical pumping information to the

Middle East/North Africa region. The premier issue of Pumps & Systems

MENA will launch in early October 2014. It also will be distributed at the

Pumps & Systems booth Nov. 10, 2014, at the Abu Dhabi International

Petroleum Exhibition & Conference, the regions leading conference

for oil and gas professionals. Pumps & Systems MENA will publish

bimonthly in 2015 following the October 2014 launch and will cover case

studies and technical information in the following industries:

Oil & gas (upstream and downstream)

Water & wastewater

Power generation

Food & beverage processing

Building services

Chemical, petrochemical & refi nery

The regular editorial coverage will also include strategic and insightful

market data from respected market research analysts Frost & Sullivan.

The magazine will be supported digitally with a website,

www.pump-zone.com/mena, and a twice-per-month e-newsletter, Pump

Users Digest MENA. Subscribe to the e-newsletter and magazine at

www.pump-zone.com/mena.

pump-zone.com | August 2014

11

HENRI V. AZIBERT, FSA

WAYNE, Pa. (June 13,

2014) The Fluid Sealing

Association (FSA) announced

the appointment of Henri V.

Azibert as its new technical

director. Pumps & Systems

has partnered with the FSA for

10 years and posted exclusive

Sealing Sense articles in every issue. Azibert

will now coordinate these articles, which provide

the readers of Pumps & Systems with crucial

technical information about mechanical seals,

compression packing, gaskets, expansion joints,

sealing components and molded packing. Azibert

has also joined the prestigious Pumps & Systems

Editorial Advisory Board. FSA is an international trade association. Members are involved in the

production and marketing of virtually every

kind of fl uid sealing device in the world. www.

fl uidsealing.com

JOHN DONAHUE, AWWA

BOSTON (June 12, 2014)

In a spirited event at the

conclusion of the American

Water Works Associations

Annual Conference and

Exposition in Boston, John

Donahue, chief executive

offi cer of North Park, Illinois,

Water District, accepted the ceremonial AWWA

gavel and began his term as president. The gavel

passing ceremony was the culmination of a fi ve-

day conference that drew more than 11,000 water

professionals and water technology providers to

Boston. The American Water Works Association is the largest nonprofi t, scientifi c and educational

association dedicated to managing and treating

water. www.awwa.org

GREG HEWITT, BALDOR

ELECTRIC COMPANY

FORT SMITH, Ark. (June

9, 2014) Baldor Electric

Company promoted Greg

Hewitt to mounted bearing

engineering manager. In this

role, he will be responsible for

all mounted bearing product-

related engineering and will manage the product

development team in Greenville, South Carolina.

Baldor Electric Company markets, designs and manufactures industrial electric motors, drives

and mechanical power transmission products.

www.baldor.com

Henri V. Azibert

John Donahue

Greg Hewitt

5300 Business Drive, Huntington Beach, CA 92649 USA 714-893-8529 [email protected]

www.blue-white.com www.proseries-m.com

AAAAAAAAAAAAAAAAANNNNNNNNNNNNNNNNNDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDAAAANNNNDDDD

NENENENENENENENENEEEMAMAMAMAMAMAMAMAMAMAMAMAMAMAMAMAAA 44444444444444444XXXXXXXXXXXXXXXXWASWASWASWASWASWASWASWASWASWASWASWASASASSHH DH DH DH DH DH DH DH DH DH DH DH DH DH DDOOOWOWNOWNOWNOWNOWNOWNOWNOWNOWNOWN

IPIPIPIPIPIPIPIPIPIPIPIPIPIPIPP666666666666666666666666666666666666

Three Models Available with Feed Rates Ranging from 0.1 GPH/.03 LPH to 158 GPH/600 LPH.

Smooth, Quiet and Ecient Pumping Action.

Brushless Variable Speed Motor.

Terminal Blocks in Junction Box for Remote Connections.

Patented Tube Failure Detection, Patented Safety Switch, Patented Method for Extended Tube Life.

One or Two Pump, Engineered Skid System is Available.

FLEX-PRO

Peristaltic Metering Pump

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NEMNEMNEMNEMNEMEMEMEMEMMA 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 44XXXXXXXXXXXXXXXXXWWWWASWASWASWASWASWASWASWASWASH DH DH DH DH DH DH DH DH DH DDDOOOWOWNOWNOWNOWNOWNOWNOWNOWNOWNOWNOWNWNWNWN

Standard 61

Sonic-Pro S4 accurately measures flow using the Transit Time method. It can be used with water containing low levels of chemicals and up to 5% particulates. Optional communication protocols include Industrial Ethernet, Profibus and Modbus.

Ultrasonic Transit Time operation.

Optional factory configuration for easy installation.

Inline spool piece (inline fitting).

4-20mA and Pulse Outputs.

Special low power mode permits operation with battery for limited functions.

Advanced communication.

