PM 6359

The Magazine for Pump Users Worldwide November 2011
pump-zone.com
The Magazine for Pump Users Worldwide
pump-zone.com
November 2011
Special Section:
Predictive & Preventive
Maintenance
ChemShow Coverage
CHEMICAL
PUMPS
Equipment in
Harsh Applications
CHEMICAL
PUMPS
Equipment in
Harsh Applications
From ITT comes Xylem.
Xylem is a world leader in the design, manufacturing and application of highly engineered technologies for the water
industry. We are 12,000 people uniied in a common purpose: creating innovative solutions to global water challenges.
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innovation and forward thinking youve come to expect from the collection of market-leading brands in the Xylem
portfolio. For more information on what this transformative shift can mean to your business, go to xyleminc.com.
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PUMP TUBING
THATS STRONGER.
AND LASTS LONGER.
Its a stronger tube, for a stronger bottom line.
Introducing GORE
Style 400 High-Resilience Tubing.

Our tubing lasts more than
50 times longer than standard
VITON
peristaltic pump
tubing, because its reinforced
with multiple layers of tough,
durable ePTFE. Whats more,
GORE
Style 400 maintains a consistent ow rate

for thousands of hours. It offers superior burst
resistance and easily withstands the rigors of constant
peristaltic pumping action and aggressive chemicals.
Which means less frequent tube replacements and
fewer disruptions in productivity. In fact, you might say
GORE
Style 400 High-Resilience Tubing lasts almost

as long as the pump itself. To nd out more about
GORE
Style 400 High-Resilience Tubing, please visit

www.gore.com/industrialtubing.
GORE and design are trademarks of W. L. Gore & Associates. 2011 W. L. Gore & Associates.
2 NOVEMBER 2011 www.pump-zone.com PUMPS & SYSTEMS
Letter from the Editor
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Pumps & Systems, a member of the 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 other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call (630) 739-0900 inside
or outside the U.S. POSTMASTER: Send changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. 2011 Cahaba Media
Group, Inc. No part of this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of
any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed
are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or
appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us
your submission, you grant Cahaba Media Group, Inc. permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions.
You are free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.
is a member of the following organizations:
W
hen GE Energy executives Jim
Rogers and Matthew Conkrite vis-
ited our Birmingham, Ala., o ces a
few months ago, they got our attention when
they talked about maintenance as a prot center.
It is common knowledge that maintenance
is a key to getting the most out of industrial
plants. Achieving the correct balance in system
maintenance can positively aect plant e -
ciency and the bottom line.
Like GE Energy, many industrial compa-
nies continue to look at predictive maintenance
as a way to prevent unexpected equipment fail-
ures. By detecting the onset of equipment degra-
dation and addressing the problems when iden-
tied, downtime can be avoided, and money can
be saved. A key element is gathering the right
information at the right time.
Preventive maintenance explores ways to
maintain equipment by providing for systematic
inspection, detection and correction of failures
before they occur and develop into catastrophic
problems using time-based intervals. hese tech-
niques can also maximize uptime and reliability
and increase prots in the long term.
here is a subtle but important distinc-
tion between the two strategies, but one thing
is certaincompanies will continue to look for
new ways to minimize the risk of equipment
failure and unscheduled downtime and extend
the life of their equipment. he bottom line . . .
reducing risk increases prots.
In this issue, we explore some specic strate-
gies in our Predictive & Preventive Maintenance
special section, which begins on page 24.
As this common trend continues to gain
momentum, we also encourage you to register
for our free webinar this month on Redening
Repair as a Failure of Maintenance: Using Life-
Cycle Asset Management to Minimize Repairs
and Maximize Plant E ciency. Register at
www.pump-zone.com, and then tune in on
November 10 at 1 p.m. eastern to learn how to
use improved maintenance to virtually elimi-
nate the need for repairs, instead of living with
the results of unplanned failure. he webinar is
sponsored by ITT Goulds Pumps and provides
actionable advice on improving pump reliabil-
ity, lowering repair costs and avoiding equip-
ment breakdowns.
his issue also examines chemical pumps
and equipment used in harsh conditions (page
32). Look for the Pumps & Systems team at the
ChemShow this month.
Best Regards,
Michelle Segrest
Editor
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
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
WEB EDITOR
Jane Longshore
jlongshore@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
Ashley Morris
amorris@pump-zone.com
205-561-2600
INTERN
Jennifer Polzin
A Publication of
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Birmingham, AL 35209
Phone: 205-212-9402
Advertising Sales
2126 McFarland Blvd. East,. Suite A
Tuscaloosa, AL 35404
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, Grundfos Pumps
Corporation
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
John Malinowski, Sr. Product Manager, AC Motors,
Baldor Electric Company, A Member of the ABB
Group
William E. Neis, PE, President, NorthEast Industrial Sales
Dr. Lev Nelik, PE, Apics, President, Pumping Machinery,
LLC
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
American-made, API 541 Fourth Edition and API 547 First
Edition, large AC induction motors from Siemens deliver
unrivalled life expectancy, energy efficiency, and the
lowest Total Cost of Ownership.
State-of-the-art manufacturing processes allow our
customers to benefit from the broadest range of power
outputs (up to 18,000 HP and 13.2 kV), lower noise and
operating temperature, minimized vibration, smaller
footprint, and the toughest, most reliable motors
available anywhere in the world.
www.usa.siemens.com/motors
Petroleum and Chemical Industry Applications
With decades of proven performance in both critical and
severe duty refining and processing applications and the
power of a global R&D team, Siemens delivers innovation
and excellence in every motor we build.
Siemens is the leading provider of electric motors
worldwide and the leading provider of electric motors to
the petroleum and chemical industries. What can we build
for you to make your job easier?
The most reliable, longest lasting API 541
and API 547 certified Above NEMA motors.
Siemens meets both American Petroleum Institute standards with
the fewest comments or exceptions.
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SPECIAL SECTION:
PREDICTIVE & PREVENTIVE MAINTENANCE
p
Pump Vibration Analysis
Brian P. Graney, MISTRAS Group, Inc.
Monitoring vibrationa valuable tool in predictive/preventive maintenance
programs.
p
Predictive & Preventive Maintenance
Michael Walsh, GE Energy
Do not let a catastrophic event be your wake-up call to adopt a proactive
strategy.
COVER SERIES:
CHEMICAL PUMPS
p
Peristaltic Pumps in
Chemical Applications
Rick Balek, Watson-Marlow Bredel Pumps
Providing a low life-cycle choice for chemical metering
p
Safe Chemical Transfer
Mark L. Jones, Asahi America
The development of PE resin for industrial piping applications
p
ChemShow 2011
SEALING
p
New Leak Prevention Technology
Jack Tyler, P.E., Jack Tyler Engineering Company,
& Art Evans, Art Evans & Associates
Air-operated piston assembly, injectable packing and air ush
enhance this sealing systems performance in harsh applications.
p
Oil & Gas Project Sets New Standards
Ellen Klier & Franz Schfer, EagleBurgmann Germany
Tailored sealing solutions supply high-pressure sealing for Russias
East Siberia Pacic Ocean pipeline system.
PRACTICE & OPERATIONS
p
Safe Flushing
Ken Comerford, Vanton Pump and Equipment Corp.
Remove grit from pumped uids to safely ush bearings and seals
Table of Contents
DEPARTMENTS
P&S News. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Joe Evans, Ph.D.
Suction Specic Speed and Wastewater Pumps
Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 18
Luis Rizo, SABIC Innovative Plastics, & Lev Nelik,
Contributing Editor, P&S Editorial Advisory Board
How to Size Shims
Centrifugal Pump Hydraulics by the Numbers . . . . 22
Terry Henshaw
The Impact of the Area Ratio
Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Dale Evers, EnviroGear
The Real Golden Age of Sealless Pumps
Maintenance Minders. . . . . . . . . . . . . . . . . . . . . . . . . 44
Ross George, Littelfuse, Inc.
Microprocessor-Based Pump/Motor Protection Relays
FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 48
What are the key steps to cutting packing for optimum
performance?
HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
What is a balanced mechanical seal, and when is it usually used?
What is a pusher type seal, and what are the advantages of this
design? What is an energy efcient method for controlling the rate
of ow in pumping systems?
Product Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . 68
P&S Market. . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
November 2011
Volume 19 Number 11
The Magazine for Pump Users Worldwide November 2011
pump-zone.com
The Magazine for Pump Users Worldwide
pump-zone.com
November 2011
Special Section:
Maintenance
ChemShow Coverage
CHEMICAL
PUMPS
Equipment in
Harsh Applications
CHEMICAL
PUMPS
Equipment in
Harsh Applications
24
29
33
36
39
56
60
63
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K
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B
T8P 0H2 deliveries in
15-19 weeks ex factor]
T8NP BB8 deliveries in
22-25 weeks ex factor]
0ther APl models under
8O weeks ex factor]
Industry Leaders in API & Process
Deliveries!
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OPENING NOV. 2011
P&S News
NEW HIRES, PROMOTIONS &
RECOGNITIONS
SIEMENS (ATLANTA, GA.) announced
that Daryl Dulaney has been appointed
chief executive o cer of the companys
newly-formed Infrastructure & Cities (IC)
Sector in North America, which comprises
the U.S., Canada, Mexico and Central
America. Dulaney will also continue to
serve as president and chief executive
o cer of Siemens Industry, Inc., the legal entity comprising
both the Infrastructure & Cities and Industry Sectors in the U.S.
Siemens Infrastructure & Cities Sector provides inte-
grated mobility solutions, building and security technology,
power distribution, smart grid applications and low- and
medium-voltage products.
www.usa.siemens.com/infrastructure-cities
ANVIL INTERNATIONAL (PORTSMOUTH,
N.H.) announced that Todd Beckley has
joined the company as mechanical special-
ist covering Kansas, Missouri, Nebraska
and Iowa. Jim Roland has joined the com-
pany as Mechanical/Industrial Specialist for
the Midwest Region.
he company also announced the pro-
motion of Shawn Farrell to national mate-
rial control manager. Farrell has been with
Anvil for 19 years, serving for the past ten
years as a material control manager, with
responsibility for the Midwest, Northeast
and Canadian Regions.
Anvil International, a subsidiary of
Mueller Water Products Inc., is a manu-
facturer of pipe ttings, pipe hangers and
piping support for a wide range of applica-
tionsincluding plumbing and mechani-
cal, HVAC, industrial, re protection,
mining and oil and gas. www.anvilintl.com
BEARINGS PLUS (PEWAUKEE, WIS.)
announced that Dr. Bugra Ertas has been
appointed as the business unit director at
Bearings Plus. From 2000 through 2004,
Dr. Ertas collaborated with Bearings
Plus on development projects and rotor-
dynamic analyses. His work was instru-
mental in the upgrade of machinery with
new technology products.
Bearings Plus, a business of Waukesha Bearings
Corporation, designs, manufactures and services uid lm
bearings, seals and exible couplings for turbomachinery
applications. www.bearingsplus.com
NOV MONOFLO (HOUSTON, TEXAS)
announced that Dwight Waters joined
the NOV Monoo team as sales director.
Waters brings 20 years of international
selling, consulting, project management,
engineering and distribution experience in
the PC pump industry.
NOV Monoo manufactures pro-
gressing cavity pumps. www.monoo.com
FLUID AUTOMATION (GATESHEAD, U.K.)
announced that Kate Kilday has been
appointed the new role of sales develop-
ment and marketing manager. he manu-
facturer has created the role with the aim of
U.K. sales development and brand growth.
Fluid Automation is a
manufacturer of pumps and
pumping systems. www.uidautomation.co.uk
AROUND THE INDUSTRY
LAROX FLOWSYS (LITHICUM, MD.) changed its name to
Flowrox, eective September 15, 2011. he reason for the
signicant renewal of the corporate brand and image is the
recent acquisition of the parent company Larox by Outotec.
he pump and valve supplier Larox Flowsys was not included
in the deal and continues to develop and grow its business as
an independent company.
Flowrox provides solutions for abrasive, corrosive and
other demanding shut-o, control, pumping and dosing
applications serving a range of process industries.
www.owrox.com
WILO USA LLC (MELROSE PARK, ILL.) announced that its
corporate o ces moved to Rosemont, Ill. he rst business
day at the new facility was October 3, 2011.
WILO manufacturers pumps and pump systems for
heating, cooling and air-conditioning technology, water
supply and sewage and drainage. www.wilo-usa.com
KSB (HENRICO, VA.) will supply 20 pump sets worth several
million dollars for one of Mexicos largest infrastructure proj-
ectsa combined wastewater/stormwater pumping station
planned for completion in 2012. he KSB pumps involved
are the largest submersible motor units in the companys his-
tory. Each pump can handle 2,000 liters per second at a head
of almost 44 meters.
KSB produces pump products for industrial and utility
power plant services, environmental applications and water
and wastewater processing. www.ksbusa.com
KISTLER (FARMINGTON HILLS, MICH.) announced the
opening of its latest group company in Mexico, Kistler Instru-
Daryl Dulaney
Dwight Waters
Kate Kilday
Dr. Bugra Ertas
Todd Beckley
Jim Roland
Shawn Farrell
ments S de R.L. de C.V., based in Mon-
terrey NL, Mexico.
Kistler provides sensors and instru-
mentation that are used in R&D and
critical manufacturing operations.
www.kistler.com
NETZSCH (EXTON, PA.) announced the
expansion of the distribution territory of
Voigt-Abernathy from Alabama and the
Florida panhandle to include Eastern
Tennessee. Voigt-Abernathy will service
the industrial, chemical, pulp and paper
industries in this region.
NETZSCH oers progressing
cavity pumps, rotary lobe pumps, mac-
erators, dosing systems and accessories.
www.netzschusa.com
RUHRPUMPEN (TULSA, OKLA.)
announced that it acquired TIGER-
FLOW Systems, LLC. TIGERFLOW
manufactures packaged pumping sys-
tems for domestic water, re water sys-
tems, HVAC, industrial, heat transfer,
municipal, landscape irrigation and cus-
tom controls. It will continue operations
at the Dallas, Texas, manufacturing loca-
tion and will operate as an independent
subsidiary.
Ruhrpumpen manufactures centrif-
ugal pumps for the oil and gas, chemi-
cal, power, industrial, water and mining
applications. www.ruhrpumpen.com
NORD-LOCK (MATTMAR,
SWEDEN) acquired U.S.
company Superbolt Inc. and
Swiss company P&S
Vorspannssysteme AG. Superbolt and
P&S oer products for critical bolting
applications. he products are used in
heavy industries such as oshore, energy
and mining.
NORD-LOCK manufactures
securing systems for bolted joints.
www.nord-lock.com
THE FLUID SEALING ASSOCIATION
FSA(WAYNE, PA.) announced the
enhancement of its Mechanical Seal Life
Cycle Cost Estimator, which allows end
users to estimate life cycle costs for seal-
ing solutions on a comparative basis to
P&S News
CeraComp Components
45678
Greene, Tweed & Co.
|
PetroChem & Power
|
Tel: +1.281.765.4500
www.gtweed.com
08/11-GT AD-US-PP-011
A single pump failure can disrupt your plant for days bringing
production to a halt and impacting your bottom line.
Replacing your silicon-carbide components with CeraComp dramatically
reduces your risk of pump failures! This new ceramic-matrix composite
offers the chemical and thermal resistance you require with the increased
toughness and fracture resistance youve been looking for. CeraComps
superior material properties deliver increased reliability and MTBR (mean
time between repair), eliminating catastrophic failure and keeping your
plant running efciently.
Contact Greene, Tweed today to learn more about this exciting new material!
Wouldnt it be great
if everything was
FRACTURE RESISTANT?
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STOP
WASTING
CHEMICALS
SMART
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With precise dosing you can reduce chemical waste
and increase savings
Grundfos SMART Digital Dosing
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precision in water treatment and chemical and process engineering.
icroconIrolled sIepper moIor drives a Iurndown raIio oI up Io
onIinuous Iull sIroke lengIh displacemenI provides accuraIe smooIh and conIinuous dosing
low moniIor alerIs you Io Iailures in Ihe dosing process
uIoal IuncIion auIomaIically recalibraIes Ihe pump in case oI IlucIuaIing sysIem pressure
or inIelligenI Ilow managemenI and opIimum eIIiciency geI
www.grundfosalldos.com/smartdigital
P&S News
assist in decision-making when specifying capital projects or
upgrading existing rotating equipment technology. To access
this tool, visit www.uidsealing.com/lifecycle.html.
FSA is a source of technical information that supports the
development of related standards and provides education in the
uid sealing area. he organization promotes a safe, clean envi-
ronment for society and a safe work place for employees. www.
uidsealing.com
THE ENVIRONMENTAL PROTECTION AGENCYEPA
(WASHINGTON, D.C.), with other agencies, announced a
strategy for the responsible electronic design, purchasing,
management and recycling that will promote the burgeoning
electronics recycling market and jobs of the future in the U.S.
he announcement included the rst voluntary commitments
made by Dell, Sprint and Sony to the EPAs industry partner-
ship aimed at promoting environmentally sound management
of used electronics.
he Administrations strategy also commits the federal
government to take specic actions that will encourage more
environmentally friendly design of electronic products, pro-
mote recycling of used or discarded electronics and advance
a domestic market for electronics recycling that will protect
public health and create jobs.
he EPA also proposed a rule to advance the use of carbon
capture and sequestration (CCS) technologies, while protect-
ing Americans health and the environment. CCS technolo-
gies allow carbon dioxide (CO
2
) to be captured at stationary
sourcessuch as coal-red power plants and large industrial
operationsand injected underground for long-term storage
in a process called geologic sequestration.
he proposal is consistent with recommendations made by
President Obamas interagency task force on CO
2
. sequestra-
tion and helps create a consistent national framework to ensure
the safe and eective deployment of technologies that will help
position the U.S. as a leader in the global clean energy race.
In addition, the agency launched a new tool to allow 28
industrial sectors to submit their 2010 greenhouse gas (GHG)
pollution data electronically. Prior to being nalized, more than
1,000 stakeholders, including industry associations, states and
NGOs tested the electronic GHG Reporting Tool (e-GGRT)
to ensure clarity and user-friendliness.
he data collected with e-GGRT will provide the public
with important information about the nations largest station-
ary sources of greenhouse gas pollution. Industries and busi-
nesses can also use the data to help nd ways to decrease carbon
pollution, increase e ciency and save money.
For more information on the tool, visit www.epa.gov/cli-
matechange/emissions/ghgrulemaking.html.
he EPA was established to protect human health and
Larox Flowsys Peristaltic Pumps
THE SOLUTION YOUVE BEEN LOOKING FOR
With a range of sizes to choose from,
we have a pump to a accommodate every application
Larox Flowsys Inc. North America Tel. 410-636-2250 Fax 410-636-9062
info@larox.us www.larox.us
NEW Patented Technology:
single roller design.
Uses up to 50% less
energy than traditional
peristaltic pumps.
100% savings on
maintenance
and operational costs.
PUMPS & SYSTEMS www.pump-zone.com NOVEMBER 2011 11
to safeguard the natural environmentair, water and land
upon which life depends. www.epa.gov
GODWIN PUMPS (BRIDGEPORT, N.J.) announced new loca-
tions in the MidwestIndianapolis, Ind.; Evansville, Ind.; and
Cincinnati, Ohio.
Godwin Pumps is a direct, wholly-owned subsidiary of
ITT Corporation and maintains a eet of over 6,000 portable
rental pumps and 3,200 pieces of related equipment for dewa-
tering in construction; mining and quarrying; drinking water
supply; and in wastewater bypasses in municipal, industrial and
environmental markets. www.godwinpumps.com
THE HYDRAULIC INSTITUTEHI(PARSIPPANY, N.J.)
announced that both the Centrifugal Pump Test Standard (ANSI/
HI 1.6 2000) and the Vertical Pump Test Standard (ANSI/HI
2.6 2000) have been superseded by the newly released Stan-
dard for Rotodynamic Pumps for Hydraulic Performance Accep-
tance Tests, (ANSI/HI 14.6 2011).
he new test standard contains signicant updates from
the 2000 version(s) and is considered the new global reference
for testing centrifugal and vertical pumps.
HI is an association of pump producers and suppliers to
the pump industry in North America. Its mission is to serve as a
forum for the exchange of industry information, while providing
value-added services to member companies and pump users
worldwide. www.Pumps.org or www.PumpLearning.org
AERCO INTERNATIONAL, INC., (BLAUVELT, N.Y.) announced
the move of its corporate headquarters to 100 Oritani Drive,
Blauvelt, N.Y. 10913. AERCO previously operated out of three
separate facilities in Northvale, N.J. With 156,000 square feet,
the new headquarters is more than twice the size of AERCOs
former location.
AERCO oers commercial boilers and water heaters that
simplify infrastructure, reduce project costs and minimize life-
cycle expenses. www.aerco.com
INVENSYS OPERATIONS MANAGEMENT (LON-
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I
n the February 2010 issue of Pumps & Systems, I wrote
an article on my Excel-based Suction Specic Speed and
Suction Energy calculators and how they can be used to
predict the onset of suction recirculation. During the past
year, I have received several requests to revisit this topic and
its application to wastewater pumps.
Clear Water Impellers
Clear water impellers are usually designed for high e ciency,
but they can also be designed for low NPSHr. Increasing
the eye diameter decreases the inlet velocity and, therefore,
reduces the NPSH required to maintain uniform ow. It
is this reduction in inlet velocity that causes the NPSHr to
drop as ow moves to the left of a typical H/Q curve and
when the rotational speed of the same pump is reduced.
hese impeller designs can work well as long as ow
remains at or near the best e ciency point (BEP). If ow
moves too far to the left of BEP, the increased peripheral
velocity of the larger eye distorts the ow into the inlet and
directs a portion of the ow back out of the impeller (suc-
tion recirculation). During recirculation, intense vortices
arise and cause low pressure areas that will lead to cavitation
and severe pressure pulsations. he eect of the impeller eye
diameter on potential suction recirculation can be evaluated
using suction specic speed (S or N
ss
).
Suction Specic Speed
Igor Karassik and two of his associates, G.F. Wislicenus and
R.M. Watson, developed suction specic speed (S) in 1937
during their tenure at Worthington Pump. It is a dimension-
less number that describes the suction conditions that occur
due to the relationship of rotational speed, ow
and NPSHr. Its development overcame the lim-
itations of the homa-Moody constant, which
attempted to describe suction conditions by
relating head to NPSHr.
S can range from about 5,000 to over
20,000 and is computed by the equation
S = NQ/NPSHr
3/4
Where:
N is the rotational speed
Q is BEP ow
NPSHr is the NPSHr at BEP
Several pump organizations including the Hydraulic
Institute (HI) and American Petroleum Institute (API) rec-
ommend an S of under 10,000 to maintain a reasonable
range of ows without the potential for suction recirculation.
Wastewater Impellers
Wastewater pump impellers are not intentionally designed
for low NPSHr, but the relatively large eye required to pass
solids can often lower their NPSHr and increase the value of
S. he H/Q curves for some higher ow wastewater pumps
show a continuous increase in NPSHr as ow moves to the
left of BEP. his is exactly the opposite of the NPSHr versus
ow for clear water pumps with normal eye diameters. In the
case of wastewater pumps, discharge recirculation at the vane
exits can also increase the possibility of suction recirculation.
his is due to the lack of any vane overlap on most wastewa-
ter impellers, which results in the onset of discharge recircu-
lation at higher ows than expected. For more information
on suction and discharge recirculation, see Igor Karassiks
three part series Centrifugal Pump Operation at O-Design
Conditions. It is available on the Other Pump Topics page
of www.PumpEd101.com.
Figure 1 shows the S calculation for an 8-inch, 1,780-
rpm wastewater pump with a BEP ow and head of 3,000
gallons per minute at 135 feet and a specic speed (N
s
) of
2,450. BEP e ciency and NPSHr are 82 percent and 10
feet. he calculated value for S is 17,337.
Figure 2 shows the minimum continuous stable ow
(MCSF) for pumps with a given N
s
and S. MCSF is the ow
at which the onset of suction recirculation can begin. he
Y axis is S and the X axis is percent of BEP ow. he three
Joe Evans, Ph.D.
Suction Speciic Speed and
Wastewater Pumps
Figure 1. Suction specic speed calculation for a wastewater pump
Pump Ed 101
curves represent various pump N
s
. Note
that MCSF is dependent upon both N
s

