March 2013 PDF

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From the Editor
Publisher
Walter B. Evans, Jr.
VP of Sales
George Lake
glake@pump-zone.com • 205-345-0477
F or several years, the industry has been buzzing
about pumps used in irrigation and agriculture
applications. It makes sense. Almost 60 percent
installations, use a high low rate pump and require
a large electric motor or engine. he major causes
of increased energy use are associated with pipe-
VP of Editorial of the world’s freshwater withdrawals are used for line leaks, engine and pump eiciency and well
Michelle Segrest
msegrest@pump-zone.com • 205-314-8279 irrigation, according to several sources including a maintenance. Poor uniformity of water applica-
Creative Director recent study by the USGS Water Science School. tion can also afect energy use by increasing pump-
Terri Jackson Consider this . . . power plants use 10 times ing time.
tjackson@cahabamedia.com
more water than is treated in municipal drinking As we increase our coverage of pumping systems
water plants. In fact, they extract and treat more used in agricultural, irrigation and groundwater
EDITORIAL water than all other industries combined. he only applications, our cover series this month features
Editor
Michelle Segrest larger use of water is for irrigation, according to a cutting-edge solutions to complex irrigation
msegrest@pump-zone.com • 205-314-8279 2011 study by he McIlvaine Company. installations (page 25). he lead article describes
Managing Editor Efective irrigation systems use energy-eicient how today’s agricultural irrigation is not just about
Lori K. Ditoro
lditoro@cahabamedia.com • 205-314-8269 equipment and designs that also help minimize the pumps. Variable speed drives, intelligent control
Associate Editor amount of unnecessary water use. Some common and remote management are all vital to a com-
Amanda Perry causes of wasted energy in irrigation systems, plete energy-eicient system. Complete pumping
aperry@cahabamedia.com • 205-314-8274
Contributing Editors
according to the Natural Resources Conservation systems have replaced large, isolated pumps as the
Laurel Donoho Service (NRCS), are worn or improperly sized solution moving forward.
Joe Evans, Ph.D. pumps, worn nozzles and improperly sized or Our cover series also includes two articles that
Dr. Lev Nelik, PE, APICS
CREATIVE SERVICES
designed ittings. Irrigation equipment problems describe the diesel versus electric debate for pow-
Creative Director and maintenance problems tend to go hand in ering the pump (page 30 and page 34).
Terri Jackson hand. Pumps, motors and engines that are badly Pumps & Systems will continue to research and
Senior Art Director designed or poorly maintained reduce the irriga- report about pumps in agricultural irrigation. Tell
Greg Ragsdale
Art Director
tor’s degree of control over water applications, us about your experiences and share your case
Jaime DeArman making it impossible to maintain correct soil studies by contacting me directly,
jdearman@cahabamedia.com moisture levels. his leads to crop stress, reduced msegrest@pump-zone.com.
PRODUCTION
Production Manager/Traffic
yields, runof, erosion and other problems.
Lisa Freeman Agricultural irrigation is an energy intensive
lfreeman@pump-zone.com • 205-212-9402
operation, and modifying irrigation systems can
Web Advertising Traffic
Ashley Morris reduce energy usage and costs. Pressurized irri- Michelle Segrest
amorris@pump-zone.com • 205-561-2600 gation systems, especially center pivot sprinkler Editor
CIRCULATION
Jeff Heine
jheine@cds1976.com • 630-739-0900 Editorial Advisory Board Ralph P. Gabriel, Chief Engineer—Global, John Crane
ADVERTISING Thomas L. Angle, P.E., MSc, Vice President Engineering, Bob Langton, Vice President, Industry Sales, Grundfos Pumps
Derrell Moody Hidrostal AG Larry Lewis, President, Vanton Pump and Equipment Corp.
dmoody@pump-zone.com • 205-345-0784 Robert K. Asdal, Executive Director, Hydraulic Institute Todd Loudin, President/CEO North American Operations,
Mary-Kathryn Baker Bryan S. Barrington, Machinery Engineer, Flowrox Inc.
mkbaker@pump-zone.com • 205-345-6036 Lyondell Chemical Co. John Malinowski, Sr. Product Manager, AC Motors,
Mark Goins Kerry Baskins, Vice President of Sales, Viking Pump Baldor Electric Company, A Member of the ABB Group
mgoins@pump-zone.com • 205-345-6414
Walter Bonnett, Vice President Global Marketing, William E. Neis, P.E., President, Northeast Industrial Sales
Addison Perkins
Pump Solutions Group Lev Nelik, P.E., APICS, President, Pumping Machinery, LLC
aperkins@pump-zone.com • 205-561-2603
Vince Marino R. Thomas Brown III, President, Henry Peck, President, Geiger Pumps & Equipment/
vince@pump-zone.com • 205-561-2601 Advanced Sealing International (ASI) Smith-Koch, Inc.
Chris Caldwell, Director of Advanced Collection Technology, Mike Pemberton, Manager, ITT Performance Services
P.O. Box 530067 Business Area Wastewater Solutions,
Birmingham, AL 35253 Sulzer Pumps, ABS USA Adam Stolberg, Executive Director, Submersible Wastewater
Editorial & Production Pump Association (SWPA)
David A. Doty, North American Sales Manager,
1900 28th Avenue South, Suite 110 Bruce Stratton, Product Manager, KLOZURE®, Garlock
Moyno Industrial Pumps
Birmingham, AL 35209 Sealing Technologies
Phone: 205-212-9402 Walt Erndt, Director of Market Development SSB,
Environment One Corporation Kirk Wilson, President, Services & Solutions, Flowserve
Advertising Sales Corporation
2126 McFarland Blvd. East,. Suite A Joe Evans, Customer & Employee Education, PumpTech, Inc.
Tuscaloosa, AL 35404
Phone: 205-345-0477 or 205-561-2600
is a member of the following organizations:

PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 110, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and
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2 March 2013 www.pump-zone.com PUMPS & SYSTEMS

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Table of Contents March 2013
Volume 21 • Number 3
unit in an irrigation application. Photo courtesy of Grundfos

A Grundfos Hydro MPC boosterpaq with dedicated control
Agricultural Irrigation & Dewatering
25 Pump Systems for Today’s
Agricultural Irrigation
By Vahan Bagdasarian, Grundfos
Complex irrigation applications require customized and
cutting-edge solutions.
30 Powering the Pump:

Diesel Versus Electric Motors
By Tim Albers, Nidec Motor Corporation
Make the ideal motor selection for irrigation applications.
COVER 34 Powerful Mine Dewatering

By Kristen Gurick, Godwin Pumps, a Xylem Brand
SERIES Electric and diesel centrifugal pump options
The Pump Purchase Process Practice & Operations

54 Prefabricated Treatment System Solves Water Quality
Concerns
By Mark Koester, Koester Associates, Inc.
With the simultaneous construction and site preparation, the quick turnaround
required for the project was accomplished with cost-efficient results.
57 New Optimized Aeration System Reduces Energy

Consumption
By Lars Larsson, Xylem, Inc.
A wastewater treatment plant experiences a 65 percent energy savings with the
installation of improved equipment.
SPECIAL 60 Positive Displacement Pumps in Wastewater Treatment

By Oakley Roberts, ARO Fluid Products, Ingersoll Rand
REPORT Select the right pumping technology to keep treatment processes running efficiently.
20 Pump Specification, Purchase, Installation

62 Power Generation on Demand
By Brad Chrudimsky, Baldor Electric Company, a member of the ABB Group
& Application
The application, geography, regulations and proper size must be considered when
By Amin Almasi, WorleyParsons Services Pty Ltd.
choosing a generator set.
Sharing all the information about an application can help
with the selection and installation of the ideal pump.
Departments Columns
6 Readers Respond 16 Pump Ed 101
48 Sealing Sense By Joe Evans, Ph.D.
8 20th Anniversary Top 20 List By The Fluid Sealing Association Branch-Line Pumping and Other Options
By Amanda Perry Gaskets for Rigorous Applications
Top 20 Apps for Pump Users 18 Pumping Prescriptions
12 News 51 HI Pump FAQs By Lev Nelik, P.E., Pumping Machinery, LLC
By The Hydraulic Institute Will Impeller Velocity Triangles
15 Calendar of Events Submersible Pump NPSH3, Trench-Type Wet Keep You Awake at Night?
Wells & Starting Torque Requirements
42 Efficiency Matters
By Arno Gehrer, ANDRITZ GROUP 65 Product Pipeline 2 From the Editor
Design Software Increases Hydraulic Efficiency
72 Pump Market Analysis 41 Trade Show Coverage
45 Maintenance Minders 68 Index of Advertisers
By Jordan, Knauff & Company
By Tom Davis, Maintenance Troubleshooting
68 Pump Users Marketplace
Pump Rebuild Tips

READERS RESPOND
“Pump System Design,” February 2013

Thanks for your article “Pump System Design” percent of the head at zero low,
published in the February 2013 Pumps & a shutoff head of 188 feet was
Systems. It included good items to consider for estimated.
simpliied system modiications or upgrades. Equating this shutoff head value
to Vt^2 / 2g, where Vt = [pi(D/12)
Homework Background and Answers (N/60)] is the impeller tip speed, an
For a 12-hour per day operation at 800 gallons Lee Ruiz impeller diameter of 7.21 inches was
per minute (gpm), there will need to be storage calculated.
capacity for at least 576,000 gallons of oil. An approximate 70-foot The curve for the 78-percent efi-
diameter by 21-foot deep storage tank was used in the analysis. cient pump indicated an approximate 7.25-inch diameter impeller
To keep the analysis simple, only half the 20-foot storage tank for the design conditions. The calculated minimum net positive suc-
draw-down was used to arrive at an average lift value. An average lift tion head available at 6 p.m. full 20-foot draw-down was 37 feet.
of 20/2 + 50 = 60 feet was used. The recommended pump place- This is greater than the curve net positive suction head required
ment close to the storage tank was used. value of 20 feet.
A 71-foot length of vertical discharge piping and a couple pipe By designing to the average tank draw-down, the estimated
elbows were also included. Friction losses totaled about 97.7 feet pump performance may vary between 825 gpm at 155 feet in the
including tank entrance and process end discharge losses. morning to 775 gpm at 165 feet at 6 p.m. The design point, 800
The calculated required pump head was 1.3-foot discharge gpm at 160 feet, would theoretically be seen around noon.
velocity head + 60 feet of lift + 97.7 feet for friction = 159 feet Good luck reilling the storage tank each day before 6 a.m.
(used 160 feet). Lee Ruiz
Using a 2-pole speed of 3,500 rpm, an approximate speciic Oceanside, Calif.
speed value of 2,200 was calculated. Based on the eficiency-
versus-speciic speed graph at www.mj-scope.com/pump_tools/ Lev Nelik responds:
pump_eficiency.htm, a maximum, 81-percent pump eficiency
hank you, Lee. Glad to see you got to use the Eiciency
might be expected for best-eficiency-point (BEP) operation.
I did ind a commercial reinery/API type pump with an approxi-
Estimator Program, with close correlation to an actual com-
mate 78 percent eficiency at the above design conditions. The mercial pump. I am reproducing the link you noted from
curve indicated an 80 percent best eficiency zone. the website (see Figure 1) and compared the numbers to
Assuming that the BEP operating head (160 feet) is about 85 a copy of a performance curve from a randomly selected
pump OEM catalogue.
he 800 gpm and 143-foot head come out with a 6.79-
inch impeller and 81.7 percent eiciency by the program
and about the same impeller size and 77 percent eiciency
by a random OEM performance curve. he diference in
eiciency is about 4 percent. his is a question for Pumps &
Systems’ readers. Why the diference in eiciency? (Please
feel free to share your answers to Lev’s question. Send these
answers to Amanda Perry, aperry@cahabamedia.com.)
Editor’s Note: For the Estimator Program referenced in

the February 2012 column to work, readers may need
to download a Microsot Web component from www.
microsoft.com/downloads/details.aspx?amp;display
lang=EN&familyid=982B0359-0A86-4FB2-A7EE-
F3A499515DD&displaylang=en). Readers should only
need to download the program once. P&S
To have a letter considered for Readers Respond, please send it to
Figure 1. Screen shot from www.pumpingmachinery.com Amanda Perry, aperry@cahabamedia.com.

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YEARS
1 9 9 3 - 2 0 1 3
Top 20 Apps for Pump Users
Mobile applications assist pump users in the ield and on the go.
First of Two Parts

By Amanda Perry
s we continue to celebrate 20 years as the leading magazine for pump users worldwide, we bring you a favorite Top 20
A list compiled from reader surveys and editorial research in each issue. See Part Two of “Top 20 Apps for Pump Users” in
the April issue.
Flatness App for ALiSENSOR LEVEL Alignment Supplies, Inc.

he Flatness App for ALiSENSOR Level makes geometric measurement cost-efective, more accessible
and easier to perform. he app allows users to measure the latness of surfaces of a wide range of shapes and
sizes to be calibrated to user-made ixtures of all sizes. Users can perform precise latness measurements and
customize the number of measurement points for speciic applications. he measurements are performed
quickly, and the user is guided in every step by a live 3D model of the measurement. Upon completing
their measuring, users can create an instant PDF report with all the data, including an adjustable-scale
schematic drawing of the latness results. his app requires separately purchased hardware.
Free / iPad, iPhone, iPod Touch
KoolApp: KoolCode, Refrigerant Slider,

CoolGame, Fitters App, Compass Danfoss
Danfoss designed the new KoolCode app for service technicians, refrigeration engineers and in-store
technicians to easily look up alarm, error, status and parameter codes for a range of Danfoss refrigeration
controllers with a three-digit display. KoolCode joins Refrigerant Slider, CoolGame, Fitters App and
Compass in Danfoss’ app library.
Users can look up KoolCode display codes by:
• Quick code translation without knowing the controller
• Hierarchical controller selection among Danfoss refrigeration controllers
• Automatic controller identification using a QR-code scan
Free / Android, iPad, iPhone, iPod Touch
Toolbox Technician Emerson Industrial Automation

Power Transmission Solutions
Power Transmission Solutions designed the award-winning Toolbox Technician app for HVACR
technicians. Named an Honorable Mention winner of the 2013 AHR Expo Innovation Award, it
combines the Browning Bearing & Belt Drive Pocket Reference Guide with an energy-eicient calculator.
Toolbox Technician enables users to easily search the reference guide and quickly calculate information
on eiciency savings. he material can be continually updated as new products are developed, so users will
have the most current information. he upgraded app also provides improved navigation, a belt identiica-
tion wizard and GPS functionality.

Grundfos GO Remote Grundfos Pumps Corporation
Grundfos GO Remote is an app that works as a mobile tool box. GO Remote provides handheld pump
control that can save users time on control, reporting and data collection. his app works with all of
Grundfos e-pumps and communicates with radio and infrared technology. Users have full access to
all the Grundfos Online tools with this app. Features include product dashboard, status data, alarms
and warnings, coniguration/commissioning, create installation report, and read/write proiles. Special
hardware from Grundfos is required to communicate with the pumps.
20
READERS CHOICE
Laser Align LUDECA Inc.
he Laser Align app is a reference tool for the shat alignment of rotating equipment. Users can access
important reference material and learn about key laser shat alignment concepts. Laser Align features
several tools with useful reference guides, including Short Flex Tolerance Table, Spacer Shat Tolerance
Table, hermal Growth Calculator and Sot Foot Assistant.
Laser Align also provides interactive links for additional information on Prutechnik laser shat align-
ment products and condition monitoring products.
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PUMPS & SYSTEMS www.pump-zone.com March 2013 9

TDH Pump Calculator Rain for Rent
he TDH Pump Calculator provides users with a tool to estimate hydraulic conditions required for pump
systems. he app is designed for engineers, ield operators and technicians. It is based on Hazen-Williams
equations, and users can enter the hydraulic parameters of the pumping system. he app will return the
total dynamic head (TDH). It is useful in the ield or oice. Intuitive controls allow users to simulate any
combination of pre-loaded valves and ittings.
Pump Energy Savings Calculator Rockwell Automation, Inc.

Rockwell Automation addresses rising energy costs with he Pump Energy Savings Calculator app.
his app compares conventional low control methods with PowerFlex drives and shows the diferential
power consumption of each. It calculates the potential energy savings of using variable frequency drives to
power pumps and fans. Users can calculate energy consumption by entering the minimum pump or flow
percentages, annual operating hours, cost per kilowatt and other information about their facility or by
using the built-in sample data provided by Rockwell Automation.
Free / Android, iPad, iPhone, Blackberry
seepex Pumps, SCT seepex, Inc.

he seepex Pumps, SCT app provides users with information on seepex’s Smart Conveying Technology
(SCT) for progressive cavity pumps. In addition to providing valuable information, the seepex app also
has a comparison calculator, which directly shows the potential cost savings that can be made with SCT
compared to an equivalent conventional seepex progressive cavity pump over a period of up to 10 years.
20
Versa-Matic and Sandpiper Mobile Apps READERS CHOICE
Warren
W Rupp, Inc.
he Versa-Matic and Sandpiper mobile apps are designed to help pump owners quickly i kl and easily ind the
tools to support pumps installed in the ield and pumps being built and shipped. Users can locate speciic
pump information with quick bar scanning or manual entry. Both apps allow users to review the Chemical
Compatibility Guide using the interactive guide, access the latest full line catalogs, and watch service and
repair training videos. Although not yet available for Android or Blackberry, users with these devices can
use the web version, which allows access to many of the mobile app’s tools.
20
Xylect Mobile READERS CHOICE Xylem Inc.

