July Pump

The Magazine for Pump Users Worldwide July 2012
pump-zone.com
Pumps in
FOOD &
BEVERAGE
Processing
Metering & Dosing Pumps
S P E C I A L S E C T I O N
The Magazine for Pump Users Worldwide
pump-zone.com
July 2012
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Letter from the Editor
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 110, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and
additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the right to determine qualications. Annual subscriptions: US and possessions $48, all
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may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, articles or descrip-
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is a member of the following organizations:
A
s industry standards get tougher, food
and beverage processing continues to be
a challenge. Formulation changes (with
FDA and USDA regulation updates) are a regular
occurrence. Food safety and sanitary requirements
are paramount.
Many pumps are used in food and bever-
age processingincluding centrifugal, positive
displacement, exible impeller, air-operated dia-
phragm, rotor, progressive cavity and peristaltic.
his issue of Pumps & Systems shows images of
systems pumping everything from chocolate, to
cookie dough to food pies and even wine.
Many companies have adopted clean-in-
place (CIP) to clean the interior surfaces of pipes,
vessels, process equipment, lters and associated
ttings, without disassembly. Until the 1950s,
closed systems were disassembled and cleaned
manually. CIPs advent was a boon to industries
needing frequent internal cleaning.
he benet to industries that use CIP is that
cleaning is faster, less labor intensive and more
repeatable, and poses less chemical exposure
risk to people. CIP started as a manual practice
involving a balance tank, centrifugal pump and
connection to the system being cleaned. Since
the 1950s, CIP has evolved to include fully auto-
mated systems with programmable logic con-
trollers, multiple balance tanks, sensors, valves,
heat exchangers, data acquisition and specially
designed spray nozzle systems. Simple, manually
operated CIP systems are also still used today.
If you have more information about CIP
developments, please drop me an email and tell
me about it. What are some of the challenges you
face in food and beverage processing and how do
you solve them?
In this months cover series, you can read
about the food and beverage pump market (page
29), pumping delicate food products (page 31)
and production at a California winery (page 35).
You will also nd an informative article on
proper pump-pipe alignment in a 10-step pro-
cess by Dr. Lev Nelik (page 13). Go to our web-
site (www.pump-zone.com) for a slideshow and
more information on this process. his month,
we also begin a three-part series on centrifugal
radial thrust from Terry Henshaw (page 18) that
you wont want to miss.
We want to hear from you! Be sure to join
the many conversations about these and other
topics on the Pumps & Systems LinkedIn group.
Best Regards,
Michelle Segrest
Editor
msegrest@pump-zone.com
PUBLISHER
Walter B. Evans, Jr.
ASSOCIATE PUBLISHER
VP-SALES
George Lake
glake@pump-zone.com 205-345-0477
EDITOR/VP-EDITORIAL
Michelle Segrest
msegrest@pump-zone.com 205-314-8279
MANAGING EDITOR
Lori K. Ditoro
lditoro@cahabamedia.com 205-314-8269
CONTRIBUTING EDITORS
Laurel Donoho
Joe Evans, Ph.D.
Terry Henshaw
Dr. Lev Nelik, PE, APICS
SENIOR ART DIRECTOR
Greg Ragsdale
ART DIRECTOR
Terri Jackson
PRODUCTION MANAGER
Lisa Freeman
lfreeman@pump-zone.com 205-212-9402
CIRCULATION & MARKETING
MANAGER
Jaime DeArman
jdearman@cahabamedia.com
CIRCULATION
Jeff Heine
jheine@cds1976.com 630-739-0900
SENIOR WEB EDITOR
Julie Smith
jsmith@cahabamedia.com
ACCOUNT EXECUTIVES
Derrell Moody
dmoody@pump-zone.com 205-345-0784
Mary-Kathryn Baker
mkbaker@pump-zone.com 205-345-6036
Mark Goins
mgoins@pump-zone.com 205-345-6414
Addison Perkins
aperkins@pump-zone.com 205-561-2603
Vince Marino
vince@pump-zone.com 205-561-2601
ADMINISTRATIVE ASSISTANT
WEB EDITOR
Ashley Morris
amorris@pump-zone.com 205-561-2600
EDITORIAL INTERNS
Michael Lambert
Joel Langham
Savanna Lauderdale
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Phone: 205-345-0477 or 205-561-2600

Editorial Advisory Board
Thomas L. Angle, PE, Vice President Engineering,
Hidrostal AG
Robert K. Asdal, Executive Director, Hydraulic Institute
Bryan S. Barrington, Machinery Engineer, Lyondell
Chemical Co.
Kerry Baskins, Vice President of Sales, Viking Pump
Walter Bonnett, Vice President Global Marketing, Pump
Solutions Group
R. Thomas Brown III, President, Advanced Sealing
International (ASI)
Chris Caldwell, Director of Advanced Collection
Technology, ABS, & President, SWPA
John Carter, President, Warren Rupp, Inc.
Jack Creamer, Market Segment Manager, Schneider
Electric
David A. Doty, North American Sales Manager, Moyno
Industrial Pumps
Joe Evans, Customer & Employee Education, PumpTech,
Inc.
Ralph P. Gabriel, Chief EngineerGlobal, John Crane
Bob Langton, Vice President, Industry Sales, GRUNDFOS
PUMPS
John Malinowski, Sr. Product Manager, AC Motors,
Baldor Electric Company, A Member of the ABB
Group
William E. Neis, PE, President, NorthEast Industrial Sales
Henry Peck, President, Geiger Pumps & Equipment/
Smith-Koch, Inc.
Mike Pemberton, Manager, ITT Performance Services
Bruce Stratton, Product Manager, KLOZURE
, Garlock
Sealing Technologies
Kirk Wilson, Vice President/General Manager,
Integrated Solutions Group, & Vice President
Marketing, Engineering & Technology, Flowserve
Corporation
p
Peristaltic Pumps in Caustic or Abrasive Applications
By Russell Merritt, Watson-Marlow Pumps Group
New technology offers accurate metering without valves or ancillary equipment.
p
Software and Control System Improves Operations
By Balvinder Rai, Tajna River Industries
Specialized system automates a continuous process industry plant.
p
Macro Trends Drive Market Dynamics
By Sonia Francisco & Anand Gnanamoorthy, Frost & Sullivan
Challenges in the food & beverage processing industry
p
Hydro-Transport Food Pumps
By Dave Young, Cornell Pump
Correct pump conguration solves product damage problems.
p
Wine Industry Pumps
By Keith Evans, Xylem Inc., Jabsco Flexible Impeller Pumps
Many different pump types can move food and beverages.
Table of Contents
PRACTICE & OPERATIONS
p
Seal Conguration Selection
By Glenn Schmidt, EagleBurgmann
Choose the correct seal to meet the application requirements.
p
Advanced Technology Provides Control and
Mobility
By Chris Suskie, PumpTech, Inc.
Control via an iPad helps solve packaged pumping system problems.
July 2012
Volume 20 Number 7
The Magazine for Pump Users Worldwide July 2012
pump-zone.com
Pumps in
FOOD &
BEVERAGE
Processing
S P E C I A L S E C T I O N
The Magazine for Pump Users Worldwide
pump-zone.com
July 2012
22
25
35
46
50
29
31
DEPARTMENTS
Readers Respond. . . . . . . . . . . . . . . . . . . . . . . . . . 6
P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump Ed 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
By Joe Evans, Ph.D., P&S Editorial Advisory Board
Centrifugal Pump EfciencyWhen Is Efciency Important?
Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . 13
By Lev Nelik, P.E., Pumping Machinery, LLC
10 Steps for Proper Pump-Pipe Alignment
Centrifugal Pump Hydraulics by the Numbers . 18
By Terry Henshaw
Radial Thrust
Efciency Matters . . . . . . . . . . . . . . . . . . . . . . . . 38
By Edison Brito
Latex Pumping Challenges
Maintenance Minders . . . . . . . . . . . . . . . . . . . . . 40
By Peter Carlisle
Easy Shaft Alignment
FSA Sealing Sense . . . . . . . . . . . . . . . . . . . . . . . . 43
What are the current industry best practices for the assembly of
bolted ange connections?
Advertiser Index . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pump User Marketplace . . . . . . . . . . . . . . . . . . . 53
P&S Market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
COVER
SERIES
SPECIAL
SECTION
Dosing Pumps
Pumps in Food
& Beverage
Processing
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[ MOTOR TRUTH #10 ]
Are you frequently
wasted at work?
Well, forget HR. Go straight to
PT Pilot
and stop wasting your

valuable time fumbling through
catalogs, price books, and emails
to specify a gear unit or gearmotor.
PT Pilot quickly provides a quote
with all options, parts lists, and
2D/3D CAD drawings. The truth
is that there are more ways to
save energy than using a premium
efcient motor.
New for 2012! PT Pilot is now
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a quote at your ngertips anytime,
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Readers Respond
Centrifugal Pumps Hydraulics by the Numbers: Centrifugal Pump Axial Thrust
Editors Note: In
Centrifugal Pumps
Hydraulics by the
Numbers: Centrifugal
Pump Axial hrust (May
2012), Figures 1, 2 and 4
did not include their com-
plete captions and credits.
he gures are provided
below with their complete
captions and credits. We
apologize for any confusion
this may
have
caused.
P&S
Figure 1. A typical horizontal, single-stage, single-suction process pump with enclosed impeller and
wear rings, front and back
Figure 2. A typical vertical, inline, single-stage, single-suction process
pump with enclosed impeller and wear rings, front and back
Courtesy of Afton Pumps
Figure 4. Illustration of axial thrust created by back-to-back
impellers. Image provided courtesy of Flowserve Corporation.
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speed, maximum innovation and maximum bearing life, Think NSK.
MAXIMUM SPEED. MAXIMUM LIFE.
MAXIMUM INNOVATION.
P&S News
NEW HIRES, PROMOTIONS &
RECOGNITIONS
EAGLEBURGMANN (HOUSTON)
announced that John Dillon joined the
company as a territory manager for the
Southeast Region. He will report to David
Fri, Southeast regional sales manager and
will ll an open territory in the Southeast
covering North Carolina, South Carolina
and Georgia. His experience includes more
than 11 years in industrial sales. EagleBurgmann is a sealing
technology provider. www.eagleburgmann.com.
BJM PUMPS (OLD SAYBROOK, CONN.) announced that
Steve Mosley has recently joined its team as an application
engineer. Mosley will be the primary inside contact for help-
ing customers, representatives and distributors size, price and
select BJM Pump products for their pump applications.
Richard Bronson recently joined the BJM Pumps team
as an assembly technician. Bronson brings a broad range of
experience and training that ts in well with the goals of BJM
Pumps. BJM Pumps manufactures pumps for chemical, pro-
cessing and industrial applications. www.bjmpumps.com
TURBODESIGN TECHNOLGOY, INC. (NEW YORK)
announced that Michael J. Dergance was named vice
president of sales and marketing of TURBOdesign Technol-
ogy, Inc., (TDT). He will apply his more
than 30 years of leadership experience and
global high-technology software business
perspective to make fundamental changes.
TURBOdesign Technology, Inc.,
provides turbomachinery design and con-
sulting and is the exclusive U.S. distribu-
tor for the Advanced Design Technology
(ADT) turbomachinery design software,
TURBOdesign Suite. www.turbodesign-tech.com
BENTLEY SYSTEMS (PHILADELPHIA) presented Tom
Lazear, chairman of California-based Archway Systemsthe
longest-serving Bentley Channel Partnerwith the inau-
gural Bentley Institute Lifetime Achievement Award for his
steadfast commitment to inspiring students, architects and
engineers to explore and apply computer technology in the
service of design and engineering.
he company also announced that it acquired
InspectTech Systems, Inc., a Pittsburgh, Pa.-based provider
of eld inspection applications and asset management ser-
vices for bridges and other transportation assets.
Bentley provides architects, engineers, geospatial pro-
fessionals, constructors and owner-operators with software
solutions for sustaining infrastructure. www.bentley.com
AROUND THE INDUSTRY
BASETEK (NEWBURY, OHIO) celebrated the groundbreaking
ceremony on a 26,000-square-foot facility located in Geauga
County (Burton Township). he new building will more
than double its current manufacturing capacity.
BaseTek, LLC, designs and manufactures polymer com-
posite foundations for a broad range of industries. www.
basetek.com
EMERSON PROCESS MANAGEMENT (ST. LOUIS)
announced that it has acquired ISE Magtech, enabling it to
strengthen its level measurement solutions in the oil and gas,
rening, chemical and power generation industries. Terms of
the acquisition were not disclosed.
Emerson Process Management, an Emerson business,
helps businesses automate their production, processing and
distribution in the oil and gas, chemical, rening, pulp and
paper, power, water and wastewater treatment, mining and
metals, food and beverage, pharmaceutical and other indus-
tries. www.emersonprocess.com
WRTSIL (HELSINKI, FINLAND) signed an operations and
maintenance (O&M) agreement with Sasol New Energy
Holdings, a wholly-owned subsidiary of Sasol, an energy
and chemical company. he three-year agreement covers
the companys gas engine power plant project in Sasolburg,
South Africa.
Wrtsil provides complete life-cycle power solutions
for the marine and energy markets. www.wartsila.com
CLYDEUNION PUMPS (BURLINGTON, CANADA) has relo-
cated its Canadian works to a new facility in Burlington,
Ontario, almost doubling its manufacturing footprint. he
new site provides increased regional production capacity,
allowing larger between-bearings-style pumps to be manufac-
tured onsite. he 6,500-square-meter (70,000-square-foot)
facility will manufacture single- and multi-stage centrifugal
pumps to API 610 standards and reciprocating power pumps
to API 674 standards.
ClydeUnion is an SPX brand. he SPX Flow Technology
segment designs, manufactures and installs engineered solu-
tions used to process, blend, meter and transport uids, in
addition to solutions for air and gas ltration and dehydra-
tion. www.spxft.com
Michael J.
Dergance
John Dillon
Baseteks groundbreaking ceremony
PUMPS & SYSTEMS www.pump-zone.com JULY 2012 9
UPCOMING EVENTS
GROWTH, INNOVATION & LEADERSHIP
2012: SILICON VALLEY
Sept. 9 12
Fairmont Jose / San Jose, Calif.
www.gil-global.com/siliconvalley/
OIL SANDS CONFERENCE
Sept. 11 12
Suncor Community Leisure Centre
Fort McMurray, Alberta, Canada
888-799-2545
www.oilsandstradeshow.com
INTERNATIONAL PUMP USERS
SYMPOSIUM/TURBOMACHINERY/
CHEMINNOVATIONS
September 24 27
George R. Brown Convention Center
Houston, Texas
979-845-7417 / www.turbolab.tamu.edu
MINEXPO
September 24 25
Las Vegas Convention Center
Las Vegas, Nev.
www.minexpo.com / minexpoattreg@
heiexpo.com
WEFTEC
September 29 Oct. 3
New Orleans Convention Center
New Orleans, La.
www.weftec.org / 877-933-4734
POWER-GEN
December 11 13
Orange County Convention Center
Orlando, Fla.
