MPT

Don’t Be Misled by
FEBRUARY 2018

Vibration Data
How to Choose the
Right Gasket
Modern Pumping Today ®
The Internet of Things
Providing Solutions for the Worldwide Pump Industry Meets the Pump Market

www.modernpumpingtoday.com
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FEBRUARY 2018
22 30
MPT
Modern Pumping Today ®
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266

@ModPumpMag

JEFF FLETCHER Publisher

jeff@modernpumpingtoday.com
38
J. CAMPBELL Editor
jay@modernpumpingtoday.com

TONYA BROWNING Associate Publisher

tonya@modernpumpingtoday.com

DAVID MARLOW Account Executive

davidm@modernpumpingtoday.com

LISA AVERY Art Director

INGRID BERKY Office Manager

A NOTE ON THIS ISSUE:
Thank you for picking up this issue of MPT! This month’s
edition shows off both the versatility and reliability of
equipment available in the industrial pump and rotary
SUBSCRIPTION
inquiries or changes:
equipment markets. Of particular interest is the feature
“How to Choose the Type of Gasket to Use” (pg. 38) 205.380.2048
by Mike Shorts, past president of the Fluid Sealing
Association, wherein you’ll learn best practices for
matching gasket material to your application.
Submersible pumps are known for their reliability, J. Campbell, Editor
but even the sturdiest of equipment wears down. In this Modern Pumping Today
issue’s SWPA Insight (pg. 14), SWPA Executive Director
Adam Stolberg and SWPA’S Vice President Clark
Henry from Environment One Corporation tackle this crucial issue in “Repair or www.highlandspublications.com
312 Lorna Square | Birmingham, Alabama 35216
Replace? Evaluating Your Aging Submersible.”
866.251.1777
One of the highlights from this past fall’s WEFTEC was seeing the new
generation of smart pumps up close on the exhibit floor. In this month’s Pumping TIM GARMON RUSSELL HADDOCK
Trends (pg. 44), Joanne Goh, a researcher at IHS Markit, shares her insights on CEO/President COO/Publisher
how the internet of things will intersect and influence the pump market.
CHRIS GARMON DONNA CAMPBELL
CFO VP, Editorial

EDITORIAL ADVISORY BOARD:

Terry Bell Product Manager, Baldor Electric Company
Heinz P. Bloch, P.E. Consulting Engineer, Process Machinery Consulting
Robert G. Havrin Director of Technology, Centrisys Corporation
Michael Mancini Consultant and Trainer, Mancini Consulting Services
John M. Roach Engineering Manager for New Product Development, Trebor International,
Inc.: A Unit of IDEX
Lisa Riles Business Development Manager, Wastewater Pumps, Xylem Inc.: Flygt
Frank Knowles Smith III Executive Vice President, Blacoh Surge Control
Greg Towsley Director of Regulatory and Technical Affairs, Grundfos
Trey Walters, P.E. President, Applied Flow Technology
No part of this publication may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopy, recording, or any information
storage-and-retrieval system without permission in writing from the publisher. The
views expressed by those not on the staff of Modern Pumping Today, or who are
not specifically employed by Highlands Publications, Inc., are purely their own. All
Industry News material has either been submitted by the subject company or pulled
directly from their corporate website, which is assumed to be cleared for
release. Comments and submissions are welcome, and can be submitted to
jay@modernpumpingtoday.com.
CONTENTS
INDUSTRY NEWS
6 What's happening in the industry

TRADE SHOW PROFILE

12 Asia Turbomachinery and Pump Symposium

SWPA INSIGHT
14 Repair or Replace? Evaluating Your Aging Submersible

CASE STUDIES
16 Cruise Liner Finds the Right Seal for Booster Pumps
18 Don’t Let Vibration Data Mislead You

WATER & WASTEWATER FOCUS

22 Wastewater Facility Upgrades Prove Their Worth

MAINTENANCE & RELIABILITY

26 Soil Sampling for VOCs: Best Practices Part 2 of 2

PUMP SOLUTIONS
30 Improving Pump and Centrifuge Performance in Crude Oil
Tank Bottom Cleaning and Drilling Solids Control Part 2 of 2

MOTOR SOLUTIONS
34 Extending the Life of Precision Components in
Demanding Applications Part 2 of 2

SEALING SOLUTIONS
38 How to Choose the Type of Gasket to Use

MODERN PUMPING PRODUCTS

42 Featured Product: SUNDYNE'S API 682 and API 685
Upgrades for LMV 801 Line of Direct Drive Pumps

PUMPING TRENDS
44 The Internet of Things and the Pump Market
INDUSTRY NEWS

NETZSCH ANNOUNCES NEW REGIONAL SALES TENCARVA ACQUIRES ASSETS OF SALADIN PUMP
MANAGER FOR THE CENTRAL REGION AND EQUIPMENT
Netzsch Pumps North America, LLC has expanded its Tencarva Machinery Company LLC announces the
sales force by hiring Brian Johnson as the regional sales addition of Saladin Pump and Equipment Co. Inc., in
manager for the central region. He will be responsible Beaumont, Texas, and Lake Charles, Louisiana, to its
for supporting industrial and municipal distributors / operations on February 5, 2018, according to Edwin W.
representative in the states of Michigan, Indiana, Kentucky, Pearce III, Tencarva president.
southern Ohio (municipal only), Illinois, Wisconsin, Pearce explains, "Tencarva Machinery Company has
Missouri, Kansas, Nebraska, Iowa, North Dakota, South purchased the assets of Saladin Pump and Equipment
Dakota, and Minnesota. Co., located in Beaumont, Texas, and also the office in
Johnson has spent thirty years in the pump industry Lake Charles, Louisiana. Saladin Pump is a long-time
having served in varied sales management roles Goulds distributor and, in addition to the ITT companies,
during his previous employment including sales Saladin represents Xylem, John Crane, Warren-
management, district Rupp, Roper, Liquiflo and Prominent, as well as many
manager, strategic other manufacturers."
accounts manager, and John Saladin Jr., formerly Saladin Pump and Equipment
business development Co. Inc. president, and son of founder John Saladin, will
manager. His previous remain with the company for a transition period. All
responsibilities included sixteen full-time employees have become a part of the
the development Tencarva team. Henry
and management of Ritchie, Tencarva vice
distributors, OEMs, president, is overseeing
catalog companies, both the operations
and other specialized and sales activities
niche market channels for Saladin Pump
of distribution. Brian Johnson and Equipment.

6 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

INDUSTRY NEWS

BLACKMER EXHIBITING PUMPS AND SALES REPRESENTATIVES JOIN HELWIG

COMPRESSORS AT NPGA 2018 CARBON PRODUCTS
Blackmer®, part of PSG®, a Dover Helwig Carbon Products, Inc.
company, will be featuring its announces the appointment
comprehensive line of pumps and of Pawn Meksyphet as
compressors for the LPG/Autogas sales representative for
market in Booth 1221 at the National the Northern Illinois
Propane Gas Association’s (NPGA) territory. Meksyphet has
2018 Southeastern Convention over eighteen years of
and International Propane Expo. professional sales and account
NPGA 2018, which will be held from management experience
April 6 through 8 at the Georgia in telecommunications and
World Congress Center in Atlanta, nonprofit/political fund-
Georgia, is the largest propane- raising industries. He has Pawn Meksyphet
related tradeshow in the world with held positions at Verizon
over 250 exhibitors and more than 4,000 participants. Wireless, U.S. Billing, and Sprint, and was most recently
At this year’s show, Blackmer will be featuring its sliding involved in the development, marketing and launch of
vane pumps for the LPG market, including its LG, LGL, and over a dozen, independently owned and operated, Sprint
TLGLF models. LPG Series pumps offer the best combined prepaid retail locations in the state of Wisconsin. Pawn
characteristics of sustained high-level performance, served in the Army Reserve and studied at the University of
energy efficiency, trouble-free operation and low Wisconsin–Milwaukee.
maintenance cost. Designed for maximum performance Harold Katz will also join Helwig as sales representative
and reliability in a wide variety of LPG applications, for Southern California. Katz has thirty-five years of sales
these pumps are ideally suited for cylinder filling, motor and sales management experience in the ball bearing,
fueling, bulk transfer in liquid terminals, vaporizers, and on power transmission, linear bearing, and motion control
bobtails and transports. industries. He spent over three decades with Bearing