Xylect Mobile is designed to give users quick and easy access to detailediled product info
information from any
location. Since users oten work on site, the ability to access this information is important. he app allows
users to input speciic requirements and search for the ideal product to meet their needs. It gives users the
ability to search by application or product type, input required low and pump head speciications, and
identify all available spare parts for a product by inputting the product’s serial number. It also allows users
to search products from a deined duty point (low and head) and from a product denomination.
Free / Android, iPhone, iPad
Amanda Perry is associate editor of Pumps & Systems.

Send information about your favorite mobile
app to her at aperry@cahabamedia.com.

NEWS
engineering, engineering-related departments, and new

NEW HIRES, PROMOTIONS & RECOGNITIONS business growth and development. RACO Manufacturing
and Engineering Co. provides municipalities, industry and
TIM CALLANDER, SJE-Rhombus
government with remote communications systems and
DETROIT LAKES, Minn. (Feb. 6, 2013)
RTUs for data logging, alarm auto dialing, remote monitor-
SJE-Rhombus announces the addition of Tim
ing, reporting and control. www.racoman.com
Callander as regional sales manager for their
wholesale controls product line. He will sup-
port customers in the central region of North Tim Callander ERIC FORD, Graphite Metallizing Corporation
America from Texas to Canada. SJE-Rhombus YONKERS, N.Y. ( Jan. 28, 2013) – Graphite Metallizing
is a control solutions provider for the water and wastewater Corporation named Eric Ford vice president of sales and
industry. www.sjerhombus.com marketing. Ford joined Graphite Metallizing in 2007
as director of sales. Graphite Metallizing manufactures
GRAPHALLOY, a graphite/metal alloy that is a unique
GREG DUNCAN & CHRIS DISTASO, Pump
self-lubricating bearing material used in machinery and pro-
Solutions Group
cess equipment. www.graphalloy.com
OAKBROOK TERRACE, Ill. (Feb. 1, 2013)
Pump Solutions Group (PSG) named Greg
Duncan senior director of business develop- AROUND THE INDUSTRY
ment and Chris Distaso director of engineer-
Greg Duncan BIO-MICROBICS and HELD & ASSOCIATES Meet with
ing. Duncan will be responsible for leading the
organization’s growth and proitability eforts. Nigerian Delegation
Distaso will be responsible for the overall SHAWNEE, Kan. ( Jan. 30, 2013) – Bio-Microbics, Inc.
supervision and management of the Research and Held & Associates, Inc., hosted an event welcoming the
and Development function. PSG is a business visiting delegation of the U.S. Ambassador to Nigeria. he
unit within Dover Corporation and manufac- purpose of the visit was for the Delegation to participate in
tures positive displacement pumps and related Chris Distaso AG CONNECT, an international trade show for the agri-
technologies. www.psgdover.com culture industry. Bio-Microbics is a manufacturer of decen-
tralized wastewater. www.biomicrobics.com
STUART CAMPTON, Precision Polymer
NATIONAL PUMP & COMPRESSOR Opens New Branches
Engineering Ltd
BEAUMONT, Texas ( Jan. 24, 2012) – National Pump &
BLACKBURN, England ( Jan. 28, 2013)
Compressor (NPC) starts 2013 with the opening of three
Precision Polymer Engineering (PPE)
new locations in Williston, N.D.; Fort Collins, Colo.; and
appointed Stuart Campton as new distribu-
Wilmington, Del. In addition, NPC announced the grand
tion manager for its EMEA (Europe, Middle Stuart opening of the branch in Bakersield Calif. NPC produces
East and Africa) sales territories. his is a Campton
industrial pumps, industrial compressors, industrial dryers,
new role to enhance the support that PPE gives to exist-
and related equipment for the industrial, petrochemical,
ing dealers and distributors and to identify new partners in
reinery, construction, marine, oilield, municipal, environ-
new geographies. PPE provides o-rings, technical moldings
mental and mining industries. www.npcrents.com
and sealing solutions to a diverse range of industries. www.
prepol.com
MCILVAINE COMPANY Revises Growth Forecast
CHICAGO ( Jan. 22, Continent 2013 ($ Millions)
MICHAEL JAMMAL, RACO Manufacturing and
2013) – McIlvaine Com-
Engineering Company Inc. Africa 2,913
pany has revised its forecast
EMERYVILLE, Calif. ( Jan. 29, 2013) – RACO Manu-
for growth in the industrial America 15,483
facturing and Engineering Company Inc. announced the Asia 23,956
valve industry over the
addition of a new director of engineering and manufactur-
next ive years. he current Europe 13,340
ing. Michael Jammal, former program manager at Rockwell
forecast is for 5 percent Total 55,692
Automation, joins the RACO team and will oversee

growth. his is being revised to 5.5 percent CAGR for the HYDRAULIC INSTITUTE Publishes New Standards
2013 to 2017 period. he basis is the increased anticipated PARSIPPANY, N.J. ( Jan. 18, 2013) – The Hydraulic
revenues from the sales of smart valves. his is the latest Institute (HI) has published ANSI/HI 9.6.1–2012
forecast in Industrial Valves: World Markets published by Rotodynamic Pumps Guideline for NPSH Margin.
the McIlvaine Company. McIlvaine Company is a market
research company. www.mcilvainecompany.com MERGERS & ACQUISITIONS
NSF INTERNATIONAL
FLUKE CORPORATION Recalls Digital Clamp Meters acquires INASSA Group LLC Jan. 29, 2013
EVERETT, Wash. ( Jan. 21, 2013) – Fluke Corporation is
recalling certain digital clamp meters that were manufac- BILFINGER
tured between Sept. 1, 2010, and Oct. 31, 2012. Certain acquires Johnson Screens Jan. 22, 2013
Fluke 373, 374, 375 and 376 Digital Clamp Meters are DANFOSS
afected by the recall. If you own one of these clamp meters, acquires ownership of Danfoss Turbocor Jan. 21, 2013
please stop using it immediately, and send it back to Fluke AES ENGINEERING LTD GROUP
for repair. he printed circuit assembly in these units may acquires AVT Jan. 16, 2013
not be properly fastened to the test lead input jack. his
may result in inaccurate voltage readings, including a low or SKF GROUP
no voltage reading on a circuit energized with a hazardous to acquire Blohm + Voss Industries Gmbh Jan. 9, 2013
voltage, presenting a shock, electrocution or thermal burn SULZER METCO
hazard. Fluke Corporation is a manufacturer of compact, acquires Protective Coatings LLC Dec. 19, 2012
professional electronic test tools. www.luke.com For details about industry M&A activity subscribe to
Pump Industry Insider and visit www.pump-zone.com.
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1. Spill prevention & leak containment 2. Diaphragm seals/gauge guards 3. Inlet stabilizers
4. Pulsation dampeners 5. Pressure relief valves 6. Back pressure valves 7. Surge suppressors
800.603.7867 Q 951.342.3100 Q www.BLACOH.com Q Sales@Blacoh.com

NEWS
HI also updated the 1998 edition of the ANSI/HI stan- he Hydraulic Institute’s mission is to be a value-adding
dard on pump intake design and published ANSI/HI 9.8– resource to member companies, engineering consulting
2012 Rotodynamic Pumps for Pump Intake Design. irms and pump users worldwide. www.pumps.org
In addition, membership in HI has been opened to pump
and supplier companies that manufacture wholly outside XYLEM Expands into the Middle East
North America but who sell into the North American ABU DHABI, UAE ( Jan. 16, 2013) – Xylem Inc. will
market. his change signiicantly expands HI membership expand its presence in the Middle East region with the open-
opportunities globally. ing of a new oice in Saudi Arabia in
the coming months, as well as up to
three additional oices in other key
regional markets later this year. Xylem
is a global water technology provider.
www.xyleminc.com
Providing Solutions for the Diicult to Pump KIRLOSKAR BROTHERS LIMITED
Applications Worldwide Inaugurates New Delhi Facility
NEW DELHI, India ( Jan. 11, 2013)
Industries include: Oil & Gas, Subsea, Pharmaceutical,
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Chemical, Wastewater, Mining, Biofuels, Power Generation inaugurated its second Authorised
and Food. Refurbishment Centre (ARC). he
facility will ofer services such as
Unique features of the patented disc design are: overhauling pumps, impeller bal-
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WASHINGTON ( Jan. 13, 2013)
The National Association of Clean
These features give Disclo the ability to produce a superior
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ronment Research Foundation and
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boundary layer and viscous drag to produce
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CALENDAR
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wastewater treatment function and Indianapolis Convention Center
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Industry Award, Pulse of Industry
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SENECA FALLS, N.Y. ( Jan. 10,
2013) – ITT Goulds Pumps is now
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deadline is March 1, 2013.
ITT Goulds Pumps is a manu-
facturer of pumps for a wide range
of industrial markets. www.gould-
spumps.com
HYOSUNG GOODSPRINGS
Announces Supplier Agreement
with Siemens
PITTSBURGH (Nov. 20, 2012)
Hyosung GoodSprings announced
that Siemens selected the company as
the supplier for condensate extraction
pumps (vertical can) and conden-
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for ive combined cycle plants being Flygt. Godwin NC series Dri-Prime® pumps incorporate
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PUMP ED 101 By Joe Evans, Ph.D.,
PumpTech, Inc.
P&S Editorial Advisory Board
Branch-Line Pumping and Other Options

Last of Two Parts
L ast month, this column reviewed several examples of

open low, branch-line pumping applications. We used
the Branch Line Pumping Calculator (available at www.
SYSTEM COMPARISON
he upper pipeline shown in Figure 1 is the same open-low,
branch-line design illustrated in Part 1. he pump at Point
PumpEd101.com) to compare a branch-line system with A produces 600 gallons per minute (gpm) at a total dynamic
two diferent discharge elevations to a multi-line system head (TDH) of 200 feet and supplies outlows of 400 gpm
that used two individual pumps. Based on the input data, and 200 gpm at branch Points B and C. he power required
the multi-line system was more eicient, and its breakeven to meet the two branch lows is 43.2 horsepower. he high
point was barely more than 2 years. horsepower is required because the total head seen by the
pump is directly proportional to the elevation at Point C.
ALTERNATIVE SYSTEMS he pumping system in the lower portion of Figure 1 is
In addition to multi-line, multi-pump systems, a system diferent. he pump at Point A still provides 600 gpm, but
designer has several other alternatives to open-ended, since it is pumping to Point B only, its discharge head is
branch-line systems with multiple elevations. One of the reduced to 100 feet. A second pump, located at Point B and
most common is the tank-based system. In this type appli- operating in series, moves the remaining water to Point C.
cation, a storage tank is installed at or above the upper most his design reduces the total power required by 33 percent.
elevation. A lower low pump is used to keep the tank illed, his results in a smaller pump at Point A that requires 21.6
and gravity supplies water, under pressure, to the lower ele- horsepower and an even smaller one at Point B requiring
vation discharge points. just 7.2 horsepower. Figure 2 is the calculator portion and
One of the more common examples is a municipal water compares the variables involved in these two alternatives.
supply system. Elevated tanks or those located on hillsides As in the conigurations in Part 1, the required data are
use gravity to supply pressure to the surrounding areas. entered into the yellow cells, and the column to the let is
Another example is high-rise buildings. Many older build- the open-low, branch-line system. he two columns in the
ings use roof-mounted tanks to supply pressurized water to middle represent the series system from Points A to B and B
the upper loors. One more option is to use a single-service to C. he initial cost of the branch-line system is $44,000.
line with two or more pumps operating in series. Figure 1 When converting to a series system the cost is reduced by
compares this design to an open-branch system. $8,000 because of the smaller pump required at Point A.
he additional pump and controls
required at Point B adds an addi-
tional $11,000 to the cost of the series
system. herefore, the total additional
cost for the series system is $3,000.
Based on an annual electrical savings
of about $3,300, the payback is less
than one year.
For this example, the series system
is more eicient than the single pump
system. It also trumps the two pipe-
line design shown in Part 1 of this
series. he horsepower required for
the series system and the two pipeline
design are exactly the same, but the
Figure 1. Comparison of a single service line with two or more pumps operating in series to an
lower piping cost of the series system
open-branch system makes it a more cost-efective system.

As I stated in Part 1, my branch-line pumping calculator several alternatives. Once a choice is made, any number
is not a design tool. Instead, it is an evaluation tool that of sotware systems can assist with the design phase. he
allows you to compare traditional branch-line systems with Branch Line Pumping Calculator can be downloaded from
the “Pump Evaluation, Selection
& Testing Tools” page at www.
PumpEd101.com. P&S
Note: Part 1 (February 2013) of

this series contained an error. When
describing Figure 2, I said that Point
A was at an elevation of 100 feet and
Point B is 100 feet higher. Point A
should have been Point B and Point
B should have been Point C.
Joe Evans is responsible for customer and

employee education at PumpTech, Inc., a
pump and packaged systems manufacturer
and distributor with branches throughout
the Paciic 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
Figure 2. The Branch Line Pumping Calculator computations of the systems an email.

PUMPING PRESCRIPTIONS By Dr. Lev Nelik, P.E., Pumping Machinery, LLC
P&S Editorial Advisory Board
Will Impeller Velocity Triangles

Keep You Awake at Night?
Last of Two Parts
Editor’s Note: Lev Nelik received many comments on this subject after Part 1 (Pumps & Systems,
January 2012). Alberto Delgado, a former process engineer with Brown & Root, provided interesting
feedback and detailed figures that resulted in several exchanges of ideas between the two. his infor-
mation is presented as a follow up on this advanced and specialized subject of pump hydraulic design
and is coauthored by Delgado.
A pparently, impeller velocity triangles do keep some folks the low direction reversed compared to the pump impel-
awake at night. ler, are shown as inlows rather than outlows like the other
Part 2 contains information that is similar to what was examples. In particular, note the match between the vectors
discussed in Part 1, but it includes more detail regarding at the inlet of the pump and the outlet of the turbine wheel.
the vectors for each vane outlet at the same location for the We also assumed, for simplicity, that the tangential veloc-
three types of impellers. his detail will hopefully make the ity components at the pump impeller outlet can be consid-
interpretation of the triangle more realistic. ered equal to the turbine inlet and the turbine outlet equal
We have shown only three positions on each type to pro- to the pump inlet.
vide the best possible illustration without sacriicing clarity.
his also helps show, more clearly,
the velocity vectors on Figures 1
and 2 from Part 1.
As shown in Figures 1 and 3,
the locations for the backward
and forward vane inlets are dif- v
2
ferent, assuming that the same W 2

u
2 v
inlet vane angle is maintained. 2 W
2
2
2
2
Note that the impeller curvature v
u 2
(inlet and outlet) is set by a cir-

cumference used to ix the rela-
tive inlet and outlet velocities.
A tangent is drawn to the inlet
and outlet from the center of the
circumference. Inlet and outlet
peripheral velocities are drawn
using tangents from the center of
the impeller.
In the case of the radial impel-
ler (see Figure 2), the vanes are
straight to the center of the cir-
cumference. Any vane curvature
is ignored for simplicity.
Note that for the turbopump
(see Figure 4), the low vectors
for its turbine wheel, which has Figure 1. Backward-bladed centrifugal impeller (β < 90 degrees)

he following legend applies to Figures 1 through 4, β = blade vane angle
which are used to illustrate the velocity triangles: ω = angular, rotating velocity P&S
U = rotational, peripheral, tip velocity vector Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machinery, LLC, an Atlanta-
based irm specializing in pump consulting, training, equipment troubleshoot-
v = absolute resultant velocity ing and pump repairs. Dr. Nelik has 30 years of experience in pumps and pump-
W = relative velocity to blade tip ing equipment. He can be contacted at www.pump-magazine.com.
α = absolute vector angle
Alberto Delgado is a retired process engineer who formerly worked at Brown
& Root.
v2
W2
v2
2 u2 W2 v2
2 2 v2
2 2 W2
u2
v u2 u2
v
W2
Figure 2. Radial-bladed centrifugal impeller (β < 90 degrees) Figure 3. Forward-bladed centrifugal impeller (β < 90 degrees)
v2 2
W2
2
v u2
v
u3 v3
3
W3
v2
u2
3
W3
u3
v3 W2
v v1 W1
1
1
u4 u1
4 v4 v
W4
Figure 4. A pressure recovery hydraulic turbine, backward bladed (left) and a turbopump, forward bladed (right)

SPECIAL REPORT
Pump Speciication, Purchase,

Installation & Application
Sharing all the information about an application can help with the selection and installation
of the ideal pump.
First of Two Parts

By Amin Almasi, WorleyParsons Services Pty Ltd.
M ore than 90 percent of all pumps in many diferent

industries are centrifugal pumps. Variable-speed, large
centrifugal pumps are well-known for critical and large
When developing a pump system and before specifying and
purchasing a pump, many factors should be considered—
including the application, installation, lubrication system,
pumping services. Centrifugal pumps exhibit a suitable pump operation and pump noise generation. hese consid-
operating curve compared to other pumps (for example, erations are discussed in the irst part of this article. Part 2
axial pumps and positive displacement pumps ofer relatively will be in the April 2013 issue of Pumps & Systems.
steep curves). he curve characteristics can be matched with
the system requirements. A more backward angle could PUMP SPECIFICATION AND PURCHASE
make a higher reaction (from the pump impeller) and a he pump operation conditions should be divided into a set
relatively steeper curve. of normal conditions and a set of abnormal conditions. he
As pump stages are put together, the overall low range entire anticipated range of operating conditions should be
of the combined stages could be less than the smallest low deined either by range limits or alternative operating con-
range of the individual stages. Because of the compound- ditions. Unusual operating conditions, even insigniicant
ing efect, as the low is changed, the combined curve of ones, should be indicated when developing a list. All avail-
a multistage pump could have a smaller operating range. able details should be shared with the pump manufacturer.
Above: An example of different pump sizes/models in a pump family. These are sealless magnet drive ANSI pumps. Six models
are in this family.