918-831-9160 / www.power-gen.com
To have an event considered for Upcoming
Events, please send information to Lori Ditoro
at Pumps & Systems, P.O. Box 530067,
Birmingham, AL 35253, 205-314-8269,
lditoro@cahabamedia.com.
P&S
VERDER (VLEUTEN, THE NETHERLANDS) opened a Denmark
o ce on June 1, 2012, in the Copenhagen area. Verder A/S will
sell diaphragm pumps, peristaltic pumps, other Verder brands
and universal spare parts for progressing cavity pumps.
he Verder pump trading companies are suppliers for the
chemical, water treatment, food and process industries. www.
verder.com
To have a news item considered for P&S
News, please send information to Lori
Ditoro at Pumps & Systems, P.O. Box
530067, Birmingham, AL 35253, 205-
314-8269, lditoro@cahabamedia.com.
AW-LAKE COMPANY (FRANKSVILLE, WIS.) announced its
new partnership with POMTAVA, a manufacturer of gear
pumps. AW-Lake Company will be POMTAVAs rst Master
Distributor serving North America.
AW-Lake Company designs, manufactures and services
ow measurement technology for. www.aw-lake.com
800.603.7867
p
951.342.3100
p
www.BLACOH.com
p
Sales@Blacoh.com
Specically designed for hygienic applications requiring clean-in-
place components, our inline ow through design and unique patent
pending tube bladder eliminate problems with product holdup and
trapped particles. Ideally suited for handling slurries and viscous
uids, its gentle enough for the most delicate products.
p
316L polished stainless steel self-draining single body
construction for easy clean-in-place
p
USP Class VI pharma-grade silicone bladder connects directly
to piping with Tri-Clamp fasteners
THE CLEAN ALTERNATIVE
FOR PULSATION AND
SURGE CONTROL.
FLOW THROUGH PULSATION DAMPENER
T
he power required by a pump is directly propor-
tional to both the ow and the head that it produces.
As ow and/or head increase(s) so does the power
required. Conversely, power is inversely proportional to
hydraulic e ciency. For the same ow and head, an increase
in e ciency reduces the power requirement. he two equa-
tions below illustrate this relationship:
P = (Flow x Head) / E
f
BHP = ((Flow x Head) / 3960) / E
f
Where:
P = Hydraulic power
BHP = Brake horsepower
E
f
= Pump e ciency
Pumps that run continuously or for extended periods
can experience a substantial reduction in energy costs with
a relatively small increase in e ciency. Figure 1 shows two,
3,000-gallon-per-minute pumps that operate 24/7. With
e ciencies of 87 percent and 84 percent, the horsepower
required is 130 and 135 respectively. he electrical cost per
thousand gallons is 5.7 and 5.9 cents. Two-tenths of a cent
is not a huge dierence, but if you consider the annual cost
of electricity, the lower e ciency pump adds an additional
$3,200 to the total electric bill.
Another factor that can increase the attractiveness of higher
e ciency is the cost of electricity. he energy cost of 10 cents
per kilowatt hour, used in Figure 1, is the average commercial
rate for 2010. However, it can vary signicantly by state.
In some states, the cost of electricity can be as low as
6 cents, and in certain parts of Washington, cooperative
rates can be as low as 4 cents. New
England states costs, however, are
in the high teens. What is the worst
case? Hawaiiwith Oahu at 23
cents and some outer islands topping
out near 40 cents.
As the cost per kilowatt hour
increases, so will the savings due to
increased pump e ciency. Seeing
what the average rates will be for
2011 will be interesting. I suspect
that they have increased substan-
tially. Another factor to consider
when selecting a pump that will not
run continuously is the actual ow
rate required. Does the end user
really need 3,000 gallons per minute,
or can the same results be achieved
by running a 2,000-gallon-per-min-
ute pump longer?
If you have the same head and
e ciency at these two ow rates, the
cost per thousand gallons pumped
is the same for both. In most cases,
reducing ow by 1,000 gallons per
minute will result in a substantial
decrease in friction head. Since BHP
is directly proportional to head,
By Joe Evans, Ph.D., P&S Editorial Advisory Board
Centrifugal Pump Eficiency
When Is Eficiency Important?
Figure 1. The wire-to-water information for two, 3,000-gallon-per-minute
pumps that operate 24/7
Pump Ed 101
Sixth of Six Parts
an end user could see a substantial
reduction in the cost per thousand
gallons pumped with the lower
volume pump.
When Is Efciency Not
As Important?
Selecting the most e cient pumps
and motors will always reduce the
cost of electrical power, but some-
times, the payback versus initial
cost does not pencil out. Examples
include smaller pumps, pumps that
are used infrequently and those
installed for back-up or emergency use only.
In many industrial applications, e ciency will take a back
seat to a pumps ability to reliably perform a particular process.
A good example is a slurry pump, with which larger clearances
increase useful life. Another is the vortex pump, which is pop-
ular in both industrial and wastewater applications.
Figure 2 shows the H/Q curve for a 4-inch, vortex waste-
water pump. At 800 gallons per minute, its hydraulic e -
ciency is just 48 percent. A standard 4-inch, non-clog pump
with similar performance would have an e ciency of 68 to
75 percent20 to 27 points better. he reason for the lower
e ciency is that vortex action is a two-step process, and the
overall e ciency is the product of the two individual e -
ciencies. However even though e ciency is much lower than
normally desired, there is an extremely positive side. Almost
anything that enters the suction of a vortex pump will exit its
discharge.
his is because the vortex impeller is recessed and seldom
contacts any of the solids or other material in the pumpage.
his can be benecial when smaller wastewater pumps are
required. he more e cient 4inch, non-clog pump can plug
frequently when rags and stringy material are present, and this
Figure 2. The H/Q curve for a 4-inch, vortex wastewater pump
Pump Ed 101
often results in removing the pump from service for cleaning
on a weekly basis.
In these applications, a vortex pump can be far more reli-
able, and the maintenance cost savings is much greater than
the additional energy costs due to lower e ciency. One of
the seminars I present to specifying engineers is titled How
Lower Pump E ciency Can Reduce Costs. It usually gets
their attention.
If a pump is run by a gasoline engine, the case could be
made that the pumps e ciency is not too important. Although
an 80 percent e cient pump should save quite a bit of energy
over one that is 65 percent e cient, the gas engine (approxi-
mately 20 percent) brings their totals down to 16 percent and
13 percent respectively.
It may be hard to justify a higher initial pump cost for
such a small energy savings, unless the pump is used frequently
and for long periods of time.
Finally, some application design points exist for which
reasonable e ciency cannot be attained, but a pump is still
required. Suppose some million-dollar process line cannot use
a positive displacement pump but, instead, requires a centrifu-
gal pump that can deliver 20 gallons per minute at 3,000 feet
of head.
Would it really matter if a single-stage pump had to be
driven at 23,000 rpm and that its e ciency was less than 25
percent? Probably not, and there are far more of these types of
applications than you might suspect.
here is denitely more than one side when it comes to
pump e ciency. E ciency is a good thing, and we should
always consider a higher e ciency pump if the return on
investment pencils out.
Often, a peak e ciency that adds one or two percentage
points is not that important since few pumps operate at their
best e ciency points (BEPs). he breadth of high e ciency,
on either side of BEP, can be far more benecial.
P&S
Joe Evans is responsible for customer and employee educa-
tion at PumpTech, Inc., a pump and packaged system
manufacturer and distributor with branches throughout the
Pacic Northwest. He can be reached via his website www.
PumpEd101.com. If there are topics that you would like to
see discussed in future columns, drop him an email.
Read more articles from Joe Evans, including
the irst ive articles of this series.
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Model 8900
T
he initial version of this procedure was
published several years ago by me. Since
then, a large amount of feedback has
been accumulated. he most recent reection
appeared in the March 2012 issue of Pumps
& Systems with discussion on how the thermal
eects of pipe growth inuence the supports,
anchors and other restrictions. he 10 steps
outlined in this article reect modications,
corrections, your questions, challenges and
practical considerations and limitations.
Piping issues directly aect a pumps
life and its performance. Bringing the pump
to the pipe in one operation and expecting a
good pump ange or vessel t is a di cult task.
When bringing the pipe to the pump, the last
spool (suction side and discharge side, each) should always
be left until the pump has been leveled in place and rough
aligned. he nal alignment will be a free bolt condition, and
no come-alongs would be needed, which may be a surprise
to some readers. With an initial, common-sense investment
and proper attention to details, the pumps will last longer,
with fewer failures of seals, shafts, bearings and couplings.
More equipment uptime and less lost production will result
in signicant cost savings and fewer headaches.
Step 1
Note: his step is only for cases in which NO thermal growth is
experiencedotherwise skip to Step 2.
At this point the pipe should be securely anchored just
before the last spool, to prevent future growth toward the
pumps anges. he piping lay out should not be nalized
until certied elevation drawings are received from the engi-
neering group or from the pump vendor. Once the nal
certied drawings are received, the nal isometrics can be
completed and the piping takeo can be performed.
he delivery of the equipment can either be early or
it can be late in arriving at the site.
When the equipment is late it is criti-
cal to have certied elevation prints
of the equipment. he certied prints
ensure that the isometrics required
for the piping takeos can be made
without impacting the construction
schedule. If the equipment is early, it
will arrive at the site before the con-
struction team needs it for installa-
tion. Preparations must be made for
long-term storage. Using oil mist
lubrication is customary to keep the
equipment in as-shipped condition
while it is stored. he pressuriza-
tion of the bearing housing and the
casing with just 10 to 20 H
2
O pres-
sure prevents moisture and contami-
nants from entering the sealed areas
By Lev Nelik, P.E., Pumping Machinery, LLC
10 Steps for Proper
Pump-Pipe Alignment
Pumping Prescriptions
Figure 1. Occasionally, anchors (only if NO thermal growth, which is rare) can be
used for the pump piping.
Figure 2. Rough alignment phase (note that the motor and the pump are not coupled yet
and the baseplate is still sitting free, not grouted)
A. Correct congurationSliding support does not keep the piping from sliding up/away.
B. Piping is restrained (cannot slide up/away) with high thermal expansion loads.
C. Anchor will allow pipe to expand toward/into the pump. This is a problem, causing
high axial loading.
and damaging the components. In addition, early delivery of
equipment to the site allows for the verication of the actual
measurements.

Step 2
When the location of the equipment is set, the baseplate can
be put in place, leveled and rough-aligned, with the equipment
mounted. Rough alignment should happen prior to building
the grout forms. To avoid stresses caused by the thermal expan-
sion of pipes, expansion loops should be installed in the suction
and discharge lines. he sliding pipe supports near the pump
suction and discharge are required to eliminate the weight loads
of piping on the pump, which can cause excessive loads and
misalignment, leading to seal, bearing and coupling failures.
However, anchors (three dimensional restraints) should
not be used because they could cause signicant stresses and
casing distortions from thermal expansion. Consider, an exam-
ple (Figure 2, Example C) of an incorrectly placed anchor
(restraining growth in ALL directions, not simply a vertical,
sliding support), even 2 feet away from the pump suction, and
the case of pipe expansion by only 30 F (morning to afternoon):
L
L
= T = (6.9 x 10
-6

in
/inF) x 30 = 0.0002
in
/in
L = LT = (2' x 12") x 0.0002 = 0.0005"
Stress =
L
L
= (30 x 10
6
) x 0.0002 = 6,000 psi
Where:
L = Pipe length
L = Change in pipe length
T = Change in temperature
For the pipe, the area of contact between the pump and
pipe anges depends on the pipe size. Assume, for example, a
20-square-inch contact area (or use the pipe/ange number).
he resultant force on the pump will be:
F (force) = 6,000 x 20 = 120,000 pounds
his is high and will distort the pump casing, feet, shafts,
etc., and cause problems. If, in addition to that, the pumped
product is hot, the piping expansion could be worse. However,
even the daily uctuations of ambient temperature alone could
cause problems, as shown in the calculation above.
Step 3
Once rough alignment has been completed, remove the equip-
ment (pump, motor gearbox) from the baseplate. Level the
baseplate to a maximum out of level of 0.025 inch (0.06 mil-
limeter) from end to end in two planes. Use machined pads as
the base for the leveling instruments. Inspect the foundation
for cleanliness, and if not clean, use a solvent to remove grease
and oil.
Step 4
Allow time for the cleaning substances to evaporate. Form the
base using the appropriate techniques to allow for the weight,
temperature rise and uidity of the grout material. Use epoxy
grout to secure the base, and allow the grout to cure, follow-
ing the grout manufacturers recommendations. his normally
requires 24 hours at 80 F (27 C). Remove the forms and clean
all sharp residue and edges from the foundation.
Step 5
he rough alignment step, mentioned above, is critical to mini-
mize the changes that will be required to appropriately t the
piping to the pump. At the last stage, when the nal spools
are installed, the nal alignment will be achieved with small
Figure 3. Baseplate leveling pads and grout location
Figure 5. Potential bolt-bound situation due to tight clearances
between bolt, feet and base
Figure 4. Typical anchor bolt and leveling wedges
adjustments. his will minimize the adjustments required on
the motor feet/bolts. Unfortunately, motor hold-down bolts
are often too tight and allow for only small adjustments to the
motor before becoming bolt bound.
Motor manufacturers could improve this situation signi-
cantly if motor feet were slotted by design rather than drilled for
bolts. Figure 5 shows the tightness of space available to insert
the foot hold-down bolt. his illustrates
once again why good alignment at Step
3 can save time and the cost of having to
alter motor feet (which can be a night-
mare) by slotting or reaming.
Step 6
Reinstall the pump and the motor on the
baseplate. Rough align the equipment
again, using a reverse indicator, laser
alignment or similarly accurate tech-
nique. It should now be easy to ne-tune
the motor movement within the allow-
able alignment target without becom-
ing bolt bound. his is possible because
of completion of the rough alignment
during Step 4. Note: Never install shims
under the pump feet. If the shims are
lost or misplaced then alteration to the
piping may be required to get the pump
within the required alignment specica-
tion. he normal procedure is to place
0.125-inch (3.2-millimeter) thick shims
under the motor feet. his allows for
adjustments that will be required during
nal alignment.
Step 7
Make up the nal spool pieces for the
suction and discharge spaces. Bring the
piping to the pump now.
Step 8
As a nal alignment step, bring the
piping to the equipment. Take nal
measurements, and tack weld the spools
in place. At this time, the spools can
be removed and taken back to the hot
work permit area to nalize the weld.
Leave a square and parallel gap between
the ange faces. he gap should be wide
enough to accommodate the size of the
gasket required, plus to inch,
depending on the piping sizing. his
is the only distance through which the
piping will be pulled. However, because
it is properly anchored before the spool
pieces, this length is short, and stresses are minimized. Finally,
align the equipment, considering hot and cold operating condi-
tions, using two indicators on the pump shaft coupling area.
