June 2013

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From the Editor

Publisher
Walter B. Evans, Jr.

VP of Sales
George Lake glake@pump-zone.com 205-345-0477

VP of Editorial
Michelle Segrest msegrest@pump-zone.com 205-314-8279

Creative Director
Terri Jackson tjackson@cahabamedia.com
EDITORIAL Editor
Michelle Segrest msegrest@pump-zone.com 205-314-8279

Managing Editor Lori K. Ditoro lditoro@cahabamedia.com 205-314-8269 Associate Editor Amanda Perry aperry@cahabamedia.com 205-314-8274 Contributing Editors
Laurel Donoho Joe Evans, Ph.D. Lev Nelik, Ph.D., PE, APICS
CREATIVE SERVICES Creative Director
Terri Jackson
Senior Art Director
Greg Ragsdale
Art Director Jaime DeArman jdearman@cahabamedia.com PRODUCTION Print Advertising Trafc
Lisa Freeman lfreeman@pump-zone.com 205-212-9402

Web Advertising Trafc Ashley Morris amorris@pump-zone.com 205-561-2600 CIRCULATION Jeff Heine jheine@cds1976.com 630-739-0900 ADVERTISING
ore than half of all electrical energy consumed in the U.S. is used by electric motors, according to the Department of Energy (DOE). Federal law requires most general motors sold after October 1997 to meet or exceed the National Electric Manufacturers Associations (NEMA) denition of energy ecient2 to 8 percent more ecient than standard motors. A coalition of nine associations, including NEMA, Appliance Standards Awareness Project (ASAP) and the American Council for an Energy-Ecient Economy (ACEEE) met with the DOE on May 13 for an update on an August 2012 petition that recommended specic energy conservation standards for electric motors. According to NEMA Industry Director William Hoyt, the petition oers a solution that would achieve the DOEs goals for energy savings but will lessen the stress on the industrys end users and manufacturers. he proposed DOE upgrades will require motors to be made with more material to create a bigger frame, Hoyt said. he diameter is larger and longer and will no longer t into the pre-engineered space. It will also require changes to the electrical circuits. Our petition provides a solution for more energy savings but one that is easier for end users and OEMs to implement. he DOE reports that key design improvements and more accurate manufacturing
Thomas L. Angle, P.E., MSc, Vice President Engineering, HidrostalAG Robert K. Asdal, Executive Director, Hydraulic Institute Bryan S. Barrington, Machinery Engineer, Lyondell Chemical Co. Kerry Baskins, Vice President of Sales, Viking Pump Walter Bonnett, Vice President Global Marketing, Pump Solutions Group R. Thomas Brown III, President, Advanced Sealing International (ASI) Chris Caldwell, Director of Advanced Collection Technology, Business Area Wastewater Solutions, Sulzer Pumps, ABS USA Jack Creamer, Market Segment ManagerPumping Equipment, Square D by Schneider Electric
tolerances have contributed to the higher performance of energy-ecient motors. Lengthening the core and using lower-electrical-loss steel, thinner stator laminations and more copper in the windings can reduce electrical losses. Improved bearings and a smaller, more aerodynamic cooling fan can further increase eciency. Hoyt said that NEMA believes there is an easier way to increase the eciency level using existing products. He also emphasized that the motor ruling will be the beginning of the framework for an early investigation into improved pumping system standards. he Small Motor Rule is proceeding for March 9, 2015, adoption. A NEMA white paper on the details of this topic is available through a link on my blog on www.pump-zone.com, along with additional updates that happened after this issues press time. Look for a more detailed article in an upcoming issue of Pumps & Systems. his months cover series (page 28) features articles about motor nameplate letter code designations, the importance of clearance on bearing life, eciency, electric motor repair and reliability and VFDs in pump applications. Visit us at Booth #826 at EASA in Las Vegas, June 30 July 2.
Editorial Advisory Board

Bob Domkowski, Business Development Manager Transport Pumping and Amusement Markets / Engineering Consultant, Xylem, Inc., Water Solutions USA Flygt David A. Doty, North American Sales Manager, Moyno Industrial Pumps Walt Erndt, Director of Market Development SSB, Environment One Corporation Joe Evans, Ph.D., Customer & Employee Education, PumpTech, Inc. Ralph P. Gabriel, Chief EngineerGlobal, John Crane Bob Langton, Vice President, Industry Sales, Grundfos Pumps Larry Lewis, President, Vanton Pump and Equipment Corp. Todd Loudin, President/CEO North American Operations, Flowrox Inc. John Malinowski, Sr. Product Manager, AC Motors, Baldor Electric Company, A Member of the ABB Group William E. Neis, P.E., President, Northeast Industrial Sales Lev Nelik, Ph.D, P.E., APICS, President, Pumping Machinery, LLC Henry Peck, President, Geiger Pumps & Equipment/Smith-Koch, Inc. Mike Pemberton, Manager, ITT Performance Services Scott Sorensen, Oil & Gas Automation Consultant & Market Developer, Siemens Industry Sector Adam Stolberg, Executive Director, Submersible Wastewater Pump Association (SWPA) Bruce Stratton, Product Manager, KLOZURE, Garlock Sealing Technologies Kirk Wilson, President, Services & Solutions, Flowserve Corporation
Derrell Moody dmoody@pump-zone.com 205-345-0784 Mary-Kathryn Baker mkbaker@pump-zone.com 205-345-6036 Mark Goins mgoins@pump-zone.com 205-345-6414 Addison Perkins aperkins@pump-zone.com 205-561-2603 Vince Marino vince@pump-zone.com 205-561-2601
P.O. Box 530067 Birmingham, AL 35253 Editorial & Production 1900 28th Avenue South, Suite 110 Birmingham, AL 35209 Phone: 205-212-9402 Advertising Sales 2126 McFarland Blvd. East,. Suite A Tuscaloosa, AL 35404 Phone: 205-345-0477 or 205-561-2600
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 additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the right to determine qualications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call (630) 739-0900 inside or outside the U.S. POSTMASTER: Send changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. 2013 Cahaba Media Group, Inc. No part of this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media Group, Inc., permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 21, Issue 6.
June 2013
www.pump-zone.com
PUMPS & SYSTEMS
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Table of Contents
Motors & Drives
29 32
Motor Nameplate Letter Code Designations
By Thomas H. Bishop, P.E., EASA Learn how to avoid misinterpretations.
June 2013
Volume 21 Number 6
Photo courtesy of WEG Electric Corp
Internal Clearance & Its Effect on Bearing Fatigue Life

By Miles Woodard and Ryan Thomas, NSK End users must include bearing clearance as an integral part of designing or building a pump.
40 44
Long-Term Motor Reliability

By Timothy Albers and Steve Hauck, Nidec Motor Corporation A variable frequency drives effect on system efciency and motor life
Electric Motor Repair and Reliability

By Howard W. Penrose, Dreisilker Electric Motors, Inc. Repetitive motor failures may be caused by a lack of diagnostic or forensic repair information reported to the motor owner.
28
COVER SERIES
Rotary Lobe Pumps in Sugar Processing
By Marino Curati, Vogelsang This pump type manages the temperature and viscosity challenges of handling this difcult product.
50
VFDs Save Energy in Pump Applications

By Tom Neuberger, Eaton Using variable frequency drives provides many benets to end users.
Practice & Operations

83
Pump Repair & Maintenance

57
Reverse Engineering of a Vertical Pump Suction Bowl
By Jeff Smith, Hydro Parts Solutions Inc., & Dr. T. Ravisundar & Werner Barnard, HydroAire Inc. The pump was returned to service at a nuclear power plant after reverse engineering of an unavailable part and complete pump testing.
86
Peristaltic Pump Speed Considerations

By Todd Loudin, Flowrox Inc. Operating speed requirements must be a factor when selecting a pump.
62
Maintenance Minders: Root Cause Analysis & Problem Solving

By Chris Eckert, Sologic Basic solutions that limit the involvement of a slowly dwindling staff are ideal in todays workplace.
SPECIAL SECTION
76 HI Pump FAQs By The Hydraulic Institute
56
Columns
16 Pump Ed 101
By Joe Evans, Ph.D. Why Wye? Why Delta?
Departments
6 20th Anniversary Top 20 List By Amanda Perry
Top 20 Pump Industry Trade Shows
20 Pumping Prescriptions
By Lev Nelik, Ph.D., P.E., Pumping Machinery, LLC Do Vibration Measurements Depend on Probe Placement and Probe Type?
10 News 68 Efciency Matters By Edison Brito

ATEX: The Symbol of Safety in Dangerous Chemicals Handling
Outdoor Installations, Rotodynamic Vertical Pumps & Drooping Head
80 Business of the Business By Sakthi Pandian & Anand Gnanamoorthy, Frost & Sullivan
Food & Beverage Industry Pump Market
2 54 92 92
From the Editor Trade Show Coverage Index of Advertisers Pump Users Marketplace June 2013
72 Sealing Sense By The Fluid Sealing Association

Improved Torque Tension
89 Product Pipeline 96 Pump Market Analysis By Jordan, Knauff & Company
www.pump-zone.com
PUMPS & SYSTEMS
REDA HPS G3
HORIZONTAL MULTISTAGE SURFACE PUMPS
Reliable, cost-effective surface pumping with no daily maintenance.

A proven alternative to split case, vertical turbine, and positive displacement pumps, the REDA HPS G3 pumping system features a modular design that is delivered quickly and preassembled to the site. All major components of the lexible unit can be replaced in the ield within 2 to 3 hours. These reliable pumps have provided MarkWest more than 5 years of cost-effective NGL production, achieving trouble-free operation with no downtime other than scheduled oil changes. Find out more at
slb.com/redahps
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YEARS
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Top 20 Pump Industry Trade Shows

Pumps & Systems readers told us about their favorite pump industry trade shows. The second part of the Top 20 list is provided here, in alphabetical order. View the full slideshow with all 20 favorites on www.pump-zone.com. Second of Two Parts
By Amanda Perry
Chem Show
Chemical & Process Industry New York, N.Y. Occurs every 2 years www.chemshow.com he Chem Show is an event for process industry professionals. Attendees have the opportunity to learn about the latest process equipment, systems and products and attend comprehensive educational programs that provide information on how to increase process eiciency, reduce costs and develop more sustainable operations.
MINExpo International
Mining Process Industry Las Vegas, Nev. Occurs every 4 years www.minexpo.com MINExpo is sponsored by the National Mining Association and exhibits mining and minerals processing technologies, machinery and equipment for the coal, metal and nonmetal mining processing industries.
NACS/PEI Show ConExpo

Construction Industry Las Vegas, Nev. Occurs every 3 years www.conexpoconagg.com More than 130,000 construction professionals attend ConExpoincluding contractors, dealers, distributors, service providers, engineers, producers and municipalitiesto learn about the latest technologies. Convenience and Fuel Retail Industry Location changes each year Annual event www.nacsonline.com Professionals from the convenience and fuel retailing industry attend this four-day event for educational sessions, products and networking. NACS/PEI show is awesome. here are many educational and networking opportunities. Ian Pickering, Marketing Director Dixon Pumps, Billings, Mont.
INTERPHEX
Pharmaceutical and Biopharmaceutical Industry New York, N.Y. Annual event www.interphex.com INTERPHEX is an annual pharmaceutical and biopharmaceutical trade show that provides networking opportunities, products, services and information to ensure quality and solve manufacturing and supply chain problems.
NGWA
Groundwater Industry Location changes each year Annual event www.ngwa.org his show for groundwater professionals provides educational, networking and business opportunities for water well drillers, contractors, manufacturers, suppliers, scientists and engineers.
June 2013
www.pump-zone.com
PUMPS & SYSTEMS
Oil Sands Trade Show and Conference

Oil & Gas Industry Fort McMurray, Alberta, Canada Annual event www.oilsandstradeshow.com/2013 Oil Sands Conference examines critical issuessuch as stakeholder engagement, implementing innovative technology to meet environmental challenges and accessing new markets for bitumento safeguard the economic development and energy resource availability in Canada.
POWER-GEN International
Power Industry Orlando, Fla. Annual event www.power-gen.com More than 22,000 power industry professionals attend POWER-GEN International to learn about the trends and technologies in the generation sector with an emphasis on solutions and innovations.
OTC
Oil and Gas Industry Houston, Texas Annual event www.otcnet.org he Ofshore Technology Conference (OTC) was founded in 1969 and is an event for the development of ofshore resources in the drilling, exploration, production and environmental protection ields.
NACS/PEI show is awesome. There are many educational and networking opportunities.
Proven Performance with Flowrox Pumps

Proven Performance
With a range of sizes, we have a pump to accommodate every application.