8 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

INDUSTRY NEWS

Engineers, Inc./ Motion single highest individual

Solutions, Inc. in the roles recognition in all of Genuine
of sales representative, Parts Company.
assistant sales manager, sales Mr. Breen began his
manager, vice-president, career with Berry Bearing
and president. He left to form Company in 1982 and has
his own independent sales held significant key positions
representation organization since Berry Bearing
in 2017 with focus on motor was acquired by Motion
manufacturing, repair, and Industries in 1993. Prior to
overhaul industries. becoming executive vice
Harold Katz
Helwig Carbon Products, president and chief operating
Inc. is one of the last American owned manufacturers officer for U.S. operations
Tim Breen
of carbon brushes, brush holders, and mechanical in 2011, he led Motion
carbons. Helwig Carbon Products is also the only sliding Industries as a senior vice president for the Central United
electrical contact manufacturer that designs, engineers, States. Breen was named President in 2013 before becoming
and manufacturers the complete brush circuit in the company’s president and CEO the following year.
the same facility. “Each year since 1959, we have recognized one Manager
of the Year out of all our associates worldwide,” says Paul
TIM BREEN NAMED 2017 GPC MANAGER Donahue, president and CEO of Genuine Parts Company.
OF THE YEAR “We appreciate the critical role Tim and his Motion Team
Motion Industries, Inc., a leading distributor of maintenance, play in making Motion Industries the successful business
repair, and operation replacement parts is pleased to it is today, and in delivering the excellent results the team
announce that its parent company, Genuine Parts Company delivered in 2017. This award, the highest honor at GPC, is
(GPC), named Motion Industries president and CEO a significant and well-deserved recognition for Tim and the
Tim Breen as its 2017 GPC Manager of the Year. It is the outstanding leadership he provides to the Motion Team.”

10 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

T R A D E S H OW P R O F I L E

Asia Turbomachinery
and Pump Symposium
Exchanging ideas and impacting the industry

T
he Turbomachinery career and industry.
Laboratory at The exhibition will
Texas A&M showcase products and
University is embarking support technologies from
on its second biennial leading rotating machinery
Asia Turbomachinery original equipment
and Pump Symposium manufacturers (OEMs).
(ATPS) in Singapore. Full-size equipment,
ATPS is modeled after cutting-edge technology,
the longstanding Houston and emerging industry
Turbomachinery and Pump trends will be on display.
Symposia (TPS), held
annually since 1972. ATPS is an international assembly for A STRONG FOUNDATION
turbomachinery and pump end-users and manufacturers. It Rooted in the history and successes of the Turbo Lab and
features a renowned technical program that is hand-selected TPS, ATPS promotes professional development, technology
by an advisory committee of engineers, and an international transfer, peer networking, and information exchange among
exhibition. The inaugural 2016 event drew more than 900 industry professionals.
attendees from 38 countries. To further the mission of ATPS, the Turbo Lab has partnered
ATPS 2018 will be held March 13-15 at the Suntec with a number of organizations including major sponsor
Singapore International Convention and Exhibition Centre, Mitsubishi Heavy Industries Compressor Corporation and
with full-day short courses offered in conjunction with badge lanyard sponsor Elliott Group; association partners
the symposia. Paid delegates may choose to engage in Korea Rotating Machinery Engineers Association, Institute
a combination of seven full-day short courses, seventeen of Engineers, Singapore and Institution of Engineers,
tutorials, twenty-five lectures, thirty-nine case studies, eleven Malaysia; and academic partners Nanyang Technological
technical briefs, and twelve discussion groups. New to the University, National University of Singapore and Universiti
symposium are two panel sessions on digitalization and Teknologi Malaysia.

12 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


“ATPS is an invaluable networking opportunity for end-
users and suppliers alike—made even more essential at this
time of flux for the industry,” says Dag Calafell, chairman
of the 2018 event. “I look forward to a robust, meaningful
symposium sharing leadership insights and successes that
strengthen our industry. Together we can create opportunities
despite the challenges we face.”
TECHNICAL PROGRAM
Technical Session
ATPS hosts the premier professional continuing education
program relied upon by rotating equipment engineers and
technicians worldwide, spanning oil and gas, petrochemical,
power, aerospace, chemical, and water industries. The
program, hand-picked by an influential industry advisory
committee, is led by highly-respected practitioners and
leaders in their fields. Topics include maintenance, reliability,
troubleshooting, instruction on emerging designs, technology,
and best practices that include case studies with real-world
relevance on problems-solved and lessons-learned.
Industry and Career Panel and Networking Session
This panel and networking session is intended for delegates
enrolled in university, and early-career professionals. The
keynote, by Deloitte Consulting, will cover trends in the
oil and gas industry and its role in society and economics.
Panelists will give an overview of their industry experience
www.modernpumpingtoday.com
T R A D E S H OW P R O F I L E
including benefits and challenges of working in the oil and
gas sector. A question-and-answer session will follow, with a
networking reception closing out the event.
Successful Applications of Digitalization in Oil and Gas
Digitalization is expected to transform the industrial segment,
both oil and gas and power. The latest technological
innovations in the industry are not fully understood, due to
hype versus reality. This session seeks to widen technological
perspective for ATPS attendees and remove silos in industry
for a multidisciplinary approach. The latest trends and
anticipated changes will be addressed. The discussion will
feature first-hand accounts of successful applications, latest
available developments in digitalization, as well as pain
points and potential approaches. The panel will address how
OEMs are able to help customers with successful application
of digitalization. A question-and-answer session will follow the
panel discussion.
INDUSTRY EXHIBITION
At the centerpiece of ATPS, a remarkable exhibit hall hosts
leading companies from across the globe. Companies
and industry experts demonstrate full-size equipment and
products, and share insights on current practices and future
trends. Networking opportunities abound for attendees,
rounding out the valuable transfer of knowledge that has
become the hallmark of ATPS. ◆
Modern Pumping Today | February 2018 | 13
S W PA I N S I G H T

Repair or Replace?
Evaluating
Your Aging
Submersible
By SWPA Executive Director Adam Stolberg
and Clark Henry, Environment One

S
ubmersible pumps are known for their
reliability, but even the sturdiest of
equipment wears down or, eventually,
needs replacement. When to end a pump’s
life cycle rather than extending it is one of the
most important questions a pump owner can
ask. Below, SWPA Executive Director Adam
Stolberg and SWPA’S Vice President Clark
Henry from Environment One Corporation
tackle this crucial issue.

What should pump owners look for when

assessing the need for a replacement?
Pump owners should look at the combination
of the cost and the longevity of the pump
for each instance. The repair cost might be
lower than a new pump, but so too might be
the longevity of the repaired pump. Items
that can drive up repair costs are excessively
corroded castings, damaged electrical
components or items that require more The service technician should be capturing data on every
hours to replace. There are also practices that can drive service call. That data should provide insight into the
up repair costs unnecessarily—especially the mindset: “I system. Reviewing data collected over several sites over
might as well replace this while I’m here.” time can provide further insight into system performance.
That mindset can turn an average repair into an If the replacement pump is able to deliver sufficient
expensive repair and perhaps into a pump replacement. pressure and scouring velocities, it can clean lines that
Repairs should typically only be performed on may have collected deposits with underperforming
components that are damaged. That keeps the labor and pumps. The cleaner lines can improve wastewater
financial impact to a minimum. transmission efficiency and performance.

How can a replacement pump kickstart improved To stay on top of a pump’s performance, which inspection
efficiency and performance for an entire system? schedules work best for different applications?
Is replacing a pump the best time to assess The best pumps are those that do not require regular
system performance? maintenance schedules. If the pump contains floats or

14 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

level sensing probes, they typically will require cleaning to
maintain proper performance. The frequency of cleaning
is proportional to the FOG (fats, oils, and grease) content
in the wastewater. The lower the FOG content for the
application (laundromat, conscientious homeowner, etc.)
the less frequently they need to be cleaned (annually, or
semi-annually). If the application has a heavy FOG content
(restaurants, etc.), then very regular maintenance (monthly
perhaps) is required.

What are some key efficiency and

performance points to consider?
Efficiency and performance depends on the type of pump
being used. For centrifugal pumps, understanding the
hydraulic dynamics of the system is critical to selecting
the correct motor/impeller combination. That will ensure
the pumps will perform at the correct point on the pump
curve, which will allow them to perform as well as possible
for as long as possible.
For semi-positive displacement pumps, the pump
selection is a little more straight forward. Because the
discharge volume is relatively constant, the same pump
can be used across the sewer system. Monitoring the
amperage at a location over time can help assist in
identifying line blockages or worn pump components.

