pm6782

The Magazine for Pump Users Worldwide February 2012

pump-zone.com

The

AftermarketR P R

The

AftermarketR P R

Also Inside:

Pumps & Seals for Harsh Conditions

Centrifugal Pump Effi ciency

Repair Standards for Vertical Pumps

Also Inside:


Centrifugal Pump Effi ciency


The Magazine for Pump Users Worldwide

pump-zone.com

February 2012

Hydro, Inc. l Chicago, IL

Headquarters

800.223.7867

www.hydroinc.com

HydroAire, Inc. Chicago, IL

800.223.7867

40th Street Facility

Hydro Performance Test Lab

Madison Street Facility

Hydro South, Inc.

Atlanta, GA

770.475.3393

HydroTex Dynamics, Inc.

Houston, TX

713.937.9001

HydroTex Golden

Triangle, Inc.

Beaumont, TX

409.842.3619

HydroTex Deer Park, Inc.

Deer Park, TX

713.937.9141

U.S. Service Centers

Repair is an Opportunityfor Improvement

Evans Hydro, Inc.

Los Angeles, CA

310.608.5801

Hydro East, Inc.

Philadelphia, PA

610.497.7867

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Hydraulic Modifications

Hydro's engineers analyze pump hydraulic performance and tailor new designs to meet

current requirements within a much shorter time period than previous methods allowed.

Repair is an Opportunityfor Improvement

CW Hydro, Inc.

Incheon Metropolitan, Korea

82.32.561.0971

Hydro Australia, Pty. Ltd.

Morwell, Australia

61.3.5165.0390

Hydro Vietnam, Co. Ltd.

Ho Chi Minh City, Vietnam

84.9.141.9914

Hydro Scotford, Inc.

Edmonton, AB Canada

780.992.0100

Safe-T Hydro, Inc.

Port Coquitlam, BC Canada

604.941.1116

Hydro Middle East, Inc.

Dubai, United Arab Emirates

Saudi Arabia

971.50.5547129

International Service Centers

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Mechanical Upgrades

Our engineers review pump design, check the existing geometry and make recommendations to change any of the variables which can affect your pump’s strength and ability to meet performance requirements.

Material Upgrades

Hydro’s engineering team will evaluate the metallurgy of your pump components and recommend upgrades specific to your application which often translates into improved efficiency, reduced energy costs and enhanced reliability.

Performance Testing

Testing can be an important verification tool for not only ensuring proper performance

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rebuilt. With the ability to configure hundreds of different suction and discharge

configurations, our state-of-the-art 5000HP Test Lab was built to meet the needs

of pump users across the globe.

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circle 100 on card or go to psfreeinfo.com

2 FEBRUARY 2012 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 subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call (630) 739-0900 inside or outside the U.S. POSTMASTER: Send changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. ©2012 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:

Thanks for all the kind; productive; and in some cases, critical feedback about our January 2012 feature, “h e History

of Pumps.” We knew our readers would come through with additional information on the rich history of this great industry, and you did not disappoint us. As promised, we are incorporat-ing all the relevant, new information on the complete timeline on www.pump-zone.com. Some of these additional highlights (and a few interesting historical images) can be found on Page 6.

In a way, Pumps & Systems is also making history. We feel confi dent that our online “h rough the Years” account is the ultimate and most comprehensive record of the history of pumps! With your help, we will continue to update it.

Many of you sent glorious historical photos that we did not have the space to include in the print edition. We are creating an online slide-show of “Reader Favorites” and welcome your contributions. If you have a historical photo, please send it to me with a detailed description.

h is provides the perfect opportunity to invite you to explore our freshly redesigned web-site. In addition to the world’s largest collection of pump-related technical articles and case stud-ies, it now off ers automatic twitter feeds, a more easily searchable manufacturers directory, inter-esting web-exclusive slideshows, in-depth White

Papers and daily pump industry news updates. If you crave more news, subscribe to one or

both of our monthly e-newsletters. Pump Users Digest delivers news about the industry, people and products, web-exclusive articles and some of the most interesting social media conversations.

Pump Industry Insider is the only industry resource that pulls together the latest news about M&A activity, contracts and orders, new proj-ects for bid, industry buzz and also off ers exclu-sive insight into the pump market with analysis from Jordan, Knauff & Company.

In this issue of Pumps & Systems, check out our cover series on h e Aftermarket (Page 34), which includes articles about pump replace-ment part availability, inspection and repair, replacement part options and genuine parts and replacement kits.

h is month also features a special section on Pumps and Seals for Harsh Conditions (Page 18). h is section includes the fi rst of a six-part series on dry gas seal selection, a case study on pumps exposed to extreme altitudes and an arti-cle which details the benefi ts of coating specifi -

cation sheets.

Best Regards,

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

CONTRIBUTING EDITORS

Laurel DonohoJoe Evans, Ph.D.Terry Henshaw

Dr. Lev Nelik, PE, APICS

SENIOR ART DIRECTOR

Greg Ragsdale

ART DIRECTOR

Terri Jackson

PRODUCTION MANAGER

Lisa [email protected] • 205-212-9402

CIRCULATION & MARKETING

MANAGER

Jaime [email protected]

CIRCULATION

Jeff [email protected] • 630-739-0900

WEB EDITOR

Jane [email protected]

ACCOUNT EXECUTIVES

Derrell [email protected] • 205-345-0784

Mary-Kathryn [email protected] • 205-345-6036

Mark [email protected] • 205-345-6414

Addison [email protected] • 205-561-2603

Vince [email protected] • 205-561-2601

ADMINISTRATIVE ASSISTANT

Ashley [email protected] • 205-561-2600

EDITORIAL INTERNS

Grace McNair Jeremy Salter

Courtney Woods

A Publication of

P.O. Box 530067Birmingham, AL 35253

Editorial & Production1900 28th Avenue South, Suite 110

Birmingham, AL 35209Phone: 205-212-9402

Advertising Sales2126 McFarland Blvd. East,. Suite A

Tuscaloosa, AL 35404Phone: 205-345-0477 or 205-561-2600

Editorial Advisory Board Thomas L. Angle, PE, Vice President Engineering,

Hidrostal AG

Robert K. Asdal, Executive Director, Hydraulic Institute

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

Kerry Baskins, Vice President of Sales, Viking Pump

Walter Bonnett, Vice President Global Marketing, Pump Solutions Group

R. Thomas Brown III, President, Advanced Sealing International (ASI)

Chris Caldwell, Director of Advanced Collection Technology, ABS, & President, SWPA

John Carter, President, Warren Rupp, Inc.

Jack Creamer, Market Segment Manager, Schneider Electric

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

Joe Evans, Customer & Employee Education, PumpTech, Inc.

Ralph P. Gabriel, Chief Engineer—Global, John Crane

John Malinowski, Sr. Product Manager, AC Motors, Baldor Electric Company, A Member of the ABB Group

William E. Neis, PE, President, NorthEast Industrial Sales

Dr. Lev Nelik, PE, Apics, President, Pumping Machinery, LLC

Henry Peck, President, Geiger Pumps & Equipment/Smith-Koch, Inc.

Mike Pemberton, Manager, ITT Performance Services

Bruce Stratton, Product Manager, KLOZURE®, Garlock Sealing Technologies

Kirk Wilson, Vice President/General Manager, Integrated Solutions Group, & Vice President Marketing, Engineering & Technology, Flowserve Corporation

In the tradition of groundbreaking innovations comes…

Flygt Experior™

Welcome to a new era in wastewater pumping. Where engineering excellence and

a pioneering spirit combine with an unmatched understanding of your needs. The

result is Flygt Experior, a uniquely holistic experience that combines state-of-the-art

hydraulics, motors, and controls.

Today, Flygt Experior combines N-technology hydraulics and its adaptive functionality,

premium efficiency motors and SmartRun – the all-new intelligent control. Flygt Experior

comes from years of listening to you and applying our knowledge and expertise, to

develop the most reliable and energy-efficient wastewater pumping. It is therefore the

ultimate in our commitment to you.

Flygt Experior™. Inspired by you. Engineered by us.

flygt.com/FlygtExperior

Flygt is a brand of Xylem, whose 12,000 employees are dedicated to addressing the most complex issues in the global water market. Let’s solve water.



SPECIAL SECTION: PUMPS & SEALS FOR HARSH CONDITIONS

p Dry Gas Seal RequirementsGlenn Schmidt, EagleBurgmann

Find a reliable dry gas seal system for any application.

p High-Altitude Condensate PumpingKamran Mirza, seepex Inc.

A progressive cavity pump provides an ideal solution to a diffi cult pumping application.

p Choose the Right CoatingIvan Ordaz, Belzona

Understand coating manufacturers’ specifi cation sheets.

COVER SERIES: THE AFTERMARKET

p Pump Replacement Part Availability

Jeff Smith, Standard AlloysAddress this problem to avoid the possibility of future crises.

p Inspections and Repair Enhance Pump Performance

Bob Bluse, Hydro, Inc.Improvement can result from repair opportunities.

p Specialty Replacement PartsSally Huynh, NOV Monofl o

When stator wear was an issue, a custom-made replacement part was the solution.

p The Value of Industrial Pump Genuine Parts and Repair Kits

Christine Gfrer, IDEX CorporationMany options are available when pump repair is required.

Table of Contents

DEPARTMENTS

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

P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Joe Evans, Ph.D.Centrifugal Pump Effi ciency—What Is Effi ciency?

Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 16Lev Nelik, Contributing Editor, P&S Editorial Advisory BoardRepair Standard for Vertical Pumps

Maintenance Minders. . . . . . . . . . . . . . . . . . . . . . . . . 50Peter Carlisle, John CraneSmooth Equipment Operation

Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54F. Scott Jackson, BlackmerThe DEF Market

FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 60Why don’t my PTFE gaskets seal FRP, plastic and other light load fl anges?

HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 What guidelines should be followed regarding pump selection based on good wear resistance? Besides the obvious fi nancial benefi ts derived from energy savings, what are the other important economic benefi ts of pump systems optimization that affect the total cost of ownership? What different types of couplings can be used on pumps, and what is are their functions?

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

Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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

P&S Market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

February 2012

Volume 20 • Number 2

The Magazine for Pump Users Worldwide February 2012

pump-zone.com

The

AftermarketR P R

The

AftermarketR P R

Also Inside:


Centrifugal Pump Efficiency


Also Inside:


Centrifugal Pump Efficiency


The Magazine for Pump Users Worldwide

pump-zone.com

February 2012

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Editors Note: In the January 2012 issue of Pumps & Systems, we were proud to bring you an in-depth look at some of the highlights of ground-breaking achievements in pump technology through the years. We suspected that our readers would come through with some information that we did not have. We are happy to give you some of the additional information provided by our readers on the greatest moments in pump history. For the complete version of this feature, continuous updates from our readers and entertain-ing slideshows on the subject, please visit www.pump-zone.com.

In the “Letter from the Editor” in the January 2012 issue, we referred to leather pump seals. A friend of the industry, Inpro/Seal principal Dave Orlowski, let us know that the seals were most likely bearing housing seals and not liquid end seals and produced by the Chicago Rawhide Company. (Now CR Industries, a division of SKF).

h e following are a few interesting additions to our “History of Pumps” timeline:

1874 Charles Barnes of New Brunswick invents the vane pump.

1899 Robert Blackmer invents rotary vane pump tech-nology, a pump design that was an important depar-

ture from the old gear principle and predecessor to today’s sliding vane pumps.

1900 Siemens fi les the fi rst German patent for liquid ring vacuum pumps and compressors.

1908 Hayward Tyler creates its fi rst electric motor for use under water and develops the wet stator motor

for use as a boiler circulation glandless motor-pump.

1910 Lewis H. Nash fi les the fi rst U.S. patent for liquid ring vacuum pumps and compressors.

1923 Ruthman Companies designs the world’s fi rst seal-less vertical pump.

1937-1939 Smith Precision Products Company (Smith Pumps) designs three pumps, two

of which (models 300 and 200) were specifi cally designed for LP-gas transfer.

1939 Smith Pumps develops the fi rst liquei ed gas trans-fer pump for LP-gas.

1940 Reuben Smith, of Smith Precision Products Company (Smith Pumps), receives the fi rst

approval for an LP-gas pump from the California Industrial Accident Commission. h is was for the model 4X pump and the approval was a “suitable for use” certifi cate.

1948 Smith Precision Products Company receives the patent for the fi rst mechanical seal supplied for

liquei ed gas transfer pumps (production in 1947).

1950Vanton develops the Flex-I-Liner® sealless self-prim-ing rotary pump which handles corrosive, abrasive

and viscous fl uids as well as those that must be transferred free of product contamination.

1954 Smith Precision Products Company (Smith Pumps) begins work with the Underwriters

Laboratories to develop their fi rst standard for liquefi ed gas pumps, UL-51, which is still in use today.

1954 World’s fi rst atomic-powered submarine is equipped with Ingersoll-Rand boiler-feed pumps and

compressors.

1960 Development of GIW trademark GASITE hard iron for longer wearing pumps and parts.

1960 GIW vice president and inventor, Danforth Hagler, invents the Hydraulic Slide Rule.

1965 Warren Rupp’s heavy-duty, diverse AODD pump is introduced to the industrial market to address the

vigorous demands of the steel mills.

1971 Gusher develops a purge hole system to enable pumps to handle 30-40 percent entrained air.

MORE PUMP

HISTORYThe fi rst pump designed specifi -cally for LP-gas, (the model 300; which was fi rst sold in 1939).

This is an under-ground installation using a Parkhill-Wade dispenser in Los Angeles, 1940. Photo courtesy of Smith Precision Products Company (Smith Pumps)

Nash Hytor #1 being loaded on a train for shipment, c. 1929. Photo courtesy of Gardner Denver Nash

PUMPS & SYSTEMS www.pump-zone.com FEBRUARY 2012 7

1979 Gusher develops multistage pumps for higher pressures required by the machine tool industry and

designs the fi rst top pull-out pump.

1980sGIW develops wear modeling technology for predicting pump performance.

1985 Sims manufactures the fi rst structural composite pump, the Simsite Vertical Pit Pump, for which it

won the Innovative Product Award in 1990.

1990s GIW develops a hard metal slurry pump for hydraulic transport of oil sands tailings.

1994 Sims receives the U.S. Navy’s honor of approval for composite centrifugal pump intervals.

1995 Sims manufactures the largest structural composite pumps in the world—two Simsite vertical turbine

pumps for Potomac Electric Power Company.

2000s GIW introduces computer designed LCC rubber-lined pump to the market.

2000s GIW develops an innovative slurry diverter to improve wear.

2002 Siemens (Elmo Division, liquid ring pumps) merges with Nash.

2002 Sims introduces the fi rst structural composite verti-cal in-line pumps.

2006 Sims manufactures the largest structural composite centrifugal impeller, installed in a cooling tower

pump for Puerto Rican Electrical Power Company.

Readers Respond to

“The History of Pumps”I really enjoyed your article on the history of pumps. I am

sure a lot of research had to go into that. I was also surprised to learn how much the Italians contributed to pumps in the early years. I knew we were good for something! Great article!

Rich Greatti, Mechanical/Industrial Engineer Knoxville, Tenn.

We have been receiving your magazine, Pumps & Systems, for a good number of years, although we are not an advertiser. We recently received your January 2012 issue and the segment “h e History of Pumps” caught my eye. My company shares a very long history in the pump industry and my family’s roots go very deep. I found the history very fascinating, and give your magazine a big thumbs up for the research required to put this together. I know this is not an easy task.

Walter W. Smith, PresidentSmith Precision Products Company (Smith Pumps)

I always look forward to the new issue of P&S. h e Jan. 2012 issue is unique not only for the usual informative and interesting articles but for all the good information of the World Pump History. Congratulations! h is issue is a keeper. I always recommend P&S to my friends and clients in the chemi-cal process industry. h is issue is a fi ne example of the high quality of your magazine. What a way to start the year!

Keep up the good work,Jose M. Sentmanat, ConsultantLiquid Filtration Specialist, LLC, Conroe, Texas

In 1965 the AODD was introduced to the industrial market. It wasn’t until this time when Mr. Warren Rupp’s con-cepts of having a heavy duty diverse AODD pump to better address the vigorous demands of the steel mills and the indus-trial markets applications lead the way to industrial distribution.

