Pump & System - August 2014

8/18/2019 Pump & System - August 2014

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OPTIMIZE

PUMPING SYSTEMSDiligent analysis, rigorous scrutinylead to longer system life

AUGUST 2014

PUMP-ZONE.COM

TURBOMACHINERY &PUMP SYMPOSIATrade Show Preview

SEALS & BEARINGSTips for MaximizingPERFORMANCE

6 Considerationsfor REFINERY PumpMAINTENANCE


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We’ll Find It

Before It FailsHydro’s highly skilled pump improvement engineers provide complete reliability support for

your pump installation base, whether the equipment is recently commissioned or has been in

service for many years. Using the latest technology and our broad experience from the field,

we identify problems early – ensuring longer life and improved performance. And if you’re

faced with an existing problem that is difficult to solve, our field engineers are here to help.

Expert On Site Testing and Diagnostics

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Sometimes what doesn’t happen matters most.


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Hydro’s driving force is engineering. To

help our customers maintain critical pump

equipment, Hydro’s pump improvement

engineers review the pump operating and

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site inspection, and perform in-depth pump,

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Vibration Analysis

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August 2014 | Pumps & Systems

From the EditorT

his month we introduce an exciting, fresh,

modern look to our logo and design that has been

thoughtfully crafted to make the magazine easier for

you to read and navigate. While the look has been

updated, the content remains the same high-qua lity

technical pumping information that you can’t find

anywhere but in the pages of Pumps & Systems.

It makes sense that we introduce this change with

a focus on the increasingly vital topic of pump system

optimization. Not long ago, the components of a

pumping system were designed separately, purchased

separately and maintained separately. anks to

advancements in technology and increased standards

and awareness and the Hydraulic Institute’s devel-

opment of Pump Systems Matter, today the entire system is examined and modified to

decrease life-cycle costs and save energy.

On average, industria l pumps operate at less than 40 percent effi ciency, and more than10 percent of pumps run at less than 10 percent effi ciency. is impacts the bottom line.

“e cost to pump ineffi ciently is beyond your wildest imagination,” says Mike Pember-

ton, ITT Performance Services Manager and Pumps & Systems Editorial Advisory Board

member. “In the past several decades, pump effi ciency has only increased 3 percent by

design. e biggest advantage in increasing effi ciency is happening with automation and

controls.” e infrastructure is in place, but the question remains, “How do we optimize?”

is year, Pumps & Systems published a three-part series from HI examining the Depart-

ment of Energy’s pump effi ciency regulation changes (Jan.-March 2014, www.pump-zone.

com). e series describes how to reduce the burden on U.S. pump manufacturers and support

the DOE’s efforts to achieve energy savings and effi ciency improvements in the marketplace.

According to Pump Systems Matter, the most likely candidates for optimization are

large systems, systems with high operating hours, problem systems and production-crit-ical systems. e most common red-flag symptoms are high energy costs, throttle valves

that are generally closed, bypass va lves/recirculation lines that are generally open, fre-

quent failures or repair requirements, high operating noise levels (especially at the valve

or pump), vibrations in the system and/or pump assembly, systems with multiple parallel

pumps with the same number of pumps always operating, constant pump operation in a

batch environment or frequent cycle batch operation in a continuous process, and systems

that have undergone a change in function. Learn more by visiting www.pumps.org.

You can find a wealth of solutions by reading this month’s cover series, which begins on

page 60. As always, pump effi ciency will be a major topic at the 43rd Turbomachinery and

30th Pump Symposia in Houston, Sept. 23 – 25. Visit the Pumps & Systems team at Booth

514, and tell us about your pump optimization success stories.

EDITORIAL

EDITOR: Michelle [email protected] • 205-314-8279

MANAGING EDITOR: Lori K. [email protected] • 205-314-8269

SR. EDITOR, PRODUCTION & CONTENT MARKETING:

Alecia [email protected] • 205-314-3878

ASSOCIATE EDITOR: Michael [email protected] • 205-314-8274

ASSOCIATE EDITOR: Savanna [email protected] • 205-278-2839

CONTRIBUTING EDITORS: Laurel Donoho,Joe Evans, Lev Nelik, Ray Hardee

CREATIVE SERVICESSENIOR ART DIRECTOR: Greg Ragsdale

ART DIRECTORS: Jaime DeArman, Melanie Magee

WEB CONTENT EDITOR & WEB ADVERTISING TRAFFIC:Robert Ring

PRINT ADVERTISING TRAFFIC: Lisa [email protected]

205-212-9402CIRCULATIONAUDIENCE DEVELOPMENT MANAGER:

Lori [email protected] • 205-278-2840

ADVERTISING

NATIONAL SALES MANAGER:

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

MARKETING ASSOCIATES:

Ashley [email protected] • 205-561-2600

Sonya [email protected] • 205-314-8276

PUBLISHER: Walter B. Evans, Jr.

VP OF SALES: Greg Meineke

VP OF EDITORIAL: Michelle Segrest

CREATIVE DIRECTOR: Terri Jackson

CONTROLLER: Tim Moore

P.O. Box 530067Birmingham, AL 35253

EDITORIAL & PRODUCTION

1900 28th Avenue South, Suite 200Birmingham, AL 35209205-212-9402

ADVERTISING SALES

2126 McFarland Blvd. East,. Suite ATuscaloosa, AL 35404205-345-0784

Pumps & Systems is a member of the following organizations:

PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicalspostage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves theright to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US andpossessions $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 andform 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. ©2014 Cahaba Media Group, Inc. No part ofthis publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, thefactual accuracy of any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered bythe authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions ofCahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any adver-tisements contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending usyour submission, you grant Cahaba Media Group, Inc., permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submis-

sion in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissionswill not be returned. Volume 22, Issue 8.

Michelle Segrest with ITT’s MargaretGan at the 2014 Offshore TechnologyConference. The Pumps & Systems team returns to Houston for theTurbomachinery/Pump Symposia inSeptember.

Editor, Michelle Segrest


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Motors | Automation | Energy | Transmission & Distribution | Coatings

Features that make a difference:

Dual rated for 60 Hz and 50 Hz @ 190-220/380-415 V

Optimized ventilation system for cooler operation

Robust feet design for the toughest applications

Frames 182/4T and larger have two eyebolts for easy mounting in any position

Oversized diagonally split aluminum terminal box that exceeds IP55 requirements. (Ideal for easy

installation and tough environments).

Terminal box is rotatable in 90 degrees increments for easy installation

AEGIS® ring inside (optional) to extend bearing life when used with VFDs

IP55 ingress protection is standard

Suitable for VFD operation per NEMA MG1 part 31.4.4.2

Color coded leads for easy installation

Motor paint resistance exceeds 500 hours of salt spray test

Transforming Energy into Solutions www.weg.net/us

Please contact your authorized WEG distributor or go to weg.net/us for further

information or additional specifications.

1-800-ASK-4WEG

WEG Rolled Steel LineGreat WEG quality and flexibility in a new LIGHTER frame

Investing over 2.5% of our revenue in R&D for electric motors every year, WEG takes pride in engineering and

manufacturing motors that run cooler, last longer, and are easy to install and maintain.

Available in Open Drip and Totally Enclosed designs our WEG Rolled Steel line is the perfect example of these efforts.

A product line with superior features that make a big difference for our customers.



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AUGUSTThis issue

60 STREAMLINED MOTORMANAGEMENT SYSTEM BOOSTSBIOMASS POWER GENERATION

BY Matthias Borutta

Phoenix Contact

Trusted gateway connections allowfor system growth, effi ciency andconsistent maintenance at Swedishpaper mill.

64 INTELLIGENT MONITORINGDELIVERS REAL-TIMEPUMP PERFORMANCE DATA

By Mike Pemberton

ITT Pro Services

An energy effi ciency and reliabilitystudy helped one plant save $1 millionannually by avoiding downtime.