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Flowrox has provided solutions for high-wear and aggressive processes already in almost 50 000 installations in mining, metallurgy and mineral applications around the world.
More info about Flowrox, scan this code or visit WWW.FLOWROX.US
circle 125 on card or go to psfreeinfo.com PUMPS & SYSTEMS www.pump-zone.com June 2013
Wasser Berlin International

Water and Wastewater Industry Berlin, Germany Occurs every 2 years www.wasser-berlin.de Wasser Berlin International is a trade show for water and wastewater professionals and addresses new technologies and technical challenges in the industry. Wasser Berlin is a good opportunity for business and has a large fair ground and lots of exhibitors, said an online reader.
TOP 20 TRADE SHOWS

ACHEMA AWWA Calgary Pump Symposium Chem Show ConExpo Electra Mining EASA Global Petroleum Show INTERPHEX Mid-Atlantic Pump & Process Equipment Symposium MINExpo NACS/PEI NGWA NFPA Conference & Expo Oil Sands OTC POWER-GEN International Pump Turbo Symposia Wasser Berlin International WEFTEC
For more information, see the slideshow on www.pump-zone.com.
Amanda Perry is associate editor of Pumps & Systems. Send information about your favorite pump industry trade show to her at aperry@cahabamedia.com.
Need to create or duplicate a critical part?

Alpha Grainger has the experience and reputation of producing the finest, custom, mill-turn parts for American industry. Quality parts that work in demanding applications and harsh environments. Alpha Grainger has installed the finest equipment from Germany and Switzerland and modified it to higher standards, that surpass anything our competitors can offer. We purchase our raw material from trusted suppliers and employ the best machine operators available. Quality control begins with the design and production cycles and is followed by a multi-level inspection process to ensure the best products possible. Superior quality is no accident, see for yourself what Alpha Graingers American manufacturing can do for you!
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June 2013
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PUMPS & SYSTEMS
BECAUSE THERES NO TIME FOR DOWNTIME.

You need the right equipment, at the right place, right now. With an unmatched rental leet and branch network, we are ready to help you maximize productivity and proitability. And our round the clock service and support means the equipment will work just as hard as you do.
UnitedRentals.com | 800.UR.RENTS
Visit us at APWA 2013, August 25-28, Booth #734
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NEWS
NEW HIRES, PROMOTIONS & RECOGNITIONS

MICHAEL J. BURDULIS MECHANICSBURG, Pa. (April 29, 2013) Michael J. Burdulis passed away April 18, 2013. He was 67. Burdulis was a retired corporate executive from Coltec Industries. He joined Garlock in 1968 as an entry-level accountant and advanced to increasingly responsible positions including vice president and general manager of Garlocks Lubrikup Operation in 1986 and president of Garlocks Industrial Sealing Products unit. He was named president of Coltecs Central Moloney Transformer Division in 1991 and was named president of Garlock Mechanical Packing in 1994. JOHN BIAGIONI, Viatran NEW YORK (April 29, 2013) Viatran announced the appointment of John Biagioni as its new vice president/general manager. Biagioni has been with the Dynisco organization for ive years in diferent executive management roles throughout the organization. Viatran, a Dynisco company, has more than 40 years of experience providing solutions for pressure and level measurement. www.viatran.com HI & PUMP SYSTEMS MATTER Recognize Achievements PARSIPPANY, N.J. (April 25, 2013) Pump Systems Matter (PSM) announced the 2013 board of directors and oicers during the Hydraulic Institutes (HI) annual meeting. he new board will be primarily responsible for providing organizational oversight to PSM and guiding the direction of its strategic training plan.
Geof Wickes, product manager, Emerging Technologies, Northwest Energy Eiciency Alliance, was acknowledged as and will remain chairman of the board for 2013. Additional PSM board members include:
Dennis Wierzbicki, president, Grundfos USA Robert K. Asdal, executive director, Hydraulic Institute Dean Douglas, president, Dover Pump Solutions Group John Miersma, president & CEO, Iwaki America Incorporated Mick Cropper, director, Product Development, Sulzer Pumps (U.S.) Inc. Ann Garbow, senior product portfolio manager, Xcel Energy Bruce Lung, director, Industrial Team, Alliance to Save Energy (non-voting member)
HI also recognized and honored Colfax Fluid Handlings David McKinstry, SVP Engineering & Special Projects, as its Lifetime Achievement Award recipient. In addition, with the approval of the American National Standards Institute (ANSI), HI is seeking qualiied individuals in North America for the review process for the drat of updated Standard ANSI/HI 2.1-2.2 Rotodynamic (Vertical) Pumps of Radial, Mixed and Axial Flow Types for Nomenclature and Deinitions. PSM is a nonproit educational organization established by HI and utility and energy eiciency organizations, www. pumpsystemsmatter.org. he mission of HI is to be a valueadding resource to member companies, engineering consulting irms and pump users worldwide, www.pumps.org. JIM KULLER & RON MAIORANA, Vogelsang RAVENNA, Ohio (April 11, 2013) Vogelsang USA, Inc., announced the hiring of Jim Kuller as sales manager for Washington, Idaho, Montana, Wyoming, California, Nevada and Alaska. He will also manage the Canadian provinces of British Columbia and Alberta. he company also announced the hiring of Ron Maiorana as sales manager for Utah, Colorado, Arizona, New Mexico, Texas, Oklahoma, Arkansas, Louisiana and Mississippi. Vogelsang is a designer and manufacturer of pump and process equipment. www.vogelsangusa.com ANDREW PASCAL & MARIO ALVAREZ, BJM Pumps OLD SAYBROOK, Conn. (April 11, 2013) Andrew Pascal joined BJM Pumps as the production and inventory
MERGERS & ACQUISITIONS

PSG acquires Ebsray Pumps GE agrees to acquire Salof Companies ABB to acquire Power-One ARKEMA acquires majority stake in AEC Polymers May 2, 2013 May 2, 2013 April 22, 2013
April 4, 2013
ELGIN FASTENER GROUP acquires Vegas Fastener Manufacturing April 2, 2013

For details about industry M&A activity, subscribe to Pump Industry Insider and visit www.pump-zone.com.
Andrew Pascal
Mario Alvarez
10
June 2013
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PUMPS & SYSTEMS
control coordinator. Mario Alvarez joined the BJM sales team as regional sales manager for Latin America. BJM Pumps specializes in submersible pumps for a variety of applications. www.bjmpumps.com STEVEN WIDDICOMBE, Boerger, LLC CHANHASSEN, Minn. (April 11, 2013) Boerger, LLC, named Steven Widdicombe as Biogas and Agriculture sales manager for North America. He completed Steven training in Germany Widdicombe and is familiar with Boerger technology on farms and anaerobic digestion plants. Boerger manufactures rotary lobe pumps and macerating and feeding technology. www.boerger.us RUSSELL SITKA & DOUG CUMPSTON, Pump Solutions Group OAKBROOK TERRACE, Ill. (April 10, 2013) Pump Solutions Group (PSG) named Russell Sitka director of business development, Americas, and Doug Cumpston as director, Global Segment Marketing (Energy). Dovers PSG manufactures positive displacement pumps and other technologies. www.psgdover.com THOMAS GAVINSKI, Fristam Pumps MIDDLETON, Wisc. (April 4, 2013) homas Gavinski joined Fristam Pumps as sales manager, Americas. Gavinski will oversee Fristams North, South and Central American sales departments and the customer service department. Fristam Pumps USA is a manufacturer of sanitary centrifugal and positive displacement pumps, blenders and mixers used by the beverage, dairy and food industries. www.fristam.com
JOSHUA STANDRIDGE, Pioneer Pump, Inc. CANBY, Ore. (April 2, 2013) Pioneer Pump promoted Josh Standridge to vice president of sales. Standridges initial focus will be on North and Latin American markets. Pioneer Pump manufactures and designs centrifugal Josh Standridge pumps. www.pioneerpump.com
INNOVATION INNOVATI TION | ENGI ENGINEERING GINEE ERING | PE P PERFORMANCE ERFORMANC CE
FLEX-PRO A2
PERISTALTIC P ERISTA STALTIC TECHNOLOGY TECHNOLOGY EXCELLENT TECHNOLO EXC XCEL X ELLE LLE LENT EN NT TP PRICE RICE P RI POINT OINT
IP6 P6 66
NEM EM MA 4X
WA WASH WAS WA ASH DO DOW WN
Standard 61
Self-priming Valve-less Design Cant Vapor-lock Near Continuous Output, Even at Low Feed Rates Smooth, Quiet Pumping Action Optional Advanced Serial and Ethernet Communications Patented Tube Failure Detection System
5300 Business es ss Drive, Driv Dri Dr ive, Huntington ive Hun u ti tin ing ngto ngt ton Beach, ton Beach Beac ac ch, CA CA 92649 9264 92 649 64 9 USA USA t t TBMFT!CMVFXIJUFDPNt www.blue-white.comtfax:
PUMPS & SYSTEMS
www.pump-zone.com
June 2013
11
NEWS
AROUND THE INDUSTRY

SULZER PUMPS & SINOPEC CORPORATION Form Partnership WINTERTHUR, Switzerland (April 23, 2013) Sulzer Pumps and Sinopec Corporation have established a
long-term strategic partnership to develop their commercial activities within the hydrocarbon processing industry. hrough this collaboration, both companies will beneit from joint technology development, research and development, and commercial and logistics cooperation. Sulzer Pumps also opened its third service center in China, located in Chengdu, the capital of Sichuan province in Southwestern China. Sinopec Corporation is an integrated energy and chemical company in China with upstream, midstream and downstream oil and gas operations, www.sinopec.com. Sulzer Pumps designs, develops and supplies pumping solutions and related equipment worldwide, www.sulzer.com. Water Leaders Approach Congress Regarding Infrastructure Challenges WASHINGTON (April 17, 2013) Nearly 200 water utility leaders from across the U.S. ascended the steps of Capitol Hill, urging their members of Congress to vote for legislation that addresses the nations water infrastructure challenge and confronts mounting afordability concerns. he water utility leadersin Washington as part of the Water Matters! Fly In, sponsored by the American Water Works Association (AWWA) and the Water Environment Federation (WEF)asked members of Congress to support the Senate Water Resources Development Act (S.601). his act would include a provision creating a Water Infrastructure Finance and Innovation Authority (WIFIA). WIFIA, modeled ater a successful program in the transportation sector, would make low-interest federal loans available for large water, wastewater and storm water projects and help create jobs. AWWA is an international, nonproit, scientiic and educational association committed to the safety and improvement of water quality and
THE ENGINEERED PERFORMANCE RUNS DEEP

XEMC VERTICAL HOLLOW-SHAFT MOTORS are primarily designed for deep well turbine pump applications. Each model is built to NEMA standards and features a special bearing arrangement to carry heavy thrust loads. Couplings are equipped with a non-reverse ratchet to prevent motor rotation from backspin at shutdown. Conidence: Produced by one of the most reliable motor manufacturers in the world Cost-Savings: Motors run 30% more eiciently, and are competitively priced Convenience: Less equipment creates more space, making installations easier
For the best solutions to your application challenges, consult with your XEMC distributor. To locate a distributor, scan the QR code or visit www.lt-eng.com/products/ind-a-distributor.
FOR ADDITIONAL PRODUCT DETAILS, VISIT www.lt-eng.com/products/vertical-hollow-shaft

12
June 2013
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PUMPS & SYSTEMS
supply, www.awwa.org. WEF is a not-for-proit technical and educational organization of 36,000 individual members and 75 ailiated member associations representing water quality professionals around the world. www.wef.org Water Community Calls for Water Infrastructure Reinvestment ALEXANDRIA, Va. (April 17, 2013) Top water leaders from the private and public sectors met in Washington, D.C., to make the business case for water infrastructure investment during the well-attended National Water Infrastructure Summit and concurrent testimony before the House Interior and Environment Subcommittee on Appropriations. WEF is a not-forproit technical and educational organization of 36,000 individual members and 75 ailiated member associations representing water quality professionals around the world. www.wef.org SIEMENS & CH2M HILL Agreement MUNICH (April 10, 2013) Siemens formed a global strategic collaboration agreement with CH2M Hill. he company also acquired specialized knowledge of organic Rankine cycle technology from insolvency administrators managing the assets of Maxxtec AG and Adoratec GmbH in Sinsheim, Germany. he purchase agreements have been signed and the transaction will soon be concluded. Siemens Industry Sector is a supplier of products, solutions and services for industrial customers. www.siemens.com SKF Extends Network CLEVELAND (April 7, 2013) SKF has extended service with ive new SKF Solution Factory facilities. he global network of 21 sites ofers knowledge and resources from all
PUMPS & SYSTEMS
SKF technology platforms. SKF supplies bearings, seals, mechatronics, lubrication systems and other services (technical support, maintenance and reliability services, engineering consulting and training). www.skf.com P&S
To have a news item considered for publication, please send the information to Amanda Perry, aperry@cahabamedia.com.
Tired of snails pace lead times?
At PumpWorks 610, our pump manufacturing lead times are as short as 16 weeksthe fastest in the industry. Offering a full line of centrifugal API 610 pumps for the oil, gas and petrochemical industries, we manufacture and test only in the United States to ensure each pump meets your standards.
For more information on how to get your business up and running faster, visit us at www. pumpworks610.com or talk to one of our pump experts at 888.405.0209.
When Quality & Delivery Matter
circle 123 on card or go to psfreeinfo.com www.pump-zone.com June 2013
13
NEWS
CALENDAR
SEPTEMBER
PUMPTEC 2013
Sept. 16 17 Georgia World Congress Center Atlanta, Ga. 770-310-0866 www.pumpconference.com
JUNE
AWWAS ANNUAL CONFERENCE & EXPOSITION (AWWA ACE)
June 9 13 Denver, Colo. 800-926-7337 www.awwa.org
WEFTEC
Oct. 5 9 McCormick Place Chicago, Ill. 800-666-0206 www.weftec.org
WORLD ENERGY CONGRESS