The Pump Purchase Process
In many cases, insigniicant system or environmental condi- been prevented if the purchaser communicated improper
tions can cause considerable problems. Examples could be speciications. A good example is the use of austenitic stain-
corrosive traces in the liquid, even if they are in the parts- less steels, which are normally considered premium materi-
per-million level. als. However, they cannot be used if chlorides are present in
he purchaser should know as much as possible about the pumped liquid because of intergranular corrosion and
the system in which the pump will be installed and the luid subsequent cracking problems.
that the pump/system will move and then inform the manu- he orientation of the inlet piping and its inluence on
facturer. Particularly, the purchaser should be aware of any pump performance is important. here should be neither
unusual conditions and potential upsets that could afect pre-rotation nor anti-rotation. he low should be free from
the pump. An example is the liquid temperature runaway random distortion. Based on the design, the liquid veloci-
potential in some hot liquid units. he pump speciication ties and the system/process conditions, a minimum length
should note all expected maximum temperature values, and of straight pipe may be required before the pump inlet.
the pump vendor should be asked about the maximum tem-
perature that the pump can handle. BID EVALUATION FOR PUMPS
Another example is the potential of the sudden dead- A bid evaluation should be made that factors the energy
heading of a centrifugal pump when switching operations cost, irst cost and reliability issues using an established eco-
during some batch-type processes. he pump manufac- nomic equation. If the data are available, the total cost of
turer should also be informed of any fouling potential. he ownership can be estimated, which is the best available mea-
potential pump conditions should be carefully explored and sure for the bid evaluation of a pump. It is absolutely nec-
any fouling potential should be noted. By correctly includ- essary to ix all items and clarify all issues before the pump
ing the fouling potentials in the description of the system purchase order placement. Until the vendor is sure he has an
conditions, the pump vendor may be able to include a solu- order, he will stay in a trading posture.
tion—such as additional head margins—when selecting/ he successful bidder becomes the vendor when a con-
manufacturing the best pump for the application. tract is written and accepted. his is important because the
he pump requisition should include a complete list of clock has started at this time, and all future dates will be ref-
the scope of supply and service (preferably in a table format). erenced back to this date. his also is the date from which
he pump nozzle orientation is important as well. Ideally, the pump delivery is counted.
the nozzle orientation details should be agreed upon with
the pump manufacturer from the beginning.
Do not assume that the pump vendor is completely knowl-
edgeable about the material requirements for the system/
process. Stating the minimum material of construction
requirement can help the pump vendor during the pump
design/selection phase and avoid future problems. he
vendor’s focus is to provide a pump that is compatible with
the speciications and reliable enough to cover the vendor’s
guarantee period at the minimum possible cost. With the
proper wording of the pump speciications, the minimum
material requirements can be noted. It can also invite com-
ments that may reveal the vendor’s experience with pump
material selection.
A large number of unscheduled shutdowns are traced
back to the vendor design; the vendor material selection;
or the component selection—such as seal problems, bear-
ing issues, excessive fouling, high degradation, corrosion,
erosion and other factors. However, these problems actually
relect a lack of application knowledge, which could have
Figure 1. An example of different pump sizes in a pump family

SPECIAL REPORT
PUMP LUBRICATION SYSTEM dynamics. Long slender rotors can cause problems in cen-
Based on some reports, considerable reductions in the trifugal pumps. Some high-speed pump rotors are subjected
oil low of the manufactured lubrication oil system can to critical speeds, which are encountered during startup
occur compared to the initially-proposed system that was (particularly in high-pressure pumps).
included at the biding stage. he purchaser and vendor have Sensitivity to unbalance can also cause operational prob-
many discussions and debates regarding this issue. lems. During operation, as time passes, pumps experience
In some cases, the lubrication system’s capacity can be degradation, which usually manifests in ever-increasing
reduced by 20 to 30 percent, occasionally by as much as levels of unbalance. he more sensitive the rotor, the shorter
40 percent for some large and critical pumps. he proposal the runtime.
technical data (the bid technical details) are not inal and In many cases, the decision to replace or redesign a pump
some modiications could be expected. train component was incorrect. An incorrect diagnosis or
However, an oil low reduction of more than 25 per- wrong interpretation of the reason for a pump failure some-
cent, compared to the purchase order, should not usually times results in a solution that appears to ix the problem.
occur. Any reduction in excess of 30 percent would require However, if it is incorrect, the solution could possibly
a detailed justiication. he vendor should supply the data lead to worse problems in the future because an incorrect
and the basis for any oil low reductions that occur, particu- symptom-cause relationship is established. Careful problem
larly any signiicant reduction in the oil low of the hydrody- solving should accurately determine the real cause of a prob-
namic bearings. Suicient oil supply to the hydrodynamic lem and prevent complications.
bearing(s) and the gear units is always a concern. he cleanliness of the liquid stream is a key factor, as well,
for smooth pump operation and reliability. he corrosive
PUMP INSTALLATION substances and traces require a special material selection
How and where the pump/pump system will be installed and operation considerations. Fouling because of contami-
must also be considered. he prime function of the pump nation or liquid reaction can cause rapid degradation.
foundation is to hold the pump train in alignment during
all operating modes. To perform this function, the foun- PUMP NOISE
dation should be rigid. Establishing and maintaining the he overall sound pressure level is generally based on 1
alignment between pump train components—particularly meter from the pump skid’s edge. his means that the sound
for large pump trains delivered in several skids—is diicult pressure level of each component at 1 meter from the skid’s
if the foundation is prone to excessive delections. edge could be diferent, usually lower for the large pump
he foundation should be large enough to prevent exces- packages, than the indicated noise value for each compo-
sive diferential delections and dynamic vibrations, which nent, which is the noise at 1 meter from that component.
can have considerable efects on long-term operation. he pump package noise is not simply the sum of the noises
Another aspect is the foundation’s natural frequency. he of diferent package components.
foundation should be tuned in such a way that any founda-
tion natural frequency is not in coincidence with any of the
pump train excitation frequency. It is desirable to have all
the foundation’s natural frequencies well above any pump
excitation speed, as far above as practical.
Ideally, the pump can be placed on the foundation, aligned
and grouted, and piping can be connected according to the
pump installation procedure. Lags oten occur between dif-
ferent steps. Carelessness can delay start-up and could result
in an unsuccessful pump installation. More details on instal-
lation will be covered in Part 2 in the April 2013 issue.
PUMP OPERATION
In many cases, the main contributors to centrifugal pump
problems are related to the seal, the bearing and rotor Figure 2. An example of a belt-driven ANSI pump—the ANSI pump
design can sometimes help overcome issues, such as space
restrictions or low NPSH.

The Pump Purchase Process
he gear unit, if used in a pump package, is the major attention to details, changes and requirements, reliable and
source of noise. For the noise emission of a gear unit, the high performance pumps can be expected. he keys to suc-
design of the gear unit has more inluence than the trans- cess are up-to-date knowledge, correct specifying, proper
mitted power. A gear unit may generate the same noise or review of pump vendor documents, correct inspection of
sometimes a slightly higher noise during part-load opera- vendor activities, and modern operation and maintenance
tion compared to full-load operation. As another example, policies. he true proitability and cost savings in a pump
a 1-megawatt gear unit and a 1.5-megawatt gear unit using installation can only be achieved by combining perfor-
the same design principles may generate practically the same mance, reliability, safety, availability and maintainability.
noise level. See the April 2013 issue of Pumps & Systems for more infor-
he pump vendor’s sound calculation programs usually mation on installation and alignment. P&S
do not simulate any sound boundary condition near the
pump package. For example, the boundary conditions (such
Amin Almasi is lead rotating equipment engineer at
as a wall close to the pump skid) can inluence the noise WorleyParsons Services Pty Ltd., Brisbane, Australia. He pre-
measured in the plant. herefore, an allowance is needed viously worked at Technicas Reunidas (Madrid, Spain) and
to accommodate for this efect. Based on experience, an Fluor (various ofices). He holds a chartered professional
increase of around 3 to 5 decibels of the expected sound engineer license from Engineers Australia (MIEAust CPEng
– Mechanical) and a chartered engineer certiicate from
level for a pump package is observed at some unfavorable IMechE (CEng MIMechE), RPEQ (Registered Professional
boundary conditions. Engineer in Queensland). He specializes in rotating machines es including cen-
trifugal, screw and reciprocating compressors, gas and steam turbines, pumps,
condition monitoring and reliability. Almasi is an active member of Engineers
CONCLUSION Australia, IMechE, ASME, Vibration Institute, SPE, IEEE, and IDGTE. He has
When the pump user and the pump vendor work together authored more than 60 papers and articles dealing with rotating machines.
as a team and if all the engineers involved give suicient Almasi can be reached at amin.almasi@ymail.com or +61 (0)7 3319 3902.
Premiere Alternative for Progressing

Cavity Pumps and Replacement Parts
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®

COVER
SERIES
COVER
SERIES
Agricultural
Irrigation
Photo courtesy of Grundfos .
& Dewatering
Pump Systems for Today’s

Agricultural Irrigation
Complex irrigation applications require customized and cutting-edge solutions.
By Vahan Bagdasarian, Grundfos
M odern agricultural irrigation is a complex interplay

of sustainable energy consumption, water use,
market conditions, and the application of experience
of the potential savings from more efective and eicient
energy use.
Modern agriculture requires irrigation solutions that
and knowledge to ensure the best design for irrigation optimize uniformity, reduce energy costs, safeguard the
applications. Understanding past practices, current water water resource and keep productivity at its best. he agri-
and energy issues, and developments in pump technology cultural market changes require greater focus on applying
contributes to building pumping systems that best service knowledge, experience and total irrigation solutions inte-
the needs of modern agriculture. he agricultural market is grating all components.
changing rapidly, and farmers cannot rely on the technology
and practices of the past. WHAT TO CONSIDER WHEN GETTING WATER TO THE CROP
To keep productivity high and stay competitive in the Irrigation starts with sourcing water for the crop from
market, farmers need to focus on proitability, which groundwater or surface water from a channel or storage
includes energy optimization and better
use of water resources. Pumping systems
play a vital role in providing optimized
solutions for energy and water use.
WHAT IS IRRIGATION?
Irrigation is an artiicial application of
water to plant roots with the purpose of
assisting the growth of agricultural crops.
Fertilizer and chemicals can be added to
an irrigation system. Irrigation can also
play a role in frost protection.
Successful agriculture depends on
farmers having suicient access to water.
In the middle of the last century, the
common perception was that water was
an ininite resource. Today, we know that
water is a resource that must be man-
aged. his is not only a question of more
mouths to feed—people consume more
calories and eat more meat. his requires
more water to produce food.
Farmers must consider energy con-
sumption. Energy for irrigation pumps A pump system for today’s irrigation is not only about the pumps. Variable speed drives,
is one of the highest single cost drivers intelligent control and remote management all necessitate the integration of components
for farmers. However, many are unaware in an irrigation system.

COVER
SERIES
pond. Next is water treatment, if necessary, and perhaps the attached to a pump that can supply the necessary amount
addition of fertilizer or chemicals. Finally, water is delivered of water, pressure and signiicantly more, as a precaution. A
to the crop using diferent techniques—such as looding, valve handles the excess low and pressure.
sprinkler irrigation or drip/micro-spray applications. Drip and micro-spray irrigation are used for low-pressure
Mechanized sprinkler systems, such as pivot irrigation, are applications in which reducing as much potential evapora-
efective for covering large areas. hese systems are typically tion and run-of as possible is a requirement. Keeping the
pressure constant is vital to ensure
uniform application throughout
each zone in the system. his can be
the most energy-eicient method
of irrigation, if managed properly.
Achieving this requires that the
system be able to compensate for vari-
ations in low to ensure constant pres-
sure as zones cut in and out.
TRADITIONAL APPROACHES AND

PUMPING SOLUTIONS
Groundwater withdrawal has typi-
cally involved submersible or vertical
turbine pumps that bring water to
the surface. For surface water intake,
centrifugal pumps in diferent con-
igurations, split case pumps and end
suction pumps have been traditional
solutions.
hese pumps are required to meet
changing conditions above and below
ground, which have an efect on the
pressure and low required from day
to day and from season to season. A
pumping system must deliver the
right amount of pressure and low
at the nozzle. he simple solution is
to oversize the pump, so the pump is
able to handle a worst case scenario.
However, as a result, the pump will
almost never operate at its optimal
duty point. It will produce too much
pressure and consume too much
energy, which is not used produc-
tively in any way.
Traditionally, water has been dis-
tributed from the water source—
either groundwater or surface
water—at low or constant pressure
from pumps operating at single speed.
Delivery to the crop has been from

nozzles, where the focus has been on To keep productivity high and stay competitive in
surface coverage, without much atten-
tion placed on run-of, canopy evapo-
the market, farmers need to focus on proitability,
ration and wind drit. Soil moisture which includes energy optimization and better use
monitoring to ensure an even spread of water resources.
over the irrigated area is a relatively
new discipline.
In contrast, pressure management
has long been an issue. hrough the
years, pressure reduction valves have
been used to reduce pressure in the
system. However, valves are costly to Variable frequency.
install and require frequent service
and replacement, and their operation
consumes a lot of energy.
Unchanging innovation.
If end users think of an agricul-
tural irrigation system as a car and the Introducing the M2L 3000 Series
Medium Voltage Variable Frequency Drive.
pump as the motor, would it make
sense to drive the car at constant
full throttle and control the speed
with the brakes? his is a common
approach for irrigation pumps.
MEETING THE CHALLENGES OF

MODERN AGRICULTURE
Complete pumping systems instead
of large, isolated pumps are the solu-
tion going forward. For example, the
costly and time-consuming use of
pressure reduction valves to maintain
constant pressure can be eliminated The M2L 3000 Medium Voltage Our innovative patented topology
by investing in pump controllers for Variable Frequency Drive is a step — modular multilevel converter
efective pressure management. his change in motor control power (M2LC) — is powered by state-of-the-
saves costs in the long term, reduces technology. Though designed for art hardware and software control.
the need for service and minimizes industrial applications, it benefits Our control algorithms are setting the
energy consumption. from Curtiss-Wright’s wide ranging stage for the next generation of VFDs.
he same can be said of using valves experience in defense and nuclear-
Developed, designed, and
in sprinkler irrigation. Using a vari- related technologies, an arena where
manufactured in the USA.
able speed pump and a pressure sensor products must meet the most rigor-
Supported around the globe.
on the pivot, which would automati- ous standards and where failure is
cally adjust the pump performance to simply not an option.
match the requirements for the pivot,
is a much better approach. his would
ensure higher irrigation uniformity To learn more about the M2L 3000,
and keep energy costs down. A visit http://benshaw.cwfc.com,
call 412-968-0100 or e-mail
pump controller ofers the additional benshawRFI@curtisswright.com.
advantage of protecting the pump
from dry-running or power supply