Step 9
As the piping is tightened into place, the shaft must not be
moved more than 0.002 inch (0.005 millimeter). Otherwise,
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Clamp-on transducers.
Works with clean or dirty uids
modify the spool pieces until the piping misalignment is xed.
Several conditions are common when piping is misaligned.
Some of these conditions are the mechanical seal and/or the
bearings running hot and other component failures. A quick
analysis of the failed parts will clearly show the signs of piping
misalignment. To make a nal conrmation of the symptoms,
unbolt the piping while measuring the movement in the verti-
cal and horizontal plane. Again, piping that moves more than
0.002 inch (0.005 millimeter) must be modied to correct the
situation.
Step 10
Place an indicator in the horizontal and vertical planes, using
the motor and pump coupling.
Uncouple the pump and motor, while watching the indi-
cators for movement. Start unbolting the anges, and continue
watching for movement in the indicators. If the needle jumps
more than 0.002 inch (0.005 millimeter) the piping has to be
modied to improve the pumps performance.
References
1. AlChE Equipment Testing Procedure for Centrifugal Pumps (Newtonian
Liquids), 2nd Edition, AlChE, New York, 1984.
2. AlChE Equipment Testing Procedure for Rotary Positive Displacement Pumps
(Newtonian Liquids), Second printing, New York, N.Y., 1968.
3. AlChE Equipment Testing Procedure, New York, N.Y., 1999.
4. API 610 Standard for Centrifugal Pumps, 8th Edition, American Petroleum
Institute, Washington, D.C., August 1995.
5. API 676 Standard for Rotary Pumps, 2nd Edition, American Petroleum
Institute, Washington, D.C., December 1994.
6. Nelik, L., Centrifugal and Rotary Pumps: Fundamentals with Applications,
CRC Press, Boca Raton, Fla., March 1999.
7. Pump Standards, Hydraulic Institute, ANSI/HI 1.1 1.5 1994, Parsippany,
N.J., 1994.
8. Rizo, L., Nelik, L., Piping-to-Pump Alignment, Pumps & Systems, April
1999.
P&S
Dr. Lev Nelik (aka Dr. Pump) is president of Pumping
Machinery, LLC, an Atlanta-based rm specializing in
pump consulting, training, equipment troubleshooting and
pump repairs. Dr. Nelik has 30 years of experience in pumps
and pumping equipment. He can be contacted at www.
PumpingMachinery.com.
Find more information and images on this
topic. Also read other articles by Dr. Lev Nelik.
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T
his article is the rst of three on centrifugal pump
radial thrust. It relates the authors experience with
the use of the traditional equation to calculate radial
thrust, subsequent measurements of radial thrust and com-
parison of the two. Part Two will show a plot of measured
radial thrusts imposed on a performance curve and will dis-
cuss the pattern revealed. he nal part will discuss varia-
tions in impeller and casing designs which reduced radial
thrust.
Stepanoff Radial Thrust Equation
It was 1958. I was fresh out of college and working in New
York City for a major manufacturer of industrial machin-
ery. One of my early assignments was to calculate the shaft
deections of a number of pumps being bid for hydrocar-
bon processing to a major contractor who required calcula-
tions demonstrating that the wear rings would not rub when
operated at low capacities. I calculated the radial thrust on
the impellers probably using data from Stepano [1]. His
book oered the following equation for calculating the radial
thrust:
P =
KHD
2
B
2
2.31
(1)
Where:
P = radial force, pounds
H = pump head, feet
D
2
= impeller diameter [outside diameterOD],
inches
B
2
= impeller overall width including shrouds [at the
impeller OD], inches
K = a constant that varies with capacity, determined
experimentally
Notice that the product D
2
x B
2
is the projected area
of the discharge of the impeller, and H/2.31 is the total dif-
ferential pressure produced by the pump. he product of
pressure x area, therefore, calculates a force. he K factor is
intended to adjust that force to the actual radial thrust. he
absence of specic gravity in the equation indicates that its
use was intended only for cool water. Although the Stepano
data was precise and detailed, it reported thrust character-
istics for only one size pump. In 1959, Agostinelli, et al,
reported radial thrust test results for 16 dierent pumps [2],
while continuing the procedure of considering the eective
pressure area being the impeller OD x width (D
2
x B
2
).
By Terry Henshaw
Radial Thrust
Centrifugal Pump Hydraulics by the Numbers
First of Three Parts
Figure 1. Radial thrust factor at shutoff for single-volute
(constant-velocity) pumps (From Reference 3. Courtesy of the
Hydraulic Institute, www.pumps.org, Parsippany, N.J.)
Figure 2. The current Hydraulic Institute radial thrust factor
graph for single-volute (constant-velocity) pumps (Courtesy
of the Hydraulic Institute, www.pumps.org, Parsippany, N.J.)
Hydraulic Institute Curve
In 1969, the Hydraulic Institute (HI) published a curve show-
ing K values at shut-o for single-volute pumps as a function
of specic speed [3] (see Figure 1). Although the HI values
agreed with Agostinelli [2] in the higher specic speed range
(around 3,000), they were almost twice the Agostinelli values
in the lower range (around 600). he current HI K value
graph, as seen in Figure 2, shows shut-o K values lower than
the 1969 graph, and which compare favorably with Agostinelli
[2]. he procedure continued to consider the eective area to
be D
2
x B
2
.
Actual Radial Thrust of Vertical,
In-line Pumps
I learned that, using Equation 1an accepted, published
equationand K values, produces signicantly inaccurate
radial thrust values for some pumps. I was asked by a pump
manufacturer to determine the actual radial shaft deection,
at the mechanical seal, for a line of vertical, in-line centrifugal
pumps, similar to that in Figure 3. he pump shaft was rig-
idly coupled to the motor shaft so that, when the pump was
equipped with a mechanical seal, the motor bearings absorbed
both axial and radial thrusts from the pump.
he pumps were equipped with semi-open impellers. he
impeller faces were machined at an angle of 20 degrees, result-
ing in vanes that got wider (an increasing B
2
dimension) as
the diameter was reduced. Such design is common for impel-
lers in pumps provided to the chemical industry, although
uncommon for enclosed impellers and some semi-open impel-
lers. Because the casings were volutes, maximum radial thrust
occurred at shut-o (zero gallons per minute).
Figure 3. A vertical
in-line pump with
semi-open impeller
and rigid coupling
Centrifugal Pump Hydraulics by the Numbers
ANSI Specication B73.2 [4] (partially
written by this author) required that the cal-
culated shaft deection not exceed 2 mills
at the gland end of the stu ng box, under
maximum radial load. Questions had been
raised about a 3 x 2 x 11 single-volute pump,
running at 3,500 rpm. To minimize the
radial thrust, the impeller exit width (B
2
), at
the 11-inch (maximum) diameter, had been
designed at inch. he D
2
x B
2
area (see
Figure 4) was, therefore, 2.06 square inches.
he shut-o head of 480 feet created a dif-
ferential pressure, on cool water, of about 208
psi. Specic speed was about 650. Using K
= 0.18, from Figure 1, the calculated radial
thrust was 77 pounds. With the appropriate
motor, the 77 pounds would produce a shaft
deection, just above the mechanical seal, of
an acceptable 2 mils. But two competitors
reported that measured shaft deection was
considerably higher. It was necessary that we
measure the radial shaft deections.
Our test procedure was similar to that
used by Stepano [1]. A rigid steel table was
fabricated, to which was bolted a motor-
coupling-shaft assembly. he shaft position
one-half inch above the location of the seal
faceswas measured by a pair of proximity
probes, located at right angles. Force gages
were used to pull on the end of the shaft (at the location of the
impeller) to establish an accurate relation between the radial
force at the impeller and shaft deection, inch above the
seal faces. We were able to accurately calibrate the motor-
coupling-shaft assembly, even including the eect of looseness
in the bearings.
When the pump was tested, we learned that the radial
thrust imposed on the 11-inch impeller, at shut-o, was 240
pounds, more than three times the value calculated using the
information in Figure 1almost six times the value calculated
using K values from the other references. Instead of using just
the projected area of the impeller discharge, as illustrated in
Figure 4, if we use the total projected area of the impeller, from
the 3-inch diameter eye to the 11-inch outside diameter, D
2
,
(see Figure 5) the area changes from the 2.06 calculated above,
to 6.56 square inches.
Multiplying that by the 208 psi and by the 0.18 K value
from Figure 1, results in a calculated radial thrust of 246
pounds, which is only 2 percent above the measured 240
pounds. he closeness of the agreement indicates that we
should consider using this procedure for impellers that get
wider as the diameter is reduced (and it may well work for all
impellers). More sizes of pumps should be tested to determine
if this concept applies to all sizes.
References
1. Stepano, A. J., Ingersoll-Rand, Centrifugal and Axial Flow Pumps, John
Wiley & Sons, New York, 1948.
2. Agostinelli, A., Nobles, D., and Mockridge, C.R., Worthington, An
Experimental Investigation of Radial hrust in Centrifugal Pumps, Paper
59-HYD-2, Transactions of the ASME Journal of Basic Engineering,
American Society of Mechanical Engineers, 1959.
3. Hydraulic Institute Standards For Centrifugal, Rotary & Reciprocating
Pumps, twelfth edition, 1969, Hydraulic Institute, New York, N. Y.
4. Specications for Vertical In-Line Centrifugal Pumps for Chemical Process,
ANSI B73.2 1975, he American Society of Mechanical Engineers,
New York, N.Y.
5. Karassik, Igor J., Worthington, Centrifugal Pump Construction,
Section 2.2 of the rst edition of the Pump Handbook, edited by Karassik,
Krutzsch, and Fraser, McGraw-Hill Book Co., New York, 1976.
6. Lobano, Val S & Ross, Robert R, United, CENTRIFUGAL PUMPS:
Design & Application, Gulf Publishing Co., Houston, 1985.
7. Hydraulic Institute Standards for Centrifugal, Rotary & Reciprocating Pumps,
2009, Hydraulic Institute, Parsippany, N.J.
P&S
Terry Henshaw is a retired engineer living in Magnolia,
Texas. He worked for more than 50 years in the pump indus-
try. He can be reached at pumprof@att.net.
Figure 5. A semi-open impeller showing the impeller suggested effective area to
calculate radial thrust
Figure 4. A semi-open impeller showing the impeller discharge area traditionally
used to calculate radial thrust
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SPECIAL SECTION
I
n recent years, process engineers have increasingly turned
to peristaltic pump technology for metering highly caus-
tic and corrosive chemicals. Peristaltic pumps are especially
suited to dosing, metering and transferring chemicalssuch as
hydrochloric acid, sodium hydroxide, sodium hypochlorite and
sulfuric acid.
In addition, new peristaltic pump technology is available
that is designed specically for chemical metering in industrial
markets. hese high-performance pumps accurately meter
chemicals without valves or ancillary equipment, keeping costs
minimal. In fact, the total cost of ownership is less than that of
a typical solenoid or stepper-driven diaphragm pump.
New Peristaltic Pumps Meet Key
Selection Criteria
Process engineers face a number of challenges. hey must nd
a pump that withstands chemical attack, runs reliably, meters
accurately to optimize chemical usage and is quick and simple
to maintain and operate. Meeting all these requirements, the
latest peristaltic pumps help plants reduce life-cycle costs and
drive gains in process e ciency.
With no valves in the pump to clog, leak or corrode, the
new peristaltic pumps can safely and securely handle uids that
are caustic, abrasive, viscous, shear-sensitive, gaseous or slurries.
It can also pump uids that contain suspended solids. he uid
is fully contained within the tubing, eliminating any risk of
cross contamination. Such chemical process containment, in
combination with accurate and linear ow, helps reduce chemi-
cal use, providing cost savings.
he pumps range generates ow rates up to 7.9 gallons
per minute at 100 psi, with speed control of 1,600:1 in ana-
logue mode. he pump also accepts 4-20 mA input and output
analog signal control.
he new technology boosts process e ciency by providing
accurate, repeatable and linear ow performance, even when
transferring di cult uids with varying pressure, viscosity and
solid content. Potential applications include:
Disinfection of drinking water
pH adjustment of drinking water
pH adjustment of industrial process water
Flocculation, industrial cooling water preparation
Reagent dosing in mineral processing and paper colorants
Simple Operation
Based on the physiological principle of peristalsis, a term refer-
ring to the alternating contraction and relaxation of muscles
around a tube (for example, the throat or intestine) to induce
ow, a peristaltic pumps operation is elegantly simple. A ex-
ible tube or hose element is compressed between rotating rollers
or shoes and a track. Between each roller pass, the tube or ele-
ment recovers to create a vacuum and draw in uid.
It is well documented that acids, caustics and solvents
attack the valves, seals, stators and moving parts of diaphragm
and progressive cavity pumps, causing disruptive downtime and
high life-cycle costs. By contrast, the use of peristaltic pumps
allows engineers to mitigate these costs because they contain no
valves, seals or glands and have no mechanical parts contacting
the product stream. he uid only contacts the inside of the
hose or tube, which is a low-cost, low-maintenance and easily-
serviceable component.
Hose and tube materials, which in the past were the only
prohibitive factor against the widespread adoption of peristal-
tic pumps for caustic chemical applications, are now available
in dierent elastomers, formulated specically to balance long
mechanical pumping life with sustained resistance against con-
centrated acids, bases and solvents.
Peristaltic Pumps in
Caustic or Abrasive
Applications
By Russell Merritt, Watson-Marlow Pumps Group
New technology offers accurate metering without valves or ancillary equipment.
For example, chlorosulfonated polyethylene (CSM), an elastomer
available for hose pumps, can handle toluene and other corrosive sol-
vents that are used to manufacture certain productssuch as gaskets,
aerosol paints, lacquers, paint strippers, adhesives, cosmetics, perfumes
and anti-freeze.
Some of the latest chemical-duty elements are capable of thou-
sands of hours of continuous service operating at ow rates up to 350
gallons per minute and 282 psi. Furthermore, peristaltic pumps have
the ability to self-prime, dry-prime and self-clean. hey are also revers-
ible to dislodge blockages or drain lines.
he lack of valves makes peristaltic pumps attractive to industries
such as paper and pulp. For instance, one peristaltic pump is being
used to handle sodium hydroxide for bleaching pulp and disinfecting
water at a paper mill.
Precise Metering
he inherent accuracy of positive displacement pumps is another
reason that they are chosen whenever exact chemical metering or
dosing is required. In peristaltic pumps, where metering accuracy is
better than 1 percent, ow is proportional to pump speed. Complete
tube element closure gives the pump its positive displacement action,
preventing ow drop or erosion from backow and eliminating the
need for check-valves, which are typically the primary source of any
metering inaccuracy.
A 350-gallon-per-minute hose pump
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Accuracy is particularly important at power plants, as dem-
onstrated by a power generation servicing company that uses
peristaltic pump technology to meter 65 gallons per minute
of sulfuric acid when cleaning power plant condensersdriv-
ing the pH down to less than 4.0 to break down scale. Precise
control of acid ow is necessary to ensure that, after scale is dis-
solved, the discharge to the municipal wastewater system will
have a neutral pH.