Oct. 13 17 Daegu Exhibition & Convention Center Daegu, Korea +82 (2) 739-7045 www.daegu2013.kr
PACK EXPO INTERNATIONAL ELECTRICAL APPARATUS SERVICE ASSOCIATION CONVENTION (EASA)

June 30 July 2 Mandalay Bay Resort & Casino Las Vegas, Nev. 314-993-2220 www.easa.com Sept. 23 25 Las Vegas Convention Center 571-612-3187 / www.packexpo.com
INTERNATIONAL PUMP USERS SYMPOSIUM & TURBO MACHINERY SYMPOSIUM

Sept. 30 Oct. 3 Houston, Texas turbolab.tamu.edu
IFAT INDIA
Oct. 24 26 Bombay Convention & Exhibition Centre Mumbai, India +49 89 949-20299 www.ifat.de/en/Hidden/ifatindia
AUGUST
BECKWITH & KUFFEL, INC., OPEN HOUSE/SYMPOSIUM
Aug. 1, 2013 Seattle, Wash. 800-767-6700 www.b-k.com/open-house
OCTOBER
CHEMINNOVATIONS CONFERENCE & EXPO
Oct. 1 3 Houston, Texas www.cpievent.com
NOVEMBER
POWER-GEN INTERNATIONAL
Nov. 12 14 Orange County Convention Center Orlando, Fla. 888-299-8016 / www.power-gen.com
To have an event considered for publication, please send the information to Amanda Perry, aperry@cahabamedia.com.
ere Wh
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14
June 2013
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PUMPS & SYSTEMS
Downtime
DENIED
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PUMP ED 101
By Joe Evans, Ph.D. PumpTech, Inc. P&S Editorial Advisory Board
Why Wye? Why Delta?

By Joe Evans, Ph.D.
First of Three Parts
ne of the more confusing elements of three-phase power is the winding connection schemes for inductive devices such as transformers and motors. Although most of us with a basic knowledge of AC power understand how motors and transformers operate, we seldom delve into those mysterious winding connections and their impact on performance. his simple, three-part series will not make you an expert, but I hope it will make these connections a little more understandable. SINGLE-PHASE CONNECTIONS A simple illustration of why a Wye or Delta connection is required in a three-phase circuit is to look at a single-phase connection. Figure 1 shows the schematics for two typical single-phase transformers. he one on the let takes a higher primary voltage and produces 120 volts in the secondary. he schematic on the right takes that same primary voltage and produces 240 volts. It also has a grounded, neutral center tap that produces 120 volts between the tap and the outside terminals. Note that
these illustrations do not show any diference in the number of primary and secondary turns. If it did, more would be in the primary than in the secondary since both are reducing the primary voltage. he turns ratio determines the increase or decrease in voltage and current between the primary and secondary coils. What stands out in Figure 1 is that only two connections are at any point on the schematics. Both primary and secondary coils have two. he secondary on the let is connected hot to ground, and the one on the right is connected hot to hot. he two center tapped voltages are also hot to ground. With three incoming phases, the connection scheme is diferent, and that is the purpose of Wye and Delta connections. THREE-PHASE CONNECTIONS hree-phase transformers consist of three separate sets of coils, each of which is connected to an individual phase. For voltage and current to low through the coils, some common connection must be among them. Figure 2 shows
Figure 1. The two typical single-phase transformer schematics
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PUMPS & SYSTEMS
The turns ratio determines the increase or decrease in voltage and current between the primary and secondary coils.
the two possible connections. he Delta connection joins the coils as an equilateral triangle and applies the individual phases at each of the vertices. he Wye connection joins together one end of each of the coils and applies the individual phases to the open ends. hese two connections produce very diferent results when power is applied. An advantage of the Delta connection is higher reliability. If one of the three primary windings fails, the secondary will still produce full voltage on all three phases. he only requirement is that the remaining two phases must be able to carry the load. If one of the windings in a Wye primary fails, two of the phases of a Delta secondary will see a reduced voltage. If the secondary is also Wye connected, two phases will have reduced voltage and the other will have zero volts. An
T1
T1
T3 Delta
T2
T3
Wye
T2
Figure 2. Two possible connectionsDelta & Wye
Figure 3. The schematic for a Delta/Wye conguration
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PUMP ED 101
The Delta connection joins the coils as an equilateral triangle and applies the individual phases at each of the vertices.
advantage of the Wye connection is that it can provide multiple voltages without the need for additional transformers. his can reduce cost in many applications. he primary and secondary of a three-phase transformer can be designed as Delta/Delta, Wye/Wye, Delta/Wye and Wye/Delta. Delta/Delta is used in many industrial installations, while Delta/Wye is the most common coniguration. Wye/Delta is used in high voltage transmission, and Wye/ Wye is seldom used because of potential unbalance. Figure 3 is the schematic for a Delta/Wye coniguration. he primary is wound as Delta, and the secondary is wound as Wye. he incoming phase voltages are applied at P1, P2 and P3. S1, S2 and S3 are the output voltages. I mentioned earlier that the output of the two connections is diferent. Either can be wound to produce a particular phase voltage, but the phaseto-phase voltages will be diferent for the Wye and Delta connections. Lets take a look at two examples. Figure 4 shows the secondary (output) side of a Wye-connected, three-phase transformer. he green line is a center tap that leads to ground. In Figure 4, the individual phases are 120 volts, and each produces 120 volts when connected to the center tap. When connected phase to phase, the voltage is only 208not the 240 volts we might expect. Why? he answer is Wye. Wye connections produce a diferent phase angle among the phases, and the phase angle determines the phaseto-phase voltage. If you are interested in learning more about phase angles and the phasor diagrams that measure them, see the Changing Voltage Puzzler on www.PumpEd101.com. he beneit is that a constant allows you to compute the phase-to-phase voltage produced by a Wye connection. he phase-to-phase voltage will
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PUMPS & SYSTEMS
208V
120V
240V
208V 120V
240V
208V
120V
240V Figure 5. The secondary (output) side of a Delta-connected, three-phase transformer
Figure 4. The secondary (output) side of a Wye-connected, three-phase transformer
always be 1.732 times the phase voltage. Figure 5 shows the secondary (output) side of a Delta-connected, three-phase transformer. As in the Wye example, the individual phases produce 120 volts. In this example, the phase-to-phase voltages are twice the individual phase voltages, or 240 volts. It may appear that the Delta is a more eicient design, but phase angle also has a role here. he phase-to-phase current in a Delta circuit is only 1.732 times the phase current, but it is two times the phase current in a Wye circuit. his is why the constant of 1.732 appears in the equations used to calculate wattage and other values in three-phase circuits. It accounts for the phase angles efect on voltage and current in the two diferent connections. Power (Watts) = E x I x 1.732 x Power Factor Next months column will investigate three mutations of the common Delta secondary and how they can be problematic. P&S
Joe Evans is responsible for customer and employee education at PumpTech, Inc., a pump & packaged system 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 an email.
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PUMPING PRESCRIPTIONS
By Lev Nelik, Ph.D., P .E. Pumping Machinery, LLC P&S Editorial Advisory Board
Do Vibration Measurements Depend on Probe Placement and Probe Type?

T
ypically, vibration measurements are taken with a handheld accelerometer probe in four places: Pump outboard bearing housing Pump inboard bearing housing Motor inboard bearing housing Motor outboard bearing housing For new installations, during unit commissioning, the allowable vibration values are smaller. hey are typically half those described in the previous paragraph. hey are most oten 0.15 inch/second (warning) or commissioning acceptance of the contractual level.
hese measurement locations are shown in Figure 1. At each location, readings are taken in horizontal, vertical and axial directions. he probes are typically one-directional accelerometers (readings in g-forceG). What is more commonly used is the vibrations integrated value (velocity of vibrations, inches/second), and less common, its second integral, which is displacement (mils). SMALL PUMPS For a small pump, the exact position of the probe is not critical. Because of the bearing housings small size, there is not much room to choose the exact location of the probe. It may also be diicult to establish a irm contact between the probe magnet and the curvature of the housing. hese factors inluence the accuracy of the readings, but a typical error does not change much more than about 0.01 to 0.02 inch/second or so. For example, a 0.20 inch/second value may vary between 0.19 inch/ second and 0.21 inch/second, depending on how well the probe sits on the housing and the exact position. Typical ield allowances are usually 0.3 inch/second (warning) and 0.5 inch/second (alarm). In most cases, an absolute value is not as important as trend data (see Figure 2).
PUMP
MOTOR
P-out
(outboard)
P-in
(inboard)
M-in
(inboard)
M-out
(outboard)
Figure 1. Identication of pump/motor probe locations
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A tri-axial probe reads vibrations in three directions and monitors the temperature at the point of attachment. It performs the same tasks as three single-directional probes and a temperature probe.
LARGE PUMPS facility may include 30 to 40 units. Perhaps one or two For larger units, however, probe placement can make a big units were identiied as problematic. On these units, more diference. In Image 1, the accelerometer is positioned near the end of the outboard side of the pumps outboard bearing housing and is reading the axial vibration. Locating the probe on the same housing (pump outboard in relation to the coupling) but on the inside (assuming enough room is available to insert the probe) may show a signiicantly diferent reading. With the larger housing, diferent parts will vibrate at signiicantly different levels. his diference, however, is not a direct indication of a bearing problem. he difering vibrations may Provided to Our Customers For Over 125 Years indicate the structural integrity of Condition Monitoring Systems the housing, such as cracks in certain areas, loose bolting or the attachment Vibration Analysis Equipment to the main pump body. Spin Test Systems he information in the previous paragraph applies to routine or periMoment Weighing Scales odic (monthly, quarterly) measureHigh Speed Facilities ments. Overall (RMS) vibrations are Dynamic Balancing Machines suicient to reveal any issues beyond the norm. When issues are identi Its a relationship that begins when the negotiations end. iedan increasing trend or a sudden Its balancing equipment that goes beyond specications and spike occurrencemore precise trouexceeds expectations. bleshooting and examination should Its a higher level of service that is responsive and maximizes be employed. performance. For example, an end user should Its comprehensive support to guide you through the perform a full spectral analysis (Fast challenges, elevate your capabilities and train your experts of Fourier transformFFT), instead of the future. the RMS. In routine RMS readings, a diference between 0.02 inch/second is not critical. herefore, positioning the probe within the housing is not critical either.
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THE CASE FOR CONTINUOUS MONITORING A typical monthly route within a plant or other industrial/municipal
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extensive vibration monitoring was conducted, which included a full spectral FFT analysis, with the probe placed at diferent locations within the housing. In some problematic cases, continual monitoring of the unit may be needed. In this case, a portable vibration system could be installed that closely and continuously monitors the pumps to determine when a sudden (but repeatable) spike in vibration occurs. Sometimes, unexpected reasons for vibration can be discovered, such as loor vibrations because of an 18-wheeler delivering cement every Tuesday at 4 a.m. A monitoring system like this would read data at the same four
Figure 2. Periodic (monthly, quarterly) vibration trends (overall root mean squareRMSvalues)
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locations, but with tri-axial probes. A tri-axial probe reads vibrations in three directions and monitors the temperature at the point of attachment. It performs the same tasks as
Typical ield vibration allowances are usually 0.3 inch/second (warning) and 0.5 inch/second (alarm).
Image 1. Outboard side probe placement
23
three single-directional probes and a temperature probe (see Image 2). In Image 2, the probes were connected to a box that transmitted the data to a local cell tower (or local Ethernet) and could be viewed online in real time. Using this data (see Figure 3), the end user can see that one of the four tri-axial probes, which was installed on top of the pumps inboard bearing housing, read approximately 0.2 inch/second in two directions. However, the reading in the third, axial direction was double that at 0.4 inch/second. An independent probe was installed at the end of the housing (where the axial readings were more commonly measured by a single-dimensional probe). his independent probe also produced a reading of 0.2 inch/second, indicating that, in the axial direction, the bearing
Image 2. Continuous vibration monitoring
Figure 3. Data from the tri-axial vibration and temperature probes
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PUMPS & SYSTEMS
housing vibrated more at its top portion as compared to its end portion. he four locations of the vibration probes (pump and motor outboard and inboard) are typically used for double suction or multistage pumps. For vertical pumps, only two probes are used. his is because the motor is the only accessible component since the pump is under the sole plate. For municipal inluent sewage lit station pumps, two or three locations are used
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more commonly, with tri-axial probes providing live continual data to operators over the Web (see Image 3).
PUMP QUIZ In Images 4a through 4c, vibration measurements are taken in three directions at the pump outboard bearing housing (horizontal, vertical, axial). Which photos would you consider problematic, and why? he best answers and comments will be published in an upcoming Pumps & Systems. P&S
Figure 4a. Vertical direction measurements
Figure 4b. Horizontal direction measurements Dr. Nelik (Dr. Pump) is an Editorial Advisory Board member for Pumps & Systems. He has more than 30 years experience as a pump designer, ield troubleshooter and trainer. He conducts Pump School (Basic) sessions at his central training facility in Atlanta, Ga., and advanced sessions on site per speciic requests. For more information on the Pump School schedule, visit www.pumpingmachinery. com/pump_school/pump_school.htm.
Figure 4c. Axial direction measurements
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Photo courtesy of WEG Electric Corp