COVER
SERIES
irregularities, which will extend the lifetime of the pump. in a car will end up a costly afair and ofers no guarantee of
he rises and falls in water level, below ground and for a comfortable or fuel-eicient ride.
surface water, essentially change the speciications for a hink about this in an irrigation system, in which the
pumping system because these variations change the head. pump must do more than simply deliver water to the pipes
A single speed pump dimensioned to lit from the lowest to be efective. For example, adding variable speed drives
water level will burn energy dollars when the level is high. improves the eiciency of groundwater withdrawal when
On the other hand, a variable speed pump adjusts its head pumping directly into an irrigation system. Surface water
and low to compensate for water level changes, reducing intake and distribution can be improved by using multi-
energy costs. pump pressure boosting systems. Across the board, moni-
toring and control systems further safeguard the reliable
DESIGNING AN IRRIGATION SYSTEM FOR low of water by protecting the pump from dry-running,
TODAY’S APPLICATIONS motor breakdown or power supply irregularities.
Farmers and pump system providers need to think through All these elements must be fully integrated into the design
the speciic irrigation applications in new ways, and in par- to provide the beneits that a modern irrigation pump
ticular they need to think about irrigation system design in system can ofer the farmer. Maintaining correct pressure
the application. he pumps must be much more integrated and low in the pipes and at the nozzle means more water
with the rest of the irrigation system. his means the pump per kilowatt hour and savings on energy, which is one of the
must be designed to match the irrigation equipment or the highest cost items in farming.
irrigation equipment must be designed to match the pump. Earlier, the importance of maintaining a constant pressure
he current approach of simply installing a pump capable in a pivot irrigation system was explained. his becomes rel-
of always delivering more than enough water ends up wast- evant if the pivot is equipped with an end gun and maybe
ing money and energy. Returning to the aforementioned even a corner section. As soon as the end gun or corner
metaphor, which compares the system to a car and the section comes on, the pressure in the pivot’s main line will
pump to its motor: Purchasing an over-sized motor to place drop. his will impact the irrigation uniformity.
Figure 1. If a pump is specified to run continuously at

the highest level—for example when the corner section
comes on—energy is wasted. The different requirements
The range of pump applications in agricultural irrigation is many and varied. The for optimal energy use on a pivot application can be met
key to success is intelligent pump controls that are designed specifically for by using a variable speed pump. This offers substantial
each application. energy savings while maintaining pressure requirements.

he solution is to replace the pivot’s main pump with a Vahan Bagdasarian is innovation manager, Irrigation, for
Grundfos. He can be reached at vbagdasarian@grundfos.
variable speed pump, which will immediately react to a pres- com. With an annual production of more than 16 million
sure drop when an end gun or corner section cuts in. In such pumps, Grundfos is a provider of pump solutions and special-
a coniguration, it is possible to maintain the same pressure izes in circulator pumps for heating and air conditioning and
on all the sprinklers and, therefore, deliver high uniformity centrifugal pumps for industrial applications, water supply,
sewage and dosing. www.grundfos.us
(see Figure 1).
THE FUTURE: TOTAL SOLUTIONS,

TAILORED TO THE APPLICATION INNOVATION
INNOVATI
TION | ENGI
ENGINEERING
GINEE
ERING | PE
P
PERFORMANCE
ERFORMANC
CE
FLEX-PRO A2
he development in irrigation sys-
®
tems described in this article reveals
a need for careful consideration of
the entire irrigation system and each
component’s integration, tailored to PERISTALTIC
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TECHNOLOGY EEXCELLENT
TECHNOLO XCEL
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the application.
his requires experience and knowl-
edge. he ability to follow water from
the source to the crop—from water
intake, water treatment and distribu-
tion to the irrigation application—
and carefully monitor it along the
way is critical for an irrigation pump
system.
Modern agriculture requires a
broader understanding of component
integration, and the system must ensure
that the farmer is able to respond to
issues of energy consumption and water
supply, speciically by isolating areas in
which savings can be made, generating
increased proit per acre.
his is not an exercise that can be IP6
P6
66
carried out in isolation. All relevant NEM

EM
WA
MA 4X
WASH
WAS
WA
ASH DO
DOWWN
local conditions must be added to the
equation—such as soil conditions,
the crop, topography and weather
Standard 61
patterns. Pump control, including
monitoring and intelligent manage-
ment, is then the way forward.
Energy savings are there to be made Self-priming Valve-less Design – Can’t Vapor-lock
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eit for the farmer is, in addition to Smooth, Quiet Pumping Action
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COVER
SERIES
Powering the Pump:

Diesel Versus Electric Motors
Make the ideal motor selection for irrigation applications.
By Tim Albers, Nidec Motor Corporation
O f the 6.3 million farms in the U.S. in January 1925, only

205,000 received centralized electric services. Private
utility companies that supplied electric power to most of
he trend toward switching from diesel to electric began
gaining steam within the last 15 years. Environmental con-
trols and regulations on the operation of diesel engines and
the nation’s consumers argued that it was too expensive to the rising cost of diesel fuel have accelerated the conversion.
string electric lines to isolated rural areas, and most farmers Changing from diesel to electric makes sense from several
were probably too poor to aford it. diferent standpoints.
To rectify that situation, the Rural Electriication
Administration (REA) was created by executive order and COST
was charged with administering loan programs for electri- Operating and maintenance cost advantages are available
ication and telephone service in rural areas. Between 1935 when switching from diesel to electric. On the operational
and 1939—the irst 4½ years ater REA’s establishment— front, end users must consider the cost of diesel fuel. It is
the farms using electric services more than doubled. expensive, and likely to remain so as global demand rises.
Even though farmers were gaining access to the power Figure 1 illustrates that running an engine on electricity is
grid, they were still using diesel engines to power their less expensive than running one on diesel. hat was not the
pumps. One reason for this is that they had already invested case in 1992, but times have changed. he economics of irri-
in diesel. Also, in most cases there simply was not enough gation pumping favor electric motors.
juice to power the farmhouse and the pump house. Figure 2 details the operating hour scenarios and cost
By the early 1970s, about 98 percent of all U.S. farms had points for diesel and electricity. It shows estimates of the
access to afordable electric service. Many farmers, though, total costs of operation for an irrigation pumping system.
were still using engines to power their pumps and would he costs include estimates for energy, repairs, ixed cost
continue to do so. Most would argue that despite some price depreciation, maintenance and service. Because each pump-
spikes, diesel fuel was still cheaper than electricity. Ater all, ing station will be unique, the costs are an estimate, but they
those diesel engines still worked. Why switch to electric? clearly show the economics of today.1
he cost for electricity can vary depending on when and
where it is consumed. Avoiding peak power demand times
can lower the costs of electricity even further. In some parts
of the U.S., irrigating at of-peak hours is a good economic
idea and oten mandated.
From a maintenance standpoint, electric motors win
this battle, too. Maintenance on a diesel motor requires
more time and attention than electric motors. Depending
on the application, a pump engine may be required to run
for extended periods if that pump drives multiple systems
during the irrigation season. If so, the diesel engine will con-
Figure 1. Total annual costs in thousands to operate a 75-horsepower stantly need to be refueled and the oil levels and ilters will
irrigation pump 1,500 hours per year using an electric motor or require monitoring.
diesel engine. Electric motors do not have to be refueled. hey also do
Source: Curley, Robert G. & Gerald D. Knutson,“Cost Comparison: engines vs. not have engine oil and ilters that must be checked and
electric motors for irrigation pumping,” California Agriculture, Vol. 48, Num. 5
replaced. hey only require lubrication once every season.

ENVIRONMENTAL IMPACT works to spend more money on new motors, even if those
Perhaps the overriding motivation to change to electric, par- new motors will eventually pay for themselves in reduced
ticularly in the past few years, is the concern with environ- operating costs and improved eiciency and have less impact
mental issues. An electric motor runs cleaner than a diesel- on the environment.
powered engine. Electric power plants continue to create he question becomes when to make the switch. he
power in cleaner ways. Also, the addition to the grid of alter- answer is easy if and when that diesel engine fails. However,
nate energy sources, such as wind and
solar, provide electricity with virtually
zero carbon emissions.
An electric motor allows for the use
of much lower carbon emission power
versus a comparable diesel engine.
he harmful environmental efects
from internal combustion engines
outnumber those from electricity.
PUMP CONTROL
In addition, installing pump controls
and variable speed controls is easier on
an electric motor than it is for a diesel
engine. While these types of con-
trols can be added to diesel engines,
they are costly, and more important,
they can reduce the eiciency of the
engine.
his is not the case when adding
controls and variable speed features to
electric motors, which when applied
correctly, greatly increase the ei-
ciency and durability of the motor,
improve control in pipelines and Keeps You Running.
canals and reduce energy use. Electric
Recovery rate is essential to cyclone performance.
motors can be automated and con- GIW’s hydrocyclone assures continuous delivery
trolled remotely. Variable speed drives of sized material to further processing. Our design
and sot starters in electric motors replaces glued in rubber liners with metal reinforced
are components that help mitigate high energy urethane. Our ceramic is bonded directly
to rigid urethane backing providing extra protection
power surges. he technology exists
against tramp or grinding balls that iniltrate your
and is growing quickly based on ever system. For consistent and continuous operation,
decreasing costs to monitor and con- count on GIW. We will keep you running!
trol an electric-driven irrigation pump www.giwindustries.comt1.706.863-1011
system remotely.
THE DECISION
Diesel engines remain in use today and
for good reason. In some areas of the
world, electricity is unavailable. Also, A KSB Company t
Pumps Valves Service

the diesel engines installed years ago

continue to work today. Operators
do not want to scrap something that

COVER
SERIES
if end users’ engines are operating well, they should Reference
consider having a plan in place to switch to electric 1. Curley, Robert G. & Gerald D. Knutson,“Cost Comparison: engines vs.
electric motors for irrigation pumping,” California Agriculture, Vol. 48,
motors at some point in the future. Hopefully, they Num. 5.
can make that switch when they want to instead of
being forced to repair a broken diesel engine to com- Timothy Albers is the director of product management and OEM marketing for the
Industrial Motor Division of Nidec Motor Corporation and is responsible for product
plete the irrigation season. management, marketing and quotation support. During the past 16 years, Albers has
he bottom line is this—in 2013, for many irriga- held different positions in marketing for Nidec Motor Corporation and Emerson Motor
tion applications, operators choose electric motors, if Company, including product-line manager for NEMA motors. Before joining Emerson, he
was employed by General Electric Company in the marketing and sales of electric motors
electricity is available, to power their pumps. P&S and drives. Albers’ career includes a stint in the U.S. Navy as an operating engineering
oficer. He is a senior member of IEEE.
Figure 2. Operating scenarios and costs for diesel fuel and electricity.
NETZSCH TORNADO® T2 Rotary Lobe Pump

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NETZSCH Pumps North America, LLC

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email: TORNADO@netzsch.com
www.netzschusa.com/T2

COVER
SERIES
Powerful Mine Dewatering

Electric and diesel centrifugal pump options
By Kristen Gurick, Godwin Pumps, a Xylem Brand
M ining applications are as diverse as construction or water

and wastewater applications. Each jobsite has speciic
requirements and needs. Underground and open pit mines
and planning stages. A system analysis should be performed
irst. hen pump selection can begin. Factors to consider in
mine planning include portability, easy maintenance and
have several layout and design obstacles. Regardless of the solids-handling.
mine and its setup, water is a mine’s biggest enemy. Another consideration is pH. Pumps can be customized
Getting water out—and keeping it out—is the primary with durable materials of construction speciically designed
focus of any mine plan. he deeper the mine, the more for low pH and other corrosive liquids.
water that will be encountered and need to be removed. Pump systems are completely customizable, and the right
Once dewatering begins, mine planners can get back to one can only be selected ater the operator or mine engineer
what they do best. understands the mine plan. Pump and piping design and
pump control can be tailored to the mine plan. In addition
MINE DEWATERING to length of low, elevation and discharge, consider layout
A pump company or dewatering solutions provider can drawings, hydraulic grade lines and pipe wall thickness.
partner with mine planners and engineers in the design Perform friction loss calculations.
A centrifugal pump with a fuel cube

Also, consider present and future requirements.

A mine’s design can change based on weather
conditions, landscape vulnerability and market
demands. A dewatering pump company can help
design the mine plan, so mine operators and engi-
neers can focus on mining. A reliable dewatering
system allows them to continue working.
he power source is another component to
consider for mine dewatering pump selection.
When selecting a centrifugal pump to it their
needs, many mine operators select diesel-driven
centrifugal pumps. As with any other application,
operators have options. he initial setup costs
should be measured against the lifetime costs of
pumping for the project. For a temporary job in
a mine or quarry, diesel-driven pumps will typi-
cally be the most logical choice. Setup costs are
virtually zero. he pumps run on diesel fuel for
the short duration of the project. If available near
the mine, natural gas is also an option.
Hydraulic submersible pumps are another
option for mine planning. hese pumps feature a A diesel-driven centrifugal pump

GE Works to boost mine efficiencies.
In the mining industry, GE’s SPS pumping systems
work to increase efficiency, reduce environmental

impact and provide versatile pumping solutions.
For example, our multi-stage centrifugal SPS pumps
are used in a wide range of mining and mineral
processing applications including water supply
and transfer, water disposal, cavern leaching
operations, dewatering, dust suppression, mine
drainage, chemical processing, boiler feed and in
water processing plants. Our SPS systems provide
enhanced pumping efficiencies by lowering noise
and vibration levels, decreasing construction lead
times and delivering improved reliability and
extended runtimes. With GE, you have a worldwide
support system ready to provide engineering, field
service or sales support.
Take a look at our results, and see how
GE can work for you.
Call +1 713 260 6731 or e-mail sps.inquiry@ge.com
www.geoilandgas.com/sps

power pack itted to a submerged pump. he pump ends high speciic gravity (such as that found in slurries) and can
usually sit at varying levels of submergence, and their power ofer a total dynamic head up to 600 feet. hese hydraulic
packs sit above ground. hey are ideal for abrasive ine sand, submersible pumps can be diesel driven or electric, depend-
ing on system requirements.
ELECTRIC-DRIVEN PUMPS
If a project is more long-running, con-
sider electric-driven pumps. Electric
submersible pumps have a solid history
in mining applications. hese pumps
can handle moderately large lows (up
to 2,500 gallons per minute) or extreme
high heads (up to 750 feet).
In addition to these submersible
pumps, electric-driven centrifugal
pumps are ideal for both prolonged tem-
porary pumping and permanent installa-
tions. Designed for long-lasting durabil-
ity, these pumps were initially used in
industrial and municipal applications.
However, their beneits span many more
A diesel-driven hydraulic power pack in the foreground (pumps in the background are diesel- applications. A permanently installed
driven booster pumps)
s
Flow
In n ov
ati
o n
Advancing
Wh
ere the Ability of
AODD
Pumps
Advanced™ is more than just our product line’s brand name. It’s our promise to
industrial and municipal Water and Wastewater facilities worldwide. Wilden® Advanced™
Series air-operated double-diaphragm (AODD) pumps are the most advanced, versatile,
reliable, easy-to-use and energy-efficient AODD pumps available.
t Bolted design provides leak-free performance
t Lower energy costs with Pro-Flo X™ air-distribution system 22069 Van Buren Street
t Streamlined liquid path design maximizes flow and efficiency Grand Terrace, CA 92313-5607
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O: +1 (909) 422-1730
Contact your authorized Wilden distributor: F: +1 (909) 783-3440
www.wildendistributor.com www.wildenpump.com

COVER
SERIES
electric-driven centrifugal pump will provide reliable, con- site location is not extremely remote, an electricity source
tinuous pumping and reduced operating and maintenance can be found and power lines run to the jobsite. Accessing
costs. electricity can outweigh the lifetime costs of a diesel-driven
While not frequently used in mining applications, elec- pumping system if the timeframe is long enough. Costs for
tric-driven centrifugal pumps are a viable option for a perma-running electric-driven pumps will eventually be the more
nent installation or lengthy temporary pumping job. If the economical choice, even factoring in initial setup costs.
For temporary jobs in which refu-
eling is diicult, an electric pump is
the ideal solution. Once power lines
are established, pump accessibility is
HIGH PERFORMANCE PRODUCTS, almost a nonissue. Lines can be run
world class solutions. into underground mines and bolted
to the ceiling. Mine planners may
not consider this option, but once
designed and implemented, electric-
driven pumps require less access.
hey do not need refueling, and their
motors require less servicing. hese
centrifugal pumps also reduce the
carbon footprint of any job.
Case Study: Electric-Driven Pumps

A gold mine had an environmental
restriction that would no longer allow
diesel-driven pumps, which had been
operating at their site, provided by a
rental company. he mine requested
a solution for a portable pumping
system that could use the voltage that
was available at the tailings dam. he
pumps needed to supply 7,500 gal-
UGREQ̶"ECP"UCXG"[QW"OQTG"VJCP"QWT"RTQFWEVU"EQUV0
lons per minute (gpm) to the roaster
Ugg"jqy"vq"tgfweg"{qwt"ycvgt"cpf"gpgti{ facility (the location used to heat the
eqpuworvkqp."kpetgcug"gswkrogpv ore and extract the gold) and 4,000
tgnkcdknkv{"cpf"kortqxg"{qwt gpm to the autoclave system (similar
dqvvqo"nkpg"ykvj"UGREQ̶Óu to the roaster facility, but using pres-
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sure along with heat) at the mine.
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A pump provider designed a system
qyp"rgceg"qh" that used the electricity available
okpf."ejgem"qwv onsite. he electro center—the house
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containing the switch gear, variable
IHQ."kv"kupÓvÑ frequency drive (VFD) and all the
pump controls—was on a portable,
structural skid and housed within an
enclosure. his unit was placed on the
Ugcnkpi"Gswkrogpv"Rtqfwevu"Eq0."Kpe0 crest of the tailings dam. Using this
800.633.4770 – www.sepcoUSA.com solution, the company provided three
IHQ̶"ku"c"tgikuvgtgf"vtcfgoctm"qh""Y0"N0"Iqtg"cpf"Cuuqekcvgu0

electric-driven, 12-inch centrifugal Getting water out—and keeping it out—is the

pumps, each capable of heads up to
390 feet and solids-handling capabili-
primary focus of any mine plan. The deeper the
ties up to three inches. hese pumps mine, the more water that will be encountered and
provided the necessary low rates and need to be removed.
allowed the system to be moved up-
gradient as the tailings levels rose.
DIESEL-DRIVEN PUMPS
Considering all the beneits of elec-
tric-driven pumps, diesel is still the
right it for many mining applica-
tions. If no on-site power can be
made available, a permanent diesel-
or natural gas-driven pump is a great
option. Diesel-powered centrifugal
pumps come equipped with a diesel
engine for stand-alone operation.
hese pumps will work on any site, no
matter how remote. Engines should
meet the latest emissions regulations 1971 Plymouth Duster
and tier compliance standards.

