pump & system - august 2014
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OPTIMIZE
PUMPING SYSTEMSDiligent analysis, rigorous scrutinylead to longer system life
AUGUST 2014
PUMP-ZONE.COM
TURBOMACHINERY &PUMP SYMPOSIATrade Show Preview
SEALS & BEARINGSTips for MaximizingPERFORMANCE
6 Considerationsfor REFINERY PumpMAINTENANCE
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HYDRO INC. HEADQUARTERS
CHICAGO, IL
800.223.7867
hydroinc.com
A WORLDWIDE PUMP SERVICE ORGANIZATION
ATLAN TA l BEAUMONT l CHICA GO l DEER PARK l DENVER l HOUST ON
LOS ANGELES l PHI LADELPH IA l AUSTRALI A l CANADA l ENGLAND
FRANCE l INDIA l KOREA l MALAYSIA l UNITED ARAB EMIRATES l VIETNAM
We’ll Find It
Before It FailsHydro’s highly skilled pump improvement engineers provide complete reliability support for
your pump installation base, whether the equipment is recently commissioned or has been in
service for many years. Using the latest technology and our broad experience from the field,
we identify problems early – ensuring longer life and improved performance. And if you’re
faced with an existing problem that is difficult to solve, our field engineers are here to help.
Expert On Site Testing and Diagnostics
– for Optimized Performance
Sometimes what doesn’t happen matters most.
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Hydro’s driving force is engineering. To
help our customers maintain critical pump
equipment, Hydro’s pump improvement
engineers review the pump operating and
maintenance history, provide a thorough on
site inspection, and perform in-depth pump,
driver and system testing. Our field engineers
provide global support and are available for
both routine and emergency situations.
In Field Pump Performance Testing
Vibration Analysis
Support Systems Analysis
State-of-the-Art Equipment Used
Maximize Pump Efficiency
Predictive Maintenance Services
Root Cause Analysis
Engineered Pump Upgrades
Condition Monitoring Program
Health Audits
To learn more about Hydro Reliability Services,
please contact us at 800-223-7867 or visit us at hydroinc.com
Hydro Reliability Services
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August 2014 | Pumps & Systems
From the EditorT
his 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-qua lity
technical pumping information that you can’t find
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 Institute’s devel-
opment of Pump Systems Matter, today the entire system is examined and modified to
decrease life-cycle costs and save energy.
On average, industria l pumps operate at less than 40 percent effi ciency, and more than10 percent of pumps run at less than 10 percent effi ciency. is impacts the bottom line.
“e cost to pump ineffi 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 effi ciency has only increased 3 percent by
design. e biggest advantage in increasing effi 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 Energy’s pump effi 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 DOE’s efforts to achieve energy savings and effi 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-flag symptoms are high energy costs, throttle valves
that are generally closed, bypass va lves/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 find a wealth of solutions by reading this month’s cover series, which begins on
page 60. As always, pump effi 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 SERVICESSENIOR ART DIRECTOR: Greg Ragsdale
ART DIRECTORS: Jaime DeArman, Melanie Magee
WEB CONTENT EDITOR & WEB ADVERTISING TRAFFIC:Robert Ring
PRINT ADVERTISING TRAFFIC: Lisa [email protected]
205-212-9402CIRCULATIONAUDIENCE DEVELOPMENT MANAGER:
Lori [email protected] • 205-278-2840
ADVERTISING
NATIONAL SALES MANAGER:
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
MARKETING ASSOCIATES:
Ashley [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. Periodicalspostage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves theright to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US andpossessions $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 andform 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. ©2014 Cahaba Media Group, Inc. No part ofthis publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, thefactual accuracy of any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered bythe authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions ofCahaba 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 usyour 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. Submissionswill not be returned. Volume 22, Issue 8.
Michelle Segrest with ITT’s MargaretGan at the 2014 Offshore TechnologyConference. The Pumps & Systems team returns to Houston for theTurbomachinery/Pump Symposia inSeptember.
Editor, Michelle Segrest
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Motors | Automation | Energy | Transmission & Distribution | Coatings
Features that make a difference:
Dual rated for 60 Hz and 50 Hz @ 190-220/380-415 V
Optimized ventilation system for cooler operation
Robust feet design for the toughest applications
Frames 182/4T and larger have two eyebolts for easy mounting in any position
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
Please contact your authorized WEG distributor or go to weg.net/us for further
information or additional specifications.
1-800-ASK-4WEG
WEG Rolled Steel LineGreat WEG quality and flexibility in a new LIGHTER frame
Investing over 2.5% of our revenue in R&D for electric motors every year, WEG takes pride in engineering and
manufacturing motors that run cooler, last longer, and are easy to install and maintain.
Available in Open Drip and Totally Enclosed designs our WEG Rolled Steel line is the perfect example of these efforts.
A product line with superior features that make a big difference for our customers.
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August 2014 | Pumps & Systems
AUGUSTThis issue
60 STREAMLINED MOTORMANAGEMENT SYSTEM BOOSTSBIOMASS POWER GENERATION
BY Matthias Borutta
Phoenix Contact
Trusted gateway connections allowfor system growth, effi ciency andconsistent maintenance at Swedishpaper mill.
