9 Pumps and Systems - October 2010

The Magazine for Pump Users Worldwide October 2010

pump-zone.com

The Magazine for Pump Users Worldwide

pump-zone.com

October 2010

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2 OCTOBER 2010 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 offi ces. Subscriptions: Free of charge to qualifi ed industrial pump users. Publisher reserves the right to determine qualifi cations. Annual sub-scriptions: 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) 482-3050 inside or outside the U.S. POSTMASTER: send change of address to Pumps & Systems, PO BOX 9, Batavia, IL 60510-0009. ©2010 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:

One of civilization’s earliest inventions, pump technology has not changed much through the years. Since 200

B.C., pumps have moved water and other vis-cous materials from Point A to Point B. No matter the consistency of the liquid—whether it’s peanut butter or oil—a pump can suck, push or lift it to its destination.

However, the pump industry continues to be innovative and intelligent in the advance-ments of technology. Because of constant developments, Pumps & Systems covers instru-mentation, monitoring and controls in every issue (coverage this month begins on page 28). As manufacturers continue to see the value in pump system optimization, “Smart Pumping” is revolutionizing the industry.

“From the cell phones we carry to the cars we drive, technology advancements have transformed the way we live,” explains Dan Kernan, manager of monitoring, controls at ITT Industrial Process. “On-board intelligence and digital communications make the machines we use every day more effi cient.

“But if you work with industrial machines, walking onto the shop fl oor can be a step back in time. Some pumps being sold today have barely changed in 50 years. h at’s because too many pump manufacturers have been slow to integrate digital and interactive technologies with their products.”

ITT and other companies are working to change that, as illustrated in this month’s cover series Smart Pumps (page 18). “Our process pumps ship with onboard digital sensors—the pumping equivalent of a “check engine” light to warn of temperature or vibration issues,” says Kernan.

h e PumpSmart® drives on this month’s cover are the digital version of an automatic transmission, adjusting pump speed to process conditions. ProSmart™ condition monitoring is similar to auto safety systems, such as OnStar®, that assess conditions remotely and use wireless communications to provide help when needed.

Intelligent pumping systems continue to improve performance and reduce energy con-sumption by combining a pump and a variable frequency drive with digital control capabilities (page 19). Learn how intelligent pumping sys-tems have become a driving force in the pump market (page 22) and how single phase pump-ing can be made safer and smarter (page 25).

Best Regards,

Michelle [email protected]

PUBLISHER

Walter B. Evans, Jr.

ASSOCIATE PUBLISHER

VP-SALES

George [email protected]

205-345-0477

EDITOR

VP-EDITORIAL

Michelle [email protected]

205-314-8279

MANAGING EDITOR

Lori K. [email protected]

205-314-8269

MANAGING EDITOR—

ELECTRONIC MEDIA

Julie [email protected]

205-314-8265

CONTRIBUTING EDITORS

Laurel DonohoJoe Evans, PhD

Dr. Lev Nelik, PE, APICS

SENIOR ART DIRECTOR

Greg Ragsdale

PRODUCTION MANAGER

Lisa [email protected]

205-212-9402

CIRCULATION

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P.O. Box 530067Birmingham, AL 35253

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Editorial Advisory Board

William V. Adams, Director, New Business Development/Corp. Mktg., Flowserve Corporation

Thomas L. Angle, PE, Vice President, Product Engineering, Weir Specialty Pumps

Robert K. Asdal, Executive Director, Hydraulic Institute

Bryan S. Barrington, Machinery Engineer, Lyondell Chemical Co.

Kerry Baskins, Vice President, Grundfos Pumps Corporation

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.

David A. Doty, North American Sales Manager, Moyno Industrial Pumps

Ralph P. Gabriel, Director of Product Development,

John Crane

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

Earl Rogalski, Sr. Product Manager, KLOZURE®, Garlock Sealing Technologies

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COVER SERIES: SMART PUMPS

p Optimization SolutionsJack Creamer, Dan McGinn and Jim Morgan,

Schneider ElectricImprovements in performance and energy reduction can be achieved.

p Intelligent Pumping MarketRam Ravi and Douglas Weltman, Frost & Sullivan

Current analysis and future outlook

p Safer and Smarter Single Phase PumpsAaron Wolfe, P.E., & Bill Chandler, Jr., CSI Controls

New motor starting controller provides one solution.

SPECIAL SECTION: INSTRUMENTATION, CONTROLS & MONITORING

p Reliable and Efficient Remote Lift Stations

Paul S. Twaddell, Eaton CorporationControl panel products enhance smooth operations.

p Mass-Based Propane Odorant Injection SystemWesley Sund, Brooks Instrument, LLC

Details of a mass-based chemical injection system

p Improving SCADA Operations Using Wireless Pumps

Hany Fouda, Control MicrosystemsMany reasons for wireless conversion reluctance are resolved with new technology.

PRACTICE & OPERATIONS

p Flexible Impeller Pumps in the Food IndustryDavid Farrer, Depco Pumps

One of the best kept secrets in pumping technology

p Pump CastingsAlfred ‘Fritz’ Hall, Benton Foundry

The most misunderstood, most overlooked and possibly most important pump component.

p Not All ANSI Pumps Are Created EqualPatrick Prayne, ITT Goulds

OEM pumps and parts outperform replicated products and can save thousands per year in operating costs.

p Data Loggers and Flow MetersEvan Lubofsky, Onset Computer Corporation

Low-cost additions help bottle maker manage compressed air use and energy costs on a shoestring.

Table of Contents

19

22

25

29

32

36

54

57

58

63

39TH ANNUAL TURBOMACHINERY SYMPOSIUM AND EXHIBIT SHOW

p Show Preview

DEPARTMENTS

Readers Respond. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Joe Evans, Ph.D.Variable Frequency Parallel Pump Analyzer

Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 16Dr. Lev Nelik, P.E., APICS, President, Pumping Machinery, LLC Eben Walker, Graphalloy CompanySpecialty Materials Help Improve Pump Reliability and Save Energy

Maintenance Minders. . . . . . . . . . . . . . . . . . . . . . . . . 40Mark D. Hinckley, SKF USA Inc.The Attraction of Magnetic Bearings

Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Wallace WittkoffEffi ciency Through Indirect Measures

FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 50What Is the Sealing System Energy Footprint for Removing Diluents from the Process Stream?

HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Bearings used in high-temperature applications, suction recirculation in pumps and Newtonian and non-Newtonian fl uids

Product Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Bulletin Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Pump Users Marketplace. . . . . . . . . . . . . . . . . . . . . . 69

P&S Stats and Interesting Facts . . . . . . . . . . . . . . . . 72

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The Magazine for Pump Users Worldwide October 2010

pump-zone.com

The Magazine for Pump Users Worldwide

pump-zone.com

October 2010

65

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Readers Respond

Grouting: Pumps and Telephone Poles,

July 2010No part of the anchor bolt should contact the grout. It

should be sleeved through the grout so the tension is trans-mitted to the foundation. I have sleeved and also used several wraps of duct tape where a sleeve is not practical. h e grout will not stick to the duct tape.

Duct tape also makes a great non-stick surface when applied to the forms. It works better than wax to keep epoxy grout from sticking.

Roy Lightle PTA Maintenance Superintendent

Lev Nelik responds: Excellent point—thanks, Roy. As promised, you get the

free admission to our Pump School! If interested, we have room for our class in August (19 – 20) in Atlanta:www.pumpingmachinery.com/pump_school/pump_school.htm.

Enjoyed your latest article, “Grouting: Pumps and Telephone Poles”, in the July Pumps & Systems magazine. Good info.

In response to the “parting quiz,” no part of a bolt should be in contact with the non-shrink grout. However, “J”-type and sleeve-type anchors, are commonly embedded into the concrete below the grout. Figure 3, in the article, illustrates the grout above the concrete. If the bottom nut, below the baseplate in this illustration, was removed the anchor should be able to stretch, from tensioning, approximately from the top nut to the concrete surface.

Lee RuizOceanside, Calif.

Lev Nelik responds: Your note echoes the one just sent to me by another engi-

neer at BP, with both of you essentially echoing the same good point. Right on! I will ask the P&S Editors to publish your input in Readers Respond.

As promised, you get the free admission to our Pump School! If interested, we have room for our class in August (19 – 20) in Atlanta.

Great articles in the Pumps & Systems magazine…I look forward to reading each month.

Your article in July that discussed grouting and base plates was very good. Is there an accepted technical standard for base plate design? I have looked at the HSI standard for centrifugal pump design and application, but it is mostly qualitative. It does not provide much in the way of specifi cs. If you know of a better more specifi c base plate standard, please let me know.

And keep up the good work in your articles; it helps.Bob Pritchard

Lev Nelik responds: h ank you for your kind words. h ere are several specs

which touch on the base plating and grouting, such as API-610 for pumps, ANSI and also articles by the folks involved in this business. However, there is no formal specifi cation for this subject, as I know, which is unfortunate, as the subject is very important.

I have raised the need for such specifi cations in several of my publications and have added references to this in various articles in Pumps & Systems and elsewhere.

If there is suffi cient interest on this further, I would be glad to lead a team eff ort to help develop such much needed standards.

Perhaps a starting point would be to compile the articles into a set to which we can add more, and then a committee would form to expand and develop them into a formal speci-fi cation. I will also raise this issue with the PumpTec-2010 Advisory Committee in Atlanta this month,www.pumpingmachinery.com/pump_school/pump_school.htm, and we will plan to add such a session to the next PumpTec Conference in 2011.

Sealing Sense, October 2007Water quality is an important consideration. Can you

please give me the minimum required fl ush water quality?Jay Wen

FSA Responds:h e following are suggested water quality specifi cations:Particle Size: 50 micron max.Solids Content: 10 milligram/liter max.Percent iron: 1 milligram/liter max.Water should be free of clay and humusPermanganate Number: max. 30Total Hardness: Max. 10 degrees dH

What Is a Safe NPSH Margin for a

Centrifugal Pump? Can You Provide Too

Much NPSH? June, 2009I have a question on NPSH margin. h e typical industry

standard (i.g. PIP) would use a 3-foot margin from minimum stable fl ow to 110 percent of the rated operating point. I’m not sure if HI 9.6.1 1998 is still applicable (ratio of NPSHA/NPSHR = 1.1). Would it be appropriate to use HI in this case as well? h is is for the power generation industry.

William NguyenMechanical Engineer

Terry Henshaw responds: I addressed the complex and controversial subject of

Lee Ruiz

PUMPS & SYSTEMS www.pump-zone.com OCTOBER 2010 7

NPSH margin for centrifugal pumps in the June 2009 issue of Pumps & Systems, as well as in my article in the September 2001 issue (which I think resulted in HI withdrawing their margin recommendations). I hope these will answer your question. If the product is water, keep the 3-percent-head-drop suction spe-cifi c speed, at bep, when tested at 1,800 rpm, at or below 8,500 (in U.S. units). Please see my articles in the September, October and November 2009 issues.

Net Positive Suction Head: NPSHR and

NPSHA, May 2008 (These comments

are part of this article’s discussion on

LinkedIn.)NPSH calculations for positive displacement reciprocat-

ing plunger type pumps—I am requesting software and calcu-lations that apply. For anyone who has good information avail-able, I would like to include it on my website.

Bruce SchuetzChicago, Ill.

NPSH required is performed at the pump manufacturer. NPSH available is depending on the design and static head. h e last one can be easily calculated via a spreadsheet program.

Most so called cavitation problems are not NPSH related but are the result of a poor suction line design. Valves, poor designed reducers and pipe bends are disturbing the fl ow towards a pump causing lots of collision losses and collision noise, and the client blames the pump for having a poor NPSH value...I have also experienced poorly designed (cheap and locally made) pumps running with cavitation, although the NPSHa is far above the NPSHr. h e most common solution is to redesign the suction line. I have had lots of pump problems solved after suction line modifi cations. Pump effi ciency was increased by 5 to10 per-cent, and the pump effi ciency came back to test-bed measured values.

For reciprocating pumps with a constant speed, a dynamic fl ow computer analysis may determine a certain pipe length and diameter to use for the dynamic behavior to increase the pump’s suction action.

Huub JanssenApeldoorn, Netherlands

h e key to determining NPSHA is working in terms of absolute pressure. It is always best to think in terms of the margin of NPSHA over NPSHR. Also, keep in mind that the NSPHR that value your pump vendor provides is based on a certain percentage of head loss based on cavitation present at that NSPH value. So if your system is operating with NSPHA

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Readers Respond

= NPSHR, then you will have cavitaiton.If you measure the suction pressure of your incoming fl uid

relatively close to the inlet of the pump, then you have a pretty good idea of your suction pressure. Based on the temperature and pressure of the fl uid coming in you can estimate the vapor pressure of the fl uid as it enters the pump.

Suction pressure in (PSIA) minus the vapor pressure of

the fl uid (PSIA ) equals NPSHA at that location. Convert that (PSIA) number into feet of fl uid (PSIA x 2.31 / specifi c gravity = feet of fl uid).

Add any elevation corrects (feet of elevation) to get to your pump centerline, and add any velocity head corrections (feet of head).

Note that if you’re close to the pump, and in the center of a straight section of pipe, your estima-tions will be much more accurate. h e farther away from the pump you get the less accurate your calculations. As high-lighted by Huub, the more twisted your piping gets, the more piping losses you have, and more errors in your pressure measurements will increase due to the uneven fl ow distribution in the pipe. I work with centrifugal pumps, but the measurements should be identical

Paul WegnerPortland, Ore.

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P&S News

PEOPLE

PLIDCO (WESTLAKE, OHIO)—the Pipe Line Development Company—recently promoted Pete Haburt to general sales manager. In his role, Haburt will oversee all export and domestic sales staff . Haburt has 35 years of experience with PLIDCO.

PLIDCO has been helping companies avoid shutdowns with pipeline repairs for more than 60 years. h e company is a designer and builder of standard and custom engineered products for pipeline repair and maintenance. www.plidco.com

AROUND THE INDUSTRY

SEPCO (ALABASTER, ALA.) held its 2010 Distributor’s Conference on August 26 – 27. Distributor’s from across the globe—including Argentina, Mexico, Australia and Can-ada—attended the two-day event. On August 26, attendees toured SEPCO headquarters and were briefl y introduced to new products. On August 27, they learned the details about new product off erings for 2011. www.sepcousa.com

DICKOW PUMPEN KG (WALDKRAIBURG, GERMANY) cel-ebrated 100 years of manufacturing on September 10, 2010. Founded by Karl Dickow in 1910, the fi rm began as a man-ufacturer of heating plants and water pipes. After WWII, Dickow was relocated to its present location. Since then, the company has grown from producing water pumps to fuel transfer pumps and pumps for the chemical industry.

Dickow is represented in North America by Dickow Pump Company of Marietta, Ga., and is best known for its line of sealless, magnetically coupled centrifugal pumps. www.dickow.com

COLFAX CORPORATION (RICHMOND, VA.) announced that its Allweiler AG business unit will deliver a €5 million fuel-injection skid order through Siemens AG for use in gas tur-bines in Iraq. h e skids will be used for power plant expan-sions in Kirkuk as well as new plants being built in Baiji and Baghdad. h e fi rst two skids will be completed in early 2011. h e Iraqi Ministry of Electricity has ordered an additional fi ve and has options to purchase three more.

Colfax Corporation is a manufacturer of fl uid-handling products and technologies. Colfax manufactures positive dis-placement industrial pumps and valves used in the oil & gas, power generation, commercial marine, defense and general industrial markets. www.colfaxcorp.com

EMERSON PROCESS MANAGEMENT (MARSHALLTOWN,

IOWA) has been awarded two multimillion dollar purchase orders from Westinghouse Electric Company for critical con-trol valves to be used in the fi rst of two AP1000™ pressur-

ized water reactors at both the Sanmen and Haiyang nuclear power plants in China. Emerson’s Fisher® air-operated con-trol valves will serve several functions related to operational safety in the nuclear containment area. As part of the safety-related system, the valves are engineered to comply with government requirements, including ASME Section III standards for components of nuclear facilities, and undergo rigorous qualifi cation testing at the new Emerson Innovation Center in Marshalltown, Iowa.

Emerson Process Management, an Emerson business, helps businesses automate their production, processing and distribution in the chemical, oil and gas, refi ning, pulp and paper, power, water and wastewater treatment, mining and metals, food and beverage, life sciences and other industries. www.emersonprocess.com

INPRO/SEAL (ROCK ISLAND, ILL.) announced the launch of its new website on September 1, 2010. h e site addresses each of Inpro/Seal’s engineered system and bearing protec-tion technologies. Visitors to the site can check the ROI of their Inpro/Seal Bearing Isolator; submit an electronic RFQ form; run new, informative product animations; and view the new Inpro/Seal video.

Inpro/Seal has been delivering sealing solutions for more than 30 years and is now part of Waukesha Bearings and Dover Corporation. www.inpro-seal.com

TORCUP (EASTON, PENN.) announced its sponsorship of the FAZZT race team and driver Alex Tagliani in his Honda Powered #77 IndyCar for the balance of the 2010 IZOD IndyCar Series.