Never to be forgotten! Mike Weed, Application EngineeringWarren Rupp, Inc., Units of IDEX Corporation

I always look forward to receiving my copy of Pumps & Systems. h e January 2012 edition was of particular interest with the inclusion of the “History of Pumps” article. Having been in the pump design business for more than 40 years, it was very interesting reading.

For over 50 years, our company has manufactured a vari-ety of fuel transfer pumps with the majority being positive dis-placement vane pumps. I have taught many courses within the company on vane pump technology over the years and have always presented Charles Barnes of New Brunswick as the inventor of the vane pump, citing his patent issued in June of 1874. I was surprised that your list credits Robert Blackmer with that achievement in 1899.

I can’t remember where I got my information about Barnes, but Wikipedia lists Barnes as the inventor also citing the fol-lowing reference: Marlo h eriault, Great Maritime Inventions 1833-1950, Goose Lane Editions, 2001, p. 53.

h anks for all of the great articles each month and all of the work that goes into them.

Tim Hoehn, Sr. Mechanical Engineer,Tuthill Transfer Systems

Pumps & Systems Editor Michelle Segrest responds:h e reference to Blackmer inventing vane pump technol-

ogy was a mistake that I made. Blackmer had sent me the cor-rect information. It should have read that Blackmer invented rotary vane pump technology. I have corrected this on our website version and added the 1874 item citing Charles Barnes and the inventor of the vane pump. h ank you very much for bringing this to my attention. h is was a huge undertaking and I want to get it right!

Please check www.pump-zone.com often for continuous updates on “h e History of Pumps.”

Nash Engineering exhibits at the 1922 Chem Show at Grand Central Palace. Photo courtesy of Gardner Denver Nash


P&S News

NEW HIRES, PROMOTIONS &

RECOGNITIONS

EAGLEBURGMANN (HOUSTON, TEXAS) announced that Paul van Wyk is the new head of the Americas Region. He joined EagleBurgmann South Africa in 1997.

EagleBurgmann is a sealing technology provider. www.eagleburgmann.com

MEGGITT SENSING SYSTEMS (SAN JUAN CAPISTRANO,

CALIF.), a Meggitt group division, announced the promotion of Sharon Nelson to vice president, Contract Management.In this role, Nelson is responsible for the overall management of a newly established, fully dedicated contract management function, to include customers, partners and supplier rela-tionships across all development sites of Meggitt Sensing Sys-tems. Also, Meggitt announced that it now off ers a lifetime warranty on its products that serve a range of applications.

Meggitt Sensing Systems, is a supplier of sensing and monitoring systems for physical parameter measurements in extreme environments. www.meggitt.com

OPW FLUID TRANSFER GROUP (MASON, OHIO) announced that it has named Ross Pliska vice president of its transportation business unit. Pliska assumed his new responsibilities January 1, 2012, and will report directly to OPWFTG president, Tim Warning.

OPW Fluid Transfer Group, organized in 1998, is part of Dover Corporation and is comprised of two business units: OPWFTG Global Transportation Business Unit and OPWFTG Global Chemical & Industrial Business Unit. www.opwftg.com.

THE WATER ENVIRONMENT FEDERATION (ALEXANDRIA,

VA.) awarded seepex the Innovative Technology Award. h e Innovative Technology Awards are presented annu-ally to WEF associate members who have introduced new, innovative products or services related to the construction, operation, or maintenance of treatment facilities. seepex was recognized in the solids handling & disposal category for its Smart Conveying Technology.

WEF is a not-for-profi t technical and educational orga-nization that works to preserve and enhance the global water environment. www.wef.org

AESSEAL (MILLCLOSE, ROTHERHAM, U.K.) was named the International Trade Company of the Year in a ceremony at the House of Lords. h is follows being named as the overall winner at the 2010/2011 International Trade Awards, which honored the U.K.’s leading exporters. AESSEAL manufac-tures mechanical seals. www.aesseal.co.uk

MOTION INDUSTRIES, INC., (BIRMINGHAM, ALA.) recog-nized 62 of its key suppliers as participants in its Operational Excellence Supplier Partnership program at the North Amer-ican 2011 meeting in Atlanta, Ga. Suppliers were recognized for making signifi cant contributions in the area of supply chain integration and process improvement. h is program has spanned seven years and has resulted in more than 1,000 individual implementations to improve supply chain effi -ciency. Suppliers achieving the highest level of improvement for 2011 are Climax Metal, ITW Devcon, General Bearings and RBC Bearings.

Motion Industries is a wholly-owned subsidiary of Genuine Parts Company and is a distributor of industrial maintenance, repair and operation (MRO) replacement parts. www.motionindustries.com

SIEMEN’S INDUSTRY (ATLANTA, GA.) was recognized by the city of West Chicago, Ill., with its Brilliance in Business “Green Initiatives” award during a ceremony at city hall. h e Brilliance in Business program features six categories, includ-ing green initiatives, economic development, outstanding not-for-profi t, community service, community image and small business of the year. Siemens invested approximately $10 million upgrading two buildings at the location. Siemens West Chicago manufacturing facilities comprises 200,000 square-feet in two buildings.

Siemens Industry is a supplier of products, solutions and services for industrial customers. www.usa.siemens.com

PURALYTICS (BEAVERTON, ORE.) announced that it was named in the prestigious 2011 Global Cleantech 100, pro-duced by Cleantech Group, a leading research fi rm focused on global clean technology innovation. Puralytics is a water purifi cation equipment company. www.puralytics.com

AROUND THE INDUSTRY

DRESSER-RAND GROUP INC. (HOUSTON,TEXAS) announced that it closed the previously announced acquisi-tion of Synchrony, Inc., for approximately $50 million net of cash acquired. Synchrony is a technology development company with a portfolio of technologies and products for clean, effi cient and reliable rotating machinery.

Dresser-Rand is a supplier of rotating equipment to the oil, gas, petrochemical and process industries. www.dresser-rand.com

GODWIN PUMPS OF AMERICA, INC., (BRIDGEPORT, N.J.), eff ective January 1, 2012, changed its name to Xylem Dewa-tering Solutions, Inc. Also, the company announced a dona-tion to the National Coalition Against Domestic Violence (NCADV). NCADV works to eliminate domestic violence, empower battered adults and children, promote and unify direct service programs, alert and educate the public and pro-

Paul van Wyk


mote partnerships.Godwin is

a direct, wholly-owned subsidiary of Xylem, Inc. Godwin maintains a fl eet of more than 6,000 portable rental pumps and 3,200 pieces of related equipment for dewatering in construction, mining and quarrying; in drinking water supply; and in wastewater bypasses in municipal, indus-trial and environmental markets. www.godwinpumps.com

THE ENVIRONMENTAL PROTECTION AGENCY—EPA—

(WASHINGTON, D.C.) marked 25 years since the passage of the federal Emergency Planning and Community Right-to-Know Act (EPCRA). h e act was passed in 1986 as a part of the reau-thorization for Superfund. EPCRA has played a signifi cant role in protecting people’s health and the environment by providing communities and emergency planners with area-specifi c infor-mation on toxic chemical releases. h e EPA issued the Mercury and Air Toxics Standards, the fi rst national standards to protect American families from power plant emissions of mercury and toxic air pollution—such as arsenic, acid gas, nickel, selenium and cyanide. h e standards will slash emissions of these pollut-

ants by relying on widely available, proven pollution controls that are already in use at more than half of the nation’s coal-fi red power plants.

h e EPA protects human health and safeguards the natural environment—air, water and land. www.epa.gov

SINCLAIR GROUP (THE WOODLANDS, TEXAS) and Allied Reliability Group—a global maintenance and reliability con-sulting, services and training company—have formed a strategic partnership to support clients’ needs for sustainable operating performance improvements. h e partnership is the result of a need for integrated solutions in operational and organizational best practices, work processes, operating procedures and tools.

Sinclair Group is a global operations management consul-tancy. www.sinclairgroup.com

DAMALINI AB/EASY-LASER (GOTEBORG, SWEDEN) announced that Cascade Machinery Vibration Solutions of Houston, Texas, will become the authorized U.S. distributor for Easy-Laser products. Damalini AB develops, manufactures and markets Easy-Laser measurement and alignment solutions. www.damalini.se

ITT GOULDS PUMPS (SENECA FALLS, N.Y.), in celebration of the new changes company-wide, has launched a fun way to

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“To get the best yields from the vineyard it is extremely important to get

all the water allowed to us. Without automated controls there were times

when our pumps wouldn’t run fast enough or would even run dry.”

“The Ranch Systems monitor with FW Murphy’s EMS PRO controller helps

us maintain engine and pump up-time by instantly notifying us of engine

performance and potential breakdowns. The new control system can stop

and start the engine, vary the speed and smooth out the peaks and valleys

of water levels in the canal.”

“Thanks to the remote monitoring capabilities, we can check the water

level and monitor engine performance all through a cell phone. I no longer

have to start and end my day at the pump site, which saves valuable time

and increases the up-time of our sites.”

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Ranch Systems www.ranchsystems.com

Murphy has introduced it’s new EMS PRO Lite controller -

perfect for irrigation and dewatering applications.

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1110918



P&S News

show how much pump users know about the world of pumps and to celebrate pumps as the “heart of industry.”

Every other week through April 1, 2012, pump users have a chance to answer a question about industrial pump applica-tions around the world. For each question answered correctly, ITT Goulds will make a donation to support International CPR and First Aid Training.

1. Visit www.gouldspumps.com.2. Answer the current question correctly and a donation

will be sent to the global Emergency Cardiovascular Care (ECC) Program of the American Heart Association. Donations will be made on April 10, 2012, during Pump Appreciation Day.

3. Watch e-mail for the next question and another opportu-nity to help keep the world pumping.

ITT Corporation is an engineering and manufacturing company operating in three markets: water and fl uids man-agement, global defense and security and motion and fl ow control. www.itt.com

BENTLEY SYSTEMS, INC., (AMSTER-

DAM, NETHERLANDS) announced the acquisition of FormSys, based in Perth, Australia. h is software development company has a 20-year track record in 3D design, analysis and construction software for structural engineering, off -shore engineering and naval architec-ture. h e acquisition will expand Bent-ley’s SACS off erings for the design and analysis of fl oating structures, further extending the company’s reach in the off shore energy market. Bentley is dedi-cated to providing architects, engineers, geospatial professionals, constructors and owner-operators with comprehen-sive software solutions for sustaining infrastructure. www.bentley.com

GE (LEWISTOWN, PA.) is investing more than $10 million to expand its Inspection Technologies headquarters site in Lewistown, Pa. Key features of the project include a new global cus-tomer applications center and a nonde-structive testing(NDT) academy. h is 52,000-square-foot expansion project will increase the facility’s fl oor space by more than 63 percent and is scheduled to be completedin 2012. GE is a tech-nology, services and fi nance company www.ge.com.

P&S

To have a news item considered for ‘P&S News,’ please send information to Lori Ditoro at Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253, 205-314-8269, [email protected].

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TURBOMACHINERY LABORATORY CONTINUING EDUCATION SHORT COURSESMarch 6 – 9Hilton Westchase HotelHouston, Texas979-845-7417www.turbolabtamu.edu/articles/short_courses

WQA AQUATECH USAMarch 6 – 9Las Vegas Convention CenterLas Vegas, Nev.630-505-0160www.wqa.org

PUMPS AND MOTORSApril 10 – 12University of Wisconsin Pyle CenterMadison, Wis.800-462-0876http:epd.engr.wisc.edu/webM792

TEXAS WATERApril 10 – 13 San Antonio, Texas512-251-8010www.texas-water.com WORLD FILTRATION CONFERENCEApril 16 – 20 Messe Center Graz / Graz, Austria+49 (0)2132 93 57 60 / www.wfc11.at

OFFSHORE TECHNOLOGY CONFERENCE (OTC)April 30 – May 3Reliant Park / Houston, Texas972-952-9494 / www.otcnet.org

INTERPHEXMay 1 – 3Jacob K. Javits Convention CenterNew York, N.Y.203-840-5897 / www.interphex.com

WINDPOWER CONFERENCE & EXHIBITIONJune 3 – 6 Georgia World Congress CenterAtlanta, Ga.202-383-2500 / www.windpowerexpo.org

ECWATECH: INTERNATIONAL WATER FORUMJune 5 – 8 International Exhibition Centre “Crocus Expo” / Moscow, Russia+7 (495) 225 5986 / www.ecwatech.com

AMERICAN WATER WORKS ASSOCIATION CONFERENCE & EXHIBITION (AWWA)June 10 – 14Dallas Convention CenterDallas, Texas800-926-7337www.awwa.org/ACE12

EASAJune 24 – 26Gaylord Opryland Resort and Convention Center / Nashville, Tenn. 314-993-2220 www.easa.com/convention

Send event information to Lori Ditoro at

[email protected]. P&S

Creating Value.Carver Pump Company2415 Park AvenueMuscatine, IA 52761563.263.3410Fax: 563.262.0510www.carverpump.com

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In this multi-part series, we will investigate several aspects of centrifugal pump effi ciency. First, I will defi ne effi ciency and give some examples. Next, I will examine

some of the design criteria that ultimately dictate the effi -ciency exhibited by a particular pump.

I will also try to make that somewhat nebulous quan-tity, known as specifi c speed, more meaningful. I will illus-trate its eff ect on the shape of a pump’s performance curve and overall pump effi ciency.

Next, I will explain the contributions of individual pump components to a pump’s overall effi ciency and show why the combined effi ciency of a pump and its driver is the product, not the average, of the two effi ciencies.

How pump effi ciency can be preserved by changing impeller speed rather than reducing it diameter will also be examined. h en I will compare the value of peak effi ciency versus the breadth of effi ciency over a range of fl ow. h e dis-cussion will end with the importance, or sometimes unim-portance, of effi ciency as it relates to a particular application or process.

What Is Pump Effi ciency?When we speak of the effi ciency of any machine, we are simply referring to how well it can convert one form of energy to another. If one unit of energy is supplied to a machine and its output, in the same units of measure, is one-half unit, its effi ciency is 50 percent.

As simple as this may seem, it can still get a bit com-plex because the units used by our English system of mea-surement can be quite diff erent for each form of energy. Fortunately, the use of constants brings equivalency to these otherwise diverse quantities.

A common example of such a machine is the heat engine, which uses energy in the form of heat to produce mechanical energy. h is family includes many members, but the internal combustion engine is one with which we are all familiar. Although this machine is an integral part of our everyday lives, its eff ectiveness in converting energy is far less than we might expect.

h e effi ciency of the typical automobile engine is around 20 percent. To put it another way, 80 percent of the heat energy in a gallon of gasoline does no useful work.

Although gas mileage has increased somewhat over the years, that increase has as much to do with increased mechanical effi ciency as increased engine effi ciency itself.

Diesel engines do a better job but still max out around 40 percent. h is increase is due, primarily, to its higher com-pression ratio and the fact that the fuel, under high pressure, is injected directly into the cylinder.

In the pump industry, much of the work involves two extremely simple, yet effi cient, machines—the centrifugal pump and the AC induction motor. h e centrifugal pump converts mechanical energy into hydraulic energy (fl ow, velocity and pressure), and the AC motor converts electrical energy into mechanical energy.

Many medium and larger centrifugal pumps off er effi -ciencies of 75 to 93 percent and even the smaller ones usu-ally fall into the 50 to 70 percent range. Large AC motors, on the other hand, approach an effi ciency of 97 percent, and any motor—ten horsepower and above—can be designed to break the 90 percent barrier.

h e overall effi ciency of a centrifugal pump is simply the ratio of the water (output) power to the shaft (input) power and is illustrated by the equation below:

Ef = PW / PS

Where:

Ef = effi ciencyPw = the water powerPs = the shaft power.

In the U.S., Ps is the power provided to the pump shaft in brake horsepower (BHP) and Pw is:

Pw = (Q x H) / 3960Where:

Q = Flow (gallons per minute—GPM) H = Head (feet)

h e constant (3,960) converts the product of fl ow and head (GPM-feet) into BHP. h ese equations predict that a pump that produces 100 GPM at 30 feet of head and requires 1 BHP will have an overall effi ciency is 75.7 percent at that fl ow point. An extension of the second equation also

Joe Evans, Ph.D.