Data logging

SONIC-PRO Ultrasonic Flowmeter

circle 12

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n ca

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r visit p

sfreeinfo.co

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12 NEWS

CHARLES WHISMAN, CH2M HILL

DENVER (June 5, 2014) CH2M HILL announced

that Charles Whisman joined the fi rm as vice

president and U.S. oil and gas operations

manager for the environment and nuclear

market. CH2M HILL provides consulting, design, design-build, operations and program

management for government, civil, industrial

and energy clients. www.ch2m.com

DAVE MORROW, OPW

LEBANON, Ohio (June 6, 2014) OPW announced the promotion of

Dave Morrow to director of product management for its Chemical &

Industrial business unit. Before this appointment, he was product

manager for OPW Engineered Systems. OPW Engineered Systems provides loading and

coupling systems for the safe and effi cient

loading and unloading of critical hazardous

fl uids. www.opw-es.com

JOHN MOLNAR,

ARMSTRONG FLUID TECHNOLOGY

TORONTO (June 5, 2014) Armstrong Fluid

Technology announced that John Molnar joined

the company as technical sales representative,

commercial and engineering. In his new role,

he will develop and grow relationships with

engineers, contractors and service dealers in the

Ontario territory.

His main focus

will be working

with standard and

confi gured building

products and design envelope solutions.

Armstrong Fluid Technology designs, engineers and manufactures integrated

solutions within the building-oriented

fl uid-fl ow equipment industry. www.

armstrongfl uidtechnology.com

Charles Whisman Dave Morrow

John MolnarYASKAWA AMERICA, INC. acquired Solectria Renewables, LLCJuly 17, 2014GE acquired MonsalJuly 1, 2014ACOEM acquired FIXTURLASERJune 30, 2014DES-CASE acquired ESCOs sight glass product lineJune 19, 2014

BLACKHAWK SPECIALTY TOOLS acquired Trinity Tool RentalsJune 10, 2014FRANKLIN ELECTRIC acquired Bombas Leo S.A.June 9, 2014NATIONAL PUMP COMPANY acquired Bayou City PumpJune 3, 2014

MERGERS & ACQUISITIONS



13

AROUND THE INDUSTRYEXONE to Open Combined

Production Service Center

in ItalyNORTH HUNTINGDON, Pa. (June

19, 2014) The ExOne Company

announced the planned opening of

a new combined production service

center and machine sales center in the

Lombardy region of Italy. Said Omar,

most recently ExOnes European sales

director, will be ExOne Italys managing

director. ExOne provides 3-D printing

machines and printed products,

materials and other services to

industrial customers. www.exone.com

WEATHERFORD Opens

Integrated Colombia

LaboratoryBOGOTA, Colombia (June 13, 2014)

Javier Betancourt, the president of

Agencia Nacional de Hidrocarburos

Colombia, marked the offi cial

opening of the new Weatherford lab in

Bogota, Colombia, during a ribbon-

cutting ceremony. This new facility

provides traditional core and fl uid

analysis combined with specialty

services such as shale rock properties,

geochemistry, wellsite geosciences,

frac fl uids, drilling fl uids and elastomer

testing for progressive cavity pumps.

Weatherford International provides

oilfi eld products and services across

the drilling, evaluation, completion,

production and intervention areas.

www.weatherford.com

DYNAMIC INDUSTRIES

INTERNATIONAL LLC Receives

SAGIA LicenseHOUSTON (June 11, 2014) Dynamic

Industries International LLC

announced that its Saudi Arabian offi ce

received its license to operate from

the Saudi Arabian General Investment

Authority (SAGIA). Dynamic

Industries International LLC provides

full-service fabrication, construction

and maintenance services to the

offshore worldwide markets. www.

dynamicind.com

SIEMENS Invests in

Software Grants RICHMOND, Va. (June 5, 2014)

Siemens announced more than $1

billion of in-kind software grants

for manufacturing programs at

community colleges and universities

in Virginia. The series of in-kind

grants was established as a result of

an industry need for skilled workers

and is designed to support the states

largest industrial employer, Newport

News Shipbuilding, a division of

Huntington Ingalls Industries, and

other companies with local ties such

as Rolls-Royce. Siemens Industry

Sector supplies products, solutions and

services for industrial customers.

www.siemens.com



14 NEWS

AROUND THE INDUSTRYABB TURBOCHARGING

Inaugurates Denmark FacilityBADEN, Switzerland (June 4, 2014)

ABB Turbocharging announced a

ceremony that celebrated the opening

of a new service facility in Fredericia,

Denmark. The ceremony also marked

the completion of the amalgamation of

its activities in Norway, Denmark and

Sweden into a single Local Business

Unit. ABB Turbocharging Scandinavia

comprises service stations in Oslo and

Bergen in Norway, Gteborg in Sweden,

and the new central workshop for

Denmark in Fredericia. Additionally,

the company has two service

engineers and a sales team stationed

in Copenhagen. This geographical

footprint will soon be furthered by a

new service point in Troms, Norway.

ABB Turbocharging manufactures and

services turbochargers. www.abb.com

GRUNDFOS, PUB to Collaborate

on Water TechnologiesSINGAPORE (June 3, 2014) Pump

manufacturer Grundfos and PUB,

Singapores national water agency,

have signed a memorandum of

understanding (MOU) to collaborate on

the development of water technologies

and solutions. The MOU sets out to

support PUB in its mission to ensure a

robust and sustainable water supply

for Singapore and to continuously

explore new technologies and solutions

to meet current and future water

challenges. PUB is a statutory board

under the Ministry of the Environment

and Water Resources. It is the water

agency that manages Singapores

water supply, water catchment and

used water. www.pub.gov.sg Grundfos

is a pump manufacturer, offering

water solutions with modular, energy

effi cient and intelligent products

and services that can be tailored for

industrial, water utility, water supply,

urban and agricultural applications.

www.grundfos.com

EPA Proposes Guidelines

to Cut Carbon Pollution WASHINGTON (June 2, 2014) At the

direction of President Obama and after

an unprecedented outreach effort,

the U.S. Environmental Protection

Agency (EPA) released the Clean

Power Plan proposal, which for the

fi rst time cuts carbon pollution from

existing power plants, the single largest

source of carbon pollution in the U.S.