64 INTELLIGENT MONITORINGDELIVERS REAL-TIMEPUMP PERFORMANCE DATA
By Mike Pemberton
ITT Pro Services
An energy effi ciency and reliabilitystudy helped one plant save $1 millionannually by avoiding downtime.
69 CLOSE INSPECTIONSOLVES HIGH THRUST BEARINGTEMPERATURE PROBLEM
By Gary DysonHydro Inc.
Careful analysis identified the issuewith this multistage oil transfer pump.
73 SYSTEM SELECTION CRUCIAL FOR LONG WASTEWATER
PUMP LIFE
By Lars Bo Andersen
Grundfos Wastewater
Driving down investment, energyand maintenance costs translatesinto big savings throughout an
installation’s lifetime.
76 REDUCER FITTINGS DECREASEPIPE SIZE TO PREVENT FAILURE
By Ross Mahaffey, Aurecon and Stefanus Johannes vanVuuren, University of Pretoria
Design of the pump inlet piping canprotect overall operation.
COVERS E R I E S
PUMP SYSTEM
OPTIMIZATION
COLUMNSPUMP 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 EquipmentSelection Process
PUMP SYSTEM IMPROVEMENT
28 By Ray HardeeEngineered Software, Inc.
System Validation & Troubleshooting
GUEST COLUMNS
36 By Heinz P. Bloch, P.E.
Pushing Fluid Machinery Leadsto Failure
40 By Amin Almasi
Estimate Pump Installation Costs
DEPARTMENTS
84 EFFICIENCY MATTERS
Smart Air Distribution SystemsUpgrade Traditional AODD PumpTechnology
89 MAINTENANCE MINDERS
6 Refinery Pump Maintenance Tips
94 MOTORS & DRIVES
e Differences Between Submersible& Immersible Motors
98 SEALING SENSE
Expansion Joint Selection OptimizesPiping Systems
102 HI PUMP FAQS
Understand Specific Speed & DiscDiaphragm Pump Coupling
64
60
Volume 22 • Number 8
Cover photo courtesy of Colfax Fluid Handling
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©
2 0 1 4 W
e a t h e r f o r d .
A l l r i g h t s r e s e r v e d .
Your business can’t runon a fabrication order.
PUMP AND FLUID SYSTEMS
Contact and collaborate with us at [email protected]
We deliver the pump you need without the wait.
Pressure ratings from500 psi (3.6 MPa) to10,000 psi (207 MPa)
Flowrates from
1 to 1,680 gpm
Power ratings from
2 to 700 hp
Formation Evaluation | Well Construction | Completion & Stimulation | Production
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August 2014 | Pumps & Systems
This issueSPECIALS P E C I A L
S E C T I O N
THOMAS L. ANGLE, P.E., MSC, Vice PresidentEngineering, Hidrostal AG
ROBERT K. ASDAL, Executive Director,Hydraulic Institute
BRYAN S. BARRINGTON, Machinery Engineer,Lyondell Chemical Co.
KERRY BASKINS, VP/GM, Milton Roy AmericasWALTER BONNETT, Vice President GlobalMarketing, Pump Solutions Group
R. THOMAS BROWN III, President,Advanced Sealing International (ASI)
CHRIS CALDWELL, Director of AdvancedCollection Technology, Business AreaWastewater Solutions,Sulzer Pumps, ABS USA
JACK CREAMER, Market Segment Manager –Pumping Equipment, Square D by SchneiderElectric
BOB DOMKOWSKI, Business DevelopmentManager – Transport Pumping and AmusementMarkets/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 & EmployeeEducation, PumpTech, Inc.
RALPH P. GABRIEL, Chief Engineer – Global,John Crane
BOB LANGTON, Vice President, Industry Sales,Grundfos Pumps
LARRY LEWIS, President, Vanton Pump andEquipment Corp.
TODD LOUDIN, President/CEO North AmericanOperations, Flowrox Inc.
JOHN MALINOWSKI, Sr. Product Manager, ACMotors, Baldor Electric Company, A Member ofthe ABB Group
WILLIAM E. NEIS, P.E., President, NortheastIndustrial Sales
LEV NELIK, Ph.D., P.E., APICS, President,PumpingMachinery, LLC
HENRY PECK, President, Geiger Pump &Equipment Company
MIKE PEMBERTON, Manager, ITT PerformanceServices
SCOTT SORENSEN, Oil & Gas AutomationConsultant & Market Developer, SiemensIndustry 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 MARKETPLACE128 PUMP MARKET ANALYSIS
SEALS & BEARINGS
42 CANNED MAGNETIC BEARINGSMINIMIZE CORROSION IN
OIL & GAS PROCESSING
By Richard R. Shultz
Waukesha Magnetic Bearings
Safely immerse motor compressorsin process gas without riskingcostly damage.
45 THE RIGHT SEAL & LUBRICANTCOMBINATION CAN PREVENTBEARING CONTAMINATION
By James Wong
Garlock Sealing Technologies
Lip and labyrinth seals provideprotection in harsh oil andgas applications.