PUMPS & SYSTEMS
Motors & Drives
Motor Nameplate Letter Code Designations

Learn how to avoid misinterpretations.
By Thomas H. Bishop, P .E., EASA
he nameplates of alternating current (AC) motors built to National Electrical Manufacturers Association (NEMA) standards reference a system of alphabetical letters that designate the principal characteristics of each motorcode, design and insulation class. hough critical to proper motor selection, these designations are easy to misinterpret. he letter B, for instance, might represent the design code, insulation class or kilovolt amperes (kVA) code (though highly unlikely). herefore, understanding what the diferent designations mean and reconirming their appropriateness for all replacement motor applications is important. CODE For motors less than horsepower, the code letter on the nameplate represents the locked-rotor kVA. On larger motors, it identiies the locked-rotor kVA per horsepower. NEMA Stds. MG 1, 10.37.2, deines the latter codes using a series of letters from A to V. Generally, the farther a code letter is from A, the higher the inrush current per horsepower. his is important because a replacement motor with a higher code letter may require diferent upstream electrical equipmentsuch as a larger motor starter. Note: Similar letters are used on the nameplate to designate other motor characteristics (for example, design and insulation class). Read the nameplate carefully to avoid misinterpretations. DESIGN Based on torque and current characteristics, NEMA Stds. MG 1, 1.18, deines four motor design classiications: A, B, C and D (see Table 1). Common headings that precede the design letter on motor nameplates include Des, NEMA Design and Design. NEMA Design
Starting current Starting torque Breakdown torque
Most motors, such as centrifugal pump motors, fall into the Design B category, which is characterized by comparatively high energy eiciency and torque ratings. Although Design A is best from an eiciency standpoint, these motors are used sparingly because their relatively high starting currents can cause nuisance tripping of motor protection circuitry. Design A motors may also require largerthan-standard starters. Some motors may not conform to any of the torque-current characteristics deined in NEMA Stds. MG 1. In such cases, the motor manufacturer may assign a letter that is not an industry-deined standard or simply not list a design letter on the nameplate. When replacing a motor, always check for the design letter and determine if the same design is still appropriate for the application. Consider all changes that may have occurred since the original motors installation. One of the more common misapplications is the attempt to replace a Design C or D motor with a Design B. he unfortunate outcome is usually that the Design B motor,
High Medium Medium Medium Medium Medium High Very high High Medium High Very High
Figure 1. Speed-torque curves for NEMA design motors
Table 1. Characteristics of NEMA design motors
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Generally, the farther a code letter is from A, the higher the inrush current per horsepower.
with its lower starting torque (see Figure 1), cannot accelerate the load to operating speed. Although Design B is applicable to the vast majority of pumps, positive displacement pumps that start with a load require a design C motor, and oilield pump motors with lywheels need design D motors. INSULATION CLASS Oten abbreviated Ins. Cl. on nameplates, insulation class is a standard, industry classiication of the thermal endurance of the motor winding. Insulation class is indicated by a Insulation System Temperature Classiication
Class A Class B Class F Class H 105 C 130 C 155 C 180 C 221 F 266 F 311 F 356 F
Table 2. Temperature classication of insulation systems
letter designation such as A, B, F or H (see Table 2), depending on the windings ability to withstand a given operating temperature for a given life. Insulation classes with a letter deeper into the alphabet perform better. For example, Class F insulation has a longer nominal life at a given operating temperature than Class A, or for a given life, it can survive higher temperatures. Manufacturers produce some motors using a higher insulation class than indicated on the nameplate. A motor wound using Class F insulation, for instance, may be listed for a Class B rise. he reason for doing so is to provide a more thermally robust winding capable of better handling real-world operating conditions. For similar reasons, many Electrical Apparatus Service Association (EASA) service centers upgrade winding insulation to Class H. Operating temperature is a result of ambient conditions plus the energy lost in the form of heat (causing temperature rise) as the motor converts electrical energy to mechanical work. he ultimate temperature in the winding is the sum of the ambient and the winding temperature rise. For example, if a motor is rated with a 1.15 service factor and has a class B (130 C) insulation system, the temperature rise according to NEMA Stds. MG 1 is 90 C, and the maximum ambient temperature limit is 40 C. he windings total temperature would be 90 C + 40 C, or 130 C. Operating at above-rated temperatures will shorten the life of the winding, generally reducing it by half for every 10 C increase. P&S
Thomas H. Bishop, P .E., is a senior technical support specialist at EASA, St. Louis, Mo., 314-993-2220. EASA is an international trade association of more than 1,900 irms in 59 countries that sell and service electrical, electronic and mechanical apparatus. For more information about EASA, visit www.easa.com.
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Internal Clearance & Its Effect on Bearing Fatigue Life

End users must include bearing clearance as an integral part of designing or building a pump.
By Miles Woodard and Ryan Thomas, NSK nternal clearance is one of the most important factors DIFFERENT TYPES OF CLEARANCES afecting bearing performance within pump applications. What is the ideal clearance? Before considering this question, he bearings internal clearance is the relative movement of diferent types of clearance will be deined in this section. the outer and inner rings when they are lightly pushing in opposite directions. Movement in the diametrical direction Measured Internal Clearance (1) is deined as radial clearance. Movement in the shats his is the internal clearance measured under a speciied measuring load and can be called apparent clearance. It direction is axial clearance. Internal clearance is critical to bearing performance for includes the elastic deformation (FO) caused by the measurmultiple reasons. he amount of clearance inluences the ing load. load distribution in a bearing, which ultimately afects 1 = 0 + FO bearing life. It also inluences bearing running noise and vibration. In addition, it can inluence whether the rolling elements move in a rolling or sliding motion. Normally, bearings are installed with interference on either the inner or outer ring. his leads to its expansion or contraction, which causes a change in clearance. During operation, the bearing temperature will increase until it reaches saturation temperature. However, the temperature of the inner ring, outer ring and rolling elements are all diferent from each other, and this temperature diference changes the clearance (see Figure 1). In addition, when a bearing operates under load, an elastic deformation of the inner ring, outer ring and rolling elements also leads to a change in clearance. Quantifying all these changes can make calculating bearing internal clearance a Figure 1. Changes of radial internal clearance of a roller bearing complex task.
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PUMPS & SYSTEMS
Motors & Drives
Theoretical Internal Clearance (0) his is the radial internal clearance, which is the measured clearance minus the elastic deformation caused by the measuring load. 0 = 1 + FO FO is signiicant for ball bearings but not for roller bearings, where it is assumed to be equal to zero, and therefore 0 = 1. Residual Internal Clearance (f) his is the clearance let in a bearing ater mounting it on a shat and in a housing. he elastic deformation caused by the mass of the shat, etc., is neglected. Assuming the clearance decrease caused by the ring expansion or contraction is f, then: f = 0 + f Effective Internal Clearance () his is the bearing clearance that exists in a machine at its operating temperature, excluding the elastic deformation caused by load. In other words, this is the clearance when considering only the changes because of the bearing itting f and temperature diference between the inner and outer rings, t. he basic load ratings of bearings apply only when the efective clearance is =0. = f t = 0 (f + t) Operating Clearance (F) his is the actual clearance when a bearing is installed and running under load. In this situation, the efect of elastic deformation F is included and the itting and temperature. Generally, the operating clearance is not used in the calculation. F = + F
IMPORTANCE OF EFFECTIVE CLEARANCE he most important bearing clearance is the efective clearance. heoretically, a bearing with a slightly negative efective clearance will have the longest life. A slightly negative clearance (or preload) will actually become positive under the inluence of bearing load. However, making the
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clearance of all the bearings the ideal efective clearance is impossible. End users must consider the geometrical clearance 0 to achieve a zero or slightly negative efective clearance minimum value. To calculate this value, a user needs to know the clearance reduction caused by the interference of the inner ring and outer ring f and the clearance change caused by the temperature diference between the inner ring and outer ring, t. CALCULATING RESIDUAL INTERNAL CLEARANCE AFTER MOUNTING When the inner ring of a bearing is press it onto a shat, or when the outer ring is press it into a housing, the radial, internal clearance will naturally decrease because of the resulting expansion or contraction of the bearing raceways. Generally, most pumps have a rotating shat that requires a tight it between the inner ring and shat and a loose it between the outer ring and housing. In these cases, only the efect of the interference on the inner ring needs to be considered. An example calculation is shown below for a 6310, singlerow, deep-groove ball bearing. he shat tolerance used is K5, while the housing is H7. he interference it is applied only to the inner ring. Shat diameter, bore size and radial clearance are the standard bearing measurements. Assuming that 99.7 percent of the parts are within tolerance, the mean value (mf) and standard deviation (f) of the internal clearance ater mounting (residual clearance) can be calculated. Measurements are given in millimeters (mm). s = RS/2 = 0.0018 3 R i/2 = 0.0020 i = 3 0 = R0/2 = 0.0028 3 f 2 = fs2 + i2 mf = m0 i(ms mi) = 0.0035 f = 02 + i2 f2 = 0.0035 Where: s = Standard deviation of shat diameter I = Standard deviation of bore diameter f = Standard deviation of interference
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PUMPS & SYSTEMS
Motors & Drives
0 = Standard deviation of radial clearance (before mounting) f = Standard deviation of residual clearance (ater mounting) ms = Mean value of shat diameter (50+0.008) mi = Mean value of bore diameter (50-0.006) m0 = Mean value of radial clearance (before mounting) (0.014) mf = Mean value of residual clearance (ater mounting) Rs = Shat tolerance (0.011) Ri = Bearing bore tolerance (0.012) R0 = Range in radial clearance (before mounting) (0.017) I = Rate of raceway expansion from apparent interference (0.75 from Figure 2) he average amount of raceway expansion and contraction from apparent interference is calculated using: i (mm mi).
he following equation is used to determine, within 99.7 percent probability, the variation in internal clearance ater mounting (Rf): Rf = mf 3f = +0.014 to -0.007
Figure 2. Rate of inner ring raceway expansion ( i) from apparent interference
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In other words, the mean value of residual clearance (mf) is +0.0035and the range are from -0.007 to 0.014 for a 6310 bearing. RADIAL INTERNAL CLEARANCE AND TEMPERATURE When a bearing runs under a load, the temperature of the entire bearing will rise. his includes the rolling elements. However, because this change is extremely diicult to measure or estimate, the temperature of the rolling elements is generally assumed to be the same as the inner-ring temperature. Using a 6310 bearing again as an example, the reduction in clearance caused by a temperature diference of 5 C between the inner and outer rings can be calculated using the following equation: t = tDe t (4D + d) 5 -6 12.5 x 10 x 5 x (4 x 110 + 50) 5 6 x 10-3(mm) Where: = Decrease in radial internal clearance caused by a temperature diference between the inner and outer rings (mm) = Linear thermal expansion coeicient for bearing steel, 12.5 x 10-6 (1/ C) t = Diference in temperature between inner ring (or rolling elements) and outer ring (C) D = Outside diameter (6310 bearing, 110 mm) d = Bore diameter (6310 bearing, 50 mm) De = Outer-ring raceway diameter (mm) he following equations are used to calculate the outerring raceway diameter: Ball bearings: De = 4D + d 5 3D +d Roller bearings: De = 4 Using the values calculated for f and t, the efective internal clearance () can be determined using the following equation: D = Df dt = (+0.014 to -0.007) 0.006 = +0.008 to -0.013 In Figure 3, note how the efective internal clearance inluences bearing life, in this example, with a radial load of 3,350 Newtons (or approximately 5 percent of the basic load rating). he longest bearing life occurs under conditions in which the efective internal clearance is -13 micrometers. he lowest limit to the preferred efective internal clearance range is also -13 micrometers. APPLICATION In theory, targeting a slightly negative clearance is optimal for bearing life. However, in practice, end users must be careful when designing or building a pump with bearing preload. As shown in Figure 3, the life ratio peaks at -13 micrometers, but decreases dramatically with additional preload. Incorrect assumptions regarding machining tolerances or operating temperatures can easily result in a shorter life than anticipated if the bearing becomes preloaded too heavily.
PUMPS & SYSTEMS
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June 2013
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BaldorDodge Disc couplings offer industry leading torque capacity and misalignment capability for longer life and improved reliability. With high torque speed, misalignment, and maintenance-free features, BaldorDodge Disc couplings meet API 610 specifications for pumping and compressor applications used in the oil and gas industry. Count on BaldorDodge for all your disc coupling needs. And, you can find BaldorDodge disc couplings at your local Motion Industries location. Our local sales and service specialists are experts Over 500 locations More than 4 million products in application and technical Industrial maintenance training courses Call. Click. Visit. support, providing the parts and the know-how you need to stay up and running. The brands you count on from the people you trustthats BaldorDodge and Motion Industries.
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2013 Motion Industries, Inc.
MotionIndustries.com
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On the other hand, too much clearance can result in the bearing slipping and poor pump performance. End users must evaluate the trade-ofs of clearance and bearing preload based on the needs of the application. Understanding the importance of bearing internal clearance will help increase bearing life and optimize overall pump performance. P&S
NSK Application Engineer Miles Woodard is a qualiied Chief Engineer Oficer in the U.S. Navy and has worked extensively with pump and compressor manufacturers for the past seven years. As the segment manager for the pump and compressor market, Ryan Thomas extensive knowledge and expertise includes more than a decade of experience e in the motion control industry. Thomas and Woodard are members of NSKs North American Pump & Compressor team, which addresses the needs of the pump industry with engineering support, application analysis and innovative new product development. For more information, visit www.nsk. com/industries/pumpscompressors.html or contact NSK at info@nsk-corp.com.
Figure 3. Relationship between the effective clearance and the bearing life for a 6310 ball bearing
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June 2013
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PUMPS & SYSTEMS
Motors | Automation | Energy | Transmission & Distribution | Coatings
Severe Duty is Standard with WEG W22 motors.
You do not need a special motor for severe duty. Severe Duty is standard with WEG W22 motors.
High performance with maximum energy efciency is the goal of the WEG W22 electric motor. High efciency and low cost of ownership throughout the entire motor lifetime have been the basis for the W22 development. A design created to maximize performance and energy savings. Optimized cooling system, large and accessible terminal box, exclusive bearing seal system, low vibration levels, and a 1.25 service factor are just a few of s. many STANDARD features of our W22 motors. emium Efciency levels. Available in NEMA Premium or Super Premium
To learn more about the W22 features and benets or to locate a WEG Distributor near you, please contact
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2013 WEG Electric Corp.
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Long-Term Motor Reliability