With regard to turndown ratio, a high-quality peristaltic
pump is capable of a ow range greater than 2,000:1 simply
by controlling rotor speed. With the added versatility of inte-
grating dierent tube sizes into a single pump, ow range can
expand to 1,000,000:1. Diaphragm pumps are normally lim-
ited to 20:1.
New Pump Head Technology
An interesting feature of the new peristaltic tube pump technol-
ogy is a new pump heada sealed, single component, no tools
maintenance element that is at the core of the pump range.
his ensures the delivery of accurate, linear and repeatable ow
for uids of wide-ranging viscosities. It also maximizes valu-
able process uptime by facilitating quick and easy pump head
removal and replacement. here is no need for tools, training
or maintenance technicians. he contained pump head design
also eliminates safety concerns.
Low Life-Cycle Costs
While the initial cost of a peristaltic pump can be slightly
higher than other positive displacement pumps, a quick assess-
ment of life-cycle costs quickly tips the scale in favor of peri-
staltic pumps. For instance, no seals, ball valves, rotors or sta-
tors need replacement, and hose/tube replacement usually takes
only a few minutes. he low-cost tube or hose can be replaced
in-situ and without special tools or skills, making the process
extremely economical in comparison with conventional posi-
tive displacement pumps where replacement parts can cost up
to 75 percent of the pumps initial purchase price and take sev-
eral hours to t.
For example, the new pump technology delivers ow rates
up to 7.9 gallons per minute at 100 psi, while maintenance
intervals are up to six months, at typical usage, reducing the
impact of downtime.
Another added cost is the need for a separate control panel
or variable frequency drive to achieve variable ow meter-
ing, with the incremental cost if high turndown is required.
Peristaltic pump manufacturers, however, build high turn-
down, closed-loop speed control capability and expansive I/O
connections for DCS, SCADA and PROFIBUS systems into
standard pumps for simplied integration.
Process-duty pumping is being taken to the next level with
a new, integrated PROFIBUS networking capability that has
been added to a peristaltic pump. With two-way, real-time
communications, the new technology oers increased diag-
nostic capability and faster response, helping optimize process
control and minimize plant downtime.
Pumping Abrasive Fluids
Frequently, uids contain corrosive and abrasive material.
Peristaltic pumps stand up well to the challenge, as a U.S.-based
construction product manufacturing plant can verify. A peri-
staltic hose pump was used in the manufacture of ber cement
siding products. he cement mixture had little eect on the
hose, despite being highly abrasive and strongly alkaline.
Peristaltic pumps are also used for other abrasive uids,
including lime slurry and underow in mining operations,
alum in wastewater treatment and titanium dioxide for pig-
mented inks and paints.
In contrast with peristaltic pumps, abrasion takes a toll
on other positive displacement pumps. Abrasive uids may
cause the erosion or clogging of valves in diaphragm pumps.
he same eect in progressive cavity pumps widens clearances
between the rotor and stator, which may cause internal slip.
A Growing Choice
he advantages peristaltic pumps oer mean that they repre-
sent a rapidly growing percentage of the positive displacement
pump market. Plant managers tasked with reducing pump life-
cycle costs embrace the functionality and benets of peristaltic
pumps, which are fast becoming the rst choice for chemically
aggressive and abrasive applications.
P&S
Russell Merritt is the marketing manager for Watson-
Marlow Pumps Group. He can be reached at
support@wmpg.us.
Peristaltic pumps are also used for other abrasive
fluids, including lime slurry and underflow in mining
operations, alum in wastewater treatment and
titanium dioxide for pigmented inks and paints.
T
ajna River Industries is a continuous process chemical
industry that manufactures bleached lac, shellac akes,
shellac wax and seedlac. In addition to production
oors, the plant also has a water treatment plant, chiller units,
a steam producer, a sodium hypochlorite preparation plant, a
gasier (wood to producer gas) and diesel generator (DG) sets.
To improve its system by reducing inputs, manpower,
power consumption and downtime, Tajna River Industries
decided to automate and control the manufacturing unit with
a custom system. he chosen system was National Instruments
LabVIEW software that created an automation and control
system that met the plants application needs. his article sum-
marizes the improvements provided by the new software.
Speed Control of Diesel Generator Sets
he DG sets are powered by a mixture of diesel and producer
gas created in an 80-kilowatt gasier. he engine speed increases
as more gas is input, so the diesel fuel intake must be reduced to
achieve constant engine speed and line frequency. he engine
speed is detected by using the software to nd the frequency
of the tone generator output attached to the engine shaft. he
closed-loop control system generates signals through the mul-
tifunction software systems data acquisition (DAQ) device to
control diesel ow in the engine. he output from the DAQ
device is applied to a small DC motor through a DC regulator
IC that screws or unscrews the generators fuel control screw.
Power Factor Control
he system performs power factor sensing through the analog
signal from a power factor transducer. he signal is fed from the
multifunction I/O DAQ device to the control system built into
the software. he control system has a set of digital outputs that
switches 24 relay switches on and o. he relay switches control
Software and Control
System Improves
Operations
By Balvinder Rai, Tajna River Industries
Specialized system automates a continuous process industry plant.
Figure 1. Closed-loop speed control of DG set Figure 2. Closed-loop power factor control
SPECIAL SECTION
contactors that add or
remove 15 capacitors in
a capacitor bank. he
power factor remains
near the desired 0.92
set point.
Automatic
Control of
Chiller Machine
Previously, the system
used a programmable
logic controller (PLC)
for the chiller machine,
but spare parts were
costly and problems
occurred with the PLC
main card. he deci-
sion was to replace it
with a software system.
Operators monitored
the temperature at ve
points in the machine.
he chiller machine is
energized by steam and
controlled by rst gen-
erating a ramp output
during a 12-minute
span from the DAQ
device attached to a
system that supplies
steam to the high-
temperature generator
of the chiller machine.
Using the software,
operators implemented
automatic switch con-
trol to open and close
the steam valve from 100 percent to 0 percent. Water is cooled to 4 C, and the
steam control valve is modulated depending on the current temperature.
Electric Load Management
he total connected load is 75 kVA and 85 kVA in two units. he plant operators
must manage the load to avoid going beyond the maximum limit or exposing the
system to instability. he same load management system that was used to remove
the possibility of sudden loading on the DG sets (125 kVA, 110 kVA, 40 kVA, or
20 kVA depending on load needs) when attempting to start several loading units
at the same time was used in this process. he plant runs 80 subunits through this
power supply. he operators introduced a scheme in which each piece of equip-
ment released a pulse for a duration of its startup. his varied depending on the
type of equipmentfans, centrifuges, pumps or motors. Sequence starting was
implemented on a rst come, rst serve basis using digital I/O cards. he software
system was used to log the starting and stopping of dierent units.
Figure 4. Sample VI
Figure 3. Electric load management
Figure 5. Sample VI
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1
2
3

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Maximum Demand Control
With maximum demand control, overload of the multiple
power sources is prevented. Before starting a load, operators
veried the running load and load limit of the power supply.
he load that added to start a particular load, the running load
of the source and the load limit of a power source were known.
Based on these simple calculations made in the software, the
system accordingly gives permission to
start on a particular source. If the power
supply changes, then the changed load
limit and running load are updated.
Following a similar algorithm to account
for frequency considerations for DG
sets, a starter cannot start a DG set if it is
running on low frequency.
Plant Maintenance
Scheduling
Because the system keeps a record of the
starting and stopping of each unit, oper-
ators can easily calculate the number of
run hours for each piece of equipment.
Plant maintenance can be scheduled
based on the run hours. A maintenance
alarm activates after a set number of run
hours. Online condition monitoring is
used in other areas, as well. For example,
the temperature and vibration of bear-
ings and motors can be checked to deter-
mine if they need maintenance.
System Benets
his system had several benetssuch
as cost reduction, improved monitoring
and control of the plant and machinery,
manpower reduction, power system sta-
bility, savings in power tari and better
care of the equipment through the plant
maintenance system. All these benets
could be achieved through the system.
It also made it possible to use the exist-
ing hardware which otherwise would not
have been used.
System Success
LabVIEW training taught the opera-
tors good programming practices, which
drastically reduced development time
(see Figures 4 and 5 for sample VIs).
he schemes can be applied to any con-
tinuous process industrysuch as paper,
textile and chemicals and oer many
benets.
P&S
Balvinder Rai is technical director for Tajna River
Industries Pvt. Ltd. Rai can be reached at +91 33
22483299. For more information about the LabVIEW
system, visit www.ni.com.
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COVER
SERIES
PS & SYSTEMS
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COVER
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2228 28 28 28 28 JUL JUL UL UL ULYYYYY 20 20 20 20 20112 12 12 12 www www wwppu .pump- mp- p zon zon zon zonee c e.com omm PUM PUM PUM PUM PUM UM UM PUM PUM PUMPP
Pumps in
FOOD &
BEVERAGE Processing
Pumps in Food & Beverage Processing
T
he food and beverage industry, key users of pumps, is
expected to be a dynamic sector during the next 5 to 10
years, based on several critical, top-level trends inu-
encing the market. hey include:
It has never been tougher to build and sustain a successful
food and beverage business. Even with a recovering economy,
conducting business is challenging in North America due to
regulatory changes, dynamic societies and diseases, raw mate-
rials pricing, corporate sustainability goals and changing con-
sumer demands, among others. Globally, challenges include
establishing foreign operations, safety and reliability of oshore
suppliers, impact of currency uctuations and competition for
talent. he list continues with a growing global population put-
ting immense pressure on food security and supplies.
A renewed focus on healthy foods means pure
is the new natural. Natural products are becoming
the rule rather than the exception in many western
markets, despite ongoing issues with a clear deni-
tion of what natural encompasses. his trend is also
spreading to the developing regions. Increasing eco-
nomic prosperity will enable the BRIC countries of
Brazil, Russia, India and China, as well as Mexico,
Poland and South Korea, to expand and diversify their
food and beverage oerings, including nutraceutical
products. Naturally-derived substancesconsist-
ing of herbal and botanical extracts and animal- and
marine-based derivativeswill be the fastest growth
among the major groups of nutraceutical ingredients.
While these ingredients have earned their eects
as indispensable substances, they can be di cult to
handle for transfer equipment, such as pumps. For
example, glucose is an abrasive and fast drying sub-
stance and puts stress on the pump, leading to wear-
ing and eventual breakdown of the pump. New prod-
ucts, such as nutraceuticals, may also put a strain on
pumps because they are complex and time consum-
ing when adhering to the current good manufacturing practice
(CGMP) regulations.
Hygiene, convenience and exibility play a critical role in
the industry, while ensuring the highest quality. Product con-
sistency is the key to maintaining brand equity. At the same
time, keeping costs low forces operators to looking at energy
costs and the e ciency of their production lines. While main-
taining hygiene during food processing is important, it is also
important to focus on the hygiene and sanitary implications of
waste management and disposal. For example, bird or animal
waste from processing is highly viscous, making pumping the
material a challenge.
Macro Trends Drive
Market Dynamics
By Sonia Francisco & Anand Gnanamoorthy, Frost & Sullivan
Challenges in the food & beverage processing industry
Clockwise from top: Kinnerton Confectionary uses MasoSine SPS-3
to pump caramel, photo courtesy of Watson-Marlow Pumps Group;
cookie dough in a custom hopper of a seepex BTCS food-grade pro-
gressive cavity pump, photo courtesy of seepex, Inc.; photo cour-
tesy of Cornell Pump; and Pukka Pies relies on the MasoSine SPS-4
to pump pie lling, photo courtesy of Watson-Marlow Pumps Group.
COVER
SERIES
Market Metrics
Figure 1 shows the forecasted growth for pumps in
the global food and beverage sector. his segment is
expected to witness one of the highest growth rates
of all pump-user segments, rivaled by the water and
wastewater and pharmaceutical segments. Trends
described in this article are driving strong growth
in the food and beverage segment throughout the
mid and long term.
Regional analysis shows that the Asia Pacic
region is expected to march ahead of all the regions
with double digit growth, closely followed by
Latin America, then the Middle East and Africa.
Increasing economic prosperity, foreign direct
investments (FDIs), foreign institutional investor
(FII) investments and a keen focus on government
infrastructure investments, are driving growth in
these regions. Pump manufacturers cannot aord
to under serve these regions.
Fuelled by continuing economic woes, Europe
is the slowest growing market, even in the mid and long term.
While Western Europe continues to face nancial di culty,
Eastern European countries enjoy a more optimistic economic
climate and, therefore, more pump manufacturers are expand-
ing into these regions.
North America is expected to witness a nominal growth
rate (around 5 percent) through the mid and long term. While
the food and beverage sector is expected to be fairly stable in
North America, pump manufacturers are seeing more oppor-
tunities in maintenance and repair aspects of the value chain.
Conclusion
Driven by mega trends, the food and
beverage industry is one of the fastest
growing end-user segments across the
globe. End-user preferences are con-
stantly shifting, requiring pump manu-
facturers to be able to support end-user
agility in production requirements. As
North American pump manufacturers
go global, they need to adapt to regional
market conditions, requiring further
innovations. Food and beverage is an
exciting vertical segment due to expected
growth rates, but innovation is a key suc-
cess factor.
P&S
Sonia Francisco is a Frost &
Sullivan Research Analyst track-
ing the pumps market. She can
be reached at britni.myers@frost.
com.
Anand Gnanamoorthy is a Senior
Research Analyst for Frost &
Sullivan, covering various prod-
ucts in the industrial segment. He
can be reached at britni.myers@
frost.com.
Figure 1. Pumps used in the food and beverage industry
P
rocessing plants look for continuous and trouble-free
operation from a pump that is capable of transporting
even the most delicate whole food products or processed
foods, while keeping product damage to a minimum. Pumping
food products has an overriding issueany food product
damage can result in degradation to the nal product and prot
losses at the plant.
While damage is a concern, hydro-transport systems do
provide an advantage lacking in other mechanical conveyance.
hey can be used, with a consistent level of product safety, to
convey and clean many foodscarrots, cranberries, pickles,
cherries, onions, beans, peppers, leafy vegetables, crawsh,
shrimp and hatchery sh. Many food products are hydro-trans-
ported. In fact, most packaged salad producers use food han-
dling pumps to process and transport their products, without
damage, for the fresh pack industry.
System Components
A hydro-transport system involves several components that
must function together to safely process and transport food.
Vortex Tank
In a hydro-transport system, the vortex tank is where the
product rst comes in contact with the hydraulic conveyance
medium. It is traditionally constructed of stainless steel to min-
imize clean-up time and enhance sanitation levels. he tank is
designed to receive product on its return from the reclamation
system and mix it with water, reducing air injection and entrap-
ment. Solids are mixed with the liquid at a uniform rateto
minimize loss of primeand vortexed into the pump suction.
he pump must be located su ciently below the liquid
level in the suction bay to ensure that adequate suction head
is maintained. he vortex should draw the product uniformly
into the pumps suction. Product vortexing is especially impor-
tant with light foods that normally oat.