PRACTICE &OPERATIONS
106 ENERGY EFFICIENT VERTICAL
TURBINE PUMPS PROMOTESUSTAINABLE MINING EFFORTS
By Petar Ostojic
Neptuno Pumps
e computational fluid dynamicsprocess advances highly effi cient pumpdesigns for diffi cult applications.
110 SPECIFIC PUMP & VALVEFEATURES SERVE LIQUEFIEDNATURAL GAS APPLICATIONS
By Gobind Khiani
Fluor Canada Ltd.
LNG benefits have increased thedemand for this cleaner burningfuel and associated production anddistribution equipment.
114 DEWATERING PUMPS HANDLESAND SLURRIES IN POST-HURRICANE RECOVERY
By Mike Bjorkman
BJM Pumps
Reconstruction and infrastructureupgrades require pumps fromdurable materials.
50 SELECT SEALS THAT MEETTHE CHEMICAL CHALLENGES
OF HPLC PUMPS
By Jerry Zawada
Trelleborg Sealing Solutions
Abrasive processing and widetemperature range are some ofthe pumping diffi culties for high-performance liquid chromatography.
54 TREATED CARBIDE SURFACESENHANCE RUNNINGPERFORMANCE
By Mark Slivinski
Carbide Derivative Technologies Inc.is technology self-lubricates, reducesfriction, and performs in wet or dryoperating conditions.
AUGUST
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Borets Equipment is a HPS horizontal
multistage pump manufacturer that
provides pumping solutions withexceptional 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, verticalturbine 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, we’ll 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
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August 2014 | Pumps & Systems
READERS RESPOND
“A Salute toFrank 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 withsomeone, so I decided to give you more
background. Frank was my first boss
when I joined Smith and Loveless in
1983, fresh out of graduate school. I
won’t 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 witha quiet determination and knew
exactly what he was trying to
achieve, even if it didn’t fit with
the views of management at the
moment! He had an amazing
influence 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 influence
had more impact on me thananyone I have worked with since
that time.
I am now back in Kansas City
and was fortunate enough to
attend the 50th anniversary of
Frank’s work at Smith and Love-
less in 2004. As was typical for Frank,
he didn’t want it to be a big deal, so the
ceremony was held on the shop floor.
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 aboutFrank Weis (www.pump-zone.com/blog/ salute-frank-weis) and for responding
with these nice comments. e additionalinsight into the life of this legendary pumpinnovator is greatly appreciated. FrankWeis was well respected in the pumpindustry and will be missed by all whoknew him.
READERS responD
To have a letter considered for Readers
Respond, please send it to Michael Lambert,
Frank Weis
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August 2014 | Pumps & Systems
0 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 company’s
president and chief executive officer. Lewis has
served as Vanton’s president since 2010. Vanton
Pump and Equipment Corp. supplies chemically
inert, thermoplastic pumps and systems thatsolve fluid 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-efficiency compressor portfolio
to respond to changing customer needs that
are being influenced by new refrigerant and
energy-efficiency regulations. Danfoss supplies
technologies that meet the growing need for food
supply, energy efficiency, 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 willoversee 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-profit
technical and educational organization of 36,000 individual members
and 75 affiliated 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 Office, the award honors inventors
who made significant 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 forprofessionals 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 region’s 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 & refinery
The regular editorial coverage will also include strategic and insightfulmarket 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.
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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. Aziberthas 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 fluid sealing device in the world. www.
fluidsealing.com
JOHN DONAHUE, AWWA
BOSTON (June 12, 2014)
In a spirited event at the
conclusion of the American
Water Works Association’s
Annual Conference and
Exposition in Boston, John
Donahue, chief executiveofficer 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 five-
day conference that drew more than 11,000 water
professionals and water technology providers to
Boston. The American Water Works Association
is the largest nonprofit, scientific and educational
association dedicated to managing and treating
water. www.awwa.org
GREG HEWITT, BALDOR
ELECTRIC COMPANY
FORT SMITH, Ark. (June9, 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 USA714-893-8529 • [email protected]
www.blue-white.com • www.proseries-m.com
Three ModelsAvailable withFeed RatesRanging from0.1 GPH/.03 LPHto 158 GPH/600LPH.
Smooth, Quietand EfficientPumping Action.
BrushlessVariable SpeedMotor.
Terminal Blocksin Junction Box
for RemoteConnections.
Patented TubeFailure Detection,Patented SafetySwitch, PatentedMethod forExtended TubeLife.
One or Two Pump,EngineeredSkid System isAvailable.
FLEX-PRO
®
Peristaltic Metering Pump
Standard 61
Sonic-Pro S4 accurately measuresflow using the Transit Timemethod. It can be usedwith watercontaining lowlevels of chemicalsand up to 5%particulates.Optionalcommunicationprotocols includeIndustrial 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 permitsoperation with battery for limitedfunctions.
Advanced communication.
Data logging
SONIC-PRO ®
Ultrasonic Flowmeter
c i r c l e 1 2 6 o n c a r d o r v i s i t p s f r e e i n f o . c o
m
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August 2014 | Pumps & Systems
2 NEWS
CHARLES WHISMAN, CH2M HILL
DENVER (June 5, 2014) – CH2M HILL announced
that Charles Whisman joined the firm 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 efficient
loading and unloading of critical hazardous
fluids. 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
configured building
products and design envelope solutions.