A variable frequency drives effect on system eficiency and motor life
By Timothy Albers and Steve Hauck, Nidec Motor Corporation
ariable frequency drives (VFDs) are typically added to a system for economic reasons. While the realized economic beneits may be drastic throughout the life of the motor, several factors must be addressed to ensure the motors long-term reliability. NON-INVERTER DUTY MOTORS he use of a VFD adds several areas of stress that noninverter duty motors are unable to cope with long term. he most common type VFD is pulse width modulated (PWM). A PWM drive uses short bursts of electricity to simulate a sine wave. his approximation of the sine wave adds several types of stresses to the controlled motor. Shat grounding rings, insulated bearings and line ilters are some of the most common ways customers protect their motor investment from negative VFD attributes. SYSTEM EFFICIENCY While VFDs are not 100 percent eicient, they do make economic sense when the operating speed of a motor needs to be lower than its rated speed. herefore, choosing the correct motor for the application becomes crucial because motor eiciency drops as speed and load decrease. VFD eiciency also declines with motor speed, so it too needs to be correctly sized to the application. he motor and drive eiciencies combine to form part of the system eiciency. he systems eiciency is the product of: VFDs eciency Motors eciency (average motor eciency when operated on a VFD is reduced by one NEMA band versus sine wave operation) Driven equipments eciency (for example, pumps and fans) MOTOR PROTECTION When VFDs are used, steps must be taken to protect the motor and ensure eicient system operation. hese steps are discussed in this section.
Motor Speed VFDs are used to run motors at speeds other than their nameplated speed. When a motor is subjected to a constant torque load, slower speeds may require an additional cooling method to avoid degrading the motors electrical insulation. However, if the load is a variable torque load, motor cooling is usually a non-issue when running at slower speeds. Resonant Frequency Another problem that typically arises is the resonant frequency of the system. If a motor is run at the systems resonant frequency, many components of the system can be damaged because of excessive vibration. However, once this frequency is known, the VFD can be programmed to skip the resonant area during operation. Switching Frequency he switching frequency of a drive is another area for concern. When the frequency is too fast, voltage overshoot will occur. his overshoot is a result of the capacitance of the motor charging and discharging at a rate that is diferent from the drive. his large voltage spike experienced by the motor in a short time period can cause an uneven distribution of voltage in the windings. When a motor is repeatedly exposed to overshoot, it is normally seen in the irst few turns of the windings ater failure.
Figure 1. Flow rates at different motor speeds www.pump-zone.com PUMPS & SYSTEMS
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Motors & Drives
Connections he cables between the VFD and motor should also be considered. When a mismatch in impedances happens, relections occur in the lines that add with the nominal voltage signal sent to the motor. his phenomenon can be intensiied by the switching frequency of the drive. Startup Several downsides exist when starting an induction motor on full line voltage. Large magnetic ields are created that lead to movement in the motors windings while large inrush currents cause rapid heating. he movement of the windings can eventually lead to abraded insulation and shorted conductors. he rapid heating becomes an issue because the windings expand faster than the stator core, leading to eventual insulation damage. VFDs reduce this extreme mechanical stress by ramping up the frequency and voltage to bring the motor to operating speed, which lowers the motors inrush current. High-Frequency Voltage A common issue seen with VFD usage is an induced, high-frequency voltage in the motors rotor assembly. hese voltages, typically referred to in the industry as shat currents, wreak havoc on bearings. Once the bearings lubrication insulation breaks down, the voltage has a path to ground, which results in premature failure. One way to combat this issue is using insulated bearings. Insulated bearings work just as the name implies. hey are insulated from the motor with a non-conductive material that removes the ground path for the damaging currents. If the motor is coupled to any other devices (such as pumps and gearboxes), the shat currents can discharge through their bearings. A preventive measure in that scenario
would be a shat grounding ring. A shat grounding ring is normally attached to the motor and uses carbon brushes that contact the rotating shat of the motor. he brushes provide a path for the shat currents to dissipate through while protecting all the equipment within the system.
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Harmonics, Surge & Power Factor Line ilters or terminators are another component used to reduce harmonics and surge voltages, correct power factor, and improve the overall power quality delivered to the motor. Line ilters greatly reduce relections and voltage spikes that lead to winding failure. hey also mitigate common mode voltages that drive shat currents. SAMPLE SYSTEMS Looking at the hypothetical graph in Figure 1, a low rate of approximately 125 gallons per minute (gpm) is obtainable at Points A or B. Point A is the pump low at normal motor speed, and Point B marks the low at a reduced motor speed. Using a lower pump speed reduces the current draw and load placed on the pumping compoTable 1. A pump operating at full speed 75 percent of the time nents while delivering the same low as the higher pressure setting. and at 85 percent of rated speed the remaining 25 percent Suppose an end user has a 20-horsepower motor running the pump used in Figure 1. Assume that the pump runs at a full speed 75 percent of the time and is operating at 85 percent of its rated speed the remaining 25 percent of the time. In this case (see Table 1), the VFD is not being optimized for best economic impact. Now, assume that the same motor is operating at 90 percent of rated speed for 75 percent of its operation time and at 75 percent of rated speed the remaining time (see Table 2). In this example, a $671.64 energy savings is achieved. If the example shown in Table 2 is applied to a 50-horsepower motor, the energy savings is even more pronounced (see Table 3). he bottom line is that VFDs ofer cost savings to the user when prop- Table 2. A pump operating at 90 percent of rated speed for 75 percent of the erly itted to an application. P&S time and at 75 percent of rated speed for the remaining 25 percent
Steve Hauck is a design engineer in the New Product Development group for Nidec Motor Corporations Industrial Motors Division/U.S. Motors. Hauck received his undergraduate degree in electrical engineering from the University of Missouri St. LouisWashington University joint undergraduate engineering program. His current responsibilities include the development of both small and large motor designs. Hauck can be reached at steve.hauck@nidec-motor.com. Timothy Albers is the director of product management and OEM marketing for Nidec Motor Corporations Industrial Motor Division/U.S. Motors. His current responsibilities include product management, marketing and quotation support for the Industrial Motor Division. Albers has held positions in marketing for Nidec Motor Corporation Table 3. Data from a pump operating with a 50-horsepower motor and Emerson Motor Company, including productline manager for NEMA motors. His past experience includes marketing and product development at U.S. Motors/Emerson and marketing and sales in electric motors and drives at General Electric and as a qualiied U.S. Navy operating engineering oficer.
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PUMPS & SYSTEMS
NOTHING GOOD HAPPENS AFTER MIDNIGHT
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2013 Yaskawa America Inc.
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Electric Motor Repair & Reliability