Standard models of centrifugal 855 Series
pumps are oten used for high-volume Low NPSHa on your vacuum receiver got
you down? Fail to resume pumping as
low (which can reach 15,000 gpm or suction levels resume? You need Carver
more), average total dynamic heads Pump 855 Series muscle!
and solids-handling capabilities. Carver 855 Series are designed for use on
vacuum receivers operating with up to 26” Hg
Advanced lines of centrifugal pumps vacuum. Flange mounted directly to the vacuum
are better suited to applications with receiver tank eliminates suction piping/NPSH
high or extreme high heads, or those problems. Whether operating at a trickle or full flow,
specially designed impellers allow pumping to resume even
that are used as jetting pumps. after periods of interrupted flow.
he total dynamic head of these Capacities range to 600 GPM depending on discharge head
pumps, single staged, can reach or TYPICAL and speed of operation. Available in 6 sizes ranging from 1”- 4”,
RECEIVER
TANK standard materials of construction include All Iron, CD4MCu and
exceed 600 feet. his means that, in a Rubber Lined. The 855 Series features an overhead v-belt drive
mining application, one of these high- arrangement as standard, with options for
either close coupled or frame mounted drives.
head pumps can be suicient to meet OVERHEAD
DRIVE Packing is standard in the stuffing box with
the pumping needs, or great heights V-BELT
DRIVE mechanical seals as an option, and don’t
ASSEMBLY forget to ask about our Swing-Out design.
can be achieved with just a few pumps MOUNTS
DIRECTLY Let us build the muscle you need!
staged together. TO TANK
FLANGE
Carver
Safety should always be a consid- Series 855
eration. When running diesel-driven

centrifugal pumps in an underground
mine, air should be vented in to bal- Creating Value.
ance the diesel exhaust. his safety Carver Pump Company
condition is eliminated with electric- 2415 Park Avenue
Muscatine, IA 52761
driven pumps. 563.263.3410
Fax: 563.262.0510
www.carverpump.com

COVER
SERIES
Case Study: Diesel-Driven Pumps

A coal mine needed to dewater its mine loor ater a 100-year rain event.
All mine operations were stalled. he mine operators needed to get the
process back online as quickly as possible. Given the amount of water, the
pumps needed to supply 1,100 gpm with 760 feet of total dynamic head.
A solution was designed that required a six-man crew; 15,000 feet of
high density polyethylene (HDPE) pipe; two diesel-driven, eight-inch
high-head centrifugal pumps; and onsite fusion machines. All equipment
was onsite within 10 days of the lood event. he pipe was fused on loca-
tion, and the mine was quickly operational again.
CONCLUSION
When water creeps into a mine, it becomes the most important aspect
of mine planning. It needs to be dewatered as quickly as possible, but a
design also needs to be developed that makes the most sense for the mine.
Operators must consider available power sources for the most economi-
cal mine plan and reliable mine dewatering system. P&S
Kristen Gurick is a marketing communications specialist for Godwin, a Xylem

brand. She can be reached at kristen.gurick@xyleminc.com or 856-467-3636.
www.godwinpumps.com. A centrifugal pump equipped with a Tier-4 diesel engine
Award Winner.
Complete Cake Pump System Solution
Our progressive cavity pumps handle highly viscous, non-
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injection. Low capital, operating and maintenance costs,
along with simple integration with dewatering and drying
equipment is why seepex helps take the load off.
Contact your seepex expert today to learn more about the

Cake Pump System.
seepex Inc.
511 Speedway Drive sales@seepex.net
Enon, Ohio 45323 www.seepex.com

TRADE SHOW COVERAGE
T he WQA Aquatech USA conference brings multiple

water industry groups together in one event for
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provides business and
technical educational
sessions and opportuni-
he conference attracts diferent water industry groups ties to network with col-
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WQA Aquatech USA represents residential, commercial data and discover new
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other key products and services.
he comprehensive water quality forum provides the
latest information, tools, resources and strategies for build- Exhibition Hours
ing business. Attendees have the opportunity to connect Wednesday, April 3 11 a.m. – 5 p.m.
with manufacturers, suppliers and service providers. It also Thursday, April 4 10 a.m. – 5 p.m.

EFFICIENCY MATTERS
Design Software Increases

Hydraulic Eficiency
Pump manufacturer streamlines the design and production process.
By Arno Gehrer, ANDRITZ GROUP
A n international technology group supplies equipment and services for hydropower

stations, the pulp and paper industry, solid/liquid separation in the municipal and
industrial sectors, the steel industry and the production of animal feed and biomass
pellets. he company, headquartered in Graz, Austria, operates more than 180
production sites and service and sales companies worldwide.
he pump division develops and manufactures customized large pumps and standard
centrifugal pumps for a wide range of applications and industries, such as:
• Water transport and irrigation
• Energy sector (cooling water and flue gas desulfurization pumps)
• Pulp and paper, sugar and bioethanol industries
Many years of experience in hydraulic machinery construction and comprehensive

process knowledge form a solid footing for the performance standards met by these
pumps. he company is a single-source supplier—including development, model tests,
design, manufacture, project management, and ater-sales service and training.
DESIGN PROCEDURE
he pump manufacturer has developed a modern design system that consists of com-
puter-aided-design-based geometry deinition, hydraulic optimization by means of
numerical low simulation and analysis of mechanical behavior.
For an initial impeller or guide vane design, TURBOdesign1 (design sotware) is
extensively used within the company. he sotware provides good solutions in a short
time period, especially when starting from scratch.
he hydraulic behavior is then evaluated by solving the full 3D-Navier-Stokes equa-
tions in combination with a robust turbulence model. Based on the initial design sot-
ware solution, the blade proile is further optimized by experienced designers and inter-
action with the stationary components, such as the casing, must be tuned. Finally, the
progress in hydraulic design is veriied by model test results.
APPLICATION OF THE SOFTWARE TO PUMP DESIGN

Two years ago, the sotware was introduced to the pump manufacturer for hydraulic
development of a new vertical line shat pump (see Figure 1). his pump type is typi-
cally used for irrigation and cooling water supply to thermal power plants.
Because of changing requirements, the pump’s operating range had to be shited to
higher low rates and higher heads. herefore, the company needed to develop new
Figure 1. Pump assembly model of a
runner blades and new guide vanes. he hydraulic designs were veriied by computa- vertical line shaft pump with adjust-
tional luid dynamics (CFD), including all low-relevant components (see Figure 2). able impeller blades

RESULTS • Cavitation observations
An extensive series of measurements was carried out in the • Hydraulic forces (axial thrust, radial force and
pump company’s in-house hydraulic laboratory on a fully momentum)
homologous model. hese experiments provided: • Stability limits (for example, pressure pulsations)
• Performance data (flow rate, head, power and
efficiency) Compact Design
Compared to the old reference pump, the new design was
smaller and had signiicantly higher blade loading and pro-
vided greater head and low rate (see Figure 3). he ei-
ciency at the design point (OP1) could be improved.
Figure 3. Model test result—head and efficiency comparison with

Figure 2. CFD pump model reference design

EFFICIENCY MATTERS
Enhancement of Cavitation Limits customers. In conclusion, the sotware considerably sup-

Regarding cavitation, the net positive suction head required ported the pump manufacturer in accelerating the hydraulic
(NPSHrequired) curve of the reference design had to be shited design process. P&S
to higher low rates to avoid pressure-side cavitation in the
start-up condition, OP2 (see Figures 4 and 5). Arno Gehrer has been a research engineer at ANDRITZ
Finally, the new design fulilled the fundamental condi- GROUP since 2001. He obtained his Ph.D. in mechanical
tion NPSHplant ≥ NPSHrequired for the whole operating range engineering from the University of Graz in Austria. At present,
(see Figure 5), and the measurements were completed with his main focus is the hydraulic design of turbines and pumps,
both with CFD and model testing. He is leading the group for
a successful acceptance test, witnessed by the manufacturer’s hydraulic development & CFD.
Figure 4. CFD result, reference design (old) at OP2—pressure field

and ISO surface of cavitation on the impeller blade surface Figure 5. Model test result—NPSH comparison with reference design
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MAINTENANCE MINDERS
Pump Rebuild Tips

Avoid common mistakes to get the longest life from a rebuilt pump.
By Tom Davis, Maintenance Troubleshooting
A few years ago, I took a class to learn to be a

horologist—a person who repairs antique mechanical
clocks. My instructor said that some of the students may
in place is with a magnet base. One indicator is placed on
the side of the coupling half to detect horizontal movement.
he other is placed at the top to detect vertical movement.
learn to be good clock repair people, but time will tell. Depress the indicators and set them at zero. hen release
hat expression started with clock repair. the bolts on the suction and discharge langes. hey do
If a horologist does a quality job repairing a wall clock, it not have to be removed, just backed of to be inger tight.
can be wound and will run for eight days before a rewind If either indicator moves 0.001 inch or more, piping strain
is needed. If the horologist repaired the clock poorly, the exists and must be corrected before re-installing the pump
clock might quit ater only four days and keep bad time. he ater the rebuild.
device can be rebuilt, but the quality of the time it keeps his step is oten skipped. Chances are the new or rebuilt
relects on the horologist. Do a bad job, and time tells on pump put in the same location with the same piping will
you. have a short life because of the twist and stress induced
In a tighter economy, plants and facilities rebuild their when the piping is secured.
own pumps to cut costs. Some plant managers believe that
using plant personnel instead sending it out for repair is less INSPECT BEARING FITS
expensive. Time will tell with pumps rebuilds, too. Installation of anti-friction bearings involves some mea-
I have participated in the supervision of many electrical surement steps. he bearing is round when it is removed
and mechanical repairs. If an electrical mistake is made, it is from the box. It has certain prescribed internal clearances
known quickly. he lights go out; sparks ly; or even worse, that allow for smooth movement. If the shat is oversized
something melts. or slightly tapered in the bearing seat or if the housing bore
However, mechanical repair mistakes are less obvious. is “belled out,” the bearing will not remain round during
Miss a critical step in alignment, ignore the bearing it or operation. Roundness in a bearing means long life.
allow the shat to wobble, and the pump continues to run. It Check the housing bores and shat seats with a microme-
pumps, but time will tell how long it will last. he unit might ter capable of reading to ten-thousandth of an inch (0.0001
only last two years when it should have lasted 10 years. Ater
two years, supervisors may forget who previously serviced
the pump, and two years may become the normal expecta-
tion. If it stopped working ater a week, management may
pay more attention. Rebuilding a pump to last requires skill
and a focus on detail. his article provides steps to follow
when rebuilding a pump to lengthen the time interval
between repairs.
CHECK FOR PIPING STRAIN

A simple check can be made to avoid piping misalignment
and the strain that it puts on critical pump components,
such as bearings and mechanical seals. When the pump has
been properly shut down with safety locks in place, separate
the coupling between the pump and the driver. Trimming the impeller diameter to give a better performance, even if
Place two dial indicators on the pump coupling half or completed on a lathe, removes unequal amounts of metal from the
the pump shat if it is accessible. A good way to hold them cast surfaces resulting in dynamic unbalance.

MAINTENANCE MINDERS
inch) to ensure proper it. his step must be completed. If an bore is smaller than the pump shat and must be pressed on
end user does not know the proper dimensions, they should or heated to expand the bore before assembly. An anti-fric-
ask the pump vendor for a “critical dimension checking tion bearing is a great example of metallurgy. he bearing
print,” or look up the proper it using Machinery Handbook companies use excellent quality control to produce a bear-
or a similar industrial reference. ing that is hard, but not too hard, to provide a long service
Unfortunately, if a machinist fails to make a shat cor- life. If the bearing is overheated, it becomes annealed and
rectly, he/she will oten leave it slightly oversize and the will not last for its intended life.
housing bore a bit undersize. Metal is easier to remove than Modern shops use induction heaters or cone heaters to
to add back, so they shoot high on the shat and low on rapidly heat the inner race to allow shat assembly. However,
the bore (always leaving metal that can be removed). hey the temperature-sensing mechanism on the heater can
sometimes leave more than desired. he pump bearing will oten be out of calibration or non-existent. In that case, the
install, but it will be pinched on the outside diameter (OD) mechanic must use an infrared thermometer or temperature
or expanded too much on the inside diameter (ID) and will sensitive crayon that melts at the correct temperature value
fail quickly. Remember, the pump bearing might last a year to make sure that the bearing is not overheated.
in this condition, but it should have lasted 10 or more if the he magic number to avoid is more than 250 F. Most
dimensions were correct. good pump shops never heat them to more than 230 F to
avoid the possibility that they will overheat the bearings.
ENSURE PUMP SHAFT STRAIGHTNESS Overheating a bearing during assembly removes years from
Pump shats are subjected to unbalanced impellers, worn its life, and plant management may never know the true
bearing its, impeller rubs and other mechanical strains reason for the shortened life cycle.
that can cause them to bow. With the pump shat removed
from the pump during the rebuild and all other components SQUARE THE BEARING TO THE SHAFT SHOULDER
removed, end users should take the opportunity to check Improper squareness causes frequent problems. All pump
the shat for straightness. shats have a shoulder that determines the stopping point
A pool player takes the cue, lays it on the pool table and for a bearing on the shat. he face of the inner race of a
rolls it back and forth. If it bumps as it rolls, it is not straight. bearing should meet this shoulder all around the shat—
A similar check on a shat can be completed on a shop bench it makes the bearing square to the shat (at a perfect right
with a dial indicator and two V-blocks. angle).
Place the shat bearing seats on the V-blocks and position Pump manuals caution, “Make sure the bearing is square.”
the indicator at the center of the shat. Turn the shat slowly However, many do not indicate how. he check is an easy
while watching the indicator hand. On a 24-inch pump one. A feeler gauge of 0.001 inch to 0.002 inch is used to see
shat (or smaller), the indicator should not delect more if any gap exists between the face of the inner race and the
than 0.002 inch. In the 24-inch to 60-inch range, 0.003 shat shoulder at the 12, 3, 6 and 9 o’clock positions.
inch is the limit. For 60-inch to 120-inch pump shats, the When using a press to install a bearing, a gap is usually not
delection can be to 0.006 inch at the present, or less chance exists of one. If
midpoint. If a shat is bowed in places, thermal means are used to expand the
an unnecessary push on the bearings inner race (no more than 230 F), the
and seal faces occurs with each revo- bearing must be held against the shat
lution. Seal life is reduced to months shoulder so it does not shrink away as
instead of years. it cools. Most mechanics may think
that holding the bearing in place for
CAREFULLY HEAT THE BEARING a minute or two will be enough to
FOR SHAFT INSTALLATION avoid a gap. his line of thinking is
Almost all pump bearings have an incorrect. he bearing should be held
interference it between the ID of the in position for 3 to 5 minutes. his
bearing (the bore of the inner race) If the bearing is not square to the shaft shoulder, simple step, if not performed, leads
and the shat seat (the place where the bearing misalignment occurs. Checking square- to cocked bearings and rapid bearing
bearing sits on the shat). he bearing ness is vital to ensure that a pump spins freely. wear following installation.