Armstrong Fluid Technology designs,
engineers and manufactures integrated
solutions within the building-oriented
fluid-flow equipment industry. www.
armstrongfluidtechnology.com
Charles Whisman Dave Morrow
John Molnar
MERGERS & ACQUISITIONS
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pump-zone.com | August 2014
13
AROUND THE INDUSTRY
EXONE to Open Combined
Production Service Centerin ItalyNORTH HUNTINGDON, Pa. – (June19, 2014) The ExOne Companyannounced the planned opening ofa new combined production servicecenter and machine sales center in theLombardy region of Italy. Said Omar,most recently ExOne’s European salesdirector, will be ExOne Italy’s managingdirector. ExOne provides 3-D printingmachines and printed products,
materials and other services to
industrial customers. www.exone.com
WEATHERFORD OpensIntegrated ColombiaLaboratoryBOGOTA, Colombia (June 13, 2014)Javier Betancourt, the president ofAgencia Nacional de Hidrocarburos– Colombia, marked the officialopening of the new Weatherford lab in
Bogota, Colombia, during a ribbon-cutting ceremony. This new facilityprovides traditional core and fluidanalysis combined with specialtyservices such as shale rock properties,geochemistry, wellsite geosciences,frac fluids, drilling fluids and elastomertesting for progressive cavity pumps.
Weatherford International provides
oilfield products and services across
the drilling, evaluation, completion,
production and intervention areas.
www.weatherford.com
DYNAMIC INDUSTRIESINTERNATIONAL LLC Receives
SAGIA LicenseHOUSTON (June 11, 2014) – DynamicIndustries International LLCannounced that its Saudi Arabian officereceived its license to operate fromthe Saudi Arabian General InvestmentAuthority (SAGIA). DynamicIndustries International LLC provides
full-service fabrication, construction
and maintenance services to the
offshore worldwide markets. www.
dynamicind.com
SIEMENS Invests inSoftware GrantsRICHMOND, Va. (June 5, 2014)Siemens announced more than $1billion of in-kind software grantsfor manufacturing programs atcommunity colleges and universitiesin Virginia. The series of in-kindgrants was established as a result ofan industry need for skilled workersand is designed to support the state’slargest industrial employer, Newport
News Shipbuilding, a division ofHuntington Ingalls Industries, andother companies with local ties suchas Rolls-Royce. Siemens IndustrySector supplies products, solutions and
services for industrial customers.
www.siemens.com
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August 2014 | Pumps & Systems
4 NEWS
AROUND THE INDUSTRY
ABB TURBOCHARGINGInaugurates 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 andSweden into a single Local Business
Unit. ABB Turbocharging Scandinavia
comprises service stations in Oslo and
Bergen in Norway, Göteborg 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 Tromsø, Norway.
ABB Turbocharging manufactures and
services turbochargers. www.abb.com
GRUNDFOS, PUB to Collaborateon Water TechnologiesSINGAPORE (June 3, 2014) – Pump
manufacturer Grundfos and PUB,
Singapore’s national water agency,
have signed a memorandum ofunderstanding (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 Singapore’s
water supply, water catchment and
used water. www.pub.gov.sg Grundfos
is a pump manufacturer, offeringwater solutions with modular, energy
efficient and intelligent products
and services that can be tailored for
industrial, water utility, water supply,
urban and agricultural applications.
www.grundfos.com
EPA Proposes Guidelinesto Cut Carbon PollutionWASHINGTON (June 2, 2014) – At the
direction of President Obama and after
an unprecedented outreach effort,
the U.S. Environmental Protection
Agency (EPA) released the CleanPower Plan proposal, which for the
first 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 fight 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
23544 © A.W. Chesterton Company, 2014. All rights reserved.
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Supplies the NGL industry with products for electric motorand engine-driven pump skids and booster stations.
· Engine Management - Murphy’s 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 performanceand advanced functionality.
· Gages & End Devices - Murphy has a
robust and value priced line of gages and
sensors, including vibration sensors, level
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For more about Murphy’sNatural Gas Liquids products
visit: fwmurphy.com/nglpsPhone: 918-317-4100 1 3 1 1
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August 2014 | Pumps & Systems
6 NEWS
AROUND THE INDUSTRY
below 2005 levels, which is equal tothe emissions from powering morethan half the U.S. homes for one year
• Cut particle pollution, nitrogenoxides and sulfur dioxide by morethan 25 percent
• Avoid up to 6,600 premature deaths,up to 150,000 asthma attacks inchildren, and up to 490,000 missedwork or school days—providing upto $93 billion in climate and publichealth benefits
• Shrink electricity bills roughly8 percent by increasing energyefficiency and reducing demand inthe electricity system
EPA’s 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 itsownership position in its majorityowned subsidiary, MesoCoat Inc., to a87.5 percent direct and 89.9 percentdirect and indirect ownership. Theincrease is the result of converting anadditional $6.2 million in MesoCoatinvestment into equity and exchanging21 percent of ownership in Powdermetfor 65.3 percent of Powdermet’s sharesof MesoCoat. Abakan develops,manufactures and markets advanced
nanocomposite materials, fabricated
metal products and metal compositesfor 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 InternationalWater Association (IWA) signed amemorandum of understanding (MOU)intended to accelerate joint work togrow and disseminate water knowledgeand to serve and advance the globalwater profession. WEF is a not-for-profit technical and educational
organization representing water
quality professionals around the world.
www.wef.org IWA is a global networkof water professionals that spans the
continuum between research andpractice, 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].