Repetitive motor failures may be caused by a lack of diagnostic or forensic repair information reported to the motor owner.
By Howard W. Penrose, Dreisilker Electric Motors, Inc. series of studies by the Institute of Electrical and Electronics Engineers, Inc. (IEEE) and the Electric Power Research Institute (EPRI) from 1983 until 19951, 2, 3 that covered all industries reported that bearing faults, followed by winding faults, were prevalent (see Figure 1). hese studies, one performed by Advanced Energy4 and another performed by the Electrical Apparatus Service Association (EASA)5 also revealed that repaired motors, in many cases, do not last as long as they should because of poor repair practices. he repetitive failures of these motors may have resulted, in part, because of a lack of diagnostics or forensics reported to the motor owner during the repair process. REPAIR AND COMMUNICATION While many studies and surveys performed through 2013 identify that a good repair will last longer, few have identiied the importance of providing the motor owner with feedback on the possible root causes of the failures. How does the owners maintenance department or the reliability engineers respond to a report of replaced bearings or a rewound stator? Do they respond in a way that prevents the problem from recurring? A signiicant diference between the 2003 and 2013 Motor Diagnostics and Motor Health Studies (MDMH)6 was that in 2003, 56 percent of organizations reported
electricians as the person responsible for electric motors, and only 2 percent were reliability engineers. In 2013, the number shited to 43 percent reliability engineers and 26 percent electricians with a signiicant decrease in mechanical and general maintenance personnel. By deinition, a reliability engineer requires feedback to pursue his trade, meaning that an understanding of the equipment failure including potential root causes and corrective recommendationsbecomes more critical in the repair process. For instance, if the motor failed because the bearings were noisy, what caused them to become noisy? Were they over or under greased? Was the belt experiencing over-tension or misalignment? Was there bearing luting because of shat currents? his information, including recommendations, will assist the motor owner or reliability engineer in developing a plan to mitigate future problems. For example, the bearings in a motor that is operated by VFD are luted (see Image 1). his luting is an indicator of shat currents. Corrective action using a shat brush or a shat brush and insulated bearing should be taken. his also means that either the repair facilitys representative should be asking application questions, and/or the motor owner should be providing that application information. Rewind related failure modes must also be identiied. If the winding has been single phased and that information is not communicated, the failure will likely reoccur.
Figure 1. Comparison of three motor reliability studies
Image 1. Bearing uting caused by shaft currents www.pump-zone.com PUMPS & SYSTEMS
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Motors & Drives
Identifying that the failure occurred would be important, in this instance, because an electronic overload with single-phase protection would mitigate similar failures in the future. If, on the other hand, the winding failed because it was overloaded, the reliability engineer should recommend that the overload protection is also evaluated. REPAIRS IMPACT ON RELIABILITY As noted by the U.S. Department of Energy, Of the quality assurance procedures shops used, 40 percent were repair procedure speciications, 25 percent were test speciications, and 21 percent were EASA standards. Only one of the 65 shops surveyed used any form of quality assurance testing.7 In fact, per the same report, almost half the shops surveyed performed no winding tests during the entire repair. Of the repair shops, 81 percent also reported that they changed winding coniguration in electric motors during the repair process primarily for shop preference or ease of winding (73 percent), 10 percent with the owners knowledge and only 4 percent for the purpose of reliability or durability. he remainder did not provide a reason. Proper repair practices are vital to
the reliability of the repaired electric motor. While the studies primarily focus on energy consumption or eiciency of the machines, the 2013 MDMH identiied a solid 0 percent of interest in energy as a driver for a motor program (only 3 percent in 2003). he key driver for the motor program was reliability (75.5 percent).
Image 2. Overloaded winding PUMPS & SYSTEMS
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Following the reliability perspective and study results, the only reason for modiications from the original manufacturers design must be for improvements to the durability of the machine or engineering modiications to improve the reliability of the application. Modiications to make the repair less expensive or because the repair shop does not maintain the appropriate metric or half-size wire does not beneit the end user and can become expensive in the short term and extremely expensive in the long term. Companies that peen or glue bearing its should be strenuously avoided. Such repairs should only ever be considered to get by while awaiting a replacement with the knowledge that the risk of catastrophic failure is high. Properly maintaining its through testing and machining to tolerance using welding, sleeving or remanufacturing will maintain potential bearing life and decrease friction and windage losses. While these losses relate to energy consumption, they also result in increased operating temperature. Just as with winding insulation life, for every 10 C increase in bearing temperature, the grease life reduces by half. In 1984, David C. Montgomery published a paper that identiied the impacts of core loss increases of 50 percent, 100 percent, 150 percent and 200 percent and related it to temperature rise, resulting insulation life and impact on grease/bearing life based on winding removal processes using high temperatures.8 he machine used in the example was a 50-horsepower, 3,600-rpm, drip-proof motor. He also related that the core loss impact is greater as the motor size increases. % Core Loss Watts/lb Temperature % Potential Approximate % he burnout oven stripping issue of electric Increase Increase Rise Increase Insulation Life Grease Life motors has been a long-standing one. he use of 50 515 7C 62 85 high-temperature stripping results in a limit to 100 1,030 14 C 38 69 the number of times a winding can be rewound, 150 1,545 21 C 24 58 an impact on the mechanical its and sot foot, an 200 2,060 29 C 14 46 increase in associated greenhouse gas emissions Table 1. Impact of core losses because of burnout ovens because of drops in eiciency and community health issues.9 he use of repair processes that involve high-temperature stripping must be carefully considered because it may impact overall system reliability. While the close monitoring of thermal stripping methods is strongly recommended based on the studies, professional societies and trade associations, the number of cores damaged from excessive temperatures is on the rise. If an end user has a motor that has an increase in operating current, then the core is probably damaged. Just the change of an amp of current can cause a signiicant increase in core losses and excessive shims required for alignment, related to frame distortion. Mechanical and induction processes using low temperatures are available that have no negative impact on core losses.10 Testing throughout the repair process is critical and must be recorded. he repairs must also be performed with calibrated equipment. Testing must include:
circle 141 on card or go to psfreeinfo.com June 2013 www.pump-zone.com PUMPS & SYSTEMS
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Phase resistance Insulation resistance High potential testing Surge testing Rotor testing Core loss testing Other tests depending on the type of electric motor A maintenance technician has a success rate of improper installation, resulting in an average life expectancy of a motor installation being about one year because of issues such as loose connections, improper belt tension or alignment. His reliability would be 0.368 (36.8 percent). When this technician is paired with the low reliability repair, the result is (0.05 * 0.368 = R) 0.0184, or a 2 percent chance that the motor will survive the irst year. If, however, a high reliability repair is used, then the result is (0.905 * 0.368 = R) 0.333, or a 33.3 percent chance that the motor will survive the irst year. While an organizations improvement of installation and maintenance is important, a higher quality repair is even more critical in an evolving maintenance department. When considering that the average cost per hour of downtime is $10,000 for critical machines (from both the 2003 and 2013 MDMH studies), the improvement in repair savings can be staggering. P&S
References 1. Albrecht, Appiarius, McCoy, Owen and Sharma, Assessment of the Reliability of Motors in Utility Applications Updated, IEEE Transactions on Energy Conversion, Vol. EC-1, No. 1, March, 1986. 2. Motor Reliability Working Group, Report of Large Motor Reliability Survey of Industrial and Commercial Installations, Part 1, IEEE Transactions on Industry Applications, Vol. 1A-21, No. 4, July/August, 1985. 3. horson and Dalva, A Survey of Faults on Induction Motors in Ofshore Oil Industry, Petrochemical Industry, Gas Terminals, and Oil Reineries, IEEE Transactions on Industry Applications, Vol. 31, No. 5, September/October, 1995. 4. Advanced Energy, Achieving More with Less: Eiciency and Economics of Motor Decision Tools, Advanced Energy, USA, 2006. 5. EASA/AEMT, he Efect of Repair/Rewinding on Motor Eiciency, Electrical Apparatus Service Association, Inc. and Association of Electrical and Mechanical Trades, Inc., USA and UK, 2003. 6. Penrose, Howard W., 2013 Motor Diagnostics and Motor Health Study, motordiagnostics.com, April, 2013. 7. Schueler, Leistner and Douglass, Industrial Motor Repair in the United States, Bonneville Power Administration, USA, 1995. 8. Montgomery, David, he Motor Rewind Issue A New Look, IEEE Transactions on Industry Applications, Vol 1A-20, No. 5, September/October 1984. 9. Penrose, Howard W. and Dreisilker, Leo F., he Mechanical Efects from hermal Stripping Induction Motor Stators, 1997 EIC/ EMCWA Conference Proceedings, IEEE, 1997. 10. Penrose, Howard W. and Dreisilker, Leo F., Evaluation of Induction Warming Stator Cores for Coil Removal, Conference Record of the 2012 International Symposium on Electrical Insulation, IEEE, 2012. Howard W. Penrose, Ph.D., CMRP , is the vice president of Engineering and Reliability Services for Dreisilker Electric Motors, Inc.; the webmaster for the IEEE Dielectrics and Electrical Insulation Society; and the outreach director for the Society for Maintenance and Reliability Professionals, Inc. He can be contacted at hpenrose@dreisilker.com.
Mechanical tests must be performed with calibrated measuring instruments. Running tests should include voltage, current, vibration and audible tests. With the low cost of digital memory, digital photos of the motor should be taken when it is received by the repair shop and prior to shipping, at a minimum. Unusual faults should be photographed and provided in a inal report along with any data required by the reliability engineers, as appropriate. It is also recommended that forensic analysis and root-cause failure analysis be performed with input by the end user and repair facility when critical machines fail or if repeat failures occur. INSTALLATION CONSIDERATIONS Some end users ask, Why should I have a Cadillac repair when I have Yugo mechanics? Meaning, what is the point of having a reliable repair when the machine is going to be misaligned, miss-tensioned or have other issues? One simple answer, which is not even buried in reliability or industrial engineering, should be given: two unreliable systems create an even more unreliable system. A combination of poor reliable installation with reliable repairs will increase the reliability of the system. In efect, a highly robust repair can result in a system that is better able to withstand poorly applied or installed motors. CASE STUDY A low-quality repair has a poor bearing installation and a damaged core. Instead of a motor that would last 10 years (120 months), the end user has a motor that lasts about six months. When applied to the reliability formula (Equation 1), the result is a reliability of 0.905 (90.5 percent chance of surviving the irst year) for a reliable repair example and 0.05 (5 percent) for the low-quality repaired motor. (Equation 1) R = e-t Where: = 1/Mean time between failure (MTBF) t = Time in months
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PUMPS & SYSTEMS
EQP Global Motor
VTX Vertical Hollow Shaft Motor
ONE CALL. ONE SOLUTION.

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The Toshiba EQP Global low voltage motor product line is designed to perform beyond the competitive demands of severe duty pumping applications. Building on over 20 years of success with our EQPIII motor series, the EQP Global line features multiple new design enhancements that make it one of the lowest cost-ofownership products in the industry.
Toshiba would like to thank our distribution network, pump OEMs, and end-users for your unwavering support as we continue to experience unprecedented growth and associated challenges.
Introducing the Toshiba VTX

The Toshiba VTX Vertical Hollow Shaft medium voltage motor is Toshibas latest innovation for the pumping industry. Featuring a self-cooled thrust bearing that uses proven thermal siphon technology, the VTX is built to withstand even the toughest upstream geothermal pumping applications. circle 117 on card or go to psfreeinfo.com
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toshiba.com/motors
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VFDs Save Energy in Pump Applications

Using variable frequency drives provides many beneits to end users.
By Tom Neuberger, Eaton
Head or Pressure (ft)
ccording to the Department of Energy, motor-driven can connect to rotating equipment such as pumps, fans and equipmentsuch as pumps, fans and compressors machinery. he limitation of the induction motor is that it consume about 16 percent of the energy used in U.S. can only rotate at a speed comparable to the frequency of industrial applications, amounting to $30 billion spent the AC power provided. annually. For variable torque applications, installing a he AC VFD signiicantly changed the way that AC variable frequency drive (VFD) with the latest motor induction motors could be used by providing an eicient, control technology is a simple and cost-efective way to electronic way to vary the frequency of the supply current, achieve signiicant energy savings. Whether moving air or which then varied the speed of the motor. Early on, VFDs water, or controlling production speed, the ability to match were used in process control for manufacturing synthetic the speed of the motor or Graph C Graph A Graph B pump to the desired output can reduce energy consumpPower or Energy Flow or Pressure or tion and save on costs and Consumption (%) Volume (%) Head (%) resources. Energy and the associated cost savings are the main Speed (%) Speed (%) Speed (%) motives for using VFDs. When a drive is applied to a 2 3 Head1 RPM1 RPM1 RPM1 Power1 Flow1 fan or pump, the return on = = = Power2 Flow2 Head2 RPM2 RPM2 RPM2 investment can be realized in as few as three to four Figure 1. The afnity laws 1. Flow / volume varies linearly with speed. (Graph A) months. 2. Pressure / head varies as a square of the speed. (Graph B) VFDs are designed to 3. Power or energy consumption varies as a cube of the speed. (Graph C) provide variable speed control. hey maintain the 180 optimal speed required for an application to enhance proSystem Curve 160 duction and save energy. Low- and medium-voltage drives gradually accelerate and decelerate motors and pumps, 140 helping protect mechanical components and extend their 120 life, while reducing inrush currents, which helps save 100 energy. VFDs are used in a broad range of industries and Friction Head applicationsincluding HVAC, water and wastewater, 80 and oil and gas.
60 40 20 0 0 40 Static Head or Lift 80 120 160 200
HISTORY OF VFDS AC induction motors were developed in the late 1800s, using polyphase electrical current to develop a rotating magnetic ield. he rotor of the alternating current (AC) induction motor follows the rotating magnetic ield and
Flow Rate (gpm)
Figure 2. Elements of a system curve
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PUMPS & SYSTEMS
Motors & Drives
iber, steel bars and aluminum foil. VFDs improved process performance and reduced maintenance costs. As a result, they were used to replace motor generator sets and direct current (DC) drives. Later, during the 1970s energy crisis, saving energy was crucial. VFDs were increasingly tapped to help reduce energy consumption in large pump applications and eventually in HVAC fan systems. VFDs are a critical component of motor speed control. hey improve eiciency, reduce wear on mechanical components and improve system performance. Fundamentally, they are used to control the frequency and voltage supply to the motor and match the applications speed requirements. THE AFFINITY LAWS he ainity laws can determine the system performance for centrifugal devices, deining both theoretical load requirements and possible energy savings. he three ainity laws are shown in Figure 1. Determining the system curve (see Figure 2) is important to select the proper system pump. his curve describes what low will occur given a speciic pressure. Static head or lit and friction head need to be deined. Static head/lit is the height that the luid must be lited from the source to the outlet. Friction head is the power required to overcome losses caused by the low of luid in the piping, valves, bends and other devices in the system. hese losses are low-dependent and are nonlinear. In Figure 2, the system curve and pump performance curve intersect at the desired operating point of 120 feet of pressure and 160 gallons per minute of low. he system will have a single operating point unless a device is added, and a pumping application rarely requires the pump to produce maximum low.
PUMPS & SYSTEMS
VFDS VERSUS THROTTLING DEVICES A mechanical throttling device is oten used to limit low. his is an efective control method. However, it wastes both mechanical and electrical energy. Energy use with a throttling device is shown in Figure 5. he lower curve shows energy use with a VFD. Since VFDs adjust the frequency
and
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of an AC motor, low and energy consumption are reduced. he green shaded area shows the energy saved. A throttling device is typically used as a mechanical way to reduce the low rate in a pumping system. Applying a throttling device to the system changes the system curve (see Figure 3). he throttling device reduces the low of the system, yet the pump curve is not changed. his wastes energy and creates mechanical stress. Since the pump operates at full speed, a tremendous amount of energy is used. Also, mechanical stresses on the pump system can prematurely result in seal or bearing failures. THE ADDITION OF VFDS VFDs electronically control power supplied to the motor, closely matching power requirements to produce a speciied low. his is similar to using a new pump with a smaller impeller. To see the energy savings with VFD technology, Figure 7 combines Figure 4 and Figure 6. he blue shaded area demonstrates the resulting energy savings realized by using a VFD instead of a throttling device. By using VFDs, additional cost savings can be realized because fewer components are needed for valve control. With a throttling control system, losses occur in the valve, and additional piping is needed to bring the valve to a height at which it can be adjusted. Because of these losses and the internal pump loss, to obtain a head equivalent to 50 horsepower, an equivalent of a 90 horsepower pump and a 100 horsepower motor is required. With a VFD, no valve or pipe losses occur because of bends or additional piping, reducing the piping losses to 8 horsepower. With the reduction of these losses, a smaller pump can be used with lower losses. For the same equivalent of 50 horsepower of head, only a 68 horsepower pump and a 75 horsepower motor are required. his results in a substantial system cost and installation savings, economically justifying the VFD. ENERGY SAVINGS & EXTENDED EQUIPMENT LIFE By matching power consumption to changing system requirements, VFDs are relied upon to provide steady, eicient power for variable speed pump applications. VFDs protect motor and pump assets by controlling power and minimizing the mechanical stress caused by starting and stopping the pumps. he latest generation of VFDs is more eicient, accurate and reinedleading to increased energy savings. New and sophisticated technologies are impacting eiciency.
Valve
kW Meter
VFD kW Meter
Figure 3. A pumping system using a mechanical throttling valve and the same system using a VFD
180 160 Head or Pressure (ft) 140 120 100 80 60 40 20 0 0 40
Pump Performance Curve at Full Speed Required hp at Full Speed System Curve (Throttling Device)
80
120
160
200
Flow Rate (gpm) Figure 4. System characteristics using a mechanical throttling device. The energy consumed is represented by the blue shaded area.
100 Power Consumption (%) 80 60 40 20 0 0 20 40 60 80 100 Flow (%)