Centrifugal Pump Efi ciency—What Is Efi ciency?

First of Five Parts

Pump Ed 101


allows the computation of the BHP required at any point on a pump’s performance curve if we know its hydraulic effi ciency. I will show some examples of this later in this series.

How Is Pump Effi ciency Attained?h e overall effi ciency of a centrifugal pump is the product of three individual effi ciencies—mechanical, volumetric and hydraulic. Mechanical effi ciency includes losses in the bearing frame, stuffi ng box and mechanical seals. Volumetric effi ciency includes losses due to leakage through the wear rings, balanc-ing holes and vane clearances in the case of semi-open impel-lers. Hydraulic effi ciency includes liquid friction and other losses in the volute and impeller.

Although mechanical and volumetric losses are impor-tant components, hydraulic effi ciency is the largest factor. h e

centrifugal pump has a lot in common with the induction motor when it comes to the design phase. h e commonality is that both have only two major components that can be modi-fi ed by the designer. In the case of the motor, it is the rotor and the stator. For the centrifugal pump, it is the impeller and the volute (or diff user). Let’s start our investigation of centrifugal pump effi ciency with the impeller.

h e affi nity laws tell us quite a bit about the inner work-ings of an impeller. We know that, for any given impeller, the head it produces varies as the square of a change in speed. Double the speed and the head increases by a factor of four. If you keep speed constant, the same rule holds true for small changes in its diameter.

h e fl ow through an impeller follows a similar rule, but in this case, its change is directly proportional to the speed

A change in rotational speed or impeller diameter

refers to its peripheral speed or the speed, in feet

per second, of a point at its periphery.

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Pump Ed 101

or diameter change—double the speed or diameter, and the fl ow doubles. Actually, a change in rotational speed or impeller diameter refers to its peripheral speed or the speed, in feet per second, of a point at its periphery. It is this speed that deter-mines the maximum head and fl ow attainable by any impeller.

h e head produced by an impeller is almost entirely dependent upon its peripheral velocity, but fl ow is infl uenced

by several other factors. Obviously, the width and depth (cross sectional area) of the fl ow passages (vanes) and the diameter of the impeller eye are important considerations as they deter-mine the ease with which some volume of water can pass through the impeller.

Other factors such as vane shape also infl uence an impel-ler’s performance. But where do you start if you want to design

an impeller from scratch? Do you take a wild guess about dimensions and shapes, make some samples and then test them?

In the early days, that is exactly what pump designers did. Today, how-ever, they can draw on years of experi-ence and, at a minimum, fi nd a suitable starting point for the design. h at start-ing point is specifi c speed. Next month, we will investigate specifi c speed and how it can predict the performance of a particular impeller.

Where Can You

Learn More?

h ere are many great pump books available today, but one of the classics is now available as a free download at Google Books. Pumping Machinery was authored by Arthur M. Green, a professor of mechanical engineering at Rensselaer Polytechnic Institute and was published by John Wiley & Sons over 100 years ago. It begins with a compre-hensive history of pumps and ends with a detailed review of centrifugal pumps and their advances over the previous twenty years. You will be impressed at the level of knowledge possessed by the author. h e number of illustrations is amazing and accounts for a signifi cant portion of its 725 pages. h is one gets an A+ rating from me.

P&S

Joe Evans is responsible for cus-tomer and employee education at PumpTech, Inc., a pump & packaged system manufacturer & 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.

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Since the original publication of this draft standard in the January 2008 issue of Pumps & Systems, I have received feedback, encouragement, numerous questions and

criticism. h e draft listed three basic levels of repair:• Level 1: Basic repair• Level 2: Extended repair• Level 3: Complete overhaul

Each adds increasingly extensive machining work and cost. While most of the comments strongly encouraged a need for such a standard, many wondered how a specifi c level (1, 2 or 3) can be prescribed and quoted before the pump is pulled, reassembled and examined at the shop.

Determine the Need for RepairCommercial considerations and the logistics of the quotation process further complicate this issue. With vertical pumps, a need for a repair is usually determined by the plant operating and maintenance personnel and is based on increased vibra-tions. Most of the vertical pump body is below the soleplate, making assessing the pump’s condition diffi cult.

Spectral vibration analysis can reveal some potential problems—a bent shaft, worn bushings, etc. However, prac-tically speaking, the extent of the repair cannot be deter-mined without the pump being removed and examined. h e dilemma for a repair shop is what level of repair to quote?

ExampleOne example involves mid-size, single-stage vertical pump. Assume that a Level 1 repair costs $20,000, including pull-ing the pump, cleaning/blasting, replacing a few bushings, reassembling, painting and other standard maintenance and repair. A Level 2 repair might cost $50,000, and a Level 3 repair it might be $120,000. Obviously, the cost of each level will also depend on the pump length, metallurgy, number of stages and other factors.

If the pump had already been removed and repair shops were asked to inspect it and provide competing quotes, then the quotation process would be simple and straightforward. h e quoted numbers, provided by several (usually at least three) repair shops, would be relatively close: $20,000 (Shop A), $22,000 (Shop B) and $24,000 (Shop C). In this case, Shop A with the lowest quote would get the job (assuming that all three bidders are technically capable and qualifi ed

to handle the repairs). h e problem is, however, that the pump had not been removed. h is makes the quotation pro-cess more diffi cult. h e repair shops are now faced with the dilemma of which level to quote?

One QuoteShop A assumes that the repair will be completed at a mini-mum extent and quotes $20,000 (Level 1). Shop B assumes an extended repair and quotes $50,000 (Level 2). To do things right, Shop C decides that a full restoration of fi ts, clearances, the replacement of worn rings and other measures will be needed and quotes $120,000 (Level 3).

h e purchasing department of the plant will likely award the job to the lowest bidder (Shop A). Once shop A pulls the pump, reassembles and examines it, its personnel may discover that the extent of damage is actually at a Level 2 requirement ($50,000). However, the committed quote of $20,000 prevents them from conducting that level of work.

Presenting a new quote to the pump owner would seem reasonable, but with shops B and C by now out of the pic-ture, such an approach may, in the long run, raise the eye-brows of purchasing.

Three QuotesRequesting to prepare three diff erent quotes based on each level also presents a dilemma. For example: Level 1 Level 2 Level 3

Shop A $20,000 $50,000 $120,000

Shop B $22,000 $52,000 $122,000

Shop C $10,000 $100,000 $300,000

What would be the basis for the purchasing decision? If awarding the job based on the Basic Level ($10,000) but afterward having to pay $300,000 for the full repair (by which time the award is made), then plant would end up paying almost three times more compared to what the other two shops would have charged.

Only Quote for Level ThreeBecause of such dilemma, there are two main approached taken by the plants when soliciting the quotations. h e fi rst is to specify the full blown overhaul (Level 3), which guaran-tees the pump will be done “perfectly” and, as rightly hoped, last a long time, - but knowingly paying more regardless if

Dr. Lev Nelik, P.E., P&S Editorial Advisory Board

Repair Standard for Vertical Pumps

Pumping Prescriptions


the inspection confi rms the need to such full repair (repair shop making modest profi t), or just a minor damage – in which case a repair shop makes very good profi t.

Only Quote Simple Workh e second strategy is to specify just a bare bone work (clean/blast, change bushings, reassemble and paint), with any addi-tional work to be found during inspec-tion to be quoted then – allowing the repair shop charge a very high premium, as it is usually not practical to shop the reassembled pump to another shop for a new quotation of the extended repair need.

Weighted AverageAnother strategy is to consider a bid award decision based on a weighted average of variety of factors, besides the cost, such as technical competency, past experience, fi eld support, and other fac-tors. Finding root cause of failure is one of the factors (P&S April 2009 article), as repeated repairs without pinning down the root cause, are likely.

Refi ning the StandardOther types of pumps (“Repair and Upgrades of Multistage Centrifugal Pumps,” December 2007) have similar considerations as far as purchasing deci-sions. However, since assessing the extent of damage for pumps operating on the surface is usually easier, such variations in quotes are usually less signifi cant.

h e diff erent quote processes of course pose more questions, and many other variables, both technical and commercial, that need to be consid-ered. Reviewing such variations and parameters and expanding and refi ning the draft Vertical Turbine Pump (VTP) Repair Standard would be desirable. h e standard could be refi ned by pump

sizes, materials, number of stages, etc., to help end users make better estimates of the quality of repair that is needed and to receive these repairs at an aff ordable price.

h e original draft was reviewed by the committee. h e second draft is targeted for release by next September. Let us know your input.

P&S

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

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PUMPS & SEALSPUMPS & SEALS

FORFOR

HARSH CONDITIONSHARSH CONDITIONS

A Special Section of

February 2012


As manufacturers continue to increase production capa-bilities to meet customer orders, the demand for com-pressors with higher speeds, higher pressures, lower and

higher temperatures and larger sizes is also growing. A properly functioning compressor is critical to optimal plant operation. Compressor failure can bring down an entire plant or bring production to a halt, costing a company $250,000 an hour or destroying millions of dollars of catalyst. h erefore, a reliable, well-designed dry gas seal system included with a compressor can make a diff erence to a plant’s bottom line.

Typically, compressors with dry gas seals are used in appli-cations in which they are critical parts of the entire process. A well-designed dry gas seal system will prevent extensive damage to the dry gas seal, compressor and process. Compared to pump operations, dry gas seals and compressors usually operate at higher speeds and pressures. Every component of a dry gas seal must be designed to manage exposure to extreme conditions.

Five factors infl uence the reliability of dry gas seals: • h e seal• Separation and process seals• Seal selection• h e dry gas seal panel • Auxiliary systems

Each factor must be analyzed to identify what is required for the application. When selected correctly, they will provide the best dry gas seal system and deliver the highest reliability achievable from dry gas seals. Not only will this provide reliable dry gas seals with a minimum of six years mean time between repairs (MTBR), it will also reduce utility, maintenance and repair costs.

Improvements Increase ReliabilityOver the years, features in dry gas seals have changed, improv-ing the technology. Many small adaptations have taken place

to correct the fl aws or defi ciencies of past dry gas seal systems. h ese changes range from adjusting the hardness/durometer of an o-ring for handling high-pressure dry gas seals to using polymer gaskets, which have no depressurization limits and will not take a set such as elastomers do. h e question is, “Although these are small improvements, how do they aff ect the reliability of dry gas seals?”

Since the fi rst dry gas seal was developed, tested and installed 32-years ago, the knowledge gained from upgrading oil seals to dry gas seals, analyses of dry gas seal failures and troubleshooting dry gas seal failures at site have identifi ed the need for auxiliary systems and the necessity for improvements in the dry gas seal.

h rough all this, many dry gas seal designs were identifi ed as unsuited for the applications in which they were installed—including the use of improper materials of selection that resulted in seal failures, incorrectly installed seals that limited

Dry Gas Seal RequirementsGlenn Schmidt, EagleBurgmann

Find a reliable dry gas seal system for any application.

First of Six Parts

Figure 1. Basic components and fl ow illustrating the operation

of a dry gas seal


Special Section: Pumps & Seals for Harsh Conditions

seal life and poor dry-gas-seal panel designs that caused unnec-essary compressor shutdowns. In many instances, when design-ing dry gas seal panels, little consideration has been given to piping confi gurations, auxiliary systems and utility costs even though all these aff ect the reliability of dry gas seals.

Choosing Seal FeaturesBecause dry gas seals operate under extreme conditions, choos-ing the right seal features can substantially increase the reliabil-ity by ensuring that they maintain a gap between the rotating seat and the stationary face. To understand this, let’s start with the basic principles of a dry gas seal (Figure 1).

A dry gas seal creates a fi lm of gas (3) between a rotat-ing seat (1) and a stationary face (2). h is fi lm of gas (or gap) between the seal faces must be generated and maintained at 150 to 200 micro-inches so the seal faces do not touch and the smallest amount of gas is allowed to leak through the seal.

h is gap can be generated in two ways• When applying pressure to the seal • When the rotating seat is turned fast enough to pump gas

between the rotating seat and the stationary face

h e rotating seat is fi xed to the compressor rotor, and the stationary face is connected to the compressor case. h e stationary face must adjust axially to maintain the gap as the

rotating face/compressor rotor moves and as the compressor case expands and contracts from changes in heat and pressure. To manage axial movement, the sta-tionary face must move freely when required, and as a result, the dynamic secondary sealing design is key to attaining a response to axial changes without resistance or delay. h erefore, a reliable dry gas seal will have a parallel gap of 150 to 200 micro-inches between the rotating seat and the stationary face even when axial movement occurs.

Because the gap is so small between the faces, a clean dry gas is required with particles less than 150 micro-inches because larger particles will expand the gap. With smaller particles, if the groove does not have a feature to ensure that particles pass through the seal faces, even fi ner fi ltration will be required to minimize build-up of contamination in the grooves.

Do not be mislead when people say: “h e gas being supplied is clean.” Everyone has a diff erent defi nition of “clean gas,” and almost no piping or process has a gas quality with debris of 150-micro-inches or less. How can end users ensure that their dry gas seal will only encounter clean dry gas? Essentially, a clean dry gas environment must be cre-ated for the seal. When this is done correctly, the seal will provide a long and profi table life.

Process and Separation SealsTo create the right environment for the seal, con-tamination must be prevented from entering the

Figure 2. Separation seal—

A coaxial barrier seal prevents

lubrication oil from contaminating the dry gas seal.

Figure 3. Seal confi gurations are available to fi t every application.


seal. From the process side, a process seal is required to prevent process gas from contaminating the dry gas seal environment. On the atmospheric side, where lubrication oil is present, the oil must be stopped from entering the dry gas seal environment.

To prevent a dangerous condition, process gas cannot leak into the bearing cavity, which could cause an explosion or expose operators or the environment to hazardous or toxic gas. To eliminate this danger, a separa-tion seal (Figure 2) is used on the atmo-spheric side of the dry gas seal. Since a number of separation seals are available, selecting the correct seal for the applica-tion is important.

Choosing a Seal

Confi gurationNext, a seal confi guration must be chosen (Figure 3). h ere are single seals, double seals, tandem seals, and tandem with intermediate labyrinth seals. So how do you know which seal to use for your application? To assess what seal confi guration will meet the require-ments for the application, it is impor-tant to know: the operating conditions of the seal and the process gas; what seal supply gas is available; and if a back-up seal is required.

Available utilities can aff ect which seal confi guration is used. Other aspects to consider include: • Safety• How to manage a primary seal failure• h e length of space available and

how it aff ects the compressor’s rotor dynamics

All these factors must be identifi ed when selecting the dry gas seal confi gu-ration, process seal and separation seal to assemble the best dry gas seal cartridge for the application.

Dry Gas Seal Panels Once a seal confi guration has been selected, a panel (Figure 4) must be designed to support the dry gas seal car-tridge. h e panel design must deliver suffi cient, quality seal supply gas to the dry gas seal. h is will prevent liquid from forming in the seal gas when subject to changes in temperature or pressure. h e panel will monitor the leakage rate of the dry gas seal and provide alarms and

shutdowns to prevent process gas from leaking should a pri-mary seal failure occur. It will also verify that the secondary seal or back-up seal is intact and provide process gas containment in the event of a primary seal failure.

If an intermediate labyrinth is part of the cartridge, a secondary seal supply will be provided to fl ush all the process gas to the vent system. A system to control the secondary seal




supply fl ow will then be needed. Some applications require that the compressor to continue to operate on the secondary seal when the primary seal has failed. Continued operation allows for a controlled shutdown of the process and prevents the loss of millions of dollars of catalyst. In this case, the secondary vent must be monitored.

Lastly, a system to control fl ow to the separation seal is required. All these components are needed to provide an

effi cient system for controlling the supply and quality of gases to the dry gas seal and to monitor the seal’s health.

Identifying Auxiliary Systems h e fi nal factor that infl uences the reliability of a dry gas seal is the auxiliary system. Typically, auxiliary systems (Figure 5)

Figure 4. Dry gas seal panel—Seal management systems control

supply gases and monitor seal health.Figure 5. Auxiliary systems condition seal gas and ensure continu-

ous seal gas fl ow.