In addition, the vortexwhich should be limited to mini-
mize air entrainmentcauses long foods, such as string beans,
to enter the stream with their length parallel to the ow. he
pump must have an adequate and uniform supply of water to
minimize loss of prime and prevent surge.
Materials of Construction
Food handling pumps are traditionally constructed of all iron
with stainless steel shaft sleeves. Applications associated with
abrasive or aggressive pH values often warrant the use of
optional construction materials. Optional materials can also be
used to resist attack by soaps, detergents and the germicidal
agents used to clean the system. Table 1 shows the recom-
mended materials for each pH value range.
Stainless steel should be avoided for salt brine applications.
Monel metal can be used for brines. However, monel metal
should be avoided when corn, lima beans or peas are pumped
since copper may darken the product. Bronze is fairly corrosion
resistant but is not recommended for conveying brines in which
foods are canned because of possible product discoloration.
Optional materials for applications associated with abra-
sive material traditionally include hardened ductile iron. he
impeller commonly wears 200 percent faster than the back
plate or volute. A hardened impeller with a cast iron volute and
back plate will normally sustain a similar life cycle.
Piping
In principle, the transport line should be as short as possible
and free of sharp bends, protruding edges and rapid increases or
decreases in pipe size. he piping coe cient should be strongly
considered to avoid abrasion to the product by the pipe wall.
he pipe length is traditionally determined by the retention
time required for disinfection, hydro cooling, blanching, etc.,
or the shortest available route. For practical purposes, horizon-
tal and vertical pipe length should be limited to 250 feet and
65 feet respectively. he rst part of the evaluation should focus
on determining the appropriate line size, which will allow the
Hydro-Transport
Food Pumps
By Dave Young, Cornell Pump
Correct pump conguration solves product damage problems.
pH Range Recommended Material
0 4 Corrosion resistant alloy steels
4 6 All bronze
6 8 All iron
10 14 Corrosion resistant steels
Table 1. pH value of the materials of constructions
COVER
SERIES
engineer to design a system with optimum line velocity. Water
volume should be determined in gallons per minute. his is
accomplished by determining the product to be transported
in pounds per minute. hen the recommended volume-to-
product ratio is applied, which provides the designer with an
equivalent volume of water. he water-to-product ratio should
be as great as economically possible and should vary depending
on the type of food being transported. Traditionally, highly
sensitive products require a greater water-to-product ratio. he
piping conguration should be designed to maintain optimum
line velocities to prevent the product from falling out of sus-
pension, dragging along the bottom of the pipe or stacking up.
High line velocities should also be avoided to reduce product
impact. Short radius ells, rough pipe joints or heads inside the
welded pipe can cause more damage to
the product than the pump.

System Design and Pump Selection
he speed of the pump should be
selected to meet the head requirements
of the system. he system should be
designed to keep the head as low as pos-
sible. Excess pump speed produces an
excess volume of water used. his results
in excess line velocity and increases the
possibility of impact damage. Pumping
excess water is a needless waste of power.
A pump that is too slow produces
insu cient water volume, and as a result,
a loss of lift capacity, retention time, etc.,
which may further damage the product.
Although the pump capacity
required will depend upon the tonnage
to be handled, the pump preferably
should be selected so that it will operate
at its point of peak e ciency or slightly
to the left of this point on the character-
istic curve.
Consideration should be given to
the choice of a food handling pump
with either a standard or expanded
volute. Typically, the expanded volute is
selected for leafy, stringy, large or fragile
products. If a water knife will be used in
the system, the product will need to be
accelerated considerably for the slicing
action to be eective.
At the dewatering screen, products
should be carefully separated from the
liquid, since this is a common point of
product damage. Deceleration prior to
dewatering may be required. Careful
motor selection is also needed to ensure
a non-overloading operating environ-
ment. he horsepower characteristics
included on a traditional performance
curve can be used.
he mounting conguration of
hydro-transport food handling pumps is
traditionally an overhead V-belt mount.
his allows the end user to employ
the food handling pumps in dierent
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operating environments while maintaining relatively slow oper-
ating speeds. Variable frequency drives are also commonly used.
his option allows end users to address dynamic operating
environments in an automated way.
Selection Guidelines
he following suggestions, based on eld experience, are
oered as a guide in pump selection and
applications.
he vortex should be controlled so
that air is not drawn into the pump.
Although the pump capacity required
will depend on the tonnage to
be handled, the pump should be
selected so that it will operate at its
point of peak e ciency or slightly
to the left of this point on the pump
curve. his induces a pre-rotation in
the suction eye that results in reduced
product damage on the leading edge
of the impeller.
he speed of the selected pump
should meet the system head require-
ments. Heads up to 110 feet have
been successful with some foods. he
system should be designed to keep
the head as low as possible.
he ratio of water to food solids
should be as great as is practical or
economical. One to 3 gallons per
pound is the general range.
A pump with a single port food han-
dling impeller is recommended for
most foods. A pump with a bladed
impeller can cause damage.
Food solids should be carefully sepa-
rated from the liquid at the dewater-
ing screen because this is a common
point of product damage.
For new uses, the rst pumping unit
should be installed with a provi-
sion for variable speed operation
and observation of the products
condition after passing through the
pump. Evidence shows that short
radius elbows, rough pipe joints or
beads inside the welded pipe can
cause more damage to foods than
the pump. A velocity in the pipe of 5
feet per second should be tried rst,
because this velocity appears to be
above the critical for movement of
food suspensions without clogging.
When pumping food with hot water,
contact the pump manufacturer for
the required minimum suction head to obtain performance
comparable to pumping with cold water.
Case StudyOnion Damage
A food processor was experiencing signicant product damage
with the 8-inch pump handling whole onions. Not only was
the system plugging, but much of the nal product was also too
COVER
SERIES
damaged to sell. his waste and ine ciency cost the processor
thousands in lost revenue.
In examining both the pump and the design of the system,
three issues were identied:
Incorrect pump typehe pump in service was consid-
ered a non-clog style pump, with an enclosed, multiple vane
impeller and a volute cutwater. While this style of pump
can work well in some food waste applications, it is not
recommended for delicate, whole-food products.
Low water-to-product ratiohe water-to-product ratio
was low, causing inadequate pipe velocities and clogging.
he system only pumped approximately 20 percent of the
recommended 1 to 3 gallons per pound of product. he
onions fell out of suspension and were damaged.
Discharge pipe would be too small for potential solu-
tionsAltering the water ow to achieve correct water-
to-product ratio would make the existing discharge pipe
diameter too small, causing higher than recommended
pipe velocity. he high velocity would keep the onions
suspended in the pipe, but could lead to damage when the
product reached the dewatering screen.
Possible Pump Solutions
hree possible solutions were examined to mitigate the product
damage and plugging. he rst option was to replace the whole
system with a more expensive mechanical conveyer. his would
have taken the plant o ine for a signicant amount of time
compared to other options and cost the most money to imple-
ment. he second option was to keep the existing pump and
replace the discharge pipe to accommodate the recommended
ow based on the water-to-product ratio. he concern was that
the existing pump would still produce a high product damage
rate. It did, however, have the advantages of being the fastest x
with the least initial expense.
he third option was replacing the existing pump with a
new pump designed to handle whole foods. his pump design
allows food to pass through the pump and exit through the
center of the discharge nozzle, minimizing contact with any
pump surface. Along with the new pump, replacing the dis-
charge pipe to the correct diameter would be required.
SolutionHydro-Transport Food Pump
he third option was deemed the most advantageous, in terms
of time, design and overall cost.
he food processor recalculated the correct gallons per
minute needed to transport the desired pounds per hour of
onions and recalculated the total dynamic head of the system
with the correct discharge pipe diameter. After this assessment, a
10inch, hydro-transport food pump with a single port impel-
ler and expanded oset volute was chosen for the job. his size
pump was needed to handle the systems
ow and pressure requirements and to
ensure that the largest onions would not
plug the pump.
With the new pump in place and
following the guidelines for handling
food productsincluding water-to-
product ratio and pipe velocitythe
food processor reduced damage to
onions by more than 90 percent. he
up-time of the pump and energy e -
ciencies have been working well since
2010saving tens of thousands for
nearly two years.
P&S
Dave Young is the
northwest regional
manager for Cornell
Pump Companya
Clackamas, Ore.,
manufacturer of
centrifugal pumps
for industrial, agricultural, mining,
oil, gas and municipal applications.
Young has more than 17 years of
experience in food and agricultural
pump solutions. He can be reached
at dyoung@cornellpump.com or
503-653-0330.
P
umps are used in many beverage and food process appli-
cations. For example, egg whites, honey, food oils, apple
sauce, apple juice, donut glaze and pancake batter are all
moved using pumps. Pumps can also be used to gently circu-
late uid when fermenting high alcohol beer where oxygen is
injected into the process to signicantly reduce the fermenta-
tion time.
Pumps can provide a winemaker with the ability to trans-
fer just-harvested grapes from a de-stemmer/crusher to the
tank for fermentation. hey can also be used for pump overs
in fermentation tanks to allow for color enhancement on red
wines and providing a way to move the juice from the tank to
barrels for aging.
Pumps are also used to move the wine to the ltering pro-
cess to remove sediment or solids and then to move the wine to
the bottling line for packaging. Regardless of the style, pumps
provide time savings to the winemaker and should be consid-
ered part of the wine production lifeline.
he winemaker should
choose a pump that has the
greatest versatility for the par-
ticular operation. A versatile
pumpone that can run at vari-
able speeds and provide a winery
with multiple task fulllment
capabilitiesis a cost advantage
to a winemaker. Some other
advantages of a versatile pump
are self-priming, reversible ow,
portability and ease of cleaning.
his article discusses some
typical pumps found in the wine
industry. However, they can also
be used in other food and bev-
erage industry segments. Pump
styles can be oered in ow
ranges from a trickle to hundreds
of gallons per minute and with
AC or DC voltages.
Pumps can be obtained as
a pump alone, with the motor
attached and or mounted on a cart for ease of movement
within the winery. Some pumps oer low pressure and some
can produce high discharge pressures. Picking the ow and
pressure to meet the needs of the application is important for
successful and continuous production.

Flexible Impeller Pumps
Flexible impeller pumps (FIPs) are self-priming with either
wet or dry at start up. hey oer gentle, smooth and variable
ow rates. his design includes a exible impeller that rotates
in a xed cavity. he use of an oset cam causes the vanes on
the impeller to deect, decreasing the cell volume initially.
When the vanes leave the cam contact, the volume
increases between the vanes, and uid is drawn into the larger
cell cavity with the help of atmospheric pressure. As the impel-
ler rotates, it reduces the cell volume at the discharge port on
contact with the cam.
Wine Industry Pumps
By Keith Evans, Xylem Inc., Jabsco Flexible Impeller Pumps
Many different pump types can move food and beverages.
A portable, exible impeller pump used in wine production
COVER
SERIES
Each cavity then produces a nearly-even and perfect
smooth ow and is repeated on each revolution of the impel-
ler. hese pumps can transfer solids suspended in liquid. hey
are reversible and can be mounted above or below the liquid
source. he uid has contact with the rubber exible impeller
and the interior of the body housing. Pump bodies and mate-
rials, preferably, should be manufactured from sanitary stain-
less steel with sanitary rubber compounds. hese are positive
displacement pumps.
Rotary Lobe Pumps & External
Circumferential Piston Pumps
Rotary lobe pumps and external circumferential piston (ECP)
pumps, positive displacement pumps, oer high e ciency,
gentle pumping action and corrosion resistance. hese pumps
are reliable and can be cleaned in place (CIP) or steamed in
place (SIP). Rotary lobe pumps are capable of handling thick
or thin solids, liquids and paste products. Some models of
rotary lobe pumps perform well on self-priming if wetted.
hey can produce signicant pressure.
hese pumps, like FIPs, can have the direction of uid
ow reversed. Run dry capability is possible if the seals are
wetted during the run dry timeframe. Rotary lobe pumps
have two alternating direction rotating rotors that mesh in
operation. he uid or product ows into the pump and is
captured by the rotating lobes. he product is transferred in
the cavities around the outside of the lobe body. he product
does not eectively travel between the meshing actions of the
two lobes.
Centrifugal Pumps
Centrifugal pumps use gravity to push water into the pump
cavity, and the high speed of the pump impeller then dis-
charges the uid from the discharge port. hese pumps tend
to be the most e cient with a smooth, pulse-free delivery.
Minimal wear is associated with the pump components, the
impeller and pump head are generally easily disassembled.
Most centrifugal pumps are small, but can produce a high
volume of ow. Most can be obtained in AC and DC versions
and are relatively inexpensive. he main draw back to centrifu-
gal pumps is that they are not self-priming and may cavitate
easily. he most common form of centrifugal pumps is a radial
ow design.
Air-Operated Diaphragm Pumps
Air-operated diaphragm (AOD) pumps use air to power them.
he pump design is self-priming, capable of handling high
solids content, can run dry, is portable, explosion proof, has
Keith Evans, of Xylem Inc., is product manager, Americas,
for Jabsco Flexible Impeller Pumps. He can be reached at
keith.evans2@xyleminc.com.
a high pumping e ciency and can deliver a variable ow rate
and discharge pressure. One disadvantage is the requirement
to have an air compressor on hand for use. his is a positive
displacement pump.
Peristaltic Pumps
Peristaltic, or roller, pumps are positive displacement pumps
that transport uid inside a exible tube or hose in a circular
casing. A rotor rolls inside the tube, not making any contact
with the uid or product transferred. Operation of the pump
powers a piston through a chamber, opening a one way check
valve drawing uid into one part of the pump cavity. When the
air drives the piston back to its rst position, it opens another
one way check valve and discharges the uid from the cavity.
his type of pump can also handle solids.
Progressive Cavity or Eccentric
Screw Pumps
Progressive cavity or eccentric screw pumps transfer uids by
using a progressive cavity where the helical rotor turns inside
an inner housing. he stator, which is typically made of rubber,
is where the uid is contained in the cavity of screws until it
reaches the discharge end of the pump housing. he uid con-
tacts the screw and the rubber inner housing. his is a positive
displacement pump and is a good choice when pumping vis-
cous uids or at high pressures.
Motor- or Cam-Driven Diaphragm Pumps
Motor- or cam-driven diaphragm (MDD) pumps use a mul-
tiple diaphragm that is driven by an oset cam. he cam
positions one way valves to draw in uid on one cycle and
on the next cycle pushes open another one-way check valve
to discharge the uid. hese positive displacement pumps are
ideal for the home winemaker packaging reasonable volumes.
MDD pumps can handle high pressures, run dry, are self-
priming and are available in AC and DC versions.
The Final Decision
To make the best choice for the operation, consider the cost
and the value return. Often, a higher initial investment on a
pump will be benecial because it will last longer. If possible,
go with the best. If a winemaker produces small volumes, a
good low-cost pump can take care of the production needs.