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August 2014 | Pumps & Systems
8 NEWS
EVENTSPumpTec-USA
Sept. 10 – 11, 2014Georgia World Congress Center
Atlanta, Ga.770-310-0866www.pumpconference.com
Turbomachinery/Pump SymposiaSept. 23 – 25, 2014George R. BrownConvention CenterHouston, Texas979-845-7417
pumpturbo.tamu.edu
WEFTECSept. 27 – Oct. 1, 2014New Orleans MorialConvention CenterNew Orleans, La.www.weftec.org
International Association
of Amusement Parks andAttractions (IAAPA)Nov. 18 – 21, 2014Orange County Convention CenterOrlando, Fla.703-836-4800www.iaapa.org
PumpTec-IsraelDec. 3 – 5, 2014Jointly with Electricity-Israel2014 ConferenceEilat, Israel
770-310-0866www.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 MeetingDec. 9 – 12, 2014Las Vegas Convention CenterLas Vegas, Nev.www.ngwa.org
AHR EXPOJan. 26 - 28, 2015McCormick PlaceChicago, Ill.www.ahrexpo.com
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• Dry run ability, self-priming, gentle fluid handling, no rotating parts, no shaft seals
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Performance
Reliability
Durability
Powerful, reliable and versatile - the PP86S17diesel pump package
Model PP86S17
Size 8” x 6”
200 x 150 mm
Flow, Max 5,400 USGPM
1230 m3 /h
340 l/s
Head, Max 440 feet
130 meters
Flow at BEP 3,200 USGPM
730 m3 /h
200 l/s
75%
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www.pioneerpump.com(503) 266-4115
The PP86S17 is a solids handling pump tha
general purpose diesel package is the righ
Full Pioneer Pump Product Range
Centrifugal
general
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temperature rise due to the motor
load. e temperature rise is usu-
ally measured using the resistance
method. Each insulation class has
a specific 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 20,000hours.
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 slots—the
temperature can be higher than the
average measurement. e hot spot
allowance is reserved to protect
these areas. is reduces the actual
operating temperature (ambientplus 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 li fe 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 about50,000 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
pump-zone.com | August 2014
21
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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 effect of higher
temperature. Measuring voltage unbalance and
fixing 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. IfImage 1. Windings of a motor that failed because of high voltage unbalance.(Image courtesy of EASA)
2 PUMP ED 101
August 2014 | Pumps & Systems
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23
Visit Booth 1543
43rd Turbomachinery
30th Pump Symposia
Houston, TX
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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 wi ll probably safely
operate. A less desirable alternative is
to derate the motor’s 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 effi ciency. At 1 percent
unbalance, effi ciency remains at
the nameplate nominal effi ciency.
However, at 3 percent unbalance,
actual motor effi 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
Pacific 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 efficiency.
4 PUMP ED 101
August 2014 | Pumps & Systems
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When the pump selection
process starts, the
required flow of the is
often the only known var iable
for an application. For example, a
system must move 2,000 gallonsper 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 willgenerate. A good way to pick a pipe
size is to ca lculate its diameter from
an empirical but simple starting
formula. is wil l help establish an
approximate range. Pipe velocity is
usually between 5 and 10 feet per
second (ft/sec).
e smaller a pipe’s diameter, the
faster fluid flows through it. e
larger the pipe, the more expensive
it is. Also, flowing too slowly may
cause particulate matter to settleand clog the line, but flowing 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 = flow 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 figure out the
amount of pressure in the system
if the pump is 5,000 feet away
from the process’discharge. isdetermination is more complicated
because some hydraulic informa-
tion is needed. Several options can
provide this information: come to
class, consult a piping frict ion 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 flow and head deter-
mined, the motor can be sized (see
Table 1). Also, an online Effi ciencyEstimator, which can be found at
www.mj-scope.com/pump_tools/
pump_effi ciency.htm, offers useful
formulas.
To handle the process specifica-
tions, a single-stage pump was se-
lected. e Effi ciency Est imator cal-
culated that a 42-horsepower and
84.5-percent pump effi ciency can
be expected from a typical pump.
is number can be confirmed with
quotes from pump distributors.
e Effi ciency Estimator a lso
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 preliminar yinformation 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 ofsafety.
Simplify the EquipmentSelection 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 flow (gpm) 2,000
Total pump head (ft) 70
Specific gravity (SG) 1.00
Number of stages 1
Speed (rpm) 1,800
Header per stage (ft) 70
Impeller diameter (in) 9.77
Specific speed U.S. (Ns) 3,326
Specific speed metric (ns) 64.5
Specific speed universal (Os) 1.22
Effi ciency (%) 84.5
Power (hp) 42
August 2014 | Pumps & Systems
6 PUMPING PRESCRIPTIONS
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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 affects the operation andthe relationship between the flow
(as a percent of the best effi 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 find
the right balance. My next column
will describe in detail the beginningof 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 firm
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 find the right balance.
pump-zone.com | August 2014
27
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August 2014 | Pumps & Systems
8 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 off
or the full system may not be
accurately represented in the design
documents.
is month’s article demon-
strates how cross-validating the
calculated results can ensure the
energy cost balance sheet accurately
reflects 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 (seeFigure 1).