The proposal aims to protect public

health, move the U.S. toward a cleaner

environment and fi ght climate change

while supplying Americans with reliable

and affordable power. By 2030, the

steps that the EPA is taking will:

Cut carbon emission from the power

sector by 30 percent nationwide

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Engine Management - Murphys Engine Integrated Control System (EICS)

provides a turnkey engine integration package that ensures extended engine life,

optimized emissions and simplified diagnostics.

Controls - Murphy delivers a complete line of annunciators and

controls that can be packaged to provide optimum performance

and advanced functionality.

Gages & End Devices - Murphy has a

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Did You Know?Did You Know?



16 NEWS

AROUND THE INDUSTRYbelow 2005 levels, which is equal to

the emissions from powering more

than half the U.S. homes for one year

Cut particle pollution, nitrogen

oxides and sulfur dioxide by more

than 25 percent

Avoid up to 6,600 premature deaths,

up to 150,000 asthma attacks in

children, and up to 490,000 missed

work or school daysproviding up

to $93 billion in climate and public

health benefi ts

Shrink electricity bills roughly

8 percent by increasing energy

effi ciency and reducing demand in

the electricity system

EPAs mission is to protect human

health and the environment.

www.epa.gov

ABAKAN Increases Direct

Ownership in MesoCoatMIAMI (June 2, 2014) Abakan Inc.

announced that it has increased its

ownership position in its majority

owned subsidiary, MesoCoat Inc., to a

87.5 percent direct and 89.9 percent

direct and indirect ownership. The

increase is the result of converting an

additional $6.2 million in MesoCoat

investment into equity and exchanging

21 percent of ownership in Powdermet

for 65.3 percent of Powdermets shares

of MesoCoat. Abakan develops,

manufactures and markets advanced

nanocomposite materials, fabricated

metal products and metal composites

for applications in the oil and gas,

petrochemical, mining, aerospace and

defense, energy, infrastructure, and

processing industries.

www.abakaninc.com

WEF, IWA Sign Water

Management MOUALEXANDRIA, Va. (May 27, 2014)

The Water Environment Federation

(WEF) and the International

Water Association (IWA) signed a

memorandum of understanding (MOU)

intended to accelerate joint work to

grow and disseminate water knowledge

and to serve and advance the global

water profession. WEF is a not-for-

profi t technical and educational

organization representing water

quality professionals around the world.

www.wef.org IWA is a global network

of water professionals that spans the

continuum between research and

practice, covering all facets of the

water cycle. www.iwahq.org

To have a news item considered, please send the information to Savanna Lauderdale, [email protected].



18 NEWS

EVENTSPumpTec-USA

Sept. 10 11, 2014Georgia World Congress CenterAtlanta, Ga.770-310-0866www.pumpconference.com

Turbomachinery/

Pump Symposia

Sept. 23 25, 2014George R. Brown Convention CenterHouston, Texas979-845-7417pumpturbo.tamu.edu

WEFTEC

Sept. 27 Oct. 1, 2014New Orleans Morial Convention CenterNew Orleans, La.www.weftec.org

International Association

of Amusement Parks and

Attractions (IAAPA)

Nov. 18 21, 2014Orange County Convention CenterOrlando, Fla.703-836-4800www.iaapa.org

PumpTec-Israel

Dec. 3 5, 2014Jointly with Electricity-Israel 2014 ConferenceEilat, Israel770-310-0866www.pumpingmachinery.com/conference_2014_Israel/conference_2014_Israel.htm

POWER-GEN International

Dec. 9 11, 2014Orange County Convention CenterOrlando, Fla.918-831-9161www.power-gen.com

NGWA Expo & Annual Meeting

Dec. 9 12, 2014Las Vegas Convention Center Las Vegas, Nev.www.ngwa.org

AHR EXPO

Jan. 26 - 28, 2015 McCormick Place Chicago, Ill. www.ahrexpo.com

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In my July 2014 column, I

demonstrated that three-

phase voltage variation can

signi cantly a ect several alternat-

ing current (AC) motor character-

istics. If that variation is large, it

can also reduce motor life. Voltage

unbalance can be an even bigger

problem and is one of the major

causes of premature motor failure.

A relatively small unbalance of

just 2 percent can reduce expected

insulation life by half.

Calculating Voltage

Unbalance

Unlike voltage variation, unbal-

anced voltage occurs when the

three phases are not at the same

voltage. An example of perfectly

balanced phase voltage is L1/L2 =

460 V, L2/L3 = 460 V and L3/L1 =

460 V. e average voltage is 460

volts.