TorcUP designs bolting tools. www.torcup.com

LEE MATHEWS EQUIPMENT (KANSAS CITY, MO.)—now known as Cogent—has been identifi ed in the most recent edition of Inc. magazine as one of the 5,000 fastest-growing private companies in America, receiving this honor for the fourth year. Honorees were noted for their proven success in the face of a national fi nancial meltdown, serious recession and continuing economic turmoil. Lee Mathews (Cogent) has demonstrated a three-year growth rate of 64 percent since 2008.

In the second quarter of this year, Lee Mathews Equipment, along with Vandevanter Engineering and BRI launched opera-tions under the new fl agship brand, Cogent. However, the management teams, operations, locations and customer rela-tionships of the partner companies have remained unchanged.

Cogent has offi ces in fi ve states and is a distributor of fl uid pumping, water treatment/processing and rental equip-ment in the Midwest. www.cogentcompanies.com

Pete Haburt



P&S News

DREISILKER ELECTRIC MOTORS (GLEN ELLYN, ILL.) celebrated its 55th anniver-sary at its headquarters.

Dreisilker provides complete electric motor solutions to commercial, industrial and municipal customers. www.dreisilker.com

CSI CONTROLS (ASHLAND, OHIO) named Gilbert Pump & Mechanical, Inc., (Ft. Walton Beach, Fla.) as its authorized engineered distributor. Gilbert Pump will serve

municipal and industrial water and waste-water customers in the Florida Panhandle and Alabama and supply them with cus-tom engineered control panel solutions.

CSI Controls® manufactures con-trol panels, pump controllers, septic tank alarms and accessories for water and wastewater. www.csicontrols.com

VALVE AND FILTER (ARVADA, COLO.) announced that Valve and Filter and Olson Irrigation jointly won the IA Award for best New Golf Product at the Irriga-tion Association Show for a water saving fl ushing system for automatic fi lters.

Valve and Filter produces industrial water fi lters and self-cleaning automatic water fi lters. www.valveandfi lter.com

APOLLO ASSOCIATED SERVICES

(MIDLAND, MICH.) has partnered with Chemir Analytical Services (St. Louis, Mo.) to provide one-stop shopping for analytical testing, root cause analysis and investigation services. Apollo clients who face quality and safety issues can use the forensic, investigative and analytical ser-vices of Chemir.

Apollo off ers root cause analysis solutions. www.apollorca.com

Dreisilker employees during 55th anniversary

Award for best New Golf Product

A “DESIGNATED DRIVER” FOR YOUR ROTATING EQUIPMENT

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UPCOMING EVENTS

WEFTEC

October 2 – 6Ernest N. Morial Convention Center / New Orleans, La.Presented by the Water Environment Federation 877-933-4734 / www.weftec.org

TURBOMACHINERY SYMPOSIUM

October 5 – 7George R. Brown Convention Center / Houston, TexasPresented by the Texas A&M Turbomachinery Lab979-845-7417 / turbolab.tamu.edu

SMRP CONFERENCE

October 18 – 21Midwest Airlines Center / Milwaukee, Wisc.Presented by the Society for Maintenance and Reliability Professionals703-245-8011 / www.smrp.org

FSA FALL MEETING

October 19 – 21Austin, TexasPresented by the Fluid Sealing Association 610-971-4850 / www.fl uidsealing.com

CERTIFIED OPC PROFESSIONAL

TRAINING

Level 1: OPC & DCOM Diagnostics – October 19 – 20 Level 2: OPC Security – October 21 – 22Level 3: OPC Unifi ed Architecture – October 25 – 26Level 4: OPC Integration Projects – October 27 – 28ExecuTrain Houston / Houston, Texas780-784-4444 / www.opcti.com

PACK EXPO

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Pump Ed 101

There are several ways to control two iden-tical, parallel pumps operating under variable frequency control in pump-

ing applications. One method is to size a single drive to handle both pumps and vary the speed of both synchronously. A more effi cient method uses two drives to control the pumps. Once one pump reaches its maximum speed, the second pump is brought online and both are operated at synchronous speeds (as in the previous example). Yet another two-drive method keeps one pump at maximum speed and varies the speed of the other. h is example can also be achieved with a single drive and a transfer switch. When the drive reaches full speed, the switch causes a contactor to operate that pump across the line, and the drive is trans-ferred to the second pump. h e downside to this control scheme is that there is no back up drive.

h e fi rst example can work if the normal fl ow is always greater than the maximum fl ow of one pump. Otherwise, it can be ineffi cient. Examples two and three are better alternatives, but which is best? It depends upon the breadth of a pump’s hydraulic effi ciency and the system conditions in which it is operating. Comparing these two control schemes to see which can provide the best operating conditions is valuable. h e beta version of variable frequency parallel pump analyzer (VFPPA) allows for the comparison of the hydraulic effi ciencies of identical, parallel pumps oper-ating under synchronous or independent speed control.

Figure 1 is a screen shot of the data input tab of VFPPA Excel sheet. It shows the required data (yellow cells) and the

tabs that are generated. h e “One Pump” tab shows the H/Q curves and hydraulic effi ciencies of a single pump at speeds of 45 to 60 Hz. h e “Two Pumps” tab shows the same infor-mation for two pumps running at synchronous speeds. h e other tabs show both single and two-pump operations at dif-ferent speeds and are used if a more detailed view is required. h e Average Effi ciency Calculator and the Energy Savings Calculator normally seen online at the right of the screen are shown in Figure 4 and will be discussed later.

Synchronous Speed Controlh e example included with the analyzer is vertical multistage with a BEP fl ow of 350 gallons per minute (gpm) and a BEP

effi ciency of 78 percent. h e rather fl at H/Q curve is typical of this design. h e system curve shows a required static pressure of 206 feet.

Figure 2 is the plot produced in the “Two Pumps” tab and shows the H/Q curves produced from 45 to 60 Hz under synchronous speed con-trol. h e data labels show the average hydraulic effi ciency. As shown, when both pumps run at full speed (60 Hz), they produce a fl ow of 700 gpm at 206 feet TDH and operate at BEP effi ciency (78 percent). h e black angled line is the operat-ing point of both pumps at single pump maxi-mum fl ow (350 gpm). h e speed is approximately 54 Hz and the effi ciency drops to slightly below 60 percent. As fl ow (speed) increases, so does the

Joe Evans, Ph.D.

Variable Frequency Parallel Pump Analyzer

Figure 1. VFPPA Data Input Tab

Figure 2. Plot produced by two pumps running at synchronous speeds


average effi ciency of the two pumps. h e red angled line crosses the system curve at 450 gpm at a speed of approximately 56 Hz, and effi ciency is increased to about 67 percent. Let’s take a look at individual speed control and compare the two operating effi ciencies at 450 gpm.

Individual Speed ControlFigure 3 is the plot produced in the “One Pump” tab. As shown, a single pump operating at 60 Hz will produce a maximum fl ow of 350 gpm at 78 percent hydraulic effi ciency. Under this control scheme, when the pump reaches maximum fl ow, it is maintained at full speed and the second pump is brought online at some reduced speed. h e red angled line crosses the system curve at 100 gpm at a speed of about 52 Hz. h is is the fl ow that must be provided by the second pump to match the 450 gpm fl ow produced by two pumps running at synchronous speeds. h e hydraulic effi ciency at this fl ow point is about 50 percent.

Determining the Most Effi cient OptionTo compare the effi ciencies of these two control techniques, the information above is entered into the Average Effi ciency Calculator, which is used to determine which control technique is best for a particular pump and application.

h e calculator, seen in Figure 4, requires the fl ow and effi -ciency of the pump running at full speed and the fl ow and effi -ciency of the pump running at a reduced speed. Upon entry, it calculates the percent of total fl ow contributed by each pump and the average hydraulic effi ciency of the two pumps. h e calculator shows an average effi ciency of 71.8 percent, which is about 5 per-cent higher than the 67 percent produced at synchronous speed.

h e Energy Savings Calculator (also in Figure 4) requires the effi ciency of the pumps operating at synchronous speed, the motor effi ciency and the cost per kW of power. It calculates the total BHP and cost per hour of operation for each control scheme. As shown, synchronous operation requires an addi-tional 2.9 BHP, and the cost per hour is increased by 24 cents.

When the effi ciencies of the two control techniques at 400 gpm are compared, individual control trumps synchronous control by about six percentage points, and at 500 gpm, it will

still have a one point advantage. As fl ow increases to 600 gpm, the two effi ciencies get closer, but individual control is still higher by about 0.3 percentage points. h is trend continues until fl ow reaches 700 gpm, and both control techniques operate at 78 percent.

For this particular pump, individual speed con-trol is the best control choice. For others, synchronous control may work equally as well, or even better. It will depend upon the application and the effi ciency range. When three or more pumps operate in paral-lel, individual speed control should still be compared. However, it will have less of an impact as more pumps are brought online. For example, when the second pump is brought online and operated synchronously, each pump will initially operate at 50 percent of its BEP fl ow. When a third pump is added, each will begin at 66.6 percent, and if a fourth pump is added,

each will begin at 75 percent of BEP fl ow. h ese increased min-imum fl ows will also result in an increase in average effi ciency.

Now, you may wonder if a savings of $0.24 per hour is worth the trouble. I think that it is. If the system operates just above one pump fl ow for extended periods, even this small savings will add up over several years of operation. Also, the savings can be much larger as application BHP increases. Finally, it costs nothing because both schemes require the same com-ponents. h ink of it as one small step that, when included with others, allows the best possible increase in overall effi ciency.

h e beta version of VFPPA is available for download from the “Pump Sizing & Selection Tools” section of www.pumped101.com. h e fi nal version will support the generation of a system curve that is composed of both static and friction head. It should be available early next year.

P&S

Figure 4. Average Effi ciency and Energy

Savings Calculators

Figure 3. Plot produced by one pump running at 60 Hz

Joe Evans is responsible for customer and employee educa-tion at PumpTech, Inc., a pumps and packaged systems manufacturer and distributor with branches throughout the Pacifi c Northwest. He can be reached via his website, www.pumped101.com. If there are topics that you would like to see discussed in future columns, drop him an email.


Effi ciency degradation in pumps can be related to three areas. Worn clear-

ances between the wear rings of the impeller and the casing can increase leakage and drop the volumetric effi ciency of the pump. Rough, rusty and dam-aged internals increase friction, reducing hydraulic effi ciency. Finally, rubs, galling, friction in the mechanical seals and bear-ings, can result in the reduction of mechanical effi ciency.

Together, these three pumping problems reduce the available fl ow, lower pressure and/or require more power con-sumption. h ese three issues also make a pump less reliable. Pump effi ciency and reliability are often intertwined.

Centrifugal Pump Reliability ProblemsConsider, for example, a case of reliability problems in a multistage, horizontally-split centrifugal pump in service at a pipeline booster station. h is pump had been de-staged from the original, four-stage opposite impeller design, to a three-stage modifi cation. Originally, the pump service was for lower fl ow and pressure. To match a new set of operat-ing conditions (3,100 barrels of gasoline per hour, at 690-psi pump developed pressure) the fi rst stage of this pump was replaced with a blank pass-through spool.

In the case described above, the pump rotor seized, on average, nearly once per year, resulting in poor reliability, increased repair costs and lost production. Upon inspection, a low suction pressure zone was found, which resulted in periodic fl ashing of the product, causing cavitation, which aff ected the side of the bushing adjacent to this low pressure zone, as evidenced by the pitting that was found on the rotor and bushing area. Flashing of product in that area resulted in a loss of the needed lubricating fi lm of liquid within the clearance of the bushing. h is lack of lubrication liquid also contributed to the rotor seizure at the bushing area.

Figure 1 illustrates the fl ow of product through the pump, indicating pressure increase from one stage to another, as well as showing the orientation of the internal bushings

with their clearance separating internal regions of pressure from each others.

Four main types of clearances are:• h roat bushing, which separates the suction (inlet) pres-

sure (50 psig) from the mechanical seal cavity (to the right of the illustration, not shown in Figure 1). Since the seal area is immediately adjacent to the suction area, it is under the same pressure as suction.

• Center bushing, which separates the intermediate-pressure from the high-pressure zones. h is pressure diff erential has increased due to the de-staging, making this a more important leakage path.

• h rottle bushing, which separates the intermediate pres-sure from the suction pressure (the area to the left of the illustration, past the throttle bushing, is connected to the suction area via a balance line).

• Impeller-to-case wear rings. Typically, there is one stage pressure across these rings.

• Hub wear rings. Typically a minimum fl ow area with little diff erential pressure. h is pump has only one such clearance between stages 3 and 4.

In trying to solve the reliability problem, the designer or engineer needs to balance the confl icting requirements of effi ciency and reliability. With a power level nearly 2,000 hp, each percentage point of effi ciency savings translates to approximately $13,000 per year, assuming non-stop opera-tion, at 10 cents energy cost of each kilowatt-hour. Effi ciency

Dr. Lev Nelik, P.E., APICS, President, Pumping Machinery, LLCEben Walker, Graphalloy Company

Specialty Materials Help Improve Pump Reliability and Save Energy

Pumping Prescriptions

Figure 1. Product fl ow through the pump


is a key criteria for these large high energy pumps.We try to solve the reliability while keeping the clearances

as close as possible to reduce leakage (eff ect on volumetric effi -ciency), but not so tight that contact occurs the the high speed (3,600 rpm): rotating parts would gall and seize to the station-ary parts (the casing and impeller wear rings).

The Solution

h e answer to the problem was apply-ing a graphite/metal alloy, to allow the reduction of clearances (this material is non-galling). As a non-galling material clearances can be cut to half the normal API clearances for metal fi tted pumps. h is change improved reliability as well as saving energy. Initially, only the throt-tle bushing, the most critical part, was made from Graphalloy to replace the originally supplied metal part. h e clear-ance was reduced from 0.014 inches to 0.008 inches, which resulted in effi -ciency improvements of approximately 2.2 percent. h is improvement resulted in nearly $30,000 in yearly energy sav-ings. At the same time—due to the non-galling qualities of the new material, an occasional rotor contact was not a prob-lem, and rotor seizures were eliminated, making this pump much more reliable, and production uptime was improved2.

P&S

References and Bibliography

1. Nelik, L., “How Much Energy is Wasted

When Wear Rings Are Worn to Double h eir

Initial Value?,” Pumps & Systems, March 2007,

page 18.

2. Knoch, H., Kracker, J., and Long., W.,

“Sintered Alpha Silicon Carbide Pump

Bearings – Tribological Materials Optimization

to Improve Reliability,” Texas A&M Pump

Symposium, October 1993, Houston, Texas.

3. Komin, Robert P., “Improving Pump

Reliability in light Hydrocarbon and

Condensate Service With Graphite/Metal

Alloy Wear Parts” Texas A&M Pump

Symposium, 1990, Houston, Texas.

4. Walker, Eben T., “Bearings Take the Heat,”

Machine Design, May 2004.

5. Komin, Robert P., “Improving Boiler

Feedwater Pump Reliability With Graphite/

Metal Alloy Wear Parts,” Pump Engineer, May

2004.

6. “GRAPHALLOY Pump Application Guide,”

Graphite Metallizing Corp., USA copyright

2008.

Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machinery, LLC, an Atlanta-based fi rm specializing in pump consulting, training, equipment troubleshooting and pump repairs. Dr. Nelik has 30 years of experience in pumps and pumping equipment. He can be contacted at www.PumpingMachinery.com.



Cover Series: Smart Pumps

Photo courtesy of Alejandro Oscar de la Fuente, Schneider Electric, oil and gas solutions business manager.

Cover SeriesCover Series


Intelligent pumping is simply defi ned by ARC Advisory Group as the combination of a pump and a VFD with digital control capability. While this defi ned the beginnings of the intelligent

pump trends, we now see numerous specifi c drivers around topics such as energy management, application specifi c algorithms and pump OEM-specifi c application programs.

h e term intelligent pumps is broadening to include the sen-sors that collect data and transmit pumping system performance. Some key attributes involved with intelligent pump systems include variable speed and multiple pump control.

Intelligent Pumps and Energy SavingsWhile the building automation industry has embraced the intel-ligent pumps trend strongly, accounting for almost 50 percent of all intelligent pumping revenues, many other industries are leading the way—such as water/wastewater, mining and minerals, pulp and paper and oil and gas.

Figure 1 shows the areas in which industries can take action to reduce energy consumption. While many companies focus on areas such as HVAC systems and motor retrofi ts, it is clear that pump system upgrades provide the largest energy savings potential. Figure 2 provides insight into the key industry segments that have the most to gain from energy-savings initiatives. h e potential in energy savings with intel-ligent pumping can add as much as 20 percent to the bottom line, according to the U.S. Department of Energy.

In addition to energy, other key drivers include OEM initiatives, such as OEM personalization. OEMs can customize software to either match pumping systems to application needs and/or pre-load pump data to greatly simplify start up and commissioning requirements.

Intelligent Pumps in the Oil & Gas Industryh ere is excitement about intelligent pumping solutions in the oil and gas industry, specifi cally in the opportunities to improve the output of mature oil fi elds.

Most mature, onshore oil wells are not big producers, with many producing less than 10 barrels of oil per day. Pumpjack systems, pro-gressive cavity pumps (PCP) and electrical submersible pumps (ESP) work hard to bring oil to the surface, and more operators are deploying carbon dioxide injection and other enhanced recovery techniques to boost production rates and extend fi eld life.