Prioritizing the System
e pump elements provide all
the energy that enters the system.
at energy is then consumed by
the system’s 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 find meth-
ods to cross-validate the initial
estimates.
Pump PerformanceIn the example, the pump’s flow
rate was determined using the
manufacturer’s pump cur ve. With
a known flow rate, the pump ef-
ficiency can be determined from
the curve.
Because the pump effi 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 pumpperformance. Because of internal leakage, the installed pump is notoperating as designed.
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pump-zone.com | August 2014
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 reflects the
pump curve’s operation.
Figure 2 shows a pump curve for
the process pump along with an
example of the effect 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 flow rate of lessthan the 4,000 gal lons per minute
(gpm) used in t he previous energy
system balance.
In addition, the effi ciency of a
worn impeller would differ from
the manufacturer-supplied test
curve.
is would result in inaccurate
power consumption and operation
costs calculations.
Operators have other options to
determine the flow rate throughthe pump, including portable
ultrasonic flow meters.
ese meters provide a reason-
ably accurate flow measurement
in a pipeline without physically
changing the piping system.
If the observed flow rate on the
temporary flow meter equals the
value determined using the pump
head and the pump curve, the flow
rate is validated, and the effi 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
flow, head and effi ciency values as
show in Equation 1, at the bottom
of page.
kW = .746 ×Q × H × ρ
247,000 × ηP × ηM
Equation 1
Where:
Q = flow rate in gpm
H = pump head in ft
ρ = fluid density lb/ft3
ηP = pump effi ciency
ηM = motor effi ciency
XRS
The XRSSplitSeal
assembles in
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August 2014 | Pumps & Systems
0 PUMP SYSTEM IMPROVEMENT
If the power into the motor as
read on its power meter is the sameas the calculated power consump-tion using Equation 1, the pump’sflow, head and effi ciency values arevalidated.
If a power reading is not availablefor the motor, the motor’s powerconsumption can be calculated bymeasuring the current and voltagesupplied to the pump’s motor, thenusing Equation 2. e motor’s powerfactor can be read on its nameplate.
P3ϕMotor = √3 × V × I × Pf 1,000
Equation 2Where:P3ϕMotor = motor power in kW V = voltage voltsI = current ampsPf = motor power factor
If the calculated value of motorpower equals the pump’s power con-sumption, the pump flow, head andeffi ciency va lues are val idated.
Tank Levels and Pressures
e tanks and vessels make excel-lent piping system boundaries. eenergy at each tank can be deter-mined by using the elevation of theliquid level in the tank and pressureon the liquid surface.
From these values the energyconsumed for the static head compo-nent can be easily calculated.
e results can be cross-validatedusing installed pressure and levelinstrumentation.
e liquid level can be checkedwith a sight glass or by manuallymeasuring the liquid level in thetank. e pressure in a closed vesselcan be compared using the installedplant instrumentation, installedpressure gauges or a temporary pres-sure gauge.
Control Valves
In last month’s example, the dif-ferential pressure across the controlvalve was calculated by subtractingthe sum of the head losses of theprocess elements from the pumphead. is approach is easy, but anyerrors made in the previous calcula-tions will compound and can greatlyreduce the energy cost balancesheet’s accuracy.
Valve manufacturers define theoperation of control valves based on
tests that are outlined in publishedindustry standards. Manufacturersuse the ANSI/ISA-75.01.01 FlowEquations for Sizing Control Valvesto size control valves for pipingsystems. e data used in valvesizing can also be used to calculatethe differential pressure across thecontrol valve.
Equation 3 shows the basic for-mula for valve sizing.
Cv =Q
FP √ P1 – P2
S
Equation 3Where:Cv = manufacturer-supplied valve
coeffi cientQ = flow rate in gpmFP = piping geometry factor (unit-
less)P
1 = absolute pressure measured
at valve inlet in lb/in2
P2 = absolute pressure measured
at valve outlet in lb/in2
S = fluid specific gravity (unit-less)
Rearranging the control valve
sizing equation and solving for dif-ferential pressure results in Equa-tion 4.
dP =Q 2S
(C v FP)2
Equation 4
In the example system with a flowrate through the level control valveof 2,500 gpm, the control valve posi-tion is 65 percent. According to the
manufacturer’s data for the controlvalve, the Cv at this position is 391.e FP of .9996 was calculated
by the manufacturer and includedin the valve data sheet. e spe-cific gravity of the process fluid wascalculated at .993. e flow ratethrough the level control valve wasmeasured at 2,500 gpm. Insertingthe values into Equation 4 providesthe differential pressure across thecontrol valve.
Converting the control valve’sdifferential pressure of 40.6 poundsper square inch (psi) to feet of fluidresults in a head loss of 94.3 ft. isresult for the control valve calcula-tion validates the number from lastmonth’s calculations.