If pump users decide to repair an aging pump, where can

they best find quality parts? Will this require a different
approach to maintenance schedules and inspection?
It is always best to use OEM parts for pump repair to
ensure your pump performs as the manufacturer intended.
The use of non-OEM parts can occasionally save a little
amount of cost up front, but will usually lead to more
frequent repairs and significantly more cost in the long
run. Also, the part quality is typically not as high, which
leads to more frequent pump repair as well. This can hurt
the reputation of the product and perhaps the particular
sewer technology.
If a pump is repaired properly (using manufacturer’s
instructions and OEM parts), the repaired pump should be
treated the same as a new pump. Attention should be paid
to maintaining accurate historical service records. Those
records are the key to identifying faulty site conditions that
could be the root cause of repeated failures. ◆

READ MORE

MPT
Modern Pumping Today
Providing Solutions for the Worldwide Pump Industry
®

Visit www.ModernPumpingToday.com

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 15

CASE STUDIES

Cruise Liner Finds

the Right Seal for
Booster Pumps
DiamondFace-coated mechanical seals provide
reliable operational safety and long runtimes under
heavy-duty conditions

E
CAs (Emission-Controlled Areas) were established the lubrication required for the seal faces, and thus on how
a few years ago in the North Sea and Baltic reliably the seals function. In HFO operation, water vapor
shipping areas, the English Channel and the U.S. can be mixed in with the fuel to reduce the amount of soot
and Canadian coastal regions. Ships that operate in these in the exhaust gas.
waters must reduce their sulfur Furthermore, HFO can contain up to
emissions to 0.1 percent m/m. While 30 percent of substances that cannot
heavy fuel oil (HFO) is used as a fuel be defined more precisely according
outside these ECAs, ships switch to to current standards, and thus can
light fuel oil (MDO - Marine Diesel potentially impair the seal. In addition,
Oil) with its lower sulfur content temperature jumps of around 126
within the environmental zones and degrees Fahrenheit (70 degrees
in harbors. Celsius) occur at the booster pumps
These fuel changeovers are and their seals during fuel changes.
particularly frequent on cruise liners, As the vertical screw pumps used
which often go to new destinations have mechanical seals installed
every day. This puts considerable at the top, gas building up in the
strain on machines and components, seal compartment can also cause
including the booster pumps that a lack of lubrication. Furthermore,
transport the fuel from the bunker to the temperature limits for the FKM
the ship’s engines under pressure— (fluoroelastomer) secondary seals
and consequently the mechanical applied as standard are regularly
seals in these pumps, which are exceeded. The operating conditions
designed for stable operating immediately suggest the application
conditions and continuous lubrication of double mechanical seals, but this
of the seal faces. is often impossible due to the limited
installation space and is undesirable
PROBLEM MEDIA AND EagleBurgmann single mechanical seal DF-M7S91. on cost grounds. Conventional
The seal faces of the rotating ring and stationary seat
SPECIAL CONDITIONS are diamond coated.
mechanical seals used to achieve
The seals applied to seal the pump a limited service life of 50 to 500
shafts are exposed to extreme stresses operating hours before unacceptable
due to the lack of lubrication of the seal faces and the leakages occurred. This contrasts sharply with the
constantly changing pressure and temperature conditions. operators’ demand for a MTBF of 8,000 hours.
In addition to the changes between HFO and MDO, the Early wear of the mechanical seals thus caused massive
quality of the heavy fuel oil also has a negative effect on problems for shipyards and cruise ship owners. Time and

16 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

 CASE STUDIES

time again, the unavoidable replacement of seals resulted

in a lot of time and money being spent on maintenance.

SOLUTION IN SIGHT: DIAMONDFACE

EagleBurgmann DiamondFace is the key to solving such
sealing problems. The positive experiences gained from
other applications, such as high tolerance to dry running
and significantly longer service life, are impressively
demonstrated yet again in these applications.
The four booster pumps in each of five cruise liners
operated by one of the world’s largest ship owners have
been equipped with type DF-M7S91 single mechanical
seals coated with DiamondFace since 2011. While the
pumps in the first two ships were retrofitted, the DF-M7S91
seals were installed in the other three ships while they
were under construction in Papenburg, Germany.
These twenty seals with the high-tech coating have Vertical screw pumps are used as booster pumps for different grades of fuel.
been working perfectly and without a hitch since
commissioning. The massive leakages that used
to occur have been eliminated and reduced to a
minimum. Running times of up to 10,000 hours are now EagleBurgmann is one of the worldwide leading providers of
achieved by the M7S91, promoted by its extraordinary industrial sealing technology. Mechanical seals, seal supply
tolerance to dry running and the extreme chemical systems, magnetic couplings, carbon floating ring seals, expansion
joints, gaskets and packings as well as comprehensive services
resistance of DiamondFace. This is combined with are used wherever reliability and safety are needed. For more
never before achieved MTBF values, much to the information, visit www.eagleburgmann.us.
operator’s satisfaction. ◆

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 17

CASE STUDIES

Don’t Le t Vibration
Data M islead You
Perform electrical signature analysis
alongside vibration analysis to properly
diagnose motor problems
By Richard Scott, ALL-TEST Pro, LLC.

E
asyTool is a condition monitoring solutions provider THE APPLICATION
with service and support representatives in Italy. A VFD-driven, 15-kilowatt induction motor was used
Located in the town of Fabriano, in the province of to drive an industrial fan on a drying section hood of
Ancona, EasyTool represents ALL-TEST Pro instruments a machine that produces paper. While the machine
and performs regular condition monitoring services for produces paper, this industrial fan extracts the fumes
a local paper manufacturer. Every three months, a field from the machine and sends them through a filter before
engineer travels to the paper manufacturing facility to test releasing the exhaust out to atmosphere.
their equipment, including fans, motors, rollers, and gear
boxes. Data is collected four times throughout the year
for trending and predictive analysis to support the paper
manufacturer’s safety and equipment reliability programs.
In September 2016, Ettore Di Pasquale, field engineer,
used a multi-technology approach to properly diagnose an
issue with an induction motor.

ABOUT SPM INSTRUMENT

SPM Instrument has over forty years’ VFD-driven, 15-kilowatt induction motor

experience with machine condition

monitoring, working with several
industries in more than 50 countries
to provide technical service, support,
and training in condition monitoring
practices. SPM offers a wide product
range, from high-tech portable
instruments to online systems and a
comprehensive condition monitoring
software. SPM Instrument’s intelligent
solutions are cost-effective, constructive
and complete. For more information, visit
www.spminstrument.us.
WHEN VIBRATION ANALYSIS AND ELECTRICAL
SIGNATURE ANALYSIS DISAGREE
The initial vibration analysis showed high vibration values
(see figure 1) and a spectrum which could have been
interpreted to be motor unbalance (see figure 2). Even
though the first portion of the spectrum looked similar to
an unbalance pattern, the field engineer knew to continue
investigating investigating.
Speed was measured with a strobe and showed that the
revolutions per minute (RPM) had been changing very
quickly—even though the VFD was set to run the motor at a
fixed speed of 1,470 RPM. Seeing the speed of the induction
motor change rapidly is indicative of broken rotor bars.
At this point, the field engineer continued with his multi-
technology approach and performed an Electrical Signature

18 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

 CASE STUDIES

and operating current to identify existing and developing

faults in the entire motor system. When in ESA mode, the
ATPOL II™ evaluates the condition of incoming power,
the control circuit, the motor itself, and the driven load.

Figure 1. Portable data collector detected high values of vibration at 1X as shown in

the spectrum.

Figure 3: ESA showed very strong variations of motor current confirming speed
variations with current amplitude modulation of 30 percent.

Figure 2. The time waveform in the axial direction showed signs of

frequency modulation.

Max RPM Line Freq 2997,4 (RPM)

3000 RPM Running Speed 1482,9 (RPM)
1000 Hz PPF 63,446 (RPM)
Figure 4: ESA confirms broken rotor bars with values of PPF sidebands of -20 db
20 Ordini THD-I (Max.) 8.865 % related to severe damage (condition 7).