Many operators deploy conventional time-on/time-off pump con-trols to prevent a pumped off condition from occurring. h ese con-trollers stop the pump jack for a predetermined period to ensure fl uid is available before restarting the lift. Although simple to operate and

Optimization SolutionsJack Creamer, Dan McGinn and Jim Morgan, Schneider Electric

Improvements in performance and energy reduction can be achieved.

Table 1. Intelligent pump capabilities

Figure 1. Areas with potential for energy savings

Figure 2. Industry segments that can most benefi t from

energy-saving initiatives



adjust, they do not ensure maximum production recovery is achieved and only work as a safety mechanism to prevent dam-ages caused by pumping a dry well.

Process effi ciency is most improved with an intelligent pumping solution that employs a variable frequency drive to provide pump off control by varying the speed of the well and maintaining an eff ective fi ll level. Effi ciency can be further

improved by using information about the condition of the well to optimize the pump speed. h e ultimate, intelligent pump-ing solution is one that takes advantage of this information in real-time and constantly optimizes the pump speed. In some more shallow wells, this can be done by using the motor load information in the drive as the primary data point. Deeper wells should take advantage of load profi le information directly

from the rod and, ideally, the calculated or “down-hole” load profi le information. A typical productivity improvement for fully-optimized systems might be 5 per-cent. h e results vary substantially up or slightly down based on the natural per-formance of the well in its previous, un-optimized state.

Pumpjack optimization can include scalable options for an operator:• Torque only. h is solution uses

pump motor load information to understand well conditions and determine optimum speed. It is the least costly solution for wells with depths of up to 500 meters.

• Surface card. h is solution uses feed-back from a rod-mounted load cell (dynamometer card) to analyze well conditions. It can optimize speed and fi ll rate for deeper wells.

• Down-hole card. h is solution uses an advanced algorithm to compute the rod load at the bottom of the well. h is represents the ultimate solution with the greatest optimiza-tion and return on investment.

h e elements of such a system include a variable frequency drive to control the pump motor speed, instru-mentation to detect well conditions and an embedded controller to operate the well, read the instrumentation, calculate an optimized speed command for the drive and provide host communication.

A fully optimized pumpjack is not only more productive but also has a higher availability and longer equipment life. Most of the wear and maintenance issues associated with pumpjack opera-tion are reduced as the optimized system automatically reduces operating condi-tions that cause undo wear (i.e., fl uid pound, gas compression). Optimized wells also require much less human inter-vention because the optimization adapts

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to changing conditions in the well automatically. Maintenance-related downtime for a pumpjack system can be reduced by as much as 80 percent.

Beyond individual pumpjack systems, the oil fi eld as a whole can be further optimized by making an enterprise of the entire fi eld. A “digital oil fi eld” is based on a suite of interac-tive and complementary technologies that allow operators to gather and analyze information from wells to more strategically manage a lease. It employs a scalable, modular and collaborative architecture that leverages intelligent pumping solutions and the capabilities of modern information tech-nology to deliver actionable information directly from a well to the fi eld’s central control station.

Implementing the digital oil fi eld starts with extending remote com-munication to the oil fi eld assets. h is includes the pumpjack systems as well as other pump system types (PCP, ESP, Injection, etc.) and ancillary equipment such as tank level and fl ow monitor-ing applications. Radio and cellular telemetry options are a must for intel-ligent pumping applications in oil fi elds. Telemetry can provide remote monitor-ing and secure control of oil fi eld assets. In the form of remote individual opera-tors or more sophisticated central, con-trol station operating rooms connected to intelligent pumping systems.

It is important to keep wells consistently pumping at an optimum level rather than just creating new wells. In addition to injection methods, intelligent pumping solutions can repre-sent a more scalable investment to maintain and improve oil fi eld production.

P&S

Jack Creamer is the market segment manager for pumping equipment at Schneider Electric, Square D, 8001 Knightdale Blvd., Knightdale, NC 7545. He can be reached at 1-919-217-6464, [email protected], www.schneider-electric.us.

Dan McGinn is the director of engi-neering and projects for Schneider Electric’s Industrial Solutions Center. He has over twenty years experience in industrial control systems.

Jim Morgan is the business develop-ment manager, oil and gas sector, for Schneider Electric’s North American Operating Division. Based in New Orleans, Jim has more than 20 years of experience in the oil and gas industry.

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The advantages of adopting intelligent pumping systems has been well-documented, including the adaptability to process conditions, lower operating

costs and contribution to decreased plant downtime. h ese advantages resonate in mature markets in which reduced maintenance staff s drive companies to improve process effi ciency to maintain cost-competitiveness. Although demand is increasing, intelligent pumps have not yet enjoyed the wider adoption that their operational benefi ts would imply due to several restraining factors.

Market OverviewAs a result of environmental regulations and incentives in North America and Europe, end users are searching for alternative ways to save energy. Intelligent pumping systems can facilitate energy effi cient processes. Another driver is the cost of unplanned plant downtime, primarily due to rotating equipment failure. h ese expenditures can have a signifi cant impact on a company’s profi t margin.

h e possibility of equipment failure also requires companies to retain a large in-house maintenance staff to monitor and make repairs in an effi cient manner. Intelligent pumping solutions can help mitigate maintenance labor challenges through facilitating equipment monitoring and reducing equipment wear.

Sales of intelligent pumping systems are aff ected by the excess production capacity that currently exists in key end-user verticals. Without higher levels of industrial capacity use, expenditures on capital equipment are limited. h is might only be a minor issue for the solution providers of intelligent pump-ing modules that are designed to control installed equipment. However, it can be a daunting challenge for solution providers of the more expensive, bundled intelligent pumping solutions.

Another important limiting factor in the market is the shifting of industrial production toward countries with a low-cost labor force. h e move toward overseas production reduces the demand for new pumping equipment in mature economies that benefi t most from intelligent pumping solutions. In addi-tion, intelligent pumping solutions have higher acquisition

costs versus standard pumping equipment, which challenges solution providers to prove the cost-value ratio of their prod-ucts to end users.

Value Chain—Challenges and SolutionsOriginal equipment manufacturers (OEMs) of pumps can off er the broadest array of intelligent pumping solutions. Many have made strategic investments in adjacent technologies that can accommodate the necessary instrumentation. h is has allowed them to bundle various products to provide turnkey solutions to end users. In addition to new systems, OEMs have also begun off ering intelligent pumping modules that can be used to control existing pumps. Most of these modules are compat-ible only with the OEM’s installed base of equipment, limiting their use. However, some fi rms have introduced vendor-agnos-tic modules that can control diff erent OEMs’ equipment. As manufacturers penetrate their captive equipment markets, the

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trend toward vendor-agnostic intelligent pumping modules is expected to strengthen, altering the competitive dynamics in this market.

One of the most signifi cant growth challenges for the intelligent pump market for distributors is the need to develop the necessary instrumentation and electronics background to sell and support intelligent pumping systems. Although most large distributors can develop adequate expertise in-house, these investments in human capital can be prohibitively expensive for products that still need to demonstrate commercial potential.

Another signifi cant constraint includes the need for a strong local presence and the ability to confi gure new intelli-gent pumping systems. h ese factors are critical to distributors who want to facilitate a broader adoption of this technology.

Aftermarket Benefi ts

Major OEMs can use intelligent pumping solutions to win asset management agreements. Intelligent pumping systems allow end users to address shrinking headcounts. One attractive feature of asset management agreements is that they enable an ongoing engagement with the end users. Intelligent pumps sys-tems’ reliance on instrumentation and data analysis tools off er improved outsourced service opportunities for OEMs.

Distributors benefi t in a similar way to OEMs. Intelligent pumping solutions give them a natural way to enter the

asset management business with their end users while more tightly integrating their customers’ businesses with their own. Intelligent pumping aftermarket services allow distributors to expand their menu of pre-market services and product value enhancements.

h ere are several challenges impeding the widespread adoption of intelligent pumping systems in today’s mature markets. To overcome them and increase market penetration, solution providers must understand the needs of their custom-ers and prove the product’s value. Intelligent pumping solu-tions must be able to seamlessly integrate into a plant’s existing infrastructure, reduce unplanned plant downtime and lower operating costs.

P&S

Ram Ravi, an industry analyst with Frost & Sullivan, has expertise in growth consulting and research projects within the industrial process control and automation practice. He analyzes emerging trends, technologies and market dynam-ics for pumps, valves and compressor. Douglas Weltman, a research analyst with Frost & Sullivan, works on research and consulting projects in process control equipment, after-market services and welding technology. He examines end-user behaviors, disruptive technologies and industry best practices. For further information, visit www.frost.com.

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Pump systems come in all sizes, from large municipal plants to small resi-dential systems using single phase

pumps that are 3 horsepower or smaller. All systems require reliability, but because of the large volume of smaller systems, the consis-tent dependability of these stations is impor-tant. One of the largest problems facing service personnel in servicing these pumps and controls is the traditional start circuit. Without any real protection on the start winding and start circuit, the start capacitor commonly fails. h is often means the capac-itor explodes, sending hot oil and capacitor debris into a control panel—or worse and more dangerous, onto a service technician.

The External Start ProcessAll single phase pumps with external start components use a start relay along with a start capacitor and a run capacitor to start and run the pump. A run capacitor stays in the motor circuit continually, while the start capacitor is designed to be removed from the circuit once the pump motor is up to speed. h e purpose of the start capacitor is to cause the voltage applied to the start winding to be out of phase with the voltage coming from the power source. h is phase change gives the motor increased torque when starting. h e start relay’s job is to remove the start capacitor from the circuit when the motor gets up to speed. Traditionally, this is accomplished by using a potential relay as the start relay. As the motor increases in speed, the voltage potential across the start winding increases. Once the voltage potential reaches a predetermined value, the start relay will energize, opening the circuit to the start capacitor. Under normal operation, the start capacitor will be removed from the circuit less than a second after power has been applied to the motor.

h e start capacitor has a lower voltage rating than the voltage that will be applied to it from the start winding. In

most instances, this is because the capacitor is expected to be in the circuit for a short period of time, and a capacitor that is rated for the full voltage would cost more money and require more space. If the start capacitor does not get removed from the circuit, the capacitor will fail because of the lower voltage rating. Often, this results in the top exploding off the capacitor spraying hot oil (300 degrees F and hotter) and projectiles and exposing dangerous electrical voltages. Several situations may cause the start circuit not to open. One of the most common is a locked rotor on the pump. In this case, the pump is plugged or jammed from debris, and the motor cannot rotate. If the pump cannot rotate, it will not build up the voltage on the start winding needed to drop out the start capacitor, which will create the conditions that allow the capacitor to fail.

Motor Module Replaces Starter,

Start RelayA motor power module (MPM) will soon be available to replace the motor starter (contactor and overload) and the start relay, all in one compact unit. One of the most signifi cant features of the MPM is that it protects the start capacitor by

Safer and Smarter Single Phase PumpsAaron Wolfe, P.E., & Bill Chandler, Jr., CSI Controls

New motor starting controller provides one solution.

Failed start capacitor



monitoring its usage. If its usage is excessive, the MPM will disable the capacitor for a period of time, allowing for cool-down time, typically a few minutes.

In applications using single phase grinder pumps, the MPM improves the pump performance in another way. During normal operation, the pump often sucks debris through the cutters of the pump, introducing an added load to the pump motor. Depending on the type of debris and the condition of the cutters on the pump, this load can be signifi cant and slow the pump. A traditional start circuit with a potential relay

allows the pump speed and fl ow to drop below 40 percent of its normal operat-ing speed/fl ow before pulling in the start circuit to provide the added torque needed to prevent the pump from stall-ing during the grind. h is reduction in speed compounds the problem of grinding and expelling the debris as the water fl ow through the pump is greatly reduced. h e MPM begins “boosting” the pump by pulling in the start circuit when the pump speed and fl ow reach 85 percent of normal. h e MPM controls just how much boost is given to the start circuit, providing only the amount of boost needed to maintain speed, maxi-mizing the amount of usage available for the start capacitor.

Another advantage of using the MPM is that it reduces the complexity of matching proper start components with motors. With traditional systems, every pump motor on the market has its own combination of start relay, start capacitor and run capacitor. Applying the wrong component combination can cause start capacitor failure. h e MPM monitors the characteristics of the motor as it starts and removes the start capacitor at the proper time based on those characteristics. One MPM can be used for any pump within the

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MPM’s rated current range. Even if the wrong start capacitor is chosen, the MPM is designed to protect against fail-ure. h e motor torque will be aff ected by the wrong capacitance, but relatively normal pump operation may still be possible depending on the pump motor and the value of the capacitance.

All in One

h e MPM combines the functions of the motor contactor, overload relay and start relay in one compact unit, which is approximately the size of a comparable standard motor contactor. h is com-bined unit saves at least 60 percent of the panel space taken up by a traditional start circuit.

One of the ways the MPM is able to provide this kind of space reduction is by using patented zero-cross technol-ogy, which controls the exact timing of the opening and closing of the contacts that supply the power to the motor. Without zero-cross technology, the con-tacts would open randomly compared to the AC voltage waveform, often causing arcing across the contacts. h is normally requires larger contacts, and a larger contactor to handle the motor power. With zero-cross technology, the arcing is almost eliminated, which increases the life and reliability of the relay, while allowing the use of a smaller contactor to control the pump.

In addition to zero-cross technol-ogy, the MPM includes advanced motor protection and monitoring, and imple-ments a Class 10 electronic overload while monitoring for under-current to protect the pump from a “run dry” situ-ation. h e MPM monitors incoming voltage and can be set to protect against a low-voltage situation either from the power line, or because too small a wire gauge was used to supply the power to the pump (causing too much voltage drop in the source feed wires).

h is approach, using new tech-nology in pump controls, will con-tinue to enhance safety, reliability and serviceability.

P&S

Aaron Wolfe is the R&D electronic lead engineer for CSI Controls. Aaron has over ten years of experience with controls in the waste water industry. He can be reached at [email protected].

Bill Chandler, Jr., founded CSI Controls in 1993 and is currently the director of prod-uct development for CSI Controls. Bill holds several patents for water treatment and pump controls. He can be reached at [email protected].

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Special Section: Instrumentation, Controls & Monitoring

Operator diagnoses

station fault remotely

and takes a pump off line.

Photo credit: ITT Water &

Wastewater USA Inc.

A Special Section of

October 2010

A Special Section of

October 2010


Operating reliable, effi cient lift stations can be chal-lenging. Increasingly lean staff s maintain hundreds of remote stations in a wastewater system, which are

often located in diffi cult-to-access or hazardous areas making maintenance and troubleshooting time intensive.

Maintenance is critical when control panels and compo-nents are subjected to extreme weather conditions and caustic liquids and gases. Downtime can be caused by many issues: pump ragging and overheating, broken impellers and malfunc-tioning level sensors. Environmental hazards and hefty fi nes can result.

Advanced Overload RelaysBy monitoring energy and power factor, facilities can avoid peak demand charges, shed non-vital loads, identify and correct increased consumption, spot the discrepancies between equal loads and see power factor line items.

Advanced overload relays can monitor current and voltage in each phase and identify conditions that can lead to motor or pump failure with greater speed, reliability and repeatabil-ity than traditional failure detection devices. With remote, real-time data monitoring, facilities are able to protect assets, prevent energy waste and manage costs—all while maintaining system integrity and uptime.

Overload relays identify unusual and ineffi cient operations in real time. h ey can monitor energy use to avoid peak demand charges, shed non-vital loads and detect increased energy con-sumption, discrepancies between equal loads and power factor line items. With industry standard communication protocols and central supervisory control and data acquisition (SCADA) systems, customers can identify and correct situations to pre-vent downtime before incurring energy costs. h rough fi eldbus commands and online via the operator interface (OI), custom-ers can remotely monitor and control their systems and shut-down nonessential assets. Energy use between similarly-sized pumps can be compared and spot checks can be eliminated. When maintenance is necessary, remote lift station operators can dispatch personnel. Neglected conditions can be remedied as they occur. Without the ability to detect and fault when low-power conditions occur, pumps can heat up, damaging the seal,

and failing the pump. Without an overload relay that detects low power, the

pump would continue to run. h e water level would not increase and the fl oat switch would not drop. A second pump may be turned on to compensate, and two pumps would be running and doing the work of a single pump. h e protective-fault, low-power feature of today’s overload relays can help avoid needless run-time hours and component wear would be reduced.

VFDs and Soft StartersToday’s sophisticated variable frequency drives (VFDs) are better able to fi ne-tune motor speed to regulate and control fl ow, resulting in energy savings from 10 to 50 percent. Soft start controllers reduce motor demands during startup, result-ing in reduced energy and increased mechanical system life.

h e latest VFDs are more accurate and energy effi cient. Enhancements in capacitors, direct current (DC) link reac-tors, insulated gate bipolar transistors (IGBTs), heat manage-ment, processing power and measuring technology, and new algorithms that improve drives’ effi ciency to greater than 97 percent.

Reliable and Effi cient

Remote Lift StationsPaul S. Twaddell, Eaton Corporation

Control panel products enhance smooth operations.