and S.
he example in this column has
an N
s
of 2,450, so the upper curve will
be used. he red horizontal line at Y =
17,337 intersects the curve at X = 80
percent. herefore, this pump could
potentially begin suction recirculation
when the ow drops to just 80 percent
of BEP ow. If the suction energy ratio
(Pumps & Systems, February 2010) of
this pump is examined, an NPSHa to
NPSHr margin of 4.0 could be required
to provide stable operation at or below
80 percent of BEP ow.
Many higher ow pumps with rela-
tively low values of S can still exhibit an
increase in NPSHr as ow is reduced.
For example, the performance curve for
an 18-inch by 16-inch wastewater pump
(N
s
= 2,735) with a BEP ow of 16,000
gallons per minute at 200 feet shows an
NPSHr of 31 feet. he calculated value
of S is 11,072, which predicts an MCSF
Figure 2. Minimum continuous stable ow
Pump Ed 101
of approximately 50 percent. However, at 13,000 gallons per
minute (a ow reduction of just 19 percent), the NPSHr, as
shown on the curve, increases to 44 feet.
Submersible Wastewater Pumps
Submersible wastewater pumps can be especially problematic.
Although some undergo comprehensive NPSHr testing, many
are not tested at all. Others are tested at BEP only, and NPSHr
values are calculated at other ow points. Often it is assumed
that the additional inlet pressure provided by submersion will
provide adequate NPSH.
Actually, submersion oers no NPSH advantage since
pumps installed in dry pits also have a similar level of submer-
sion due to the water level in the wet well. Submersibles do
have one advantage, and that is lower
inlet losses due to no inlet piping and
ttings. his, of course, goes away when
they are installed in a dry pit submersible
application.
If the manufacturer does not pro-
vide NPSHr data, how can end users
identify potentially problematic sub-
mersible pumps? here is no perfect
way, but what I do is compare untested
pumps with similar ones from other
manufacturers that have been tested at
multiple ow points. To get a good com-
parison, end users need to compute the
N
s
of the untested pump and compare it
to tested pumps with the same or similar
N
s
, rotational speed, hydraulic e ciency,
eye diameter ratio, ow and head.
Here are some rules of thumb. S is
directly proportional to rotational speed
and the square root of ow. herefore,
higher speed and higher ow pumps will
more likely have higher values of S. I
have found that most 1,750-rpm pumps
with 4-inch discharges and ows under
800 gallons per minute will have an S
under 10,000, and 1,750-rpm pumps
with 6-inch discharges and ows under
1,750 gallons per minute have similar
values of S. However, as the eye diam-
eter ratio of either approaches 0.6, S can
exceed 13,000. If an end user plans to
run a wastewater pump to the left of
BEP and NPSHr is not part of the test
curve, he should get the manufacturer to
sign o on the application.
P&S
Joe Evans is responsible for customer
and employee education 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.
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I
received many comments and
suggestions on proper instal-
lation practices, following
my article Grouting: Pumps and
Telephone Poles, Pumps & Systems,
July 2010). My long-time friend
and colleague, Luis Rizo, discussed
these comments and wanted to
share with the readers some addi-
tional recommendations and ideas
on the subject.
Question
How is the width and length
of a shim determined for level-
ing machinery during align-
ment or installation? Are there
general rule-of-thumb practices?
We have a recycle gas Ingersoll-
Rand barrel compressor pow-
ered by an Electric-Machinery
1, 500-horsepower/2, 300-Vol t
motor with a 3420-S frame. he
motor rests on two continuous
60-inch long by 6-inch wide sole
plates. he two motor feet measure
59 inches by 5 inches each. What is
the potential damage to alignment
and/or the motor by using small
(6-inch by 6-inch) shims versus
large (24-inch by 6-inch) or con-
tinuous (60=inch by 6-inch) shims?
Jerry Choate
Murphy Oil USA, Inc.
Superior, Wisc.

The Answer
Luis Rizo oers this advice:
he question you should focus
on is How do I create a mono-
lith that will absorb all the force
to the base and foundation of the
equipment? he unbalanced force
of a reciprocating compressor is
Luis Rizo, SABIC Innovative Plastics, &
Lev Nelik, Contributing Editor, P&S Editorial Advisory Board
How to Size Shims
Pumping Prescriptions
Steps for Using Shims to Level Machinery
No. Step Description Date/initial
1. Inspect all the shims to be sure that they are either 306 or 316 SS
steel.
2. Inspect the shims to be used to make sure that no single shim
less than 0.005 inch (0.13 millimeter) is used alone. Any smaller
shims must be sandwiched between heavier shims0.040 inch (1
millimeter) to 0.060 inch (1.5 millimeter).
3. Verify that large stacks of shims have been replaced with equiva-
lent thicker shims to avoid creating a spring condition under the
base as a support.

4. Verify that the initial stack of shims under the baseplate is large
enough to allow for multiple level adjustments. For example, start
with a shim pack under each foot made up of one 0.062-inch.
(1.6-millimeter) and one 0.31-inch (7.9-millimeter), one 0.025-
inch (1-millimter) and two 0.015-inch (0.5-millimeter), 0.010-
inch (0.25-millimeter) and 0.005-inch (0.127-millimeter). his
combination has proven to allow great adjustment exibility.

5. Check, with a torque wrench, that all anchor bolts have been
properly tightened to the same torque value. Check to make sure
that this procedure is followed after every shim change. See stan-
dard torque values for B-7 bolts for the diameter used.

6. Using a machinist level (Starrett 98 or a master level), check the
level of the pads with respect to each other. Maximum out of level
is 0.002 inch (0.05 millimeter).

7. Inspect that all the machined surfaces on the baseplate are leveled
within 0.0005 inch (0.013 millimeter)/foot in two directions 90
degrees, after the anchor bolts have been snugged down. Use of a
master level (0.0005 inch/div.) is recommended. Do not exceed an
overall level variation greater than 0.010 inch (0.25 millimeter).

8. Inspect that the shim packs or wedges used for leveling are
located on both sides of the foundation bolt.

9. Inspect that the baseplate height has been set to the correct eleva-
tion as called for in the drawing.

10. Check that all the leveling devices are in full and solid contact
with the concrete or the baseplate.

11. After nal anchor bolt tightening, recheck the level. Do not
exceed 0.010 inch/(0.25 millimeter) maximum out of level over
the entire length of the baseplate. Consult the responsible reli-
ability team member before continuing.