69 CLOSE INSPECTIONSOLVES HIGH THRUST BEARINGTEMPERATURE PROBLEM

By Gary DysonHydro Inc.

Careful analysis identified the issuewith this multistage oil transfer pump.

73 SYSTEM SELECTION CRUCIAL FOR LONG WASTEWATER

PUMP LIFE

By Lars Bo Andersen

Grundfos Wastewater

Driving down investment, energyand maintenance costs translatesinto big savings throughout an

installation’s lifetime.

76 REDUCER FITTINGS DECREASEPIPE SIZE TO PREVENT FAILURE

By Ross Mahaffey, Aurecon and Stefanus Johannes vanVuuren, University of Pretoria

Design of the pump inlet piping canprotect overall operation.

COVERS E R I E S

PUMP SYSTEM

OPTIMIZATION

COLUMNSPUMP ED 101

20 By Joe Evans, Ph.D. Pump Tech Inc.

ree-Phase Voltage Variation& Unbalance

PUMPING PRESCRIPTIONS

26 By Lev Nelik, Ph.D., P.E. Pumping Machinery, LLC

Simplify the EquipmentSelection Process

PUMP SYSTEM IMPROVEMENT

28 By Ray HardeeEngineered Software, Inc.

System Validation & Troubleshooting

GUEST COLUMNS

36 By Heinz P. Bloch, P.E.

Pushing Fluid Machinery Leadsto Failure

40 By Amin Almasi

Estimate Pump Installation Costs

DEPARTMENTS

84 EFFICIENCY MATTERS

Smart Air Distribution SystemsUpgrade Traditional AODD PumpTechnology

89 MAINTENANCE MINDERS

6 Refinery Pump Maintenance Tips

94 MOTORS & DRIVES

e Differences Between Submersible& Immersible Motors

98 SEALING SENSE

Expansion Joint Selection OptimizesPiping Systems

102 HI PUMP FAQS

Understand Specific Speed & DiscDiaphragm Pump Coupling

64

60

Volume 22 • Number 8

Cover photo courtesy of Colfax Fluid Handling


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©

2 0 1 4 W

e a t h e r f o r d .

A l l r i g h t s r e s e r v e d .

Your business can’t runon a fabrication order.

PUMP AND FLUID SYSTEMS

Contact and collaborate with us at [email protected]

We deliver the pump you need without the wait.

Pressure ratings from500 psi (3.6 MPa) to10,000 psi (207 MPa)

Flowrates from

1 to 1,680 gpm

Power ratings from

2 to 700 hp

Formation Evaluation | Well Construction | Completion & Stimulation | Production



8/133


This issueSPECIALS P E C I A L

S E C T I O N

THOMAS L. ANGLE, P.E., MSC, Vice PresidentEngineering, Hidrostal AG

ROBERT K. ASDAL, Executive Director,Hydraulic Institute

BRYAN S. BARRINGTON, Machinery Engineer,Lyondell Chemical Co.

KERRY BASKINS, VP/GM, Milton Roy AmericasWALTER BONNETT, Vice President GlobalMarketing, Pump Solutions Group

R. THOMAS BROWN III, President,Advanced Sealing International (ASI)

CHRIS CALDWELL, Director of AdvancedCollection Technology, Business AreaWastewater Solutions,Sulzer Pumps, ABS USA

JACK CREAMER, Market Segment Manager –Pumping Equipment, Square D by SchneiderElectric

BOB DOMKOWSKI, Business DevelopmentManager – Transport Pumping and AmusementMarkets/Engineering Consultant, Xylem, Inc.,Water Solutions USA – Flygt

DAVID A. DOTY, North American Sales Manager,Moyno Industrial Pumps

WALT ERNDT, VP/GM, Crane Pumps & Systems

JOE EVANS, Ph.D., Customer & EmployeeEducation, PumpTech, Inc.

RALPH P. GABRIEL, Chief Engineer – Global,John Crane

BOB LANGTON, Vice President, Industry Sales,Grundfos Pumps

LARRY LEWIS, President, Vanton Pump andEquipment Corp.

TODD LOUDIN, President/CEO North AmericanOperations, Flowrox Inc.

JOHN MALINOWSKI, Sr. Product Manager, ACMotors, Baldor Electric Company, A Member ofthe ABB Group

WILLIAM E. NEIS, P.E., President, NortheastIndustrial Sales

LEV NELIK, Ph.D., P.E., APICS, President,PumpingMachinery, LLC

HENRY PECK, President, Geiger Pump &Equipment Company

MIKE PEMBERTON, Manager, ITT PerformanceServices

SCOTT SORENSEN, Oil & Gas AutomationConsultant & Market Developer, SiemensIndustry Sector

ADAM STOLBERG, Executive Director,Submersible Wastewater Pump Association(SWPA)

JERRY TURNER, Founder/Senior Advisor,Pioneer Pump

KIRK WILSON, President, Services & Solutions,Flowserve Corporation

JAMES WONG, Associate Product Manager –Bearing Isolator, Garlock Sealing Technologies

EDITORIAL ADVISORY BOARD

2 FROM THE EDITOR

8 READERS RESPOND

10 NEWS

80 TRADE SHOW COVERAGE

118 PRODUCT PIPELINE

124 PUMP USERS MARKETPLACE128 PUMP MARKET ANALYSIS

SEALS & BEARINGS

42 CANNED MAGNETIC BEARINGSMINIMIZE CORROSION IN

OIL & GAS PROCESSING

By Richard R. Shultz

Waukesha Magnetic Bearings

Safely immerse motor compressorsin process gas without riskingcostly damage.

45 THE RIGHT SEAL & LUBRICANTCOMBINATION CAN PREVENTBEARING CONTAMINATION

By James Wong

Garlock Sealing Technologies

Lip and labyrinth seals provideprotection in harsh oil andgas applications.

PRACTICE &OPERATIONS

106 ENERGY EFFICIENT VERTICAL

TURBINE PUMPS PROMOTESUSTAINABLE MINING EFFORTS

By Petar Ostojic

Neptuno Pumps

e computational fluid dynamicsprocess advances highly effi cient pumpdesigns for diffi cult applications.

110 SPECIFIC PUMP & VALVEFEATURES SERVE LIQUEFIEDNATURAL GAS APPLICATIONS

By Gobind Khiani

Fluor Canada Ltd.

LNG benefits have increased thedemand for this cleaner burningfuel and associated production anddistribution equipment.

114 DEWATERING PUMPS HANDLESAND SLURRIES IN POST-HURRICANE RECOVERY

By Mike Bjorkman

BJM Pumps

Reconstruction and infrastructureupgrades require pumps fromdurable materials.

50 SELECT SEALS THAT MEETTHE CHEMICAL CHALLENGES

OF HPLC PUMPS

By Jerry Zawada

Trelleborg Sealing Solutions

Abrasive processing and widetemperature range are some ofthe pumping diffi culties for high-performance liquid chromatography.

54 TREATED CARBIDE SURFACESENHANCE RUNNINGPERFORMANCE

By Mark Slivinski

Carbide Derivative Technologies Inc.is technology self-lubricates, reducesfriction, and performs in wet or dryoperating conditions.

AUGUST


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Borets Equipment is a HPS horizontal

multistage pump manufacturer that

provides pumping solutions withexceptional customer service.

HORIZONTAL PUMPING SYSTEMS

SERVICESERVICEReliable. Quality. Modular.

Horizontal Pumping System (HPS) by Borets Equipment.

Cost-competitive and customizable for your specific application, the HPS equipment

requires less inventory and delivery time than traditional API 610 multistage, verticalturbine can and reciprocating pump equipment.