Facilities can monitor volts, amps, thermal capacity, frequency,

power, power factor and easily translate this data to motor or

pump conditions.


Soft start controllers provide smooth acceleration and deceleration of the load, minimizing shock to mechanical components, extending the life of the system, increasing reliability, reducing downtime and lowering costs. Soft starters reduce slip-page, squealing and the stretching of belts. With special pump control algorithms, the soft starter can control motor deceleration, reducing the water hammer eff ect. A compact soft starter provides the same benefi ts of soft starting without the need for a change in enclosure sizes or additional assemblies. High performance soft starters have extensive monitoring and protection functionality, improving troubleshooting.

Using a drive with a bypass-built-in soft starter provides enhanced control, fl ex-ibility and protection. Adding a soft starter allows the motor to be ramped up to full speed when in the bypass, reducing mechanical and electrical stress.

Sophisticated Controls, Interfaces and PushbuttonsToday’s innovative and small programmable logical controllers (PLCs) moni-tor diverse parameters in remote lift stations to reduce maintenance and improve effi ciency. OIs help operators visualize equipment activities, monitor and control equipment, provide real-time and historical trending, alarms, database interface and the ability to run soft logic and make decisions. PLCs monitor the moisture level and temperature and the operation of the pump helping optimize maintenance and prevent downtime. Rugged OIs and human machine interfaces (HMIs) help moni-tor processes and keep them running.

PLCs are also able to share remote information with operators of an unexpected event. In larger systems, they can help facilitate load sharing so that the operational hours can be balanced between pumps to extend equipment life. Sophisticated OIs off er lift station operators connectivity with ruggedized electronics for increased reliability in harsh environments. High performance interfaces feature increased memory to run larger applications, store event histories and record operational trends. h ey also have enhanced display brightness and resolution and faster appli-cation performance and allow operators to move easily among machines and pro-vide time-saving access to PLCs and other devices. Some interfaces can combine the functionality and fl exibility of Microsoft® products with the reliability of solid-state hardware design.

Global suppliers provide customers with comprehensive 22.5 millimeter and 30.5 millimeter pushbuttons to meet diverse needs. Remote lift station controls include fl ush and extended pushbuttons, along with selector switches, pilot lights and emergency stops (E-stops).

E-stops are red operator buttons used in the case of emergency to protect per-sonnel and equipment. h ese need to meet EN 418 IEC 609475-5, which does not allow for “teasing” the contact block but requires trigger action.

Molded Case Circuit Breakers Molded case circuit breakers (MCCB), sometimes up to 99.99 percent reliable, are designed to provide circuit protection for low-voltage distribution systems and pro-tection against overloads in conductors and short circuits in connected equipment.

Panel boards use either fuses or breakers, which off er enhanced safety, improved reliability and energy savings. Compared to fuses, circuit breakers save energy with less watt loss for similar ratings. Circuit breakers can be remotely reset after tripping, while fuses must be replaced.

In a remote lift station, a walking beam solution can be useful. It prevents the main and emergency from being “on” at the same time.

P&S

Paul Twaddell is the industry segment manager for pumps and compressors at Eaton Corporation. He can be reached at [email protected]. For more information, go to www.eaton.com.c

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In 1937, a natural gas leak at a school in Texas killed 237 stu-dents. h e gas leak in the school

was not detected even though it had been leaking for a long time. To solve the problem of detecting odorless, hydrocarbon, gaseous fuels, laws were passed that required natural gas and propane to be odorized, so they can be detected by the average human nose at 1/5 the lower explo-sive limit in air.

Propane is primarily sourced as a byproduct of the production of natu-ral gas. To maintain the heating value of natural gas within a narrow range, heavier components (natural gas liquids) are removed from the natural gas near the production well. h e liquids are sent to an additional plant where these liquids are separated for higher value uses. Propane is sold as a fuel and is distributed throughout the country via pipeline or rail car.

Mercaptans are sulfur-containing analogs of alcohols (oxygen replaced by sulfur), and the human nose is sensitive to these chemicals. A skunk’s smell, for instance, is a mixture of methyl and butyl mercaptans. For propane, the most common mercaptan used for odorization is ethyl mercaptan, which matches the vapor pressure of propane but is also resistant to decomposition. Ethyl mercaptan must be added to propane to meet Department of Transportation (DOT) standards for over-the-road shipment at a minimum of 1 pound per 10,000 gallons of propane.

Propane OdorizationTo effi ciently handle the distribution of propane from a single pipeline across a wide geographical area, pipeline storage terminals are built along the pipeline. At periodic intervals, propane is withdrawn from the pipeline and stored in large

horizontal cylinders. h e delivery window to withdraw from the pipe-line is fi xed, and it is critical that all delivery equipment be in good oper-ating condition to take the delivery. Any equipment failure can interrupt or stop delivery. Lost propane deliv-eries equal lost sales . . . resulting in lost profi ts for the terminal operator.

Propane is odorized as the pro-pane is withdrawn from the pipe-line. Odorant injection equipment operating perfectly is critical to the terminal operation’s fi nancial health.

h is is the primary reason why a propane terminal operator in the upper Midwest invested in a more accurate, reliable and consistent propane odorization system.

Positive displacement dosing pumps have been the tradi-tional method for metering odorant into propane. A fl owmeter measures the propane delivered to the terminal, and a control system commands the metering pump to periodically inject a known quantity of mercaptan in the propane at a frequency to meet the desired dosing rate. h e stroke detector on the pump sends a signal back to the control system as confi rmation that odorant is being injected.

If after a number of commands to stroke the pump there is no signal indicating stroking, the terminal control system will stop delivery of propane. Problems with the injection pump might put the delivery of propane in jeopardy.

Metering pump system seals must be replaced on a peri-odic basis. Pump-based systems are typically set to overdose to compensate for any inaccuracies, with the result being higher operating costs to purchase odorant.

A better solution was sought that would provide the fol-lowing benefi ts:• Higher accuracy to minimize odorant consumption

Mass-Based Propane Odorant Injection SystemWesley Sund, Brooks Instrument, LLC

Details of a mass-based chemical injection system

Ethyl mercaptan must be added to propane to meet

DOT requirements for safe transportation and usage.


• No moving parts for reliable operation, minimal maintenance

• Documentation of actual odorant dosing rates

Mass-Based Odorant InjectionA liquid mass fl ow controller based on Coriolis technology was selected to provide these desired benefi ts. h e operat-ing concept of a mass fl ow controller-based odorization system is simple. h e odorant injection control system takes a reading from the propane delivery meter and calculates the fl ow set point required to meet the odorant mass/propane volume ratio specifi cation. h e fl ow controller is sized to meet a wide variation in propane delivery rates expe-rienced from summer to winter.

h e key technology in the liquid mass fl ow controller is the Coriolis sensor tube. Coriolis sensor technology has been used in process fl ow metering since the 1970s but only recently has the technology been reduced in size to meet the lower fl ow requirements for injection of chemicals like odorants.

Coriolis mass fl ow measurement technology is simply a momentum

metering device to determine fl uid mass fl ow rate. A vibrat-ing tube acts as the sensor. h e momentum of the fl uid fl ow-ing through the tube will change the shape of the tube as it vibrates. Detectors are used to measure the change in shape and, when calibrated, a linear relationship exists between the degree of tube twist and the fl uid’s mass fl ow rate.

Coriolis devices accurately measure fl uid mass fl ow

Mass fl ow injector designed to be mounted

in a hazardous environment associated

with propane terminal operations.


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independent of fl uid properties such as viscosity and density. Water is used as the calibrating fl uid at the factory, and there is no change in accuracy when measuring mercaptans. h e

measurement accuracy is better than 0.5 percent of rate, and calibration can be NIST traceable. h e controller system con-tains an integrated control valve, which is sized to control the

Coriolis

Mass

Flow

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Control

Valve

Tescom

Pressure

Reducing

Tracking

Regulator

Ethyl

Mercaptan

Tank

Wanner

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Diaphragm

Pump

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Backpressure

Regulator

Recirculation

568 liters/hr

Pro

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De

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0 p

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Flow Control

225 psig

PID Control Loop

Propane

Delivery

Flow

Meter

Odorant Injection

Control System Propane Flow

Injection

Setpoint

Injection

Report Printer

Propane Pressure

Process schematic for an injection system illustrating the use of a mass fl ow controller with pump

pressurization system to inject odorant into propane in proportion to fl ow rate.


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fl ow of odorant over the range of delivery rates from summer to winter, 0.25 to 25 pounds of odorant/hour.

To drive the fl uid through the injector system, the mer-captan must be pressurized to at least 60 psig above line pres-sure. Nitrogen gas pressurization is not acceptable due to the volume of gas required and the diffi culty of disposing the mer-captan saturated gas during odorant tank refi lling.

h e solution design uses a positive displacement pump in a recirculation loop with a back pressure regulator as a source of pressurized liquid to drive the liquid through the control-ler and into the propane. A three stage diaphragm pump was selected for this application. Mercaptan is a non-lubricating fl uid, and this particular pump design uses an elastomeric seal to isolate the pumping pistons from the mercaptan.

A critical device that maintains a constant diff erential pres-sure across the fl ow controller from summer to winter opera-tion is a dome-loaded diff erential pressure tracking regulator. h e dome of a regulator is connected to the propane pressure, and the regulator will maintain a constant downstream pres-sure as the propane pressure varies with ambient temperature.

Documenting that the correct amount of mercaptan has been injected in the propane was an important consideration in designing the new system. h e previous injector-based system could not provide a positive confi rmation of actual odorant

delivery. h e new system with the fl ow sensor is capable of pro-viding a printed report of actual odorant injection mass versus propane delivered volume. An integrated printer generates a report detailing the delivery specifi cs.

Conclusion

h e business results for the new system are positive. h ere have been no propane delivery stoppages due to odorization equip-ment failures since installation. h e injection rate of odorant has been reduced from 1.5 to 1.2 pounds per 10,000 gallons due to the higher accuracy of the system. h is has resulted in chemical savings. h e system provides a high level of docu-mentation that can be used to prove propane was odorized to meet DOT minimum standards. Finally, the pump pres-surization system has saved the purchase cost and handling of nitrogen cylinders.

h e basic design of this mass-based chemical injection system could be applied to any application that requires criti-cal dosing of a trace chemical into a continuous fl owing fl uid.

P&S

Wesley Sund is a marketing manager for Brooks Instrument, LLC. Contact him at [email protected].




During the last 10 years, dramatic change has occurred in radio technology and, more important, in how control engineers use it. Radio modules prices have

plummeted recently, and this has made integrating them into pumps for monitoring, diagnostics, data acquisition and even control easier for industrial vendors.

Pumps are an ideal device for wireless connections. h ey are often located in remote pumping stations or installed in areas of the plant that are diffi cult to access by maintenance personnel. But many plants remain reluctant to install wireless control because of perceived problems with reliability and con-nection to the SCADA system. Modern wireless devices solve these problems.

Why Wireless?h e business case behind deploying wireless pumps is a compelling one. By eliminating cabling and trench-ing, the cost of deployment can be dramatically reduced—sometimes by as much as 70 percent. Since wireless instrumentation is battery powered, it is much easier to deploy in the fi eld relative to its conven-tional counterparts. Wired systems can take days or weeks to be prop-erly installed. Wireless instruments require only the installation of the sensor in the process, saving hours or days and valuable resources.

If the business case is that strong and the return on invest-ment is solid, why are some still reluctant to deploy wireless pumps in their facilities?

ReliabilityIn industrial applications, reliability is a major concern. Wireless pumps must be as reliable as conventional, wired units. Even in simple applications, such as remote monitoring, users come to expect a certain level of reliability and network availability. Radio signals are subject to refl ection as a result of structure, trees, bodies of water and buildings. Other wireless interfer-ence adds more challenges. Radio frequency (RF) design is becoming more eff ective in addressing many of these issues. By designing sensitive radio receivers and using transmit power effi ciently and high gain antennas, engineers can establish reli-able RF point-to-multipoint links.

AdaptabilityWireless instrumentation networks are required to adapt to

the existing environment. Finding a location for an access point or base radio that provides reliable communication with the wire-less instruments can be diffi cult. Relocating the access point or base radio to improve the RF link with one sensor could result in degrad-ing the links with other sensors in the same network.

IntegrationManaging and debugging dis-persed wireless networks presents a new level of complexity to fi eld operators that could deter them from adopting wireless instrumen-tation, despite the exceptional sav-ings. h e wireless network integra-tion dilemma is more apparent in

Improving SCADA Operations Using Wireless PumpsHany Fouda, Control Microsystems

Many reasons for wireless conversion reluctance are resolved with new technology.

Figure 1. Bridgeport, Calif., replaced phone lines with a

900 MHz wireless system.


SCADA systems. Since wireless instrumentation networks are designed to tie into the same SCADA infrastructure available at the site to relay valuable operating data to the SCADA host, the ability to manage the complete infrastructure as one network becomes essential.

Despite the abundance of tools that are available to cap-ture, process and analyze data, ensuring data integration is still a major problem. Some SCADA systems even have a separate historian module that must be purchased as an add-on to handle the data from wireless instru-mentation networks.

Wireless ChallengesA new generation of base station radios or gateways integrates both a wire-less instrumentation base radio and a long range industrial radio in the same device.

Adaptability can be addressed by using lower frequency bands, such as the license-free 900 MHz, which tend to provide better coverage, longer range and better propagation characteris-tics, allowing the signal to penetrate obstacles.

h e City of Bridgeport, Calif., was using dedicated telephone lines to con-nect its well pump stations to the cen-tral control system, but the system was unreliable. It failed periodically without warning, resulting in inconsistent pump control. Other problems included inac-curate tank-level readings and nonexis-tent system alarms, which required fre-quent operator visits.

Bridgeport installed 900 MHz spread-spectrum radios (Figure 1) and SCADAPak controllers at each well and tank site. Pump control is now handled at each site, and the SCADAPak con-trollers send level, fl ow and other data to the main control room via wireless.

A similar situation existed at a wastewater treatment plant in Ottawa, Ontario, Canada. h e City of Ottawa serves a huge area of 2,758 km2, and the pump sites communicated mostly via dial-up phone lines. h e system was unreliable and expensive.

Ottawa installed 900MHz wireless modems at each pump station and local SCADAPak controllers, which commu-nicate to the main control system via a

wireless LAN (WLAN). h e WLAN allows operators and staff to access any pump site over a wireless connection from por-table laptops.

Older wireless installations can be updated easily. In 2000, a GPRS cellular system was installed in Sofi a, Bulgaria, to help control its water and wastewater system. Unfortunately, the unintelligent GPRS modems were diffi cult to use and

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consumed high rates of electrical power at solar-powered remote pump locations. h e solution was simple. Modern SCADAPak controller installations at each site solved the com-munications problem. h e SCADAPak manages the reporting of events to the SCADA system, saving bandwidth and reduc-ing network traffi c. h e SCADAPak saves power with its “sleep mode” and reduced power mode capabilities.

Modern Solutions

Other solutions to wireless problems include high-gain, external antennas that can be mounted as high as possible on a structure. Improved receive sensitivity of radio modules also plays a crucial role in ensuring network adaptability in industrial environments.

A modern, long-range remote radio is confi gured as a remote device for relaying information to a master radio at the

main SCADA center. h e serial ports on the radio are confi gured to tunnel Modbus® polling and diagnostic data simultaneously to the wireless instru-mentation base radio. h is allows opera-tors to manage and diagnose the wireless instrumentation network through the existing long-range SCADA infrastruc-ture. Live data and status information for all fi eld units are displayed in a sepa-rate view or integrated in the SCADA host.

On the data integration front, modern SCADA host software off ers a fully integrated environment that includes an integrated and scalable his-torian to handle additional data without going through expensive and some-times lengthy upgrades. Developing the SCADA screens based on templates allow engineers to add data points easily and rapidly to their systems.

Conclusion

As the adoption of wireless instrumen-tation networks increases, users will be faced with a number of challenges to ensure successful integration within their existing infrastructure. New RF and antenna designs help address reliabil-ity and adaptability challenges. Hybrid gateways, allow users to view, manage and diagnose their dispersed wireless systems from a single point. Similarly, advanced SCADA host software, with an integrated historian and rapid devel-opment environment using templates, can facilitate the integration of new data points generated by a growing network of wireless sensors.

P&S

Hany Fouda is the VP of marketing at Control Microsystems. He can be reached at [email protected].

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40 OCTOBET 2010 www.pump-zone.com PUMPS & SYSTEMS

Maintenance Minders

Magnetic bearing systems represent a dif-ferent approach from rolling bearings to support rotating machinery, and in recent

years, their benefi ts have attracted attention for more applications.

As a non-contacting technology, magnetic bear-ings will exhibit negligible friction loss and no wear. h ey can attain high speeds with undetectable vibra-tion and are valued for their energy-effi cient per-formance and savings in applications ranging from vacuum pumps to gas and air compressors.