Figure 5. The amount of energy saved by using a variable frequency drive versus a valve to control ow
Throttling Device
Energy Savings
VFD
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Motors & Drives
Speciically, advancements in capacitors and DC link reactors, insulated-gate bipolar transistors, heat management, processing power and measuring technology enable the development of solutions to problems that were not recognized earlier. Additionally, new and advanced algorithms afect energy eiciency. P&S
180 160 Head or Pressure (ft) 140 System Curve
Tom Neuberger is a product manager at Eaton in Menomonee Falls, Wis. For additional information, he can be reached at TomRNeuberger@Eaton.com.
180 160 Head or Pressure (ft) 140 120 100 80 60 40 20 0 0 40 80 Required hp at Reduced Speed Required hp at Full Speed
120 100 80 60 40 20 0 0 40 80 120 Required hp at Reduced Speed
Pump Performance Curve at Full Speed System Curve (Throttling Device) System Curve Pump Performance Curve at Reduced Speed (VFD)
Pump Performance Curve at Reduced Speed (VFD)
160
200
Flow Rate (gpm)
120
160
200
Figure 6. The pump curve and the energy used with VFD control; note that the pressure is also reduced, helping reduce the mechanical stresses that are created with throttling devices.
Flow Rate (gpm)
Figure 7. The resulting energy saved by replacing a throttling device with a VFD
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EASA Convention
June 30 July 2, 2013 Mandalay Bay Resort and Casino Las Vegas, Nev.
he Electrical Apparatus Service Association, Inc., (EASA) is an international trade organization of more than 1,900 electromechanical sales and service irms in 59 countries. he EASA Convention is an annual event for electrical industry professionals. his year, the three-day event will be held in Las Vegas, Nev. EASA provides an opportunity for manufacturers and end users of motors and drives to network. Attendees have access to technical sessions and opportunities for optional service center tours. Many electrical apparatus will also be on display during the event, and attendees will be informed about recent updates and changes in the industry.
he event features educational sessions presented by industry professionals that provide an overview on failure analysis and information on restructuring sales organizations. Last year, almost 550 service centers were represented at the exhibition. Young researchers will also have the opportunity to share their research papers with international industry professionals during the event. For more information, visit www.easa.com. Exhibition Hours Sunday, June 30 1 p.m. 4:30 p.m. Monday, July 1 Noon 4 p.m. Tuesday, July 2 9 a.m. Noon
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Severely eroded suction bowl Photo courtesy of Hydro Inc. PUMPS & SYSTEMS
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Reverse Engineering of a Vertical Pump Suction Bowl

The pump was returned to service at a nuclear power plant after reverse engineering of an unavailable part and complete pump testing.
By Jeff Smith, Hydro Parts Solutions Inc., & Dr. T. Ravisundar & Werner Barnard, HydroAire Inc.
he population of industrial pumps is aging. An article from Pumps & Systems August 2012 issue chronicled the repair of an 82-year old pump still in service in a major reinery. Like this reinery, many industrial operations use pumps that have been in service 30 to 50 years or more. his article presents a case study of a recently refurbished vertical pump. he case study demonstrates how the problem of an unavailable, critical part was overcome through reverse engineering. It also shares the lessons learned and how to develop a strategy to overcome part shortages for old or obsolete pumping equipment. CRITICAL PART SHORTAGE IDENTIFIED A single-stage, vertical pump in a service water application was sent for repair by a nuclear power plant to a qualiied, independent pump service and engineering provider. A thorough inspection was performed. Although several important parts had to be reverse engineered and manufactured, all but one were machined parts for which raw material was available. One large cast part, a large aluminum bronze suction bowl weighing more than 500 pounds, was identiied as the critical delivery issue. MODERN TECHNOLOGY APPLIED he independent service provider had a skilled, in-house engineering team that used process control procedures for reverse engineering under its Nuclear Procurement Issues Committee (NUPIC) audited quality assurance program. his service organization understands that reverse engineering is not the same as replicating. he service centers engineering team evaluated the
critical characteristics of the component, which is an essential step in developing a replacement part that will meet the same form, it and function as the original. he engineers started the process by producing a 3-D model and a 2-D drawing of the suction bowl, capturing the parts geometry with the aid of a state-of-the-art coordinate measurement machine (CMM). he portable CMM, with a seven-axis articulation and equipped with both contact and non-contact (laser) probes, enabled the engineers to quickly capture the dimensions of the suction bowl with high precision. To address the missing geometry of the eroded vanes, an engineering analysis
Solidication simulation Image courtesy of Hydro Parts Solutions Inc., a Hydro Company PUMPS & SYSTEMS www.pump-zone.com June 2013
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was performed to reconstruct the original geometry. With this information, a 3-D model was created. In addition to measuring the geometry of the part, all the critical characteristicssuch as hardness, chemical composition, surface inish, its and toleranceswere evaluated. he reverse engineered data of the bowls hydraulic passageways was then thoroughly reviewed. his included vane-to-vane distance, vane curvature from the leading edge to the trailing edge, hub and shroud curvature, vane thickness distribution, and all other critical dimensions. he hydraulic contours of the 3-D model were then smoothed without signiicantly afecting the original geometry, and the vane thickness distribution was made uniform. he 3-D model developed for the casting was completed by adding machining allowances for bores, lange outer diameters and faces. Once the 3-D model for the casting was complete, the service providers engineers worked with a reliable foundry known for producing excellent aluminum bronze castings to develop a manufacturing
Typical sand-printed core Image courtesy of Hydro Parts Solutions Inc., a Hydro Company
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and quality plan to cast the replacement suction bowl. With a thorough understanding of the latest rapid casting processes, the engineering team created a casting plan that included a layout for the risers, gates, runners, sprue and other mold package details. his plan was engineered using solidiication simulation sotware so the engineers could determine the optimal layout for the mold package. A well-designed mold package reduced the risk of a failed casting and maintained the rebuild schedule. Once the casting plan was complete, the 3-D model was used to make a large, sand-printed mold package. he mold package consisted of several mold pieces and a large core for creating the intricate details within the bowl. his modern technology allowed the service provider to produce a successful casting in a timely manner without a hard pattern or core box. INSPECTION AND TESTING he cast suction bowl was sent to the service center for inspection by the quality assurance team. he chemical and physical characteristics were analyzed and found to be within the American Society for Testing and Materials (ASTM) ranges. It was also observed that the castings surface inish and dimensional accuracy was superior to that of conventional castings for the given material. he service centers engineering team proceeded with a part comparison to ensure equivalency. Using a CMM, a 3-D model was created with the cast part and overlaid onto the 3-D model of the reverse engineered suction bowl. In Figure 1, the yellow area shows the reverse engineered model. he blue area shows the cast bowl model. he overlapping surfaces of both models conirm the conformance of the geometry of the cast bowl to the geometry of the reverse engineered bowl. Any observed deviations from the geometry of the reverse engineered bowl were determined to be negligible and were far less than the deviations that typically occur in conventional castings. Furthermore, the
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critical hydraulic dimensions on every vane passage were conirmed to be correct and uniform to ensure hydraulic performance and operational stability. he suction bowl was inish machined, and ater passing
Figure 1. Comparison of 3-D models Image courtesy of Hydro Inc.
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another inspection by the quality assurance team, the vertical pump was rebuilt using the proper assembly procedures. he completed pump was then performance tested at the service providers independent test lab. he test results conirmed that the pump performed with improved eiciency, and it proved the integrity of the reverse engineered part. he nuclear power plant accepted the certiied test report and returned the vertical pump to safety-related service. A STRATEGY FOR DIFFICULT-TO-SOURCE PARTS As this case study clearly demonstrates, the ability to reverse engineer and manufacture major pump components, especially cast components, coupled with the experience necessary to repair and performance test those pumps, has proven to be an efective way to extend the life of older pumps. Adopting this concept as a strategy requires that end users and operators establish these steps as part of their long-term supply stream and fund the personnel and systems necessary to put the strategy on a successful path. Critical steps are: Evaluate the facilitys pump population by age and by OEM. Determine which pumps (age and OEM) are still supported with spare parts availability by the OEM. hree groups will likely emerge. Group 1 will be pumps still supported by inventory that is available for immediate delivery. Group 2 will be pumps that are not supported by inventory but are supported by drawings and patterns (if needed). Group 3 will be pumps that are no longer supported. While Group 3 may appear to be the highest area of concern, Group 2 is also a problem because the lead-time needed to manufacture spare parts may exceed the lead-time that supports end users operations. Adding Group 3 to Group 2 pumps that have a clear lead-time problem would create a group labeled unsupported pumps. Identify the unsupported pumps in the group of critical pumps. his allows end users to set priorities since, usually, a facility cannot focus on all pumps.
Bronze suction bowl on horizontal boring mill Photo courtesy of Hydro Inc.
Performance test for an Ingersoll Rand vertical service water pump Photo courtesy of Hydro Inc. www.pump-zone.com PUMPS & SYSTEMS
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The ability to reverse engineer and manufacture major pump components, especially cast components, coupled with the experience necessary to repair and performance test those pumps has proven to be an effective way to extend the life of older pumps.
Identify the existing inventory of parts related to the unsupported pump population and immediately begin a reverse engineering program for these parts before the last part is used. Reverse engineering could be conducted internally or by using qualied external resources. Make sure that parts are reverse engineered during routine maintenance events, while they are available and before they go back into the pump. hese steps will not solve all problems. At some point, new pumps must be introduced into the system and old pumps must be removed. However, an active program to extend the life of the current pump population will save signiicant amounts of money. P&S
Jeff Smith joined Hydros pump service organization in 2012 as president of Hydro Parts Solutions Inc., a company created to support the pump aftermarket with its parts needssuch as dificultto-source impellers, diffusers, , discharge heads, casings, bowls and suction bells. Smith can be reached at jsmith@hydroinc.com or 281-415-8612. With a Ph.D. in luid dynamics, Dr. T. Ravisundar provides engineering support to Hydros global network of pump service centers. With a BSC in metallurgical engineering, Werner Barnard plays a major role in supporting Hydros reverse engineering processes and pump parts program.
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Root Cause Analysis & Problem Solving