Engineered for reliability, modularity, and quick replacement of components, the HPS

pump has a lower life cycle cost, thanks to minimized downtime and low maintenance

requirement. The result is a reliable, flexible and innovative pumping system.

You provide the application, we’ll provide the Pump Power and Service.

RELIABLE – FLEXIBLE – INNOVATIVE

w w w . b o r e t s . c o m / H P S

Low Pro Design



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READERS RESPOND

“A Salute toFrank Weis,”

From the Editor

MARCH 2014

I was sent your article

while I was at the

American Water

Works Association

conference in Boston. ank you so

much for writing this and sharing some

of your thoughts on Frank.

I just wanted to share more withsomeone, so I decided to give you more

background. Frank was my first boss

when I joined Smith and Loveless in

1983, fresh out of graduate school. I

won’t go into all the engineering details

I learned from just watching him but

wanted to share the personal side.

I worked for, with and shared lunch

with Frank many days over my next

six years of employment. He treated

everyone the same, from the janitor to

the president of the company. He was

friendly to all, had a great sense of hu-

mor, enjoyed pulling pranks on select

employees, and I never, ever saw him be

upset or have a bad day!

We were both alumni of the Univer-

sity of Missouri, and he loved sports,

had coached his kids baseball and bas-

ketball teams and loved to talk sports

of all kinds. He shared his knowledge

with any that asked, but he was the

most humble guy I have ever known.

He went about his work witha quiet determination and knew

exactly what he was trying to

achieve, even if it didn’t fit with

the views of management at the

moment! He had an amazing

influence on my professional

and personal life, and I tell sto-

ries related to him almost every

week. I left the company in

1989 and moved to Degremont

in Virginia, but his influence

had more impact on me thananyone I have worked with since

that time.

I am now back in Kansas City

and was fortunate enough to

attend the 50th anniversary of

Frank’s work at Smith and Love-

less in 2004. As was typical for Frank,

he didn’t want it to be a big deal, so the

ceremony was held on the shop floor.

Several former employees attended,

many who had long since retired!

I knew then how unique Frank was

but have understood this even more

in the years that have passed. As great

a man as he was from the engineer-

ing and invention side, he was an even

better man overall. e world was a

better place for the time he was here

and for all the individuals that got to

know him.

Andy Mitchell

Director, Business Development

Metawater USA, Inc.

Pumps & Systems Editor Michelle

Segrest responds:

ank you for reading my column aboutFrank Weis (www.pump-zone.com/blog/ salute-frank-weis) and for responding

with these nice comments. e additionalinsight into the life of this legendary pumpinnovator is greatly appreciated. FrankWeis was well respected in the pumpindustry and will be missed by all whoknew him.

READERS responD

To have a letter considered for Readers

Respond, please send it to Michael Lambert,

[email protected].

Frank Weis


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0 NEWS

NEW HIRES,PROMOTIONS & RECOGNITIONS

LARRY LEWIS, VANTON PUMP

HILLSIDE, N.J. (July 10, 2014) – The Board of

Directors of the Vanton Pump and Equipment

Corp. voted to name Larry Lewis as the company’s

president and chief executive officer. Lewis has

served as Vanton’s president since 2010. Vanton

Pump and Equipment Corp. supplies chemically

inert, thermoplastic pumps and systems thatsolve fluid containment, dosing and transfer

problems. www.vanton.com

DAVID BOEZI, DANFOSS

BALTIMORE (June 24, 2014) – Danfoss hired

David Boezi as senior director, strategy and global

platforms. In this role, Boezi will help Danfoss

tailor its high-efficiency compressor portfolio

to respond to changing customer needs that

are being influenced by new refrigerant and

energy-efficiency regulations. Danfoss supplies

technologies that meet the growing need for food

supply, energy efficiency, climate-friendly solutions and modern

infrastructure. www.danfoss.com

DICK SHEAR, MULTI W SYSTEMS

EL MONTE, Calif. (June 20, 2014) – Multi W

Systems Inc. announced the appointment of

Dick Shear as general sales manager. Multi

W Systems manufactures and distributes

pump systems, electrical controls and related

engineered machinery. www.multiwsystems.com

PAMELA HENRY, WEF

ALEXANDRIA, Va. (June 19, 2014) – The Water

Environment Federation (WEF) promoted Pamela

Henry to the position of deputy executive

director. Having been with WEF for more than

25 years, Henry is a seasoned leader who willoversee a number of key organizational programs

including WEFTEC operations and exhibitions,

advertising and sponsorships, marketing,

communications and creative services, human

resources, and facilities management. WEF is a not-for-profit

technical and educational organization of 36,000 individual members

and 75 affiliated Member Associations representing water quality

professionals around the world. www.wef.org

CHUCK HULL, 3D SYSTEMS

ROCK HILL, S.C. (June 17, 2014) – 3D Systems announced that Chuck

Hull received the 2014 European Inventor Award in the non-European

countries category in recognition of his invention of the three-

dimensional (3-D) printing technology Stereolithography. Presented

annually by the European Patent Office, the award honors inventors

who made significant contributions to technological progress and

the advancement of society. 3D Systems provides 3-D printing

centric design-to-manufacturing solutions including 3-D printers,

print materials and cloud-sourced on-demand custom parts forprofessionals and consumers in materials including plastics, metals,

ceramics and edibles. www.3dsystems.com

EDWARD CRANER, HOLT CAT

SAN ANTONIO, Texas (June 16, 2014) – HOLT

CAT named Edward Craner senior vice president,

strategy and marketing. In his new role, Craner

will continue to lead and develop corporate

strategy, marketing and customer experience

initiatives to support sales growth. HOLT CAT

sells, rents and services Caterpillar machines,

engines, generator sets and trucks.

www.holtcat.com

Edward Craner

Larry Lewis

David Boezi

Dick Shear

Pamela Henry

SPOTLIGHT

PUMPS & SYSTEMS LAUNCHES

MIDDLE EAST/NORTH AFRICA MAGAZINE

BIRMINGHAM, Ala. (July 2, 2014) – Pumps & Systems, the leading

magazine for pump users worldwide for more than 20 years, expands its

international coverage of powerful technical pumping information to the

Middle East/North Africa region. The premier issue of Pumps & Systems

MENA will launch in early October 2014. It also will be distributed at the

Pumps & Systems booth Nov. 10, 2014, at the Abu Dhabi International

Petroleum Exhibition & Conference, the region’s leading conference

for oil and gas professionals. Pumps & Systems MENA will publish

bimonthly in 2015 following the October 2014 launch and will cover case

studies and technical information in the following industries:

• Oil & gas (upstream and downstream)

• Water & wastewater

• Power generation

• Food & beverage processing

• Building services

• Chemical, petrochemical & refinery

The regular editorial coverage will also include strategic and insightfulmarket data from respected market research analysts Frost & Sullivan.

The magazine will be supported digitally with a website,

www.pump-zone.com/mena, and a twice-per-month e-newsletter, Pump

Users Digest MENA. Subscribe to the e-newsletter and magazine at

www.pump-zone.com/mena.


13/133

pump-zone.com | August 2014

11

HENRI V. AZIBERT, FSA

WAYNE, Pa. (June 13,

2014) – The Fluid Sealing

Association (FSA) announced

the appointment of Henri V.