Risoluzione: 0,63 Hz THD-V (Max.) 3.784 %

37,5 CPM Induction Motor (LF: 50 Hz)
Tempo di acquisizione:
Power factor PF is below 0.85
7,2 Secondi
N. di rivoluzionic 360 Current OK
FFT bandwidth was 37.5 RPM and PPF was 63.4 RPM. The spectrum did not show Voltage OK
evidence of PPF sidebands around 1X and harmonics.
Load OK (Ld: 83.1%)
Analysis with the hand-held Vlt-GND ref. NOT neutral OK
ALL-TEST PRO On-Line
Connection OK
II™ energized motor
testing instrument to Rotor RB health is questionable (C:7)
investigate the condition of
Stator (mechanical) OK
the motor’s rotor bars.
Air gap OK
ELECTRICAL
Harmonic distortion Too much (V)
SIGNATURE ANALYSIS
CONFIRMS BROKEN Misalignment/Unbalance OK
ROTOR BARS
Bearing/Unidentified OK
Electrical signature analysis
(ESA) is a diagnostic Bottom line Suspicious operation
technology that uses Figure 5: ATPOL II™ displays results "RB health is questionable (C:7)”. As shown in the
the motors supply voltage table, C7 reports severe damage to the rotor bars.

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 19

CASE STUDIES

The ESA of this induction motor showed significant
variations in current (see figure 3—when the motor
speeds up, it draws more current; when it slows down,
it draws less current). The large fluctuations in current
varied about 30 percent because the motor was varying
load due to speed variations.
PREVENTING MOTOR FAILURE AND KEEPING
EMPLOYEES SAFE
The field engineer reviewed his comprehensive analysis
with the paper manufacturer’s predictive maintenance
and reliability manager, and the suggestion was made to
replace the motor. A new motor was promptly installed
during a planned shutdown, and another vibration analysis
was performed on the new motor to make sure it was
working as intended.
Vibration analysis of the new motor showed that the
vibration had significantly decreased. Where the original,
damaged motor had shown high values of vibration
around 11 mm/sec., the vibration analysis of the new motor
showed values around 0.35 (30 times less vibration).
More importantly, the new motor was operating at a
constant speed, ensuring the industrial fan could evacuate
fumes from the paper production machine with consistent
air flow. Maintaining speed and air flow for fume suction
meant creating a healthy and safe work environment for
the manufacturer’s employees.
LESSONS LEARNED
1. If the broken rotor bars had not been detected, the
motor would have failed. Motor failure would have led
to unsafe working conditions inside the manufacturing
facility. Condition monitoring and predictive
maintenance (PdM) programs are very important
initiatives that every manufacturer should implement.

2. Vibration analysis, while very informative and

important, does not always clearly identify motor faults.
Vibration testing should be performed alongside
Electrical Signature Analysis. It is critical to take a multi-
technology approach when checking the condition of
your motors, as one technology is usually not ‘enough’ to
properly diagnose motor health.

3. There are easy-to-use portable instruments, like the

ALL-TEST PRO On-Line II™ energized motor testing
instrument, that can help you check the health of your
motors. The ATPOL II™ is an invaluable monitoring and
Internals of motor with broken rotor bars (broken rotor bars are not visible in this diagnostic tool that can help you see what is really going
picture).
on with your equipment. Make sure you have the proper
tools to support your condition monitoring program. ◆
Condition db Value Rotor Condition Action
1 >60 Excellent None
2 54-60 Good None
3 48-54 Moderate Trend
Rotor fracture or Increase test
4 42-48 high resistance intervals and Richard Scott is general manager at ALL-TEST Pro, LLC. Since
joint trend 1985, ALL-TEST Pro, LLC has provided industry with the most
Two or more Confirm with advanced predictive maintenance testing and troubleshooting
tools for AC and DC motors, coils, windings, transformers,
5 36-42 bars cracked or motor circuit
generators and more to a wide range of industries worldwide.
broken analysis With a full line of testing instruments, software, accessories
Multiple cracked and training programs, ALL-TEST Pro has the tools you
or broken bars need to perform advanced non-destructive motor testing
6 30-36 Overhaul and analysis for both de-energized motor circuit analysis
and end ring
problems and energized electrical signature and power analysis.
The extensive capabilities of the instruments, coupled with
Multiple broken dependable post-sale training and technical support, ensure
rotor bars and Overhaul or improved productivity, reduced downtime and a rapid return on
7 <30
other severe replace investment. For more information, visit www.alltestpro.com.
rotor problems

20 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

WATER & WASTEWATER FOCUS
Wastewater Facility
Upgrades Prove
Their Worth
Spiraflo Clarifier and Raptor Screen
team up for a dirty job
W
orking alone in New York
State, approximately 90
to 100 miles south of
Rochester and Lake Ontario, plant
operator Chuck Wright depends on
the good performance and reliability
of the equipment he diligently looks
after near the Village of Addison.
With such a high level of
responsibility, the beauty of well-
engineered, low maintenance
equipment cannot be
underestimated—and following a
$3.34 million upgrade to bring the
thirty-four-year-old treatment facility
up to code and meet New York
State Department Environmental
22 | February 2018 | Modern Pumping Today
Clarifier pre-construction at Addison; worn gearbox, cracked walls and a worn arm that would often stick.
Conservation (DEC) requirements,
Chuck is rightly proud of the clean
and well maintained Addison
Wastewater Treatment Plant.
CLEAN AND RUNNING
SMOOTHLY
The Village of Addison had retained
emerging national architecture,
engineering, and survey firm Larson
Design Group (LDG) for design and
construction services, developing
the project scope and funding
applications for rehabilitation of the
anaerobic digester unit, replacement
of a wastewater pumping station,
installation of a stand-by emergency
generator and a mechanical
bar screen.
Other improvements under LDG’s
contract included the major task
of replacing the clarifier internals,
as well as raw wastewater pumps,
trickling filter recirculation, and
HVAC upgrades. Larson Design
Group has also provided engineering
services for the Village’s water
supply and treatment system, local
streets, and drainage problems within
the Village.
Amid the substantial improvements,
two pieces of equipment that have
very steadily kept on doing their job
at the (average) 220,000 gallons per
www.modernpumpingtoday.com
 WATER & WASTEWATER FOCUS

day (420,000 permitted) plant are a

Spiraflo Clarifier and a Raptor Fine
Screen, which were both supplied
by Lakeside Equipment Corporation
in 2008.
“I do my best to keep everything
clean and running smoothly,” says
Chuck Wright at Addison, “but I have
no problems at all with the clarifier or
the screen. Apart from occasional oil
changes and a few squirts of grease,
these keep working very well”
He adds, “Compared to some
pieces of equipment, Lakeside’s
seals and bearings are of exceptional
quality. Nothing gums up or clogs.
The Raptor Fine Screen does a great
job getting rid of the paper and
heavier particles before they can get
to the clarifier.”

RETROFITTED TO FIT THE NEED

New Lakeside Spiraflo Clarifier at Addison.
The Lakeside Spiraflo Clarifier was
retrofitted into the existing concrete
structure to replace an old center-
feed peripheral take-off clarifier
that performed poorly due to short-
circuiting. With the new peripheral-
feed center take-off Spiraflo Clarifier,
Chuck Wright certainly doesn’t
have to worry about short-circuiting
because its spiraling flow pattern
flows around the baffle skirt and
under the skirt to ensure maximum
use of the entire tank volume
(26-feet diameter—and shallow
8.5-feet depth).
This is in contrast to a typical
center-feed clarifier flow pattern that
is subject to the waterfall effect and
sludge wall creep, which allows the New Lakeside Raptor Screen at Addison.
influent to short-circuit directly to the
effluent weirs, allowing solids carry
over. The center-feed flow pattern
flows counter-current (outward),
compared to the sludge scraper that
is moving solids inward to the sludge
draw-off pit.
This short-circuiting prevents
complete use of the tank volume for
the settling process.