Process Equipment
e differential pressure across theprocess equipment was calculatedusing the pressure drop data sup-plied by the manufacturer and the
dP = Q 2S
(C v FP)2 = 2500
2 × .993(391 × .9996)2
= 40.6 psi
If the calculated value of motor power equals the
pump’s power consumption, the pump flow, head
and efficiency values are validated.
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31
flow rate obtained from the installed
flow element. In the example, the
heat exchanger pressure drop of
10 psi was assumed based on the
manufacturer’s supplied data. If the
heat exchanger tubes were fouled
due to internal deposit, the actual
differential pressure across the heat
exchanger would be greater than
the value used in the energy cost
calculation.
e differential pressure across
the process equipment can be
validated by installing temporary
pressure gauges.
Most process equipment has vent
and drain lines instal led for main-
tenance.
By install ing temporary pressure
gauges on the vent and drain lines—
and correcting the pressure values
for any difference in elevation of the
gauges—the differential pressure
and head loss across the item can be
measured.
Pipelines
In the example, the head loss in theindividual 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 avai lable
computer programs can also greatlysimplify the task.
Problems that could affect the
head loss calculation include fouling
or sedimentation in the pipelines,
partially closed valves, or obstruc-
tions in the pipe, valves or fittings.
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 fittings.
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August 2014 | Pumps & Systems
2 PUMP SYSTEM IMPROVEMENT
size or schedule, or inaccurate esti-
mates of the number of fittings orpipe length can a lso affect the head
loss calculation.
Total System
If the energy cost balance sheetdoes not balance, either the mea-
sured plant data or the equipment
(pumps, process components or
control valves) could be causing theproblem.
To confirm 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 first step is to check for
cavitation throughout the whole
system. Cavitation is caused when
the local pressure drops below, thenrises above, the vapor pressure of
the process fluid. Some of the fluid is
converted from liquid to vapor. e
vapor bubbles take up extra space
in the flow stream, which causes a
reduction in the mass flow rate.
All standards and calculat ion
methods used to determine head
loss assume single phase flow. If
cavitation occurs, the calculated re-
sults wil l not accurately reflect 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
system’s 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 ex planation
for this change is that the head loss
across the process element increased
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S e e U s A t P
u m p
S y m p o s i u m
B o o t h 9 0 3
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UnitedRentals.com/Pumps | 800.UR.RENTS
Following our recent acquisition of the second largest pump
rental company in North America, United Rentals has
further expanded its specialty offerings to meet customers’
diverse business needs. Our team is proud to provide the best
equipment, tools and solutions in the industry.
You’re building the future. We’re here to help.™
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© 2014 United Rentals, Inc.
Aerial | Earthmoving | Material Handling | Pumps
Power & HVAC | Trench Safety | Tools | Technology
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August 2014 | Pumps & Systems
4 PUMP SYSTEM IMPROVEMENT
from the manufacturer’s published
value of 23 ft to 46 ft. is is a clearindication of fouling in the process
equipment.
Conclusion
Gaining a clear picture of how apiping system operates is key to as-
sessing the system.
Because most operating plants do
not have suffi cient installed plantinstrumentation 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 thatadversely affect 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 standardscommittee 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
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August 2014 | Pumps & Systems
6 GUEST COLUMN
Despite their simplicity,
centrifugal pumps often
experience repeat failures
that even seasoned maintenanceand reliability professionals have
trouble preventing. is four-part
series explains the reasons behind
repeat pump failures and uses a
real-world field example involving
boiler feedwater pumps. Devia-
tions from best practices or over-
sights can range from seemingly
insignificant to stunningly elusive.
ese can combine and often cause
costly failures.
Operating DifferentPumps in Parallel
e negative experience of a
metal producing facility best
demonstrates the consequences of
operating pumps beyond their ap-
propriate flow ranges. is example
serves as a reminder of the meritsof 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 plant’s installed in-
strumentation is shown
in Figure 1. e flow rate
into the destination tank
averages 2,500 gallonsper minute (gpm) to
maintain the tank level.
is system currently op-
erates for 8,000 hours per
year to meet the plant’s production
needs. e system has operated in
this way since being commissioned
five years ago.
Pushing Fluid Machinery Leadsto Frequent FailuresSecond of Four Parts
By Heinz P. Bloch, P.E.
Image 1. This riveted cage bearing failed because of ax ial (rotor thrust) overload.( Article images and graphics courtesy of the author.)
Figure 1. Pump manufacturers usually plot only the net positive suctionhead required (NPSHR) trend associated with the lowermost curve. At thatpoint, a head drop or pressure fluctuation of 3 percent exists at BEP flow.1
Figure 2. A typical head-versus-flow performance curve
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37
is case history is one of
many examples that validate the
importance of examining the
flow-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
producer’s boiler house. Two of the
facility’s 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 mayhave prompted operating four
pumps in paral lel when only three
were required to provide a specific
flow 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-
flow and high-internal-recircula-
tion range illustrated in Figure 1.
Low-Flow Range
At least two of the pumps had
flat H/Q curves, similar to the
curve in Figure 2. Running in
the low-flow range forced one or
both pumps into the flat portion
of their respective performance
curves. When operating in the flat
range, even a small change in head
(a small change in ∆p) results in
large differences in throughput.