12. When all the steps have been accepted, the baseplate leveling is
complete, and the baseplate is ready to be grouted.

proportional to the reactive force. In a liquid slug scenario as
you probably know, this force is not measurable, so it amounts
to an innite amount of force.
I would try to get a shim as large as practical to cover
the width of the foot for the hold down bolt at each of the
feet. Another option is to use a liquid chock to level and hold
your machine down, so that the complete structure becomes a
monolith. Figure 1 is a similar compres-
sor, grouted many years ago, that it is still
operational today at the Exxon Baytown
renery/chemical plant complex.
On www.pump-zone.com, see the
gure with some ideas on leveling tech-
niques for horizontal baseplates. here
are four methods to provide vertical
adjustments to a horizontal baseplate. A
single wedge, parallel wedges, shim packs
and jacking screws on metal plates. he
preferred method of the author is the
jacking screw on metal plates combined
with metal shim plates. he following
drawings illustrate the four methods.
Julien Le Bleu adds:
he rst question is generally to
try to size the shims to match the feet if
possible. When I was with GE, we often
had large sole plates. We would make several, non-shrink grout
pads along the length of the plate and the same width as the
plate. his was done after the plate was leveled with jacking
screws and checked for no humping or sagging. he small pads
were made with Styrofoam and liquid non-shrink grout poured
in and allowed to set up.
he plate was then pulled and the foam form was removed.
Figure 1. A compressor, grouted many
years back, that it is still operational at the
Exxon Baytown renery/chemical plant
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Pumping Prescriptions
he grout was cleaned and the plate set down again. If all is correct, make another
form around the entire plate and pour non-shrink grout into it and have it include the
small pads poured previously.
If the plates need to be shimmed up to get to elevation do it with stainless steel
shims on each of the small pads. When all is as you need it, then complete the step
above, and put it all in the nal pour of non-shrink grout.
P&S
Dr. Nelik (aka Dr. Pump) is presi-
dent of Pumping Machinery, LLC,
an Atlanta-based rm specializing
in pump consulting, training, equip-
ment troubleshooting and pump
repairs. Dr. Nelik has 30 years of
experience in pumps and pumping
equipment. He can be contacted at
www.PumpingMachinery.com.
Figure 3. Positioning of plates for jacking
screws near the anchor bolts
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I
n March 1980, I attended the ASME symposium on
Predicting the Performance of Centrifugal Pumps and
Compressors in New Orleans. I was about three rows
from the podium, sitting next to a fellow who introduced
himself as Hal Anderson from Scotland. He said that he
had one foot on his motorbike and the other in the grave. It
turned out that he was H. H. Anderson of area-ratio fame
and was at the symposium to deliver a paper on his area-
ratio principle.
As we walked to the cafeteria and ate lunch together,
Anderson was approached by people requesting his auto-
graph (one was from Australia). He was well-known and well-
respectedand his area-ratio principle was well-founded.
Anderson introduced the area-ratio principle in 1938
[1]. he denition is:
Y =
A
R2
A
4
(1)
Where:
A
R2
= total relative discharge area of impeller = b
2
L
R2
b
2
= width of impeller vane at the outside diameter
(OD) of the impeller
L
R2
= distance from discharge vane tip to the closest
point on adjacent vane
A
4
= total throat area
Figures 1 and 2 illustrate the two areas.
Andersons work (1, 2, 4, 5) showed a denite correla-
tion between Y and N
S
(specic speed). he higher values of
Y correlated to lower values of specic speed. Both horne
[3] and Jekat [6] also wrote about the area ratio principle.
What seems to be the most useful is contained in reference
6.
Figure 3 is a redrawn graph from Jekat [6], with straight
lines substituted for slightly curved lines. he text says that
the band results from the authors data and shows the con-
siderable range of area ratios which are used in actual pump
designs. (Jekat recommended against extrapolating the
graph to lower values of N
S
.) It is possible to write equa-
tions for the (straightened) lines on the graph. Jekats high
e ciency line can be expressed as:
Terry Henshaw
The Impact of the Area Ratio
Centrifugal Pump Hydraulics by the Numbers
Figure 1. Partial impeller plan view showing pertinent perfor-
mance parameters
Figure 2. Partial impeller prole view showing pertinent
performance parameters
Figure 3. Jekats chart plotting 1/Y, the inverse of the area
ratio, as a function of N
s
Y =
275
N
s
(2)
where N
S
is dened by the following equation:
N
S
=
NQ
bep
(H
bep
)
0.75
(3)
Where, in U.S. units:
N
S
= specic speed
N = rotative speed of impeller
(revolutions/minute)
Q
bep
= capacity of pump at the
best e ciency point (gallons/
minute)
H
bep
= head of a single stage of the
pump at the best-e ciency-
point (feet)
I have obtained high-e ciency
pumps with numerators ranging from
2,450 to 2,750. Note that a Y value of
1.0 occurs where N
S
is about 2,500,
right in the middle of the Worthington
graph, right where maximum pump
e ciencies reach their peak. Is that just
a coincidence? (To view the graph, see
Centrifugal Pump Specic Speed in
Pumps & Systems, September 2011.)
hree years after that visit in New
Orleans, I wrote to Mr. Anderson with
a question about throat area. My letter
was returned, unopened, containing a
hand-written note gone away. Had he
taken his second foot from his motor-
bike and placed it also into the grave? I
never heard.
P&S
References
1. Anderson, H. H., he Harland Engineering
Company, Scotland, he Hydraulic Design
of Centrifugal Pumps and Water Turbines,
ASME paper 61-WA-320, American Society of
Mechanical Engineers, New York, N.Y., 1961.
2. Anderson, H. H., he area ratio system,
World Pumps magazine, June 1984.
3. horne, E. W., Worthington-Simpson Ltd.
U.K., Design by the Area Ratio Method,
Pumps 1979, Sixth Technical Conference of
the British Pump Manufacturers Association,
Canterbury, England, 28 30 March, 1979.
4. Anderson, H. H., Prediction of Head,
Quantity and E ciency in Pumps the Area
Ratio Principle, he 22nd Annual Fluids
Engineering Conference, he American
Society of Mechanical Engineers, New
Orleans, La., March 9 13, 1980.
5. Anderson, H. H., Weir Group, Centrifugal Pumps, hird Edition, Trade &
Technical Press LTD., England, 1980.
6. Jekat, Walter K., Centrifugal Pump heory, Section 2.1 of the rst
edition of the Pump Handbook, edited by Karassik, Krutzsch, and Fraser,
McGraw-Hill Book Co., New York, N.Y., 1976.
Terry Henshaw is a retired engineer living in Magnolia,
Texas. He worked 50-plus years in the pump industry. He
can be reached at pumprof@att.net.
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Special Section: Predictive & Preventive Maintenance
T
he most revealing information
on the condition of rotating
machinery is a vibration signa-
ture, according to some sources. his
article will introduce the basics of using
vibration data to determine the mechan-
ical condition of pumps and implement
it in a predictive/preventive mainte-
nance program. Vibration consists of
amplitude, frequency and direction.
hese provide the information needed
to diagnose the machines condition.
Pumps come in several types (such
as centrifugal, turbo, propeller and posi-
tive displacement). hey generate pump-
ing frequencies due to ow and recircu-
lation (i.e., number of vanes multiplied
by rpm for centrifugal/turbo pumps or
number of screws, lobes or axial piston
for positive displacement pumps).
Pumps also have other mechanical prob-
lemsimbalance, misalignment, loose-
ness, worn bearings, pipe strain and
resonance.
Vibration measurements are taken on each
bearing location in three planes: vertical, hori-
zontal and axial. he diagnostic information from
vibration analysis will be determined by:
Severity Amplitude In/Sec Peak
Frequency Cycles per Minute CPM or Hz
Cycles per Second
he direction of the vibra-
tion measurement or plane of
measurement will also determine
the machine vibratory prob-
lem. Since vibration can occur
throughout a broad frequency
range, Table 3 has recommended
frequency ranges and lines of
resolution to help nd particu-
lar machine problems. Severity
Pump Vibration Analysis
Brian P. Graney, MISTRAS Group, Inc.
Monitoring vibrationa valuable tool in predictive/preventive maintenance programs
Table 1. Overall Vibration Standards Velocity In/Sec Peak
STANDARD MEASUREMENT ALERT LEVEL ALARM LEVEL
Hydraulic Inst. Casing 0.3
ISO 2372 Casing 0.25 0.6
E.P.R.I. FP 754 Shaft 0.5 0.8
A.P.I. 610 Shaft 0.4
Rathbone Chart Casing 0.3 0.6
Figure 1. Vibration severity chart with frequency as follows: Left - Velocity In/Sec Peak,
Bottom - Frequency in CPM, Top Diagonal Down - Displacement Mils Peak-Peak
Table 2. Overall vibration velocity guide line for various motor pump assemblies and speeds
Machine Type
1000+ RPM ALERT FAULT ADVANCED. FAULT
Motor/Pump Horizontal Centrifugal 0.3 0.45 0.6
Motor/Pump Horiz. Belt Driven Centrifugal 0.4 0.6 0.8
Motor /Pump Vertical Centrifugal (<5) 0.3 0.45 0.6
Motor/Pump Vertical Centrifugal (5<8) 0.4 0.6 0.8
Motor/Pump Vertical Centrifugal (8<12) 0.5 0.75 1
Motor/Pump Horizontal Hydraulic 0.2 0.3 0.4
(continued on page 25)
indicates how bad the problem
(Table 2) is, and frequency indi-
cates what is causing the problem
(Table 4). Vibration measure-
ments have three dierent ampli-
tudes as follows:
Displacement Mils
Peak-Peak:
Good for determining movement of
the machine
Turning speed vibration levels
Normally used to measure large
sleeve bearing machines
Severity requires the need to know
the frequency
Velocity In/Sec Peak:
Used for broad frequency ranges 100
Cpm 120,000.00 Cpm
he most common measurement
used for machine vibration analysis
Velocity severity is independent of
frequency, which is why it is used by
most severity guidelines
Acceleration Gs RMS
Good for determining high-fre-
quency vibration problems due to
worn rolling element bearings or
gears
Severity requires the need to know
the frequency
When analyzing vibration data, an
FFT vibration spectrum may be broken
down into several frequency ranges to
help determine the machine problem.
Commercially available machine vibra-
tion software has narrow band selective
alarming, which is used to help screen
vibration data and assist the analyst in
determining the machine problem.
Horizontal center hung centrifugal
pumps and vertical center hung cen-
trifugal pumps have dierent vibration
measurement locations. For images of
these locations, please go to www.pump-
zone.com.
Overall vibration severity is used for
determining the condition of a machine.
here are several standards and guide-
lines for determining severity of machine
vibration as shown in Table 1.
600-900 RPM
Motor/Pump Horizontal Centrifugal 0.27 0.4 0.54
Motor/Pump Horiz. Belt Driven Centrifugal 0.36 0.54 0.72
Motor /Pump Vertical Centrifugal (<5) 0.27 0.4 0.54
Motor/Pump Horizontal Hydraulic 0.18 0.27 0.36
Table 2. (continued from page 24)
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Table 4. Frequency diagnostic chart to help determine the machine problem
Frequency Plane Problem
1 x rpm Radial Imbalance - Sinusoidal TWF
1 x rpm Radial Eccentric Rotor/Sheave
1 3 x rpm Radial/Axial Misalignment - Sinusoidal TWF
1 2 x rpm Axial Bent Shaft
Multiplies of rpm, with orders Radial Rotor Rub - Truncated Time Wave Form
1 x rpm Vertical Looseness - Structural - Asymmetrical TWF
Multiplies of rpm Radial Looseness - Mechanical - Impacting TWF
1 x rpm Radial Resonance 3:1 Amplitude Difference
1 x rpm Vertical Bearing Clearance - Sleeve Bearing
Multiplies of rpm Vertical Bearing Wear - Sleeve Bearing
.4 x rpm Radial Oil Whirl Sleeve Bearing
1 x rpm Axial Thrust Clearance Sleeve
Multiple, non-synchronous peaks Radial/Axial Roller Bearings High Frequency
#Vanes x rpm Radial Vane Passing - Cavitations Pump
0.4 x rpm of pump Radial Turbulence Pump
Multiplies of rpm Radial Reciprocating - Compressors Diesel
#Gear Teeth x rpm Radial Gear Meshing Gears
Multiplies of sub-synchronous vibration Radial Drive Belt Wear - Belt Driven
2 x Line frequency - LF Radial/Axial Electrical Vibration - Motors - Generators
#Rotor bars x rpm side bands at 2 x LF Radial High Frequency Electrical Vibration
#Stator slots x rpm side bands at 2 x LF Radial High Frequency Electrical Vibration
6 x Line Frequency Radial/Axial High Frequency Electrical Vibration
1 x rpm - side bands at slip frequency Radial/Axial Broken Rotor Bar
Table 3. General guidelines for how to set up motor/pump assembliesfrequency ranges,
lines of resolution, averaging typefor various speed ranges and bearing type
Machine Type RPM BRG Type Orders x RPM Fmax - Hz LOR Averaging # Averages
Motor/Pmp 450 Roller 50 375 800 Normal 6
Motor/Pmp 1,200 Roller 50 1000 1600 Normal 6
Motor/Pmp 450 Sleeve 20.0 150 400 Peak-Hold 6
Motor/Pmp 1,200 Sleeve 20.0 400 800 Peak-Hold 6
Case Study
A boiler feed pumpa horizontal centrifugal pump with a
roller bearinghad a history of elevated vibration levels at
turning speed (3,525 rpm) in the horizontal plane. his was
due to imbalance and oset misalignment.
his pumps problem was that the outer pump bearing,
horizontal plane, had roller bearing deterioration. he rapid
rate of bearing deterioration was due
to the increased load from the turning
speed vibration in the horizontal plane.
How can this data be analyzed?
he overall vibration velocity levels
are over 0.8749 In/Sec Peak (Refer to
Table 2 for three tier alarm criteria for
1,000-plus rpm horizontal centrifugal
pump). Overall vibration was in excess
of 0.6 In/Sec Peak which indicates an
advanced fault. Refer to Figure 1. Go
to the left-hand side, amplitude In/Sec
Peak, and look up 0.8749 In/Sec Peak
which indicates danger failure near.
he turning Speed Vibration is
more than 0.486 In/Sec Peak. Refer to
severity in Figure 1 with amplitude on
the left-hand side and frequency along
the bottom in Cpm. Machine speed
vibration is occurring at 3,525 Cpm
with an amplitude of 0.486 In/Sec Peak.
Cross reference amplitude and the fre-
quency is on the boundary of danger
failure near. Refer to Table 4, frequency
diagnostic chart, Line 1, Imbalance.
he Non-Synchronous Peaks due
to fault frequencies at 3.2 multiplied by
the turning speed is the roller bearing,
ball pass frequency outer (BPFO). his
indicates an outer race defect. he high-
est amplitude of this defect is 0.171 In/
Sec Peak at the fourth harmonic of the
fault frequency. Refer to Figure 1, cross
reference amplitude 0.171 In/Sec Peak
with frequency at 44,770 Cpm - danger
failure near. Refer to Table 4, frequency
diagnostic chart, Line 13, roller bearing,
non-synchronous peaks.
When a rolling element bearing
is failing, it produces high frequency
vibration, therefore generating high
acceleration levels measured in gs. his
is another severity indication of how
advanced the bearing deterioration had
becomea time wave form amplitude
of 121 gs Peak-Peak with an RMS value
of 16.2 gs. Refer to Figure 1, acceleration
right-hand side of chart bottom diagonal up, 16.2 gs RMS
indicates danger shut down.
Refer to Table 5 and nd the trend data 1st and 2nd bear-
ing bands. he amplitudes are 0.827 In/Sec Peak and 0.278 In/
Sec Peak. he rst bearing band alarm is 0.12 In/Sec Peak, 40
percent of the overall level. he second bearing band alarm is
0.09 In/Sec Peak, 30 percent of the overall level.
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Conclusion
Becoming a skilled vibration analyst
takes years. However, vibration mea-
surements can reveal important infor-
mation regarding the mechanical reli-
ability of a machine and are a critical
component of any predictive/preven-
tive maintenance program.
P&S
Brian P. Graney is currently the Vibra-Metrics national sales manager for MISTRAS Products & Systems
and is responsible for the overall Vibra-Metrics business development. Brian is certied in Vibration Analysis
Level II; is an American Bureau of Shipping Recognized Condition Monitoring External Specialist; and is
a member of Vibration Institute, Society of Maintenance Professionals and ASNT.
Table 5. Simple narrow band alarms for sleeve and roller bearings
Percentage of Overall Value for each Narrow Band Alarm
Sleeve Bearing Simple
Band Name Band No. Percent Band Fault
Sub. Synchronous 1 15 20% Oil Whirl
1 x rpm 2 80 90% Imbalance/Misalignment
2 4 x rpm 3 60 67% Misalignment/Looseness
5 20 x rpm 4 30 40% Bearing Wear/Vane Passing
Roller Bearing Simple
Band Name Band No. Percent Band Fault
Sub. Synchronous 1 15 20% Cage Defect
1 x rpm 2 80 90% Imbalance/Misalignment
2 4 x rpm 3 3 Misalignment/Looseness
5 20 x rpm 4 30 40% 1ST Bearing Band Note:1
21 50 x rpm 5 20 30% 2nd Bearing Band Note:2
Note: 1 Fundamental Bearing Defects Outer & Inner Race.
Note: 2 Harmonics for Bearing Defects Outer & Inner Race
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A
ll too often, we have found the tipping point to pre-
dictive maintenance is a costly breakdown of motors,
pumps and related systems, or worse, a serious catas-
trophe that not only damages equipment and cripples your
operations, but impacts employee safety as well. According to
a recent U.S. Department of Energy study, 55 percent of those
responsible for industrial plant maintenance admitted to char-
acterizing their program as reactive and 31 percent as pre-
ventive only. It does not have to be that way.
It is established in the industry that predictive, rather than
just reactive or preventive maintenance of existing equipment,
will likely save money in the long run and can also help prevent
the development of serious hazards leading to a safety problem.
Whether an organizatin is a pharmaceutical facility using small
25-horsepower motors or an oil and gas plant operator requir-
ing a 60,000-horsepower synchronous machine, the same pre-
cepts apply: Take care of it now or pay later.
Predictive and Preventive Maintenance
You Need Both
Predictive and preventive maintenance are dierent, but both
are complementary and one should not be conducted exclusive
of the other. hey each can help protect equipment and people.
Predictive maintenance is a process that is custom-designed
for your specic system, built out of regular observation and
recordkeeping to understand trends and uncover anomalies.
End users can, therefore, leverage this historical data to take
future actions to optimize their operational e ciency.
Preventive maintenance is similar to following the mainte-
nance directions in an auto manualsuch as when to change
the oil, when to check the belts, when to rotate the tires, etc.
Most original equipment manufacturers (OEMs) rigorously
test their equipment for a battery of conditions that ensure
peak performance in many applications. Following included
operating and maintenance documentation is always advisable.
Reaching out to the OEMs of major pump platform com-
ponents may also be a good idea. In many cases, they will have
deep engineering expertise, application performance knowl-
edge and global experience that your team could use.
With larger companies, a good knowledge base often exists
in-house on most system components. However, in many of
the best organizations, this knowledge is refreshed regularly
with instruction by acknowledged industry experts with deep
domain expertise. his internal expertise can also be supple-
mented from time to time with consulting experts in advanced
diagnostics and troubleshooting technologies. Diagnostics can
make all the dierence in the world, and used in a healthy pre-
dictive maintenance program, will catch problems before they
severely impact operations.
A few OEMs may have deep technical knowledge on
multiple components of equipment and could be made avail-
able as a consultant on the ner points of condition monitor-
ing instrumentation and diagnostic services for monitoring
machinery vibration. Casting a wider net for knowledge of the
system components will help develop a rm foundation upon
which a truly predictive maintenance program can be built.
Economics and Safety
he primary outcomes of predictive and preventive
maintenance can have a real impact to an end users bottom
line. hese measures, too, can provide savings based on the
avoidance of downtime, damage to equipment and employee
wellbeing.
Many risk studies use similar numbers to illustrate the