THE SPIRAFLO CLARIFIER: A

CLOSER LOOK
Conversely, wastewater enters the
Spiraflo Clarifier at the periphery

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 23

WATER & WASTEWATER FOCUS
Looking into the new Lakeside Raptor Screen at Addison.
of the tank and is directed along the
narrow raceway formed by the baffle
skirt and the outer wall. This flow
pattern dissipates the wastewater's
hydraulic energy as it flows around
the raceway and eventually spirals
down under the skirt. Wastewater
enters the main settling area from the
full circumference of the skirt and
slowly rises to pass over the centrally
located effluent weirs. The inflow
is prevented from flowing directly
to the effluent weir by the specially
designed race baffle skirt, which
extends down to approximately two
feet above the tank floor. The Spiraflo
hydraulic flow pattern is in the same
direction (inward) as the sludge
collector is rotating and moving the
24 | February 2018 | Modern Pumping Today
solids (inward) to the sludge draw-off
pit. The spiralling flow pattern makes
use of total tank volume for more
effective solids settling.
Twin Tiers Director of LDG’s
Operations (Civil Division) Gregory
M. Cummings, PE, comments,
“Before the recent main upgrade,
the previous clarifier was getting
overloaded and had started
exceeding recommended values,
so we had to act then to keep the
Addison plant in compliance.”
He adds, “We’d had previous
experience with Lakeside and always
found them good to work with. We
also knew of the many advantages
of the Spiraflo Clarifier, the Raptor
Screen and their proven track record.
Nine years later, this equipment
certainly meets the ‘fit and forget’
description. There haven’t been any
problems at all.”
SCREENINGS THROUGH THE
PROCESS
As well as screening Addison’s
wastewater, the Lakeside Raptor also
washes, compacts, and transports the
screenings. With a screen diameter
of 26 to 71 inches and maximum flow
capacities higher than 20 million
gallons per day, liquid flows through
the Raptor’s 3-plane screening
basket, with solids efficiently trapped
by the screen bars that form the
circular basket. When liquid rises
to a predetermined level, the rake
www.modernpumpingtoday.com

begins to rotate, cleaning the screen
bars. The rake's teeth pass between
the bars of the screen to remove
captured materials. When the rake
reaches the top of the screen, the
captured material drops into the
central screw conveyor. For complete
cleaning, the rake reverses direction
and passes through a hinged comb.
The central screw conveyor then
transports the material as it is
washed, compacted, and dewatered
on its way to the discharge chute.
After discharge, dewatered
screenings have a solids content
exceeding 40 percent.
Screenings are initially washed as
they are deposited in the collection
trough. In the upper section of
the transport tube, screenings
are washed a second time.
The macerating action of the screw
breaks down large organic particles,
which are then washed back into the
flow stream. A spray wash system in
the dewatering chamber removes
www.modernpumpingtoday.com
WATER & WASTEWATER FOCUS
any collected material to ensure
free drainage of water, which is then
removed in the compaction process.
SUPERIOR PERFORMANCE
LDG is currently working with
the Village to address infiltration
and inflow (I&I) issues into the
wastewater collection system.
During periods of wet weather, the
flow through the wastewater system
can sometimes triple, indicating
that water is entering the system
where it shouldn’t be. Work includes
uncovering buried manholes,
televising the entire collection
system and rehabilitating portions
of the system where I&I issues are
identified to be at their worst.
Gregory M. Cummings adds, “At
Larson Design Group we very much
embrace innovation and welcome
cutting-edge, new approaches
within our practice areas, but the
tried and tested design and cost-
effectiveness of the Lakeside Spiraflo
Modern Pumping Today
is hard to beat. There’s the superior
performance, not to mention the
savings that are made on construction
and installation. The Raptor Screen
is also very well designed and
extremely durable, so we are happy
with the knowledge that as the
village of Addison’s trusted advisor,
we are providing high quality long-
lasting solutions for the wellbeing of
the community.” ◆
Lakeside Equipment Corporation
is an engineering and manufacturing
company concentrating on helping
to improve the quality of our water
resources. Lakeside started in the
Spring of 1928 to engineer, develop,
and provide water purification
systems to municipalities and
companies throughout North
America. For more information, visit
www.lakeside-equipment.com.
| February 2018 | 25
MAINTENANCE & RELIABILITY

Soil Sampling for

VOCs: Best Practices
An overview of methods and equipment options
Part 2 of 2
By David Kaminski, QED Environmental Systems, Inc.

See Part 1 on
modernpumpingtoday.com

26 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

 MAINTENANCE & RELIABILITY

A
s we touched on in
part 1 of this series, there
are some limitations to low
level analysis. Low level analysis
is considered to be only semi-
quantitative because the aqueous
solution used is a poor solvent for
soil VOCs, which causes results
to be biased low. In addition, high
concentrations of acetone can be
formed by the preservative itself in
some organic-rich soils.
Despite the limitations of low
level analysis, sub-core sampling
using field preservation techniques
is an effective methodology and
is widely accepted by regulators. stable throughout the fourteen-day preserved sub-core samples is more
It is an advantageous method for hold time and beyond. complicated than other methods
laboratories because it requires no There are disadvantages to sub- and can be even more difficult in
further preparation of samples by the core sampling with field preservation. adverse conditions. Lastly, shipping
laboratory doing the analysis, and For example, the seals of the vials restrictions may apply to high level
also doesn’t require any special tools used to collect samples can leak samples as they contain methanol
or procedures for the laboratory to causing a loss of preservative or (although this typically is not an issue
process samples. In addition, VOC VOCs. Another issue is the need if the samples are properly labeled
concentrations in samples collected for more experienced field staff, and have a volume of less than
using field preservation remain as the process used to collect field 500 mL).

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 27

MAINTENANCE & RELIABILITY
THE EN CORE® SAMPLER
The only alternative method to sub-
core sampling with field preservation
within US EPA Method 5035A is
sampling using an En Core sampler.
The En Core sampler is the only
commercially available sampler
listed in Method 5035A, and is
both a sampling tool and a sample
container. There are three major
components to the En Core sampler:
the reusable T-handle, which holds
the sampler and is used to push it
into a soil core, the En Core sampler
itself, which is where the soil sample
is collected and stored, and the cap,
which seals the sampler shut for
transport to the lab. Once the sample
is collected, excess dirt is cleaned
from the sampler upon removing it
from the soil, the cap is snapped into
place on the sampler, and then the
sampler is removed from the T-handle
and placed in a pre-labeled VOC-
proof bag to be shipped to the lab.
The En Core sampler has several
advantages over field preservation
and bulk sampling methods. First,
because it eliminates transfer of the
soil sample into vials and the need
to weigh vials in the field, it is faster
and easier than other methods,
28 | February 2018 | Modern Pumping Today
allowing for more sample throughput
per day. Additionally, it requires
minimal training to use effectively,
doesn’t require field staff to handle
preservative in the field, and has
a long shelf life (no preservative
expiration dates to consider).
Because there are no preservatives
involved in field work using the En
Core, there are no sample shipping
restrictions, and random error in
sample results, which often come
from mistakes in field preservation,
is much less common. Finally, the
En Core samples are shipped to the
laboratory in a proprietary VOC-
proof bag, which further prevents
random error in results. The En Core
sampler delivers such consistent
results in spite of variations in the
experience of the field staff that use
it that it is often used to minimize
liability concerns.
The En Core sampler is also very
reliable—millions of En Cores have
been sold without one reported
analytical incident. This is in part
due to the manufacturing quality
standards of the En Core, which are
higher than those of sample vials.
Every lot of En Core samplers is
tested and analyzed for performance
and cleanliness, including tests at
extremely high and low temperatures.
In fact, En Core samples can be
stored frozen without any damage.
There are some limitations to the
En Core sampler. If the En Core
is being used under sampling
Method 5035A, the samples must
be preserved at the lab within
forty-eight hours. Additionally, En
Core samples are reported in dry
weight, so an extra jar of soil must
be collected along with En Core
samplers to measure the moisture
content of the soil at the laboratory.
Lastly, the per-sample cost of using
the En Core sampler is higher than
that of the field preserved sub-core
method, though some of this extra
cost is offset by the time savings
created by the En Core sampler.
SUMMARY
To collect quality soil samples that
will deliver accurate data, one of
two different methods of sampling
should be used: field preservation
of sub-core samples, or sampling
using an En Core sampler. While
widely used in the past, studies
have shown that the bulk sampling
method is unreliable and highly
prone to sample bias due to VOC
losses. Under either of the two viable
methods, it is vital to carefully follow
the best practices for handling a soil
core and sampling from that soil core
in order to ensure a quality sample,
and in turn, quality VOC data. ◆
David Kaminski is senior vice
president at QED Environmental
Systems, Inc. QED Environmental
Systems is the leading manufacturer
of innovative environmental
products. For over thirty years their
expertise has included pumping
systems, landfill products, and air
strippers. For more information, visit
www.qedenv.com.
www.modernpumpingtoday.com
PUMP SOLUTIONS

Improving Pump and

Centrifuge
Performance
in Crude Oil Tank
Bottom Cleaning and
Drilling Solids Control
Part 2 of 2 See Part 1 on
modernpumpingtoday.com
By Jim McMahon

I
n part 1 of this series, we saw that
uses of grinders in petroleum-
related pump situations can vary
widely, from complex crude oil tank-
bottom cleaning to simple portable
grinders used on location. In this
month’s conclusion, we’ll take a
closer look at reclamation of drilling
mud from drill cuttings as well as
the use of grinders for protecting
pumps in petroleum applications.