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are chosen when the seal and seal supply are selected, as these choices have major infl uences on what is included in the aux-iliary system. When identifying what to include in an auxil-iary system, the reliability of the seal gas supply fl ow must be assessed to determine if it will provide a fl ow during all condi-tions, such as start-up and recycle. If an alternate gas is used, can pressure build up in the compressor be managed?

h e quality of the seal supply gas must also be assessed to ensure that no liquids are formed during changes in gas pres-sure and temperature. h e seal gas will drop in pressure from the supply pressure all the way to the atmospheric side as it leaks through the dry gas seal. Factors that can infl uence seal gas temperature are process gas temperature or environmental conditions, which can drop the temperature of pipes or the

compressor to the point that liquid will form in the seal gas supply. All these con-ditions must be identifi ed to ensure that no liquids form that will aff ect the oper-ation of the dry gas seal during dynamic as well as static conditions.

Conclusion

All these factors—seal design, process and separation seal, seal confi gurations, dry gas seal panels and auxiliary sys-tems—must be reviewed, assessed and designed for the seal’s intended appli-cation. With strict adherence to these guidelines, a dry gas seal system can be designed that off ers the highest effi -ciency and reliability, preventing unnec-essary plant shutdowns and subsequent loss of production and catalysts.

h e next article, in the March 2012 issue, will focus on selecting the proper seal fea-tures—face materials, groove geometries, secondary sealing elements and gasket extrusion/explosive decompression—to pro-vide a reliable dry gas seal system.

P&S

Glenn Schmidt is Eag l eBur gmann’s regional compressor seal specialist sup-porting the American region with techni-cal and sales support

for designing, servicing, repairing, troubleshooting and upgrades of dry gas seals and systems. His 16 years of experience with dry gas seals includes instructing a Texas A&M dry gas seal systems course and providing input as a member of the API 692 committee developing the standards for dry gas seals and systems. He can be reached at [email protected] or 713-939-9515.

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Pumping applications come in vary-ing degrees of diffi culty and com-plexity. It is not unique to any one

industry or pump type. h is makes select-ing the right pump for a set of operating conditions an interesting challenge.

Shear-Sensitive, Abrasive &

Mixed FluidsProgressive cavity pumps (PCP), due to their inherent design and performance—are suitable for diffi cult applications. h e handling of shear sensitive fl uids; highly abrasive slurries; or a mixture of solids, liquids and gases can be effi ciently han-dled by this type positive displacement pump.

Unlike many industries, applications in oil and gas are more diffi cult since the incoming fl ow can be non-uniform and is almost always a mixture of solids, liq-uids and gases—the percentage of which is not constant. Further complication results from gases being dissolved in the oil and water mixtures and the presence of condensates.

Gas CondensatesEven slight changes in temperature and pressure can cause condensates to vaporize resulting in major damage to pumps. Gas condensates can also lead to the formation of waxes, which alters the fl ow characteristics signifi cantly from Newtonian to non-Newtonian. Related problems result in increased operating costs.

Condensates at High Altitudesh e handling of gas condensates is a diffi cult problem and draws upon the challenges of all pump technology. One such prob-lem was extraordinarily diffi cult because the location, Evanston Wyo., was at an altitude of approximately 7,000 feet above sea level. h e Net Positive Suction Head Required (NPSHR) in this case was extreme due to the altitude. At higher altitude, the density of the air is much thinner than at sea-level. h erefore the equipment, pumps and motors, have to be adjusted to work effi ciently in a less air-dense environment. h is made every-thing much more diffi cult, and restricted the pump choices.

h e PCP was the only pump that could handle the

High-Altitude Condensate PumpingKamran Mirza, seepex Inc.

A progressive cavity pump provides an ideal solution to a diffi cult pumping application.


operating conditions and also the low NPSHR. In addition to the performance, it also off ered the most economical alternative.

h e selection of the PCP to solve the condensate pumping problem was based on several advantages: • It is able to handle very high gas fractions, in excess of 99

percent, and was able to handle the condensate stream. • h e PCP was not aff ected by changes in the proportion of

condensates or liquids, so the performance of the pump was not aff ected by variability in condensation or vaporization of the pumped medium.

• It was able to function in a low NPSHR situation with a high vapor pressure and a low atmospheric pressure.

Any other type of pump used in this well-site-to-storage- pumping application would have required a much higher NPSHR, which would have meant expensive methods to place the pump at a lower altitude. h e overall cost of such an arrangement would have been prohibitive.

h e PCP operated with ease at the higher altitude even with the motor de-rated, resulting in savings to the customer. It had a compact design, with all wetted parts made of duplex stainless steel. h e Duktil coated rotor and fl uoropolymer stator were selected for service life longevity with minimum maintenance. A 100-horsepower motor operated the pumps at

225 rpm for a fl ow rate of 350 gallons per minute. h e pump was equipped with special dry running protection device.

A Long-Term Solutionh e PCPs have been operating trouble free for more than eight years. h ere are many diffi cult applications, but this one was unique because every parameter was extreme in its scope, and the collective conditions imposed additional restrictions. However, the carefully engineered PCP provided a long-term solution that continues to operate successfully.

P&S

Kamran Mirza is director of business development, at seepex, Inc. in Enon, Ohio. He has 34 years of experience in progressive cavity pumps. Mirza developed the progressive cavity multiphase pump for Robbins & Myers and served as director of engineering and manufacturing for the

Dyna-Drill Division of Smith International and director of manufacturing for Baker Hughes Drilling Systems. He has authored several technical papers and holds two pat-ents in multiphase pump technology. Mirza has an M.S. in Mechanical Engineering from the University of New Mexico.




Choosing a coating for a pump can be a challenging task. A good coating can extend the life cycle

of a pump, providing cost and downtime reductions. Alternatively, a poor coating can do the opposite. It could jeopardize the pump and increase costs and downtime.

Information for comparing the coat-ing options is generally limited to three possible sources: anecdotal evidence, a salesman pitch or a manufacturers’ speci-fi cation sheets. h e fi rst two can be judged by impression or level of trust and are somewhat subjective. h e third is possibly the most misunderstood and diffi cult to judge. h is article provides insight into the general makeup and applicability of the typical manufacturer’s coating specifi ca-tion in hopes of making the decision easier and increasing the odds of choosing what is best for each pump.

StandardsMost reputable coating manufacturers carry out their performance testing as per industry recognized testing standards. Standards have one purpose, to make a test as repeatable as possible. It does not guarantee that the results have real world meaning, although many make an attempt at doing so. h is is important to under-stand when choosing a material based on a specifi cation sheet.

A common mistake is to compare values side-by-side and make the assump-tion that the higher the better. Without a basic understanding of the true meaning of the numbers, an objective comparison is impossible. End users must resist the basic human instinct to compare the quick and obvious number and make a swift

Choose the Right CoatingIvan Ordaz, Belzona

Understand coating manufacturers’ specifi cation sheets.

Figure 1. High-tech coatings lab

Figure 2. VICAT heat distortion temperature


judgment when, in reality, the not so obvious is many times more meaningful and rarely represented by a single numerical value.

Reading the standard itself off ers much insight. Never take the number simply for what it is and understand that not all standards are created equal. Some are specifi c and detailed while others might be broad with wiggle room. Some standards are also much more representative of desir-able properties for a specifi c application. For example, compressive strength is a value, which for a pump coating appli-cation, does not have much signifi cance. However, for a machine shop fl oor coat-ing with heavy machinery and traffi c, it could be more relevant.

General Data

When analyzing a product specifi ca-tion sheet, keep in mind that thousands of possible tests could be listed for a polymeric coating. What is listed is, therefore, carefully chosen by the manu-facturer for a specifi c reason. Perhaps the manufacturer feels that the data is important for a specifi c market that it is targeting. Maybe it is limited by testing capabilities, but it could also be limited to the strong points only of the product and intended to make the best impres-sion possible.

Regardless of the reason or intent, what matters is that the end user identi-fi es the data that is most critical to the success of the application. If dealing with coatings that will see chemicals, end users should focus on chemical testing, and identify how the products are tested and how rigorous the testing procedures are. If the pump moves fl uid with entrained solids, then abrasion resistance and heat distortion tempera-ture are absolutely critical.

Some basic data that should be present on a specifi cation sheet are:• Physical properties—density, appear-

ance, consistency, viscosity, slump resistance, peak exotherm, time to peak exotherm, working life, percent solids and shelf life. h e more details the better because these physical properties allow for proper applica-tion planning.

• Strength and hardness—compressive strength, fl exural strength, tensile

strength and hardness are values that could be considered performance data but because they are so generic in nature, they seldom become a critical focal point during coating selection.

Polymer materials could also be formulated in ways that amplify these basic mechanical characteristics but serve little

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purpose as far as performance in the intended environment or in some cases could be detrimental to the coatings real world performance.

Performance Data

At a minimum, the general performance data in this section should be present in a manufacturer’s coating specifi cation sheet.

Adhesion Cross hatch for thin coatings, direct ten-sion and lap shear adhesion for thick coat-ings. Adhesion is critical to the success of any coating. A coating that is unable to maintain a tight bond with the substrate stands little chance of successfully protect-ing that substrate. Adhesion of coatings is highly dependent on methods of surface preparation.

Some coatings are designed specifi -cally to adhere to poorly prepared or con-taminated surfaces. If your application has restrictions on surface preparations, these are important char-acteristics that could benefi t your application. Such coatings should have appropriate data to prove the claims.

Dry Heat Resistance h e thermal stability of a coating is dependent on the formula-tion of the resin systems. Heat resistance is generally subdivided into dry heat resistance and wet (immersion) heat resistance. h e temperature at which a coating will begin to break down is

defi ned as the dry heat resistance of the material. Exposures to temperatures above this value will cause permanent irreversible damage to the coating eventually leading to its destruction.

Immersion Heat Resistance Immersion heat resistance is almost always lower than dry heat resistance. When immersed in a liquid, a polymeric coating will generally experience a lower heat resistance due to increased permeation of the liquid as the temperature increases. h e per-meation can lead to blistering, chemical attack, under coating

corrosion and other detrimental eff ects. Coatings chosen for immersion service should be tested by a rigorous method to determine the immersion heat resistance.

Atlas cell testing is among the most widely accepted and most scrupulous methods available. Atlas cell testing will not only expose the coating to the hot fl uid but also incorporates the eff ects of a cold wall. A cold wall will make condi-tions much more aggressive to the coating by introducing a strong thermal gradient across the coating. h e strength of the cold wall depends on the thickness of the coated metal panel. h icker panels will dampen the cold wall eff ect since they will contain a larger thermal mass.

Heat Distortion Temperature h e heat distortion temperature of a mate-rial defi nes a temperature at which the material begins to soften. When a material

Figure 3. Performance testing equipment

Figure 4. Lab based accelerated UV chamber


exceeds its heat distortion temperature, it will lose most of its physical strength and soften. It is important to note that this is not a permanent eff ect. Once the temperature has decreased below the heat distortion temperature, the material will regain its rigidity, returning to normal.

h e heat distortion temperature is extremely important in situations and meaningless in others. Any coating that will be subject to mechanical stress or chemical exposure should never be put in service above its heat distortion temperature. For pumps, I this is a critical property since high velocity fl uids and possible abrasion are the norm.

Abrasion Resistance

Abrasion is diffi cult to simulate and generalize in a test due to the nature of the eff ect. Abrasion of a coating can occur by diff erent means such as fl uid impingement, impact abrasion and ero-sion by entrained solids. Sliding abrasion is often tested by the Taber method in which abrasive wheels slide over a rotat-ing sample for a given number of cycles. h e mass loss is then determined. h is method is eff ective for comparing slid-ing abrasion of coatings. Several param-eters need to be established and quoted along with the results.

When using Taber abrasion for comparison of coatings, all these param-eters need to be the same. h e param-eters are mass of weights, wheel used, number of cycles and abrasive condition (wet or dry). Only when all these are the same can two test results be compared side by side. Taber results are determined by measuring the mass of the sample before and after the test. h e mass loss represents the degree of abrasion.

Considering the density of the coat-ing when comparing values is impor-tant. Because coatings have diff erent densities, mass alone is a poor tool for comparison. Many coatings manufac-turers will convert mass loss to volume loss. However, one should never com-pare diff erent material by mass loss. Comparison by volume is the only accurate way to compare two coating’s abrasion resistance. A gram of coating A does not necessarily equate a gram of coating B if their densities are diff erent. A cubic millimeter of coating A and a

cubic millimeter of coating B will always be the same quantity. After all, the interest is in how quickly the coating will wear down not how much mass is being lost as it wears.

Cathodic Disbondment

Coatings that will work alongside cathodic protection sys-tems should be tested for cathodic disbondment resistance.



h e presence of a polarizing potential on exposed sections of a cathode will produce an aggressive environment for a coating, which could lead to disbondment and corrosion creep.

Corrosion Resistance Accelerated corrosion testing generally performed in a salt spray cabinet to demonstrate the coatings ability to provide

protection in corrosive environments reveals how well the coat-ing withstands this eff ect.

Accelerated WeatheringTesting for discoloration, loss of gloss, blistering, fl aking, rust-ing or other break down when exposed to harsh environments. h is test can be performed in a test chamber designed to simu-

late such environments or in outdoor exposures.

Outdoor exposure should be in geographical areas of harsh weather con-ditions such as Florida or Arizona.

Key StepsAs this article shows, choosing a pump coating is no easy feat. It consists of sev-eral steps in which the decision maker must have extensive knowledge of the structure or equipment that will be coated, as well as the coatings them-selves. Otherwise, a signifi cant number of coating failures can result.

h e key steps to choosing the right coating is fi rst to understand what key properties are required of the coating.

Once this is accomplished, end users can start looking at specifi cations sheets to determine if the standards quoted accurately simulate the expected real-world conditions.

h is should lead to an educated and correct decision. In essence, a properly chosen coating will prolong pump life by repairing it, reduce downtime by pro-tecting it and possibly even improve its effi ciency.

P&S

Ivan Ordaz is an accomplished engi-neer in the fi eld of industrial coatings and corrosion protec-tion. A graduate from Georgia Institute of

Technology’s school of chemical engi-neering, he has focused his career on high performance coatings. He man-ages a product development depart-ment Belzona. Additionally, he is a certifi ed NACE Level 3 coating inspector, having presented in NACE International coating symposium and prides himself in being immersed in the coatings community.



No matter which pump type you have, KSB can handle the diagnostics, repair or

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Cover Series: The Aftermarket

The

AftermarketR P R

The

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Inside this Section:

Pump Replacement Part Availability. . . . . . . . . . . . . . 35

Inspections and Repair Can Enhance Pump Performance. . . 40

Specialty Replacement Parts . . . . . . . . . . . . . . . . . 44

The Value of Industrial Pump Genuine Parts and Repair Kits . 46

Inside this Section:

Pump Replacement Part Availability. . . . . . . . . . . . . . 35

Inspections and Repair Can Enhance Pump Performance. . . 40

Specialty Replacement Parts . . . . . . . . . . . . . . . . . 44

The Value of Industrial Pump Genuine Parts and Repair Kits . 46Photo courtesy of KSB


The crumbling infrastructure of our roads and bridges is the hot topic in today’s political discourse.

However, an even bigger problem may be the pump infrastructure in our nation’s industrial base.

Pumps are the heartbeat that enables most industries to run the processes that create products. Untold thousands of pumps are now in the 25-to-75-year-old age group and must continue running even though the original life was probably pre-dicted to be 20 years. h is is because of the extremely high cost of replacing the pumps with newer model pumps.

h e manufacturers of many of these pumps are either out of business or have moved on to selling new models and no longer support the older models with replacement parts. h e question becomes “what are the strategies for continuing to maintain sources for these old pump parts in the coming years?”

In 1973, I was involved in an expan-sion project at a large refi nery in St. Croix, U.S. Virgin Islands. h irty-nine years later, that plant is still there, and many of those pumps are probably still in service. I can remember that we manually set up spare parts inventory, minimums and maxi-mums, based on the list sent to us by the vendors.