inherent advantage of adopting a more proactive maintenance
approach. hey can also be used as a template to uncover the
resulting costs in operations to craft a more realistic model.
Consider that a reactive maintenance strategy would likely
contain up to 14 percent risk, which equates to $140,000 of
yearly maintenance on every $1 million worth of existing assets.
Compare this to a predictive maintenance strategy, which
would contain less than half the risk, about 6 percent, which
equates to $60,000 of yearly maintenance per $1 million of
existing assets. hat is a dierence of $80,000 per year. End
Maintenance
Michael Walsh, GE Energy
Do not let a catastrophic event be your wake-up call to adopt a proactive strategy.
users may nd that these resulting savings will easily pay for a
predictive program.
hen consider the other savings not mentionesuch as
unplanned downtime, injured workers and strained customer
relationships. he business reasons that justify this path become
more evident as the real costs are investigated.
hrough experience, making adjustments nowperhaps
investing money nowis better than waiting for a disaster to
happen and paying ten-fold from having personnel injuries,
line stoppages and equipment replacement.
Some recommendations are given below to make end
users systems as fail-safe as possible. hese can make mainte-
nance managers, plant operations personnel, nancial person-
nel and the CEO rest better at night.
Based on sound industry practices
and experience, a comprehensive pro-
active maintenance strategy requires a
system that captures repetitive failures
so that appropriate corrective changes
are made. his demands good record
keeping of all maintenance pro-
grams and a root-cause-analysis of
any maintenance performed. hese
records should be reviewed annually
and semi-annually.
Conduct both preventive and
predictive maintenance on systems.
Follow the manufacturers minimum
maintenance recommendations.
Regularly take non-intrusive measure-
mentssuch as vibration analysis,
infrared (IR) analysis and insulation
readingsand then compare these
measurements so that equipment
failure can be predicted. Making
these predictions allows maintenance
and production departments to work
together to schedule repairs.
In todays facilities, power quality
problems can wreak havoc on high-
tech controls and electrical devices
such as transformers, switchgear,
switchboards, power panels, motor
control centers and variable frequency
drive systems. A recent study found
that up to 80 percent of these power
quality issues are born in facility
electrical distribution and ground-
ing systems. Consider using a power
system study to maintain (and
upgrade if necessary) the power-deliv-
ery infrastructure.
Apply vibration diagnostics to detect
mechanical and electrical anomalies
in motors and the rotating equip-
ment that they drive. Problems can
involve misalignment, improper
mounting, infrastructure contamina-
tion, bent shafts, a faulty motor or an
unbalanced motor or pump.
Apply IR analysis to detect electrical system overloading,
under-loading or faults with connection. It also detects
mechanical abnormalities, such as temperature dierentials
in the bearings or couplings. Detecting temperature dier-
ences or elevated temperatures along pump seals or gaskets
can indicate impending failures.
Motor insulation testingor static testingveries typical
motor faults. Insulation testing helps
verify if there are high-resistance con-
nections within the motor winding,
ground wall insulation condition and
turn-to-turn insulation. Anomalies
discovered in test results can lead to
catastrophic failure if not corrected.
Bearing troubles are often a lead-
ing causes of motor failure.
Contamination and poor lubrication
are leading causes. Excessive load-
ing or preassembly damage (from
misalignment, pump cavitation,
excessive pump ow and exposure to
temperatures outside bearing thermal
limits) can result in failures as well.
Misalignment occurs when coupling
the motor shaft to the pump shaft.
In such cases, dynamic testing is
required, and the equipment is acti-
vated until the operating temperature
is reached, and then the equipment is
shut down. Alignment is performed
while the motor and pump are at, or
close to, operating temperatures.
If a motor fails, the maintenance
manager must decide if the motor
should be replaced or rewound.
Waiting for a motor failure is not the
best maintenance strategy. Every facil-
ity should have a repair/replace policy.
Possible, a rewound motor can work
ne and, perhaps, provide even more
horsepower than the original. he key
bywords are reliability and e ciency.
Some motors will not be put into
service for months and instead are
stored. he storage location must be
clean and dry. Storage temperatures
must be between 50 and 120 degrees
F. Relative humidity must not exceed
60 percent. Motors with anti-friction
bearings must be lubricated.
Conclusion
he goal is to take care of problems
before they occur. In the process,
end users can ensure the operational
e ciency and reliability of their equipment and the safety of
their employees.
P&S
Michael Walsh is general manager of global Industrial
Services for GE Energy. He has over 20 years of technical
and operational experience in upgrades, maintenance and
repair of industrial equipment. He resides in Atlanta, Ga.,
and can be reached at michael1.walsh@ge.com.
Cover Series: Chemical Pumps
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CHEMICAL PUMPS
Equipment in Harsh Applications
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I
n recent years, peristaltic pumps have become a
more popular choice than diaphragm metering
and progressing cavity (PC) pumps for chemi-
cal metering and sludge pumping. Peristaltic pumps
have the lowest total life cycle cost (LCC). Recent
design improvements and advances in tubing materi-
als are extending the technologys range even further.
The Basics
Peristaltic pumps work by forcing uid along by
waves of contraction produced mechanically on
either exible tubes or hoses. Tubing pumps use a
single rotating piece that incorporates rollers that
occlude (squeeze) an extruded piece of synthetic
elastomeric tubing. In between each roller pass, the
tube restitutes (opens) to create a vacuum and draws
in the pumped uid. his continuous dynamic eect creates
a positive displacement ow, pushing the uid through the
pump.
In a hose pump, a sliding shoe with proled or crescent
shaped leading and trailing edges gives a gradual lead-in and
termination to each hose occlusion. his prevents an abrupt
imposition and release of pressure and increases hose life. A spe-
cially developed lubricant in the pump head eliminates external
hose wear from contact with the sliding shoes.
In the past, the fundamental problem in applying peristal-
tic hose pump technology to chemical metering was the devel-
opment of a hose element that could accommodate continuous
duty and required ow rates, with the ability to handle highly
abrasive and chemically aggressive uids.
Due to advancements in hose and tubing materials and the
integration of sophisticated electronics, including micropro-
cessor-controlled robotic grade drives, peristaltic pumps have
become the fastest growing type of positive displacement (PD)
chemical metering and sludge pumps.
Todays heavy-duty peristaltic pumps are designed to oper-
ate around the clock and combine precise PD ow and low
maintenance requirements with the ability to handle extremely
abrasive and aggressive uids.
Peristaltic Pumps Versus Diaphragm &
Progressing Cavity Pumps
In the past, the accepted pump choice for chemical metering
had been the diaphragm metering pump, either mechanically,
hydraulically or solenoid actuated. For sludge applications, the
most frequently used pump was the PC pump. Both are so
ubiquitous that operators simply accepted the need for opera-
tor attention, along with routine maintenance and its attendant
costs. A comparison shows that peristaltic pumps oer a reduc-
tion in these costs.
For example, diaphragm pumps have internal check valves
that can clog or wear out. his is a common problem in chemi-
cal pumping, when diaphragm pumps move solid-laden uids,
such as lime or carbon slurry. Dirty chemicalsfor example,
ferric chloride or reclaimed methanolalso pose a threat.
Peristaltic pumps have no internal check valves to clog or
wear out. Also, if air is accidentally introduced into the lines
when pumping sodium hypochlorite, the hypo may partially
Peristaltic Pumps in
Chemical Applications
Rick Balek, Watson-Marlow Bredel Pumps
Providing a low life-cycle choice for chemical metering
Figure 1. Peristaltic chemical metering pump installation
crystallize and the this solid may cause havoc with a
diaphragm pumps check valves. his is no concern
for peristaltic pumps, because the crystals will pass
through the system.
Another common diaphragm pump concern is
the pumps inability to move entrained air, for exam-
ple, in sodium hypochlorite applications. Sodium
hypochlorite naturally erodes over time and emits an
o gas, which can cause a diaphragm pump to lose
prime even though the pump is still running.
When this phenomenon occurs, an operator
must bleed the air from the line and re-prime the
pump. Peristaltic pumps will move the pocket of air
(o-gas) as e ciently as it pumps the hypochlorite.
When a diaphragm pump is repaired, a new
pump head is often required. If the actual diaphragm
fails, the internal workings of the pump would be
contaminated by the pumpage and could easily be
corroded or worn if an abrasive product wearing the
many metal-to-metal contacting parts. Replacement
can be expensive.
By comparison, with a peristaltic tubing pump,
one may simply slide the same piece of tubing that
is currently installed just one foot or so, such that a
new section of the tube is located within the pump
head, allowing for new pinch points to be occluded
by the rotor. his preventative maintenance takes
only seconds and since a 50-foot spool of tubing
costs approximately $150 and lasts about ve years,
the maintenance cost is negligible.
With PC pumps, the stator will quickly burn
up if allowed to run dry. If the stator is not replaced
soon after signs of initial wear, the chrome or ceramic plating
may also wear, causing a signicant negative impact on the
rotor. he combination of these two most commonly replaced
parts can easily equal 65 to 70 percent of the cost of an entire
PC pump. By contrast, peristaltic pumps can run dry with-
out damage. Replacement cost for a peristaltic hose pump is
roughly 10 percent of the cost of a new pump.
Additionally, most PC pumps require two complex univer-
sal joints to transmit torque from the pumps drive shaft to the
connecting rod and then to the rotor. hese parts are typically
protected by an elastomeric joint seal or cover, which frequently
fails, allowing sludge to enter the joint and quickly wear out
the pumps internal components. By comparison, the rotating
parts of a peristaltic pump are separated from the pumped uid
because the uid only contacts the inside of the hose or tubing.
Servicing a typical PC pump can be a time consuming task
that requires removing the motor from the pump, removing
the pump from its base plate and transporting the pump to a
workbench in a plants maintenance shop.
Servicing most peristaltic hose pumps is simple. As the
hose is the only wearing part of the pump, one simply drains the
lubricating uid from the pump housing, removes the pump
ttings, and then runs the pump to expel the failed hose. To
install the new hose, the procedure is reversed. he pump does
not need to be removed from its base, and the pump motor can
remain in place. his self-loading design signicantly reduces
maintenance time and cost while the pump actually performs
the physical work.
One primary reason for the increasing acceptance of hose
pumps in some applications is their ability to pump extremely
abrasive sludges, even grit itself, without damage. Hose pumps
do not wear due to abrasion, whereas the PC pump sustains
pressure from the pumps seal line equaling the length and
circumference of the pumping elements, the rotor and stator.
When pumping abrasive uids, this interference or compres-
sion t between these elements will erode until there is a surface
contact t, resulting in an ever-widening clearance t.
his wear causes slip of the abrasive sludge, a primary
reason for stator/rotor failure in PC pumps. Sometimes, the
higher viscosity of the sludge may cause the automated variable
speed drives integrated with programmable logic controllers
(PLC) to automatically increase the speed of the PC pump.
his increased speed also greatly increases wear (4 times PC
pump wear = 2 times rpm). By comparison, wear on a hose
pumps hose is linear (as opposed to exponential), as pump
speed increases.
A nal major advantage of peristaltic pump technology
Table 1. Key advantages of peristaltic pump technology
Only one wearing part: the tube or hose
Can run dry without damageno expensive protection package to buy
Hose does not wear due to abrasionno slip
Metering accuracies to 0.5 percent
Turn down ratios to 1,000,000:1 with same pump
Tubing change in as little as three seconds
Can pump gassespump will never vapor lockperfect for hypo
Can handle very high solid content materials
Reversible100 percent efcient in either direction
Suction lift to 31 feet
No internal ball check valves to clog or wear out
Pump is sealless: No mechanical seal or packing
Eliminates seal water ush systems & piping
Eliminates in-line check valves as the pump is the check valve
Eliminates de-gassing valvesthe air is easily pumped through
Eliminates back pressure valvesperistaltic pumps do not require a
minimum sustained back pressure to operate correctly
Pulsation Dampeners are often eliminated
Eliminates in-line strainers
Multiple pump heads on one drive
Flows from 0.1 micro liter to 350 gpm and pressures to 232 psi
Small footprint
Lowest life-cycle cost (LCC)
is the reduction of ancillary equipment required in a chemical pumping
system. he capital, installation and maintenance costs of this extra equip-
ment must be added to that of the pump/motor to provide a true LCC for
the entire pump system.
For example, Figure 1 shows an example of a chemical metering appli-
cation in which three diaphragm pumps were replaced with three peristal-
tic tubing pumps. Ancillary equipment for the diaphragm pump includes
pulsation dampeners, articial back-
pressure valves, degassing valves and in-
line strainers. None of these items are
required with peristaltic tubing pumps.
In addition, ow meters are often elimi-
nated, as the accuracy of a peristaltic
pump is usually superior to that of the
ow meter itself.
Typical ancillary equipment for a
peristaltic pump includes a high-pres-
sure cut out sensor/switch combination
to prevent pumping against a plugged
line or closed valve. About 1 percent of
tubing pump installations and 35 per-
cent of hose pump installations incor-
porate pulsation dampeners, which
remove about 98 percent of trace pul-
sation. his device is recommended in
most belt lter press and centrifuge feed
applications. On occasion, a calibration
column may be included as a simple way
to calibrate the pumps ow if the pump
is ow paced from a remote input signal.
Benets & Limitations
No PD pump technology is ideal for all
applications. Limitations for peristaltic
pumps include a maximum tempera-
ture of 180-degrees F and a maximum
pressure of 232 psi. Flow rates can range
from 0.1 micro liters per minute to 350
gallons per minute (gpm).
Peristaltic hose pumps are virtu-
ally maintenance free, with no seals to
replace, no check valves to clog and no
rotors or stators to wear. Unlike other
pumps, the highly abrasive nature of
materials pumped does not aect pump
life because the uid is fully contained
within the hose element and does not
contact the moving parts, prevent-
ing abrasive wear. With its self-loading
design, hose replacement is quick and
easy. he pumps also oer a reduced
footprint due to less need for ancillary
systems. Table 1 has a complete list of
advantages.
P&S
Rick Balek is the national sales
manager for Watson-Marlow
Bredel Pumps. He can be
reached at rbalek@wmbpumps.
com or 317-580-0031.
S
electing the right material for any industrial piping appli-
cation can be a daunting task. he life expectancy and
overall success of a system is based on the material selected
and the media running through it. With material choices rang-
ing from metal to berglass to plastics, it is helpful to rst
examine the systems specic application and then choose the
material best suited to handle the job long-term.
Sulfuric acid and sodium hypochlorite are just two noto-
riously troublesome chemicals that are di cult to safely store
and transport through piping systems. Titanium, PVC, CPVC
and uoropolymer-lined piping are potential system solutions,
but each requires that certain conditions be met. Temperature,
pressure and installed location are factors that should be taken
into consideration when determining the best material f.
he inherent properties of thermoplastics make them
an ideal choice for corrosion resistance and more cost eec-
tive than metal piping systems. PVC and CPVC have been the
solution to sulfuric acid and sodium hypochlorite applications.
However, their weaknesses are in the joining method, which
requires solvent cement and glue. his has made them a less
ideal choice for these aggressive chemicals.
hermally fused high density polyethylene (HDPE) is the
leading thermoplastic material used for piping applications.
Polyethylene outperforms other materialsincluding metal,
berglass and other thermoplastics such as PVC and CPVC,
with a more-aordable installed cost.
Previously, HDPE had been limited to water and some
chemical applications. However, a new generation of the resin
provides a cost eective solution to corrosion and enables its
use in chemical systems. his new resin, the fourth generation
of HDPE, is PE 100-RC.
The Evolution of
a New Resin
HDPE was developed in
1953 by chemists at the
Kaiser Wilhelm Institute
in Germany. Two years
later, HDPE was being
used to manufacture
pipe. Before the mid
1950s, industrial piping
systems were primarily made of metal. During the past six
decades, HDPE resins developed for piping applications have
evolved to cover four generations. he current classication
of HDPE materials is based on a minimum required strength
(MRS) European standard according to ISO 4427. (See Table 1.)
Generation 1 includes PE 32, 40 and 63. hese grades
of HDPE material are suitable for low- to medium-pressure
liquid applications. Generation 2 is PE 80 (also known as PE
3408 in the U.S.). PE 80 is suitable for low-pressure gas appli-
cations and higher pressure liquid applications up to 1.6 MPa
(230 psi). Generation 3 is PE 100 (also known as PE 4710 in
the U.S.). PE 100 is suitable for higher pressure gas and liquid
applications.
Like all materials used in chemical applications, HDPE
has its limitations. he upper temperature limit is +140 degrees
F and the lower limit is -40 degrees F. he primary weakness of
generations 1, 2 and 3 is susceptibility of the material to crack
Safe Chemical Transfer
Mark L. Jones, Asahi America
The development of PE resin for industrial piping applications
Table 1. ISO 4427 MRS for HDPE
Designation of Material MRS at 50 Years and 20
Degrees C MPa (psi)
PE 100 RC (generation 4) 10 (1450)
PE 100 (generation 3) 10 (1450)
PE 80 (generation 2) 8 (1160)
PE 63 (generation 1) 6.3 (913)
PE 40 (generation 1) 4 (580)
PE 32 (generation 1) 3.2 (464)
Figure 1. PE pipe installation
Figure 2. Full notch creep test
under stresses, such as point loads. If an end user is burying the
pipe, the trench needs to be dug wider so it can be backlled
with the proper bedding material to avoid point loads from
rocks on the pipe.
Any point load can develop a crack and, over time, cause
premature failure. his is known as environmental stress crack-
ing and is certainly true of the rst three generations of HDPE.
Cracking can also be caused by chemical attack.
Despite these limits, the benecial properties of HDPE are
abundant. Some of PE 100s benets are:
Excellent resistance to a wide range of chemical applications
Can handle a pH from 1 to 14
Highly ductile, exible and light-weight
hermally joined, eliminating the use of solvents and glues
Excellent uid ow characteristics
Extremely low coe cient of thermal conductivity
Will not rust
Cost-eective and easy to install
Long life expectancy
The Next Generation