RECLAIMING OF DRILLING
MUD FROM DRILL CUTTINGS
Drilling fluids (drilling mud) are
integral to the drilling process,
serving to lubricate and cool the
drill bit, as well as convey the
drilled cuttings away from the bore
hole. These fluids are a mixture
of various chemicals in a water-
based, oil-based or synthetic-
based solution. Drill cuttings are
broken bits of solid material that
are produced as the drill bit breaks

30 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


the rock. Drill cuttings vary in
size and texture, ranging from fine
silt to gravel.
For both environmental reasons
and to reduce the cost of drilling
operations, drilling fluid losses are
minimized by stripping them away
from the drill cuttings before the
cuttings are disposed of. On drill
sites, the systems used to reclaim
mud are considered to be of critical
importance to the process throughput
and efficiency of the operation. Mud
reclamation is primarily accomplished
using shale shakers with vibrating
screens to separate the mud from the
shale, with subsequent processing of
larger cuttings with centrifuges.
The mud passes through the screens
and is collected into mud tanks. The
drill cuttings remain on top of the shale
shaker screens. The vibratory action of
the shakers moves the cuttings down
the screen and off, where they can be
collected and stored in a tank or pit for
further treatment or disposal.
www.modernpumpingtoday.com
PUMP SOLUTIONS
The separated drill cuttings,
which were not sifted through the
screens, but still coated with a large
quantity of drilling mud, are slurried
to centrifuges for separation.
Since centrifuges perform better
when particle size is consistent,
solids control companies grind the
cuttings to a specific size to achieve
maximum throughput rates.
“Centrifuges spin at a very
high G-force, and particles that
are too large will wear the throat
of the centrifuge more rapidly,”
says Gary Smith, industrial
distribution sales manager with JWC
Environmental (www.jwce.com),
based in Santa Ana, California, a
leading manufacturer of grinders
for municipal and industrial
applications, including for the oil
and gas industry.
“The solids control people found
that when they ground up the big
cuttings into small pieces there
was more surface exposure, and
Modern Pumping Today | February 2018 | 31
PUMP SOLUTIONS

they reclaimed more mud,” adds

Smith. “An important point, because
it increased their mud return by
about 100 percent. This helped
them drill faster, and get on and
off the rig sites in less time. It has
really pushed the efficiency of these
drill operations.”
“For grinding drill cuttings, which
are essentially rock, dual-shafted,
slow-speed, high-torque grinders,
using two stacks of hardened steel
cutters, are the preferred equipment
choice,” continues Smith. “These
grinders will get from three months
to a year grinding solid rock before
the cutters need to be replaced.
That outperforms any other
equipment for this purpose. Plus,
they provide complete protection for
downstream equipment, like pumps
and centrifuges.”

GRINDERS PROTECT PUMPS IN

PETROLEUM APPLICATIONS
Powerful, high-torque grinders
are being employed in a number
of different petroleum-related
applications where pumps need to
be protected. One of these is in the
extraction of oil sands.
Oil sands (tar sands) are a mixture
of sand, water, clay, and bitumen
found in several locations around
the globe, with the largest reserve
located in Alberta, Canada, which
can be upgraded into synthetic
crude oil and other petroleum

32 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


products. They are scooped up from
open pit mines and transported
to extraction facilities for finer
processing. The tar sands are mixed
with very hot water, allowing oil
to separate out at the top of huge
separation tanks.
In the separation process, roots,
plant life, and sometimes petrified
wood is present that would cause
pumps to plug in the extraction
facility, thereby creating problems
throughout the production line.
In-line grinders are a necessity here
to grind materials to a size that will
not plug the pumps.
“Pumps are designed for different
applications, so you are going
to be more efficient at pumping
clean water than you will be at
pumping a slurry,” says Daniel
Namie, with Superior Pumps of
Sycamore, Illinois, a distributor
of pumps for municipal and
industrial applications, including for
petroleum applications.
www.modernpumpingtoday.com
“When a pump impeller is
cruising along at 3,600 rpm the
velocities at the tip are extremely
fast, and can easily destroy all
the metal on the impeller passing
too large of a solid. So, in many
applications we specify high-torque
grinders, preferably dual-shaft, to
grind up sludge or debris that could
harm the pump.”
The uses of grinders in petroleum-
related pump situations can vary
widely, from complex crude oil tank-
bottom cleaning to simple portable
grinders used on location.
“One of our customers had a
large settling pond that was laced
with petroleum, and needed to
use polymers to bind with the
petroleum for extraction,” adds
Namie. “The polymer coagulated
the petroleum, and those big solids
could not be run through their pump
without clogging it. So, we supplied
a portable high-torque, dual-
shafted grinder which protected
Modern Pumping Today
PUMP SOLUTIONS
his pump from potential damage.
A simple solution that may have
saved them thousands of dollars in
pump damage.” ◆
JWC Environmental designs, builds, and
services the world’s most dependable
waste shredders and screening systems
to help municipal facilities and industrial
companies solve challenging waste
reduction and recycling applications.
Founded in 1973, the company has
built and shipped over 35,000 Monster
shredders and screens to its customers
around the world, in diverse industries
like energy, wastewater, recycling,
oil, chemicals, marine, and facility
management. For more information,
contact Kevin Bates, director of global
marketing, JWC Environmental; at
949.833.3888 or kevinb@jwce.com; or
visit www.jwce.com.
| February 2018 | 33
MOTOR SOLUTIONS

34 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

 MOTOR SOLUTIONS

Extending the
Life of
Precision
Components
in Demanding
Applications
Specialized PVD coatings
increase surface hardness and
durability of precision components
Part 2 of 2 See Part 1 on
modernpumpingtoday.com
By Jeff Elliott

A
s we saw in part 1 of this
series, bearings, gears,
rollers, and other precision
components can experience
excessive wear in applications
with metal-to-metal interaction,
repetitive friction at high speeds,
or where little to no lubrication is
present. To address this problem,
product engineers and component
manufacturers often turn to
specialized PVD (physical vapor
deposition) coatings, and in this
month’s conclusion, we’ll take a
closer look at how specialized
PVD coatings increase surface
hardness and durability for potential
applications such as bearings, gears,
and rollers to significantly increase
lifespan under high load conditions.
POTENTIAL APPLICATIONS:
BEARINGS
Bearings often suffer from severe
and disproportionately distributed
abrasive wear. A coating such as
BALINIT C is particularly suitable
for case-hardening as well as ball-