An example of unbalanced phase

voltage is L1/L2 = 462 V, L2/L3 =

468 V and L3/L1 = 450 V. Again,

the average voltage is 460 V, but the

unbalance is 2.2 percent. Voltage

unbalance is calculated by the fol-

lowing equation:

Percent unbalance = 100 x

(maximum voltage deviation from

average / average voltage)

In the example above, the

maximum voltage deviation from

the average voltage is 10 V (460

minus 450). Motors from member

companies of the National Electri-

cal Manufacturers Association

(NEMA) are designed to tolerate

no more than 1 percent of voltage

unbalance.

Why does voltage unbalance

shorten motor life? One percent of

voltage unbalance can result in 6

to 10 percent of current unbalance.

e phase with the lowest voltage

exhibits the highest current, which

increases the operating tempera-

ture of the winding serviced by that

phase. It will also increase the over-

all operating temperature of the

motor. Figure 1 shows the increase

in operating temperature versus

voltage unbalance. As shown, an

unbalance of just 3 percent can

increase operating temperature

by almost 20 percent. At 5 percent

unbalance, operating temperature

will increase by 50 percent.

Temperature Rating

& Insulation Class

Motor operating temperature is the

sum of the ambient temperature

surrounding the motor and the

Three-Phase Voltage Variation & UnbalanceLast of Two Parts

By Joe Evans, Ph.D.

Pump Tech Inc., P&S Editorial Advisory Board

Figure 1. Overheating because of voltage unbalance

20 PUMP ED 101


temperature rise due to the motor

load. e temperature rise is usu-

ally measured using the resistance

method. Each insulation class has

a speci c temperature rating. For

example, Class F is rated at 155 C

(311 F). e temperature rating is

the maximum operating tempera-

ture allowed in order to meet an

average insulation life of 20,000

hours.

Of that rating, 10 C is reserved

for the hot spot allowance. e

resistance method measures the

average temperature rise in the sta-

tor windings, but at some places

such as the stator slotsthe

temperature can be higher than the

average measurement. e hot spot

allowance is reserved to protect

these areas. is reduces the actual

operating temperature (ambient

plus measured average) to 145 C.

For every 10 degrees over 145 C,

insulation life is reduced by half.

For every 10 degrees below 145 C,

insulation life doubles.

Suppose a motor with Class F

insulation operates at an ambient

temperature of 40 C. e mea-

sured temperature rise at full load

is 90 C. erefore, the operating

temperature is 130 C. e expected

insulation life would be about

50,000 hours or about 2.5 times

the life at 145 C. But at 3 percent

phase voltage unbalance, the oper-

ating temperature increases by 19

percent (155 C) and insulation life

is reduced by 50 percent.

Image 1 shows the windings of

a motor that failed because of high

voltage unbalance. When a motor

loses one phase (single phasing),

the other two phases have to carry

the entire load. As a result, two sets

Voltage unbalance is one of the major causes of premature motor

failure. A relatively small unbalance of just 2 percent can reduce

expected insulation life by half.

21


21


of phase windings are destroyed, and the one that

lost power is unharmed.

Motor Phase Loss & Failure

In the case of unbalance, the winding with the

highest current fails and, usually, the other two

are still functional. In the motor shown in Image

1, one of the phases has failed, one is normal and

the third is beginning to show the e ect of higher

temperature. Measuring voltage unbalance and

xing the cause are much less costly than having

it diagnosed in a motor shop. See Pump Ed 101

in the July 2008 issue of Pumps & Systems for

instructions on diagnosing the cause of unbal-

anced voltage.

Although correcting voltage unbalance is

always best, a few rules can allow operation in

unbalanced applications. For example, if the leg

with the highest current is under the nameplate

full load amperage (FLA), it will safely operate. If Image 1. Windings of a motor that failed because of high voltage unbalance. (Image courtesy of EASA)

22 PUMP ED 101



23

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it is above nameplate FLA but still

within the service factor (SF), it

may still safely operate. As a rule,

if the high current leg is less than

10 percent higher than the average

current, it will probably safely

operate.

A less desirable alternative is

to derate the motors nameplate

horsepower. NEMA suggests

derating horsepower to 75 percent

of nameplate at an unbalance of 5

percent. At 4 percent unbalance,

it is derated to 82 percent. At 3

percent, it is derated to 88 percent,

and at 2 percent, it is derated to 95

percent.

In addition to reduced insulation

life, unbalanced voltage can also

increase electrical costs by decreas-

ing motor e ciency. At 1 percent

unbalance, e ciency remains at

the nameplate nominal e ciency.

However, at 3 percent unbalance,

actual motor e ciency can be re-

duced by 2 percentage points.

Joe Evans is responsible

for customer and employee

education at PumpTech Inc.,

a pump and packaged system

manufacturer and distributor

with branches throughout the

Pacifi c Northwest. He can be

reached via his website www.

PumpEd101.com. If there are

topics that you would like to

see discussed in future col-

umns, drop him an email.

In addition to reduced insulation life, unbalanced voltage

can also increase electrical costs by decreasing motor effi ciency.

24 PUMP ED 101


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When the pump selection

process starts, the

required ow of the is

often the only known variable

for an application. For example, a

system must move 2,000 gallons

per minute (gpm) from a holding

tank to another tank or process.