For example, a 12,000 rpm, 12 MW centrifu-gal compressor at a natural gas pipeline facility in upstate New York was fi tted with magnetic bearings instead of traditional, hydrodynamic bearings. h is switch to a system that consumes a fraction of the energy (because it rotates without contact) yielded documented annual energy savings of 700,000 kWh and an overall 88 percent energy saving for the compressor system (encompassing compressor and motor). In addition, an auxiliary oil lubrication system, cooling system, gearbox (variable, high-speed motor directly coupled to the compressor), and condition monitor-ing equipment were eliminated, which reduced the footprint of the machinery and the number of potential failure points.

While, depending on the application, the advantages of magnetic bearing technology compared with the oil fi lm technology it replaces will vary in importance, the following features and benefi ts will often be cited:• Reduced wear. In normal operation, the rotating por-

tion of the machinery is not in contact with any parts. Reduced wear decreases maintenance requirements and operating costs.

• Increased effi ciency. Virtually no shaft energy is con-sumed by bearing friction. More power goes directly into the process and enhanced effi ciency follows.

• “Green” operation. Without lubrication oil, concerns about potential leakage, accidental loss and disposal

become irrelevant.• Programmable characteristics. Depending on the appli-

cation or process variables, the physical response of the bearing can be adjusted “on the fl y.” In some cases, this means that a shaft can safely pass through critical vibra-tion speeds and operate at speeds that were previously unattainable.

For all the advantages, the technology is not without some limitations. Magnetic bearings tend to be physically larger than similarly specifi ed bearing systems. Also, by necessity, magnetic bearings require electric power to drive the control systems, sensors and electromagnets.

Incorporating Distinct TechnologiesAn active magnetic bearing system consists of several dis-tinct technologies: electromagnet bearing actuators, position

The Attraction of Magnetic BearingsMark D. Hinckley, SKF USA Inc.

Minimal vibration, the elimination of lubrication and improved control

make magnetic bearings an appealing alternative.

Centrifugal compressor fi tted with magnetic bearings


sensors, control system and power amplifi ers. h e bearing actuators and sensors will be located in the machine, and the control system and amplifi ers usu-ally will be located remotely.

Magnetic bearings provide attractive elec-tromagnetic suspen-sion between the rotor and stator by applying electric current to fer-romagnetic materials used in the stationary parts (the stator) of the magnetic bearing. h is creates a fl ux path through both components and levitates the rotor, creating the air gap separat-ing them. (h e air gap between the stator and the rotor will usually be 0.5 mm to 2 mm and makes the non-contact operation possible.)

As the air gap between these two parts decreases, the attractive forces from the magnets increase. Since electromagnets are, in this way, inherently unstable, a con-trol system is necessary to constantly adjust the strength of the magnets by changing the current and provide stability of the position of the rotor.

h e control process begins by measuring the rotor position with a position sensor. h e signal from this device is received by the control electronics, which compares it to the desired position established during machine start-up. Any diff erence between these two signals results in a calculation of the force necessary to pull the rotor back to the desired position. h is is translated into a command to the power amplifi er con-nected to the magnetic bearing stator. h e current is increased, causing an increase in magnetic fl ux, an increase in the forces between the rotating and stationary compo-nents, and movement of the rotor toward the stator along the axis of control.

h e entire process is repeated thousands of times per second, enabling pre-cise control of machinery rotating with peripheral speeds of up to 200 meters per second. A closer look at each of the system components follows.

Radial and h rust BearingsA typical system incorporates two radial bearings and a thrust (or axial) bearing. Each radial bearing has a stator and sensor system mounted over a ferromagnetic rotor installed on the shaft. h e rotor consists of a stack of lamination rings mounted on a sleeve that fi ts onto the shaft. (Laminations are designed to reduce eddy current losses and improve the response of the bearing.) h e stator includes a stack of lami-nation rings with poles on the internal diameter. Coils are wound around each pole to divide the bearing into four quadrants. h e coils in each quadrant are wound in series to make each quadrant function as one electromagnet. Typically on horizontal machines, the quadrants are aligned 45 degrees from vertical. Opposing quadrants constitute an axis (each radial bearing, then, can be described by two axes). A set of sensors to measure shaft position is mounted as close to the bearing as possible.

h e thrust (or axial) bearing typically consists of two stators, one on either side of a rotor disk as well as a position sensor to indicate the rotors axial position. h e stators are made either of solid steel or solid steel wedges with radial slots between the wedges fi lled with laminations to improve the response of the bearing. h e thrust stators also have one or two circumferential slots machined into the face and fi lled with coils. With a stator mounted on each side of the rotor, the thrust bearing can counteract axial forces in both directions.

Radial Bearing

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Control System h e control system utilizes the signals from the position sensor to determine the position of the shaft. h is signal is compared to a reference to determine the error in the position. After appropriate conditioning, this signal is sent to power amplifi ers that control the current sent to the bearings.

In simple terms, the control system reduces the upper bearing current when the shaft is above the center position and increases the current when the shaft is below the center position.

Magnetic bearing control normally will be performed in a single input/single output (SISO) manner. h is means that the position information from one sensor causes only the control current in the corresponding axis to be varied. (Control systems can also be multi-input and multi-output, or MIMO. MIMO is used when higher levels of control are required or when sig-nifi cant cross-coupling between axes is expected.)

h e components of the control system include position sensors and electronics, controller, and amplifi ers. Sensors relay information about the position of the shaft to the controller in the form of an electrical voltage. Normally, the sensors are calibrated so that when the shaft is in the desired position, the sensor produces a null voltage. When the shaft is moved above this desired position, a positive voltage is produced, and when it is moved below, a negative voltage results.

h e controller receives the voltage signal from the position sensors, processes the information and sends current requests to the amplifi ers. h e controller consists of anti-aliasing fi lters, analog-to-digital (A/D) converters, a digital signal processor (DSP) and pulse-width modulation (PWM) generators.

h e voltage from the position sensors is passed through the anti-aliasing fi lters to eliminate high-frequency noise from the signal. (h is noise can cause the signal to inaccurately represent the position of the shaft.) After the high-frequency content is removed, the position signal is sampled by the A/D converter. h is converts the voltage signal to a form that can be processed by the DSP and the digital information is passed through a digital fi lter by the DSP. h is produces an output proportional to the amount of current required to correct the position error in the shaft.

h e requested current is compared to the actual current in the bearing, which is also sensed, fi ltered and sampled with an A/D converter. h e error between the actual and requested cur-rent is used to characterize the PWM signal that is sent to the amplifi ers. h is information is forwarded to the PWM genera-tors, which create the PWM wave form sent to the amplifi ers.

Each bearing axis has a pair of amplifi ers to provide cur-rent to the bearing coils and provide an attractive force to cor-rect the position of the rotor along that specifi c axis. h e ampli-fi ers are high-voltage switches that are turned on and off at a



high frequency, as commanded by the PWM signal from the controller.

When to Consider the TechnologyMagnetic bearings can both complement and contribute to applications in which particular conditions will be experienced or where specifi c performance requirements must be met. Some appropriate applications follow.

Clean EnvironmentsA magnetic bearing system will not contaminate a clean process with oil, grease or solid particles.

High-Speed Applications Because a rotor in a magnetic bearing system spins in space without making contact with the stator, drag on the rotor is minimal. h is allows the bearing to run at exceptionally high speeds. h e only limitation to speed will be the yield strength of the rotor material. h e positive outcome is that no other type of bearing can match magnetic bearings for sheer speed. Magnetic bearings have been designed with surface speeds up to 250 m/s. To achieve a fraction of this speed, conventional bearings would require a complex lubrication system.

Position and Vibration Control Since magnetic bearings use advanced control algorithms to infl uence the motion of the shaft, they precisely control the position of the shaft within microns and eliminate most vibration.

Extreme Conditions A magnetic bearing system can operate over a wide tempera-ture range—as low as -256 degrees C and as high as 220 degrees C—temperatures at which traditional bearings cannot

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function. Systems can additionally operate in corrosive envi-ronments, are not sensitive to pressure, can be submerged in process fl uid under pressure without requiring seals and can operate in a vacuum.

Machine Diagnostics h is capability can take three forms: online machine analysis,

stimulus/response diagnostics and static clearance checking. h e hardware integrated into the bearing system (instead of expensive add-on equipment) can continuously monitor, while online, changes in machine vibration against predetermined limits as an indication of machine or process anomalies.

In cases of excessive load, the system can signal process control equipment to stop the machine instantaneously before

serious damage can occur. Besides con-trolling and minimizing vibration in a shaft, an active magnetic bearing system can perform diagnostics by exciting the shaft with controlled wave forms and frequencies, either while the machine is idle or running.

During operation with conven-tional bearings, process errors may over-load the bearing system, which forces an operator to restart a potentially damaged machine or take the machine off -line for inspection. (h is usually involves dismantling a portion of the machine, accruing associated maintenance costs, and losing productivity.) A magnetic bearing system can mitigate these issues with the capability to move the shaft within its clearance limits and indicate any changes caused by eff ects such as thermal distortion or metal deformation.

Conclusion

h e evolution of sophisticated software control systems and the unique inher-ent characteristics of magnetic bearings have advanced the technology as a prac-tical solution for an increasing number of applications. In fact, failure modes of magnetic bearings tend to be limited to the control electronics, power electron-ics and electrical windings, and even in these modes, magnetic bearings provide performance and reliability levels that make magnetic bearings an attractive choice for many critical applications.

P&S

Maintenance Minders

Mark D. Hinckley is director, Mechatronics, for SKF USA Inc. Contact him at 267-436-6510 or via email at [email protected]. For more information, visit www.skfusa.com.

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For months, the focus of the Pumps & Systems “Effi ciency Matters” column has been on pump design, installa-tion and operation, factors that directly aff ect the energy

consumption of the pump itself. For example, the April and May 2010 articles on pump performance bands discussed how normally, when a positive displacement pump has less slip, it will more effi ciently pump the fl uids. h e amount of product pumped per unit of energy used would be considered a direct measure of effi ciency.

However, the decision-maker who is tasked with opti-mizing energy use and reducing costs must also consider indirect costs. h e global energy impact decisions must also be made. h is article explores how pump design can aff ect three indirect effi ciency areas: • Use of seal coolant (water) with associated cost and water

treatment• Pump design that aff ects effi ciency of product recovery• Pump design that reduces loss and waste treatment

energy usage and costs

h ese indirect factors often result in energy creep. h is is when indirect effi ciency issues are not monitored and unin-tended waste occurs.

Energy Effi ciency of Mechanical SealsWhile seal cooling or fl ush only applies to a subset of pump applications, it serves as a good example of an indirect effi -ciency issue for those analyzing the total energy footprint of pump selection. Frequent applications can be found in the food, beverage and pharmaceutical industries where trans-ferring sweeteners that tend to crystallize on seal faces can cause premature seal failure. (See Figure 1.) Traditionally, the common solution has been to use advanced seals (most of which are not permitted or adaptable for hygienic applica-tions) or using mechanical seals with water or other fl uid fl ush.

However, seal water usage on pumps is a classic case in which energy creep can occur. It is typical over time that the volume of seal water is increased to be safe. In fact, some

experts in the industry note that we typically see 10 times the amount of water used for seal fl ush than what is necessary.

Benefi ts of Eccentric Disc Design Negating the use of seal water altogether can help to avoid this cost (and possible creep). h e solution is to use pumps that have totally sealed pumping chambers and do not require seal fl ush. Diaphragm and magnetic-drive pumps may be familiar options. However, new to the fi eld are eccen-tric movement pumps that better fi t some applications that are not suitable for the former pump styles.

Most processors realize that water is becoming a valuable (and increasingly expensive) natural resource. Water is a vis-ible expense as the county, city or other sources that provide it are passing onto the processor the costs to supply and then treat it. If the processor treats the water, he can determine the energy usage and costs for this. As an example, a processor who handles sweeteners in the confectionary industry calcu-lated that his plant’s total cost for water used in fl ushing seals was more than $10,000 per year/per pump.

In another case, a processor that makes sauces in the Southeastern U.S. was faced with a permit cost of more than $400,000 if additional water was to be used in the plant. h is hurt growth. In addition, if water is used over and above limit, the county must expand its water-treatment capacity. Whether it is a per-pump water use cost or permit cost, new

Effi ciency Through Indirect MeasuresWallace Wittkoff

Indirect factors can directly impact the true effi ciency of the

product-transfer process.

Effi ciency Matters

Figure 1. Transfer line from sweetener storage


options to negate the use of water means less energy used to supply and treat the water, as well as other costs that may be incurred.

h e eccentric movement or eccentric disc design for sealing pumps is an alter-native to the magnetic drive or diaphragm, no-fl ush options. h e eccentric move-ment sealed pumps do not use mechanical seals and, therefore, seal fl ushing is not applicable or needed. Compared to magnetic drives, the eccentric movement can be implemented so that it is sanitary/hygienic and also withstands semi-abrasives better. Finally, the eccentric movement does not produce heat buildup.

h is pump also off ers effi ciency because of low slip (a direct effi ciency param-eter). With this pump, the example of indirect cost through water consumption is eliminated, and the global effi ciency of the pumping solution within the application is realized.

h e eccentric movement pump negates the use of dynamic seals. In most cases, this pump is driven by standard rotating drives. h is drives the shaft within the pump with a coupling. However, unlike most pumps, the shaft is machined on diff erent planes so that the drive end of the shaft is on a diff erent plane than the tip that is driving the pumping mechanism (See Figure 2.).

Attached to the shaft are bearings and both are enclosed by a hermetically sealed metal bellow or rubber boot. h e shaft rotates, the metal bellows or rubber boot does not rotate thanks to the bearings. Instead, it fl exes in an eccentric motion. h is fl exing is minor and within the elastic range of the stainless steel so that preven-tive maintenance inspection is recommended at 150 million duty cycles.

h e actual pumping mechanism is similar to the peristaltic eff ect of hose

Figure 2. Eccentric disc design pump cutaway

Figure 3. Eccentric disc design pump components

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Effi ciency Matters

pumps, but this pump does not use hoses, so it does not fall victim to any of the possible issues associated with them. h e disc of the pump is driven by the eccentric movement of the shaft, which produces a peristaltic eff ect on a channeled cyl-inder. Product fl ows in an inner and outer pumping chamber, producing fully complementary fl ows. h e pump, therefore, does not produce pulsation. Since this pump does not depend

on clearances for operation and, in fact, takes up clearance that could be generated by wear, the pump has negligible slip. h e result of this was illustrated in the “Effi ciency Matters” columns published in Pumps & Systems April and May 2010. With no mechanical seal, there are no surfaces on which products, such as corn syrup, liquid sugar, glucose or any number of diffi cult-to-seal fl uids can crystallize. h erefore, the need for fl ush water

to remove these products is eliminated.

Why Discard What You

Already Pumped?h e eccentric movement pump concept goes beyond resolving global effi ciency issues from a water or seal-fl ush use per-spective. During the production cycle of a traditional pumping system, startup and shutdown are highly ineffi cient because:• h e pumping system is not stabi-

lized, so the product being pumped is not to specifi cation and must be re-worked or treated.

• For most pumps, once the inlet tank is empty and the pump loses prime, the discharge line remains full of product and also becomes a loss.

It is clear that pumping a product and then not using it is an ineffi cient use of resources. Disposing or treating this unsuitable fl uid further adds to this ineffi ciency.

Effi ciencies When Starting a ProcessSince it has essentially no slip, the eccen-tric movement technology is able to pro-duce a stabilized and usable product fl ow much earlier in the startup process. h is compares with pump styles that have slip and require a control system to adjust and compensate. As a fi eld application example, companies that use spray-dry-ing processes fi nd this to be the case in their operations.

Typically, processes of this nature begin on water for calibration and sta-bilization. h e water is replaced with actual product. However, a process upset occurs when this change occurs. h e degree to which a pump has no slip and can maintain constant fl ow during the transition is related to how the process retains stability and product losses are minimized during transition. In the case of spray driers, much like shower heads,

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if fl ow changes the spray pattern changes, rendering diff erences in the product and possible rejection.

Effi ciencies When Ending a Pumping ProcessOn termination of a process, the residual product left in the pump discharge line also represents an opportunity for added costs, as well as waste-treatment costs.

In another fi eld application exam-ple, a company that produces coff ee extract was able to recover an additional 400 pounds of product at the end of each run because, even after the feed tank was empty, the pump continued to eff ectively pump air, thus helping purge the line. Pumps that are able to run dry and perform this way can pro-duce a compressor eff ect following the product. Pumps that employ the eccen-tric movement principle produce such an eff ect. When considering the eff ect of effi ciency, recovering 400 pounds per run meant: • Resources did not need to be used in

treating it as waste• All the resources to produce it were

not lost • Resources would not be used to

reproduce the lost coff ee extract

h e additional, indirect effi ciency issue was that coff ee extract was aggres-sive on mechanical seals and required advanced seals or water fl ush. Eccentric movement technology, with its sealless design, also helped in this application because resources were not expended for seal water, product was not lost, and treatment to remove the lost product was not needed.

Putting It All TogetherWhile it is important to consider the direct effi ciency parameters of a pump, such as the amount of product pumped per unit energy consumed, consid-erations should include the indirect effi ciency consequences of pump tech-nology selection. h e issues of periph-ery services to the pump—such as seal water, or consequences of the pump design, such as the amount of product loss and waste treatment costs—all com-bine to create the true effi ciency of the product-transfer process.