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 35

MOTOR SOLUTIONS
and roller-bearing steels because
it can be applied at temperatures
under 392 degrees Fahrenheit (200
degrees Celsius).
The PVD coating can be applied
not only to inner and outer races
and cylinders but also to the balls
in ball bearings in a highly uniform
coating thickness of 0.5-1 μm. The
slight increase in roughness is offset
by the good burnishing qualities
of the coating, which smoothes the
raceway of the inner and outer rings,
providing additional protection
against scuffing and pitting.
Bearings in the soft calendar
rolls of paper machines frequently
experience smearing. Not only does
PVD coating reduce the possibility
of smearing, but by making the
bearings harder with coating, it has
been shown that the life of these
parts can be increased by a factor
of three or four. As a result, paper
mills are able to hold off on bearing
replacement until the calendar
roll needs regrinding, significantly
reducing costly production downtime.
Similarly, cylindrical roller bearings
in compressors are often exposed
36 | February 2018 | Modern Pumping Today
to low loads and vibrations, causing
potential smearing. Applying PVD
coating to the bearings removes any
such possibility.
POTENTIAL APPLICATIONS:
GEARS
Gears experience similar wear
conditions. The PVD coating
significantly reduces scuffing and
pitting in gear as well. In fact,
BALINIT C has been shown to
quadruple the service life of high-
speed gears.
The standard FZG C test shows that
the fatigue strength is increased by
10-15 percent over case-hardened
but uncoated gears. In the test, the
failure criterion for gear service life
was defined as single-tooth wear of 4
percent due to pitting.
The main factors in these
improved figures were the lower
local surface pressure (Hertzian
pressure), which resulted from
reduced friction in the rolling
contact, and the superior running-in
behavior of BALINIT C.
Coatings can also benefit worm
gears, where lubrication is not
always enough to protect helical-
gear transmissions against friction
and wear.
The sliding motion and the force
between the worm and gear faces
make it difficult for a lubricant film
to form. For this reason, the gear is
most often made of bronze in order
to avoid scuffing.
In service, however, the teeth of
the bronze gear wear away quickly
and the gear must be realigned or
replaced. Coating the steel worm
with a carbon-based coating can
improve reliability and performance
by reducing wear on both the worm
and the bronze gear.
POTENTIAL APPLICATIONS:
PUMPS AND COMPRESSORS
Screw spindle-, vane-, gear-, lobe-,
and centrifugal pumps often function
in abrasive and poorly lubricating
media. This may be cooling media
in grinding machines such as screw
pumps and internal gear pumps.
BALINIT coated screws provide the
ideal combination of hardness and
low friction for preventing wear in
such poorly lubricated conditions.
www.modernpumpingtoday.com

Similarly, industrial compressor
components, such as reciprocating
pistons, screws or valve plates
can undergo extensive wear when
oil-free operation, dry gases,
refrigerants, high or low temperature
limit the use of lubricants.
CUSTOMIZED SOLUTIONS
In addition to designing and
manufacturing PVD coating equipment,
Oerlikon Balzers offers coating
services at more than 140 coating
centers worldwide, including sixteen
locations throughout the United States.
According to Dr. Florian Rovere,
director of sales for precision
components in North America,
companies like Oerlikon Balzers also
have the R&D capabilities to tailor
coating solutions to meet unique
requirements. In addition to coating
thickness and hardness, properties
such as structure, chemical and
temperature resistance, and adhesion
can be precisely controlled.
www.modernpumpingtoday.com
MOTOR SOLUTIONS
MPT
In most cases, no alteration of the
formula for the coatings is required,
as it is already optimized for high
load, high friction environments.
“I find engineers are most Modern Pumping
Modern Pumping Today
Today ®
®
Providing
Providing Solutions
Solutions for
for the
the Worldwide
Worldwide Pump
Pump Industry
surprised about two factors when Industry
learning about these specialized PVD
coatings,” says Berger. "First, that the
coating can be applied in a thickness
as low as .5 or 1 micrometers. The
other is that these coatings can
last the lifetime of the machine or
systems it is in, despite the difficult
operating conditions.” ◆
Oerlikon Balzers is one of the world's
leading suppliers of surface technologies
that significantly improve the
performance and durability of precision Visit MPT online for
components and tools for the metal and the latest industry
plastics processing industries. For more news, product
information, call 408.375.4408, email reviews, videos,
issue archives, and
balzers.components@oerlikon.com, or
exclusive content you
visit www.oerlikon.com/balzers.
won’t find in print.
ModernPumpingToday.com
Modern Pumping Today | February 2018 | 37
SEALING SOLUTIONS
How to Choose the
Type of Gasket to Use
Tips for finding the right type of
gasket material for your needs
By Mike Shorts, Triangle Fluid Controls Ltd.
M
any variables affect the
selection of a gasket for a
pressure vessel or piping
system. Our focus here will be to look
at the considerations you should make
when selecting a particular type of
gasket material, and not the variations
of gasket design offered by gasket
manufacturers and fabricators.
Gaskets are produced from a wide
array of materials including rubber
(elastomers), compressed fibre
(CNA), PTFE, flexible graphite, and
metal. Metal can be combined with
one or more of the above non-metallic
materials to reinforce the gasket.
Each material, or combination of
materials, offers specific properties
essential to effective sealing under
38 | February 2018 | Modern Pumping Today
a given set of operating conditions,
traditionally considered to be
temperature, pressure, and the nature
of the fluid being sealed. The Fluid
Sealing Association (FSA) now
recommends looking at the operating
conditions as an entire system,
including the flanges and fasteners,
which both play a prominent role in
the proper selection of a gasket type.
So how do you choose which
gasket is best for the pressure vessel
or piping system?
GASKET RELATED
CONSIDERATIONS
Gasket related considerations are by
far the most dynamic and generally
have the highest profile since this is
where things can go bad the quickest.
Traditionally, temperature, pressure,
and the fluid being sealed were thought
of as the primary considerations for
choosing a gasket material type. As
gasket materials have become more
high-tech and as equipment is being
engineered and built with higher
levels of precision, gasket thickness
and allowable gasket stress are two
additional considerations which must
be high on your evaluation list.
Gasket thickness and allowable
stress go hand-in-hand and are very
dependent on the type of material
being used. For soft materials, thinner
gaskets can withstand higher stresses
and are less exposed to the media
being sealed.
www.modernpumpingtoday.com

Storage and handleability of your
gasket should also be considered as
different materials can me more pliable
or more rigid than others. For large
gaskets, rigidity can play in your favour
to ease installation. How gaskets are
stored also play a role in the usable life
of a gasket, adding or subtracting from
its performance expectations.
FLANGE RELATED
CONSIDERATIONS
The effects of flange and gasket
interaction on the resulting bolted
joint need to be considered and are
often overlooked when selecting
a gasket type. Certain aspects of
flange construction may become the
determining factor(s) in the selection
of the gasket to produce the desired
seal. Flange type, surface finish,
compatibility, strength, and deformation
are necessary to review before making
any decision.
Flange characteristics are typically
set and can de difficult or impractical
www.modernpumpingtoday.com
SEALING SOLUTIONS
to change. However, understanding
the set of conditions relating to the
flanges is important when considering
the system and which type of gasket
material to choose.
Thin, less rigid flanges and/or flanges
designed with minimal bolting might
yield improved performance with a non-
metallic or non-reinforced gasket due to
its better conformance under low load.
Modern Pumping Today
On the other hand, tongue-and-
groove flanges with heavy bolts can
apply very high gasket stresses,
potentially damaging soft gasket
materials that are not designed for
extreme loads. Minimum, effective,
and maximum stress calculations
should be performed to determine the
gasket suitability for the application.
Gasket manufacturers can provide
information regarding these values
for a specific material to aid in the
decision-making process.
FASTENER RELATED
CONSIDERATIONS
The reliability of a bolted flange
connection depends largely on the
threaded fasteners that are one of
the most neglected components in
the connection. They work like a
spring controlling the internal and
external forces to keep the required
sealing stress on the gasket. Although
threaded fasteners are generally
considered a mature technology,
| February 2018 | 39
SEALING SOLUTIONS

the fasteners must be capable of

applying adequate load to the gasket
to achieve the desired tightness under
designated operating conditions.
The gasket must be capable of
operation within the design operating
conditions and achieve the seal, given
the available bolt load. The flange
must be rated for the design operating
conditions and of adequate stiffness
to ensure loading on the gasket is
maintained at adequate levels.
The system is complex and with
the variabilities within each category,
the iterations to consider can be
intimidating. The FSA recommends
that you work with your preferred
gasket supplier or manufacturer
whenever you may have doubts.

VALUE VS. COST

The total value of the gasket should
be considered rather than the
purchase price alone. Purchase price
is typically small when compared
with the cost of the equipment,
installation labour, down-time due to
gasket failure, or lack of equipment
availability. The true value of any
given gasket is best measured by its
reliability in the intended application,
not purchase price exclusively. ◆

significant problems continue to exist
with their use.
Problems with threaded fasteners
arise from insufficient preload,
self-loosening, tensile overload,
fatigue, galling, and thread stripping.
While design of a bolted connection
provides for a reliable connection, in
practice, fastener related failures are
not uncommon.
Uncertainties about the applied
forces, the magnitude of the preload
achieved by the tightening process,
inappropriate materials being
specified, and most notably human
error, often results in joint problems
in practice. Any problems related to
the fasteners can result in serious
consequences. Such is this spring
effect of the fasteners, the role of the
type of gasket being used can play
with or against the fasteners and
their effectiveness.
GASKET, FLANGE, FASTENER AS
A SYSTEM
In order for a bolted flanged joint
to perform satisfactorily, individual
components must be suitable for the
design operating conditions (chemical
compatibility, temperature, pressure,
etc.). These same components must
be well-suited to maintain a seal
as an assembly. More specifically,
Mike Shorts is the president of
Triangle Fluid Controls Ltd. and a past
president of FSA. Founded in 1933,
the Fluid Sealing Association® (FSA)
is an international trade association.
Member companies are involved in
the production and marketing of a
wide range of fluid sealing devices
primarily targeted to the industrial
market. FSA membership includes a
number of companies in Europe and
Central and South America, but is
most heavily concentrated in North
America. FSA members account
for a majority of the manufacturing
capacity for fluid sealing devices in the
Americas market. For more information,
email info@fluidsealing.com or visit
www.fluidsealing.com.