REBALANCE A TRIMMED IMPELLER Thomas B. Davis (Tom) is a graduate mechanical engineer
With emphasis on energy savings and a desire to operate who owns Maintenance Troubleshooting, a consulting irm
specializing in assistance for corrective repair of rotating
a pump closer to its best eiciency point (BEP), the equipment. He can be reached at mechanicalengineer@
impeller’s diameter is oten trimmed to ensure that the pobox.com or 302-690-0871.
pump more closely its the system’s requirements. he
ainity laws are used to calculate that, for instance, a
10-inch diameter impeller should
be machined down to 9½ inches
to better marry the pump curve to
the piping. If an end user orders a
9½-inch diameter impeller from the
factory, it is dynamically balanced.
However, if a machine shop trims
the impeller in a lathe, the impel-
ler is unbalanced. It is a casting. he
removal of as little as ¼ inch from the
diameter can result in massive unbal-
ance when the pump spins at 1,750
rpm or worse at 3,550 rpm.
Asking the machine shop to send
the impeller out for dynamic bal-
ancing is no trouble and costs little,
certainly less than the failed bearings
and unplanned downtime that can
occur as the pump vibrates because of
unbalance. When the pump is assem-
bled, that is not the time to think
about balance.
Balancing must take place during
disassembly. he components can be
placed on a balancing machine and
corrected before reassembly. In some
cases, the shat and impeller should
be assembled together and balanced
as a unit to ensure against excessive
vibration forces. P&S
REBUILD CHECKLIST
• Check for piping strain
• Inspect and verify bearing fits
• Ensure shaft straightness
• Use care when heating the
bearing for shaft insertion
• Square the bearing to the
shaft shoulder
• Rebalance an impeller
after trimming

SEALING SENSE
Gaskets for Rigorous Applications

What are grooved metal gaskets, and where are they applied?
By FSA members Darine Aghnim & Dave Burgess
G rooved metal gaskets with covering faces, oten called

kammproile gaskets, consist of a metal core with
grooves or serrations in each face. hey can be supplied with
TYPICAL KAMMPROFILE GASKET DESIGNS
hree typical designs are available—a gasket without a guide
ring, with a guide ring and with a loose-it guide ring. A
or without a guide ring. kammproile gasket without a guide ring can be applied in
Sot material—such as polytetraluoroethylene (PTFE), recessed lange applications—such as tongue-and-groove
lexible graphite or other high temperature facing—is connections or a heat exchanger application—to replace
applied to both sides of the concentric serrated sealing core. double-jacketed gaskets as an upgrade design (see Figure 1).
It is a problem solver for heat exchangers and large vessels Note that when a nubbin is present in the sealing area, it is
since it provides one of the tightest seals combined with strongly recommended that it be removed when upgrad-
superior load bearing characteristics. ing from a double-jacketed design. his type kammproile
gasket is acceptable in standard pipe langes as long as the
PREFERRED IN RIGOROUS APPLICATIONS gasket is sized to center itself on the bolts.
Kammproile gaskets are a preferred design when improved Kammproile gaskets with a guide ring are manufactured
performance at low seating stresses is required. heir M with an integral guide ring for centering (see Figure 2). hese
values, Y stresses and other gasket constants are lower than are recommended for application in RF, ASME B16.5 pipe
those of grooved metal gaskets without any facings, other langes and also can be sized to EN 12560-6 speciications.
reasons for their preference. Metal to metal contact seals Kammproile gaskets with a loose-it guide ring are
require a higher degree of loading. applied to nominal pipe size and pressure class langes and
While the facing materials are typically sot and easy to
seal, the deep grooves keep the facing from extruding under
high compressive loads or internal pressures. Kammproile
gaskets have the ability to seal at low compressive stresses,
but they also handle higher compressive loads and high
internal pressures, making them unique problem solvers.
DIMENSIONAL FLEXIBILITY Figure 1. Design without a guide ring

Another important use of kammproile gaskets is when the
exact contact dimensions of a lange are unknown prior to
opening the joint.
It may be known that an existing lange has a raised face
(RF), but its exact outside diameter (OD) may not be avail-
able until the old gasket is removed. A spiral wound gasket
must be sized so that the windings start and end on the Figure 2. Design with guide rings
lange.
If the inside diameter (ID) of the windings is smaller than
the lange contact area or the OD of the windings is beyond
the OD of the RF, the windings may buckle. his is not a
concern for a kammproile gasket. It can hang over the RF’s
OD without damaging the gasket.
Figure 3. Design with a loose-fit guide ring

used when thermal cycling expansions and contractions are to seal, of course. hese plugs are common on air cooler or
present (see Figure 3). he gasket is designed to comply with in fan heat exchangers. Typical heat exchanger plugs with
either ASME B16.5 lange or EN 12560-6 speciications. this type washer are shown in Image 1.
Kammproile gaskets can also be designed as a dual seal
OTHER GASKET DESIGNS solution with leak detection device incorporated into
he kammproile grooves or serrations can be applied as langed assemblies. hese might be used in critical applica-
an upgrade to a typical lat metal washer, which can be dif- tions such as phosgene service. hey have a primary inner
icult to seal. Flat washers might be used on a “plug” type sealing area with a relief section and holes on the outer por-
threaded application, where the head of the plug will turn tion of the sealing. Past these relief holes is a secondary seal-
down against the washer. Solid metal washers can be tough ing area that maintains the integrity of the bolted joint.
he kammproile design
with sot facing material
can also be applied on the
sealing area of ring joint
gaskets.
his is an ideal solution
for applications in which
cracking or embrittlement
has occurred in ring joint
lange grooves (see Figure
4). Kammproile gaskets
Image 1. Typical heat exchanger plugs with solid metal washers can be manufactured in
Portable Flow Meter
Greyline PTFM 1.0 Portable

Transit Time Flowmeter
Accurately measure water, chemicals and clean
fluids. Use it for pump tests, troubleshooting,
calibrations and balancing flow. Works with
clamp-on ultrasonic sensors on the outside of
metal and plastic pipes.
www.greyline.com
888-473-9546
info@greyline.com

SEALING SENSE
diferent metal materials, shapes (circular and non-circu- CONCLUSION

lar) and custom-engineered designs to it diferent appli- Grooved metal gaskets can efectively seal a wide range of
cations. he recommended langes sealing surface inish is applications because of their unique characteristics, design
125 to 250 microns per inch. lexibility and facing material options. End users should
consult their gasket manufacturer for recommendations for
their speciic applications. P&S
NEXT MONTH:
What are the important considerations for the proper
torque of a valve packing gland?
We invite your suggestions for article

topics as well as questions on seal-
ing issues so we can better respond
to the needs of the industry. Please
direct your suggestions and questions
to sealingsensequestions@luidseal-
ing.com.
Figure 4. Ring joint gasket

Image 2. Design with integrated leak detection

HI PUMP FAQs
Submersible Pump NPSH3, Trench-Type Wet

Wells & Starting Torque Requirements
By The Hydraulic Institute
Q. How do I determine the NPSH3 for a rotodynamic submersible pump?

In another arrangement (see Figure 11.6.7.2d), the entire
A. NPSH3 is the net positive suction head required, pump is mounted in an enclosed tank to allow the NPSH
in meters (feet) that will cause the total head (or irst-stage
testing to be done without the suction piping connection.
head of multistage pumps) to be reduced by 3 percent.
he testing for this arrangement is normally performed at
Four typical arrangements are available for determining
a constant low rate while varying the NPSHA by adjusting
the NPSH3 characteristics of rotodynamic submersible
the air pressure over the liquid in the suction tank.
pumps. For all arrangements, the low toward the pump
In each arrangement, water must be used as the test liquid.
must be uniform and free of undue disturbances. A pump
Taking the following precautions will minimize aeration:
tested with suction piping may require a low-straightening
• No cascading return flow outlets
device before entering the pump. Arrangements for cooling
• Reservoir sized for long retention time to allow air to
or heating the liquid in the loop may be needed to maintain
escape
the required temperature.
• Inlet line properly located to prevent vortexing
In one arrangement (see Figure 11.6.7.2c), the pump is
• Reservoir baffles to isolate inlet from the return line
supplied from a closed tank in which the level is held con-
• Tight pipe joints to guard against air leakage into the
stant. he net positive suction head available (NPSHA) is
system
adjusted by varying the air or gas pressure over the liquid,
varying the temperature of the liquid, or both. his arrange-
For more information about NPSH tests for rotody-
ment tends to strip the liquid of dissolved air or gas. Testing
namic submersible pumps, see ANSI/HI 11.6 Rotodynamic
with a closed loop without the closed tank on the suction
Submersible Pumps for Hydraulic Performance, Hydrostatic
side is also acceptable.
Pressure, Mechanical, and Electrical Acceptance Tests. P&S
Figure 11.6.7.2d. The entire pump is mounted in an enclosed tank

Figure 11.6.7.2c. A pump is supplied from a closed tank with a constant to allow the NPSH testing to be completed without the suction
level. piping connection.
Q. How should I design trench-type wet wells for the intake of rotodynamic pumps, and how are
these different from rectangular intake structures?
create a conined trench for the location of the pump inlets.
A. Trench-type wet wells difer from rectangular intake While limited physical modeling work has been con-
structures by the geometry used to form a transition between
ducted on trench-type wet wells, successful applications
the dimensions of the inluent conduit or channel and the
with individual pump capacities as great as 75,000 gallons
wet well itself (see Figure 1). An abrupt transition is used to
per minute (gpm) or 4,730 liters per second (L/s) and

HI PUMP FAQs
PRECISION
SERVICE installation capacities of 225,000 gpm (14,200 L/s) have been constructed for
centrifugal pumps. Axial and mixed low applications include individual pump
VALUE capacities of 46,000 gpm (2,900 L/s) and total installation capacities of up to
190,000 gpm (12,000 L/s).
2
Most applications of
the trench-type design
have been with the
incoming low directed
along the wet well’s long
wireless axis (coaxial). Physical
systems Figure 1. Trench-type well model studies shall
be conducted for any
for under installation with individual pump capacities exceeding 40,000 gpm (2,520
$10,000
L/s) or stations with capacities greater than 100,000 gpm (6,310 L/s). P&S
each Q. What information is available regarding starting torque

requirements for reciprocating power pumps with liquid bypass?
A. Using reciprocating power pumps requires carefully considering their

starting and running torque demands. hese afect the selection of driver
motors, motor starters, engines, gear reducers, belts or chain drives, couplings,
and universal joints. hese loads’ efects on an electrical distribution system
require thought, especially for a large pump.
For starting the pump with a liquid bypass, the operator manually opens
a bypass valve or a power-actuated dump valve opens automatically. his
bypasses the liquid during
We
E420
starting and stopping. A
check valve in the dis-
make it charge line remains shut
easy!
E540 if the bypass (dump) valve
remains fully or partially
open (see Figure 6.47).
he liquid pressure
exerted on the plung-
ers (or pistons) is largely
caused by liquid mass and
friction. When correctly

sized, the bypass valve and
piping cause low back-
pressure. Relatively small
torque is required while
bypassing the liquid to a
tank. With liquid bypass,
the total starting torque
requirement is mainly
www.cascademvs.com related to the mechani-
281.482.2727 cal inertia of the pump,
Figure 6.47. Schematics of liquid bypass systems
couplings, gears and

motor rotor. hese components are
heavy and require substantial starting
torque. he liquid in the pump suc-
tion line and in the bypass line must
be accelerated from standstill to full
liquid velocities.
he torque needed to accelerate
the entire mechanical hydraulic iner-
tia system depends on the inertia of
all the moving parts—including the
liquid, the rate of acceleration and the
total system friction. he rate of accel-
eration is important, and the starting
torque is directly proportional to it.
Peak torque is inversely proportional
to the time duration of acceleration.
A few pumps are provided with
mechanical suction valve unloader
devices. hey reduce the total start-
ing torque required to accelerate the
mechanical items—the pump crank-
shat, gears, couplings, etc. hey stop
liquid pumping action by mechani- circle 134 on card or go to psfreeinfo.com
cally holding open the pump’s suction
valves, allowing the liquid inducted
into each liquid cylinder to be deliv-
ered back into the pump suction.
Because no liquid pumping occurs,
the driving machinery does not need
to apply torque to accelerate the
liquid. Only the torque to overcome
mechanical inertia and friction is
needed during the start.
Ater the pump and driver have
reached full speed, the suction valve
unloading devices are retracted, and
normal pumping action commences.
At this point, the driver must supply
additional torque to accelerate the
liquid system and meet the total run-
ning torque requirement caused by
discharge pressure. P&S
Pump FAQs® is produced by the Hydraulic Institute
(HI) as a service to pump users, contractors, dis-
tributors, reps and OEMs. Visit visit www.pumps.
org for more information.

PRACTICE & OPERATIONS
Prefabricated Treatment System Solves

Water Quality Concerns
With the simultaneous construction and site preparation, the quick turnaround required for the
project was accomplished with cost-eficient results.
By Mark Koester, Koester Associates, Inc.
I nnovation comes in many forms. Ater many years of

struggling with water quality and dependability, the
residents of the Pheasant Hill Subdivision formed their own
was more expedient and more cost-eicient.
he installing contractor awarded the pumping system
contract to Dakota Pump Inc. he 14-foot wide by 51-foot
Pheasant Hill Water Corporation. hey worked with their long by 13-foot high, prefabricated water treatment build-
consultant, Clark Patterson, to perform a needs assessment ing is a multi-room water treatment plant that includes:
and applied for a Drinking Water State Revolving Fund • A stand-by generator room
(DWSRF) grant. hey were successful and received a • Space for future filtration equipment
$2-million grant and an additional $600,000 in low-interest • A chlorination room
inancing. • A separate room for pumps and controls
DESIGN he stand-by generator with automatic transfer switch

Clark Patterson designed the new water treatment system, comes on when a loss of power occurs (see Image 2). his
which included two wells, No. 4 and No. 6; a chlorination allows the plant to continue operation. he variable-fre-
system; a pumping system; and a new 30,000 gallon storage quency-driven booster pumps maintain adequate pressure
tank (see Image 1). Since this system’s source was a well, it in the distribution water main, and the chemical feed equip-
has iltration avoidance, and chlorination is the only treatment provides proper disinfection. Controls were also a key
ment. Space for a new cartridge
iltration system was designed
within the water treatment
plant, in case the wells are
reclassiied in the future.
CONSTRUCTION
Once funding was in place, the
design, construction and start-
up of the new water treatment
plant and storage tank was on
a fast-track schedule. Clark
Patterson evaluated the cost of
building the water treatment
plant in-place. he design
irm also examined an inno-
vative approach of working
with a pump station manufac-
turer to design a prefabricated
water treatment and pumping
system. he evaluation showed
that the prefabricated concept Image 1. The water treatment plant included pressure-maintaining
booster pumping and metering capabilities.

factor for the station. When the tank level lowers to
a pre-determined point, the controls call for the well
pumps to start. he components were incorporated
into a pre-manufactured and prefabricated water treat-
ment plant.
APPEARANCE
he appearance of the treatment plant was another
consideration. Since the project was located in a resi-
dential setting, the designers wanted the building to
have an appropriate residential look. Dakota Pump
Inc worked with the Pheasant Hill Water Corporation
and Clark Patterson to incorporate standard 2-inch by
6-inch construction on a prefabricated steel base plate,
reinforced to accommodate the structural needs of the
water equipment and the building.
he structural base, walls and ceiling received a high
R-value coating of spray foam insulation, and the exte-
rior of the building was covered with architectural
horizontal siding. With the help of the consultant, the
owner was able to choose the style and color for the
siding, the type of soit and fascia, and the color for Image 2. A natural gas-fired generator with automatic transfer
switch provided emergency power service.
the laminated asphalt roof shingles.
he result was a treatment building
that looks professional and blends
with the foliage of the Pheasant Hill
subdivision.
INSTALLATION
Prefabricating the water treatment
Pump Swap
plant building allowed the construc- Install a brand new Vogelsang Rotary
tion of the treatment plant at the Lobe Pump for the cost of rebuilding
factory to coincide with the general your Progressing Cavity Pump.
contractor’s site preparation. his pro-
Plus, our Rotary Lobe Pumps are easy to
vided a shorter construction window.
maintain and can be rebuilt in an hour.
Once the construction site was fully
Get a brand new pump while reducing
prepped and the prefabricated water
your maintenance budget!
treatment plant was constructed and
factory tested, the treatment plant You can even typically use your current
was transported via a specialized baseplate, motor and coupling.
tractor-trailer from Mitchell, S.D., to
Minisink, N.Y. (see Image 3).
Ater the station arrived at the site,
it was lited into place onto the con-
crete foundation. he inlet and outlet
connections were made, and the elec-
ENGINEERED TO WORK
trical hook-up was completed.
SLUDGE PUMPING SLUDGE GRINDING SLUDGE LYSING
(800) 984-9400 | vogelsangusa.com | sales@vogelsangusa.com

he station was ready for start-up and commissioning. Mark Koester has been active in the water and wastewater
industry in upstate New York for 30 years. He has a degree in
With this treatment plant, the Pheasant Hill residents sanitary engineering and retains leadership positions in the
have reliable and safe drinking water at consistent pressures New York Water Environment Association and New York Rural
and suicient storage for all conditions. he prefabricated Water Association. Koester is also active in the American
approach saved the residents money and allowed the project Water Works Association and local water works afiliates. He
can be reached at (315)697-3800 or email mark@koesteras-
to be completed on schedule. P&S sociates.com.
Image 3. The oversized treatment system and building was transported via specialized hauler from Mitchell, S.D., to Minisink, N.Y.
Whether you need high volume, repetitive control panels or a

one-off custom solution, SJE-Rhombus® is your preferred
partner. With over 35 years of experience working with
original equipment manufacturers (OEMs), we provide
high quality, cost-effective custom control solutions
for a variety of control applications:
Q Industrial, municipal, commercial and
residential water and wastewater
Q Agriculture, irrigation and dewatering
Q Variable Frequency Drives (VFDs)
Q Man-Machine Interface (MMI)
Q Programmable Logic Control (PLC)
Q Communications, data logging
and event monitoring
Q Embedded microprocessor
and controller design