What size pump do should be

installed? e size and pressure of

the piping and the power of the mo-

tor must also be determined. is

column helps explain how to make

these decisions.

Pump & Piping Size

e longer the piping, the more

pressure its internal friction will

generate. A good way to pick a pipe

size is to calculate its diameter from

an empirical but simple starting

formula. is will help establish an

approximate range. Pipe velocity is

usually between 5 and 10 feet per

second (ft/sec).

e smaller a pipes diameter, the

faster uid ows through it. e

larger the pipe, the more expensive

it is. Also, owing too slowly may

cause particulate matter to settle

and clog the line, but owing too

quickly will wear the pipe. e 5

to 10 ft/sec range is usually a good

starting point. Equation 1 can used

for a more accurate calculation.

V = Q x 0.321 / A

Equation 1

Where:

V = velocity in ft/sec

Q = ow in gpm

A = pipe area in square inches

(in2)

In our example,

5 = 2,000 x 0.321 / A

A = 2,000 x 0.321 / 5 =

128.4 in2 pipe area, or 12.8 inch

diameter

is diameter can round to a 12-

inch pipe with a velocity of slightly

more than 5 ft/sec.

e next step is to gure out the

amount of pressure in the system

if the pump is 5,000 feet away

from the processdischarge. is

determination is more complicated

because some hydraulic informa-

tion is needed. Several options can

provide this information: come to

class, consult a piping friction loss

chart or take my word for it that the

losses for cold water at 2,000 gpm

in a 12-inch, 5,000-foot pipe are

about 70 feet.

With the ow and head deter-

mined, the motor can be sized (see

Table 1). Also, an online E ciency

Estimator, which can be found at

www.mj-scope.com/pump_tools/

pump_e ciency.htm, o ers useful

formulas.

To handle the process speci ca-

tions, a single-stage pump was se-

lected. e E ciency Estimator cal-

culated that a 42-horsepower and

84.5-percent pump e ciency can

be expected from a typical pump.

is number can be con rmed with

quotes from pump distributors.

e E ciency Estimator also

suggests an impeller size of 9.77

inches. is measurement is a good

way to roughly verify the appropri-

ate sizes of existing pumps. is

process provides useful preliminary

information for pump selection.

Motor Size

A 1,800-rpm motor speed was

selected for this process because it

is one of the most common motor

speeds in the U.S. e horsepower

recommendation can be rounded to

select a 50-horsepower motor. If the

pump is expected occasionally to

operate outside the curve, choosing

a 75-horsepower leaves a margin of

safety.

Simplify the Equipment Selection Process

By Lev Nelik, Ph.D., P.E.

Pumping Machinery, LLC, P&S Editorial Advisory Board

Table 1. Sizing motors during pump selection (Graphics courtesy of the author.)

US Units

Pump ow (gpm) 2,000

Total pump head (ft) 70

Speci c gravity (SG) 1.00

Number of stages 1

Speed (rpm) 1,800

Header per stage (ft) 70

Impeller diameter (in) 9.77

Speci c speed U.S. (Ns) 3,326

Speci c speed metric (ns) 64.5

Speci c speed universal (Os) 1.22

E ciency (%) 84.5

Power (hp) 42


26 PUMPING PRESCRIPTIONS

NPSHA Calculation

e suction side must be consid-

ered. My last few columns dis-

cussed pump suction performance.

For example, I discussed how the

system a ects the operation and

the relationship between the ow

(as a percent of the best e ciency

point) and suction recirculation.

Many end users question how much

net positive suction head available

(NPSHA) they need.

If a pump has too little NPSHA, it

could experience suction problems.

Too much NPSHA leads to higher

construction costs. Users must nd

the right balance. My next column

will describe in detail the beginning

of the selection process. For those

interested in how to calculate the

piping losses estimated (70 feet of

head), my Pump School training

covers this in-depth.

Dr. Nelik (aka Dr. Pump) is

president of Pumping Machin-

ery, LLC, an Atlanta-based fi rm

specializing in pump consulting,

training, equipment trouble-

shooting and pump repairs. Dr.

Nelik has 30 years of experience

in pumps and pumping equip-

ment. He may be reached at

pump-magazine.com.

If a pump has too little NPSHA, it could experience suction

problems. Too much NPSHA leads to higher contruction costs.

Users must fi nd the right balance.


27

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28 PUMP SYSTEM IMPROVEMENT

In the previous article calcu-

lating the cost of elements

in a piping system (Pumps &

Systems, July 2014), the energy

consumed and power cost balanced

exactly to demonstrate the process.

Seldom is life that exact. In the

real-world plant, instruments are

subject to inaccuracy, pumps may

be worn, estimates may be o

or the full system may not be

accurately represented in the design

documents.

is months article demon-

strates how cross-validating the

calculated results can ensure the

energy cost balance sheet accurately

re ects system operation.

e key to validating the results

is to use multiple means for arriv-

ing at the operating cost of each

item in the energy cost balance

sheet. If the energy cost balance

sheet does not add up, trouble-

shooting skills need to be employed

to discover the reason for the dif-

ference.

is article will continue to

use the example piping system

presented in previous articles (see

Figure 1).

Prioritizing the System

e pump elements provide all

the energy that enters the system.

at energy is then consumed by

the systems process and control

elements.