When the rst three generations of HDPE pipe fail, the cause
is almost always stress cracking. Resin manufacturers have been
trying to increase the crack resistance properties of the material.
Innovations in the co-polymerization process have developed a
new PE 100 resin with just such characteristics. he new resin
has all the strength of the previous generation with a greatly
improved crack resistance (RC).
he full notch creep test (FNCT) is the standard test to
measure the resistance of HDPE materials to stress cracking
(ISO 16770). See Figure 2.
A notched test specimen is placed under load in a high
temperature aggressive surfactant bath to accelerate failure. he
Table 2. Full notch creep test requirements
PE Class Minimum Standard FNCT
PE63 30 Hours
PE80 100 Hours
PE 100 300 Hours
PE 100-RC 8,760 Hours (1 year)
Table 3. Full notch creep test average results
PE Class Average Results FNCT
Rupture time in hours
PE63 7.5 Hours (2 samples)
PE80 114 Hours (3 samples)
PE 100 533 Hours (5 samples)
PE 100-RC 14,648 Hours (2 samples)
time it takes for the crack to go all the way through the coupon
is the result of the test expressed in hours. Table 2 lists the mini-
mum standards for each grade of HDPE resin. he minimum
standard for PE 100-RC is 8,760 hours (one year).
Looking at the average results (Table 3), the benets in the
evolution can be seen. he weakness is now the strength, open-
ing new application opportunities in which polyethylene has
never been considered. he increase in crack resistance allows
contractors and installers to consider HDPE for underground
use in rough dug trenches without backll or sand grading. his
provides lower installation cost and furthers the reach of ther-
moplastic piping systems into mountain and desert terrains.
Another benet of HDPEs increased crack resistance is its
newfound industrial chemical piping applications. he chemi-
cal resistance capabilities of the previous
HDPE generations are already proven.
Now, a good portion of the previously
unacceptable applications will prove
to be successful opportunities for PE
100-RC pipe and ttings. Why? If the
material is attacked by the chemical,
the time to failure will be substantially
extended due to its greatly enhanced
ability to resist cracks. In eect, if it lasts
long enough, it is resistant.
his could change what used to be
only a short-term possibility into a long-
term solution. An application with high
concentrations of sodium hypochlorite
transported in PE 100-RC piping is only
one specic application that has already
proven to increase previous short-term
solutions into permanent, long-term
installations.
Applications using higher con-
centrations of certain acids are another
avenue now open to HDPE. Because PE
100-RC is so versatile in terms of per-
formance, low installation cost and an
extremely long expected useful life, it can
now be seriously considered for every
new and existing chemical piping appli-
cation that falls within its capabilities.
PE 100-RC is poised to be the
material of choice for aggressive chemi-
cal and water applications. Its inher-
ent physical properties makes it ideally
suited for todays safety-conscious and
budget-minded companies.
P&S
Mark L. Jones is the
business development
managerindus-
trial/environmental
productsAsahi/
America, Inc. He
has been with the
company since 1998 and has more
than 25 years experience selling
plastic piping systems. Jones can be
reached at mjones@asahi-america.
com or 781-321-5409.
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November 1 3, 2011, New York, N.Y.
Exhibit Hours
Tuesday, November 1
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Wednesday, November 2
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Thursday, November 3
10 a.m. to 3 p.m.
C
hemShow 2011 oers a diverse lineup. Educational oppor-
tunities include American Institute for Chemical Engineers
(AIChE) Engineering Technologies Tutorials and its conferences
on energy, safety and consulting. Nanotechnology workshops
and conference are also available for an additional fee.
With more than 350 exhibitors, the exhibit hall is the
place to visit. New this year and free to all visitors is the Process
Control & Automation Center, which shows attendees how
to increase productivity and streamline operations, and the
Product Technology heater, which gives an overview of new
products. For more information, go to www.chemshow.com.
T
wenty years ago, the
managers of a wide
range of manufactur-
ing and liquid-storage facilities
predicted that the industry was
about to enter the age of the seal-
less pump. With stricter federal
emissions regulations set to be introduced in 1992, this would
have been welcome news for those in the petroleum ren-
ing, petrochemical, gas processing and chemical industries in
which the use of hazardous/toxic materials or other pollut-
ants was prevalent. Faced with tighter control guidelines for
these types of emissions, plant and storage-facility operators
needed a pump technology that could deliver the environ-
mentally-sensitive, leak-free operation that they demanded,
while also addressing maintenance and cost concerns.
Extensive documentation existed to support the thesis
that sealless pump technology was the answer in these appli-
cations. For example, in June 1990, a management-con-
sulting rm produced a report for a leading manufacturer
of industrial gear drives, pumps and compressors that pre-
dicted, among other things, that:
he best available control technology (BACT) for most
rening, petrochemical and chemical plants will be seal-
less pumps.
he chemical industry is moving to use sealless pumps at
a faster rate than the petroleum industry.
he sealless market will be served two-thirds by magnetic-
drive units and one-third by canned-motor units.
he long-term answer to the new federal regulations will
be sealless pumps.
Sealless pumps will take an increased percentage of the
marketprobably 25 percent by 1995 and 50 percent by
2000.
A year earlier, a report titled An Overview of BACT
Guidelines for Centrifugal Pumps was prepared by the
South Coast (California) Air Quality Management District
which noted the No. 1 BACT in terms of e ciency in con-
trolling emissions in liquid-handling applications was seal-
less pump technology, which was becoming increasingly
important, especially in the handling of toxic and hazardous
uids.
We now know that 1990 did not signal the beginning of
the golden age of sealless pumps.
he technologyas it was designed and constructed at
the timewas not reliable enough, with too many instances
of failures that were brought about by bearing and load de-
ciencies that led to seal and leakage issues.
hese deciencies created an operational stigma that
many manufacturers of sealless pumps are still trying to over-
come today.
However after all that time, innovative sealless pump
technology is available that eliminates the bearing and load
concerns that aected the performance of traditional sealless
designs.
his technology has the capability of creating a new
category of sealless gear pump that not only eliminates leak-
age concerns that can compromise safety for both plant per-
sonnel and the environment but also allows the operator to
move all types of liquids, from thin to extremely viscous and
the hazardous to the benign.
his article will show how a fresh, clean-sheet approach
to the conundrums inherent in traditional sealless pump
design were confronted and led to the creation of a line of
sealless gear pumps.
In short, these pumps increase product sealing reliability
while eliminating the unacceptably high ownership, mainte-
nance and environmental costsas well as the reputational
taintthat have dogged past sealless pump designs.
Efciency Matters
The Real Golden Age
of Sealless Pumps
Dale Evers, EnviroGear
Critical design improvements enable the promise of sealless pump technology.
Exploded view of the improved
sealless gear pump
The Challenge
he leakage that occurs in traditional mechanically sealed pumps results in two types
of prohibitive costs for plant operators: maintenance and environmental. According
to the Hydraulic Institute, as much as 40 to 50 percent of the cost of owning a
pump is spent after the pump is purchased due to maintenance issues. he leading
causes of high maintenance in conventionally sealed pumps includes that associ-
ated with mechanical seal replacement and the premature wear of the bushings and
close-tting metal parts because of insu cient support of the pumping elements.
he environmental cost of leakage includes cleanup and potential local, state or
federal nes that may need to be paid in extreme cases. Another non-monetary cost
is the resulting bad press and community mistrust after a leak or accident occurs.
Leaks can create several costs:
Replacement of the raw materials that are lost and the nished goods that are
damaged
Paying a rm to clean up the spill
Disposal of the material cleaned up
Potential slip-and-fall hazards
Environmental compliance nes and fees
Lowered worker morale
he need to replace workers who may choose to seek employment elsewhere
As mentioned, any pump design that is deemed sealless must overcome the
stigma that has been attached to the technology for more than two decades. In fact,
while the reports cited above were trumpeting the use of sealless pumps, eorts
began almost immediately to discredit the technologys eectiveness and reliability
when handling hazardous or toxic materials.
A report entitled Meeting Emission Regulations with Mechanical Seals
released in April 1990 by the Seals Technical Committee of the Society of Tribologists
and Lubrication Engineers (STLE) stated that eliminating seals in pumps is not the
solution to emission controls. he standards committee included seven leading seal
manufacturing companies working in conjunction with chemical company clients.
he report also stated sealless pumps seem like the perfect solution but rely on
bearings being lubricated by the product being pumped. herefore, bearing prob-
lems result from converting to sealless pumps. he seal manufacturers eectively
removed themselves as the weak link and focused on the perceived and sometimes
real bearing issues.
he report listed a number of perceived problems that were present when rely-
ing on the product being pumped for lubrication, including: the sometimes poor
lubricity of the pumped product; high instances of costly downtime for in-shop
repairs; and the elevated chance that leaks will still occur, which exposes plant per-
sonnel and the environment to the pumpage. As pump manufacturers rushed their
sealless oerings to market, an overzealous sales force misapplied or over-applied
their products. Initial failures, most common among high-speed centrifugal manu-
facturers lent credibility to the seal manufacturers warnings. End-users became cau-
tious. hose burned would hesitate to consider sealless technology again.
hen, most damningly, the report concluded: Obviously, there is question-
able, if any, benet (of using sealless pumps) to the end-user who is genuinely con-
cerned with the environment and his personnel.
Times Have Changed (so Have Sealless Pumps)
Traditionally, sealless gear pumps are designed with a cantilevered load where a large
rotor gear is attached to the end of the pump shaft. As hydraulic force is applied
to the rotor during pump operation extra pressure is put on the shaft and bearings.
his pressure can lead to shaft deection and increased bearing wear, which results
in more rotor-to-casing or rotor-to-head contact wear. he result is reduced pressure
TRANSFERRING
Highland Oaks I,
1100 W 31st Street, Suite 120
Downers Grove, IL 60515
Tel: 909-512-1257
Fax: 909-512-1209
Info@pumpsg.com
pumpsg.com
22069 Van Buren Street
Grand Terrace, CA 92313-5651
909-422-1731
EnviroGearPump.com
Seal-less Internal Gear Pump for
a Safer, Cleaner, Cost-effective
Pumping Solution.
s Patented between-the-bearing
support for high reliability
s Leak-free single-uid
chamber design
s Interchangability allows for
upgrading existing gear pumps
s Lowest overall cost of ownership
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Efciency Matters
and ow rate.
Secondly, traditional sealless gear pumps feature two uid
chambersa hydraulic chamber in which the gears work
and a second chamber for the magdrive coupling unitthat
are joined together by a bracket, which also serves as a barrier
between the two chambers. his complicated design requires
that a portion of the material being pumped through the
hydraulic chamber must be used to cool the magnets in the
other chamber. hese requirements result in a long, compli-
cated pump with elongated, narrow ow paths and the need for
more parts which makes the pump more expensive and di cult
to maintain. his also limits the viscosity of the liquids that can
be pumped, as well as the types of solids that can be handled.
The Solution
he approach to nding an ultimate solution to the sealless
pump quandary removed the word sealless from the devel-
opment process. When looking to create a gear pump that is
aordable, controls leaks and reduces maintenance costs and
environmental concerns, the rst step is to identify the areas in
which sealless pumps fall short and look for improvements. As
mentioned, the No. 1 area in which traditional sealless pump
operation is compromised is the bearings and how they inter-
act with, and are aected by, the pumps cantilever load. he
second step is to nd a superior replacement for the
two-uid-chamber design
that complicated the
pumps operation
and limited its
uid-handling
range.
Taking these
main concerns into
account, and approaching
the design process with
an open mind, the result
is a gear pump line that is sealless, not because the designers
and engineers felt that it needed to be, but because its design
enhancements led them to the conclusion that it would operate
most eectively as a sealless pump.
his pump also features two design enhancements to over-
come the long-time challenges of excessive bearing wear and
a uid chamber design that complicates operation and limits
product range. hese enhancements are:
Between-the-bearing support systemAs opposed to
the performance-robbing, one-sided support found in a
cantilevered-load design that exists in traditional sealless
pumps, the new gear pump supports the rotor and idler
gears at three locations through the creation and incorpora-
tion of:
A patented eccentric spindle that is
supported in the head, the crescent
location and the back of the contain-
ment canister, eliminating much of
the eects of cantilever load. In tests
in which 200 psi of pressure was
applied to the rotor, only 0.005 inch
of shaft deection occurred in this
pump, compared to 0.056 inch of
shaft deection in a traditional seal-
less pump, giving the new design 11
times less shaft deection.
Larger diameter materials that
provide more rigid support for less
shaft deection and bearing wear.
For example, a traditional 3-inch
sealless pump will have a shaft that is
1716 inch in diameter. he diameter
of the new designs eccentric spindle
is 2 inches.
Large, long radial bushings that
support the entire length of the
rotating element, which spreads out
the hydraulic forces and allows the
bushings to last longer. he new
pumps bushings are also made of
premium-grade carbon graphite that
will last up to eight times longer than
more common bushing materials.
Single-fluid-chambered sealless gear pump
In my facility, having pumps
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Downtime is not an option.
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One-luid-chamber designAs
noted earlier, traditional sealless
pump design features two uid
chambers that are separated by a
bracket. his design creates opera-
tional di culties while limiting the
types of uids that can be handled
by the pumps. he improved design
has only one uid chamber with the
pumps magnets placed on the back
of the rotor and close-coupled, or
piggy-backed, on the rotor gear.
his design gives the pump a much
shorter, simpler ow path. It also
allows the pump to easily handle
viscosities in the 20,000 to 30,000 cP
range and as high as 50,000 cP, while
still maintaining the ability to run
thin liquidssuch as caustics and
solvents. hese redesigned pumps can
also pump liquids and slurries that
contain solids.
Another feature that this design
oers is dimensional interchangeability.
hese pumps have been designed to be
interchangeable with 95 percent of the
other gear pumps that are currently
available on the market. his means that
a plant can run a traditional sealed pump
in the morning, have it pulled out in
the afternoon and drop this single-uid
chamber gear pump into the footprint
while reusing the same piping, gear box,
motor and base plate, all while receiving
the same hydraulic performance pro-
vided by the previous pump.
While this pump is designed to
eliminate all the operational concerns
found in old-style sealless gear pumps,
its simple designwhich consists of
only seven primary parts: a magnet
housing, containment canister, casing,
rotor magnet assembly, eccentric spin-
dle, idler gear and headgreatly reduces
maintenance and environmental costs.
Conclusion
In the end, the design of these new seal-
less gear pumps makes them beyond a
traditional sealless pump. hey are an
engineered solution for environmentally
conscious uid-handling that lowers
maintenance costs and eliminates envi-
ronmental costs.
P&S
Dale Evers is the director of business development, Engineered Products, for
the Dover Corporations Pump Solutions Group (PSG), Downers Grove,
Ill. He can be reached at dale.evers@pumpsg.com. You can nd more
information on EnviroGear at www.envirogearpump.com. PSG is com-
prised of seven leading pump brandsAlmatec, Blackmer, EnviroGear,
Griswold, Mouvex, Neptune and Wilden. You can nd more information
on PSG at www.pumpsg.com.
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P
umps are indispensable in
mining, petroleum recovery
(wellhead operations), pipelines,
rening and many manufacturing
operations, so their failure causes costly
unscheduled downtime. In the case of
an electrical ground fault the pumps
drive motor can be destroyed, and it
can result in high voltage potential on
the pump equipment framework that
is a serious safety hazard to personnel.
A pump and drive motor can fail in
other ways, including pumps running
dry and jammed pumps causing the
motor to overload, which can lead to
catastrophic damage to the motor and
other electrical system problems.
Automated Prevention
Most fault conditions can be mitigated with the right kind of
protective device. Todays electronic motor protection relays
(Figure 1) can communicate motor operating information to
a programmable logic controller (PLC), motor control center
or an automated monitoring system. hese real-time diag-
nostic features are important predictive/preventative mainte-
nance functions that indicate that a problem needs attention
before a catastrophic failure.
Some motor protection relays have inputs for tempera-
ture sensors. Temperature inputs in some relays shut down
the motor before it becomes too hot and causes an insulation
failure. More importantly, collecting temperature data from
the ambient surroundings, pump and motor bearings and
the motor windings can be used for predictive/preventative
maintenance.
By monitoring and analyzing
motor thermal trends, operators can see
that the motor may become overheated
if operating conditions are not altered.
Overloading the motor, ambient tem-
perature and lack of cooling when
needed may overheat the motor. With
temperature sensor inputs, the relays
thermal model of the motor can be
biased to reect operating conditions or
adjust for hot spots on the motor, such
as windings or bearings. hese diag-
nostic features provide more e cient
troubleshooting and help avoid motor
damage, freeing up sta and eliminating
many repairs and replacements. Instead
of reacting to failures, maintenance sta
can proactively schedule corrections.
Drive Motor Ground Faults
Pumps are often used in dusty and damp environments
that can compromise insulation in the drive motor and its
input wiring. hese conditions can increase earth leakage
currentspersistent, small currents from a high potential
point to ground that may be a precursor to a major ground
fault. Some causes of phase-to-ground faults are shorts in the
motor windings or input wiring due to worn or melted insu-
lation. Ground faults can cause electrical shocks, res or even
major arc-ash events.
hermal Overload Relays