Millions of dollars of spare parts inventory were kept in the warehouse to support the pumps and other equipment—unlike today when inventories are kept at a minimum at both the plants and by the original equipment manufacturers ( OEM). In those days, we would set up the parts in our system and purchase inventory for the warehouse except for the cases, which were a “non-wear”

item. Now, almost 40 years later, I can say with certainty that pump cases are wear items…they just wear very slowly.

Pump CasesOlder pumps still in operation are creating major problems for their owners. One example is a large pump case that was

Pump Replacement Part AvailabilityJeff Smith, Standard Alloys

Address this problem to avoid the possibility of future crises.

This decades old (but critical) power plant pump case was no longer supported by the OEM.

As a short term solution, it has been built up using a synthetic polymer product. Before the

power plant puts it back in service for its fi nal run, it is being reverse engineered so that it

can be replaced with an identical case during the next maintenance cycle, ensuring that the

pump design can continue to be used.



worked on for a major customer. h e case had come into the shop for a minor repair. It looked great, but during the repair process, the mechanic checked the wall thickness and found that the wall had worn to only 1/8 inch thick. When informed, the customer immediately ordered a replacement case and paid a premium to get an expedited delivery.

Another example regarding cases happened recently. We received an email from a salesman that read, “h e customer called and said that the case currently being manufactured on overtime is now an emergency. h e sister pump is failing.” Again, this was an older pump still being used in a key operation.

One last example is truly amazing. A replacement case for a reciprocating pump still in operation was requested. A case had last been made for it 37 years ago….and the pump was not new then. h e old pattern was located and a replacement case was produced. Hopefully, it will last another 37 years.

The Current ProblemMany stories like this exist in the business, which leads to the conclusion that the current problem with replacement parts may become a crisis in the future. In most industries, pumps move products. h e industry cannot exist without its pumps. h e pumps are old, and they are starting to need more spares, including pump cases. Sources for spare parts are becoming diffi cult to fi nd, and few companies have a strategy to keep their old pumps running long-term. h is problem is only going to increase at an accelerated rate.

Proactive AnalysisPeople at the appropriate management level must determine if this is a problem in their plant. h ere are many plants in which the pumps in service are relatively new and are still supported with available spare parts. A recent informal survey indicated this to be true for 36 percent of those surveyed.

However, a majority (64 percent) of the plants have older pump populations. h is group needs to study their pumps:• h eir age• How critical they are to the process• h e availability of spares

h ey should also determine whether a problem exists today or, if not, when it may exist. At some point a problem with parts availability will exist with older

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pumps. h e survey indicated that 90 percent of plants with older pumps have either a minor problem or a growing problem with their pump spare parts sources today.

Awareness is always the fi rst step of the problem-solving process. Once the problem is acknowledged, it should be further defi ned. Each pump should be identifi ed, and a determination made as to whether spares are readily avail-able. Some parts that may be considered obsolete may still be available from after-market sources.

Other parts that may not techni-cally be obsolete may not be available because no one is making them and put-ting them in inventory. When needed, the lead time may be many months even if a delay of many months is not acceptable.

Alternative StrategiesNumerous reasons exist as to why a pump part may not be readily avail-able. For example, the pump cannot be repaired due to the unavailability of critical spares because they are no longer manufactured. In this case, a couple options are available. First is that some pre-engineering of currently available models should be conducted so that when the pump does end its useful life, a known replacement model can be ordered with minimal delay.

Another option is to determine if the pump part can be reverse engineered. Reverse engineering during downtime for normal maintenance might be a good strategy.

Some pump parts are still manufac-tured but are not stocked in inventory. In this case, lead times for manufactur-ing can be very long. For these parts, a strategy may be that the plant or the OEM should decide to maintain an inventory to prevent an interruption to operations.

h ese alternatives are some of the strategies that must be developed and implemented rather than ignoring the growing problem. In the survey we found that 64 percent had no plan in place. h e ones that had a plan were



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divided into the two groups: Replace old pumps and use repli-cators, although none of the plans were formalized.

h ese strategies should be aimed at making sure that the older pumps can be supported for some period of known time, and the related costs are considered in both maintenance bud-gets and capital budgets. If this problem is ignored, a signifi cant future operating expense due to downtime is probable.

Responsible Partiesh e responsibility of maintaining sources for older pump parts rests with the owners of the pumps. Maintenance is typically charged with keeping the pumps running and rarely has time or budget resources to plan for future problems.

Purchasing is typically only charged with buying what is currently needed and does not know what will be needed in the

future. Reliability is typically charged with making equipment last longer but would normally not have visibility as to whether replacement parts will be avail-able when needed. Regardless of who within the organization has responsibil-ity, someone should be challenged with addressing this problem.

Implementationh e last step is to implement the newly developed strategies to keep equipment operational for years to come. h is chal-lenge will grow as plants continue to age and pumps that are currently sup-ported by spare parts sources move into the obsolete or unavailable categories. A continual review of pumps and parts availability must be conducted to keep plants operational.

In addition, a closer involvement between the plants and their spare parts sources (whether OEM or aftermar-ket) must be maintained. h ese sources should not be seen simply as vendors but as partners in the challenge of keep-ing pumps and plants operating long term. Proper planning and investment are needed to keep industries, and the pumps that support them, operational now and in the future.

P&S

Jeff Smith is the executive vice president and managing director of Standard Alloys, a KSB company. He has directed the operations of Standard Alloys since 1996. Prior to arriving at Standard Alloys, Smith worked with four OEM companies in the energy and process indus-tries. For more information about Standard Alloys, contact [email protected], or visit the website at www.standardalloys.com.waukeshabearings.com

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Often all that is needed to improve a pump’s depend-ability and performance is a high quality inspec-tion and repair. Over time, a pump may have been

repaired by more than one service provider with varying levels of engineering and technical experience.

Tolerances may have been opened, fi ts and concentricities may have been lost and materials may have been changed, all of which contribute to reduced performance, loss of reliability and more frequent repairs.

h is article highlights the opportunity seized by a coal-fi red power generating facility located in Western Pennsylvania, to upgrade a Westinghouse vertical pump.

Backgroundh e Power Plant’s Unit 4 “Alpha” circulating water pump was scheduled for repair. In the process of removal, the sister pump 4 “Bravo,” exhibited severe vibration and failed in a manner that was believed to have been a result of a broken shaft. h e Alpha pump was put back into service and the Bravo pump removed and sent to the repair facility for inspection and emer-gency repair.

h is circulating water pump performs a critical function in the power plant, by cooling the low-pressure steam in the con-denser to use as feedwater for the boiler. A loss of one of these pumps in the summer means that the plant will not be able to produce to its maximum capacity until the pump returns to service.

Observed Pump Conditionh e general condition of the Bravo pump when received at the repair facility was much worse than anticipated with the top column fl ange broken about half way around. h e entire pump had been hanging from this broken joint leaving a gap of ¼ inch to ½ inch at the opening.

h e keyed coupling (internal to the pump) used to join

its two shafts was broken in several pieces. h e shaft journals were severely worn to one side, and the impeller vanes and suction bell liner surface were also severely worn as expected,

Inspections and Repair Enhance Pump PerformanceBob Bluse, Hydro, Inc.

Improvement can result from repair opportunities.

Column pipe upper fl ange as-received

Close-up of the broken pipe


considering the signifi cant pump damage. After disassembly of the pump, the repair engineers also

observed that the shaft enclosing tubes had spun in their fi ts because they were not fi tted with any anti-rotation mechanism. h is rotation caused damage to the O-ring fi t areas at both ends of the enclosing tube assembly, which resulted in the loss of a proper fl ush water supply to the pump bearings below the packing box.

Another issue observed during the inspection was that part-to-part alignment of major pump components used dowel pins, which are very diffi cult, if not impossible, to verify.

Opportunity for ImprovementWhile the typical repair scope of bearing, wear ring and small

Close-up of the broken pipe fl ange

Destroyed shaft coupling and hardware

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part replacement was employed, several issues identifi ed during the inspection were corrected with improvement to the design:• h e column pipe repair included replacing the entire upper

fl ange, adding reinforcing gussets to the fl anges on both ends, excavating defective fl ange and pipe seams and full-welding to restore integrity and improve the overall strength of the column.

• Register fi ts were machined into each component as part of the repair process with minimum clearance to assure proper alignment.

• h e impeller vanes were re-established to the proper and consistent vane lengths. h is was done instead of merely de-burring the worn edges to restore pump performance and to eliminate hydraulic imbalance. It required an extensive amount of welding to the sealing surface of the vanes and precision machining of the impeller and suction bell because this fi t has a signifi cant eff ect on the pump’s effi ciency. NDE of the impeller during inspection revealed minor cracks, which were also repaired.

• h e repair plan required the replacement of both shafts, which presented another opportunity for improvement. h e service center upgraded the shafts by manufacturing them in a stronger, more durable material to match the pump’s

application. h e improvements also included maintaining full-size shaft diameter through the coupling (the existing shafts were turned-down) and machining proper radii into all corners and keyways. A new upgraded coupling assembly was also designed and manufactured by the service center. h e new coupling consisted of a larger outside diameter, heavier thrust rings (instead of the existing thin-walled clam-shell type), improved bolting and two keys, 180 degrees apart on opposite ends for balance and strength.

• Enclosing tube O-ring fi t areas on both ends were restored, and the enclosing tube assembly was fi tted with an anti-rotation device.

• Pump fasteners were replaced, upgraded to a more durable material to resist corrosion and fatigue.

Follow-Up and Proof of DesignRepairs and modifi cations discussed in this article were com-pleted on the Unit 4 “Bravo” circulating water pump in February 2010. Modifi cation and repair of the sister “Alpha” pump was completed in December 2010, which outfi tted the design of both pumps equally.

Soon after the completion of the Alpha pump, a travel-ing screen failure forced the removal of the Bravo pump once again.

Inspection revealed severe damage to the impel-ler by a piece of wood debris that was allowed to pass through the failed screens. h is permitted an oppor-tunity to inspect the repairs and modifi cations from the previous year.

h e customer’s com-ments were: “In retrospect,

Gusset added to the column pipe fl anges Typical register fi ts added throughout the pump

New shafts and shaft coupling components during and after assembly


after our most recent repair on this pump in January 2011, replacing the shafts was typically part of the repair scope. h is is the fi rst time I can remember not replacing the shafts due to the new robust shaft and coupling upgrade that was performed.” After the Bravo pump was repaired again and returned to ser-vice, he commented that: “h e pump is currently operating as expected—quiet and smooth, ready for a long service life.”

Lessons Learned

While there are “typical” repair items such as bearing and wear ring replacement, shaft journal repair and impeller balancing, the unexpected issues are what really cause the most frustration.

Proper inspection will reveal other issues that may not be so obvious, and coordination with a qualifi ed service provider can present real opportunities for improvement of your pumps. Improvement of pump reliability, durability and performance, provides greater mean time between repairs (MTBR), which is becoming the main focus of most pump users. h e technical manager at the power station reports that working with his ser-vice provider has been a very positive experience to the power generating facility because the repairs are done right, pump inspection as-found and as-left measurements are documented and reported, and solutions to problems are identifi ed quickly.

“At the power plant, we are good at burning coal and

making electricity in a safe, reliable and environmentally responsible manner,” says the manager. “Hydro helps us do that by providing high quality pump repairs and delivering solutions on time. We are not experts at the plant in repairing pumps, but we know who to call, so we can get back to doing the things we are good at.”

Make sure to work with a qualifi ed pump service provider who can off er a thorough inspection, engineering support and review and an experienced work force dedicated to providing a quality product.

Taking the time to review the current operating conditions in relation to the pump’s original design specifi cations can lead to engineering recommendations for improving the pump’s performance and extending its life.

P&S

Bob Bluse is the general manager at Hydro East located in Aston, Pa. With more than 40 years in the pump aftermarket services business, his experience has proven valu-able in helping companies provide a higher level of operational performance and reli-ability for their pumping assets.


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When a global adhesive and sealant manufac-turer needed a main-

tenance and equipment solution for frequent and premature stator wear, a specialty rubber stator was the solution. Collaboration with a distributor and pump company helped the manufacturer save money and reduce downtime due to maintenance operations.

The CompanyBased in Ohio, the adhesive manufacturer is among the world’s largest, privately held manufactur-ers of adhesives and sealants.

h e company integrates its core competency, emulsion polym-erization, off ering a broad portfolio of products, including: adhesives, glues, hot melts, binders and sizing compounds for use in construction, wood furniture manufacturing, millwork, paper converting, pres-sure-sensitive paper products and fi berglass reinforcement. h e man-ufacturer markets an array of products to customers worldwide.

Customer Challengeh e Ohio-based manufacturing facility operates a fl eet of pro-gressing cavity (PC) pumps. h ese PC pumps are applied in the transfer of raw materials and shear-sensitive adhesive fl uids to diff erent parts of its manufacturing process throughout the facility. One of the company’s fl agship global products is a pure-white adhesive that requires very gentle, low-shear pump-ing action.

In addition, the manufacturer had two additional critical objectives: • h e company’s process requires a high cleanliness standard

to ensure the exceptional quality of the end product. • h e company required high reliability and low operating

costs to improve fi nancial performance.

A Need for a New Statorh e adhesive manufacturer was experiencing problems with premature stator wear. On average, its original PC pump sta-tors would wear out within three months.

h at meant that it had to replace hundreds of stators every

Specialty Replacement PartsSally Huynh, NOV Monofl o

When stator wear was an issue, a custom-made replacement part was the solution.

The white stators improved life and maintained the pure-white color of the adhesives.


year. With the downturn in the global market for adhesives and tight budgets, the Ohio manufacturer needed a way to cut its maintenance and operating costs.

In search of a solution, the company looked to a technical distributor to collab-orate on its critical needs. h e sales manager from the distributor partnered with a PC pump solutions company to off er special rubber compounded stators to address these challenges.

To meet the customer’s needs, this pump company developed and tested its own rubber formulation in its Manchester, U.K., research and development facility. h e solution was a special white stator for all the manufacturer’s PC pumps, instead of the traditional black, which also helped maintain the adhesives’ pure-white color.

Resultsh e fi rst shipment of pure-white stators was delivered to the adhesive manufacturer from the pump company at approximately 50 percent of the cost of the original OEM supplier. In addition, the stator life has been twice the life of the OEM sup-plied stators. h is additional stator life saved the company more than 200 stator change-outs during the year and approximately 1,600 hours of maintenance upkeep for the same period.

Future ChangesWith a change in global demand for adhesives and a shrinking maintenance budget, the manufacturer needed a signifi cant cost savings solution within its manufactur-ing facility.

As a result of the distributor’s and pump company’s eff orts in designing, sup-plying and stocking white stators, the company has been able to realize quick lead times and competitive pricing for its pumping needs.

Moving forward, the manufacturer is considering a change to a transfer pump with white stators in the future expansion of its facility. With the transfer pump technology, the manufacturer will be able to maintain a PC pump in place without removing the pump from the pipe work.

P&S

Sally Huynh graduated with a degree in marketing from h e University of Texas at Austin. She was hired into a rotational program at National Oilwell Varco to gain experience in all areas of the company. Currently, Huynh is responsible for the planning and implementation of marketing communication activity that supports North and South Americas’ business strategies and objectives at NOV Monofl o, the industrial sector of National Oilwell Varco. She can be reached at monofl [email protected] or 281-854-0300.

The stator life has been twice the life

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The word genuine defi nes something that is real and authentic. In and of itself, the word represents reliability and something worthy

of being trusted. Combine genuine with parts, and you have a winning solution in the pump industry.

A genuine part is a warranted replacement part made by the original pump manufacturer. In most cases, genuine parts are the most reliable and high-est quality parts available in the marketplace. When a pump needs to be repaired, purchasing genuine parts from the original pump manufacturer is a logi-cal solution.

When drivers need to make a repair to their vehicle, they are presented with two options com-monly used in the automotive industry: purchase genuine parts, or purchase aftermarket parts. Although the automotive industry has had much success with their genuine parts programs, many consumers choose aftermarket parts because of the lower cost. When an end users invest in an air oper-ated double diaphragm (AODD) pump or a rotary positive displacement pump (PD), they are pre-sented with the same option of selecting genuine parts or aftermarket parts.