If the energy cost balance sheet

does not balance, operators should

begin looking for the source of the

problem. e major energy users

in the system should be examined,

and operators should nd meth-

ods to cross-validate the initial

estimates.

Pump Performance

In the example, the pumps ow

rate was determined using the

manufacturers pump curve. With

a known ow rate, the pump ef-

ciency can be determined from

the curve.

Because the pump e ciency is

used in all energy cost calculations,

ensuring the accuracy of the value

is critical.

System Validation & Troubleshooting

By Ray Hardee

Engineered Software, Inc.

Figure 1. Drawing of sample piping system (Article graphics courtesy of the author.)

Figure 2. An example showing the effect internal leakage has on pump performance. Because of internal leakage, the installed pump is not operating as designed.


29

Inaccuracies can occur in

real-life operating conditions. For

example, if the pump has a worn

impeller and excessive internal

leakage, it no longer re ects the

pump curves operation.

Figure 2 shows a pump curve for

the process pump along with an

example of the e ect that excessive

internal leakage can have on the

pump curve.

Using the calculated head dif-

ference of 235 feet (ft), the worn

impeller gives a ow rate of less

than the 4,000 gallons per minute

(gpm) used in the previous energy

system balance.

In addition, the e ciency of a

worn impeller would di er from

the manufacturer-supplied test

curve.

is would result in inaccurate

power consumption and operation

costs calculations.

Operators have other options to

determine the ow rate through

the pump, including portable

ultrasonic ow meters.

ese meters provide a reason-

ably accurate ow measurement

in a pipeline without physically

changing the piping system.

If the observed ow rate on the

temporary ow meter equals the

value determined using the pump

head and the pump curve, the ow

rate is validated, and the e ciency

is validated by association.

If a power meter is installed on

the motor driving the pump, the

measured kilowatt (kW) value

can be compared to the calculated

power consumed using the pumps

ow, head and e ciency values as

show in Equation 1, at the bottom

of page.

kW = .746 Q H

247,000 P M

Equation 1

Where:

Q = ow rate in gpm

H = pump head in ft

= uid density lb/ft3

P = pump e ciency

M = motor e ciency

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If the power into the motor as read on its power meter is the same as the calculated power consump-tion using Equation 1, the pumps ow, head and e ciency values are validated.If a power reading is not available

for the motor, the motors power consumption can be calculated by measuring the current and voltage supplied to the pumps motor, then using Equation 2. e motors power factor can be read on its nameplate.

P3Motor = 3 V I Pf

1,000

Equation 2Where:P3Motor = motor power in kWV = voltage voltsI = current ampsPf = motor power factor

If the calculated value of motor power equals the pumps power con-sumption, the pump ow, head and e ciency values are validated.

Tank Levels and Pressures

e tanks and vessels make excel-lent piping system boundaries. e energy at each tank can be deter-mined by using the elevation of the liquid level in the tank and pressure on the liquid surface. From these values the energy

consumed for the static head compo-nent can be easily calculated. e results can be cross-validated

using installed pressure and level instrumentation. e liquid level can be checked

with a sight glass or by manually measuring the liquid level in the tank. e pressure in a closed vessel can be compared using the installed plant instrumentation, installed pressure gauges or a temporary pres-sure gauge.

Control Valves

In last months example, the dif-ferential pressure across the control valve was calculated by subtracting the sum of the head losses of the process elements from the pump head. is approach is easy, but any errors made in the previous calcula-tions will compound and can greatly reduce the energy cost balance sheets accuracy.Valve manufacturers de ne the

operation of control valves based on tests that are outlined in published industry standards. Manufacturers use the ANSI/ISA-75.01.01 Flow Equations for Sizing Control Valves to size control valves for piping systems. e data used in valve sizing can also be used to calculate the di erential pressure across the control valve.Equation 3 shows the basic for-

mula for valve sizing.

Cv = Q

FP P1 P2

S

Equation 3Where:Cv = manufacturer-supplied valve

coe cientQ = ow rate in gpmFP = piping geometry factor (unit-

less)P1 = absolute pressure measured

at valve inlet in lb/in2

P2 = absolute pressure measured at valve outlet in lb/in2

S = uid speci c gravity (unit-less)

Rearranging the control valve sizing equation and solving for dif-ferential pressure results in Equa-tion 4.

dP = Q2S

(CvFP)2

Equation 4

In the example system with a ow rate through the level control valve of 2,500 gpm, the control valve posi-tion is 65 percent. According to the manufacturers data for the control valve, the Cv at this position is 391. e FP of .9996 was calculated

by the manufacturer and included in the valve data sheet. e spe-ci c gravity of the process uid was calculated at .993. e ow rate through the level control valve was measured at 2,500 gpm. Inserting the values into Equation 4 provides the di erential pressure across the control valve.

Converting the control valves di erential pressure of 40.6 pounds per square inch (psi) to feet of uid results in a head loss of 94.3 ft. is result for the control valve calcula-tion validates the number from last months calculations.

Process Equipment

e di erential pressure across the process equipment was calculated using the pressure drop data sup-plied by the manufacturer and the

dP = Q2S

(CvFP)2 =

25002 .993(391 .9996)2

= 40.6 psi

If the calculated value of motor power equals the

pumps power consumption, the pump fl ow, head

and effi ciency values are validated.