Azibert as its new technical

director. Pumps & Systems

has partnered with the FSA for

10 years and posted exclusive

“Sealing Sense” articles in every issue. Azibert

will now coordinate these articles, which provide

the readers of Pumps & Systems with crucial

technical information about mechanical seals,

compression packing, gaskets, expansion joints,

sealing components and molded packing. Aziberthas also joined the prestigious Pumps & Systems

Editorial Advisory Board. FSA is an international

trade association. Members are involved in the

production and marketing of virtually every

kind of fluid sealing device in the world. www.

fluidsealing.com

JOHN DONAHUE, AWWA

BOSTON (June 12, 2014)

In a spirited event at the

conclusion of the American

Water Works Association’s

Annual Conference and

Exposition in Boston, John

Donahue, chief executiveofficer of North Park, Illinois,

Water District, accepted the ceremonial AWWA

gavel and began his term as president. The gavel

passing ceremony was the culmination of a five-

day conference that drew more than 11,000 water

professionals and water technology providers to

Boston. The American Water Works Association

is the largest nonprofit, scientific and educational

association dedicated to managing and treating

water. www.awwa.org

GREG HEWITT, BALDOR

ELECTRIC COMPANY

FORT SMITH, Ark. (June9, 2014) – Baldor Electric

Company promoted Greg

Hewitt to mounted bearing

engineering manager. In this

role, he will be responsible for

all mounted bearing product-

related engineering and will manage the product

development team in Greenville, South Carolina.

Baldor Electric Company markets, designs and

manufactures industrial electric motors, drives

and mechanical power transmission products.

www.baldor.com

Henri V. Azibert

John Donahue

Greg Hewitt

5300 Business Drive, Huntington Beach, CA 92649 USA714-893-8529 • [email protected]

www.blue-white.com • www.proseries-m.com

Three ModelsAvailable withFeed RatesRanging from0.1 GPH/.03 LPHto 158 GPH/600LPH.

Smooth, Quietand EfficientPumping Action.

BrushlessVariable SpeedMotor.

Terminal Blocksin Junction Box

for RemoteConnections.

Patented TubeFailure Detection,Patented SafetySwitch, PatentedMethod forExtended TubeLife.

One or Two Pump,EngineeredSkid System isAvailable.

FLEX-PRO

®

Peristaltic Metering Pump

Standard 61

Sonic-Pro S4 accurately measuresflow using the Transit Timemethod. It can be usedwith watercontaining lowlevels of chemicalsand up to 5%particulates.Optionalcommunicationprotocols includeIndustrial Ethernet,Profibus and Modbus.

Ultrasonic Transit Time

operation. Optional factory configuration

for easy installation.

Inline spool piece (inline fitting).

4-20mA and Pulse Outputs.

Special low power mode permitsoperation with battery for limitedfunctions.

Advanced communication.

Data logging

SONIC-PRO ®

Ultrasonic Flowmeter

c i r c l e 1 2 6 o n c a r d o r v i s i t p s f r e e i n f o . c o

m


14/133


2 NEWS

CHARLES WHISMAN, CH2M HILL

DENVER (June 5, 2014) – CH2M HILL announced

that Charles Whisman joined the firm as vice

president and U.S. oil and gas operations

manager for the environment and nuclear

market. CH2M HILL provides consulting,design, design-build, operations and program

management for government, civil, industrial

and energy clients. www.ch2m.com

DAVE MORROW, OPW

LEBANON, Ohio (June 6, 2014) – OPW announced the promotion of

Dave Morrow to director of product management for its Chemical &

Industrial business unit. Before this appointment, he was product

manager for OPW Engineered Systems. OPW

Engineered Systems provides loading and

coupling systems for the safe and efficient

loading and unloading of critical hazardous

fluids. www.opw-es.com

JOHN MOLNAR,

ARMSTRONG FLUID TECHNOLOGY

TORONTO (June 5, 2014) – Armstrong Fluid

Technology announced that John Molnar joined

the company as technical sales representative,

commercial and engineering. In his new role,

he will develop and grow relationships with

engineers, contractors and service dealers in the

Ontario territory.

His main focus

will be working

with standard and

configured building

products and design envelope solutions.

Armstrong Fluid Technology designs,

engineers and manufactures integrated

solutions within the building-oriented

fluid-flow equipment industry. www.

armstrongfluidtechnology.com

Charles Whisman Dave Morrow

John Molnar

MERGERS & ACQUISITIONS



15/133


13

AROUND THE INDUSTRY

EXONE to Open Combined

Production Service Centerin ItalyNORTH HUNTINGDON, Pa. – (June19, 2014) The ExOne Companyannounced the planned opening ofa new combined production servicecenter and machine sales center in theLombardy region of Italy. Said Omar,most recently ExOne’s European salesdirector, will be ExOne Italy’s managingdirector. ExOne provides 3-D printingmachines and printed products,

materials and other services to

industrial customers. www.exone.com

WEATHERFORD OpensIntegrated ColombiaLaboratoryBOGOTA, Colombia (June 13, 2014)Javier Betancourt, the president ofAgencia Nacional de Hidrocarburos– Colombia, marked the officialopening of the new Weatherford lab in

Bogota, Colombia, during a ribbon-cutting ceremony. This new facilityprovides traditional core and fluidanalysis combined with specialtyservices such as shale rock properties,geochemistry, wellsite geosciences,frac fluids, drilling fluids and elastomertesting for progressive cavity pumps.

Weatherford International provides

oilfield products and services across

the drilling, evaluation, completion,

production and intervention areas.

www.weatherford.com

DYNAMIC INDUSTRIESINTERNATIONAL LLC Receives

SAGIA LicenseHOUSTON (June 11, 2014) – DynamicIndustries International LLCannounced that its Saudi Arabian officereceived its license to operate fromthe Saudi Arabian General InvestmentAuthority (SAGIA). DynamicIndustries International LLC provides

full-service fabrication, construction

and maintenance services to the

offshore worldwide markets. www.

dynamicind.com

SIEMENS Invests inSoftware GrantsRICHMOND, Va. (June 5, 2014)Siemens announced more than $1billion of in-kind software grantsfor manufacturing programs atcommunity colleges and universitiesin Virginia. The series of in-kindgrants was established as a result ofan industry need for skilled workersand is designed to support the state’slargest industrial employer, Newport

News Shipbuilding, a division ofHuntington Ingalls Industries, andother companies with local ties suchas Rolls-Royce. Siemens IndustrySector supplies products, solutions and

services for industrial customers.

www.siemens.com



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4 NEWS

AROUND THE INDUSTRY

ABB TURBOCHARGINGInaugurates Denmark FacilityBADEN, Switzerland (June 4, 2014)ABB Turbocharging announced a

ceremony that celebrated the opening

of a new service facility in Fredericia,

Denmark. The ceremony also marked

the completion of the amalgamation of

its activities in Norway, Denmark andSweden into a single Local Business

Unit. ABB Turbocharging Scandinavia

comprises service stations in Oslo and

Bergen in Norway, Göteborg in Sweden,

and the new central workshop for

Denmark in Fredericia. Additionally,the company has two service

engineers and a sales team stationed

in Copenhagen. This geographical

footprint will soon be furthered by a

new service point in Tromsø, Norway.

ABB Turbocharging manufactures and

services turbochargers. www.abb.com

GRUNDFOS, PUB to Collaborateon Water TechnologiesSINGAPORE (June 3, 2014) – Pump

manufacturer Grundfos and PUB,

Singapore’s national water agency,

have signed a memorandum ofunderstanding (MOU) to collaborate on

the development of water technologies

and solutions. The MOU sets out to

support PUB in its mission to ensure a

robust and sustainable water supply

for Singapore and to continuously

explore new technologies and solutions

to meet current and future water

challenges. PUB is a statutory board

under the Ministry of the Environment

and Water Resources. It is the water

agency that manages Singapore’s

water supply, water catchment and

used water. www.pub.gov.sg Grundfos

is a pump manufacturer, offeringwater solutions with modular, energy

efficient and intelligent products

and services that can be tailored for

industrial, water utility, water supply,

urban and agricultural applications.

www.grundfos.com

EPA Proposes Guidelinesto Cut Carbon PollutionWASHINGTON (June 2, 2014) – At the

direction of President Obama and after

an unprecedented outreach effort,

the U.S. Environmental Protection

Agency (EPA) released the CleanPower Plan proposal, which for the

first time cuts carbon pollution from

existing power plants, the single largest

source of carbon pollution in the U.S.