By going directly to the manufacturer to get the genuine parts and service kits, end users will know they are an exact match to the parts with which the pump was built. Genuine parts also off er peace of mind by providing quality assurance and performance guarantees. h is option ensures that the pump remains covered by the manufacturer’s warranty (the length of warranty will vary per manufacturer), which is not the case if the repair is made with an aftermarket part.

A viable alternative to genuine parts is aftermarket parts. What exactly is an aftermarket part? Aftermarket parts are made by companies other than the original manufacturer. h e quality can range anywhere from good to poor. Aftermarket parts can be more aff ordable, and some companies, have a wide product off ering. A word of warning, some aftermarket parts may void the manufacturer’s warranty.

Genuine parts or aftermarket parts? h e choice is yours, and it will be based on the current circumstances. h e bottom line is that all aftermarket parts are not created equal, but all genuine parts are.

The Value of Industrial Pump Genuine Parts and Repair Kits Christine Gfrer, IDEX Corporation

Many options are available when pump repair is required.

Figure 1. Companies that replace pumps if repair costs exceed a

certain amount




Repair Versus ReplaceShould an end user’s AODD or PD pump fail, he may be inclined to simply replace the unit all together. However, if not fi nancially prepared to do that, the end user could consider a repair versus replace options.

Because a pump is old does not mean it needs to be replaced. Many pumps are designed to be easily repairable by experienced pump maintenance personnel. Many pumps have a functional life of thirty or more years, but pump life is totally dependent on the application, the pump system and how it is operated and maintained.

h e decision to repair or replace is based primarily on a cost comparison between the two alternatives, but other fac-tors also need to be considered—such as budgets, maintenance workload, the application duty and the need for spares on the shelf. Does an end user include the cost of maintenance labor in the evaluation? Do end users rebuild on-site, or send pumps out to be repaired? Do they sell scrap, or have to pay for disposal?

Each facility is diff erent. Figures 1, 2 and 3 are results of a survey of more than 100 industrial pump users, asking at what level of cost do they repair a pump versus replace it (Figure 1); how they normally do pump repairs, in-house versus out-

side (Figure 2); and their preferences on individual parts versus repair kits (Figure 3).

Do a facility’s pump maintenance practices and prefer-ences look like those shown in Figures 1 through 3? h e deci-sion to repair or replace is made on a case-by-case basis, but with the tools, parts, kits and expertise available from original manufacturers and local stocking distributors, end users will fi nd rebuilding pumps is normally a cost-eff ective way to keep processes operating effi ciently.

Conveniently Packaged Service KitsShould an end user make the decision to repair, it is good to know that some manufacturers now have complete service kits to save money and time. h e kits include all the parts needed to

make a typical pump repair, conveniently packaged. End users order one part number and receive all the parts for the repair. h ese kits off er the fl exibility to use one or all of the compo-nents at the same time. Some companies are making it easy to quickly identify the specifi c kits needed by putting this informa-

tion directly on the pump name plate.

W h e t h e r a genuine part is needed, an a f t e r m a r k e t part is searched for or perhaps a conveniently packaged service kit to make a pump repair is required, many m a n u f a c t u r -ers are making it easier to fi nd exactly what is

needed. For more information, end users should contact their preferred manufacturer or local Distributor.

P&S

Christine Gfrer has been with IDEX Corporation for four years. She is the global marketing communications manager for the Chemical, Food and Pharma group and works out of the Warren Rupp offi ce in Mansfi eld, Ohio. IDEX Corporation is an applied solutions company specializing

in fl uid and metering technologies; health and science tech-nologies; dispensing equipment; and fi re, safety and other diversifi ed products. Gfrer can be reached at [email protected] or 419-526-7209.

Figure 2. Replacement parts or repair kits?

Figure 3. In-house or outside repairs?


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Oil and gas industry customers are increasingly asking original equipment manufacturers (OEMs) to balance their couplings to ensure that their

equipment runs smoothly. While balancing is intended to reduce machine vibration, it can be an unnecessary and costly expense. Manufacturing methods and design toler-ances usually result in suffi cient balance so that couplings meet industry standards without additional balancing procedures.

API Balance Standardsh e oil and gas industry relies on the American Petroleum Institute’s (API) 610 standard as the internationally accepted set of standards for pumps and associated equipment, such as couplings, in rotating equipment. h e standard, which is now in its 11th edition, has three key clauses that address balancing couplings: • OEMs must provide all-metal, fl exible element, spacer-

type couplings that meet American National Standards Institute/American Gear Manufacturers Association (ANSI/AGMA) 9000 Class 9 requirements. (API 610 6.2.2)

• Couplings that operate faster than 3,800 revolutions per minute must meet the International Standards

Organization (ISO) 10441 or API 671 requirements for component balancing and assembly balance check. (API 610 6.2.2 e)

• OEMs must balance couplings to ISO 1940-1 Grade G 6.3 if the customer requests it. (API 610 6.2.3)

h e fi rst clause requires couplings to meet ANSI/AGMA 9000 Class 9, which states that the coupling’s center of rotation must not deviate more than 0.05 millimeters (0.002 inches) from the rotating axis of the machine to which it is connected. While OEMs must produce couplings accurately to achieve this standard, couplings that meet this specifi cation typically do not require additional balancing.

h e second clause states that OEMs must balance the components in higher-speed applications in compli-ance with API 671, a mandatory specifi cation that leaves little room for error. OEMs can use a balancing machine to achieve this specifi cation. For a standard coupling, the trans-mission unit and each hub normally have to be balanced to ISO 1940-1 Grade G 0.66, and the assembly check should be balanced to ISO 1940-1 Grade G 6.6. High-speed appli-cations that require this level of balance are often fi tted with keyless or two-key precision shaft ends. If the hubs have standard single keys, balancing the transmission unit should suffi ce.

Smooth Equipment OperationPeter Carlisle, John Crane

Balancing couplings may not be the ultimate solution for vibration issues.

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h e third clause requires OEMs to balance couplings to ISO 1940-1 Grade G 6.3 if the customer specifi es it. Balancing the transmission unit to ISO 1940-1 Grade G 2.5 results in a better level of installed balance, however, particularly with stan-dard bore and keyed shafts.

Some projects rely on ear-lier editions of the API 610 standard, particularly the 8th edition. h at edition includes a requirement for balancing all components to ISO 1940-1 Grade G 1.0, which, in prac-tice, means balancing the trans-mission unit and both hubs. h is requires that OEMs bal-ance the hubs before machin-ing the keyway, wasting time and resources. Furthermore, the ANSI/AGMA 9000 Class 9 coupling standard is the only mandatory requirement in the latest API standard.

Balancing Hubs with Standard Keywaysh e standard steps for balancing hubs with keyways are: • Bore the hub to the correct size• Balance the hub as a component• Machine a keyway into the bore

Because of the key and keyway’s tolerances, the volume of material removed above the key varies signifi cantly, which also aff ects the balance of the hub in an average-sized coupling. As a result, hubs with keyways that technically meet balanc-ing standards may still cause vibration in the equipment, even though the goal of balancing is to eliminate vibration. h is means that customers who request coupling balancing accord-ing to API standards often do not realize any benefi t.

As an example, the 8th edition of API 610 requires a

14.8-kilogram hub with a 100-millimeter bore installed in a machine that operates at 3,600 rpm to be balanced in two planes so that the maximum residual imbalance is less than 19.6 grams-millimeter/plane. h e standard then requires a single keyway to be machined into the coupling hub and for the hub to be fi tted to the shaft with a key. Keyway standards specify a certain amount of clearance over the key. In this example, the standard key is a 28-millimeter by 16-millime-ter key, and the permitted mean clearance is 0.65 millimeter. h us, the “missing mass” caused by this clearance is 7.76 gm. h e hub is located at a radius of 56.5 millimeter, creating a potential imbalance of 438 gram-millimeter, or 22 times the hub balance limit.

h is example demonstrates that API balancing standards ignore the imbalance caused by the key extending beyond the end of the hub boss, or the eff ect of the key’s rounded ends. While customers may meet generally accepted API standards by

Figure 1. The keyway has a clearance over the top of the key with a relatively large tolerance.

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balancing their couplings, they often do not reduce vibration.In addition, slip fi ts can disrupt the balance of a piece

of machinery. Taking the example above, a typical H7/g6 slip fi t could result in a total clearance of 0.069 millimeter or an axis displacement of 0.034 millimeter when the set screws are tightened. h is introduces an imbalance of 500 gram-millime-ter in a 14.8-kilogram hub. While this is a worst case scenario, customers could certainly expect an average imbalance of 250 to 300 gram-millimeters, more than 10 times the ISO 1940-1 Grade G 1.0 limit.

If we take this case a step further, here are the potential repercussions:• Imbalance caused by keyway: 438 gram-millimeters• Imbalance caused by slip fi t: 500 gram-millimeters• ISO 1940-1 Grade G 1.0 residual imbalance: 39.2 gram-

millimeters (19.6 gram-millimeters x 2)• ANSI/AGMA root mean square (RMS) imbalance: 666

gram-millimeters

If the hub was balanced to ISO 1940-1 Grade G 6.3 (247 gram-millimeter), then the ANSI/AGMA RMS balance would be 709 gram-millimeters, an increase of 6 percent.

It is evident from the example above that balancing a cou-pling and then machining in a keyway can cause huge issues since the clearance over the key has an inevitable eff ect on the

coupling’s overall balance. Note that this example also does not take into account other assembly errors or shaft balancing, which can create additional balance issues. If equipment has vibration problems, end users should tackle the true causes of imbalance by specifying the ANSI/AGMA class and consider-ing all causes of installed vibration.

Balancing Can Cause Production DelaysIn addition to the vibration issues that balancing can cause, balancing coupling components is an involved and time-con-suming process. As a result, the balancing process delays the fi nal assembly of equipment while providing no added value to the customer, who is paying for the balancing service.

h erefore, customers should consider their couplings’ spec-ifi cations carefully before requesting balancing. Specifi cations are particularly important when couplings operate slower than

3,800 rpm to avoid paying for services that have no benefi t.

P&S

Peter Carlisle is John Crane EAA’s product line director for couplings. His work with the com-pany has included design, application

and research on the fundamentals of power transmission couplings, and he served as group engineering manager for many years and has also held roles in sales management and operations management positions. He can be reached at +44 161 886 6290 or [email protected].

John Crane is a provider of engi-neered products and services for major process industries, including oil and gas extraction and refi ning, power generation, chemical produc-tion, pharmaceutical manufactur-ing, pulp and paper production and mining. For more information, visit www.johncrane.com.

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Growth and innovation in industrial pump design and operation are often driven by

outside forces. A common force is the creation of a new market. A recent example relating to new opportuni-ties for transfer pumps was the U.S. Environmental Protection Agency’s (EPA) announcement of tougher emission-control standards for on-road vehicles would be phased in from 2007 to 2010.

Specifi cally, all new, on-road vehicles must meet a tailpipe-emis-sion standard of 0.2 grams of nitro-gen oxide (NOx) per brake horse-power-hour (g/bhp-hr). h is is a huge reduction in NOx and particulate matter that can be legally emitted into the atmosphere, especially considering that the standard in 1994 was 5.0 g/bhp-hr in 1994 and remained at 1.2 g/bhp-hr as recently as 2007.

When the manufacturers of diesel-powered vehicles looked for ways to make their vehicles compliant with these new regulations, they turned to Europe, where similar mea-sures had been in place since the early 1990s. One of the most popular ways to control NOx emissions on European diesel vehicles was through the use of diesel exhaust fl uid (DEF), originally known in Europe as aqueous urea solu-tion 32 (AUS 32), which is a urea-based chemical reactant consisting of 32.5 percent urea and 67.5 percent deionized water that is injected into the vehicle’s exhaust stream. h e most common process for this injection is called selective catalytic reduction (SCR), in which the exhaust is turned into harmless nitrogen and water vapor.

h is commitment to the injection of DEF—which has been called the largest addition to the motor-vehicle liquids marketplace in decades—and its role in the SCR process as the main way for diesel-powered vehicles to meet the EPA’s regulations has opened a new market in the U.S. h ough

estimates vary, it is safe to say that the amount of DEF that will be consumed in the U.S. by the year 2014 will be between 300 million and 600 million gallons annually.

With the advent of this new market comes the creation of a new supply chain, one that must be populated with enough DEF to keep every diesel-powered vehicle on the road compliant with the EPA’s mandate. h is article dis-cusses how advances in DEF-handling pumping technology and its use at critical points along the supply chain will help optimize the availability of DEF to end users who rely on it to keep their diesel-powered fl eets compliant.

The Challenges of Moving DEFWhen new motor-vehicle liquid enters the marketplace, the companies that develop equipment to produce and handle it must identify the liquid’s characteristics. DEF has a number of unique characteristics to consider:• Because of its water content, DEF freezes below 12

degrees F (-11 degrees C), meaning it must be protected from extreme cold during storage.

• When DEF freezes, it goes from a liquid state directly to a solid with no intermediate “slushiness” stage.

• DEF can freeze and thaw with no resulting degradation of the urea solution.

Effi ciency Matters

The DEF Market

F. Scott Jackson, Blackmer

The diesel exhaust fl uid market creates opportunities for pump manufacturers.


• It is stable at storage temperatures up to 84 degrees F (29 degrees C). Exposing DEF to heat above 90 degrees F (32 degrees C) will decrease its useable shelf life.

• When exposed to air, the water in DEF evaporates and produces crystal-lized urea, which can harm the vehicle’s SCR unit and any transfer or pump components.

• DEF must not become contaminated during its handling. If it does, the SCR system can be compromised, which could lead to problems such as engine failure.

For pump manufacturers, the most important of DEF’s characteristics is its incompatibility with a number of materials that are commonly used in the auto-motive liquid supply chain—such as aluminum, bronze, carbon steel, copper, iron, nickel and zinc. However, stainless steel, polytetrafl uoroethylene (PTFE), fl uoro-carbon and composite plastics such as polyethylene or PVC are compatible with DEF’s corrosive properties.

Selective Catalytic Reduction Defi ned

Selective catalytic reduction (SCR) was originally developed in Europe as a way to reduce emissions in power plants and utilities. In the 1990s, German

automotive giant Daimler AG became the fi rst automotive company to use SCR technology in mobile applications for the control of emissions from light-, medium- and heavy-duty diesel vehicles.

In an SCR system, diesel exhaust fl uid (DEF)—urea and purifi ed water—combines with engine exhaust in the presence of a catalyst to convert nitrous oxide (NOx) to harmless nitrogen and water vapor.

h e actual SCR process begins when hot diesel exhaust from the engine fl ows through a diesel particulate fi lter toward the SCR system. At this point, the DEF is injected into the exhaust stream, which enters the SCR chamber. In the presence of the SCR catalyst, the exhaust and DEF solution react to convert the NOx into nitrogen and water vapor. h is process has been shown to reduce NOx emissions by up to 90 percent, while lowering particulate emissions by more than 95 percent.

Since even small amounts of impurities can severely damage the performance of a vehicle’s SCR system, high-purity water must be used, which will make the DEF in compliance with its ISO 22241 production standards. DEF impurities must also be avoided at all points along the supply chain, which necessitates the need for pumping technology that can adequately clear lines, an advantage of sliding vane pumps.

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Effi ciency Matters

Another major consideration for the DEF-handling pump manufacturers is becoming familiar with the points along the supply chain at which pumping equipment is necessary. As the U.S. DEF market grows and matures, the production and supply processes and the roles of pumps in them, are becoming more well-defi ned:• Tanker trucks and railcars deliver urea and deionzied water

to chemical plants where the components are blended to create DEF.

• h e newly produced DEF is transported by truck or railcar to a terminal storage facility.

• At the storage terminal, the DEF is pumped into packages, generally some combination of 330-gallon intermediate bulk container (IBC) tote, 55-gallon drums and two-gallon bottles.

• h ese packages are delivered to retail fueling centers, auto-motive-product retailers and maintenance-repair shops.

• In some cases, DEF is transported via tanker truck to retail fueling sites (most commonly at large truck stops) where it is transferred into DEF dispensers that are similar to gasoline/diesel pumps and is available for purchase by the public.