Earlier methods of detection and protection against ground
faults are still being used. hese electromechanical devices
include bimetallic or melted alloy (eutectic) overload
Microprocessor-Based
Pump/Motor Protection
Relays
Ross George, Littelfuse, Inc.
Todays lean maintenance staff needs pump and motor protective devices that
diagnose and predict problems before they become acute.
Maintenance Minders
Figure 1. Electronic pump/motor
protection relay
mechanisms. hey contain heating elements wired in series with the motor inputs
that cause either a pool of solder (eutectic alloy) to melt or a set of bimetallic strips
to bend and release the contacts when current becomes excessive.
Bimetallic overloads generally have a limited range of adjustable trip points.
No adjustability is possible with eutectic alloy mechanisms. Some bimetallic over-
loads will reclose automatically when the motor cools su ciently. Bimetallic over-
load design can include compensation to prevent ambient temperature changes
from aecting the trip point. Ideally, a thermal overload should be installed in the
same ambient temperature as the motor it protects. In practice, these devices are
often installed in the motor starter, which may be in an air-conditioned switchgear
room away from the motor. Whats more, their simple design precludes intelligent
feedback.
Solid-State Electronic Protection
Certain types of solid-state overload relays have been introduced to resolve the inac-
curacies of electromechanical devices. However, many of these have pre-calculated
setpoints and cannot provide the same level of protection as more recent designs. In
one type, the current is measured using a set of current transformers, which may be
internal or external to the device. his protection system includes monitoring and
current interruption in case of ground faults, overloads, unbalance, jams, etc.
However, using a current transformer may allow some level of damage to occur
before the relay trips. An alternative to current monitoring is to use an insulation
monitoring relay. his device monitors phase-to-ground insulation resistance and
prevents the motor from starting if system insulation resistance falls below a selected
set-point, avoiding potential motor damage.
An insulation monitoring relay applies a DC voltage and measures the leakage
current to determine the systems insulation resistance to ground. By establishing a
setpoint for this resistance and providing a signal output when it is too low, mainte-
nance sta is made aware of degradation, allowing for scheduled maintenance and
repair.
Another benet, compared to electromechanical relays that pass motor current
through heating elements, electronic relays do not cause excessive heat buildup on a
power panel. Besides saving on power consumption, this helps avoid panel de-rating
and the use a larger enclosure for heat dissipation.
Yet another type of electronic device combines ground fault protection with a
ground-check function, which monitors the integrity of an equipment ground. It is
used if ensuring ground continuity is the foremost issue. hese relays are also used
with trailing cables, when the equipment may be a large distance from the starter
or breaker.
By ensuring a ground connection, this prevents a potential voltage rise across
the uid or on the framework of the equipment during a ground-fault, which may
represent a shock hazard to operating and maintenance personnel. Common appli-
cation environments are surface mines, underground mines, quarries and submers-
ible pumps. hese devices are even used on the pumping equipment for golf course
watering systems. hey can also be used as a remote permissive for the pumping
equipment.
In many electrical systems, a neutral grounding resistor (NGR) is used on the
grounding system. his is sometimes called a high resistance ground (HRG), where
a resistor is placed between the neutral of the supply transformer and ground.
Using resistance grounding can minimize the amount of damage caused by a
ground fault. In some cases, it may allow operations to continue until the fault can
be cleared. In addition, an NGR used in conjunction with an NGR monitor relay
can provide a predictive maintenance function by alerting sta to the ground-fault
before excessive damage is done. Moreover, resistance grounding also prevents a re-
striking fault from elevating the system voltage relative to ground, which adds more
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stress to the insulation and can lead to a phase-to-ground-to-phase fault.
Pump manufacturers are being asked to incorporate ground-check relays into
their equipment. his includes a zener diode termination assembly that is part
of the relays open and shorted ground-check loop functions for portable power
cables. he relay feeds two dierent levels of current to the termination assembly
and checks to make sure that the voltage drop is the same across the zener diode at
both levels. his is a more desirable way of ensuring ground integrity compared to
a resistance terminated loop, as a high-impedance fault with the right amount of
resistance can provide an erroneous indication.
Benets of Microprocessor-Based Protection
Microprocessor-based relays may incorporate several of these protective and predic-
tive functions to guard pumps and motors from overload damage and some other
fault conditions. Depending on the design and feature-set, they may include a lim-
ited functions or a wide range of protection and monitoring features. Some of the
advanced features include protection in the event of phase loss, phase imbalance,
improper phase sequence, jam and undercurrent protection. Other features may
include digital inputs/outputs, internal data logging, and interfacing data commu-
nications. See Figure 2.
A useful feature for maintenance personnel is continuous real-time monitoring
of an operating motors thermal capacity. As mentioned earlier, this may prevent a
motor from becoming overloaded, avoiding insulation damage.
Combined with a data communications interface, this monitoring allows trend
analysis by a central control system computer or PLC and subsequent scheduled
maintenance.
A pump jam will cause motor overload due to excessive current that can
damage the motor windings insulation. A motor protection relay will interrupt
the supply power as it does for a ground fault. A pump running dry does not cause
an overcurrent condition but a low currenta common occurrence in submersible
pump applications. Mechanical oats may not be su cient, as they may be prone
to failure. In many cases, a pump that runs dry means a loss of lubrication, which
can lead to bearing damage or other failure modes.
A microprocessor-based relay with a low-current setpoint can protect against
Figure 2. Microprocessor-based motor protection relay simplied circuit diagram
Maintenance Minders
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a dry pump situation. During normal operation the micropro-
cessor sees nominal operating amperage.
If the pump runs dry, this current drops to an idle amper-
age level, which is dened by the motor. When that occurs, the
protective relay can send a signal to an interrupt device, or signal
to a PLC for analysis, which may actuate the interrupting device.
Cost Considerations
Microprocessor-based motor protection devices can be sophis-
ticated. In addition to current inputs, some devices have pro-
visions for voltage inputs, which can calculate power, power
factor and other parameters. hese parameters are fed back to
a motor control center or PLC where the data can be logged
and/or analyzed.
Network communication capabilities may include proto-
cols for Ethernet, DeviceNet or ProBus. With these, micro-
processor-based motor protection can be used to help optimize
a pump/motor system electrically and mechanically. Some deci-
sions and actions that may be taken are load analysis, altering
ow rate or changing power factor correction.
he cost of devices with this level of sophistication may be
prohibitive for pumping systems operating with 50-horsepower
or smaller motors. In these cases, simpler microprocessor-based
devices may be a cost-eective way to upgrade an antiquated
pumping system or add protection to a system.
Another consideration is the mea-
surement devices required for use with
the protection relays. For example, some
microprocessor-based relays have built-in
current transformers (CTs) for overcur-
rent detection circuitry with specied cur-
rent ranges. In other cases, these CTs must
be purchased and installed. In some cases,
using separate CTs may be appropriate,
allowing a protection relay to be tied into
almost any power system.
Of course, reliability in harsh
industrial environments has a signicant
impact on the overall cost of ownership
when a pump/motor protective device
is purchased. Besides exposure to water
and electrically conductive dusts, corro-
sive liquids and vapors are common in
many applications. For example, hydro-
gen sulde (H
2
S) can be present in or
around petrochemical uids, which
aects equipment used at the wellhead,
on pipelines and in reneries. It reacts
with water vapor to form sulfuric acid
that eats away at electrical components.
For these and other harsh environ-
ments, protective devices designed spe-
cically to survive in such applications
should be chosen. In addition to rugged
mechanical design for use on machinery
with strong vibrations, the electrical circuit boards need to be
conformal coated with an insulating material. When done
properly, this seals the components and circuit traces so they
cannot be attacked by corrosive liquids, vapors and gases.
A unit designed primarily for indoor factory applications
may last only a short time in a mining or petrochemical appli-
cation. However, protective devices designed for rugged envi-
ronments can supply 20 or more years of reliable service in such
environments. A long service life may be a compelling reason
to purchase a reliable protective device, even for less demanding
applications, because of its low cost of ownership.
Summary
Microprocessor-based pump/motor protection relays oer
a cost-eective way to prevent catastrophic failures due to a
number of fault conditions. In addition, they can protect oper-
ating and maintenance personnel by mitigating or removing
shock hazards and potential arc-ash events. hose with real-
time monitoring and diagnostic functions for predictive/pre-
ventative maintenance programs can reduce maintenance costs.
P&S
Ross George is a technical sales engineer with Littelfuse. He
received a Bachelor of Science degree in Electrical Engineering
from the University of Saskatchewan. He can be reached at
rgeorge@littelfuse.com.
Cartex seals are designed with greater
attention to functional details like
tighter tolerances for more accurate
seal operation, greater axial movement
to handle pump shaft movement, seal
parts with robust cross sections for
optimal seal stability in operation and
castings that meet ASTM A351/351M
standards for proven quality. Call 1-800-
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M
echanical packing is a versatile seal-
ing device. One of the best features
of braided mechanical packing in
roll form is its exibility and ease of use. In
todays world of maximizing plant e ciency
with limited maintenance resources, some
important steps to follow when installing pack-
ing are often overlooked. One of these is prop-
erly cutting the braided packing.
One of the best ways to enhance packing
life is to focus on installation. After packing
is installed, a few xes can prolong life when
a leak has occurred. As Ben Franklin stated,
An ounce of prevention is worth a pound of
a cure. his is true about packing, since instal-
lation is the key to long packing life. Cutting
packing rings incorrectly can result in a low
mean time between failure (MTBF) for valves
and pumps and is easily preventable with some
basic training. his article discusses some fun-
damental concepts to improve packing life by
properly cutting the rings.
Important Steps
he best way to cut packing accurately is to focus on a few
simple steps:
Use a mandrel to cut rings
Use a sharp knife
Use a forceful cutting motion
Sometimes, bad habits that are developed when cutting
packing rings can start at a plant and can severely limit pack-
ing performance. Training and education will help prevent
bad maintenance practices and provide understanding of
the importance of the task. Unacceptable practices for cut-
ting packing rings can be handed down from technician to
technician because it is hard to see the eect that it has on the
sealing failure of the equipment.
Sizing
One of the more prevalent practices is using the packing
rings that were removed when unpacking a valve or a pump
as a length guide for cutting the new rings. he problem is
the rings that were removed could have been incorrectly sized
the last time so the error will just be repeated. Also, the rings
that are unpacked might have been chemically attacked and
may have shrunk or become deformed while in service.
he most accurate way to cut packing rings is to use a
mandrel that is the exact size of the shaft or stem. By taking
the mandrel and placing it in a vise and wrapping the pack-
ing around it, an accurate length can be determined for the
packing ring.
What are the key steps to cutting packing for optimum performance?
This months Sealing Sense was prepared by FSA Member Ron Frisard and
sponsored by the Compression Packing division.
From the voice of the uid sealing industry
SEALING SENSE
Figure 1. Cutting on a mandrel
Cutting
he rings should either be cut on the mandrel at a 45-degree
angle for a skive cut or a 5-degree, almost-straight cut for a butt
cut. Check the installation instructions of the packing manu-
facturer for the correct cutting type required by the application.
Rings should be held tightly on the mandrel but not stretched.
When cutting skive joints, a miter board should be used so that
each successive ring can be cut at the correct angle.
After each ring is cut, it should be wrapped around the
mandrel as a double check to ensure that the ends adjoin with
each other. his is similar to a go/no-go gauge. Skillfully cut-
ting rings with a mandrel does take some practice of the pack-
ing pulling and the wrapping technique. Focusing on the end
result of the ring tting on the mandrel with no gap will quickly
provide a feedback loop to perfect the practice. Each style of
packing will pull around the mandrel slightly dierently.
Unraveling Ends
Another issue to watch for is trimming rings that have been
cut long. Cutting a small section of one of the packing ends
can result in the packing unravelinga major failure point
when it is installed. If this happens, the damaged ring should
be scrapped, and another ring should be cut, concentrating on
getting the size correct.
Tools
he second component to an accurately cut packing ring is
the tools that are used. Another major poor practice is using a
pocket knife to cut packing rings. A number of major issues can
arise from using this type of cutting tool.
he rst problem is that most knives are not very sharp,
and a dull knife will make the cutter use a back and forth cut-
ting motion instead of clean slice of the packing. his back and
Figure 2. Checking Ring Size
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FSA Sealing Sense
forth motion causes the packing to open up (bloom) making
installation and sealing more di cult. A sharp knife makes a
clean cut that keeps the strands together in the original shape.
Cutting packing will dull any type of knife quickly, so make
sure there is easy access to knife sharpeners.
he second issue with using a pocket knife is the lack of
a good grip. When cutting packing, a considerable amount of
force must be applied to cut in one stroke, and without a good
handle, this is much harder to accomplish. It is very important
that the tool used to cut packing is a straight edge blade and not
serrated. his will also help reach the goal of a clean cut without
deformed packing ends.
he correct way to cut packing is to have the knife at an
angle to the packing (handle higher) and not parallel to it. his
method results in better leverage on the
packing resulting in a better cut. Many
tutorials are available that highlight this
method when cutting in the kitchen.
Correctly cutting a piece of packing is
very similar to cutting in a professional
kitchen.
Excess Material
Cutting packing will always results in
some waste. his could be rings that are
too long or short but also can be rings
whose ends have unraveled or blossomed
to the point at which they could result
in a leak path. One of the easiest ways to
sidestep errors in cutting is to order cut
rings from the packing supplier. Besides
no scrap, there is also a considerable time
savings from not having to cut the rings.
he drawbacks to using cut rings every-
where is having good documentation of
the actual size of the packing beforehand
to know what to order. his can be a
bigger hurdle than rst thought since
a major paradigm shift needs to occur
regarding creating a database of equip-
ment dimensions.
Conclusion
A couple of other simple ways to create
a good environment that will result in
a better cut ring are rst to order (or
get a machine shop to create) accurate
mandrels for all stem and shaft sizes.
he other is to have in the cut ring area
some good knives and access to a knife
sharpener.
Next Month: What factors should be
considered for stainless steel fasteners in
bolted ange connections?
We invite your questions on sealing issues
and will provide best eort answers based
on FSA publications. Please direct your
questions to: sealingsensequestions@
uidsealing.com.
P&S
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Q. What is a balanced mechanical seal, and when is it usually
used?
A. Balancing a mechanical seal involves reducing the eective
forces on the seal faces. A general rule is to use a balanced seal
when seal chamber pressures are above 1,380 kPa (200 psi).
Each application should be reviewed because the seal faces are
aected by pressure, rotational speed, temperature and the
properties of the liquid being sealed. At higher pressures or
speeds, ensuring that an adequate lubricating lm builds up is
important. his is done by using a mechanical seal with a bal-
ance between 60 and 90 percent. See gure 5.12.
he hydraulically loaded area is 10 to 40 percent smaller
than the sliding surface area, and the closing force is reduced to
the same extent. his measure increases the leakage rate because
balanced seals tend to have higher leakage rates than unbal-
anced. Each mechanical seal is a compromise between:
Ideal liquid friction in the sealing gap (as, for example, in a
balanced seal) with the advantages of lower power con-
sumption and increased service life but the disadvantage of
higher leakage
Mixed friction (as, for example, in an unbalanced seal) with
shorter seal life as a result of increased friction but with
lower leakage; see Chapter 4 of the Mechanical Seals for
Pumps: Application Guidelines, published by HI, for more
details on seal face balancing
Q. What is a pusher type seal, and what are the advantages of
this design?
A. his is the broadest classication. It is determined by the
secondary sealing element used in the exible portion of the
seal. In a pusher type seal, the secondary sealing element moves
axially to compensate for wear, vibrations and movement of the
shaft. Several types of secondary elements are used, most com-
monly O-rings, wedges and spring-loaded polymer seals.
In the non-pusher seal, the secondary sealing elements
include bellows (elastomeric compounds, PTFE or metal). he
convolutions of the bellows compensate for wear, axial move-
ments and vibrations.
he application elds of both seal types are wide and may
overlap. he most apparent distinction is the pressure limit.
Pusher type seals cover the entire pressure range of mechanical
seals up to and exceeding 20.7 MPa (3,000 psi). Non-pusher
seals are typically limited to 7 MPa (1,000 psi) for elastomeric
bellows and 2,070 kPa (300 psi) for metal bellows. he last type
is popular for sealing of hot uids without external cooling.
Q. What is an energy e cient method for controlling the
rate of ow in pumping systems?
A. Many pumping systems require a variation of ow or head.
Either the system curve or the pump curve must be changed to
get a dierent operating point. Where a single pump has been
PUMP
FAQs
Figure 5.12. Balanced seal