The proposal aims to protect public

health, move the U.S. toward a cleaner

environment and fight climate change

while supplying Americans with reliable

and affordable power. By 2030, the

steps that the EPA is taking will:

• Cut carbon emission from the power

sector by 30 percent nationwide

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Supplies the NGL industry with products for electric motorand engine-driven pump skids and booster stations.

· Engine Management - Murphy’s Engine Integrated Control System (EICS)

provides a turnkey engine integration package that ensures extended engine life,

optimized emissions and simplified diagnostics.

· Controls - Murphy delivers a complete line of annunciators and

controls that can be packaged to provide optimum performanceand advanced functionality.

· Gages & End Devices - Murphy has a

robust and value priced line of gages and

sensors, including vibration sensors, level

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6 NEWS

AROUND THE INDUSTRY

below 2005 levels, which is equal tothe emissions from powering morethan half the U.S. homes for one year

• Cut particle pollution, nitrogenoxides and sulfur dioxide by morethan 25 percent

• Avoid up to 6,600 premature deaths,up to 150,000 asthma attacks inchildren, and up to 490,000 missedwork or school days—providing upto $93 billion in climate and publichealth benefits

• Shrink electricity bills roughly8 percent by increasing energyefficiency and reducing demand inthe electricity system

EPA’s mission is to protect human

health and the environment.

www.epa.gov

ABAKAN Increases Direct

Ownership in MesoCoatMIAMI (June 2, 2014) – Abakan Inc.announced that it has increased itsownership position in its majorityowned subsidiary, MesoCoat Inc., to a87.5 percent direct and 89.9 percentdirect and indirect ownership. Theincrease is the result of converting anadditional $6.2 million in MesoCoatinvestment into equity and exchanging21 percent of ownership in Powdermetfor 65.3 percent of Powdermet’s sharesof MesoCoat. Abakan develops,manufactures and markets advanced

nanocomposite materials, fabricated

metal products and metal compositesfor applications in the oil and gas,

petrochemical, mining, aerospace and

defense, energy, infrastructure, and

processing industries.

www.abakaninc.com

WEF, IWA Sign Water

Management MOUALEXANDRIA, Va. (May 27, 2014)The Water Environment Federation(WEF) and the InternationalWater Association (IWA) signed amemorandum of understanding (MOU)intended to accelerate joint work togrow and disseminate water knowledgeand to serve and advance the globalwater profession. WEF is a not-for-profit technical and educational

organization representing water

quality professionals around the world.

www.wef.org IWA is a global networkof water professionals that spans the

continuum between research andpractice, covering all facets of the

water cycle. www.iwahq.org

To have a news item considered, please send the information to Savanna Lauderdale, [email protected].



19/133



20/133


8 NEWS

EVENTSPumpTec-USA

Sept. 10 – 11, 2014Georgia World Congress Center

Atlanta, Ga.770-310-0866www.pumpconference.com

Turbomachinery/Pump SymposiaSept. 23 – 25, 2014George R. BrownConvention CenterHouston, Texas979-845-7417

pumpturbo.tamu.edu

WEFTECSept. 27 – Oct. 1, 2014New Orleans MorialConvention CenterNew Orleans, La.www.weftec.org

International Association

of Amusement Parks andAttractions (IAAPA)Nov. 18 – 21, 2014Orange County Convention CenterOrlando, Fla.703-836-4800www.iaapa.org

PumpTec-IsraelDec. 3 – 5, 2014Jointly with Electricity-Israel2014 ConferenceEilat, Israel

770-310-0866www.pumpingmachinery.com/conference_2014_Israel/ conference_2014_Israel.htm

POWER-GEN International

Dec. 9 – 11, 2014Orange County Convention CenterOrlando, Fla.918-831-9161www.power-gen.com

NGWA Expo & Annual MeetingDec. 9 – 12, 2014Las Vegas Convention CenterLas Vegas, Nev.www.ngwa.org

AHR EXPOJan. 26 - 28, 2015McCormick PlaceChicago, Ill.www.ahrexpo.com

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temperature rise due to the motor

load. e temperature rise is usu-

ally measured using the resistance

method. Each insulation class has

a specific temperature rating. For

example, Class F is rated at 155 C

(311 F). e temperature rating is

the maximum operating tempera-

ture allowed in order to meet an

average insulation life of 20,000hours.

Of that rating, 10 C is reserved

for the hot spot allowance. e

resistance method measures the

average temperature rise in the sta-

tor windings, but at some places—

such as the stator slots—the

temperature can be higher than the

average measurement. e hot spot

allowance is reserved to protect

these areas. is reduces the actual

operating temperature (ambientplus measured average) to 145 C.

For every 10 degrees over 145 C,

insulation life is reduced by half.

For every 10 degrees below 145 C,

insulation li fe doubles.

Suppose a motor with Class F

insulation operates at an ambient

temperature of 40 C. e mea-

sured temperature rise at full load

is 90 C. erefore, the operating

temperature is 130 C. e expected

insulation life would be about50,000 hours or about 2.5 times

the life at 145 C. But at 3 percent

phase voltage unbalance, the oper-

ating temperature increases by 19

percent (155 C) and insulation life

is reduced by 50 percent.

Image 1 shows the windings of

a motor that failed because of high

voltage unbalance. When a motor

loses one phase (single phasing),

the other two phases have to carry

the entire load. As a result, two sets

Voltage unbalance is one of the major causes of premature motor

failure. A relatively small unbalance of just 2 percent can reduce

expected insulation life by half.

21


21



24/133

of phase windings are destroyed, and the one that

lost power is unharmed.

Motor Phase Loss & Failure

In the case of unbalance, the winding with the

highest current fails and, usually, the other two

are still functional. In the motor shown in Image

1, one of the phases has failed, one is normal and

the third is beginning to show the effect of higher

temperature. Measuring voltage unbalance and

fixing the cause are much less costly than having

it diagnosed in a motor shop. See “Pump Ed 101”

in the July 2008 issue of Pumps & Systems for

instructions on diagnosing the cause of unbal-anced voltage.

Although correcting voltage unbalance is

always best, a few rules can allow operation in

unbalanced applications. For example, if the leg

with the highest current is under the nameplate

full load amperage (FLA), it will safely operate. IfImage 1. Windings of a motor that failed because of high voltage unbalance.(Image courtesy of EASA)

2 PUMP ED 101




25/133

23

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26/133

it is above nameplate FLA but still

within the service factor (SF), it

may still safely operate. As a rule,

if the high current leg is less than

10 percent higher than the average

current, it wi ll probably safely

operate. A less desirable alternative is

to derate the motor’s nameplate

horsepower. NEMA suggests

derating horsepower to 75 percent

of nameplate at an unbalance of 5

percent. At 4 percent unbalance,

it is derated to 82 percent. At 3

percent, it is derated to 88 percent,

and at 2 percent, it is derated to 95

percent.

In addition to reduced insulation

life, unbalanced voltage can also

increase electrical costs by decreas-ing motor effi ciency. At 1 percent

unbalance, effi ciency remains at

the nameplate nominal effi ciency.

However, at 3 percent unbalance,

actual motor effi ciency can be re-

duced by 2 percentage points.

Joe Evans is responsible

for customer and employee

education at PumpTech Inc.,

a pump and packaged system

manufacturer and distributor

with branches throughout the

Pacific Northwest. He can be

reached via his website www.

PumpEd101.com. If there are

topics that you would like to

see discussed in future col-

umns, drop him an email.

In addition to reduced insulation life, unbalanced voltage

can also increase electrical costs by decreasing motor efficiency.