Optimizing DEF HandlingTwo crucial pressure points in the supply chain for transfer pumps are from the production plant to the storage terminal and when the DEF is transferred at the terminal location into packages. To aid the DEF producer, transporter and packager, a series of positive displacement sliding vane pumps has been

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created that not only meets DEF’s product-handling needs but has also been designed to be materially compatible with its cor-rosive nature. Additionally, they off er energy-effi cient opera-tion that will help keep energy costs under control.

h ese pumps are also designed and manufactured to meet ISO standard 22241-3:2008, “Diesel Engines: NOx reduction agent AUS32.” h ey will meet or exceed that specifi cation, which includes recommended and not recommended materi-als of construction. h e 22241-3:2008 standard also commu-nicates the level of cleanliness for wetted surfaces that contact DEF during the transfer process to avoid contamination.

When DEF is taken from the production plant to the storage terminal, it is generally by railcar, which can transport

from 10,000 to 15,000 gallons (37,854-56,781 liters) of DEF, or transport truck, which can carry loads ranging from 6,000 to 8,000 gal-lons (22,713-30,283 liters). At the terminal, the DEF must be offl oaded quickly, at rates up to 250 gallons per minute (947 liters per minute).

h e 3-inch pump can deliver fl ow rates up to 250 gallons per minute at speeds of 800 rpm and diff erential pressures up to 125 psi (8.6 bar). h is means that a 6,000-gallon transport truck can be unloaded in as little as 24 min-utes. h e pump’s sliding-vane operation also

makes it better for these types of applications than centrifugal-pump technology because the design allows it to easily prime and pull a vacuum, which centrifugal pumps have a harder time doing, especially when dealing with piping confi gura-tions that have a restricted inlet or long runs. h e pump is also constructed of stainless steel.

When considering DEF transfer from storage tanks into IBC totes, drums and jugs, one series of sliding vane pumps with no pushrods can run at speeds up to 1,200 rpm and can deliver fl ow rates from 49 to 92 gallons per minute (186-348 liters per minute). Some diesel haulers are also dedicating a storage compartment on their straight delivery trucks for DEF


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Effi ciency Matters

and mounting pumps on them so that they can deliver a load of DEF to a fueling site when they make a fuel delivery.

Another pump for the DEF-handling market is a 2-inch pump that will be similar to the 3-inch, with one notable exception: it is designed with pushrods so that it can run at slower speeds, making it ideal for package-fi lling operations that require fl ow rates between 25 and 30 gallons per minute (95 to 114 liters per minute). h e design of the pump also means that it can be used with higher-viscosity fl uids, which opens it up for use in other non-DEF markets.

All the DEF pump models can be powered by a base-mounted electric drive, diesel motor, truck-mounted power take-off (PTO) or hydraulic drive, and they are equipped with a double-ended, straight-keyed drive shaft that allows either clockwise or counterclockwise rotation.

A Look to the Future

h ough the exact size of the DEF market in the U.S. in future years is impossible to predict, there’s no question that the EPA’s emission-control regulations, combined with most diesel-vehicle manufacturers choosing SCR as the best way to satisfy those regulations, leave no doubt that the DEF market will continue to grow. Playing a pivotal role in this growth are the pumps that will be used to deliver raw materials, transfer

fi nished products to storage locations and fi ll packages for eventual use by the end user.

Recognizing the potential in this new market, pumps that are needed at all points in the DEF production-and-supply chain. h e qualities of the sliding-vane operating principle help create transfer pumps that are not only compatible with DEF’s unique characteristics but able to operate in a way that is both energy-effi cient and cost-eff ective for the end user.

P&S

F. Scott Jackson is the product manager, Americas, for Blackmer. He can be reached at [email protected] or 616-248-9218. For more information on Blackmer, please go to www.blackmer.com. Blackmer is a member of Dover Corporation’s Pump Solutions Group (PSG) which is comprised

of several pump companies—Almatec, Blackmer, EnviroGear, Griswold, Mouvex, Neptune, RedScrew and Wilden. For more information go to PSG at www.pumpsg.com.


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Manufacturers and distributors of PTFE gaskets are being asked more frequently why PTFE gaskets do not seal fi berglass reinforced plastic (FRP),

plastic and other light load fl anges. h e answer is simple, but the solution is complex. In a majority of cases, the answer is that too little load is applied to the gasket. Unfortunately, and as is the case in many such instances, the gasket is usually considered the problem (see “Sealing Sense,” January 2008).

However, when other contributing factors are consid-ered, the gasket carries little blame. h is problem must be considered at two stages. First is the original design of the equipment, and the second is how to deal with the equip-ment during installation and maintenance.

Legacy GasketsOriginally, FRP and plastic piping evolved in the process industry due to their low cost and excellent chemical resis-tance. However, neither material approaches the strength of metallic piping. h erefore, fl ange strength limits the amount of bolt torque that can be applied, which then limits the gasket stress. Primarily, the gasket materials used then and now are elastomers, which have good recovery properties and seal at relatively low loads, often with as little as 15 percent compression. However, due to the limited chemical compat-ibility of each elastomer, the selection of the proper elasto-mer must be made carefully. When this problem was com-pounded with the diff erent elastomers often being the same color, improper gasket installations were all too frequent.

Current Gasket ConcernsIn today’s chemical process plants, more exotic chemicals used at higher temperatures and pressures sometimes demand a shift from elastomers to a more chemically inert gasket. PTFE is the logical next choice as it is chemically compatible with all common aggressive chemicals within the pH range of 0 to 14—except molten alkali metals and elemental fl uo-rine (especially at higher temperatures and pressures).

Prevailing StandardAs with metallic piping, most FRP and plastic piping manufac-turers follow ASME standards. ASME’s updated Reinforced h ermoset Plastic Corrosion-Resistant Equipment Standard RTP-1-2011 for vessels operating at pressures not exceed-ing 15 psig teaches the proper practices for design. Non-mandatory Appendix NM-9 Installation of RTP Vessels gives guidelines for gaskets, fasteners, torque, lubrication and other factors related to the success of a bolted fl ange connec-tion. While not mandatory, most in the industry use these guidelines when discussing gaskets for equipment.

Load RequirementsWhile some gasket designs seal at lower loads, most PTFE gasket manufacturers set minimum loads (from 2,500 psi to 3,000 psi) for their materials. However, the lower application pressures and temperatures typical of FRP and plastic piping may lower such requirements. Figure NM9-3 from Standard RTP-1-2011 provides the recommended torque and bolt-up procedure for standard RTP fl anges and manways.

Table 1 shows the resultant gasket stress when the

Why don’t my PTFE gaskets seal FRP, plastic and other light load fl anges?

This month’s “Sealing Sense” was prepared by FSA member Charlie Miskell

From the voice of the fl uid sealing industry

SEALING SENSE

Figure NM9-3. Flange Bolt TighteningReprinted from ASME RTP-1-2011, by permission of The American Society of

Mechanical Engineers. All rights reserved.


suggested torque (Figure NM9-3) is used. Obviously, the resulting gasket loads are well below the minimum threshold necessary to seal with a PTFE-based gasket.

Table 2 shows additional specifi c RTP details that may

aff ect the load delivered to a gasket material in these fl anges. h e third column (added for this article) indicates some sug-gested improvements needed for better PTFE gasket results.

However, at this time, no suitable answer is available for

Table 1. Flange Confi guration and Achievable Gasket Stress for Class 150 Bolting per ASME RTP-1-2011

NPS (in.) ID (in.) OD (in.) BCD (in.) BHD (in.) BD (in.) Number of Bolts

Torque (ft.-lb.)

Gasket Area (in2)

Nut Factor

Gasket Stress (psi)

2” 2.00 6.00 4.75 0.750 0.625 4 25 23.37 0.15 548

3” 3.00 7.50 6.00 0.750 0.625 4 25 35.34 0.15 362

4” 4.00 9.00 7.50 0.750 0.625 8 25 47.52 0.15 539

6” 6.00 11.00 9.50 0.875 0.750 8 25 61.95 0.15 344

8” 8.00 13.50 11.75 0.875 0.750 8 25 88.06 0.15 242

10” 10.00 16.00 14.25 1.000 0.875 12 25 113.10 0.15 243

12” 12.00 19.00 17.00 1.000 0.875 12 25 161.01 0.15 170

14” 14.00 21.00 18.75 1.125 1.000 12 30 180.49 0.15 160

16” 16.00 23.50 21.25 1.125 1.000 16 30 216.77 0.15 177

18” 18.00 25.00 22.75 1.250 1.125 16 35 216.77 0.15 184

20” 20.00 27.50 25.00 1.250 1.125 20 35 255.26 0.15 195

24” 24.00 32.00 29.50 1.375 1.250 20 40 322.16 0.15 159

Manways

24” 24.00 32.50 29.50 0.750 0.625 20 25 368.35 0.15 174

Reprinted from ASME RTP-1-2011, by permission of h e American Society of Mechanical Engineers. All rights reserved.


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FSA Sealing Sense

this dilemma. If the vessel or piping will use PTFE gaskets instead of elastomers, these gaskets have little chance of work-ing unless the recommended guidelines are changed. h is is the main reason that end users experience gasket problems. h ere are two stages of this issue. In defense of the equipment manu-facturers, they are able to increase the fl ange load capability of equipment to allow torques that provide the required stress. However, they have to make these changes in the design stages before quoting the equipment. Most manufacturers will make the appropriate adjustments to lessen this complaint.

Even when torque is increased to a level that should pro-vide the proper gasket load, many additional issues may prevent the proper load. Since end users deal with very low loads, any factor that minimizes the required load on the gasket is signifi -cant. Factors that can aff ect load include: • Misalignment, both axial and angular• Lubrication and a correct value of the lubrication friction

factor (nut factor)

• Quality and grade of the fasteners • Use of used fasteners• Accuracy of the torque wrench used

Any of these factors can determine if the end user will have a successfully sealed bolted fl ange connection. h erefore, end users and their installers must understand these factors and eliminate infl uences that may prevent a true, target gasket.

Suggestions and SolutionsWhen leakage is experienced, the usual fi rst response in the fi eld is applying more torque until the leak is reduced. Usually, this does not cause immediate or catastrophic cracking of the fl anges but puts high stresses on the fl anged connection, but it could cause cracking. FRP piping is extremely “alive” and with its constant motion, vibration, contraction and expansion, the probable result of overstressing the fl ange is to cause premature joint failure and shortened equipment life.

Table 2. ASME RTP-1-2011 Non-Mandatory Installation Guidelines

ASME RTP-1-2011 Non-Mandatory Appendix NM-9 Installation of RTP Vessels Gasket Related Details (for vessels operating at pressures under 15 psig (approximately 30 psi)

Gasket Related Issue RTP Call-Out What is missing? What is the problem created for PTFE gaskets?

Recommended bolt torques for hand lay-up fl anges

See the list in Figure NM9-3 Recommended torque results in gasket loads well below material requirements.

Gasket confi guration Full faced, in cases where a raised face fl ange mates with a fl at faced fl ange, a machined fl at

fi ller ring for the OD is required to provide a quasi-full faced gasket surface.

Flat faced fl anges have large surface areas over which limited gasket load is applied. Non-standard fl anges (top

lids, column segments) tend to have extremely wide contact areas that increase the required torque even

more.

Gasket thickness Minimum 1/8 in. thickness Good feature, no problem. Some non-standard fl anges may require thicker material to compensate for surface

defl ection problems.

Gasket material hardness Not to exceed 65 durometer (Shore A). Generally, in PTFE gasket materials, this is not a property of interest. Specifi c gravity or den-

sity in grams per cubic centimeter is frequently called out instead.

PTFE materials are much harder even when they feel soft.

Use of washers Metal washers to be used under all bolt heads and nuts to avoid fastener contact with FRP

surfaces.

Washers should be defi ned as “hardened through” to prevent cupping and poor surface contact and to more

evenly distribute the load to the gasket.

Bolt and washer seating area Spot facing, this is a slight countersink area into the FRP contact surface to assure parallel-

ism to the fl ange face.

Good feature, no problem.

Lubrication Nut and bolt threads should be lubricated before tightening.

All bearing surfaces should also be lubricated (under the bolt head and washer contact area), and nut factor should be defi ned. The problem created with poor or

incomplete lubrication is that not all the intended torque is transmitted to gasket stress.

Installation bolting practice Bolt up torque to be applied uniformly per cross torque patterns shown in Figure NM9-3

and in 5 foot pound increments.

Good Feature, no problem. Lower load requirements may need to designate increments lower than 5 foot pounds.

Maximum gasket stress Resulting stresses are far too low to effectively seal the fl anges.

Depending on the fl exibility of the vessel/piping manu-facturer to allow higher torques, these may be suitable.

Reprinted from ASME RTP-1-2011, by permission of h e American Society of Mechanical Engineers. All rights reserved.


If an end user experiences problems, the best advice is to do everything possible to improve the delivered torque and the alignment of the fl ange so that the intended gasket stress is achieved. Use new bolts each time the joint is broken apart. Lubricate all the bearing surfaces including the washers, under the head of the bolt, the bolt face and the threads themselves. Use an accurate and calibrated torque wrench, and follow the torque steps recommended in RTP-1-2011 in 5 foot-pound increments. In the case of very low torques, use 25 percent, 50 percent, 75 percent and 100 percent of target torque as a guide-line. After the fi nal circumferential torque, wait at least four hours, and do one more circumferential torque to 100 percent.

Think Ahead

An equipment manufacturer should think about the gasket before completing the design of the equipment! If the gasket will be PTFE or if the equipment may require PTFE, manufac-turers must compensate beyond the recommendations of RTP-1-2011. Not doing so may result in bolted fl ange connection failure or premature stress fatigue due to a frustrated end user applying more torque than necessary. FSA gasket manufactur-ers can help resolve these and other gasket problems.

Next Month: What properties are most important when select-ing an expansion joint or fl exible connector?

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

P&S

h e following members of the Gasket division sponsor this “Sealing Sense”:American Falcon, Inc.John Craneh e Asbury Graphite Mills, Inc.Latty International S.A.Chicago-Wilcox Mfg. Co.Leader Global TechnologiesA.W. ChestertonLamonsDaikin America, Inc.Nippon Pillar Corp. of America

Nippon Pillar Corp. of America

Donit Tesnit d.d.SGL Technic Polycarbon

Division SGL Technic Polycarbon Division

EGC Enterprises, Inc.Slade, Inc.

Empak Spirotallic Mexicana SA de CV

Teadit International Simrit - Div. of Freudenberg-NOK

EGC Enterprises, Inc.h e Flexitallic Group

Teijin Aramid USA, Inc.h e Flexitallic GroupSlade, Inc.Garlock Sealing Technologiesh ermoseal Inc.Teadit InternationalW.L. Gore & Associates, Inc.Triangle Fluid Controls, Ltd.GrafTech International

Holdings, Inc.YMT/Inertech, Inc.Teijin

Aramid USA, Inc.



Q. We plan to purchase several slurry pumps and understand that this service is considered severe duty. What guide-lines should be followed regarding pump selection based on good wear resistance?

A. Pump wear is aff ected by the pump design, the abrasive nature of the slurry, the specifi cs of the application or duty con-ditions, the way in which the pump is applied or selected for the duty and the actual conditions of service. Wear inside the pump varies signifi cantly depending on the velocity, concentra-tion and impact angle of the particles. It is normally most severe

in the impeller seal face area of the suction liner, followed by the vane inlet and exit. h e casing wear amount and location also vary with the shape of the collector and as a percentage of the actual operating conditions compared to the best effi ciency point fl ow.

With only routine maintenance, many slurry pump wear parts may last for years. Services, such as transportation of high concentrations and very abrasive or large solids, can sometimes reduce a part’s life to several months. Larger pumps with thicker sections, more wear material and slower operating speeds can improve life in all applications, although the signifi -cant associated product cost increase may not be warranted in certain cases.