P&S

Wallace Wittkoff is the Hygienic Director for Dover Corporation’s Pump Solutions Group (PSG™). He can be reached at 502-905-9169 or wallace.wittkoff @pumps-gcom. PSG is comprised of six leading pump companies—Wilden®, Blackmer®, Griswold™, Neptune™, Almatec® and Mouvex®. You can fi nd more information on Mouvex at www.mouvex.com and PSG at www.pumpsg.com.



This “Sealing Sense” series provides guidance on best practices to minimize the

size of the sealing system energy footprint. h e fi rst article discussed the energy losses from the interac-tion between the faces of a mechani-cal seal. h e second discussed the thermal energy required to maintain the proper temperature of the inter-facial lubricating fl uid. We will now discuss the thermal energy footprint of removing diluents introduced by auxiliary processes.

A fl ush is often added to the stuffi ng box or mechanical seal chamber. h is helps to extend seal life by displacing solids, removing the heat generated by packing or a mechanical seal, and heat soak from the seal chamber. h e fl ush fl uid then becomes mixed with the pro-cess fl uid as a diluent that may need to be removed from the process fl uid.

Mechanical Seal SystemAPI Plan 32 is a commonly used system for hydrocarbon service that introduces diluents to the process stream. Plan 32 accounts for nearly a quarter of all pumping system appli-cations operating above 200 degrees C (400 degrees F). Unfortunately, it can also be one of the most energy ineffi cient designs because the speci-fi ed fl ush fl ow rate is often higher than necessary.

When a cool fl ush, like the one

What Is the Sealing System Energy Footprint for

Removing Diluents from the Process Stream?

Third of Four Parts

This month’s “Sealing Sense” was prepared by FSA member Dave Casucci

Figure 1. API Piping Plan 32—energy lost through dilution and vaporization

Figure 2. API Piping Plan 32—energy lost through dilution

From the voice of the fl uid sealing industry

SEALING SENSE


illustrated in Figure 1, becomes mixed with the process fl uid, energy must be added to replace the heat lost through cooling. Additionally, fl ush fl uid must be removed from the process stream. Supplying the required heat of vaporiza-tion to remove the fl ush fl uid increases the overall energy footprint signifi cantly.

When the fl ush diluents can be toler-ated in the process stream, energy require-ments can be reduced signifi cantly, as illustrated in Figure 2, since the only heat energy needed is that which restores the process fl uid to its original temperature.

Packing SystemsIn packed pumps, fl ush fl uids may be recaptured at the stuffi ng box or later down the process stream. Recapture of diluents at the stuffi ng box is usually accomplished by the use of a double lantern ring connec-tion—one connection to introduce the fl ush fl uid and a second one to retrieve it. A fl ow restrictor may be used in the throat of the stuffi ng box to maintain adequate stuffi ng box pressure.

h e example shown in Figure 3 shows a system with poor energy effi ciency because of the greater amount of power required to remove the water diluent.

In some cases, diluent fl uids may be left unrecovered in the process stream, acting as a tolerable contaminant even though it ultimately reduces the purity, quality and value of the fi nal product. A more effi cient system is illustrated in Figure 4. It minimizes the amount of diluents that is introduced into the process fl uid.

OverviewIn either recovery system, an energy cost is associated with the removal of the diluent from the process stream and restoring

the process stream to its original state. Furthermore, the diluent itself may represent energy expenditure since it usually consists of a refi ned fl uid. h e energy cost expended in synthesizing the diluent as well as pumping and distributing it is a cost associ-ated with the sealing system. h is discussion demonstrates the importance of comparing systems rather than devices.

Conclusions• Sealing systems found in many industrial applications (even

when functioning as intended) can be extremely wasteful of energy.

• Improved technology sealing systems available today can eliminate the need for energy wasting systems that result in cooling/dilution of the process and the need for down-stream separation/evaporation and/or re-heating.

• Life-cycle costs should always be considered when designing a sealing system.

Next Month: What is the impact of reliability on the sealing system energy footprint from pump shut down, repair & re-commissioning?

We invite your questions on sealing issues and will provide best eff ort answers based on FSA publications. Please direct your questions to: sealingsensequestions@fl uidsealing.com.

P&S

Figure 3. Packing System—energy lost through dilution and vaporization

Figure 4. Packing System—energy lost through dilution

h is “Sealing Sense” was sponsored by the Mechanical Seal Divisionof the Fluid Sealing Association as part of our commitment to industry consensus technical education for pump users, contractors, distribu-tors, OEMs and reps.


Q. We are frequently replacing the ball bearings in an end suction pump that is pumping hot oil at 700 degrees F. Someone has suggested that the bearings should be replaced with C3 fi t bearings. What is C3 fi t, and how will it improve bearing life?

A. Ball bearings are made with diff erent amounts of internal clearance between the raceways and the balls. Most bearings have little clearance between the raceways and the balls to accu-rately align the rotating shaft to the stationary members and prevent any looseness or play in the shaft. However, when a pump is operating using hot liquids, the shaft and inner race-way of the bearing will expand, closing any clearance, and can impose an additional load or squeeze on the bearings. h is can be further aggravated if the bearing housing is cooled with a water jacket.

C3 fi t bearings are made with greater internal clearance, which allows for the expansion of the inner raceway and avoids the excessive load on the bearing. Bearings with even greater clearance designated as C4 and C5 are also available if C3 is not suffi cient.

Check with your pump manufacturer before replacing any bearings with bearings manufactured with an internal fi t diff er-ent than the fi t originally supplied.

Q. What causes suction recirculation in pumps? How dam-aging is it, and what can be done to avoid this condition?

A. Suction recirculation in centrifugal pumps occurs when the fl ow through the pump is lower than that for which the impeller was designed. When this happens, a portion of the fl ow is forced back to the impeller inlet (suction) as shown in Figure 5-12.

h is recirculation of fl ow creates a vortex on the impel-ler blades resulting in low-pressure regions and allows vapor bubbles to form and collapse causing cavitation damage to the impeller vanes. Vibration also results and leads to mechanical damage to the bearings and seals.

h is condition usually begins below 70 to 50 percent of the best effi ciency (BEP) rate of fl ow. One solution is to provide a bypass line from the discharge to the suction piping, which can be sized to allow suffi cient fl ow for the pump to operate

at a rate of fl ow close to the BEP.

Impellers that are designed for a higher suction specifi c speed will begin to exhibit suc-tion recirculation closer to the BEP rate of fl ow and sometimes even at the BEP. Avoid selecting pumps designed with high suction specifi c speed impellers to reduce this potential problem.

A temporary approach to minimize the problem is to add an orifi ce (some times called a bulkhead ring) at the impeller inlet. h e opening in the orifi ce should be suffi cient to allow approxi-mately 70 percent of the BEP fl ow, but this modifi cation must be coordinated with the pump manufacturer.

When suction recirculation is responsible for signifi cantly reduced service life, excessive downtime and lost production, an energy effi cient solution is to use an impeller appropriate for the actual fl ow, based on the system requirements. If the system requirements vary signifi cantly, the addition of a speed control device may be justifi ed. For a more complete explanation, see Optimizing Pumping Systems: A-Guide-to-Improved-Effi ciency-Reliability-and-Profi tability, available at http://estore.pumps.org.

Q. What is the diff erence between a Newtonian and non-Newtonian fl uid?

A. A fl uid is Newtonian when the ratio of shear stress to shear rate is a constant for all shear rates, is independent of time, and zero shear rate exists only at zero shear stress. Most min-eral oils at temperatures above the cloud point (the temperature at which the oil begins to appear cloudy), solvents and water approximate this condition and are considered Newtonian fl uids. h e viscosity of these fl uids is independent of rate of shear.

PUMPFAQs®

Figure 5-12. Impeller showing

suction recirculation


A non-Newtonian fl uid will change viscosity with changes in the rate of shear applied to the fl uid and/or the length of time at shear.

Several types of non-Newtonian fl uids are defi ned below. When the ratio of shear stress to shear rate increases as shear rate increases, reversibly and independent of time, a fl uid is said to be dilatant. Highly concentrated pigment-vehicle suspensions, such as paints, printing inks, and some starches, are dilatants fl uids. h e apparent viscosity of these fl uids increases as the rate of shear increases. Some dilatant fl uids solidify at high rates of shear. Pumping such fl uids requires low velocity through the pump.

When the shear stress to shear rate ratio is constant for shear rates above zero, it is independent of time, but when shear occurs only for shear stress above a fi xed minimum greater than zero, a fl uid is termed plastic. A plastic fl uid, such as putty or molding clay, is characterized by a yield point. h is means that a defi nite minimum stress or force must be applied to the fl uid before any fl ow takes place.

When the ratio of shear stress to shear rate decreases as shear rate increases, reversibly and independent of time, and zero shear rate occurs only at zero shear stress, a fl uid is pseudo-plastic. Many emulsions, such as water-base fl uids and resinous materials, are pseudo-plastic fl uids. h eir apparent viscosity decreases with increasing shear rates but tends to stabilize at high rates of shear.

A fl uid is thixotropic when the ratio of shear stress to shear rate decreases and is time-dependent in that this ratio increases back to its “rest” value gradually with lapse of time at zero shear rate and stress, and decreases to a limit value gradually with lapse of time at constant shear rate. Most greases, drilling mud, gels, and quicksand are thixotropic fl uids when the apparent viscosity of these materials decreases for an increasing rate of shear and for an increasing length of time at shear.

When the ratio of shear stress to shear rate is constant for all shear rates at any given instant of time, but increases with time, a fl uid is rheopectic. Some greases are intentionally manufactured to have partial rheopectic properties that facilitate pumping in a stable condition. However, upon shearing in a bearing, the grease builds up to a higher apparent viscosity.

Additional information about fl uids and the eff ect of viscosity on pump and system performance may be found in ANSI/HI 3.1-3.5 American National Standard for Rotary Pumps for Nomenclature, Defi nitions, Application, and Operation, which is available at http://estore.pumps.org.

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 provide answers

based on existing HI standards and technical guidelines.

Please direct your inquiries to: [email protected].

For more information about HI, its publications, Pump

LCC Guide, Energy Saving Video-based education program

and standards, please visit: www.pumps.org. Also visit the new

e-learning portal with a comprehensive course on “Centrifugal

Pumps: Fundamentals, Design and Applications,” which can

be found at: www.pumplearning.org.


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Practice & Operations

What’s a fl exible impeller pump? In the food indus-try, the most common

pump types are centrifugal pumps, rotary lobe pumps, rotary piston pumps (often referred to as external circumferential piston or ECP), air-operated double diaphragm pumps (AODD), peristaltic or hose pumps, and many others. However, fl exible impeller pumps (FIP) are a lesser-known pump type. h ose in the dairy industry may already know that the pump on the back of a milk collec-tion truck is a fl exible impeller pump. h is article explores FIPs, including how they work and how they are used in the food industry.

How Do FIPs Work?An FIP, as its name suggests, is a pump with a fl exible impeller, or a fl exing vane. h e impeller is made of rubber and is fi tted into a concentric bore (See Figure 1). Inside the bore, between the suction and discharge ports, is a smaller diameter bore (cam).

As the impeller rotates and the vane moves down a ramp from the small diameter bore to the larger diameter bore (Figure 1, Section 1), the cell formed between two vanes enlarges and consequently product is drawn into the pump through the suction port. h is ‘trapped’ prod-uct is carried around the body as

the impeller continues to rotate (Figure 1, Section 2). As the vanes reach the discharge port area they start to move up a ramp from the large diameter to the small diameter (Figure 1, Section 3). h e vanes are now being bent (fl exed), and the cell between the two vanes gets squeezed and the product is discharged.

h e performance characteristics of the FIP take advantage of both centrifugal pumps and positive displacement pumps. It has the head vs. fl ow characteristic of a centrifugal pump coupled with the viscosity handling capability of a positive displace-ment pump (See Figures 2 and 3).

FIPs Offer Food Processors

Many Features An FIP can off er unique features and combi-nations of features that other pumps cannot. (Table 1).

With these features, the FIP can perform many, but not all, of the duties of most other sanitary pump types, often less expnsively. In approximate terms FIPs cost about the same as a sanitary centrifugal pump, which is around one-third the cost of a rotary lobe pump.

FIPs Follow the “KISS”

PrincipleWe all know that one—Keep It Simple, Stupid. h e FIP has one moving part, the impeller, and has no rotors to time, no shims and no gears. Figure 4 is an example of a ped-estal mounted pump.

Flexible Impeller Pumps in the Food IndustryDavid Farrer, Depco Pumps

One of the best kept secrets in pumping technology

Figure 1. FIP principle


Applications in the Food IndustryFIP food applications range from simple transfer to batching, metering, fi lling and dosing right through to complex process applications with fl ows directly linked to process streams. Examples include:

Dairy (Milk, Yogurt, Cheese Curd, Cottage Cheese, Cream)h is truck has a 2-inch, sanitary FIP pump, bulkhead mounted in the cabinet on the back of the truck. h e pump is used to bring milk from the farm tank to the

Pump Performance Flexible Impeller Rotary Lobe

& ECP

Centrifugal Air Operated

Double

Diaphragm

Pressure Low Low to High Low to Moderate Low

Temperature Moderate Low to High Low to High Moderate

Flow Low to Moderate Low to High Low to Very High Moderate

Viscosity Low to High Low to Very High Low Moderate

Speeds Wide Range Wide Range Limited Range N/A

Dry Self Priming Excellent No No Excellent

Air Entrained Liquids Yes Yes No Yes

Delicate Solids In

Suspension Yes Yes No Yes

Hard Solids In Suspension Yes No No Yes

Abrasive Liquids Moderate Low Limited Yes

Corrosive Liquids Moderate Yes Yes Yes

Dry Run Capability Up to 30 seconds Yes Yes Yes

Smooth Flow Yes Yes Yes Pulsing Flow

Star�ng Torque / HP Moderate Low Low N/A

Power Consump�on Moderate Low Moderate High

Relief Valve Required Not normally Yes No No

Con�nuous Duty

With Periodic

Maintenance Yes Yes

With Periodic

Maintenance

Ease of Cleaning Yes Yes Yes No

Ease of Maintenance Simple Complicated Simple Complicated

Figure 2. Viscosity vs. effi ciency

Figure 4. Typical pedestal mount FIP confi guration

Figure 3. Head vs. fl ow

Table 1. Comparison of FIPs and other common food process pumps cir

cle

13

5 o

n c

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ee

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truck and has fl ows up to 165 gallons per minute. It is dry self priming to 20 feet – primes almost instantly through 15 to 20 feet of suction hose and has low shear so that it does not damage milk globules or release free fatty acids.

For cottage cheese transfer, a 1 ½-inch sanitary FIP is foot-mounted and coupled to a gear motor

It transfers cottage cheese to the header tank on a piston fi ller with fl ows up to 20 gallons per minute.

Beverage—Water, Wine, Juice, Concentrate & PulpIn the wine industry, a 1- to 2½-inch sanitary FIP, mounted on a cart with a VFD, is used for wine transfer. It is used to transfer from the fermentor to the press, press sump to de-stemmer, for must, for pump-over and to transfer the wine itself.

For fruit juice concentrate, a 1- to 2–inch sanitary pump mounted on a cart, close coupled to motor and using VFD speed control is used.

Meat, Fish, Poultry—Brine, Rendering, Gravy, Pet Food, Meat Sauce & Meat SlurryInjecting brine into meat and poultry is accomplished by using a 1-inch sanitary pump mounted in OEM.

A 1½-inch sanitary pump, mounted in OEM equipment, supplies batter from the holding tank to the enrobing curtain. Smooth fl ow from the pump ensures an even curtain of batter

to cover the fi sh.

Bakery—Cake Mix, Muffi n Batter With Fruit, Coatings, Icing & Fruit FillingsTo evenly spread donut glaze, a 1½-inch sanitary pump is used to recirculate donut glaze to the header tank on the enrober. h is pump can handle hard solids—such as small clumps of un-dissolved sugar and pieces of donut that fall through.

General Food—Batter, Mayonnaise, Sauces, Dressings, Pickles, Relishes, Salsa, Honey & JamsA 2-inch sanitary pump is mounted on a cart in-line, coupled to motor and that uses VFD speed control. h is pump transfers corn batter into chip-forming machines and can handle hard solids, such as small clumps of un-dissolved batter.

P&S

David Farrer is the sanitary product manager for the Depco Pump Company based in Clearwater, Fla. He can be con-tacted at [email protected] or 1-800-446-1656.

On pump-zone.com . . .

More information and images of these FIP

food applications

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In the 1950s I encountered pumps for the fi rst time while on a sales call with my father, visiting Marlow Pumps in Midland Park, N.J.. Although this pump company,

as well as its product lines, has been sold numerous times through the years, we continue to produce many castings based on the same tooling today that was used in the 1950s and 60s. However, the metal castings industry has drasti-cally evolved through the years, not only in respect to the type of machines used but also with regard to processes and procedures.

Today, the biggest changes seem to be with engineer-ing and purchasing. Although the castings that existed in the 1950s, 60s and even 70s are still being designed and pur-chased today, many of those in the industry have never had the opportunity to visit a casting operation; therefore, they may be unaware of the industry’s advancementsand the sav-ings that may be available.