Figure 5.8. Pusher type seal
Figure 5.9. Metal bellows seal
Figure 5.10. Elastomeric bellows seal
installed for a range of duties, it will have been sized to meet the
greatest output demand. It will, therefore, usually be oversized
and will be operating ine ciently for lower rate of ow duties.
Energy cost savings can be achieved by using control meth-
ods that reduce the power to operate the pump during reduced
demand. In cases where interruption of ow can be tolerated,
on/o control may be the most energy e cient option.
Varying pump performance by speed change is often an
e cient control method. Figure 4.14 shows the energy con-
sumption of other popular control methods when compared
to variable speed control. More pump control principles and
control examples can be found in Variable Speed Pumping: A
Guide to Successful Applications.
Typically, variable frequency drive (VFD) upgrades are
most viable when the systems are part of the original instal-
lation, when only the incremental premium must be justied.
However, some installations can take advantage of the possible
power savings provided by VFDs.
he typical VFD system today is a squirrel-cage induction
motor fed from a VFD. he most common VFDs use insulated,
gate, bipolar power transistors (IGBT) to create the voltage
source pulse width modulation (PWM) to generate the variable
voltage frequency for the motor. PWM/IGBT drives have the
best overall performance, with high power factors throughout
the speed range and are the most common type for small- and
medium-horsepower motors. hey generate low-speed torque,
quiet motor operation and improved low-speed stability.
PWM/IGBT drives do stress the motor and drive cable,
due to the fast output voltage rises that cause voltage doubling
in the feeder cable from voltage reections. An impedance
load reactor should be used on the load side of the VFD when
the motor lead length exceeds 100 feet. VFDs are an e cient
type of variable speed drive. he most recent generations of
VFDs perform well and have few complications when properly
applied and matched to the motor and electrical system.
Figure 4.14. Energy consumption
HI Pump FAQs
he energy consumed by a pump varies as the third power
of the speed. herefore, a 50 percent reduction in speed will
reduce the power consumed by as much as 80 percent, depend-
ing on the system head curve characteristics. It is then possible
to match pump operating speed to the exact conditions of ser-
vice without throttling.
Not all this horsepower dierence is savings, however,
because a variable speed device has its own losses. he e ciency
of a VFD (inverter) is aected by operating speed, ranging from
about 97 percent at 100 percent of rated speed to around 91
percent at 50 percent of rated speed (input frequency), for the
latest generation of drives.
A VFD causes harmonic losses in the motor, due to imper-
fect sinusoidal waves from the VFD supplying the motor. hese
losses cause the motor to heat up, which is why the motor may
need to be de-rated when running with a VFD. Inverter-rated
motor windings are required for 440 volts and above.
VFD drives can generate stray motor currents. his may
require grounding of the motor rotor and/or the use of a bear-
ing with an insulating coating on the outer ring. Small elec-
tric discharges between the rolling elements and the bearing
raceway can eventually damage (pit) the bearings and/or cause
them to run hotter, especially with larger motors over 100 kilo-
watts (150 horsepower).
P&S
Pump FAQs is produced by the Hydraulic Institute as
a service to pump users, contractors, distributors, reps and
OEMs as a means of ensuring a healthy dialogue on subjects
of common technical concern.
HI standards are adopted in the public interest and are
designed to help eliminate misunderstandings between the
manufacturer, the purchaser and/or the user and to assist the
purchaser in selecting and obtaining the proper product for
a particular need.
As an ANSI approved standards developing organiza-
tion, the Hydraulic Institute, process of developing new stan-
dards or updating current standards requires balanced input
from all members of the pump community.
We invite questions and will endeavor to pro-
vide answers based on existing HI standards and
technical guidelines. Please direct your inquiries to:
pumpquestions@pumps.org.
For more information about HI, its publications,
Pump LCC Guide, Energy Saving Video-based educa-
tion program and standards, please visit: www.pumps.
org. Also, visit the new e-learning portal with a compre-
hensive course on Centrifugal Pumps: Fundamentals,
Design and Applications, which can be found at:
www.pumplearning.org.
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EVERY SOLUTION
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Sealing
A
leak prevention system (LPS) is available that is eec-
tive in sealing pumpage with particulates and for clear
liquids. It can be used with pumps, mixers, agitators,
ribbon blenders, fans and sealing shafts for dry powder han-
dling and includes fast and slow rotating equipment.
The Technology
he LPS is analogous to a double mechanical seal that uses
a exible sealant as a barrier uid. his barrier uid is main-
tained at a pressure slightly above stu ng box pressure by an
air-operated piston. Close-tting bushings at either end of
the seal retain the exible sealant. In essence, the LPS traps
the sealant within the LPS assembly, and the pumpage has no
chance to escape from the pump since it sees no leakage path.
he pressurizing sealant does not rotate with the shaft
and, in remaining static, is actually a exible stationary seat.
he vertical edges of the machined crenellations (perpendic-
ular to the shaft axis) act as rotating heads. In an LPS with
two crenellations, four sealing surfaces are on the shaft sleeve.
Use with High and Low Shaft Speeds
he initial versions of the LPS were designed for low shaft
speeds, with shaft peripheral velocity less than 0.5 meters/
second (1.64 feet/second). hese designs, typically used on
blenders, mixers or progressing cavity pumps, require no
cooling. Higher shaft peripheral speeds, such as those of most
centrifugal pumps, require cooling of the LPS assembly. An
illustration of the cooled LPS assembly as used in centrifugal
pumps is shown in Figure 1.
he cooling chamber is formed between the LPS hous-
ing and the bore of the existing pump stu ng box with an
O-ring sealthe cooling medium does not contact the pro-
cess liquid. Guide vanes in the cooling chamber distribute
the ow from the in/out ports in a serpentine path.
he Kevlar bushings provide a tight clearance against
the shaft sleeve, limiting any intrusion of the exible sealant
into the pump. Similarly, the graphite and Teon bushing
combination limit the exible sealant from exiting the pump.
Crenellations on the shaft sleeve provide radial sealing
surfaces to accommodate shaft movement due to deection
and/or vibration. For process pumps (e.g. ANSI or paper
stock), a hook-type shaft sleeve is supplied to protect the
pump shaft and to help position the impeller on the shaft as
well as enabling axial travel for impeller clearance adjustment.
Since no process uids migrate through the stu ng box,
no solids will enter the seal assembly. Solids ejection vanes are
furnished on the shaft sleeve to keep solids from settling on
the bottom of the stu ng box.
New Leak Prevention
Technology
Jack Tyler, P.E., Jack Tyler Engineering Company, & Art Evans, Art Evans & Associates
Air-operated piston assembly, injectable packing and air ush enhance this sealing
systems performance in harsh applications.
Figure 1. Leak prevention system general arrangement
Standard material of the seal assembly
is 304SS and other materials can be fur-
nished for compatibility with the pumped
liquid.
Velocity Considerations
Shaft tangential or peripheral velocity is an
important consideration when selecting the
shaft seal type. Calculating this parameter
can be accomplished with these equations:
English/American Units
V
T
=
Dia x x rpm
720
Where:
V
T
= shaft tangential velocity, feet/
second
Dia = Shaft diameter, inches
Metric Units
V
T
=
Dia x x rpm
60,000
Where:
V
T
= shaft tangential velocity,
meters/second
Dia = Shaft diameter, millimeters
Pressure Assembly
In the LPS, the pressure on the exible
sealant within the assembly is main-
tained at about 1 bar (approximately
15 psig) above stu ng box pressure.
his is accomplished by an air-operated
piston assembly. See Figure 2.
he pressurizing piston provides
a consistent and moderate pressure
on the exible sealant. his pressure is
between four times and seven times the
pressure in the air chamber, depending
on the pump application and pressur-
izing device furnished. he required air
pressure is calculated on a case-by-case
basis.
Virtually no air consumption
occurs for this device. If air pressure is
lost, the seal will continue to operate
for at least 45 minutes before leakage
through the seal will occur. Once air
pressure is restored, the seal will return
to normal operation.
Figure 2. Sealant pressurizing assembly
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Sealing
he sealant reservoir contains approximately 2 inches
3