Analytical and numerical models are available for making qualitative predictions of wear. h eir limitations and the vari-ability of slurry service are such that wetted component life prediction is still only good for estimation and should not be used for guarantees. h ese estimates are normally based on the specifi ed operating condition of the pump and may vary greatly if the pump is operated under signifi cantly diff erent conditions. Using such an analysis, a life-cycle cost (LCC) evaluation of the capital, power, wear and other costs associated with the pump operation can be used to estimate the best balance between dif-ferent pump designs. Such analysis is largely theoretical, how-

ever, as wear can be unpredictable in actual service.Ranking the slurry into light (class 1), medium (class

2), heavy (class 3) and very heavy (class 4) services, as shown in Figure 12.3.4.2a, provides a practical tool for pump selection and, in conjunction with Table 12.3.5a, a means of recommending limiting pump operating heads.

h e boundary lines between the service class areas in the chart approximate limits of constant wear modi-fi ed for practical considerations and experience. Capital and operating cost considerations are such that diff erent (higher specifi c speed) designs may be employed for the lighter service classes.

h e slurry service ranking shown in Figure 12.3.4.2a is based on aqueous slurries of silica-based solids pump-ing (Ss = 2.65). It can also be used to provide guidance for mineral slurries if an equivalent specifi c gravity for the mineral slurry is used to determine the service class.

Additional information regarding slurry pumps can be found in ANSI/HI 12.1-12.6, Rotodynamic (Centrifugal) Slurry Pumps for Nomenclature, Defi nitions, Applications, and Operation, which is available at www.Pumps.org.

Q. Besides the obvious fi nancial benefi ts derived from energy savings, what are the other important economic benefi ts of pump system optimization that aff ect the total cost of ownership?

A. When conducting a pump system optimization analysis, it is essential to look beyond the energy savings to capture the less apparent economic factors that can have a positive eff ect on the bottom line. Plant and corporate managers’ incentives are typi-

PUMPFAQs®

Figure 12.3.4.2a — Service class chart for slurry pump erosive wear


cally to minimize initial costs as a means to increase company profi ts when considering the investment of capital funds.

Decision makers historically have been more attuned to investing in projects that translate directly to the bottom line, such as capacity expansion versus lowering energy demand. Most energy effi ciency projects have additional economic ben-efi ts that are overlooked, including the following:• Higher productivity and product quality• Higher reliability and lower maintenance• Better environmental compliance• Reduced waste byproducts• Increased capacity and throughput• Improved worker safety

It is widely recognized that energy effi ciency projects stand a better chance of being funded if their ancillary benefi ts have been taken into consideration. Another way of looking at these projects is to consider the energy savings, which are often easier to identify, as fi nancial justifi cation for more appealing improvements, such as increased equipment reliability or better process management. h erefore, it is important to identify the savings opportunities associated with all LCC elements to help decision makers move forward with projects classifi ed as energy effi ciency.

Q. What diff erent types of couplings can be used on pumps, and what are their functions?

A. h e main function of pump couplings is to provide a mechanically fl exible connection between two in-line shaft ends. Essentially, couplings join two pieces of rotating equip-ment. h eir function is to transmit power while allowing some degree of misalignment or end movement.

h ree basic types of couplings are: mechanical, elastomeric and metallic. h e mechanical element types generally obtain their fl exibility from a combination of loose-fi tting parts and the rolling or sliding of mating parts. h ey typically require lubrication unless one moving part is made of a material that provides its own lubrication.

h e elastomeric element types obtain their fl exibility from the stretching or compression of the material. Metallic element types obtain their ability to withstand misalignment and expan-sion from the fl exing of thin metallic discs or diaphragms.

h e type of pump couplings that should be used is related to the power required by the pump. A small pump can be considered a pump under 100 horsepower. Since these pumps require a relatively low power input, they are able to use cou-plings where the fl exible element can easily be inspected and replaced when necessary.

If there is a coupling failure due to high-torque loads or excessive misalignment, the fl ex element of the coupling

normally is replaced. However, typically no damage occurs to other components. Types of couplings for smaller pumps include fl exible grid, disc and elastomeric. In some small gear coupling designs, no lubrication is need because the outer sleeve is made of nylon or plastic.

Medium-power pumps use fl exible grid, gear, disc and elastomeric type couplings. h ese couplings will exhibit good longevity, with premature failure occurring only when improper application or installation, lack of proper lubrication or excessive misalignment is a factor. Elastomeric couplings are used frequently for applications in which very high cyclic peaks occur since they minimize torsional loads on the equipment.

High-horsepower pumps are essential to ensure continu-ous operation at most facilities, and therefore, the selection and installation of their couplings are critical. For high-speed, high-torque applications, high-performance gear, disc or diaphragm couplings are frequently specifi ed by the user.

h e couplings are highly engineered designs that are man-ufactured and balanced specifi cally for the application. Many of these couplings use special alloy materials and fasteners.

P&S

Pump FAQs® is produced by the Hydraulic Institute as a service to pump users, contractors, distributors, reps and OEMs as a means of ensuring a healthy dialogue on subjects of common technical concern.

HI standards are adopted in the public interest and are designed to help eliminate misunderstandings between the manufacturer, the purchaser and/or the user and to assist the purchaser in selecting and obtaining the proper product for a particular need.

As an ANSI approved standards developing organiza-tion, the Hydraulic Institute, process of developing new stan-dards or updating current standards requires balanced input from all members of the pump community.

We invite questions and will endeavor to pro-vide answers based on existing HI standards and technical guidelines. Please direct your inquiries to: [email protected].

For more information about HI, its publications, Pump LCC Guide, Energy Saving Video-based educa-tion program and standards, please visit: www.pumps.org. Also, visit the new e-learning portal with a compre-hensive course on “Centrifugal Pumps: Fundamentals, Design and Applications,” which can be found at: www.pumplearning.org.

On pump-zone.com…

Read our archive of HI Pump FAQs articles.


Regenerative Turbine PumpCorken introduces the model 060 regenerative turbine Coro-Flo pump. It is a continuous-duty design and is available with two mounting options—frame mount for direct, belt drive confi gurations or a direct mount that bolts to a standard C-Face 60 Hz (3450 rpm) motor. h e fl ow range is 7 to 22 gallons per minute (26.5 to 83.3 liters per minute) with a maximum diff eren-tial pressure of 150 psig (10.3 bar) at 60 Hz. Circle 201 or go to psfreeinfo.com

Snap-In I/O Known for its programmable logic con-trollers with integrated HMIs, Unitronics introduces the latest member of its Snap-in I/O Module series: the V200-18-E46B. h is new module brings more fl ex-ibility to the Vision series controllers by supporting more I/O, all in one low cost unit. h e PLC + HMI package exempts machine manufacturers from setting up Panel-PLC communication.Circle 202 or go to psfreeinfo.com

Immersible Wastewater PumpsSmith & Loveless introduces its I-Series Immersible Wastewater Pumps with premium effi ciency motors, off ering wastewater pump-ing with emergency fl ood protec-tion. Available for new and retrofi t applications in lift stations and treatment plant operations, these heavy-duty pumps can be immersed for up to two weeks in fl ooding conditions and have capacities up to 5,000 gallons per minute.Circle 203 or go to psfreeinfo.com

Actuator Control System Rotork Fluid Systems off ers a new actuator package designed for dependable actuator control of pump control valves. h e system protects discharge pumps and piping systems from reverse fl ow and water hammer. It has a specially designed hydraulic manifold, which eliminates control circuit piping and potential leak points. h e manifold block includes speed controls for open, close and emergency shutdown and a hydraulic solenoid control valve. Circle 204 or go to psfreeinfo.com

Product Pipeline


Pump Systems Optimization:Energy Efficiency & Bottom-Line Savings

PumpSystemsMatter.org/Training 973.267.9700 x200

TRAIN: your customers, distributors and staff by hosting a one-day

course at your desired location and date. Hosting provides opportuni-

ties for suppliers and users to learn and network together for systems

savings. Turnkey package includes instructor and up to 25 sets of par-

ticipant guides, text books and more. Please call to learn more about

pricing and participant reimbursement programs.

Knowledge = Savings2

Average Pump Systems Efficiency of 1,690 Pumps

31 Pumping System Assessments

Professional Development

$5 Million Savings

Participants Earn 7 PDH Credits

Less than 40%

U N M AT C H A B L E E X P E R I E N C E

I N P R I VAT E C O M PA N Y

T R A N S A C T I O N S

MEMBER FINRA, SIPC

Jordan, Knauff & Company is a knowledgeable and experienced provider of a comprehensive line of investment banking services to the pump, valve and filtration industries (“Flow Control”).

Our lines of business include: selling companies, raising debt and equity capital, and assistance on acquisitions.

To learn more about Jordan, Knauff & Company, contact any member of our Flow Control team. Access our Flow Control research at www.jordanknauff.com/flowcontrol.

G. Cook Jordan, Jr.Managing Principal

[email protected]

David A. KakarekaAssociate

[email protected]

[ MOTOR TRUTH #3 ]

The savings

don’t add up!

Putting a premium efficient motor onto a single stage worm gear unit does not compute! It’s because the motor is only one part of the equation.

Why gain 3% energy with a premium efficient motor and then lose up to 50% or more through the worm gear?

Visit sewmotortruth.com to get the whole story on energy-efficient drivetrains.

sewmotortruth.com

?



Product Pipeline

Pressure Sensor with New TERPS

TechnologyGE’s Trench Etched Resonant Pressure (TERPS) technology is now available for the fi rst time in a range of new pressure sen-sors from the sensing business of GE Energy, Measurement & Control Solutions. h e RPS 8000 and the DPS 8000 resonant silicon pressure sensors off er accuracy and stability greater by a factor of ten over existing piezoresistive pressure sensors and signifi cantly extend the pressure range capability conventionally associated with resonating pressure technology (RPT) sensors. Circle 205 or go to psfreeinfo.com

Thermostatic Expansion ValvesDanfoss announces that the universal TR6 thermostatic expansion valve is available in seven models that cover original equipment manufacturer (OEM) air-conditioner and heat pump designs in a wide range of applica-tions, from 1.5 to six tons in R-22 and R-410A systems. All

aftermarket TR6 valves have ⅜ -inch by ⅜ -inch connections and come with Aeroquip and Chatleff fi ttings, meaning they easily install into almost any residential air conditioning system. Circle 218 or go to psfreeinfo.com

Heavy-Duty Air CylinderAir Engineering and Supply announces the manufacture and national distribution of the widely used 1.12-inch bore and up to 20-inch standard stroke with longer strokes available upon request. h ese are the popular and widely used double acting 18D and 18SD models available in both stud and universal mounts. Both are 1.12-inch bore models and feature nitrile seals rated for 180 degrees F and 150 psi max.Circle 206 or go to psfreeinfo.com

To have a product considered for ‘Product Pipeline,’ please send information to Lori Ditoro at Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253, 205-314-8269, [email protected]. P&S

Advanced Engineered Pump, Inc. 148 70

Advanced Sealing International (ASI) 114 27

Amtech Drives 115 29

Baldor Electric Company 101 49

Blue-White Industries 116 17

Carver Pump Company 117 11

Conhagen 138 58

Dan Bolen & Associates, LLC 149 70

Dickow Pump Company 118 21

Flexitallic 102 47

Flexitallic 150 69

Frost & Sullivan 139 63

FW Murphy 119 9

Garlock Sealing Technologies 103 5

General Polygon Systems Inc. 140 63

Global Pump 104 53

Graco, Inc. 131 37

Graphite Metallizing Corp. 141 56

Heinrichs USA LLC 142 61

Hitachi America Ltd. 132 36

Hydraulic Institute 143 66

Hydro, Inc. 100 IFC-1

Inpro/Seal 121 13

International Products Corporation 152 70

ITT Process 105 23

John Crane 122 50-51

Jordan, Knauff & Company 144 66

Junty Industries, Ltd. 153 71

KSB, Inc. 106 33

Liquid Controls Group 133 45

Liquil o 107 59

Littelfuse 108 BC

Load Controls, Inc. 123 43

LobePro 151 71

LUDECA Inc. 145 61

Magnatex Pumps, Inc. 154 69

MasterBond Inc. 155 69

Meltric Corporation 156 71

Munil o 163 69

NETZSCH 146 56

NOC 157 68

PCM USA, Inc. 134 37

PPC Mechanical Seals 124 32

Pump Pros 135 57

Pump Solutions Group 136 55

Pumping Machinery 158 71

PumpWorks 610 137 52

R+W Coupling Technology 125 31

Ruthman Companies/Gusher Pumps 160 15

Scenic Precise Element Inc. 159 71

seepex, Inc. 126 22

SEPCO 127 10

SEPCO 164 70

SERFILCO, Ltd. 147 58

SEW EURODRIVE 109 67

Sims Pump Co. 110 25

Sims Pump Co. 110 69

Smith & Loveless 128 41

Summit Pump, Inc. 161 69

TECO-Westinghouse 111 39

Trachte, USA 162 70

Tuf-Lok International 166 70

Varisco 167 71

Vaughan 112 IBC

Vertil o 165 70

Vesco 168 70

Viking Pump 120 24

Warren Rupp, Inc. 129 14

Waukesha Bearings 130 38

Xylem 113 3

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

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

INDEX OF ADVERTISERS


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P&S Market


P&S Market

The Jordan, Knauff & Company (JKC) Valve Stock Index was down 12.5 percent for 2011, well below the broader S&P 500 Index, down

only 1.1 percent. h e JKC Pump Stock Index was also down 19.2 percent. Both indices kept pace with the S&P 500 during the beginning of the year and then fell behind during the last fi ve months of 2011.

h e U.S. manufacturing sector continues to record modest gains. h e Institute for Supply Management’s Purchasing Managers Index (PMI) rose to 53.9 in December from 52.7 in November. Production and employment came in at 59.9 and 55.1, respectively. Ten industries reported production gains in December—including primary metals, machinery, electrical equipment and comput-ers. Export orders were up, suggesting less risk due to European debt worries. h e New Orders Index increased 0.9 points to

57.6, a third month of growth after three months of contrac-tion. Raw material prices decreased for the third month.

h e latest National Association of Manufacturers (NAM)/IndustryWeek Survey of Manufacturers suggests that manu-facturers are more confi dent in the economy—80.2 percent recorded a positive outlook, up from September’s 65.4 percent. More than 72 percent of NAM members expect sales to increase over the next 12 months. About half expect 5 percent growth, and one out of fi ve predicts growth will exceed 10 percent.

h e Conference Board’s Consumer Confi dence Index jumped to its highest level since April 2011, from 55.2 in November to 64.5 in December. Of the components that make up this index, perceptions about the current and future eco-nomic environment improved.

h e Bureau of Labor Statistics reported that the economy

added 200,000 jobs in December. h e unemployment rate dropped to 8.5 percent, its lowest level since February 2009. Job gains occurred in transportation and warehousing, retail trade, manufacturing, health care and mining. Manufacturing employment expanded by 23,000.

Absent a signifi cant oil supply disruption, the U.S. Energy Information Administration expects the recent tightening of world oil markets to moderate in 2012 then resume in 2013. World oil consumption grew an estimated 1 million barrels

per day (BPD) in 2011 to 88.1 million BPD. h is growth is expected to accelerate during the next two years with consump-tion reaching 89.4 million BPD in 2012 and 90.9 million BPD in 2013. U.S. rig counts increased during 2011, with 2,003 rigs in operation in December. Worldwide rig counts were 3,612 in December with an average of 3,466 rigs in operation in 2011.

P&S

Wall Street Pump and Valve Industry WatchJordan, Knauff & Company

Jordan, Knauff & Company is an investment bank based in Chicago, Ill., that provides merger and acquisition advisory services to the pump, valve and fi ltration industries. Please visit www.jordanknauff .com for further information.

Figure 2. U.S. Energy Consumption and Rig Counts

Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates. h e JKC Pump and Valve Stock Indices include a select list of publicly-traded companies involved in the pump and valve industries weighted by market capitalization.

Source: U.S. Energy Information Administration and Baker Hughes Inc.

Figure 3. U.S. PMI Index and Manufacturing Shipments

Source: Institute for Supply Management Manufacturing Report on Business® and U.S. Census Bureau.

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0


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pm6782

Documents

national oilwell varco

smart conveying technology

cahaba media group

atlas cell testing

vertical pumpsalso inside

dry heat resistance

idex corporationmany options

heat distortion temperature