Controlling and equalizing load
sharing would be diffi cult.
In addition, the internal
pump clearances opened as time
progressed. is explanation was
in line w ith the recent escalated
failure frequencies. It led to the
recommendation of investigating
1970 Dodge Super Bee
Creating Value.
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Flow Instrumentation Solutions© 2014 Badger Meter, Inc.
Blancett is a registered trademark of Badger Meter, Inc.
Control. Manage. Optimize.Measuring everything from water in hydraulic fracturing
or mining operations to gases and liquids from wellheads,
the Blancett family of turbine flow meter solutions
delivers accurate, consistent, reliable and now more
informative flow measurements. The B3000 flow monitor
revolutionizes field measurements with built-in alarm
parameters that provide faster warnings when conditions
change in the process or pipeline.
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August 2014 | Pumps & Systems
0 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 manufacturingproject’s 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 package’s
transportation and installation• Providing modularized compo-
nents that are easy to change
• Reducing on-site personnel
supports and encouraging un-
manned operation
• Eliminating as many standby
pumps as possible
Very limited literature is avail-
able on pump cost estimation. is
column will focus on the cost esti-
mation of the pump installations indifferent projects.
Pump Installation
Cost EstimateHistorical data could inform pump
installation cost estimation models
within certain l imits. Results have
shown a large cost difference be-
tween different regions.
e economies of concentration
play an important role in cost.
Cost studies have indicated that
pump installation cost components
usually have economies that are
to scale to pump unit capacity and
pump train size.
e cost estimation of a pump
unit or installation in a plantcannot be fully accurate, with the
exception of the material cost,
particularly the cost of a pump
package. is cost can be estimated
from the pump package’s vendor,
and the cost of materials could be
obtained from suppliers. However,
other cost estimations are relatively
inaccurate. Labor costs have much
larger cost overruns compared to
other cost components.
e following estimation conceptcan be employed for a pump unit or
installation:
(Pump Unit Cost) = A × (Pump
Package Cost) + B
e factor A is assigned for all
auxiliaries and accessories required
for each pump package such as
the foundation, civil works, piping
and additional steel structures for
each pump package. is factor isusually between 1.3 and 2.5. e
pump package cost includes all
skid-mounted facilities such as the
driver and lubrication oil system.
e factor B is assigned for all
auxiliaries and accessories required
for each pump unit, such as unit
piping, unit utilities, protection
systems, unit pit/drain, unit electri-
cal facil ities, safety equipment,unit steel structures and unit civil
works.
Because the cost underestimating
error is generally larger than the
overestimating error, proper safety
margins for factors A and B are
always encouraged.
e cost is also a function of the
project size or the pump system
capacity. A proper set of factors
should be developed for a defined
range of the pump unit size andcapacity for a region.
Environmental conditions—soil,
terrain, cost of living, population
density, economies of scale, noise
limits, applicable codes and dis-
tances from pump supplies—could
affect the installation cost estima-
tion and should be considered when
the cost factors are estimated.
Other Costs
Studies on recent pump install-ations have shown that the cost
of civil works (site developments,
foundations and others) are about 9
to 20 percent of the total cost.
Estimate Pump Installation Costs
By Amin Almasi
Cost studies have indicated that pump installation cost
components usually have economies that are to scale to
pump unit capacity and pump train size.
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41
ey have also shown that the costof installation can be approxi-
mately 7 to 11 percent of the total
cost.
e required man-hours for the
installation and commissioning of
pumps can vary significantly. For
packaged pumps, the following
indications should be noted:
• For large pump packages (more
than 1 megawatt (MW)), the
installation and commiss-
ioning man-hours could bebetween 300 and 900 hours.
• For small pump packages (less
than 1 MW), the installation
and commissioning man-hours
could be between 100 and 300
hours.
Case Study
e first case study is presented for
a 6 MW pumping unit. e costs
of electric motor-driven pump
packages are obtained in millionsof U.S. dollars (MUSD):
• A 3 MW pump package:
0.9 MUSD
• A 1.5 MW pump package:
0.6 MUSD
• A 0.8 MW pump package:
0.45 MUSD
e factor A is estimated at
1.67 for these pump packages. e
factor B is estimated at 1.5 MUSD
for a 6 MW pump unit. Table 1compares the cost of these differ-
ent options.
As shown, smaller pumps con-
siderably increase costs. A greater
number of smaller pumps is more
expensive than using a single large
pump.
e second case study is pre-
sented for small pump instal la-
tions. e following two options
are considered:
• Option 1: A 320 kW pump,$52,000
• Option 2: A 200 kW pump,
$42,000
e factor A is estimated at
1.49 for these small pump pack-
ages. e factor B is estimated at
$45,000 for Option 1 and $34,000
for Option 2.
Table 2 shows the cost analysis
for two options of small pumps.
Based on Table 2, only about 20
percent total installed cost reduc-
tion could be expected for a pump
38 percent smaller in size. Large
pumps have economies of scale
and low unit cost. In other words,
unit costs of pump installations
usually decrease as pump size
increases.