New Optimized Aeration System

Reduces Energy Consumption
A wastewater treatment plant experiences a 65 percent energy savings
with the installation of improved equipment.
By Lars Larsson, Xylem, Inc.
B iological-secondary treatment is the most energy-

intensive phase in the wastewater treatment process
with aeration consuming between 25 and 60 percent of
he other line with aeration equipment—consisting of tube
difusers, lobe blowers and a simple dissolved oxygen (DO)
control—was let unchanged and kept as a reference line.
the total energy used in a municipal
plant.1 According to a report by the
Environmental Protection Agency (EPA)
in the U.S., these costs are increasing
because of rising energy prices and
more stringent requirements for eluent
quality.2 An increase in environmental
awareness and the rising cost of electricity
have motivated operators to reduce
the energy consumption of biological-
secondary treatment in wastewater
treatment systems.
TESTS AT SWEDISH WASTEWATER

TREATMENT PLANT
Full scale trials by a global water solution
company show that the energy consump-
tion of a wastewater treatment plant’s
aeration system was successfully reduced
by a signiicant 65 percent when more
energy eicient equipment was installed.
he tests were conducted at the Sternö
Municipal Wastewater Treatment Plant
in southern Sweden.
Built in 1997, the Sternö plant was
designed to cater to a population of
26,000 calculated on biological oxygen
demand (BOD) 7 load 70 g (pe day)-1.
Aeration consumed 44 percent of the
plant’s total energy usage.
he plant consisted of two parallel bio-
logical treatment lines that performed
the pre-denitriication of the wastewater.
During the study, one of the treatment
lines was used as a test line with the new
aeration and control equipment installed.
New aeration equipment.

he new aeration equipment installed into the test line EVALUATION PERIODS
was a screw blower; ine bubble, low-pressure difusers; and he new installations were performed in stages. he efect
measurement equipment. of each new installation was evaluated separately, and the
results were:
THE RESULTS • Phase 1 involved the installation of a new screw
he results of the full scale trials showed that the new screw blower and a non-tuned DO cascade control system.
blower reduced the energy consumption of the test line by During Phase 1, the majority of the energy savings
35 percent. was related to the increased efficiency of the blower.
he low-pressure difusers reduced the energy consump- • Aeration grids were installed during Phase 2. An addi-
tion by another 21 percent. By ine tuning the controllers, tional 23 percent of the total energy savings gained
the oxygen concentrations and the air pressure, the energy during Phase 2 was acquired by the high standard
consumption of the test line was reduced an additional 9 oxygen transfer efficiency (SOTE) and low system
percent. he inal energy savings of the test line were 65 ± head loss of the new aeration system.
2 percent. • During Phase 3, a process control system was
Each aeration equipment upgrade increased the energy installed, which increased the energy reduction by
savings with: an additional 9 percent through a combination of
• Blower, 35 percent a further decreased system head loss from the most
• Diffusers, 32 percent open valve logic and the implementation of DO
• Oxygen control with decreased DO concentrations cascade control and an energy optimized DO profile.
and air pressure, 21 percent he DO profile was energy optimized by changing
the DO set points from 1.7/0.7 milligrams per liter
circle 141 on card or go to psfreeinfo.com circle 140 on card or go to psfreeinfo.com

to 0.7/1.0 milligrams per liter,
which distributed the load more
evenly throughout the length of
the basin.
AIRFLOW & AERATION EFFICIENCY

With the new system, aeration ei-
ciency was almost three times as
high in the test line compared to the
reference line. he required airlow
was reduced by 30 percent, and the
system pressure was reduced by 15
percent. hese savings were gained by
a combination of:
• A more efficient blower
• A higher SOTE
• Lower head loss
• Energy-optimized DO control
and DO profile
• More than 40 years of expertise
in wastewater treatment system
optimization The final energy savings of the test line were 65 ±2 percent.
PAYBACK PERIOD
he payback period for implement-
ing the aeration system was calcu-
lated at four years. If both lines were
LEADING
upgraded, the payback period would THE INDUSTRY
decrease to just three years since some
of the equipment could be shared Providing A Solid Foundation Since 2001
between the lines. hese full-scale Unmatched Technical Support
tests were performed throughout Factory Direct
a 6-month period. he annual sav-
ings for the test plant was more than
$28,000 if both of the plant’s treat-
ment lines were upgraded. P&S
References
1. WEF, 2009. MOP No. 32: Energy
Conservation in Water and Wastewater
Facilities.
2. EPA, 2010. Evaluation of Energy
Conservation Measures for Wastewater
Treatment Facilities. EPA 832-R10-005. Guaranteed Price Match
■ 200+ pump bases ready for immediate delivery ■ Guaranteed flatness of ±0.002”/ft.
Lars Larsson is the global prod- ■ Rapid turnaround of custom hole patterns ■ Significant vibration reduction
uct manager, biological treat- ■ Thermal stability
ment for Xylem, Inc. He can be ■ Superior corrosion resistance
reached at +46 8 475 63 60 or

lars.larsson@xyleminc.com. Made in USA Zanite is a registered trademark of BaseTek, LLC
WWW.BASETEK.COM ■ 877-712-BASE (2273) ■ FAX: 216-274-9296

Positive Displacement Pumps in

Wastewater Treatment
Select the right pumping technology to keep treatment processes running eficiently.
By Oakley Roberts, ARO Fluid Products, Ingersoll Rand
M any manufacturers are committed to sustainable ideal for low- to mid-range low rates—up to 350 gallons
practices to improve their environmental, economic per minute—and produce enough back pressure, up to 250
and social performances. Companies that use or produce psi, to move high viscosity luids and sediment.
luids in manufacturing processes face the challenge
of properly disposing of the byproducts. For example, THE PUMP’S ROLE
chemical manufacturers, food and beverage processors and Positive displacement pumps have three main applications
metal inishers generate luids that have to be treated in in the wastewater treatment process:
accordance with local government regulations before waste • Transferring fluids from the sump to
luid is discharged into sewer systems. the reactor
he manufacturing sustainability trend is driven by cus- • Dosing chemicals into the reactor and
tomers; shareholders; government regulations; and the neutralizer tanks
increasing costs of process inputs, such as water. As the cost • Drawing slurry off the clarifier tank to feed the
of water increases, the industry is investing heavily in treat- filter press
ment processes using recycled water.
Industrial pumps are at the core of wastewater treatment A typical wastewater treatment process begins as luid
systems, and diferent pumps are used in the treatment builds in a sump tank. A positive displacement pump is
process. Positive displacement
pumps are used to transfer liq-
uids from tank to tank because
they are durable enough to
handle a wide range of luids
and solid particles.
Metering pumps play a vital
role in the treatment process
as well. his type pump has the
technology required to accu-
rately dose and meter chemicals
at low low rates and is one of
the smallest positive displace-
ment pumps on the market.
Air operated diaphragm
pumps (AODP) are the work-
horse of the wastewater treat-
ment system. his type of
positive displacement pump is
durable enough to withstand
submersion and continuous
AODPs are used in multi-step, batch waste treatment systems to remove metal precipitation. One AODP
low rates inherent in waste- moves the solution from the collection tank to the treatment tank. Others move the treated waste from
water applications. AODPs are the treatment tank to the drain.

used to move the luid to a second tank where the rinse AODPs ofer several unique advantages over other posi-
water low is equalized and pushed into a reactor tank. he tive displacement pumps:
composition and temperature of the luid running through • hey are powered by compressed air and do not
the system must be considered when specifying this pump require electrical hookups at the installation sites,
because the luids can be corrosive and abrasive. AODPs which dramatically reduces installation costs.
can be conigured to meet the chemical compatibility of the • Some AODPs can be submerged in fluids, making
luids, making them a low-risk solution. them a convenient option for sumps and pits.
Once the waste luid is transferred from the sump to the • hese pumps can be integrated with electric interface
reactor, concentrated chemicals are introduced to neutralize control devices, such as solenoids and tank fill, to
the pH balance. An electromagnetic or mechanically actu- control the pump’s operation.
ated simplex diaphragm pump, a highly controllable type • AODPs are not damaged by downstream blockages in
of metering pump, doses treatment chemicals at a low low the system.
rate. his level of accuracy ensures that the luids are treated, • hey are more compact than other pumps.
neutralized and clariied to adhere to local regulations. • hese pumps have reduced purchase prices because
Finally, the neutralized liquid lows into the locculator they do not require electric motors or gear boxes.
where a chemical is added that adheres to particulates, caus- • AODPs do not have mechanical seals that could leak
ing them to coagulate on the bottom of the clariier tank. or need replacement.
AODPs are used to draw the slurry from the bottom of the • hey are portable and have plug-and-play capability
tank and prime the ilter press. for easy installation.
AODPs can handle this abrasive and corrosive mixture
and produce enough back pressure to force the luid into TOTAL COST OF OWNERSHIP
the ilter, leaving only solid waste behind. he clean luid When evaluating if an AODP is right for a facility, plant
returns to the treatment process before being discharged managers should note the initial purchase price and then
to the sewer or reused. he cake is removed from the ilter include the total cost of ownership. hese factors will help
press and disposed as solid waste. plant managers determine if an AODP is the most econom-
ical pump for the application:
SELECTING THE RIGHT AODP • Compare the time required for maintenance on the
Pumps are critical to manufacturing processes. If one fails, AODP and how that affects productivity.
it may force the entire plant to stop production until opera- • Calculate the downtime costs of the plant and
tors can ind a way to restore it. Specifying the right pump whether it is cost effective to keep an extra AODP in
for the application to increase reliability and prevent unex- stock so it can be replaced quickly.
pected downtime is critical. • Determine whether the AODP pump shares common
Pumps must be compatible with the luids they transfer parts with other units in the plant and manage inven-
to prevent abrasive and corrosive materials from reacting tory accordingly.
with the composition material of the pump. Plant manag- • Select a modular pump design that allows mainte-
ers can ask a pump manufacturer to specify the best com- nance teams to repair one piece of the AODP without
position material for the application. disabling the entire unit.
Polymer luid chambers made from nonreactive mate- • Consider the installation costs and energy consump-
rials, such as polypropylene or polyvinylidene luoride tion required to get the pump up and running.
(PVDF), are commonly used with elastomeric ball checks
and diaphragms to prevent corrosion and increase a If speciied correctly, AODPs can be an efective and reli-
pump’s longevity. able solution to a facility’s wastewater treatment process.
Pump manufacturers can consult with plant managers to Plant managers should contact an authorized pump manu-
determine if continuous-duty pumps should be installed facturer to determine if an AODP is the right
to meet the heavy-duty cycle required in wastewater treat- choice for their application. P&S
ment. Continuous-duty pumps prevent icing and stalling,
and pulsation dampeners can be added to help equalize the Oakley Roberts is the product management director for ARO
Fluid Products, Ingersoll Rand. He can be reached at oakley_
pressure low and keep the system running reliably. roberts@irco.com or 419-633-6935. For more information,
visit www.ingersollrandproducts.com.

Power Generation on Demand

The application, geography, regulations and proper size must be considered
when choosing a generator set.
By Brad Chrudimsky, Baldor Electric Company, a member of the ABB Group
G enerator sets are available in a wide range of power

ratings—from small, portable sets to mobile power
systems or large stationary generator sets supplying power
Tier 4 or a Tier-4-capable engine. By 2015, products in a
mobile, continuous or peak shaving application will need to
meet the stringent emission regulations of Tier 4 unless the
in the demanding scenarios worldwide. To determine manufacturer uses the Transition Provisions for Equipment
if a generator set installation is required, the intended Manufacturers Program. his program gives the manufac-
application, geographical rules and regulations and proper turer lexibility to design products in a timely manner to
sizing of the generator set must be considered. meet emission regulations.
Emergency power systems have several diferent require-
APPLICATION ments. he three classiications for power systems are
Generator sets are used in many applications. he irst con- emergency systems, legally required standby systems and
sideration is to determine the generator’s intended use. Will optional standby systems
it be transported from jobsite to jobsite, provide relief in the Articles 700, 701 and 702 from the National Electric
event of a catastrophic event, or will it be used to provide Code (NEC) explain each classiication. Article 700 details
power during peak demands? he intended application emergency systems, which are required to automatically
must be reviewed to ensure that the correct equipment is supply illumination, power or both to designated areas
speciied and installed. When deciding if mobile power, essential to human safety if the normal power supply fails. In
emergency power, or a continuous or peak shaving power Article 701, legally required standby systems are intended
system is needed, several factors must be addressed. to automatically supply power (other than those classiied
Diesel mobile and continuous or peak shaving power as emergency systems) to designated areas if power fails and
systems (stationary nonemergency) must comply with the could result in safety hazards and hamper rescue eforts.
latest Environmental Protection Agency (EPA) engine Optional standby systems, highlighted in article 702, are
emission regulations. hese have become one of the most installed to supply power to public or private facilities
discussed topics in the power generation industry. hey where human safety does not depend on the performance of
must be driven by an EPA-compliant certiied interim the system and can supply power automatically or manually.
Mobile generator sets provide temporary relief.

FUEL UL2200 requires additional testing and documentation if
When choosing a fuel source, diesel, natural gas and liquid the generator is wrapped in an enclosure or any modiica-
propane have advantages and disadvantages. For example, tions are made to the generator set ater it leaves the original
diesel is portable, easy to store and readily available. Diesel’s manufacturer’s production site. To carry the UL listing, all
disadvantage is its limited shelf life (10 to 12 months). Also, system components must meet the UL standards.
the overall cost of a diesel-driven power system is typically
higher because of fuel storage requirements and the need to
reill the fuel as it is consumed.
Another option and a cleaner burning fuel is liquid pro-
pane. Liquid propane is portable and easy to store. It also
has a longer shelf life than diesel.
he third option for fuel is natural gas. It burns cleaner
than diesel and is the easiest of the three to obtain. Because
of a surplus as a result of the shale gas boom in North
America, there is a practically unlimited supply. With the
advantages of natural gas comes the hazard of leaky or burst-
ing pipes. Because of these hazards, it cannot be used in life
safety applications. Also, much more natural gas is needed
to produce the same amount of power when compared to
other fuels. When making this crucial decision, federal,
municipal, state and local codes can help deine which fuel
source should be used. Diesel fuel tanks can be installed as a sub-base for generator sets.
AGENCY APPROVALS
Minimum requirements may need
to be met when installing a genera-
tor set in certain geographical loca-
tions. hird-party safety certiication
standards—such as Underwriters
Laboratories UL2200 health and
safety of use standards, National
WHEN QUALITY AND
Fire Protection Association (NFPA)
110 ire protection standards and/or
DELIVERY MATTER
PumpWorks 610 manufactures centrifugal API 610
NFPA 20 installation of stationary pumps for oil and gas exploration and production,
ire pumps for ire protection stan- petroleum refining, gas processing, oil processing,
hydrocarbon and crude oil pipeline and offshore
dards—can ensure that the power production platform applications.
system is appropriate for the applica-
We make the purchase of your API 610 pump an
tion. Contacting the local authority enjoyable process, and we ensure that the finished
product meets or exceeds your exact specifications.
having jurisdiction (AHJ) can pro-
vide clarity of federal, state, municipal OUR PUMPS ARE:
t.BOVGBDUVSFEBOEUFTUFEJOUIF64"
and local rules and regulations. he t'VMMZDPNQMJBOUXJUI"1*TQFDT
AHJ has the inal say in the generator t4IJQQFEBOEEFMJWFSFEXJUIJOXFFLTEFQFOEJOH
POUIFQVNQNPEFMUIFTIPSUFTUMFBEUJNFTGPS"1*
set installation and commissioning. 610 pumps in the industry
If UL2200 or NFPA 110 is speciied t&BTZUPBDDFTTUISPVHIPVSPOMJOF1VNQ
4FMFDUPS1SPHSBNOPSFHJTUSBUJPOSFRVJSFE
at the time of order, several require-
'PSNPSFJOGPSNBUJPO WJTJUXXXQVNQXPSLTDPN
ments need to be met to ensure that PSDBMMUPMMGSFFBU
the complete system is a safe and reli-
able piece of equipment. For instance, .POSPF3PBEt)PVTUPO 5FYBT64"t'BY

NFPA 110 sites the importance of the power system to SIZING

human safety, the amount of time it takes the set to be at Properly sizing the generator set for operating speeds of
full power, and the runtime before the power system must motors and ire pump motors is crucial. More importantly,
be refueled or recharged. If using the generator set to supply sizing the generator set to start a motor versus a ire pump
power to a ire pump motor, NFPA 20 standards and NEC motor is the more diicult task. Typical motor starting kilo-
Article 695 standards must be met. he standards make cer- volt amperes (kVA) allows a 30 percent voltage dip, while
tain that the ire pump motor runs when needed. Correctly NEC 695-7 permits a voltage drop of only 15 percent at the
calculating the required loads helps properly size the set. controller line terminals when starting a ire pump motor.
To meet this requirement, the generator set must be upsized
by as much as three times.
he generator set can carry a UL2200 listing if the circuit
breaker does not exceed the standard’s 125-percent thresh-
old. If not sized properly, the third-party certiications may
not apply. he generator set’s fuel supply shall be suicient
to provide eight hours of ire pump operation at 100 percent
of the rated pump capacity and supply required for other
demands according to NFPA 20. Contacting federal, state,
municipal and local resources can help specify the proper
unit. P&S
Brad Chrudimsky is the product marketing specialist for

Baldor Generators and is based at the company’s gen-
erator manufacturing facility in Oshkosh, Wisc. He can be
To carry a UL2200 listing, the generator set components need to safely reached at brad.chrudimsky@baldor.abb.com. Baldor Electric
operate as a complete system. Company is a member of the ABB Group.