4 PUMP ED 101


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25



28/133

When the pump selection

process starts, the

required flow of the is

often the only known var iable

for an application. For example, a

system must move 2,000 gallonsper minute (gpm) from a holding

tank to another tank or process.

What size pump do should be

installed? e size and pressure of

the piping and the power of the mo-

tor must also be determined. is

column helps explain how to make

these decisions.

Pump & Piping Size

e longer the piping, the more

pressure its internal friction willgenerate. A good way to pick a pipe

size is to ca lculate its diameter from

an empirical but simple starting

formula. is wil l help establish an

approximate range. Pipe velocity is

usually between 5 and 10 feet per

second (ft/sec).

e smaller a pipe’s diameter, the

faster fluid flows through it. e

larger the pipe, the more expensive

it is. Also, flowing too slowly may

cause particulate matter to settleand clog the line, but flowing too

quickly will wear the pipe. e 5

to 10 ft/sec range is usually a good

starting point. Equation 1 can used

for a more accurate calculation.

V = Q x 0.321 / A

Equation 1

Where:

V = velocity in ft/sec

Q = flow in gpm

A = pipe area in square inches

(in2)

In our example,

5 = 2,000 x 0.321 / A

A = 2,000 x 0.321 / 5 =

128.4 in2 pipe area, or 12.8 inch

diameter

is diameter can round to a 12-

inch pipe with a velocity of slightly

more than 5 ft/sec.

e next step is to figure out the

amount of pressure in the system

if the pump is 5,000 feet away

from the process’discharge. isdetermination is more complicated

because some hydraulic informa-

tion is needed. Several options can

provide this information: come to

class, consult a piping frict ion loss

chart or take my word for it that the

losses for cold water at 2,000 gpm

in a 12-inch, 5,000-foot pipe are

about 70 feet.

With the flow and head deter-

mined, the motor can be sized (see

Table 1). Also, an online Effi ciencyEstimator, which can be found at

www.mj-scope.com/pump_tools/

pump_effi ciency.htm, offers useful

formulas.

To handle the process specifica-

tions, a single-stage pump was se-

lected. e Effi ciency Est imator cal-

culated that a 42-horsepower and

84.5-percent pump effi ciency can

be expected from a typical pump.

is number can be confirmed with

quotes from pump distributors.

e Effi ciency Estimator a lso

suggests an impeller size of 9.77

inches. is measurement is a good

way to roughly verify the appropri-

ate sizes of existing pumps. is

process provides useful preliminar yinformation for pump selection.

Motor Size

A 1,800-rpm motor speed was

selected for this process because it

is one of the most common motor

speeds in the U.S. e horsepower

recommendation can be rounded to

select a 50-horsepower motor. If the

pump is expected occasionally to

operate outside the curve, choosing

a 75-horsepower leaves a margin ofsafety.

Simplify the EquipmentSelection Process

By Lev Nelik, Ph.D., P.E.

Pumping Machinery, LLC, P&S Editorial Advisory Board

Table 1. Sizing motors during pump selection

(Graphics courtesy of the author.)

US Units

Pump flow (gpm) 2,000

Total pump head (ft) 70

Specific gravity (SG) 1.00

Number of stages 1

Speed (rpm) 1,800

Header per stage (ft) 70

Impeller diameter (in) 9.77

Specific speed U.S. (Ns) 3,326

Specific speed metric (ns) 64.5

Specific speed universal (Os) 1.22

Effi ciency (%) 84.5

Power (hp) 42


6 PUMPING PRESCRIPTIONS


29/133

NPSHA Calculation

e suction side must be consid-

ered. My last few columns dis-

cussed pump suction performance.

For example, I discussed how the

system affects the operation andthe relationship between the flow

(as a percent of the best effi ciency

point) and suction recirculation.

Many end users question how much

net positive suction head available

(NPSHA) they need.

If a pump has too little NPSHA, it

could experience suction problems.

Too much NPSHA leads to higher

construction costs. Users must find

the right balance. My next column

will describe in detail the beginningof the selection process. For those

interested in how to calculate the

piping losses estimated (70 feet of

head), my Pump School training

covers this in-depth.

Dr. Nelik (aka “Dr. Pump”) is

president of Pumping Machin-

ery, LLC, an Atlanta-based firm

specializing in pump consulting,

training, equipment trouble-shooting and pump repairs. Dr.

Nelik has 30 years of experience

in pumps and pumping equip-

ment. He may be reached at

pump-magazine.com.

If a pump has too little NPSHA, it could experience suction

problems. Too much NPSHA leads to higher contruction costs.Users must find the right balance.


27

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8 PUMP SYSTEM IMPROVEMENT

In the previous article calcu-

lating the cost of elements

in a piping system (Pumps &

Systems, July 2014), the energy

consumed and power cost balanced

exactly to demonstrate the process.Seldom is life that exact. In the

real-world plant, instruments are

subject to inaccuracy, pumps may

be worn, estimates may be off

or the full system may not be

accurately represented in the design

documents.

is month’s article demon-

strates how cross-validating the

calculated results can ensure the

energy cost balance sheet accurately

reflects system operation.e key to validating the results

is to use multiple means for arriv-

ing at the operating cost of each

item in the energy cost balance

sheet. If the energy cost balance

sheet does not add up, trouble-

shooting skills need to be employed

to discover the reason for the dif-

ference.

is article will continue to

use the example piping system

presented in previous articles (seeFigure 1).

Prioritizing the System

e pump elements provide all

the energy that enters the system.

at energy is then consumed by

the system’s process and control

elements.

If the energy cost balance sheet

does not balance, operators should

begin looking for the source of the

problem. e major energy users

in the system should be examined,

and operators should find meth-

ods to cross-validate the initial

estimates.

Pump PerformanceIn the example, the pump’s flow

rate was determined using the

manufacturer’s pump cur ve. With

a known flow rate, the pump ef-

ficiency can be determined from

the curve.

Because the pump effi ciency is

used in all energy cost calculations,ensuring the accuracy of the value

is critical.

System Validation& Troubleshooting

By Ray Hardee

Engineered Software, Inc.

Figure 1. Drawing of sample piping system(Article graphics courtesy of the author.)

Figure 2. An example showing the effect internal leakage has on pumpperformance. Because of internal leakage, the installed pump is notoperating as designed.


31/133


29

Inaccuracies can occur in

real-life operating conditions. For

example, if the pump has a worn

impeller and excessive internal

leakage, it no longer reflects the

pump curve’s operation.

Figure 2 shows a pump curve for

the process pump along with an

example of the effect that excessive

internal leakage can have on the

pump curve.

Using the calculated head dif-

ference of 235 feet (ft), the worn

impeller gives a flow rate of lessthan the 4,000 gal lons per minute

(gpm) used in t he previous energy

system balance.

In addition, the effi ciency of a

worn impeller would differ from

the manufacturer-supplied test

curve.

is would result in inaccurate

power consumption and operation

costs calculations.

Operators have other options to

determine the flow rate throughthe pump, including portable

ultrasonic flow meters.

ese meters provide a reason-

ably accurate flow measurement

in a pipeline without physically

changing the piping system.

If the observed flow rate on the

temporary flow meter equals the

value determined using the pump

head and the pump curve, the flow

rate is validated, and the effi ciency

is validated by association.

If a power meter is installed on

the motor driving the pump, the

measured kilowatt (kW) value

can be compared to the calculated

power consumed using the pumps

flow, head and effi ciency values as

show in Equation 1, at the bottom

of page.

kW = .746 ×Q × H × ρ

247,000 × ηP × ηM

Equation 1

Where:

Q = flow rate in gpm

H = pump head in ft

ρ = fluid density lb/ft3

ηP = pump effi ciency

ηM = motor effi ciency

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32/133



If the power into the motor as

read on its power meter is the sameas the calculated power consump-tion using Equation 1, the pump’sflow, head and effi ciency values arevalidated.