31

ow rate obtained from the installed

ow element. In the example, the

heat exchanger pressure drop of

10 psi was assumed based on the

manufacturers supplied data. If the

heat exchanger tubes were fouled

due to internal deposit, the actual

di erential pressure across the heat

exchanger would be greater than

the value used in the energy cost

calculation.

e di erential pressure across

the process equipment can be

validated by installing temporary

pressure gauges.

Most process equipment has vent

and drain lines installed for main-

tenance.

By installing temporary pressure

gauges on the vent and drain lines

and correcting the pressure values

for any di erence in elevation of the

gaugesthe di erential pressure

and head loss across the item can be

measured.

Pipelines

In the example, the head loss in the

individual pipelines was calculated,

then used to determine the head

loss in each circuit of the pipeline.

is requires a large number of

calculations.

e repetitive nature of the calcu-

lations makes this an excellent task

to be performed using a computer.

Online head loss calculators can be

found by performing an Internet

search. Commercially available

computer programs can also greatly

simplify the task.

Problems that could a ect the

head loss calculation include fouling

or sedimentation in the pipelines,

partially closed valves, or obstruc-

tions in the pipe, valves or ttings.

Inaccurate determination of the pipe

Problems that could affect the head loss calculation

include fouling or sedimentation in the pipelines,

partially closed valves, or obstructions in the pipe,

valves or fi ttings.




size or schedule, or inaccurate esti-

mates of the number of ttings or

pipe length can also a ect the head

loss calculation.

Total System

If the energy cost balance sheet

does not balance, either the mea-

sured plant data or the equipment

(pumps, process components or

control valves) could be causing the

problem.

To con rm the accuracy of the

measured data, check to see that

the instruments are calibrated. e

instrumentation department can

also make sure the instruments

are accurately reading the process

parameters.

e rst step is to check for

cavitation throughout the whole

system. Cavitation is caused when

the local pressure drops below, then

rises above, the vapor pressure of

the process uid. Some of the uid is

converted from liquid to vapor. e

vapor bubbles take up extra space

in the ow stream, which causes a

reduction in the mass ow rate.

All standards and calculation

methods used to determine head

loss assume single phase ow. If

cavitation occurs, the calculated re-

sults will not accurately re ect what

is happening in the system.

Cavitation is especially trouble-

some in pumps and control valves.

It can be a major source of mainte-

nance problems and should be cor-

rected prior to performing a system

assessment.

Next, the interaction of the

systems components should be

examined. e best way to accom-

plish this is to compare the current

observed values with previous

observed values.

For example, the average valve

position of the level control valve

increased over time from 65 percent

open to 71 percent open. e rest of

the measured plant data remained

the same.

Using Equation 4, the head

loss across the level control valve

decreased from the original 94 ft of

loss to 71 ft. e only explanation

for this change is that the head loss

across the process element increased circle 154 on card or visit psfreeinfo.com

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from the manufacturers published

value of 23 ft to 46 ft. is is a clear

indication of fouling in the process

equipment.

Conclusion

Gaining a clear picture of how a

piping system operates is key to as-

sessing the system.

Because most operating plants do

not have su cient installed plant

instrumentation to provide all the

data needed for the calculations,

many of the values must be calcu-

lated using other well-established

methods.

By performing the calculations

and comparing them to available

operating data, operators can deter-

mine how the system is currently

operating.

is information allows opera-

tors to correct any problems that

adversely a ect system operation

and perform an accurate assess-

ment of the piping system by

completing an energy cost balance

sheet.

My next few columns will inves-

tigate a variety of plant systems.

ey will demonstrate what can be

gained with a better understanding

of system operation and what can

be done to reduce operating, main-

tenance and capital cost within

piping systems.

Ray Hardee is a principal founder

of Engineered Software, creators of

PIPE-FLO and PUMP-FLO software.

At Engineered Software, he helped

develop two training courses and

teaches these courses in the U.S. and

internationally. He is a member of

the ASME ES-2 Energy Assessment

for Pumping Systems standards

committee and the ISO Technical

Committee 115/Working Group 07

Pumping System Energy Assess-

ment. Hardee was a contributing

member of the HI/Europump Pump

Life Cycle Cost and HI/PSM Optimiz-

ing Piping System publications. He

may be reached at

[email protected].

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36 GUEST COLUMN

Despite their simplicity,

centrifugal pumps often

experience repeat failures

that even seasoned maintenance

and reliability professionals have

trouble preventing. is four-part

series explains the reasons behind

repeat pump failures and uses a

real-world eld example involving

boiler feedwater pumps. Devia-

tions from best practices or over-

sights can range from seemingly

insigni cant to stunningly elusive.

ese can combine and often cause

costly failures.

Operating Di erent

Pumps in Parallel

e negative experience of a

metal producing facility best

demonstrates the consequences of

operating pumps beyond their ap-

propriate ow ranges. is example

serves as a reminder of the merits

of conducting in-depth

reliability reviews before

buying process pumps.

is case history extends

to the remaining parts of

this series.

e operating data of

the plants installed in-

strumentation is shown

in Figure 1. e ow rate

into the destination tank

averages 2,500 gallons

per minute (gpm) to

maintain the tank level.

is system currently op-

erates for 8,000 hours per

year to meet the plants production

needs. e system has operated in

this way since being commissioned

ve years ago.