PRODUCT PIPELINE
PROGRESSING CAVITY PUMPS CIRCULATOR PUMPS

Moyno, Inc., Grundfos introduces
ofers the L-Frame its energy-eicient
Progressing Cavity circulator pump.
Pump for depend- MAGNA3 is an
able performance energy-optimized, vari-
and maximum able-speed wet rotor
operating eiciency. circulator that features
hese pumps are a permanent magnet
ideal for handling motor design that will
clean, thin, shear-sensitive products to viscous, corrosive, cut power consumption up to 85 percent. he circulator
abrasive slurries and sludges. All these pumps are available uses a variable-speed electronically commutated motor
with a variety of drive options, sealing conigurations, (ECM) that uses an integrated logic algorithm, enabling
motors and controls. the sotware to automatically determine the lowest pos-
Circle 205 on card or go to psfreeinfo.com sible operating-eiciency point demand.
Circle 220 on card or go to psfreeinfo.com
SHARK GRINDERS BALL VALVE SEAT

Zoeller Engineered Products ofers Metallized Carbon
a line of grinder pumps with models Corporation introduces
available from 1 to 7 ½ horsepower. its carbon-graphite ball
Cool run design technology efec- valve seats for use in
tively disperses heat, promoting valves designed to handle
longer service life. he units are hot liquids or hot gases.
available with multiple discharge he ball valve seats are
conigurations and wet end designs. available in more than
Some models feature reversing cutter 150 grades of Metcar’s carbon/graphite material. he
design, which prevents cutter jams. seats are ideal for use in temperatures from approximately
Models are available with standard or 350 F to 800 F in oxidizing environments. hey are also
explosion proof motors. ideal for ire safe petroleum industry ball valves.
Circle 221 on card or go to psfreeinfo.com Circle 202 on card or go to psfreeinfo.com
DISINFECTION SYSTEM DATA LOGGER

Xylem Inc. has engi- Omega introduces its
neered enhancements new series of precision
to its most cost-efective resistance temperature
solution for ultra- detector (RTD) data
violet (UV) wastewater loggers. he OM-CP-
treatment with the RTDTEMP101A
WEDECO TAK 55 Smart UV light disinfection system, accepts 2-, 3- or 4-wire
which is ideal for small- to medium-sized municipalities. 100 platinum RTD input and d ffeatures a bbattery llife
f off
he solution ofers a full menu of options to help custom- 10 years, multiple start/stop function, ultra high speed
ers design their systems to meet eluent qualities—such download, 670,000 reading storage capacity, memory
as combined sewer overlows, primary or secondary wrap and programmable high and low alarms. he data
wastewater sources, lagoons, or tertiary wastewater recla- logger is ideal for chemical, water and food industries and
mation and reuse. for lab, HVAC and R&D applications.

PRODUCT PIPELINE
FUSE HOLDERS CABLE GLAND

WAGO Corporation’s 811 RST introduces its cable gland section
Series Class CC and Midget- of AlphaX, GammaX and DeltaX prod-
Style (10 x 38 mm) Fuse Holders ucts, recently approved by the new ATEX
provide machine- and panel- standard for explosion-proof products. All
builders with a new approach armored cables can be mounted with just
to branch and supplemental one gland. he DeltaX and GammaX series
protection. he holders feature can be dismounted easily and in a controlled
a DIN-rail mount clip for easy manner. he design of the grounding and
installation and removal. Circuit identiication/marking sealing inserts ensures that the spare parts
options are provided by WAGO’s WMB multi-marking cannot be lost during installation.
strip and exclusive continuous marking strip adapters. Circle 211 on card or go to psfreeinfo.com
TESTING PEN
Dwyer Instruments, Inc., introduces its WPH2 Waterproof pH Testing Pen, which accurately monitors pH
and temperature levels in many applications. he pocket-sized tester is ideal for pH level measurements in the
lab, industrial plants or on-the-go in the ield. It features an easy-to-replace electrode option and a one-touch,
three-point auto-calibration. Temperature and pH appear on the large dual display.
ANSI/HI Pump Standards on CD

Version 3.1 Now Available
U N M AT C H A B L E E X P E R I E N C E ANSI/HI Standards on CD contains all the

I N P R I V AT E C O M P A N Y current Pump Standards including:
TRANSACTIONS
— Controlled-Volume Metering Pumps for Test (ANSI/HI 7.6)
— Intake Design for Rotodynamic Pumps (ANSI/HI 9.8)
Jordan, Knauff & Company is a knowledgeable and — Rotodynamic Pumps Guideline for NPSH Margin (ANSI/HI
experienced provider of a comprehensive line of 9.6.1)
investment banking services to the pump, valve and
filtration industries (“Flow Control”). — Rotodynamic (Centrifugal & Vertical) Pumps—Guideline for
Allowable Operating Region (ANSI/HI 9.6.3)
Our lines of business include: selling companies,
— Rotodynamic Submersible Pumps for Hydraulic
raising debt and equity capital, and assistance
on acquisitions. Performance, Hydrostatic Pressure, Mechanical, and
Electrical Acceptance Tests (ANSI/HI 11.6)
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. Order the newly-published
CD Version 3.1 now at the HI
G. Cook Jordan, Jr. David A. Kakareka eStore at eStore.Pumps.org
Managing Principal Associate
cj@jordanknauff.com dkakareka@jordanknauff.com
312.254.5901 312.254.5907
MEMBER FINRA, SIPC

VARIABLE SPEED DRIVES REDUNDANCY MODULES
Zero-Max variable speed Phoenix Contact’s Quint
drives meter and dispense ORing active redundancy
seed and fertilizer guided by modules use new auto current
global positioning systems. balancing (ACB) technology
he drives provide accurate for precise load sharing. he
and repeatable settings to ACB technology, coupled
optimize the seeding and with load current monitoring,
fertilizing process. he drives remote diagnostics and visual
can be used as a prime mover connected to a motor, or as indications, ensures maximum reliability in redundant
a secondary drive connected to a shat in the machine’s power systems. he module, available in two 24-volt DC
driveline. versions, can also monitor load current.
COUPLINGS
Staford Manufacturing Corp. introduces a full line of rigid shat couplings in a broad range
of types, sizes and materials for joining unsupported shats in applications ranging from delicate
instruments to large mixers and pumps. he couplings are ofered in one-, two- and three-piece
designs, with or without keyways. he couplings are machined from stainless steel, steel and
aluminum.
To have a product considered for “Product Pipeline,” please send the information to Amanda Perry, aperry@cahabamedia.com.
WINDPOWER
is the Source
to Find Your
AWEA Business Solutions
Solutions for Success
www.WINDPOWERexpo.org
Registration
Now Open!

PUMP USERS MARKETPLACE INDEX OF ADVERTISERS
Advertiser Name Page RS#
ABZ, Inc. 70 146
Advanced Engineered Pump, Inc. 70 145
AWEA 67 110
Comprehensive Baldor Electric Company
Bartlett Bearing Company 70
7 100
147
Industry Coverage BaseTek, LLC 59 139
Benshaw Incorporated 27 112
– Positive Displacement Pumps
Blacoh Fluid Control, Inc. 13 114
– Centrifugal Pumps Blue-White Industries 29 115
– Specialty & Other Pumps Burns Dewatering Service 71 148
– Industrial Valves Carver Pump Company 39 113
– Pneumatic & Hydraulic Valves Cascade MVS 52 132
– Industrial Automation & Dakota Pump 47 111
Process Control Dan Bolen & Associates, LLC 69 149
– Electric Motors & Drives Disclo 14 131
– Actuators Flowrox Inc. 43 116
– Compressors Frost & Sullivan 68 142
– Custom Research GE Oil & Gas, Surface Pumping Systems 36 101
– White Papers General Pump 35 117
GIW Industries, Inc. 31 118
Global Pump Company IFC 109
Frost & Sullivan evaluates and implements Godwin, a Xylem brand 15 119
effective growth strategies. We employ 50 GPM, Inc. 44 120
years of experience in partnering with Global Greyline Instruments Inc. 49 170
1000 companies, emerging businesses and the Griffco 26 121
investment community from more than 40 Grundfos BC 102
offices on six continents. Houston Dynamic Service, Inc. 70 151
Hydraulic Institute 66 144
Visit us at www.frost.com Jordan, Knauff & Company 66 143
Junty International, LLC 69 152
For more information, contact Britni Myers
Load Controls, Inc. 9 122
at 210-477-8481 or britni.myers@frost.com
LobePro 69 150
LUDECA, Inc. 3 103
circle 142 on card or go to psfreeinfo.com Magnatex Pumps, Inc. 69 153
Meltric Corporation 71 154
National Pump & Compressor 41 123
NETZSCH Group 32 125
Pioneer Pump 17 124
Proco Products, Inc. 50 133
PumpWorks 610 63 138
Reason Technology Co. Ltd. 53 134
Ruthman Companies 53 135
Scenic Precise Element Inc. 70 155
seepex, Inc. 40 126
SEPCO 38 127
SEPCO 69 156
SERO Pump Systems 71 157
Sims Pump Company 33 108
Sims Pump Company 69 158
Singer Valve 58 141
SJE-Rhombus 56 136
circle 163 on card or go to psfreeinfo.com Smith & Loveless IBC 104
Summit Pump, Inc. 71 159
SWPA 64 130
Tarby, Inc. 23 128
Topog-E Gasket 71 160
Trachte, USA 71 161
Tuf-Lok International 71 162
UniqueFlo 68 163
Varisco USA Inc. 68 164
Vaughan 5 105
Vertilo Pump Company 58 140
Vertilo Pump Company 71 166
Vesco 70 165
Vogelsang USA 55 137
Wilden 37 129
Xylem USA 1 106
Zoeller Company 11 107
circle 164 on card or go to psfreeinfo.com * Ad index is furnished as a courtesy and no responsibility is
assumed for incorrect information.

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PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

By Jordan, Knauff & Company
T he Jordan, Knauf & Company ( JKC) Valve Stock

Index was up 10.4 percent over the last 12 months,
below the broader S&P 500 Index, up 13.1 percent. he
JKC Pump Stock Index was up 6.7 percent for the same
liable for claims relating to these materials and makes no warranties, express or implied, or representations as to their accuracy or completeness or for errors or omissions contained herein. his information is not intended to be
time period.1
hese materials were prepared for informational purposes rom sources that are believed to be reliable but which could change without notice. Jordan, Knauf & Company and Pumps & Systems shall not in any way be
Manufacturing began 2013 on a positive note.
In January, the Institute for Supply Management’s Source: Capital IQ and JKC research. Local currency converted to USD using historical
spot rates. he JKC Pump and Valve Stock Indices include a select list of publicly-traded
Purchasing Managers’ Index (PMI) increased 2.9 percent companies involved in the pump and valve industries weighted by market capitalization.
over December to reach 53.1 percent, the highest level
Figure 1. Stock Indices from Feb. 1, 2012, to Jan. 31, 2013
since April 2012. All ive PMI component indexes—new
orders, production, employment, supplier deliveries and Statistics. Employment numbers for November were revised
construed as tax, legal or investment advice. hese materials do not constitute an ofer to buy or sell any inancial security or participate in any investment ofering or deployment of capital.
inventories—registered growth in January. Most important, from 161,000 to 247,000 jobs, while the numbers for
the index for new orders moved from contraction at 49.7 December were revised from 155,000 to 196,000 additional
percent in December to slight growth at 53.3 percent. jobs. Including these revisions, nonfarm payrolls rose 2.2
he Commerce Department reported that shipments million in 2012, roughly 180,000 per month. Manufacturing
of manufactured durable goods increased $2.6 billion (1.1 employment was essentially unchanged in January and has
percent) to $230.1 billion in December. his followed a 1.8 changed little since July. Job gains in January occurred in
percent November increase. retail trade, construction, health care, and wholesale trade.
Total, nonfarm payroll employment increased by 157,000 Due to ongoing activity in onshore basins, the U.S. Energy
jobs in January according to the U.S. Bureau of Labor Information Administration (EIA) expects U.S. crude oil
production to continue its growth during the next two years.
Increasing from an average of 6.4 million barrels per day
(bpd) in 2012, the EIA predicts that crude oil production
will average 7.3 million bpd in 2013 and 7.9 million bpd in
2014. Drilling in tight oil plays in the Williston, Western
Gulf and Permian Basins will account for most of the fore-
casted growth, with the Western Gulf Basin accounting for
more than half the onshore domestic liquid production
growth. he Williston Basin’s Bakken formation (North
Dakota and Montana) and the Western Gulf Basin’s Eagle
Source: U.S. Energy Information Administration and Baker Hughes Inc.
Ford formation (Texas) currently produce about two-thirds
of the tight oil in the U.S.
Figure 2. U.S. Energy Consumption and Rig Counts
On Wall Street, he Dow Jones Industrial Average had
its largest January increase since 1994. Better-than-expected
earnings for the fourth quarter combined with a brighter
employment scenario and encouraging numbers from
the housing sector boosted the markets. he Dow Jones
Industrial Average increased 5.8 percent, the S&P 500 Index
gained 5.1 percent and the NASDAQ Composite rose 4.1
percent in January. P&S
Reference
1
he S&P Return igures are provided by Capital IQ.
Source: Institute for Supply Management Manufacturing Report on Business® and Jordan, Knauff & Co. is an investment bank based in Chicago, Ill., that provides
U.S. Census Bureau. merger and acquisition advisory services to the pump, valve and iltration indus-
tries. Please visit www.jordanknauff.com for further information on the irm.
Figure 3. U.S. PMI Index and Manufacturing Shipments
Jordan Knauff & Co. is a member of FINRA.
VISIT SELECTTIT.SMITH
ITT THAN ANDLOVELESSS.CO
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!SKUSABOUTENERGY SAVING3,0UMPRETROlTSÐ CALL S&L AFTER MARKET 800.922.9048 VISIT SelectIt.SmithandLoveless.com

AH A
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PROVIDING
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b.com/GrundfosPumpUSA
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www.grundfos.us

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TM

“Our goal is to keep you operational at all times through worldwide

We Know Bypass Pumping.

When it comes to bypass pumping, count on Mersino.

is a member of the following organizations:

2 March 2013 www.pump-zone.com PUMPS & SYSTEMS

ROTALIGN® Ultra iS VibXpert® II

ALIGNMENT VIBRATION BALANCING

unit in an irrigation application. Photo courtesy of Grundfos

30 Powering the Pump:

COVER 34 Powerful Mine Dewatering

SERIES Electric and diesel centrifugal pump options

The Pump Purchase Process Practice & Operations

57 New Optimized Aeration System Reduces Energy

SPECIAL 60 Positive Displacement Pumps in Wastewater Treatment

20 Pump Speciﬁcation, Purchase, Installation

4 March 2013 www.pump-zone.com PUMPS & SYSTEMS

“Pump System Design,” February 2013

Editor’s Note: For the Estimator Program referenced in

6 March 2013 www.pump-zone.com PUMPS & SYSTEMS

For more information on our

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©2011 Baldor Electric Company

First of Two Parts

Flatness App for ALiSENSOR LEVEL Alignment Supplies, Inc.

KoolApp: KoolCode, Refrigerant Slider,

Toolbox Technician Emerson Industrial Automation

8 March 2013 www.pump-zone.com PUMPS & SYSTEMS

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WHY MONITOR POWER INSTEAD OF JUST AMPS? PUMP POWER

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PUMPS & SYSTEMS www.pump-zone.com March 2013 9

Pump Energy Savings Calculator Rockwell Automation, Inc.

seepex Pumps, SCT seepex, Inc.

Xylect Mobile READERS CHOICE Xylem Inc.

Amanda Perry is associate editor of Pumps & Systems.

10 March 2013 www.pump-zone.com PUMPS & SYSTEMS

engineering, engineering-related departments, and new

12 March 2013 www.pump-zone.com PUMPS & SYSTEMS

Don’t pump without us.

800.603.7867 Q 951.342.3100 Q www.BLACOH.com Q Sales@Blacoh.com

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PUMPS & SYSTEMS www.pump-zone.com March 2013 13

14 March 2013 www.pump-zone.com PUMPS & SYSTEMS

To have an item considered for News, please

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PUMPS & SYSTEMS www.pump-zone.com March 2013 15

Branch-Line Pumping and Other Options

L ast month, this column reviewed several examples of

16 March 2013 www.pump-zone.com PUMPS & SYSTEMS

Note: Part 1 (February 2013) of

Joe Evans is responsible for customer and

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PUMPS & SYSTEMS www.pump-zone.com March 2013 17

Will Impeller Velocity Triangles

ferent, assuming that the same W 2

(inlet and outlet) is set by a cir-

18 March 2013 www.pump-zone.com PUMPS & SYSTEMS

PUMPS & SYSTEMS www.pump-zone.com March 2013 19

Pump Speciication, Purchase,

Ground-breaking timing / drive design