If a power reading is not availablefor the motor, the motor’s powerconsumption can be calculated bymeasuring the current and voltagesupplied to the pump’s motor, thenusing Equation 2. e motor’s powerfactor can be read on its nameplate.

P3ϕMotor = √3 × V × I × Pf 1,000

Equation 2Where:P3ϕMotor = motor power in kW V = voltage voltsI = current ampsPf = motor power factor

If the calculated value of motorpower equals the pump’s power con-sumption, the pump flow, head andeffi ciency va lues are val idated.

Tank Levels and Pressures

e tanks and vessels make excel-lent piping system boundaries. eenergy at each tank can be deter-mined by using the elevation of theliquid level in the tank and pressureon the liquid surface.

From these values the energyconsumed for the static head compo-nent can be easily calculated.

e results can be cross-validatedusing installed pressure and levelinstrumentation.

e liquid level can be checkedwith a sight glass or by manuallymeasuring the liquid level in thetank. e pressure in a closed vesselcan be compared using the installedplant instrumentation, installedpressure gauges or a temporary pres-sure gauge.

Control Valves

In last month’s example, the dif-ferential pressure across the controlvalve was calculated by subtractingthe sum of the head losses of theprocess elements from the pumphead. is approach is easy, but anyerrors made in the previous calcula-tions will compound and can greatlyreduce the energy cost balancesheet’s accuracy.

Valve manufacturers define theoperation of control valves based on

tests that are outlined in publishedindustry standards. Manufacturersuse the ANSI/ISA-75.01.01 FlowEquations for Sizing Control Valvesto size control valves for pipingsystems. e data used in valvesizing can also be used to calculatethe differential pressure across thecontrol valve.

Equation 3 shows the basic for-mula for valve sizing.

Cv =Q

FP √ P1 – P2

S

Equation 3Where:Cv = manufacturer-supplied valve

coeffi cientQ = flow rate in gpmFP = piping geometry factor (unit-

less)P

1 = absolute pressure measured

at valve inlet in lb/in2

P2 = absolute pressure measured

at valve outlet in lb/in2

S = fluid specific gravity (unit-less)

Rearranging the control valve

sizing equation and solving for dif-ferential pressure results in Equa-tion 4.

dP =Q 2S

(C v FP)2

Equation 4

In the example system with a flowrate through the level control valveof 2,500 gpm, the control valve posi-tion is 65 percent. According to the

manufacturer’s data for the controlvalve, the Cv at this position is 391.e FP of .9996 was calculated

by the manufacturer and includedin the valve data sheet. e spe-cific gravity of the process fluid wascalculated at .993. e flow ratethrough the level control valve wasmeasured at 2,500 gpm. Insertingthe values into Equation 4 providesthe differential pressure across thecontrol valve.

Converting the control valve’sdifferential pressure of 40.6 poundsper square inch (psi) to feet of fluidresults in a head loss of 94.3 ft. isresult for the control valve calcula-tion validates the number from lastmonth’s calculations.

Process Equipment

e differential pressure across theprocess equipment was calculatedusing the pressure drop data sup-plied by the manufacturer and the

dP = Q 2S

(C v FP)2 = 2500

2 × .993(391 × .9996)2

= 40.6 psi

If the calculated value of motor power equals the

pump’s power consumption, the pump flow, head

and efficiency values are validated.


33/133


31

flow rate obtained from the installed

flow element. In the example, the

heat exchanger pressure drop of

10 psi was assumed based on the

manufacturer’s supplied data. If the

heat exchanger tubes were fouled

due to internal deposit, the actual

differential pressure across the heat

exchanger would be greater than

the value used in the energy cost

calculation.

e differential pressure across

the process equipment can be

validated by installing temporary

pressure gauges.

Most process equipment has vent

and drain lines instal led for main-

tenance.

By install ing temporary pressure

gauges on the vent and drain lines—

and correcting the pressure values

for any difference in elevation of the

gauges—the differential pressure

and head loss across the item can be

measured.

Pipelines

In the example, the head loss in theindividual pipelines was calculated,

then used to determine the head

loss in each circuit of the pipeline.

is requires a large number of

calculations.

e repetitive nature of the calcu-

lations makes this an excellent task

to be performed using a computer.

Online head loss calculators can be

found by performing an Internet

search. Commercially avai lable

computer programs can also greatlysimplify the task.

Problems that could affect the

head loss calculation include fouling

or sedimentation in the pipelines,

partially closed valves, or obstruc-

tions in the pipe, valves or fittings.

Inaccurate determination of the pipe

Problems that could affect the head loss calculation

include fouling or sedimentation in the pipelines,partially closed valves, or obstructions in the pipe,

valves or fittings.



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size or schedule, or inaccurate esti-

mates of the number of fittings orpipe length can a lso affect the head

loss calculation.

Total System

If the energy cost balance sheetdoes not balance, either the mea-

sured plant data or the equipment

(pumps, process components or

control valves) could be causing theproblem.

To confirm the accuracy of the

measured data, check to see that

the instruments are calibrated. e

instrumentation department can

also make sure the instruments

are accurately reading the process

parameters.

e first step is to check for

cavitation throughout the whole

system. Cavitation is caused when

the local pressure drops below, thenrises above, the vapor pressure of

the process fluid. Some of the fluid is

converted from liquid to vapor. e

vapor bubbles take up extra space

in the flow stream, which causes a

reduction in the mass flow rate.

All standards and calculat ion

methods used to determine head

loss assume single phase flow. If

cavitation occurs, the calculated re-

sults wil l not accurately reflect what

is happening in the system.

Cavitation is especially trouble-

some in pumps and control valves.

It can be a major source of mainte-

nance problems and should be cor-

rected prior to performing a system

assessment.

Next, the interaction of the

system’s components should be

examined. e best way to accom-

plish this is to compare the current

observed values with previous

observed values.

For example, the average valve

position of the level control valve

increased over time from 65 percent

open to 71 percent open. e rest of

the measured plant data remained

the same.

Using Equation 4, the head

loss across the level control valve

decreased from the original 94 ft of

loss to 71 ft. e only ex planation

for this change is that the head loss

across the process element increased


S e e U s A t P

u m p

S y m p o s i u m

B o o t h 9 0 3


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36/133



from the manufacturer’s published

value of 23 ft to 46 ft. is is a clearindication of fouling in the process

equipment.

Conclusion

Gaining a clear picture of how apiping system operates is key to as-

sessing the system.

Because most operating plants do

not have suffi cient installed plantinstrumentation to provide all the

data needed for the calculations,

many of the values must be calcu-

lated using other well-established

methods.

By performing the calculations

and comparing them to available

operating data, operators can deter-

mine how the system is currently

operating.

is information allows opera-

tors to correct any problems thatadversely affect system operation

and perform an accurate assess-

ment of the piping system by

completing an energy cost balance

sheet.

My next few columns will inves-

tigate a variety of plant systems.

ey will demonstrate what can be

gained with a better understanding

of system operation and what can

be done to reduce operating, main-

tenance and capital cost within

piping systems.

Ray Hardee is a principal founder

of Engineered Software, creators of

PIPE-FLO and PUMP-FLO software.

At Engineered Software, he helped

develop two training courses and

teaches these courses in the U.S. and

internationally. He is a member of

the ASME ES-2 Energy Assessment

for Pumping Systems standardscommittee and the ISO Technical

Committee 115/Working Group 07

“Pumping System Energy Assess-

ment.” Hardee was a contributing

member of the HI/Europump Pump

Life Cycle Cost and HI/PSM Optimiz-

ing Piping System publications. He

may be reached at

[email protected].