(33 centimeters
3
or 60 grams) of sealant, which is su cient for
about 18 months of operation in most cases. If the reservoir
needs to be replenished, this can be done while the pump is
running and takes about three minutes.
he proximity rod can be tted to engage a switch that
activates a signal to an attendant when/if sealant has to be
replaced in the reservoir. he signal can be a message to a cell
phone, SCADA or other monitoring device. his allows a time
period cushion of about three weeks in which the sealant reser-
voir can be replenished before the supply is exhausted.
Since the pressure on the exible sealant must be main-
tained slightly above pump stu ng box pressure, calculating
the stu ng box pressure, which is dierent for each pump type,
is important. In many cases, the stu ng box pressure is the
same as the pump suction or discharge. Some exceptions are:
Open Impeller w/ Back Pump-Out Vanes
P
S'Box
=
P
Pump Discharge
- P
Pump Suction
4
+ P
Pump Suction
Open or Enclosed Impeller w/ Balance Holes
P
SBox
=
P
Pump Discharge
- P
Pump Suction
10
+ P
Pump Suction
When pump suction pressure is variable, use the higher
value for suction pressure for the stu ng box pressure. If the
pump is to be operated against a closed discharge valve at any
time, use the pump discharge pressure at shut-o. If the pump
is on a suction lift, the stu ng box may be at a pressure lower
than atmospheric and air may be drawn through the shaft seal.
his is no problem for the LPS since it can run dry indenitely.
Flexible Sealant
he exible sealant used in the LPS is also important. here
are several types, but the most common is injectable packing.
his has been available for decades for use in more traditional
stu ng box arrangements in which the injectable packing is
pumped into a stu ng box with a ring of packing at each end.
In this mode, the injectable packing was intended to maintain
a seal for the pumped liquid.
Over-pressurization during installation and the lack of
packing pressure maintenance led to irregular and often unsat-
isfactory performance, such as leaky stu ng boxes. Conversely
in the LPS, the injectable packing is held within the system
assembly and forms a barrier through which the pumped liquid
cannot pass. No over-pressurization occurs since the pressuriz-
ing piston assembly maintains a moderate and steady pressure.
he choice of a exible sealant depends on the requirements
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of the application. Chemical compatibility, temperature, oper-
ating pressure, shaft tangential velocity and FDA certication
for food-related products must be considered.
More than 400 variations of exible sealant are available
from injectable packing to high-viscosity greases. Higher stu-
ing box pressures may be accommodated by a Plan 13 seal
piping arrangement.
Applications
Typical applications for the LPS include sealing a uid where
ushing the seal faces with water or another barrier uid is
undesirable, applications in which cavitation of the pump is a
common occurrence and the cavitation destroys the seal faces
in a short time or applications in which abrasives in the sealed
uid lead to premature seal face failure.
Pumping brine solution when dilution of the uid with
seal ush is not wanted can be particularly challenging for con-
ventional mechanical seals. Salt particles in the brine are abra-
sive and wear traditional seal faces prematurely.
In pulp and paper, sealing black liquor can be problematic
because of the need to ush the seal faces with water or another
barrier uid to prevent the liquor from solidifying on the seal
faces and causing failure. Some black liquor processes purge
the black liquor pumps with live steam while running to clean
the system, causing severe pump cavitation. his procedure
destroys seal faces in short order. he LPS is able to handle
abrasive uids easily and pump cavitation without failure.
New Developments
he latest development for the LPS is air ush. A small
amount of compressed air, typically 0.17 SCFM at 8 psig, is
fed to the back of the stu ng box via an internal port in the
seal. his air forms a bubble between the back of the impeller
and the back of the stu ng box. he bubble expands to create
a torturous path even more di cult for the uid pumped to
penetrate than the pressurized sealant. he result is leak free
he LPS presents opportunities for handling tough-to-seal
pump applications where traditional packing or mechanical
seals cannot provide the performance required. P&S
Jack Tyler, P.E., is the CEO for Jack
Tyler Engineering Company, Inc. He can
be reached at jacktyler@jtectn.com or
901-794-1413.
Art Evans, Art Evans & Associates, can
be reached at artevans@verizon.net or
315-539-4127.
ShanIey Pump & Equipment, Inc.
2525 South Clearbrook Drive
Arlington Heights, Illinois 60005
Phone: 847-439-9200 Fax: 847-439-9388
Visit our Website at www.shanleypump.com
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Booth 400
Sealing
T
ransNeft was set up in 1992 to provide coordination
and transport of oil and petroleum products through
pipelines in Russia and other countries. he company
has 50,000 kilometers of pipelines, more than 300 pump sta-
tions and 900 oil tanks with a capacity of more than 16 million
m
3
, and transports 93 percent of the oil produced in Russia.
Construction of the rst pipeline phase, ESPO-1, got
underway ve years ago. Each year, 30 million tons of oil are
transported over a distance of 2,757 kilometers through ve
pump stations with 20 pumps from the city of Taishnet in the
Eastern Siberian region of Irkutsk to the city of Skovorodino
in Russias eastern Amur region. he planned ESPO-2 phase
will extend the pipeline for another 2,100 kilometers from the
Skovorodino station to the port of Kozmino on the Pacic
Ocean.
Including the planned extension to phases ESPO-1 and
ESPO-2, roughly 80 million tonnes of oil will be transported
annually by 2013/2014 over a distance of 4,857 kilometers
through 43 pump stations with four pipeline pumps each. he
ESPO-1 section to Skovorodino and the two-billion-dollar oil
terminal Kozmino near Nahkoka on the Pacic Ocean were
opened in 2009. Until ESPO-2 is completed, the oil is being
taken by rail from the Skovorodino station to Kozmino. his
means that Russia now has a new oil route.
No Leakage Even Under the
Harshest Conditions
he pipeline runs through earthquake hazard zones and over-
comes large geographic dierences in altitude. Once the entire
pipeline is complete, the average distance between pump sta-
tions will be roughly 150 kilometers. Currently, only seven
pump stations are on the ESPO-1 pipeline, which means that
the average spacing is around 400 kilometers. he distances
between stations, the overall length of the pipeline (which is
1.22 meters in diameter), the extreme and varied climatic con-
ditions, the transportation capacities and oil delivery commit-
ments of the operator pose substantial technical and business
challenges for machinery and component suppliers.
he seals, which are at the heart of the pumps, have to
function without personal care. he pump stations are dif-
cult to access and are located in rough terrain. his means
that the pump components have to meet stringent quality,
durability, availability and service life standards. he seals have
Oil & Gas Project Sets
New Standards
Ellen Klier & Franz Schfer, EagleBurgmann Germany
Tailored sealing solutions supply high-pressure sealing for Russias East Siberia
Pacic Ocean pipeline system.
The East Siberia Pacic Ocean (ESPO) is a project of superlatives. The state-owned Russian company
TransNeft is in the process of building the ESPO Pipeline in two phases. The 5,000 kilometer pipeline will
supply Siberian oil to China, Japan and Korea. Completion and operation at full capacity are scheduled for
2014. Phase 1 has been operating since the end of 2009.
Double mechanical seals have a proven track record in applications
with corrosive and abrasive media.
to adapt precisely to the dierent operating conditions, e.g.
pressure and temperature uctuations and speed variations, to
ensure optimal leakage protection and service life. Also given
the logistics involved, service, maintenance and repair outlay
must be kept to a minimum.
he sealing companys international footprint, Russian
subsidiary and local presence (at the Ukrainian pump manu-
facturer) played a crucial role in the contract acquisition along-
side of its technical expertise. All these factors guaranteed fast,
un-bureaucratic cooperation and compo-
nent availability.
Sealing Know-How Is the
Key
Standardized mechanical seals do not
meet stringent pipeline requirements and
are unable to withstand the loads placed
on the pumps and the seals inside them.
For that reason, engineered seals are used
almost exclusively on pipelines. he seals
are designed for the specic application in
close collaboration with the pipeline plan-
ners, pump manufacturers and users.
In 2006, the seal company received an
initial query on the ESPO-1 project from
several well-known international pump manufacturers. A lot
was expected from the seal design and the high-pressure seals.
Engineering analysis and test runs were needed to optimize
the seals for the specic application. For cost and availability
reasons, oil is used rather than water as the buer uid in this
particular project. he operating conditions were dened:
Pressure to be sealed 10 to 78 bar (pressure varies because
four pumps per station are connected in series).
Russias new oil route
24 al 26 de enero de 2012 | GEORGIA WORLD CONGRESS CENTER, ATLANTA, GEORGIA EUA www.ipeweek12.org www.ife12.org |
GLOBAL MARKETPLACE
FOR THE POULTRY AND FEED INDUSTRIES
The 2012 International Poultry Expo and International Feed
Expo will be held January 24 26, 2012, and the week of the
Expo has been oicially designated as IPE Week with an
emphasis on educational programs rounding out the week-
long event.
The Expo is shifting to a TUESDAY, WEDNESDAY, THURSDAY
format to increase the education programs available to
attendees.
t The Worlds Largest Poultry and Feed Technology Exposition
t Over 20,000 Industry Leaders from Over 100 Countries
t Over 14 Acres of Exhibits
t Exceptional Educational Programs Planned for IPE Week
- International Poultry Scientiic Forum
- Hatchery-Breeder Clinic
- Pet Food Conference
- Animal Agriculture Sustainability Summit
- Workshops on Safety and Environmental Issues
- Symposium on Egg Production
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- Executive Poultry Outlook
Sealing
Buer pressure on all pumps is set to 90 bar.
Product temperature is -15 degrees C to 60
degrees C.
he speed is 1,500 rpm or 3,000 rpm depending
on pump manufacturer.
A double mechanical seal was selected for this
application and was set up for the operating condi-
tions listed above. he seal has a solid track record
in pumping applications with corrosive and abrasive
media. During operation, the eects of pressure and
temperature deform the sliding faces. he type and
extent of mechanical and thermal deformation and
the degree of overlap depend on the design and the
face materials.
Finite element analysis (FEA) was used to deter-
mine the optimal geometry for the seal face and seat
under the given operating pressure, temperature and
speed conditions. To further improve seal running
characteristics, lubrication grooves were placed on the
face of the rotating seat. By ne-tuning the design, the
engineers were able to minimize leakage, friction loss and seal
face wear. he seals were then subjected to extensive dynamic
and static testing.
During the test phase, further modications were made to
optimize seal running characteristics under uctuating operat-
ing conditions. Friction losses and leakage volumes were con-
siderably below the minimum specied by the customer.
Further modications and optimization were made to
the seals running characteristics to accommodate the diverse
operating conditions. Friction losses and leakage volumes were
considerably below the minimum specied by the customer.
In 2007, 24 single, high-pressure seals for booster pumps,
60 double, high-pressure seals for main pipeline pumps and 24
API-Plan 53B buer systems with heat exchangers were deliv-
ered for the project. he seals have demonstrated the durability
needed for this harsh application. hey have been running for
two years without problems.
Positive Results
Following the success of the ESPO-1 project, the seal com-
pany was chosen to supply for TransNeft and the HMS
Group (Russian machinery holding company and a pump
manufacturer) including its Ukrainian production plant in
Nasosenergomash. he HMS Group and the plant in the
Ukraine were selected to supply the pumps for six additional
pump stations on the ESPO-2 project and ve pump stations
on the ESPO-1 extension. Based on the performance, the
HMS Group signed a delivery contract for double seals and
supply systems for the rst ESPO-1 extension and single seals
and cyclone separators for the ESPO-2 project.
Since last year, visitors from the HMS Group and
Nasosenergomash have travelled to the seal companys facility
to take part in the test runs on seals that were ordered.
Before this contract, we already had many years of expe-
rience with EagleBurgmann on other projects. he expert
advice and the engineering design, quality and durability of the
mechanical seals and systems have always been the reasons why
we selected EagleBurgmann as our seal supplier, says Vladimir
Jumburenko, executive board chairman and president of the
Ukrainian pump manufacturer and Igor Tverdochleb, director
of New Pump Trials & Development at the HMS Group.
he ESPO-1 and ESPO-2 extensions are planned to start
up in 2013/2014. he next extensions after that will include
22 stations and 88 pumps.
P&S
Ellen Klier is a press o cer with group
marketing, EagleBurgmann Germany.
She can be reached at ellen.klier@
de.eagleburgmann.com.
Franz Schfer is in direct sales with
Eastern Europe sales, EagleBurgmann
Germany.
Seat (left) and seal face (right)
Successful test run: sales manager for the seal company assessed the results
with the customer.
Practice & Operations
P
umps handling dirty uids risk damage to the mechan-
ical seal and line shaft wet bearings if they are not con-
tinuously ushed by clean uids. When clean water
is available, it can be routed through small diameter tubing
for lubricating and cooling purposes. However, clean water is
often unavailable, too costly and sometimes the addition of
water cannot be tolerated. In these cases, a cyclone separator
can be employed to remove dirt and grit from the uid being
pumped, before safely using it for the seals and bearings.
Pumps with product-lubricated (wet) bearings, such as
many vertical sump pumps, require a supply of clean uid to
lubricate and cool the bearings. If the pumped uid is free of
solids, a small stream can be piped directly from the pump
discharge to the bearings. A similar approach works well for
the mechanical seals and packing of horizontal pumps.
However if the pumped uid contains abrasives or other
solids, an alternate solution is needed. Sump pumps often
handle wastewater, which can contain abrasive particles. A
common solution is to arrange a separate supply of clean
water to ush wet bearings, seals and packing.
Even at modest ow rates, however, water consumption
for bearings and seals soon mounts, especially in facilities in
which a large number of pumps are operating. In other cases,
clean water may simply not be available. For applications
such as these, ush uid recirculation systems incorporating
cyclone separators can soon pay for themselves by replacing
the need for clean water.
Thermoplastic Outperforms Cast Iron
One application in which cyclone separators have proved
themselves in practice is at a renery in Louisiana. he ren-
ery operator originally installed more than 30 cast-iron, ver-
tical sump pumps for a variety of wastewater duties. Some
of these pumps were located in remote locations, making
reliability critical. he iron pumps soon began to experi-
ence corrosion, with correspondingly high maintenance and
replacement bills.
Searching for a better solution, the company contacted
a process equipment sales representative FLIP, Inc., (in Baton
Rouge, La. he company suggested using corrosion-resistant
thermoplastic sump pumps. All the uid-contact compo-
nents of the 15-foot-long (5-meter) pumps were molded
of solid polypropylene, including a thick-sectioned sleeve
encapsulating the stainless steel shaft. With no metal parts
in contact with the pumped uid, the pumps were a good
choice for this challenging service.
he thermoplastic pumps showed good resistance to
abrasion compared to their metal counterparts, but in this
application, the water was so contaminated that it called for
special measures to protect the pumps submerged line shaft
bearings. Because of the remote locations, piping clean water
for ushing would have been expensive, and the 15-foot
sump depth (5-meter) ruled out bearingless pumps of canti-
lever design. Instead, the sales representative used his experi-
ence with pump systems to create a better solution.
Strainer Plus Cyclone Saves Water
Rather than pipe in an external water supply, each pump
was tted with a large thermoplastic basket strainer plus a
cyclone separator. A small ow of wastewater from the pump
discharge passed through the strainer and to the inlet of the
cyclone, which removed ne particles. he dirty waste stream
from the bottom of the cyclone returned to the sump, while
clean water from the cyclones top discharge nozzle was piped
down the pump column to lubricate the ceramic line shaft
bearings.
Since the rst trials, the renery has installed more than
a dozen thermoplastic sump pumps with cyclone ushing
Safe Flushing
Ken Comerford, Vanton Pump and Equipment Corp.
Remove grit from pumped uids to safely ush bearings and seals.
Figure 1. The mounting plate of this vertical sump pump has
plenty of space to install a strainer and cyclone needed to pro-
vide clean water to the shaft bearings.
Practice & Operations
systems. hese have been more reliable than the cast iron
pumps.
he cyclone separators can supply clean ush water both
for wet bearings in vertical pumps and mechanical seals in
horizontal thermoplastic pumps. he cyclones themselves are
made of abrasion-resistant polyvinylidene uoride (PVDF)
with rubber seals. In the right applications, this arrangement
has proven to be both eective and economical.
Putting Solids in a Spin
Cyclone separators (also known as hydrocyclones when used
for liquid service) use centrifugal force to multiply small density
dierences between uids and particles of dirt. In pump appli-
cations, they are useful if clean ushing water is not available,
or when savings in water usage are required.
Entering the cyclone body through a tangential nozzle, the
uid is forced into a downward helical path following the coni-
cal inside cavity of the cyclone. Dirt-laden uid exits the base
of the cyclone and returns to the pump suction or drains back
into the sump beneath. A valve installed in this line allows the
ow rate to be adjusted. Clean uid ows up, inside the helix,
and leaves the top of the cyclone. From here, it is piped to the
bearings or seals for ushing.
P&S
Figure 2. A cyclone separator fed from the pump discharge sup-
plies grit-free water to ush the mechanical seal on a horizontal
thermoplastic pump.
Ken Comerford is vice president, Vanton
Pump and Equipment Corp. Since joining
the company in 1982, he has served in a
variety of roles and was promoted to vice
president in 2006. He currently sits on the
board of directors and is a member of WEF
Association. Comerford can be reached at
mkt@vanton.com or 908-688-4216.
Publication Title:Pumps and Systems Magazine
Publication Number: 1065-1084
Filing Date: 9/27/2011
Frequency: Monthly
Number of Issues Published Annually: 12
Annual Subscription Rate $48.00
Complete Mailing Address of Known Office of Publication
1900 28th Avenue South Ste 110
Birmingham, Alabama 35209
Complete Mailing Address of Headquarters or General Business Office of Publisher
Birmingham, Alabama 35209
Full Names and Complete Mailing Address of Publishers, Editor and Managing Editor
Walter B. Evans, Jr.
Birmingham,Alabama 35209
Editor: Michelle Segrest
Managing Editor: Lori Ditoro
Owner: Cahaba Media Group
P.O.Box 530067 Birmingham,AL 35253
Stockholder: Walter B. Evans Jr
P.O.Box 530067 Birmingham,AL 35253
Average No. of
Copies Each Issue
During Proceeding
12 Months
No.Copies of
Single Issue
Published Nearest
to the filing date.
Issue Date of Circulation Below: September, 2011
Total Number of Copies (Net Press Run) 42,063 42,155
Paid/Requested Outside County Mail Subscriptions Stated on form 3541
(Include advertisers proof and exchange copies) 30,652 28,935
Total Paid and/or Requested Circulation 30,652 28,935
Free Distribution Outside County as stated on 3541 10,449 11,342
Free Districution Outside mail 325 800
Total Free Distribution 10,774 12,142
Total Distribution 41,426 41,077
Copies Not Included 637 1,078
Total: 42,063 42,155
Percentage Paid and/or Requested Circulation 73.99% 70.44%
Walter B. Evans, Jr. Publisher 9/27/2011
I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes
false or misleading information on the form or who omits material or informatiotn requested on the form may be
subject to criminial sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties)
Statement of Ownership, Management and Circulation
Quarter-Turn Electric Actuators for
Rugged Industrial
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ProMation Engineerings P9-13
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feature a rugged, industrial-grade
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40,500 inch pounds. he series features a self-locking, hard-
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Flatness Measurement of Machine
Bases and Foundations
LUDECA, Inc., announces the automatic
LEVALIGN EXPERT rotating laser. his
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atness, levelness, parallelism and straight-
nesssingle operator, wireless, 3D graphics
and more.
Rubber Seated Ball Valve
Val-Matics EnerG AWWA rubber seated ball
valve is for surge control, low head loss
and energy savings. When fully open,
the valve provides 100 percent clear
ow area equal to the pipe size. he
EnerG features the advantages of a
standard fusion bonded epoxy interior
and exterior coating and a bi-directional resilient
Tri-Loc seating system. he Tri-Loc seat retention system
provides a low friction, wear resistant seat.
Progressive Cavity Template
Simerics releases the
Progressive Cavity Pump
Template for PumpLinx, the
virtual test bed for pumps
and valves. PumpLinx helps
improve performance, reduce
cavitation, cavitation damage
and noise. he Progressive Cavity Pump Template extends
virtual pump testing capabilities to the progressive cavity
pump type for a range of ow dynamics. PumpLinx is fast,
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P&S
Product Pipeline
Congratulations!
2011 Frost & Sullivan Excellence in
Best Practices Award Recipients
Vistagy, Inc. | Warren Rupp, Inc. | IFS
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contact Britni Myers at 210.477.8481 or britni.myers@frost.com.
BULLETIN BOARD
www.splitisolator.com | www.klozure.com
.mitre|etZ.tem | I.&.SS.7&J | .Keeieii:ele|er.tem
MONITOR PUMP PERFORMANCE
UNIVERSAL
POWER CELL
One Size AdjusLs for
All MoLors, lron Snall
up Lo 150HP
Works on variable lrequency
Drives, 3 Phase, DC and
Single Phase
10 Lines nore sensiLive
Lhan jusL sensing anps
4-20 Millianp, 0-10 volL
FLOW RAT
PUMP CONDITION
DRY RUNNINC
CAVITATION
BARINC FAILUR
CALL NOW FOR YOUR
FR 30-DAY TRIAL
888-600-3247
WWW.LOADCON1kOLS.COM
Theory Hands-On Live Performance Testing
Next Pump School Session
February 15-16 AtIanta, GA
EVERYTHING YOU EVER WANTED TO KNOW ABOUT PUMPS
For more information go to
www.PumpingMachinery.com
770-310-0866
Advanced Engineered
Pump, Inc. 159 69
Advanced Sealing
International (ASI) 117 15
ALMATEC 116 19
Baldor Electric Company 100 13
Blue-White Industries 118 27
Boerger, LLC 119 50
Carver Pump Company 120 16
Concepts NREC 143 57
Dan Bolen &
Associates, LLC 160 71
Dickow Pump Company 121 20
Dynalow 161 69
EagleBurgmann 137 47
Electro Static Technology 122 23
Frost & Sullivan 144 66
Garlock Sealing
Technologies 101 BC
Garlock Sealing
Technologies 156 68
Global Pump 102 55
Graco, Inc. 138 42
Greene, Tweed 115 8
Grundfos Pump Corp 103 9
Hydraulic Institute 145 58
Inpro/Seal 124 43
Jack Tyler Engineering 146 64
Jordan, Knauff & Company 147 58
Junty Industries, Ltd. 163 70
Larox Flowsys Inc. 125 10
Leistritz Corp. 126 25
Liquilo 106 51
Load Controls, Inc. 127 12
Load Controls, Inc. 157 68
LobePro 162 71
LUDECA Inc. 139 45
Magnatex Pumps, Inc. 165 70
Meltric Corporation 166 69
Met-Pro Global
Pump Solutions 107 17
Motor Protection
Electronics 148 53
Mouvex 128 28
MSE of Canada Ltd. 164 69
NETZSCH 149 49
NSK 108 21
Oberdorfer Pumps, Inc. 129 30
Poultry Expo 130 61
PowerGen 109 67
Precision Polymer
Engineering Ltd. 150 57
Pump Solutions Group 140 41
Pumping Machinery 158 68
Revere Controls Systems 151 49
Ruhrpumpen 132 31
Scenic Precise Element Inc. 167 70
SCHENCK 133 35
SEPCO 134 38
SEPCO 168 68
SERFILCO, Ltd. 135 37
SERO Pump Systems 169 70
Shanley Pump and
Equipment, Inc. 152 59
Siemens Industry, Inc 110 3
Sims Pump Co 111 7
Sims Pump Co. 111 69
Summit Pump, Inc. 171 70
Tamer Industries 172 68
TAW 178 71
TAW 179 71
TechCast, LLC 154 53
Trachte, USA 173 70
Trask-Decrow 174 71
Trulo Pumps, Inc 112 5
Tuf-Lok International 175 70
Varisco 176 71
Vaughan 113 IBC
VERTIFLO 155 59
Vesco 177 69
VibrAlign 141 46
W.L.Gore & Associates, Inc. 114 1
Watson-Marlow
Pumps Group 136 11
Xylem 104 IFC
Zoeller Company 180 69
* Ad index is furnished as a courtesy and no respon-
sibility is assumed for incorrect information.
Advertiser Name R.S. # Page Advertiser Name R.S. # Page
INDEX OF ADVERTISERS
PUMP USE RS MARKETPL ACE PUMP USE RS MARKETPL ACE
zoellerengprod.com
1-800-928-7867
DONT FIND
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clear clear
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both s both s
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seizures
Tollfree 1 866 635 7596
vesconite@vesconite.com
www.vesconite.com
OFF Button
Provides push button
circuit disconnections
Arc Flash Chambers
Prevent Exposure
to Arc Flash
Safety Shutter
Keeps NFPA 70E Hazard/
Risk Category=0
www.meltric.com 800.433.7642
Maximum protection from
electrical hazards. Minimum
downtime for pumps.
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PUMP USE RS MARKETPL ACE
ROTARY LOBE SLUDGE PUMPS
FOR SLUDGES/SLURRIES/CORROSIVES
912-466-0304 www.LOBEPRO.com Made in USA
Shutdown protection
avaiIabIe for
contaminants and over
pressure conditions.
SeIf Priming to 25'.
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at 1/3 the cost and time for
equivaIent PC pump.
INDUSTRY LEADER
OVER 35 YEARS
SALES SERVICE PARTS
www.trask-decrow.com
1-800-287-1538
The Power Behind Your Process
Distributor for Sulzer Process Pumps
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Equipment Industry since 1969
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Manufacturing
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(480) 767-9000 Fax (480) 767-0100
Email: danbolen@mindspring.com
www.danbolenassoc.com
EXECUTIVE SEARCH/RECRUITING
Employment
P&S Market
P&S Market
T
he Jordan, Knau & Company (JKC) Valve
Stock Index was down 11 percent during the
last 12 months, well below the broader S&P
500 Index, down 1.3 percent. he JKC Pump Stock
Index was down 5.1 percent for the same time period.
Economic activity in the manufacturing sector
expanded slightly in September for the 26th consecu-
tive month. he Institute for Supply Managements
Purchasing Managers Index (PMI) moved higher in
September to 51.6, up from 50.6 in August. However,
survey responses noted the weak economic environ-
ment and continued anxieties regarding global demand,
causing a high degree of caution in the marketplace. Over the
past 12 months the PMI has averaged 56.6.
he global manufacturing sectors performance has weak-
ened since January 2011. he JPMorgan Global Manufacturing
PMI was 49.9 in September, below the 50.0 mark for the rst
time since June 2009. hird-quarter production growth was
negligible and fell sharply from rst-quarter peaks.
he Bureau of Labor Statistics reported that September
hiring was stronger than expected with employers adding
103,000 jobs. he Labor Department also revised reports for
July and August, showing an additional gain of 99,000 jobs
during the summer. Industries adding jobs included construc-
tion, retail and professional and business services. he manufac-
turing sector lost 13,000 workers.
he number of oil and gas rigs in operation in the U.S.
continued to increase in September to 1,978, their highest level
since September 2008. Worldwide rig counts, at 3,662, are at
levels not seen since the beginning of 1985.
Oil prices continue to face upward price pressure due to
supply uncertainty and downward price pressure because of
lowered economic growth expectations. On the supply side,
a downward price pressure may occur if Libya is able to ramp
up production and exports sooner than anticipated. he U.S.
Energy Information Administration believes that about one-half
of Libyas pre-disruption production will resume by the end of
2012. West Texas Intermediate crude oil spot prices fell from an
average of $97 per barrel in July to $86 per barrel in August and
September.
On Wall Street, the Dow Jones Industrial Average nished
the third quarter down 12 percent, its largest percentage decline
since the rst quarter of 2009. he Dows September decline
capped its fth straight month of losses. Financial stocks were
hard hit during the quarter with many banks falling 25 percent
or more. Markets were volatile, moving up and down on a daily
(or hourly) basis. Investors grew increasingly worried that the
U.S. and European economies will slide back into recession.
P&S
Wall Street Pump and
Valve Industry Watch
Jordan, Knauff & Company
Jordan, Knau & Company is an investment bank based
in Chicago, Ill., that provides merger and acquisition advi-
sory services to the pump, valve and ltration industries.
Please visit www.jordanknau.com or email jgonder@jor-
danknau.com for further information on the rm.
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 October 2010 to September 2011
The ultimate protection for your bearings. The Garlock SGi provides maintenance-free and long
term reliable shaft voltage mitigation technology while, at the same time ensuring the highest level
of ingress and egress protection. Make uted bearings a thing of the past. Upgrade now to the
Garlock SGi!
Give us a call today to nd out more!
MICRO-TEC
II ISO-GARD
GUARDIAN
GARLOCK BEARING ISOLATOR FAMILY

www.splitisolator.com | www.klozure.com
www.microtec2.com | 1.866.556.9873 | www.oodedisolator.com circle 101 on card or go to psfreeinfo.com

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The Magazine for Pump Users Worldwide November 2011

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Figure 5.12. Balanced seal

GARLOCK BEARING ISOLATOR FAMILY

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