Daily, requests are received for various pump parts, fi t-tings and bearings. Approximately fi ve percent of these bid requests provide the information required to generate an accurate quotation. Based on the information supplied by buyers, it is not uncommon for the metal cost to represent only 10 percent of the casting price.

Regardless of the casting medium (iron, bronze or alu-minum), there are guidelines to follow when designing and purchasing metal castings.

Guidelines for Designing and

Purchasing Metal Castings• Select a foundry that has specifi c experience in casting

pumps or pressure castings.• Be thorough and accurate when developing quotation

requests. Information such as quantities, type of metal required, casting weight and special items such as anneal-ing or stress relieving, certifi cations and letters of compli-ance should be included in the formal quote request.

• Supply a legible set of blueprints or CAD fi les. Such fi les should include locations where brinell readings are to be taken on the castings, as well as tooling points, the desired parting line and draft angles and the tolerance of

angles, radii and dimensions.• Quotation responses should specify the part number,

revision level, casting weight, piece price, quantity breaks, minimum billing, current metal surcharge, pattern mate-rial, number of impressions, the number of impressions in the core box and the type of machine on which the part will be run.

• During the design stage of pumps, uniform metal thick-ness should be maintained when possible. Isolated heavy bosses or hubs have a tendency to create shrinkage and porosity.

• h e pump design should not include any square corners. To increase effi ciency, sharp 90-degree transitions should also be avoided within the pump casting.

• Purchasing should not consider or accept quotations that only state “one set of pattern equipment” for a specifi c part number.

Currently, several pump companies design their own parts and, in some cases, build the tooling prior to seeking quotations. It is well documented that during the lifetime of an electric motor, the initial cost of the motor can result in only approximately 2 to 3 percent of its lifetime cost, while energy accounts for 97 percent. A pump system is compa-rable to these fi gures.

A pump requiring a modest initial investment may prove to be fi nancially strapping over its lifetime. h e effi -ciency of the motor, the actual pump and fi ttings and the related maintenance required need to be considered to obtain an accurate estimate of the long-term investment. Some manufacturers ask the design engineer, pattern maker and metal caster to convene to discuss maintenance effi ciencies, pattern design and foundry-friendly castings.

P&S

Pump CastingsAlfred ‘Fritz’ Hall, Benton Foundry

The most misunderstood, most overlooked

and possibly most important pump component

Alfred ‘Fritz’ Hall is the president of Benton Foundry. He can be reached via phone at 570-925-6711 or via email at [email protected]. For more information about Benton Foundry, visit www.bentonfoundry.com.



Industrial process managers who purchase and maintain pumps are familiar with a marketing tug of war. On one side are the manufacturers of well-known pump brands

who claim their products off er higher quality with a lower cost of ownership. On the other side are replicators who make pumps and parts that cost less out of the box and claim to perform just as well as the OEM products.

Studies by the Hydraulic Institute show that purchase price of a medium-sized ANSI pump is only 10 percent of the life-cycle cost of a pump, with energy, maintenance and downtime costs accounting for nearly 70 percent. In many cases, the initial purchase price is the most heavily weighted factor in purchasing decisions.

h is may be especially true for process pumps that con-form to the ASME B73.1 specifi cation, commonly known as the ANSI standard. Most ANSI pumps can look similar, even to the eyes of a skilled engineer—and because they are the world’s most common process pump, with tens of thou-sands sold each year, it may seem reasonable to assume that replicated ANSI pumps and parts are likely to perform as well as those from OEMs.

To test this, engineers at an OEM pump company recently conducted a comparison of a popular OEM pump to pumps of identical size from non-OEM suppliers. h e results showed that when it comes to purchasing pumps, the short-term gain of a lower purchase price equals long-term pain in performance. In every test:• Non-OEM pumps failed to match the OEM pump

performance for fl ow, head and effi ciency.• Non-OEM pumps performed an average of 10.25 per-

cent lower in effi ciency than the OEM counterpart.• Non-OEM pumps did not perform in accordance with

their own published performance curves, and therefore did not conform to the ASME standard.

• At a standard electricity cost of 7.6 cents per kilowatt hour, the lower effi ciency of the non-OEM pumps would

translate into wasted energy costs of at least $1,100 per year per pump, and as much as $3,700 per year on a medium-sized pump, based on continuous operation.

Customers report that OEM pumps and parts also require less maintenance and reduce downtime, which con-tribute to the lower operating costs for OEM pumps. h is article provides details on the tests, and examples from two customers who switched to using only OEM pumps and parts. h ey show that OEM claims to lower the total cost of ownership are not simply marketing hype but can be verifi ed by controlled testing.

Test MethodologyPerformance tests were conducted on four sizes of ANSI pumps:• 1-inch discharge fl ange, 1.5-inch suction fl ange, 6-inch

impeller (1x1.5-6) • 1-inch discharge fl ange, 1.5-inch suction fl ange, 8-inch

impeller (1x1.5-8) • 1.5-inch discharge fl ange, 3-inch suction fl ange, 13-inch

impeller (1.5x3-13) • 2-inch discharge fl ange, 3-inch suction fl ange, 6-inch

impeller (2x3-6)

h e testing was performed in accordance with ASME B73.1 and Hydraulic Institute Standard 1.6, Level A, which includes guidelines and uniform procedures for testing, recording data and acceptance criteria for centrifugal pumps. Level A testing uses clean water and involves monitoring the rate of fl ow, system head, input power and pump speed. Level A acceptance criteria states that “no minus tolerances or margin shall be allowed with respect to rate of fl ow, total head or effi ciency at the rated or specifi ed conditions.”

Each pump was tested as-received, with only the

Not All ANSI Pumps Are Created EqualPatrick Prayne, ITT Goulds

OEM pumps and parts outperform replicated products

and can save thousands per year in operating costs.


impeller clearance being set per the prod-uct installation, operation and mainte-nance (IOM) manual.

While the size of the diff erential varied, the OEM pumps outperformed their non-OEM counterparts in every measure on every test. A close-up look at the results for two of the pump sizes tested provides a snapshot of typical fi ndings.

1x1.5-8 Test—OEM Pump

Is 17 Percent More Effi cient At 3,550 rpm, the OEM pump produced a fl ow of 150 gpm, a total dynamic head (TDH) of 271 feet, with an effi ciency of 61.1 percent.

For the non-OEM pump operating at the same speed and fl ow, the TDH was only 229 feet, which is 15 percent lower. It was operating at an effi ciency of 50.7 percent, which is 17 percent lower than the OEM of the same size.

h e 1.5 x 3-13 pumps also were tested at a speed of 3,550 rpm. h e OEM pump produced a fl ow of 484 gpm, TDH of

492 feet, and an effi ciency of 55.3 percent. For the non-OEM pump operating at the same speed and fl ow, the TDH was only 459 feet, which is 7 percent lower; and an effi ciency of 51.1 percent, which is nearly 8 percent lower.

He

ad

(ft

)

Eff (

%)

Flow (gpm)

Non-OEM 1x1.5-8 @ 3550 RPM vs. OEM

400.0 70.0%

350.060.0%

300.050.0%

250.0

40.0%

200.0

30.0%

150.0

20.0%

100.0

10.0%

0.0 25.0 50.0 75.0 100.0 125.0 150.0 175.0OEM

Legend

Non-OEM

Efficiency Curve

Flow-Head Curve

Best Efficiency Points1.5x3-13 Test—OEM Pump Is 8 Percent More Effi cient

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Small Differences Yield Big Energy

SavingsAn effi ciency delta of less than 10 percent may not sound like a lot, but it translates into major diff erences in energy costs.

Consider the 1.5x3-13 pump comparison, in a pumping application requiring a fl ow of 484 gpm at 459 feet—the actual performance result of the non-OEM pump at 3,550 rpm. h e OEM pump would produce the same fl ow and head using a smaller impeller, using 8 percent less power, saving 8.3 hp (or 6.2 kW).

According to the U.S. Department of Energy, in August 2008 the average price of electricity in the North American industrial market was just under eight cents per kilowatt per hour—$0.076 on average, ranging from $0.066 in the Midwest to $0.138 in New England. At the average price, the energy costs in this application would be more than $3,700 lower per year with the OEM pump compared to the non-OEM pump.

6.2 kW x $.076 kW/hr x 8,000 hours = $3,763 per year, per non-OEM pump

h e lower performance of the non-OEM pump has addi-

tional cost implications. Suppose the process required a fl ow of 484 gpm at 492 feet, which matches the performance of

the OEM pump in the test. Although these requirements fall within the published performance curve of the non-OEM pump, in the test, it fell short. Two costly options would be available. Either the transfer process would take longer, reduc-ing productivity and process control, or the customer could spend days or even weeks troubleshooting the underperforming pump, only to fi nd that a larger impeller or even a larger non-OEM pump is needed to meet the performance requirement.

Energy savings were also signifi cant involving the compar-ison with smaller non-OEM pumps in the tests. Consider an application for the 1x1.5-8 pump that requires 150 gallons per minute at 229 feet, which matches the maximum tested perfor-mance of the non-OEM pump. h e OEM pump would meet these requirements using 2.5 horsepower (1.9 kilowatts) or 15 percent less power. In continuous service, the cost of wasted energy for the non-OEM pump would be more than $1,100 per year.

1.9kW x $.076kW/hr x 8,000 hours = $1,135 per year, per pump

h e energy savings in these examples apply to a single pump in continuous service. In a facility with 200 same-sized pumps from non-OEM vendors, the total cost of wasted energy would range from $227,000 per year for the smaller 8-inch pumps, to

more than $700,000 for pumps with a 13-inch impeller. Engineers have repeat-edly tested the 1x1.5-8 pump to simu-late performance over the span of several years, and the results showed continuous underperformance. h is proves that the choice of one non-OEM pump could cost a facility millions over multiple years.

ASME B73.1 Is More

Than Just Dimensional

InterchangeabilityTo meet the ASME B73.1 standard, all published performance curves, as well as factory testing, must be compliant with Hydraulic Institute 1.6, level “A”—the testing procedures described in this article.

h e standard states “no minus tol-erances or margin shall be allowed with respect to rate of fl ow, total head, or effi ciency at the rated or specifi ed condi-tions.” In the OEM vs. non-OEM test-ing, none of the non-OEM pumps per-formed up to the level of its published performance curve, meaning that none of the non-OEM products complied with the ANSI standard.



A high-precision manufacturing and quality control pro-cess contributes to a higher purchase price out of the box com-pared to most non-OEM products. But the tests confi rm that most OEM pumps perform as expected, consistent with their published performance curves. Full compliance with the ANSI standard translates to lower overall operating costs throughout the life of the pump.

Dimensional interchangeability is only one aspect of the B73.1 standard. Many other design requirements are needed for full compliance:• Flanges must comply with ASME standard B16.5 or

B16.42 for pressure retaining capability, as well as leakage and safety concerns.

• Flange loading, sound, vibration, NPSH, mechanical and performance testing must also meet or exceed HI standards.

• Impeller balance must meet ISO 1940 standards for mini-mal vibration and shaft defl ection.

• Shaft diameter tolerance, shaft runout and surface fi nish must fall within acceptable limits, which ensure proper fi t and function of the shaft.

• Mechanical seal chambers must also meet alignment criteria to ensure proper seal life.

h e lab tests demonstrate the potential cost implications in a tightly controlled environment. Two customer experiences help further confi rm that manufacturing quality at the front end yields long-term savings.

Field Example 1—

“An Expensive Boat

Anchor”A customer in the Southeast U.S. pur-chased replacement parts from a non-OEM supplier that increased operating costs and caused a major loss in produc-tion. h e application was a typical con-densate service, for which the customer used a large pump, size 4x6-17. After an extended time in service, the wet-end components needed replacement due to routine wear.

Against the recommendations of the OEM company’s maintenance team, the customer decided to use non-OEM replacement parts to save money. Within an hour of the new wet end’s installation, the pump began smoking and had to be shut down. Maintenance engineers discovered that the problem was in the stuffi ng box area, where the newly installed gland had touched the pump’s shaft sleeve and damaged it.

After installation of a new sleeve from the OEM company, the team found

that the gland continued to touch on one side, and the shaft would not turn. h e OEM company’s sales engineer inspected the equipment and found that the non-OEM stuffi ng box cover bore was undersized by 1/32- to 1/16-inch, and the gland studs were off -center from the bore, causing the gland, stuffi ng box cover and shaft to be non-concentric. h e customer ordered a new OEM stuffi ng box, and remarked that the non-OEM part would now serve only as a boat anchor. Soon after, the pump was put back into service with a new OEM stuffi ng box, but still with the non-OEM impeller and casing.

h e customer’s requirements and original OEM pump were designed for 900 gallons per minute at a head of 180 feet, with an effi ciency of 68 percent and drawing 60 horsepower. With the non-OEM liquid end parts, the pump was actually running at 954 gallons per minute with a head of only 114 feet while drawing 56 horsepower at an effi ciency of 49 percent. h e ineffi ciency and underperformance of the non-OEM parts generated approximately $7,600 per year in unnecessary energy costs and lost production. In addition, the pump was down for four weeks for troubleshooting.

Field Example 2—

Paper Customer Puts Stock in OEM PartsA paper manufacturer in Central Canada conducted its own test, by comparing the performance of OEM and non-OEM




replacement parts for a stock pump connected to a machine chest, the tank that contains thick stock pulp before it is made into paper. h e pump’s performance levels fell drastically after replacing worn OEM parts with a non-OEM impeller and suc-tion sideplate. h e facility switched back to OEM parts and watched performance return to the published OEM curve within an hour.

Using this example, the company’s mechanical engineer-ing technologist convinced executives and purchasing agents to switch exclusively to OEM pumps and parts. Soon after the company began to switch, the maintenance and repair costs dropped dramatically. Labor costs for pump maintenance decreased, while the overall performance and reliability of the pumps improved signifi cantly.

In the past 10 years, the mill has increased paper produc-tion, cut its replacement parts budget in half, lowered operating costs and decreased the manpower needed for maintenance and repairs.

Case Closed:

All ANSI Pumps Are Not Created EqualTesting under Hydraulic Institute guidelines confi rms a per-formance diff erence between “ANSI pumps” from original equipment manufacturers and from replicators that produce

identical-looking pumps and parts based on OEM designs. h ough the ASME B73.1 standard is known for its dimen-

sional requirements, many additional elements are needed to ensure proper pump performance. h e OEM pumps tested were in full compliance and even surpassed the performance of their published pump curves. None of the non-OEM products met published curves, and therefore, were not in compliance with the standard.

h e increased effi ciency of OEM pumps can translate into thousands of dollars in energy savings for each pump, and have a huge global impact. According to the Hydraulic Institute, pumps use roughly 20 percent of the world’s energy, and nearly 50 percent of that energy is wasted on pump and system ineffi ciency.

Along with energy savings, fi eld experience suggests that OEM pumps and parts are manufactured with greater preci-sion, which reduces maintenance costs and downtime. Taken together, the fi ndings indicate that OEM products, despite a higher initial purchase price, have a lower total cost of owner-ship over time.

P&S

Patrick Prayne is the Global Product Manager for ANSI Process Pumps and ITT Goulds Pumps. For more informa-tion, visit www.gouldspumps.com.



Saint-Gobain Containers is a building materials com-pany that produces high-performance materials and glass containers. In North America, the company

employs 22,000 people in more than 350 locations.Among its products are wine bottles and other contain-

ers for the food and beverage industry. h e bottle-making process requires the use of compressed air that exists, in some fashion, on or around every piece of production equipment in the plant.

Leaks, a frequent problem in compressed air systems, create ineffi ciencies that add to manufacturing costs. Saint-Gobain Containers set out to fi nd an eff ective way to detect system leaks that did not require a large capital investment in monitoring and management equipment.

h e Madera, Calif., facility, which produces millions of wine and champagne bottles each year, designed a low-cost system using data loggers and fl ow meters. h e company’s investment of less than $5,000 in monitoring equipment is expected to yield tens to hundreds of thousands in annual savings. Saint-Gobain Containers estimates that it will reduce 10 to 50 cubic feet per min (CFM) of compressed air from each piece of equipment placed into the monitoring system.

DOE Recommends MonitoringCompressed air is a vital utility that is used in a wide range of industrial processes. However, these systems use a signifi cant amount of energy, so if they do not operate to full capacity—if air leaks out—energy costs can mount. As a result, the U.S. Department of Energy’s Offi ce of Industrial Technologies recommends that all facilities with compressed air systems adopt aggressive leak detection and prevention programs including quarterly system monitoring.

In addition to wasting energy, leaks create other prob-lems. h ey can cause drops in system pressure, making tools operate less eff ectively, or leaks may make equipment cycle too frequently, resulting in higher maintenance costs and shortening equipment life span.

A compressed air system in good working order should

lose no more than 10 percent of air and power capacity, but it is not unusual for systems to lose as much as 20 to 30 per-cent. Leaks are most likely to occur at joints and fi ttings and can often be averted through a simple tightening or replace-ment of connections.

Detecting Equipment Leaks

With Data LoggersIn complex or large systems, leakage monitoring and detec-tion systems can be costly and time consuming. Knowing this, Greg Rhames, an energy engineer at Saint-Gobain Containers Madera, Calif., plant, set out to fi nd a low-bud-get way to fi nd and reduce energy waste from three 1,250 hp compressors that run 24/7.