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6 GUEST COLUMN

Despite their simplicity,

centrifugal pumps often

experience repeat failures

that even seasoned maintenanceand reliability professionals have

trouble preventing. is four-part

series explains the reasons behind

repeat pump failures and uses a

real-world field example involving

boiler feedwater pumps. Devia-

tions from best practices or over-

sights can range from seemingly

insignificant to stunningly elusive.

ese can combine and often cause

costly failures.

Operating DifferentPumps in Parallel

e negative experience of a

metal producing facility best

demonstrates the consequences of

operating pumps beyond their ap-

propriate flow ranges. is example

serves as a reminder of the meritsof conducting in-depth

reliability reviews before

buying process pumps.

is case history extends

to the remaining parts of

this series.

e operating data of

the plant’s installed in-

strumentation is shown

in Figure 1. e flow rate

into the destination tank

averages 2,500 gallonsper minute (gpm) to

maintain the tank level.

is system currently op-

erates for 8,000 hours per

year to meet the plant’s production

needs. e system has operated in

this way since being commissioned

five years ago.

Pushing Fluid Machinery Leadsto Frequent FailuresSecond of Four Parts

By Heinz P. Bloch, P.E.

Image 1. This riveted cage bearing failed because of ax ial (rotor thrust) overload.( Article images and graphics courtesy of the author.)

Figure 1. Pump manufacturers usually plot only the net positive suctionhead required (NPSHR) trend associated with the lowermost curve. At thatpoint, a head drop or pressure fluctuation of 3 percent exists at BEP flow.1

Figure 2. A typical head-versus-flow performance curve


39/133


37

is case history is one of

many examples that validate the

importance of examining the

flow-versus-head characteristics

(the H/Q curves) of pumps. Such

examinations are needed during

the procurement phase of new

pumps and the troubleshooting of

installed but failure-prone process

pumps.

Seven boiler feedwater (BFW)

pumps were installed in the metal

producer’s boiler house. Two of the

facility’s seven pumps came from Vendor A, two from B and three

from C. e respective H/Q curves

from vendors A, B and C were not

identical. By 2009, these pumps

had failed often and randomly. e

need for a thoroughly experience-

based failure analysis was rec-

ognized. e analysis pointed to

hydraulic and mechanical issues.

rough the years, this facility

routinely ran several BFW pumps

in parallel. Fear of failure mayhave prompted operating four

pumps in paral lel when only three

were required to provide a specific

flow rate. If running three pumps,

each pump could have operated

closer to its BEP, but operating

four pumps led to a greater failure

risk. In other words, one or more

of these four pumps operated in

the questionable or forbidden low-

flow and high-internal-recircula-

tion range illustrated in Figure 1.

Low-Flow Range

At least two of the pumps had

flat H/Q curves, similar to the

curve in Figure 2. Running in

the low-flow range forced one or

both pumps into the flat portion

of their respective performance

curves. When operating in the flat

range, even a small change in head

(a small change in ∆p) results in

large differences in throughput.

Controlling and equalizing load

sharing would be diffi cult.

In addition, the internal

pump clearances opened as time

progressed. is explanation was

in line w ith the recent escalated

failure frequencies. It led to the

recommendation of investigating

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42/133


0 GUEST COLUMN

Cost estimation errors are

common in a variety of

projects. Recent studies

have shown the cost of machinery

can represent 20 to 35 percent of

a processing and manufacturingproject’s total cost. e estimated

costs for new plants and particu-

larly new pump installations are

very uncertain and have increased

in recent years.

e following concepts minimize

the cost of pump installations:

• Maximizing the extent of

manufacturing and installation

in the shop environment

• Simplifying a pump package’s

transportation and installation• Providing modularized compo-

nents that are easy to change

• Reducing on-site personnel

supports and encouraging un-

manned operation

• Eliminating as many standby

pumps as possible

Very limited literature is avail-

able on pump cost estimation. is

column will focus on the cost esti-

mation of the pump installations indifferent projects.

Pump Installation

Cost EstimateHistorical data could inform pump

installation cost estimation models

within certain l imits. Results have

shown a large cost difference be-

tween different regions.

e economies of concentration

play an important role in cost.

Cost studies have indicated that

pump installation cost components

usually have economies that are

to scale to pump unit capacity and

pump train size.

e cost estimation of a pump

unit or installation in a plantcannot be fully accurate, with the

exception of the material cost,

particularly the cost of a pump

package. is cost can be estimated

from the pump package’s vendor,

and the cost of materials could be

obtained from suppliers. However,

other cost estimations are relatively

inaccurate. Labor costs have much

larger cost overruns compared to

other cost components.

e following estimation conceptcan be employed for a pump unit or

installation:

(Pump Unit Cost) = A × (Pump

Package Cost) + B

e factor A is assigned for all

auxiliaries and accessories required

for each pump package such as

the foundation, civil works, piping

and additional steel structures for

each pump package. is factor isusually between 1.3 and 2.5. e

pump package cost includes all

skid-mounted facilities such as the

driver and lubrication oil system.

e factor B is assigned for all

auxiliaries and accessories required

for each pump unit, such as unit

piping, unit utilities, protection

systems, unit pit/drain, unit electri-

cal facil ities, safety equipment,unit steel structures and unit civil

works.

Because the cost underestimating

error is generally larger than the

overestimating error, proper safety

margins for factors A and B are

always encouraged.

e cost is also a function of the

project size or the pump system

capacity. A proper set of factors

should be developed for a defined

range of the pump unit size andcapacity for a region.

Environmental conditions—soil,

terrain, cost of living, population

density, economies of scale, noise

limits, applicable codes and dis-

tances from pump supplies—could

affect the installation cost estima-

tion and should be considered when

the cost factors are estimated.

Other Costs

Studies on recent pump install-ations have shown that the cost

of civil works (site developments,

foundations and others) are about 9

to 20 percent of the total cost.

Estimate Pump Installation Costs

By Amin Almasi

Cost studies have indicated that pump installation cost

components usually have economies that are to scale to

pump unit capacity and pump train size.


43/133


41

ey have also shown that the costof installation can be approxi-

mately 7 to 11 percent of the total

cost.

e required man-hours for the

installation and commissioning of

pumps can vary significantly. For

packaged pumps, the following

indications should be noted:

• For large pump packages (more

than 1 megawatt (MW)), the

installation and commiss-

ioning man-hours could bebetween 300 and 900 hours.

• For small pump packages (less

than 1 MW), the installation

and commissioning man-hours

could be between 100 and 300

hours.

Case Study

e first case study is presented for

a 6 MW pumping unit. e costs

of electric motor-driven pump

packages are obtained in millionsof U.S. dollars (MUSD):

• A 3 MW pump package:

0.9 MUSD

• A 1.5 MW pump package:

0.6 MUSD

• A 0.8 MW pump package:

0.45 MUSD

e factor A is estimated at

1.67 for these pump packages. e

factor B is estimated at 1.5 MUSD

for a 6 MW pump unit. Table 1compares the cost of these differ-

ent options.

As shown, smaller pumps con-

siderably increase costs. A greater

number of smaller pumps is more

expensive than using a single large

pump.

e second case study is pre-

sented for small pump instal la-

tions. e following two options

are considered:

• Option 1: A 320 kW pump,$52,000

• Option 2: A 200 kW pump,

$42,000

e factor A is estimated at

1.49 for these small pump pack-

ages. e factor B is estimated at

$45,000 for Option 1 and $34,000

for Option 2.

Table 2 shows the cost analysis

for two options of small pumps.

Based on Table 2, only about 20

percent total installed cost reduc-

tion could be expected for a pump

38 percent smaller in size. Large

pumps have economies of scale

and low unit cost. In other words,

unit costs of pump installations

usually decrease as pump size

increases.

Pump & System - August 2014

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