40 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

MODERN PUMPING PRODUCTS

Featured Product
SUNDYNE
API 682 and API 685 Upgrades for
LMV 801 Line of Direct Drive Pumps
Sundyne, a global leader in the design and
manufacture of pumps and compressors announces
a series of upgrades to its line of LMV 801 vertical
direct drive centrifugal pumps. Each API 610 (OH3
or OH5) pump is optimized to address flows to 380
gallons per minute, and heads to 720 feet, which
are demanded by a wide range of applications
across the upstream oil & gas, midstream
gas processing, and downstream refining,
petrochemical and general industrial markets.

New additions to the line of LMV 801 direct drive

pumps include:

• 801CS (API 682 Cartridge Seal)—utilizes a

self-contained process seal that fits seamlessly
onto the pump shaft as a single assembly. The
compact cartridge seal provides operators
and maintenance engineers with a convenient
alternative to standard component seals.

• 801S (API 685 sealless magnetic drive)—

this configuration combines the hydraulics
of Sundyne’s direct-drive pumps with the
magnetic drive technology pioneered by
Sundyne HMD/Kontro more than seventy years
ago. It is built to comply with both API 685
and API 610 standards, and is specifically
engineered to eliminate emissions and improve
personnel safety without compromising on
performance.

• Flexible Mechanical Seal and Sealless

Configurations—the line of direct drive pumps
utilizes standard seal configurations, including
single, double or tandem. Any LMV-801 pump
can be converted in the field to an ultra-
reliable, API 682 cartridge seal, or leak free API
685 sealless magnetic drive configuration.

Each Sundyne direct drive pump is designed to

operate at its best efficiency point and maximize
reliability and tolerance to system variations. The
new enhancements and upgrade options to the line
of LMV 801 pumps are designed to further enhance
performance, while simplifying installation and
maintenance requirements.

For more information, visit www.sundyne.com.

42 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com

 MODERN PUMPING PRODUCTS

GEMÜ
Plastic Diaphragm Valve
GEMÜ plastic diaphragm valves are available with a variety of high-quality
plastic body materials and connections. The plastic diaphragm valves support
a large range of industries and applications including chemical, environmental
systems, power generation, water and wastewater treatment, solar, semiconductor,
microelectronics, food and beverage, and processing just to name a few. Many
of the plastic diaphragm valves are supported by an extensive line of pneumatic
operators that can be fully integrated into automated systems allowing industries to
save time and money on their operations, while increasing accuracy and efficiency
in their performance. For more information, visit www.gemu-group.com.

LEYBOLD
EcoDry Plus Dry Compressing Vacuum Pump
The use of vacuum in analytical technology and research and
development is an essential factor that enables modern applications,
for example in the field of measuring instruments. The selection
of suitable equipment and the associated vacuum components is
therefore crucial for success in laboratories. Since 1850, Leybold
has been a partner of customers who have dedicated themselves to
research. With innovative products such as the new EcoDry plus dry
compressing vacuum pump, this company tradition is continuing into
the future. For more information, visit www.leyboldproducts.com.

C. OTTO GEHRCKENS
COG VarioPur®
With COG VarioPur®, the independent seal manufacturer C. Otto
Gehrckens presents a new product range in the premium segment:
the three high-performance materials in the VarioPur series are based
on thermoplastic polyurethanes (TPU/AU) and impress with excellent
properties and are belonging to the best-case-compounds in the TPU
class. Both the abrasion and the extrusion resistance are at least five
times higher than those of the traditional material NBR, which has a
Shore A value of 90. Furthermore, the three TPU materials impress with
excellent gas tightness and a high level of tolerance to a wide range of
gases—from oxygen and nitrogen to all of the synthetic hydrocarbons.
They exhibit no brittleness as a result of exposure to ozone or oxygen.
For more information, visit www.cog.de/en/products.

VISHAY PRECISION GROUP

BLH Nobel Strain Gage Load Cell Product
The BLH Nobel brand of Vishay Precision Group, experts in
standard and custom process weighing and force measurement
solutions, including high-quality and high-accuracy weighing and
control systems, today announced that four of its strain gage load
cell product families are now available with EN ISO 13849 and IEC
61508 functional safety certifications. The EN ISO 13849 functional
safety standard incorporates statistical analysis to help better
predict component, device, and circuitry reliability within the
safety-related parts of industrial machinery control systems. For
more information, visit www.blhnobel.com.

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 43

PUMPING TRENDS
The Internet of Things
and the Pump Market
Joanne Goh on how the pump industry will evolve
J
oanne Goh is a research analyst
in the manufacturing technology
group at IHS Markit. Her focus areas
are motor systems and motor-driven
equipment across all major verticals.
Prior to joining IHS, Goh worked at
Advanced Micro Devices (AMD) as an
equipment/process engineer, where
she was involved in cross-functional
team projects to drive yield and
process productivity improvements.
Below, she shares her insights on how
the internet of things will intersect and
influence the pump market.
MPT: What changes are on the horizon
for the pump industry as suppliers
embrace the industrial internet?
Joanne Goh: The global pump market
has been extremely volatile during
the past two years with the decline of
global oil and commodity prices. Pump
manufacturers are looking for ways to
minimize profit losses amid these trying
economic uncertainties. Topics such as
Industry 4.0 and Industrial Internet of
Things (IIoT) are growing in prominence
within the industrial automation
community, and pump manufacturers are
eyeing these as exciting opportunities
that could drive profits.
The pump market has seen a growing
trend to implement new technologies
like this to provide an opportunity
for pump manufacturers to innovate
and provide full pump solutions
as opposed to merely adding a
component to their overall equipment
portfolios. This means that pump
suppliers are improving their expertise
along the whole supply chain in pump
system applications.
44 | February 2018 | Modern Pumping Today
Joanne Goh
MPT: Do you foresee a digital
transformation in manufacturing lines?
Joanne Goh: Pump manufacturers are
undergoing a digital transformation
by embracing IIoT, big data,
and artificial intelligence. These
enabling technologies and related
transformational efforts are providing
pump manufacturers with a competitive
advantage.
Many companies such as KSB,
Sulzer, and WILO have developed
connected machines to enable real-
time monitoring in the production line
to improve productivity and reduce
downtime. Intelligence is also being
increasingly embedded into devices,
supporting decentralized analytics, and
even performing some decision making.
For instance, WILO has implemented
an augmented reality technology in its
manufacturing line with glasses that
act as training devices, as opposed to
paper manuals. The glasses can replace
paper instructions by providing virtual
work instructions that also display
complex work steps.
As pump manufacturers realized
over the past few years, the market
has generally declined and profits
were hard to come by. The successful
manufacturers have thus focused on
training programs, services, and hiring
greater expertise as ways to increase
their value-add to customers in an effort
to focus on market share growth.
MPT: How will this enhance the pump
user’s experience? Are fully integrated
solutions the future for OEMs?
Joanne Goh: Communication is key
to digitalization in the world of IoT.
Coupled with the downturn in the
mining and oil and gas industries, pump
suppliers are pushing more than ever to
become integrated solution providers.
A recent IHS Markit study shows
the numbers of connected nodes in
pump (centrifugal pumps and positive
displacement pumps) and compressor
applications will grow substantially
with a compound annual growth rate
(CAGR) of 46.5 percent from 2016 to
2021. Centrifugal pumps have more
variable flow applications than positive
displacement pumps, and they will
therefore utilize more connectivity for
live monitoring purpose. Additionally,
European motor and pump efficiency
regulations require full awareness by
the suppliers regarding full system
efficiency; therefore, the smart and
connected technology will increase in
use quite rapidly going forward. ◆
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