Rhames decided to pursue what he describes as moni-toring from “an equipment-based perspective.” h is runs contrary to the more common industry method of placing large meters of diff erent types close to the supply side of a compressed air system. Rather than monitoring the total system output, he decided to analyze the performance of individual pieces of equipment, pinpointing problems at the source through measurements taken with data loggers.

“Instead of looking at this from 300,000 feet, we were looking at it from 1,000 feet,” he says. “You can get solid results by going to the equipment and working your way back versus monitoring at the supply side. If you monitor from the supply end, you have no resolution on issues caus-ing the air leaks downstream.”

Monitoring Systems Make Process

More Effi cientRhames devised a monitoring system that uses an energy logger, a portable data logger which includes snap-in mod-ules that convert signals from nearly any type of sensor. h e 15-channel data logger can measure compressed air, gauge pressure, kW/hr output, voltage, current, air velocity, tem-perature and a range of other parameters.

Data Loggers and Flow MetersEvan Lubofsky, Onset Computer Corporation

Low-cost additions help bottle maker manage compressed

air use and energy costs on a shoestring.




For Saint-Gobain Containers’ purposes, Rhames needed the data loggers to measure the CFM consumption of every piece of equipment in the plant that used compressed air. To accomplish this, Rhames installed compressed air fl ow meters with remote displays, which he connected to the modules. As the project continues, additional meters will be installed at each compressed air receiver throughout the plant to allow depart-mental isolation and monitoring of system air pressure.

Rhames placed two data loggers in one of the centralized equipment control panels. During installation, he performed a 10-minute logging test and gathered the results to verify that all the components were operating correctly. He then redeployed the logging devices and left them to record for 24 hours. He recorded the air fl ow measurements every two seconds.

Since the data loggers are portable, he was able to unplug the modules, remove the loggers and bring them into his offi ce to download the data into a graphing and analysis software package. h e software provided a quick read out of the collected data, which could then be exported to Microsoft® Excel, which he used to manipulate the information. Using both spreadsheet and graphical formats, he set a baseline measurement, studied the eff ects of various corrective actions, compared historical records and established benchmarks. Most of the machinery cycles were between 2 to 15 seconds, depending on what was occurring. By stretching the data over the course of the day,

anomalies in the system became apparent. h e individual pieces of equipment should lose no more

than 2 to10 CFM. If there is a loss of more than 10 CFM, “you should really analyze the equipment and see where you’re losing air. Find it, fi x it and bring it back down to tolerance,” Rhames says.

“h e data so far shows we’re losing 20 to 30 CFM because of leaks,” he adds. “It is amazing how much waste occurs on one piece of equipment. h e data loggers make it immediately evident.”

Large Savings Achieved QuicklyUsing the energy logging equipment, Saint-Gobain Containers identifi ed the worst compressed air leaks and repaired them, resulting in a 10-CFM decrease in compressed air waste. Rhames calculates that the facility will save $2.24 for every CFM of High Pressure air preserved. As a result, “the savings could be huge—possibly tens to hundreds of thousands of dol-lars annually,” he says.

By working on a small budget, Rhames avoided the delay common in most corporations when requests are made for large capital expenditures. He was able to get the project up and run-ning in days, rather than the standard months or years. h e data provided by the data loggers allowed for a quick reaction to correct the leaks. As a result, Saint-Gobain Containers was

able to start saving energy, and money, sooner than it would have with a larger, more costly system.

Use of the data logger will now be standard operating procedure at the facil-ity. Data gathered and compared, during and after leaks are found and repaired, will be applied to achieve a standard, minimum, CFM-consumption bench-mark for all similar equipment.

h e data logger system proved to be an eff ective way to provide real-time analy-sis that was previously only attainable with a larger, much more expensive system. h e project showed that a large industrial facil-ity can institute a comprehensive, com-pressed air monitoring system and a com-pressed air waste reduction system, with economical, equipment-level monitoring and logging devices.

P&S

Evan Lubofsky is director of market-ing for Onset. He has been writing about sensor technologies for over 12 years and has had hundreds of articles published in trade magazines and newspapers around the world. For more information, please visit http://www.onsetcomp.com.



The 39th Annual Turbomachinery Symposium

and Exhibit Show is hosted by Texas A&M

University’s Turbomachinery Laboratory, a

group that researches the reliability and performance

of rotating machinery that removes energy from or

adds energy to fl uids. Last year’s symposium was

well-attended by industries from oil and gas to paper

and by executives, managers, engineers, sales and

technicians/service representatives. This year prom-

ises to be as well-attended and to provide a wealth

of programs to educate attendees of all levels and

interests.

38th Turbomachinery Symposium Statistics

Total attendance—3,713

Nations represented—31

Exhibitors—238

Total booths—477

Symposium Offerings

8 Short courses 12 Lectures

6 Tutorials 17 Discussions

7 Case studies

Exhibit Hours

Tuesday, October 5

Noon – 2 p.m. (private for paid symposium

attendees and exhibit staff only)

3:30 – 7 p.m. (free to the public)

Wednesday, October 6

Noon – 2 p.m. (private for paid symposium

attendees and exhibit staff only)

3:30 – 7 p.m. (free to the public)

Thursday, October 7

9:30 a.m. – noon (free to the public)

39th Annual Turbomachinery Symposium and Exhibit Show

October 4 – 7George R. Brown Convention Center, Houston, Texas


❖ Same Day Deliveries

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❖ Full Technical Submittals

❖ “Wobble Stator” Pump &Parts are also in stock

Our large inventory of spare parts is available and ready for immediatedelivery at Liberty Process Equipment,Inc. Our complete selection includesthe most common progressive cavitypump design models, sizes andmaterials in service in the USA. The genuine quality replacementparts meet or exceed the performance standards.

Call, fax or contact us online to order your pump parts or service.

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Liberty ProcessEquipment, Inc.2525 S. Clearbrook DriveArlington Heights, Illinois 60005-4623Phone: 847-640-PUMP (7867) • Fax: 847-640-7855E-mail: [email protected] site: www.libertyprocess.com


Fuji Pump AC Drive, “Eco” seriesFuji Pump introduces its FREMIC-ECO series drives. Ultimately designed for HVAC applications, the FRENIC-Eco series drives off er simple installation and quick start-up solutions for virtually all variable torque applications. FRENIC-Eco series off ers a wide power range—from 1 to 900 horsepower—and many advanced features—such as full PID control function, enhanced energy saving mode, cascade pump control, and many communication options with a three-year standard warranty. Circle 201 or go to psfreeinfo.com

Quick Motor Change-Outs Meltric Corporation introduces its UL switch rated plugs and recepta-cles. h ey allow mechan-ics to quickly connect/disconnect pump motors. Safety features protect from electrical hazards and enable easy

LOTO. NEC/NFPA 70E compliance is simplifi ed. Rated up to 200A, 60 horsepower, NEMA 4X. Available in a wide variety of mounting confi gurations. Circle 202 or go to psfreeinfo.com

XRS Split Cartridge SealSEPCO intro-duces a split cartridge seal that assembles with four easy halves. h e sealing faces are secured in the cartridge halves, and the springs are isolated from the product. h e XRS is designed as an internal, hydraulically-balanced stationary design seal, mounted outside the stuff -ing box while having the ability to handle higher speeds, internal pressures and 0.065 inches TIR. h e XRS split cartridge seal is fully assembled and pressure tested ensuring sealing integrity and is also easy to install and reliable.Circle 200 or go to psfreeinfo.com

P&S

Product Pipeline


4-20 mA vibration monitoring

Continuous monitoring of critical

assets and balance of plant

4-20 mA data is a standard input

for a PLC, DCS or SCADA system

Ideal for real-time monitoring,

alarming and simplified analysis

Makes distributed condition

monitoring cost effective and scalable

Wilcoxon Research Inc20511 Seneca Meadows Parkway

Germantown, MD 20876USA

Tel: 301 330 8811Fax: 301 330 8873

"Email: wilcoxon<iaccepp.com

www.wilcoxon.comwww.meggitt.com


INDEX OF ADVERTISERS

Advertiser Name R.S. # Page Advertiser Name R.S. # Page

ABS USA 101 45

Advance Diamond Technologies, Inc. 143 66

Advanced Engineered Pump, Inc. 151 69

Advanced Sealing International 132 60

Alignment Supplies, Inc. 142 68

All Prime Pumps 152 70

Amtech Drives 111 62

ATC Diversii ed Electronics 112 35

Aurora Motors 153 71

Benton Foundry, Inc. 102 11

Blacoh Fluid Control, Inc. 133 37

Blue-White Industries 114 13

Boerger, LLC 115 59

Carver Pump Company 116 26

Crane Pumps & Systems 118 27

Dan Bolen & Associates, LLC 154 69

Decatur Foundry, Inc. 119 49

Depco Pump Co. 113 64

EagleBurgmann 103 IBC

EFFORT FOUNDRY, Inc. 134 53

Electro Static Technology 120 38

Emerson Industrial Automation 135 55

The Full o Specialties Co. 141 61

Frost & Sullivan 144 69

Garlock Sealing Technologies 104 3

Graco, Inc. 136 67

Graphite Metallizing Corp. 145 56

Griffco 117 44

Helwig Carbon Products, Inc. 172 67

Hydraulic Institute 146 68

Hydro, Inc. 100 IFC

Inpro/Seal 105 BC

ITT Goulds Pumps 137 41

ITT Water & Wastewater USA, Inc. 106 23

Junty Industries, Ltd. 155 70

Larox Flowsys Inc. 107 39

LEWA Inc. 121 20

Liberty Process Equipment, Inc. 148 65

Liestritz Corp. 122 48

Load Controls, Inc. 123 43

LUDECA Inc. 138 30

Meltric Corporation 156 69

MSE of Canda Ltd. 157 71

NOC 170 68

NSK 108 5

Palmetto Inc. 147 65

PPC Mechanical Seals 124 8

Precise Castings, Inc. 158 71

Pump Solutions Group 139 47

Pumping Machinery 169 68

Racine Federated Inc. 125 42

REVAK 109 9

Salem Republic Rubber Co. 149 56

SCHENCK 126 33

SERO Pump Systems 159 70

Sims Pump Co. 127 17

Sims Pump Co. 127 70

SJE-Rhombus 140 34

Skinner Power Systems, LLC 128 12

Summit Pump, Inc. 161 71

Tamer Industries 162 71

Trachte, USA 163 71

Trask-Decrow 164 70

Tuf-Lok International 165 71

Valve & Filter Corp. 129 24

Vaughan 110 31

VERSA-MATIC 130 7

VERTIFLO 166 71

Vesco 167 69

Westerberg and Associates 168 70

Wilcoxon Research, Inc. 150 66

Wilden 131 21

Wood Group Surface Pumps 171 68

* Ad index is furnished as a courtesy and no responsibility is assumed for incorrect information.

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www.gracosaniforce.com

1.877.844.7226

Need to transfer 500,000 cps materials?

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• One size follower and seal to accommodate straight-sided and tapered drums


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EVERYTHING YOU EVER WANTED TO KNOW ABOUT PUMPS

For more information go to

www.PumpingMachinery.com770-310-0866


HIGH PRESSURE PUMPING SOLUTIONS

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It is illegal to duplicate this CD. Copyright © 1997-2010 Hydraulic Institu

te, In

c. 00

6011

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ANSI/HIPump Standardsp

Version 2.2

The Very Latest ANSI/HI Standards Update:

CD-ROM Version 2.2—All 29 Standards on one CD-ROM

It’s here! And ready for inclusion in your ANSI/HI Standards Library.

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on a single CD-ROM. Convenient to use, store and transport.

Exceptionally cost-effective! Just some of the important features:

✔ Includes recent Standard updates:

■ ANSI/HI 1.1-1.2 Centrifugal Pumps – Nomenclature & Definitions

■ ANSI/HI 9.6.4 Rotodynamic Pumps – Vibration Measurements & Allowable Values

■ ANSI/HI 9.6.5 Rotodynamic Pumps – Condition Monitoring

■ ANSI/HI 9.6.6 Rotodynamic Pumps – Piping Standard NEW!

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The Source for Pump Expertise

The Pumps & Systems editors have carefully

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guidelines, manuals, standards and technical

materials related to the pump and rotating

equipment industry in our online bookstore,

www.PumpBooks.com.

The Source for Pump Expertise

P U M P U S E R S M A R K E T P L A C E


Get a jump on the next issue of Pumps & Systems when you sign up for

Pump Digest, our e-mail newsletter.

Go to www.pump-zone.com to sign up.


Comprehensive Industry Coverage:

Positive Displacement Pumps

Centrifugal Pumps

Specialty & Other Pumps

Industrial Valves

Pneumatic & Hydraulic Valves

Custom Research

White Papers

Frost & Sullivan, the Growth Consulting Company, partners with clients to accelerate their growth. The company's

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For informaピ on:

(800) 803-0353

www.allprimepumps.com

All Prime self-priming centrifugal pumps are marketed in the

United States, Canada & Mexico exclusively by the All Prime

Division of Power & Pumps Inc., Jacksonville Florida. Based

on the design of Gorman-Rupp’s T SERIES® & U SERIES®,

these pumps are available as bare pumps, parts, base

mounted and assembled fi berglass lift station units.

Materials of construction available include Cast-Iron, CD4MCu,

316-SS, 304-SS, ADI, Hastelloy & High-Chrome.

T SERIES® & U SERIES® are trademarks and registered trademarks of The Gorman-Rupp Co. in the

US & other countries. All Prime is not sponsored by nor affi liated with The Gorman-Rupp Company.



“Doc’s PumpJournal”

734 pages of “Great Pump Information” Page after page of helpful material like

Friction loss tables for Plastic s/40, s/80,s/160,s/200, JM*C900 & C905,

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Corrugated suction hose,

smooth bore hose.

Fall Special ONLY $5995*

This is a great buy for any

pump industry professional.

Westerberg & AssociatesP.O. Box 567 Liberty Lake, WA 99019

email: [email protected]

*Postage Rates as follows:+$5.00 postage & handling in the USA.+$10.00 postage & handling for Canada.+$20.00 postage & handling in South America, Africa and Europe. ISBN# 978-0-9778312-2-1


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Your Best Value in ANSI Centrifugal Pumps

Model 2196

Green Bay, WIwww.SUMMITPUMP.com

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P&S Stats and Interesting Facts


P&S Stats and Interesting Facts

1100

1200

1300

1400

1500

1600

1700

1800

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

-0.30%

-0.20%

-0.10%

0.00%

0.10%

0.20%

0.30%

0.40%

0.50%

0.60%

Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10

Pump and Pumping Equipment Manufacturing

Air and Gas Compresor Manufacturing

Pump and Compressor Manufacturing

65.00%

70.00%

75.00%

80.00%

85.00%

90.00%

Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10

Chemical

Food, Beverage and Tobacco

Petroleum and Coal Products

Mining

Paper

$1.50

$1.70

$1.90

$2.10

$2.30

$2.50

$2.70

$2.90

$3.10

$3.30

Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10

Average Price of Gasoline

Average Price of Diesel Fuel

Rig Count (U.S.): Jan. 7 – Sept. 10, 2010

Nu

mb

er

of

Rig

s R

un

nin

g

Week

Month-to-Month Percentage Price Change

in Pumps and Compressors

Plant Capacity Utilization by Industry

Average Fuel Prices (U.S.)

Source: Baker-Hughes Inc.

Source: Federal Reserve Statistical Release

Source: Energy Information Administration

h e Producer Price Index program of the U.S. Department of Labor measures the average change over time in the selling prices received by domestic producers for their output. h ese charts detail the month-to-month percentage change in selling prices. Source: U.S. Department of Labor

By comparing run time to fl ow data a

technician determines that a pump needs

to be pulled for maintenance, thus avoiding

excessive energy consumption. Photo

credit: ITT Water & Wastewater USA Inc.

Bigger doesn’t necessarily mean better. You may think we’re small, but EagleBurgmann

has been producing products of uncompromising quality, durability and reliability for more than

120 years. We’ve got the engineering expertise and the know-how to meet your toughest sealing

challenge, no matter what the size. Our 5,200 employees worldwide remain strong in their

customer commitment to ensure you can always rely on EagleBurgmann for your seal and service

needs. To find out more, visit www.EagleBurgmannSeals.com or 1-800-303-7735.

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THE ORIGINAL BEARING ISOLATORSTRONGER THAN EVER

www.inpro-seal.com

As part of Waukesha Bearings and Dover Corporation, Inpro/Seal is

stronger than ever…with the horsepower to deliver our high-performing solutions

and superior customer service around the globe. Industry-leading bearing protection,

unmatched experience and same-day shipments – only with Inpro/Seal.

So don’t lay awake at night…trust Inpro/Seal to design and deliver your custom-engineered

bearing isolator, right when you need it; our installed base of over 4,000,000 speaks for itself.

Trust Inpro/Seal, the clear leader in bearing isolators.

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9 Pumps and Systems - October 2010

Documents

cahaba media

wireless conversion

onset computer

created equalpatrick

inch discharge

wireless pumpshany

paid symposium

flow metersevan