Pushing Fluid Machinery Leads to Frequent FailuresSecond of Four Parts

By Heinz P. Bloch, P.E.

Image 1. This riveted cage bearing failed because of axial (rotor thrust) overload. (Article images and graphics courtesy of the author.)

Figure 1. Pump manufacturers usually plot only the net positive suction head required (NPSHR) trend associated with the lowermost curve. At that point, a head drop or pressure fl uctuation of 3 percent exists at BEP fl ow.1

Figure 2. A typical head-versus-fl ow performance curve


37

is case history is one of

many examples that validate the

importance of examining the

ow-versus-head characteristics

(the H/Q curves) of pumps. Such

examinations are needed during

the procurement phase of new

pumps and the troubleshooting of

installed but failure-prone process

pumps.

Seven boiler feedwater (BFW)

pumps were installed in the metal

producers boiler house. Two of the

facilitys seven pumps came from

Vendor A, two from B and three

from C. e respective H/Q curves

from vendors A, B and C were not

identical. By 2009, these pumps

had failed often and randomly. e

need for a thoroughly experience-

based failure analysis was rec-

ognized. e analysis pointed to

hydraulic and mechanical issues.

rough the years, this facility

routinely ran several BFW pumps

in parallel. Fear of failure may

have prompted operating four

pumps in parallel when only three

were required to provide a speci c

ow rate. If running three pumps,

each pump could have operated

closer to its BEP, but operating

four pumps led to a greater failure

risk. In other words, one or more

of these four pumps operated in

the questionable or forbidden low-

ow and high-internal-recircula-

tion range illustrated in Figure 1.

Low-Flow Range

At least two of the pumps had

at H/Q curves, similar to the

curve in Figure 2. Running in

the low- ow range forced one or

both pumps into the at portion

of their respective performance

curves. When operating in the at

range, even a small change in head

(a small change in p) results in

large di erences in throughput.

Controlling and equalizing load

sharing would be di cult.

In addition, the internal

pump clearances opened as time

progressed. is explanation was

in line with the recent escalated

failure frequencies. It led to the

recommendation of investigating

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38 GUEST COLUMN

the minimum ow allowed for these

high-suction-energy, BFW pumps.

e concept of high suction energy

and what it means in terms of the

required net positive suction head

available (NPSHA)/net positive suc-

tion head required (NPSHR) ratio

and/or reduced allowable operating

range is thoroughly explained in

References 3 and 4.

Internal wear and operation at

lower-than-designed ow a ect

the hydraulic thrust acting on a

pump rotor. is often contributes

to thrust bearing failures similar

to the one shown in Image 1 and

might even explain the excessive

wear on the worm wheel of one of

the shaft-driven lube oil pumps. In

general, rolling element bearings

with riveted cages should be avoided

in process pumps. Part ree of this

four-part series will explain why

this is recommended.

References

1. Taylor, Irving, e Most Persistent Pump-Application Problems for Petroleum and Power Engineers, ASME Publication 77-Pet-5 (Presented at Energy Technology Conference and Exhibit, Houston, Texas, September 18 22, 1977).

2. Bloch, Heinz P., Pump Wisdom: Problem Solving for Operators and Specialists, John Wiley & Sons, Hoboken, N.J., 2011.

3. Bloch, Heinz P. and Alan R. Budris, Pump Users Handbook, 4th Edition, Fairmont Press, Lilburn, Ga., 2013.

4. ANSI/HI9.6.3-1997, Allowable Operating Region, Hydraulic Institute, Parsippany, N.J.

5. SKF USA, Inc., Publication 100 955, Bearings in Centrifugal Pumps, Version 4, p. 20, Kulpsville, Pa., 2008.

6. Bloch, Heinz P., Practical Lubrication for Industrial Facilities, 2nd Edition, Fairmont Press, p. 179, 2009; Mechanical Seals in Medium-Pressure Steam Turbines, presented at the ASLE 40th Annual Meet-ing in Las Vegas, Nev., May 1985 (later reprinted in Lubrication Engineering, November 1985).

Heinz P. Bloch has been a profes-

sional engineer for almost 50 years.

He holds a BSME and an MSME

degree (cum laude) from New Jersey

Institute of Technology and retired as

Exxon Chemical Companys regional

machinery specialist. He authored or

co-authored 18 comprehensive text-

books dealing with lubrication and

fl uid machinery topics and published

more than 570 technical papers or

articles. Bloch has taught reliability

improvement and maintenance cost

avoidance subjects on six conti-

nents. He continues to write for trade

journals and advises and teaches

machinery reliability improvement

subjects. He may be reached at

[email protected].

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40 GUEST COLUMN

Cost estimation errors are

common in a variety of

projects. Recent studies

have shown the cost of machinery

can represent 20 to 35 percent of

a processing and manufacturing

projects total cost. e estimated

costs for new plants and particu-

larly new pump installations are

very uncertain and have increased

in recent years.

e following concepts minimize

the cost of pump installations:

Maximizing the extent of

manufacturing and installation

in the shop environment

Simplifying a pump packages

ps - 08 - 2014

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