P&S
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tions or uids containing solids?
Cartex
Seals are designed with

greater attention to functional
details and tighter tolerances for
longer running, more reliable seal
operation. Their robust cross sections have up to
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optimal seal stability and exceptional performance.
To nd out more on how to improve MTBF by
up to 25%, even in well-established ap-
plications, visit us at www.getcartex.com
or contact us at 800-303-7735.
To T
uu
p
H
andling emulsions can be challenging. Even their
basic denitiona mixture of two or more liq-
uids that are normally unblendablehints at the
di culties involved in creating and handling them. Still,
examples in which emulsions have been successfully cre-
atedranging from common milk to cutting uids used in
metal workingcan be found everywhere.
Latex is a complex but stable emulsion consisting of
polymer microparticles contained in an aqueous medium.
Like emulsions in general, latexthe most recurring image
of which is a latex gloveis present in many common prod-
ucts (paints, balloons, oor polishes and carpeting). Most
latexes begin as simple emulsions in which droplets of the
substance are added to water. his initiates a process known
as emulsion polymerization in which the nal product can
be called latex.
hough latexes are versatile and can be used to enhance
a products performance characteristicssuch as durability,
dimensional stability and chemical resistancethey require
precise manufacturing and handling processes. his article
identies and explains why air-operated double-diaphragm
(AODD) pumping technology is ideal for the demands of
latex handling.
The Challenges
Two basic challenges exist when pumping latex:
Latex emulsions are extremely shear-sensitive, requiring
pumps that reliably deliver a low shear rate.
Any contact with air will further polymerize the latex,
making it imperative that the pump feature a sealless
design. Also, pumps with mechanical seals usually require
ushing, which can create a possible leak path or dilution
of the latex solution.
Other pump characteristics that are desirable when han-
dling latex emulsions include dry-run capability, ability to
handle liquids with varying viscosities, from thin to high-
grade, self-priming operation, portability and easy cleaning
and maintenance.
A lesser consideration, but still important, is the climac-
tic conditions in which the latex emulsion will be created
and handled. Since most types of latex are incapable of with-
standing repeated freezing or thawing, they need to be stored
at temperatures above 40 F (5 C). hey should also not be
kept in temperatures above 100 F (30 C) for extended peri-
ods because they can become susceptible to surface drying
that will compromise their performance.
hrough the years, the search for the perfect pump to
handle latex emulsions has led manufacturers to experiment
with a number of dierent technologies, most of which
feature operational blind spots that negatively aect their
performance in latex-handling applications. Some of these
competitive technologies and their respective operational
drawbacks are:
Gear Pumps
hey are not recommended for shear-sensitive uids.
If used, they must be oversized and operate at low speeds.
Seals are prone to leakage.
A pressure relief valve is required on the discharge side of
the pump.
Centrifugal Pumps
hey are not recommended for, but known to be used
with, thin emulsions.
he seals must have a ush pan and/or be cooled to pre-
vent product buildup around the pump shaft.
A double mechanical seal or water seal with a packing
gland is required.
Low-ow operation can cause pump failure.
hey may require priming.
Progressive Cavity/Rotary Screw Pumps
hey can be expensive to maintain.
hey are di cult to disassemble.
A pressure relief valve is required on the discharge side of
the pump.
Viscous materials require an oversized pump operating at
low speed.
Efciency Matters
Latex Pumping
Challenges
By Edison Brito
Air-operated double-diaphragm pump technology delivers the shear-sensitivity and
leak-free operation required in this application.
hey have tight internal clearances.
hey cannot be run dry.
he seals are prone to leakage.
Circumferential Piston Pumps
hey are not recommended for shear-sensitive uids.
he multiple seals are prone to leakage.
Peristaltic (Hose) Pumps
hey are only suitable for low-ow applications.
The Solution
Positive displacement, air-operated double-diaphragm (AODD) pump technol-
ogy does not have the disadvantages of other technologies. Some AODD pumps
are ideal for latex-handling applications because they feature a sealless, bolted con-
guration that ensures total product containment. he design of the wetted path
reduces internal friction, enabling the pump to deliver the level of shear-sensitive
operation that is mandatory when working with latex. he AODD pumps positive-
displacement operating principle also guarantees that the product ow rate will
remain volumetrically consistent.
AODD pumps are available in several materials of constructionincluding
aluminum or 316 stainless steel, which is generally preferred when handling latex,
with PTFE elastomers. Some AODD pumps have other benets, including:
Air-Distribution System (ADS)Provides operational exibility through an
e ciency management system that allows the user to optimize the ADS for any
application demands.
Drop-in Pump ConigurationAllows a pump to be installed in an existing
footprint without the need to disturb the piping. hey have a larger ow path,
resulting in increased ow rates and decreased energy consumption.
Full-Stroke PTFE Diaphragmshe full-stroke design results in increased
product displacement per stroke, which translates into greater ow rates and
higher e ciencies.
Easy Install DiaphragmsSome pumps diaphragms that are made of ther-
moplastic elastomer are easy to install and are a low-cost alternative to PTFE
diaphragms when used in abrasive-handling applications. hey have a at-
prole design that eliminates the need to invert the diaphragm when rebuilding
a pump, allowing for easy, cost-eective installation.
hese benets also equate into energy savings because lower amounts of com-
pressed air are needed to maintain the desired ow rates and pressures. Latex emul-
sion is, and will continue to be, a crucial component in many industries and prod-
ucts, some of which are as common as the adhesive on the back of a postage stamp.
Sensitive handling characteristics make latex a di cult substance to pump. hrough
the years, manufacturers and handlers of latex emulsions have found that AODD
pump technology reliably provides the required operational principles.
P&S
Edison Brito is chemical market manager for Pump Solutions
Group (PSG) based in Downers Grove, Ill. He can be reached at
714-396-1502 or edison.brito@psgdover.com. PSG is comprised of
several pump brands, including Almatec, Blackmer, EnviroGear,
Griswold, Maag, Mouvex, Neptune, Quattroow, RedScrew and
Wilden. Wilden is the manufacturer of AODD pumps. For more
information, visit www.wildenpump.com.
Advance
Your
Production
Capabilities.
Advanced means more than
our product lines brand name. Its
our promise for Paint & Coatings
manufacturers.
t Drop-in design ts existing
pipe conguration
t Durable leak-free operation,
even when dead-heading
t Reduce energy costs with Pro-Flo X
Air Distribution System
Contact your authorized
Wilden distributor:
www.wildendistributor.com
22069 Van Buren Street
Grand Terrace, CA 92313-5607
USA
O: +1 (909) 422-1730
www.wildenpump.com
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S
uccessful alignment of rotating machinery depends sig-
nicantly on how much emphasis is put on the align-
ment preparation and planning stages. Proper machin-
ery alignment reduces the chance of an equipment failure,
helping end users avoid unnecessary downtime and exces-
sive maintenance time and costs. Preparing thoroughly and
choosing an appropriate alignment method can help ensure
a smooth process.
Prepare for Alignment
Before starting the alignment process, follow these steps:
Make sure that the mounting faces of the bedplate and
the rotating machine are free from paint, rust, weld spat-
ters, burrs or other debris.
hrow away any shims used during previous alignments
that are rusty, painted or damaged.
Check to see if the holes for the holding-down bolts are
large enough to allow adequate movement for alignment.
his helps avoid unnecessary delays later in the process.
Check the distance between the shaft ends and align
the machines approximately. You can do this by laying a
straight edge against the machines and ensuring that the
hub faces are parallel.
One issue that end users often overlook during align-
ment is the presence of a soft foot, where the machine is not
sitting evenly on the bedplate. his can twist the machine
frame, putting an unexpected load on the bearings and, ulti-
mately, causing the frame to fracture.
End users can detect a soft foot by mounting a bracket
carrying a dial indicator on one shaft and placing the plunger
on the second shaft, with all the holding-down bolts lightly
tightened. Next, work around the machine, fully tightening
the bolts and then slackening them one at a time. Any exces-
sive movement on the indicator signies the presence of a
soft foot, which will require that the end user t shims to the
machine before starting the alignment. Modern laser align-
ment equipment also often contains a program that can check
for soft foot without undergoing this manual procedure.
Preparation Checklists
he following checklists can help end users prepare thor-
oughly for alignment. he lists can be adjusted as needed to
suit specic machinery and the chosen alignment method.
Of-Site Checklist
Safety regulations
Working permits
Time limits for stopping production
Alignment tolerances
hermal osets
Available space
Shaft rotation
Shim sizes
Alignment system
Batteries, if required for laser equipment
Specications for the machine setup
Easy Shaft Alignment
By Peter Carlisle
Thorough preparation and the right alignment method are critical.
Maintenance Minders
Precise shaft alignment starts with John Crane
ENDtoEND Solutions for rotating equipment
John Crane has the products and expertise you need to couple and align your rotating
equipment properly. See for yourself why our designs are a leading choice for equipment
operators around the world.
On-Site Checklist
Machine serial numbers
Safety conditions
Available space
Foundation condition
Bedplate condition
Bolt condition
Adjustment capacity
Shim condition
Presence of leaks
Pre-Alignment Checklist
Machine temperature
Gross soft foot check
Replacement of old shims
Coupling assembly
Adjustment of any mechanical looseness
Run-out conditions
Pipe strain
Final soft foot check to adjust small errors after removing
gross soft foot
Repeatability test to ensure that tightening and loosening
the feet bolts gives consistent results; this test also checks
the condition of any shims or binding of bolts
Choose an Alignment Method
After preparing for alignment, end users must choose an align-
ment method appropriate for their machinery. Many align-
ment methods require brackets and arms for mounting the
measuring equipment. As the length of the arms increases, the
arms become more susceptible to sagging, which can cause sig-
nicant measuring errors if end users do not take the sagging
into account. Figure 1 illustrates the typical method to check
for sagging arms. End users should add the values they record
to the readings they take during alignment. he major methods
for checking alignment are discussed in this section.
Method 1Face and Periphery
he face and periphery method is the oldest and most widely
used dial indicator method. Figure 2 illustrates the correct
setup for this method, which is good for large-diameter hubs
with a short distance between shaft ends.
Advantages:
he end user only
needs to rotate one shaft.
Visualizing shaft positions is easier compared to other
methods.
Disadvantages:
It is di cult to obtain face readings if there is any axial
oat.
An end user typically has to remove the coupling.
It is more complicated to make the graphical calculations
compared with other methods.
Any out-of-roundness in the hub periphery or out-of-
squareness in the hub facemeaning the hub ange is not
round or at and square relative to the shaftwill aect the
readings.
Method 2Reverse Periphery (Indicator) Method
he reverse periphery (indicator) method is becoming increas-
ingly popular and is the optimal method for most alignments.
Figure 3 illustrates the correct setup for this method.
Advantages:
It is generally more accurate than the face and periphery
methods.
Axial oat, or out-of-roundness or out-of-squareness in the
hub, does not aect the readings.
It is easier to plot graphically compared with other methods.
It is possible to make measurements with the coupling in
place.
Figure 2. Open lineshaft, product-
lubricated
Figure 1. Check bracket and arm sag
1.800.SEALING | www.johncrane.com
Bearings
Couplings
Packing
Mechanical Seals
Gas Seals
Support Systems Filtration Systems
Maintenance Minders
Disadvantages:
End users must rotate
both shafts.
It is not accurate for
close-coupled shafts.
Method 3the
Laser System
he modern laser system
(see Figure 4) consists of
either two laser/detec-
tor units or one laser
and one mirror/prism
reector unit. One unit
is attached to each shaft,
and the laser/detectors
are connected to a key-
board/display unit by a cable or via a wireless Bluetooth system.
he system operates using the principles of reverse periphery,
detecting the movement of the laser beams as a measure of the
misalignment.
Advantages:
he system ts a variety of shafts.
End users do not have to remove the coupling.
End users can measure long spans with no sagging issues.
It is not aected by
axial oat.
he system detects
the soft foot condi-
tion easily.
Disadvantages:
he system is
not suitable for
couplings with
backlash.
Heat or steam can
aect its accuracy.
he system is
expensive.
Other Alignment Methods
Other alignment methods include shaft-to-coupling spacer,
optical systems and electronic indicators. For equipment with
long distances between the shaft ends, it is possible to t the
coupling and check the alignment of one shaft to the spacer
and then check the spacers alignment with the second shaft.
P&S
Figure 3. Reverse Periphery Method
Figure 4. Laser Alignment
Peter Carlisle is
John Cranes global
product line direc-
tor for couplings.
He joined Flexibox
in 1978. His work
with the company
has included design, application
and research on the fundamentals
of power transmission couplings.
He served as group engineering
manager and has held roles in sales
management and operations man-
agement. He has a bachelors degree
in mechanical engineering from the
University of Manchester, U.K., and
a diploma in marketing. Carlisle can
be reached at +44 161 886 6290 or
peter.carlisle@johncrane.co.uk.
John Crane is a provider of engi-
neered products and services for
major process industries, including
oil and gas extraction and rening,
power generation, chemical produc-
tion, pharmaceutical manufactur-
ing, pulp and paper production, and
mining. For more information, visit
www.johncrane.com.
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C
urrent directives to control fugitive emissions and
eliminate leakage altogether in piping and pressure
vessel assemblies have led to activities geared toward
fully understanding the intricacies that impact bolted joint
performance. While a bolted ange joint assembly appears
relatively simple in nature, joint integrity relies to a large
extent on the skill and application of the installer. Proper
inspection and selection of materials, along with a con-
trolled, safe, documented assembly technique are fundamen-
tal to ensuring a reliable bolted joint assembly. Currently,
industrial facilities and organizations are commonly develop-
ing general process and specic service bolting procedures
and practices. A common thread in the method is a six-step
approach:
1. Clean and examine assembly components
2. Align the anges
3. Install the gasket
4. Control fastener friction
5. Control bolt tightening
6. Compensate for relaxation
Clean and Examine
Assembly Components
Remove all foreign materials from the ange seating surfaces,
fasteners, nuts and washers using tools that will not damage
the equipment. Flange cleaning must take place in a path or
direction that corresponds with the serration path and not
across the serrations. Examine ange surfaces for any pitting,
corrosion, cracks, radial scores, heavy tool marks or anything
that could prohibit proper gasket seating.
Where possible, use a straight edge to check for warp-
ing. Remove old paint and lubricant from the nut-bearing
surface of the anges. Examine the fasteners, nuts and wash-
ers for defects, such as burrs or cracks. Nuts should run freely
past the point on the fastener where it will come to rest after
it is installed and tightened. If possible, repair equipment
that is out of optimal condition. Extensive out of tolerance
conditions may require equipment replacement.
Align the Flanges
Align the ange faces and bolt holes without using exces-
sive force, reporting any misalignment in which more force
than can be exerted by hand or spud/pin wrenches. Where
alignment is not possible without excessive force, acceptable
aligning methods include replacement by removing and rein-
stalling the equipment in the properly aligned position or
using uniform heat to relieve the stresses.
Proper alignment of all joint members is at the core of
bolted ange connections. Proper alignment enables maxi-
mum seating surface contact, maximum opportunity for
even gasket loading and reduced friction between the nut
and the ange.
Install the Gasket
Ensure that the gasket is the specied size and material for
the assembly. Make sure that the gasket is free from defects.
It should be transported to the job site in a way that keeps it
protected, up to and including the time of installation.
Fasteners and washers should be checked for proper
diameter, length, threads per inch, grade and condition.
Carefully insert the gasket, centering it appropriately between
the anges. Do not force the gasket into place.
Some large gaskets may require the use of an adhesive
to hold it in place. he adhesive should be approved by the
manufacturer, the process engineers and the metallurgist.
Grease, tape, petroleum, gasket compounds or release agents
are not recommended for this purpose. Care should be taken
to keep any unwanted materials out of the process.
Fasteners should be placed into the bolt holes in a way
that protects the threads. Nuts should be assembled with
the at bearing surface against the ange or washer. When
assembled, the fasteners should have the same prole on both
What are the current industry best practices for the assembly of bolted
ange connections?
This months Sealing Sense was prepared by FSA member Joel Baulch.
From the voice of the uid sealing industry
SEALING SENSE
FSA Sealing Sense
sides, passing through the
ange at right angles. he
washers should rest paral-
lel to the ange surface.
Bring the anges together
slowly, squarely and
gently, ensuring that the
gasket is not pinched or damaged.
Control Fastener Friction
Use a specied or approved lubricant suited to the service.
Apply the lubricant generously and uniformly to all contact-
ing thread, nut and washer load-bearing surfaces. Except when
installing into tapped holes, apply lubricant after the fastener
is installed in the anges to ensure that contamination of the
ange or gasket face does not occur. Always lubricate an end
where a nut is to be turned, and always apply enough lubri-
cant to ensure that the nut does not run dry before it is tight.
Apply lubricant to the side of the washer that is against the nut.
Applying lubricant to both sides merely ensures that the correct
side is lubricated.
Bolt Tightening Control
he use of manpower to tighten the bolts, by sledgehammer,
striking wrenches and
pieces of pipe on the
end of the wrench is not
recommended, since
this oers no accuracy.
Consult the torque or
tightening specications
from the gasket manufacturer or the companys engineering
department for guidance. First, contact the gasket using only
su cient force to lightly tighten the fasteners and stabilize the
assembly.
Tighten the fasteners in a star or cross-bolt pattern (see
Figure 1), checking to ensure that the ange remains even at
ninety-degree intervals. No signicant gasket compression
should be occurring at this stage.
Once the assembly is stabilized, apply only a medium
tightening force (30 to 50 percent of the target load) using
the same star or cross-bolt pattern. In the next pass, increase
the force to an ample but restrained force (60 to 70 percent of
the target load) using the same star or cross-bolt pattern. hen
increase the force to approach full force (90 to 100 percent of
the target load) using the same star or cross-bolt pattern. Apply
full target load to all nuts in a circular pass, continuing until all
the nuts no longer turn.
For safety reasons, any retightening of
bolts must be done with the system off
and the gauge pressure at zero.
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Practice & Operations
T
his article discusses the operating conditions and
design limits; applications for single seals, tandem
seals, tandem seals with intermediate labyrinth and
double seals. It also explains tandem seals versus double seals.
To select a dry gas seal conguration, the operating con-
ditions and design conditions must be determined. Both the
operating conditions and the design conditions will inuence
the type of seal used for an application. To ensure a depend-
able dry gas system, seal conditions that must be identied
are normal sealing pressure, maximum sealing pressure, oper-
ating temperature, seal design temperature and process gas.
Normal Sealing Pressure
he rst factor to be identied is the normal sealing pres-
sure. his is the pressure that the seal must contain within the
compressor during normal operation. For beam-style com-
pressors, this is typically suction pressure. However, some
congurations, such as back-to-back compressors, can have
higherthan-suction sealing pressures. For overhung-style
compressors, the sealing pressure is somewhere between suc-
tion and discharge. he discharge pressure gas decreases in
pressure as it moves down the backside of the compressor
impeller to the seal location.
herefore, based on the design of the compressor, the
actual sealing pressure must be conrmed with the compres-
sor manufacturer. Knowing the actual sealing pressure will
provide accurate leakage information to reference during
operation and for designing the seal monitoring system.
Maximum Sealing Pressure
he next pressure information needed is the maximum seal-
ing pressure, typically the design pressure for the seal. Since
the discharge pressure is the maximum pressure identied for
the compressor, this could be used for the maximum sealing
pressure. Seals will typically never seal the discharge pressure
of the compressor, so the pressure rating will be much higher
than the maximum operating pressure of the seal. Designing
the seal to discharge pressure can also be expensive.
For example, there is usually a price change for seals at
about 1,500 psi to 1,700 psi, depending on the manufac-
turer and then another price change at about 3,000 psi to
3,300 psi. Verifying the maximum sealing pressure required
for the application can lower the cost of the seal. Usually,
the seal will never operate at higher than the settle-out pres-
sure of the compressor, estimated at the mid-pressure point
between suction and discharge pressure. Normally, this is an
estimate since the volume of gas upstream and downstream
of the compressor to the unit valves will inuence the settle-
out pressure.
A larger volume of gas from compressor to discharge
valve compared to the volume of gas from the compressor to
suction valve will result in a higher than midpoint settle-out
pressure. If the larger volume of gas is on the compressor to
suction-valve side, then the settle-out pressure will be below
the midpoint. If the discharge pressure is below the 1,500
psi to 1,700 psi for lower-pressure applications or 3,000 to
3,300 psi for higher-pressure applications, then using dis-
charge pressure as design pressure is not a big concern. If
settle-out and discharge pressures straddle the identied pres-
sure, then more time may be required to identify the actual
design pressure for the seal.
Settle-out pressure can also eect the decision to use a
tandem seal or a double seal. herefore if the application is
low-pressure and/or for a dirty gas, identify the true settle-
out pressure. Choosing a double seal for these services can
provide a much more reliable seal. For dry gas seal applica-
tions, low pressure is below 100 psi.
Operating Temperature and
Seal Design Temperature
he next step is to identify the actual operating temperature
and the seal design temperature. On a beam compressor,
the suction-end seal and discharge-end seal will operate at
dierent temperatures. No compressor original equipment
Seal Conguration
Selection
By Glenn Schmidt, EagleBurgmann
Choose the correct seal to meet the application requirements.
Fourth of Six Parts
manufacturer (OEM) can provide an exact temperature for the
seal operating temperature because typically no temperature
probes are at the seal, so the operating temperature is assumed
to be somewhere between the process gas temperature and the
bearing temperature.
Standard seals, from most manufacturers, can manage
temperatures of 300 F to 350 F. If the discharge temperature
is below this, then use the discharge temperature as the seal
design temperature. If the discharge temperature is above this,
then more time may be required to identify the actual design
temperature if eliminating unnecessary costs is a concern.
he other point about seal design temperature is seal supply
gas temperature. If there is an issue with the dew point of the
seal supply gas, then the gas should be heated to manage the
dew point. he temperature of the seal gas should be consid-
ered when identifying the seal temperature rating. As indicated,
seal temperatures are somewhere between process gas and bear-
ing temperature. If the seal experiences discharge temperature,
the bearing must be designed to handle this temperature as well
because the seal is not far from the bearing.
For minimum seal temperature, identify both the ambi-
ent temperature and the minimum compressor suction tem-
perature. Use the lower of these temperatures as the minimum
seal temperature. Typically, uorocarbon O-rings (the standard
material used in dry gas seals) have minimum temperature rat-
ings of -4 F to -20 F. Dierent types of vendor-specic uoro-
carbon O-rings are available to manage minimum tempera-
tures. If the minimum seal temperature is -4 F or lower, make
sure that the O-rings used are suitable for the application. his
is also why it is important that the O-rings in a seal are provided
by the seal manufacturer rather than purchased from an O-ring
supplier. Features in the O-ring material or even dierent types
of uorocarbon must meet the demands of the seal and appli-
cation. Using the incorrect material or a dierent uorocarbon
than originally specied can result in seal failure.
As indicated previously, the seal operating temperature
is somewhere between process temperature and bearing tem-
perature. If a minimum-rated process temperature is identied
below -50 F, the low-temperature rating should be conrmed
with the seal vendor and compressor manufacturer.
Process Gas
Now that the operating and design temperatures have been
identied, the process gas must be analyzed. Is the process gas
hazardous or ammable? Is the gas toxic? Examples of non-haz-
ardous gases are air, nitrogen and carbon dioxide. Examples of
hazardous or ammable gases are methane, ethylene or propyl-
ene. Toxic gases, such as gas with hydrogen sulde, are dened
as gases composed of components dangerous to humans and
the environment.
Once the gas is identied, the next questions are:
Is full containment of the process gas required?
What environmental or safety concerns must be considered?
Can an outside gas be introduced into the process from the
seal supply?
What is the minimum pressure available for the outside gas?
An outside seal-gas source is benecial if the process gas
is toxic, dirty or wet. If a reliable source, at su cient pressure,
is available and compatible with the process, using an outside
seal-gas source can eliminate an expensive conditioning system.
Figure 1. Single seals feature a single set of seal faces in a car-
tridge or component seal and are ideal for use in non-hazardous
applications.
Figure 2. Tandem seals have two sets of seal faces in the seal car-
tridge and are typically used in hazardous pipeline applications.
Seal Congurations and Applications
Temperature, pressure and process gas will change the features
and sealing elements in a dry gas seal cartridge. hese elements
can also aect the type of seal selected, the cost of the seal, the
system and the reliability of the system. herefore, the seal fea-
tures and the benets provided by seal vendors must be known
to understand how they will impact dry gas seal reliability and
support the sealing application through all operating condi-
tions. Carefully analyze the sealing application and work with a
knowledgeable seal vendor to make sure the best seal congura-
tion is selected for your application. his section outlines each
seal type and where it is typically used.
Single Seals
Single Seals (see Figure 1) are a single set of seal faces in a car-
tridge seal or a component seal. Single seals are the only seal
conguration that uses components, as all other seal congu-
rations are too complex to install with components. Because
they only have one set of seal faces, single seals are used in non-
hazardous processessuch as moving air, nitrogen and carbon
dioxide.
Sometimes, single seals are used with integrally geared
compressors due to space constraints for hazardous applica-
tions, but only after all other options have been eliminated.
For integrally geared compressors, the gas is typically non-
hazardoussuch as air or nitrogen. A less e cient lower-cost
seal can be used for these applications because the loss of nitro-
gen or air is not a concern. When selecting equipment, if total
life-cycle costs are part of the companys philosophy, it should
pay attention to the seals used in non-hazardous applications.
he energy savings from improved compressor e ciency and
reduced seal-gas consumption can easily pay for the cost of dry
gas seals and systems.
Tandem Seals
Tandem seals (see Figure 2) are typically used in pipeline appli-
cations. A tandem seal conguration has two sets of seal faces
in the seal cartridge. he second set of seal faces (the secondary
seal) backs up the rst set (the primary seal) if the primary seal
fails. his allows containment of the process gas, so that the
compressor can be safely shutdown and vented.
In a tandem seal, the secondary seal will operate on a
small portion of the gas leakage from the primary seal, so small
amounts of process gas will leak out of the primary and second-
ary vent ports on the compressor.
he rst type of dry gas seal installed was a tandem seal
conguration. his was in a pipeline application where tandem
seals are most commonly used, even today. he other appli-
cation where tandem seals are commonly used is low-pressure
hydrogen applications.
Tandem Seals with Intermediate Labyrinths
Tandem seals with intermediate labyrinths (see Figure 3) are the
most commonly used seal. An additional port and labyrinth,
between the primary seal and secondary seal, allow for the
supply of inert gas to the secondary seal. Any leakage from the
primary seal is ushed out the primary vent, allowing for easier
management of the gas leaking from the primary seal.
his feature makes these seals ideal for hazardous or toxic
service. he intermediate labyrinth also provides a restriction
in the event of a primary seal failure or catastrophic/total-seal
failure (primary and secondary seal failure). his allows for
safer operation in high-pressure applications. his congura-
tion should be used for all high-pressure applications. hese
seals also provide higher safety when used in standard sealing
applications.
Double Seals
Double seals (see Figure 4) are usually used in low-pressure
applications (100 psi is dened as low pressure for compressor
seal applications) and dirty, wet process gas applications. heir
conguration consists of two sets of seal faces opposing one
another. Because tandem seals were the rst dry gas seal cong-
uration to be installed, end users are hesitant to specify double
seals. he argument is that tandem seals are the proven tech-
nology, but double seals are the better technology in specic
applications. hey can provide a reliable compressor seal when
applied correctly and can prevent failures from reverse pres-
sure, which results when a tandem seal is used in low-sealing-
pressure applications. Reverse pressure for a tandem seal results
when the vent pressure is higher than the sealing pressure. If the
sealing pressure is a vacuum then reverse pressure can occur. If
the vent pressure can increase to a pressure greater than sealing
pressure, reverse pressure in a tandem seal will occur.
Figure 3. Tandem seals with intermediate labyrinths have an
additional port and labyrinth that supply inert gas to the second-
ary seal to allow for use with hazardous and toxic gases.
An example is when the primary seal vent line is connected
to the are. he are line conditions can result in the seal vent
pressure being higher than the sealing pressure. Under these
conditions, a tandem seal will be reverse pressured, and a seal
failure will occur. With the double seal, this can be eliminated.
he pressure of a double seal is limited to the seal-gas supply
pressure that is available.
Because double seals are typically used for dirty/wet ser-
vices, the seal needs an outside source of seal gas. his seal gas
must always be approximately 50 psi higher than the process
gas pressure being sealed. Since the source pressure is seal-
vendor and application specic, always contact the seal vendor
about seal-gas supply pressures. When the dry gas seal has been
set-up correctly, double seals can oer many years of reliable
operation in dirty/wet service.
Double seals can also be used for pressures greater than
100 psi, when a seal supply gas is available at su cient pres-
sure. Do not rule out discharge gas as a seal gas source. If the
discharge gas can be ltered economically and eectively, it can
be a reliable source to use for the double seal and provides a
much more dependable dry gas seal system. his eliminates the
concern of injecting nitrogen or another gas that may not be
compatible with the process.
Seal Selection Guide
his section covers the pressure, temperature, speed and appli-
cation for each seal conguration. Keep in mind, the limits for
seals continue to be pushed. Contact a qualied seal vendor
when applications are close to or beyond the limits identied.
Advancements with sealing technology continues. Also, each
seal vendor will have dierent limits for their seal designs. he
limits listed in this section are only general guidelines.
Single Seals
Non-hazardous applicationsair, nitrogen, CO
2
Pressure capabilities to 1,750 psig (Possible for use with
higher pressures, but there are safety concerns with using a
single seal at higher pressures.)
Temperature: -270 F to 410 F
Speeds to 660 feet per second
Tandem Seals
Hazardous applicationspipeline, hydrogen or high-pres-
sure, non-hazardous gas
Pressures to 8,700 psig
Tandem seals with intermediate labyrinth
Hazardous and toxic applications or high-pressure
applications
Pressures to 8,700 psig
Double Seals
Low-pressure applications (Hazardous or toxiccoker
compressors, wet gas compressor, sour gas)
Typical application pressure of - 250 psig (Possible pressure
to 1,000 psi for standard seals and systems or 1,500 psig
with special considerations)
Temperature: - 40 F to 350 F
Authors Note: For more information on identifying maximum
sealing pressure, please reference, Calculating Settle-out Pressure in
Compressor Loops, Hydrocarbon Processing, November 2006,
or discuss it with your engineering company.
he fth article in this series will discuss the instrumentation
systems used with dry gas seals.
P&S
Glenn Schmidt is EagleBurgmanns
regional compressor seal specialist support-
ing the American region with technical
and sales support for designing, servicing,
repairing, troubleshooting and upgrades
of dry gas seals and systems. His 16 years
of experience with dry gas seals includes
instructing a Texas A&M dry gas seal systems course and
providing input as a member of the API 692 committee
developing the standards for dry gas seals and systems. He
can be reached at glenn.schmidt@us.eagleburgmann.com
or 713-939-9515.
Figure 4. Double seals consist of two sets of seal faces oppos-
ing one another and are used in low-pressure and wet or dirty
applications.
L
ate in 2010, a packaged pumping system
manufacturer provided a packaged pump sta-
tion unlike anything it had built in the past.
Scappoose, Ore., needed to upgrade its wastewater
treatment plant. he consulting engineer required a
pump station that would provide continuous, vari-
able ow from its existing clariers while maintain-
ing an operating range of 12 inches when pumping
to a new lter station.
The Design Solution
Because of geological restraints, the only avail-
able site for the pump station was a narrow space
between an existing road and previously installed
process equipment. he packaged system provider
proposed a version of its system used for submers-
ible pumps, buried below grade. he wetwell with
an integral valve vault was made from berglass
and included an aluminum lid with access hatches.
Because the station was only partially buried, the
company was able to include safety handrails around
the top perimeter for operator safety and a jib crane
for equipment removal inside the station.
An Issue with the Sun
he package was completely assembled at the providers facil-
ity and delivered to the jobsite in one piece. he contractor
provided installation, and the city was pleased with the qual-
ity of the station and the operation of the equipment.
However, one small problem existed that no one had
consideredthe sun. In Oregon, when the sun shines most
people are happy. At the Scappoose WWTP, when the sun
shone it meant that the operators had to wait for a dark cloud
or dusk before they could work on the control system for the
station.
he control panel provided was well optioned with a
PLC and touch screen human machine interface (HMI) that
was enclosed in a NEMA 4X stainless steel, dead front enclo-
sure. However, once the dead front was opened to access the
PLCs HMI, it was di cult to read on a sunny day. Since
this panel faced virtually due east, even on slightly overcast
days, reading the display was di cult. Working with pumps
or other equipment with a touch screen control system that
is located outside can be problematic. Sun glare, driving rain,
panels located remotely from the equipment are just a few
Advanced Technology
Provides Control
and Mobility
By Chris Suskie, PumpTech, Inc.
Control via an iPad helps solve packaged pumping system problems.
Testing the Scappoose lter lift station with the mobile HMI.
extenuating circumstances that will make a nice installation dif-
cult to operate.
A Solution for the Glare
For this reason, the packaged system provider decided to solve
these control problems and unlocked a new way to establish
onsite mobility and document manage-
ment. his HMI ts right into the opera-
tors hands and can be taken anywhere and
used at anytime. his was the beginning of
a roving HMI and document management
system designed to run on Apples iPad
platform.
hanks to the evolution of PLC
technology for pumping control systems,
control panel novices have a much easier
time operating, maintaining, adjusting and
understanding their control systems. his
is in large part due to a general understand-
ing of how to operate a personal computer.
Computers make more sense to end users
than ice cube relays, wire, switches and
schematics. A PLC gives much the same
feeling as a computer and many more
options for controlling a system than a row
of relays. However, all this technology is
useless if the end user cannot see the screen to operate it.
Many PLC manufactures have a remote access program
that can be used on a laptop computer to connect to the PLC.
he problem is that most of these programs provide the data that
the PLC has collected and some ability to change the operating
Testing the Mobile HMI in the sun

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parameters, but the end user experience is much dierent than
standing in front of the control panel and operating the system.
he screens look dierentnot to mention a laptop is not a
touch screen. he biggest problem is that a laptop computer,
while easier to carry than a desktop computer, is still not ideally
mobile. Walking around with a laptop while typing is not easy.
he goal was to use a mobile device that more closely
resembled the PLCs touch screen HMI so that the opera-
tors felt as if they were holding the HMI in their hand. his
would also give operators onsite mobility that eectively cut the
umbilical cord between control panel and operator.
he Apple iPad was the best choice for making this happen
since it is currently the most widely used tablet on the market.
he packaged system providers team and an application pro-
grammer made the idea a reality. One year later, the application
for the iPad was completed. During the year, several features
were added and a second application was developed for man-
aging and sharing the important documents pertaining to the
pump system.
he HMI allows end users to use their iPads to connect
to the PLC in their control systems. It works exclusively with
certain color touch panel PLCs. It connects to the PLC via a
local WiFi router that does not require an internet connection.
he onsite mobility allows operators to move freely through-
out their plant or station while monitoring or controlling the
application. hey can watch dierent parts of a process while
maintaining full control of the PLC. Never again will they have
to stand outside in the rain to access their system. Sunlight will
not aect the visibility of their iPad as it does with outside,
panel mounted screens. he best part of this system is that the
iPad becomes the HMI and the graphics and controls render-
ing are the same as on the actual PLC. his allows the operator
to switch from the mobile HMI to the PLCs HMI and back
seamlessly.
he document management application works directly
with the mobile HMI to create a document management
system unique for each piece of equipment to which the PLC
is connected. It is a dynamic system because the operator and
the pump station manufacturer share important documents
regarding the pump station. he documents in the document
management system are cached or stored on the iPad for o ine
use. his ensures that the operator will always have schematics,
operation and maintenance checklists, photos, spread sheets,
Microsoft Word documents and pdf les that are pertinent to
each piece of equipment when and where they need it.
he HMI and document manager can be connected to
as many PLCs as the owner has and can be expanded to con-
trol each future PLC. his allows for a cost-eective expansion
when the operator decides to upgrade or add additional equip-
ment. Additional options are also available that give end users
osite or remote access to each PLC.
The Freedom of Mobility
For Scappoose, the roving HMI for the iPad has solved a major
problem that did not have many cost-eective solutions. By
putting the PLCs HMI on an iPad, the operators can now con-
trol and monitor their lter lift station and enjoy the freedoms
of onsite mobility. hey are able to check the system without
opening the dead front panel, move directly over the wet well
and watch the pumps operate while reviewing the trending
chart rendering on the iPad. Also, they can sit at their desks
and log in the pumps hours of operation.
P&S
Chris Suskie is the vice president of
PumpTech, Inc. He can be reached at
csuskie@pumptechnw.com or 503-659-
6230. For more information about pack-
aged pumping systems and onsite mobility,
visit www.pumptechnw.com.
Advanced Sealing International (ASI) 110 19
Advanced Engineering Pump, Inc. 140 53
Baker/Haight Pump 118 32
Bartlett Bearing Company 141 54
Blacoh Fluid Control, Inc. 120 9
Blue-White Industries 111 15
Boerger LLC 142 55
Cashco, Inc. 112 12
Dan Bolen & Associates 143 53
Darby Electric Company 144 55
EagleBurgmann 121 37
Frost & Sullivan 130 51
Graco, Inc. 122 34
Graco, Inc. 126 42
Hayward Flow Control 107 1
Hydraulic Institute 131 51
John Crane Inc. 113 40-41
Jordan, Knauff & Company 132 44
Junty International LLC 145 54
KNF Neuberger 123 26
Load Controls, Inc. 114 23
Load Controls, Inc. 147 55
LobePro 146 54
Maag Automatik, Inc. 133 44
MasterBond Inc. 148 55
Meltric Corporation 149 53
MET Motors 134 45
MINExpo International 100 21
Nidec Motor Corporation 101 3
NSK Americas 102 7
Primax Pumps 103 IBC
Pump Pros 124 30
Pump Solutions Group 125 39
Pumping Machinery 150 55
R+W America Technology 115 33
Scenic Precise Element, Inc. 151 54
seepex, Inc. 116 11
SEW-Eurodrive, Inc. 104 5
Sims Pump Co. 108 17
Sims Pump Co. 108 54
Smith & Loveless, Inc. 105 IFC
Summit Industrial Products 119 27
Thomas Pump & Machinery, Inc. 157 53
TouchSensor 152 53
Trachte, USA 135 36
Tuf-Lok International 153 54
Varisco 154 55
VERTIFLO 155 54
Vesco 156 53
Watson-Marlow Pumps Group 136 45
Worldwide Electric Corp. 117 16
Xylem USA 106 BC
* Ad index is furnished as a courtesy and no responsibility
is assumed for incorrect information.
Advertiser Name R.S. # Page Advertiser Name R.S. # Page Advertiser Name R.S. # Page
INDEX OF ADVERTISERS
PUMP USE RS MARKETPL ACE
800.433.7642 meltric.com
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(www.thomaspump.com)
is seeking qualied candidates for the
following positions:
Senior Inside Application Engineer
(Slidell, Louisiana)
Individual must be able to prepare
detailed quotations using Centrifugal
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Outside Sales Engineer (Alabama)
Self-starter to call on food, paper, and
industrial accounts selling Thomas
Pump pitot tubes and wastewater
pumps. Salary, commission, and
expenses.
Centrifugal Pump Engineer or
Engineering Firm for contract engi-
neering services. (Slidell, Louisiana)
Excellent company benets.
Salary based on experience.
Resumes:
MAIL: TPM/PERSONNEL, PO Box 2530,
Slidell, LA 70459
EMAIL: tpump@thomaspump.com
FAX: 985-649-4300
Serving the Pump & Rotating
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Specializing in placing:
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Email: danbolen@mindspring.com
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P&S Market
P&S Market
T
he Jordan, Knau & Company (JKC) Valve
Stock Index was down 4.2 percent over the last
12 months, below the broader S&P 500 Index
which was down 0.3 percent. he JKC Pump Stock
Index was down 27.6 percent for the same time period.
he Institute for Supply Managements Purchasing
Managers Index (PMI) registered 53.5 percent in May,
a modest decrease from April, indicating that manufac-
turing sector growth continues but at a slightly more
modest pace. he New Orders Index continued its
growth trend registering 60.1 percent, increasing 1.9
percentage points over April. he Prices Index fell to
47.5 percent, dropping 13.5 percentage points. New orders
increased for 13 out of 18 sectors including fabricated metals,
electrical equipment, computers, machinery and chemicals. In
addition, 13 sectors reported growth in employment.
he U.S. economy grew slower during the rst quarter
than previously reported. he Bureau of Economic Analysis
revised the real gross domestic product (GDP) growth in the
rst quarter from 2.2 percent to 1.9 percent.
he Bureau of Labor Statistics reported that the economy
added 69,000 net new jobs in May, the smallest increase in a
year. he private sector added an average of 105,000 jobs during
the past three months. However, the gains remain disappoint-
ing compared to prior economic recoveries. he unemployment
rate edged slightly higher to 8.2 percent.
Global oil markets have loosened in recent months, as
world oil production outpaced consumption by 0.7 million bar-
rels per day (BPD) in the rst quarter of 2012. he U.S. Energy
Information Administration expects world oil production to
exceed consumption by 1.2 million BPD in the second quarter
of 2012. West Texas Intermediate (WTI) crude oil spot prices
averaged more than $100 per barrel during the rst four months
of 2012. he WTI spot price fell from $106 per barrel on May
1 to $83 per barrel on June 1, reecting market concerns about
oil demand growth due to poor economic indicators in Europe,
China and the U.S.
On Wall Street, the Dow Jones Industrial Average and the
S&P 500 Index dropped more than 6 percent in May, while the
NASDAQ Composite Index declined more than 7 percent. he
weakness was fueled by fears of a slowing U.S. economy and
escalating concerns about the Eurozone debt crisis, with Spain
and Greece keeping contagion worries front and center. he
Dow and NASDAQ logged their worst monthly performances
since May 2010, and the S&P 500 posted its biggest monthly
loss since September 2011.
P&S
Wall Street Pump and
Valve Industry Watch
By Jordan, Knauff & Company
Jordan, Knau & Company is an investment bank based in
Chicago, Ill., that provides merger and acquisition advisory
services to the pump, valve and ltration industries. Please
visit www.jordanknau.com for further information.
Figure 2. U.S. Energy Consumption and Rig Counts
Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates. he
JKC Pump and Valve Stock Indices include a select list of publicly-traded companies involved in the pump
and valve industries weighted by market capitalization.
Source: U.S. Energy Information Administration and Baker Hughes Inc.
Figure 3. U.S. PMI Index and Manufacturing Shipments
Source: Institute for Supply Management Manufacturing Report on Business and U.S.
Census Bureau.
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Figure 1. Stock Indices from May 1, 2011 to April 30, 2012
WERE BOTH COMMITTED TO EXCELLENCE.
SO ITS ONLY NATURAL WE JOINED FORCES.
Allight and Primax have joined forces to offer you even better service.
www.allightprimax.com
The Allight name is already synonymous with high-
quality lighting towers and dewatering solutions.
And Primax has been a major player in the global
pump market for more than 40 years. With a shared
passion to deliver the highest quality, heavy duty
solutions for the worlds toughest mining and
construction applications, Allight and Primax are
now united under the new ALLIGHTPRIMAX
branding banner.
The ALLIGHTPRIMAX brand is all about quality,
product knowledge and a thorough understanding of
customer service, which only comes with time.
To recieve more information about the complete
services available email us at sales@allightprimax.com
or contact our sales department at 1.803.328.2035.
In the tradition of groundbreaking innovations comes
Flygt Experior

Welcome to a new era in wastewater pumping. Where engineering excellence and
a pioneering spirit combine with an unmatched understanding of your needs. The
result is Flygt Experior, a uniquely holistic experience that combines state-of-the-art
hydraulics, motors, and controls.
Today, Flygt Experior combines N-technology hydraulics and its adaptive functionality,
premium efciency motors and SmartRun the all-new intelligent control. Flygt Experior
comes from years of listening to you and applying our knowledge and expertise, to
develop the most reliable and energy-efcient wastewater pumping. It is therefore the
ultimate in our commitment to you.
Flygt Experior. Inspired by you. Engineered by us.
ygt.com/FlygtExperior
Flygt is a brand of Xylem, whose 12,000 employees are dedicated to addressing
the most complex issues in the global water market. Lets solve water.

July Pump

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