Basic solutions that limit the involvement of a slowly dwindling staff are ideal in todays workplace.
By Chris Eckert, Sologic
t seems strange to be thankful for problems. However, solving problems is what maintenance professionals are paid to do. Whether it is inding ways to make a facility run more reliably, designing a structure with limited time and money, or managing a group of 75 employees, each day the average employee is faced with multiple problems that must be resolved. hose who are successful at solving problems are usually successful in their careers. While not new, the strategies that successful people use to solve todays problems are changing.
DOING MORE WITH LESS A dynamic in the new industry reality is the change of pace at which improvements and problem solving is expected to occur. Another is the rate at which the resources available to solve them are becoming harder to secure, especially human resources. Do more with less is now business as usual. Increasingly, the strategies that delivered yesterdays solutions are not working as well, or they are becoming more diicult to implement. As an engineer on the front lines at a large chemical manufacturing company 25 years ago, I had many internal experts available to help with the challenges I faced. I had no idea how lucky I was. If I needed to know the best alloy to use in a hot, high-pressure, caustic environment, or the most efective way to execute a specialized weld repair outdoors in -20 F temperatures, all I had to do was walk down the hall or, at most, make a phone call. I normally had my Figure 1. Fan failure basic cause-and-effect chart answer in minutes or hours.
Because of this, my solutions were expert- and skill-centric. I had many bright and talented people who were available to help, so I used them and their skills to crat my solutions. Today, while people are just as bright and talented in the workforce, less of them are employed. hose who are still in place have less time to help. Accordingly, ones ability to access the right skills and expertise has been reduced. Also, fewer people are available to ill the slots where problem solving occurs most efectivelyon the front line. When problems are solved at lower levels, they do not grow into larger problems. Because front-line employees are picking up more work that was previously covered by other staf members, their expertise and experience is spread thinner. Another issue is that more time is spent in meetings. he disappearance of skilled trades and technical experts as more baby boomers retire and strategies to combat this drain have been chronicled by maintenance and reliability expert Bob Williamson for the last few years.1 If this trend continues, what does it mean for tomorrows solutions? In short, many good solutions are still available.
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In increasingly more situations, the strategies that delivered yesterdays solutions are not working as well, or they are becoming more dificult to implement.
If maintenance professionals are documenting the causes of their problems, they have options. However, they will be looking at and attacking diferent causes than they did a few years ago. With decreasing numbers of skilled cratspeople and experts, maintenance and repair professionals must now look for lasting and robust solutions that rely less on people and more on systems, hardware and automation. his trend has been growing for years. However, now it should be one of maintenance professionals irst considerations. Solutions that begin with Create new procedure, Implement new preventive maintenance (PM), Stress the importance of.. are increasingly less efective and should be avoided if possible. One major reason is that, progressively, these types of tasks are not being accomplished. CASE STUDY As an example of how solution strategies change, consider a problem from the past. A large, multi-belt-driven centrifugal fan using pillow block bearings to support the of-hung fan wheel experienced repeat bearing and belt failures, which resulted in signiicant downtime. Because of the relatively high speed and operational loads, the bearings were already heavily loaded and had experienced prior lubrication failures. he installation and tensioning of belts is critical. Too much tension results in additional radial bearing load and accelerates failure. If too
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little belt tension is applied, the belts slip, resulting in premature belt failure. Figure 1 illustrates a basic cause-andefect chart. Note: Transitory causes in Figure 1 are related to changes and are oten the result of forces applied, movements, actions, decisions, etc. Non-transitory causes are related to the status, properties and conditions of objects or the operating environment at the time the change takes place. he past solutions were: Assure that the bearings were of the proper speed/load rating. Work with a lube technician to implement new PM to grease the bearings on a specic interval with specic volumes. Work with the machinists to deploy a written and specic procedure for initial belt tensioning with a follow-up re-tension after run-in. Today, when faced with the same problem, the same solutions should not be implemented. First, the maintenance professional should go back to the cause-and-efect chart and drill deeper (see Figure 2). He/she should look for additional causes that can be attacked with solutions. Regardless of where a solution is placed, once a cause is eliminated, it breaks the causal chain and prevents the causes on the let side of Figure 2 from occurring. his prevents the high-level problemin this case, unplanned fan failure from recurring. In many cases, attacking non-transitory
causes can eliminate the need for precision work or skills, and it usually eliminates the need for a procedure. Solving a non-transitory problem usually involves a capital solution. However, when weighed against ongoing, repetitive repair costs and lost production/downtime costs, it is usually a wise decisionespecially in todays work environment. Maintenance professionals should seek solutions that do not add new tasks or PM, but instead eliminate them. hey should also look for solutions that could be successfully completed with general skills instead of precision skills. his is by no means an indictment of the current maintenance department employee base, because many highly skilled people work in these departments. Instead, it is a conservative approach in anticipation of a future in which skilled trades could possibly be even less available than now. A good solution solves the problems of today, and it anticipates changes that could occur in the future. In this case, a better solution would be eliminating the belt drive altogether and replacing it with a direct-coupled, inline drive system. Radial loads would be limited to the operational loads, because belt loads would be eliminated entirely. Because the belts would be eliminated, this historical failure mode would also be eliminated. Some work would be required to the fan drive base, so the repair/maintenance team should take the opportunity to improve the bearing life and reliability by replacing the two independent, pillow block bearings with a single, two-bearing tunnel housing (see Figure 3). 2 his system automatically aligns the bearings and would
Figure 2. Fan failure expanded cause-and-effect chart
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MAINTENANCE MINDERS
Regardless of where a solution is placed, once a cause is eliminated, it breaks the causal chain and prevents the causes to the left from occurring.
be simpler and faster for the mechanics to install while still being capable of handling the fans relatively high speeds and operational loads. With these changes, repairs and future maintenance would be simpliied and would move more toward error-prooing the installation. hese changes would eliminate multiple failure modesresulting in improved reliabilityand would reduce fan failures, the overall objective. a universitys curricula guide, the advisory board members know that one of the greatest needs they have for adding bottom-line value in todays market is efective problemsolving skills. If maintenance professionals evaluate their current strategies for solving problems, they should consider a slightly new bag of tricksone that explores solutions that are less people-dependent. he good news is that these solutions will emerge from the non-transitory causes on the causeand-efect chart that can be determined by drilling deeper. hese solutions should have the staying power needed, regardless of what happens in the future. P&S
SOLUTIONS FOR THE FUTURE he need to improve problem solving approaches is growing. For the past few years, I have served as an advisory board member for the Industrial Technology Department at a nearby university. Many of the board members are from References 1. Bob Williamson, Is the Skill Shortage Real? 2013, www.swspitcrew. manufacturing companies, many of which supply the auto com/articles/articles.asp?ID=167 & Growing Your Own, 2010, www.swspitcrew.com/articles/articles.asp?ID=140 industry. At a past meeting, the faculty chair asked the board, What skills do you need most from our graduates 2. SKF, secure.skf.com/group/products/bearings-units-housings/ bearing-units/two-bearing-units/index.html now and in the future? Better problem-solving skills, was the irst response. I do Chris Eckert is president of Sologic, LLC, a provider of root not believe that this answer is what the faculty expected or cause analysis training, software and investigations. Eckert wanted to hear. he faculty chair looked perplexed and then is a professional engineering, certiied maintenance and reliability professional. He was formerly a reliability engineer asked about the need for advanced computer aided design/ with Dow Chemical and Rohm and Haas. He can be reached computer aided manufacturing, robotics and 3-D modeling at chris.eckert@sologic.com or 989-835-3402. capabilities. A diferent board members response was, We will teach them the speciics of the given technology once they arrive at our company. he technology is changing so fast that you cannot keep up, nor do you need to. However, we do not have time to teach new engineers and technologists how to think. hat is what we need most. he remainder of the advisory board nodded in agreement. While cutting-edge courses such as 3-D modeling look and sound exciting in Figure 3. Improved bearing installation Image courtesy of SKF
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EFFICIENCY MATTERS
ATEX: The Symbol of Safety in Dangerous Chemicals Handling

Safety-conscious chemical companies are making ATEX-certiied pumps and equipment mandatory in their day-to-day operations.
By Edison Brito egislation and regulations have been implemented in the chemical industry as a direct result of accidents that could have been prevented if companies had followed necessary safety precautions. his includes the classiication, labeling and packaging of chemicals that could potentially pose a threat. For example, in 1967, the Dangerous Substances Directive (67/548/EEC) was passed, and its orangeand-black hazardous substance symbols became instantly recognizable to anyone in the world who was handling these hazardous chemicalsanything from basic cleaning products to acids. However, this applied to Europe only, and as a result, the United Nations Globally Harmonized System of Classiication and Labeling of Chemicals (GHS) was created in 1992 and standardized by 2000. In Europe, the most important legislation introduced in recent years has been Registration, Evaluation, Authorization and Restriction of Chemicalsbetter known as REACH. Implemented in June 2007 by the European Union, REACH replaced 40 existing directives. here are 73 substances on the Substance of Very High Concern (SVHC) candidate list. he regulation puts greater responsibility on the industry to manage the risks of chemicals and provide safety information on the substances. However, REACH remains a work in progress. One other way that the chemical industry is creating a safer environment is through certiications. Equipment must meet certain standards to gain certiication and must be considered safe to handle known dangerous chemicals such as acids, solvents and caustics. In the past, the CE symbol was the recognized symbol for safety. Since 1993, the CE mark has been a mandatory conformity marking for products sold in the European Economic Area. he CE mark indicates that a product conforms to essential health and safety requirements set in European Directives. In recent years, one symbol has joined CE as a trusted symbol of safety: Ex, better known as ATEX.
ATEX he ATEX directive is meant to protect employees and the surrounding communities from the risk of explosions. Deriving its title from the French Appareils destins tre utiliss en ATmosphres EXplosives, ATEX consists of two European Union directives: one for the manufacturer (ATEX 95 equipment directive 94/9/EC) and one for the end user (ATEX 137 workplace directive 99/92/EC). In July 2003, the EU made the following ATEX directives mandatory for organizations within the EU. Equipment in use before July 2003 can still be used, although a risk assessment showing that the equipment is safe is required. Equipment that is capable of causing an explosion through the equipments own potential sources of ignition falls under this mandate. Examples of these types of equipment are any machine, apparatus, ixed or mobile device, control component and instrumentation intended for the generation, transfer, storage, measurement and conversion of energy and/or processing of material. Hazardous area atmospheres are classiied into zones based on size, location and the likelihood of an explosion. Zones 0, 1 and 2 specify gas-vapor-mist, while zones 20, 21 and 22 specify dust. hese classiications dictate that those properties be protected from sources of ignition. Zones 0 and 20 require Category 1 designationthe highest risk of an explosive atmosphere being present. Other categories are Zones 1 and 21, which fall into Category 2. Zones 2 and 22 require Category 3. ATEX 95 directive 94/9/EC is designed to allow the free trade of ATEX-conformed equipment and protective systems within the EU by removing the need for separate testing and documentation for each member state. he regulation applies to all equipment intended for use in explosive environments, including electrical and mechanical. Equipment aixed with the CE marking and the Ex marking certify that the piece of equipment can be sold anywhere within the EU without further requirements.
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Some of the most common areas in which a potentially explosive atmosphere could exist include ofshore platforms, petrochemical plants and mines. hree preconditions are required for the ATEX directive to apply. First, the equipment should be intended for use in a potentially explosive environment. It should also be under normal atmospheric conditions. Finally, the equipment must have its own efective source of ignition. IGNITION SOURCES he ATEX directive deines an efective ignition source as an event thatin combination with suicient oxygen and fuel in gas, mist, vapor or dust form can cause an explosion. Many ignition sources must be taken into account by end users, including: Lightning strikes Open ames and hot gases Arcs and ashes Electrostatic discharges Electromagnetic waves Ionizing radiation Hot surfaces Mechanically generated sparks Optical radiation Chemical ame irritation Electrostatic discharge, for example, is considered one of the greatest hazards when handling dangerous chemicals. In this process, static electricity is generated by surface friction when chemicals come in contact with other materials. Typically, this occurs when the product is moved or transferred through pipes, ilters, mixers and/or pumps. Static electricity may accumulate in the liquid (liquid hydrocarbons, in particular). his can lead to sparking in a lammable, vapor-air mixture. Ignitable discharges can occur between an insulated or earthed conductive object and a charged, insulated conductive or non-conductive object. Avoiding electrostatic discharge starts with selecting the right equipment to transfer those chemicalsequipment that meets the criteria of the ATEX directive. A PUMPS ROLE IN SAFE CHEMICAL TRANSFER Dr. Georg Baum is the owner of CTB-Chemical Technologies, a Germanybased company that supplies systems and solutions for the safe transfer of hazardous material in chemical plants. As an authority on the subject of safe, ATEX-compliant chemical transfer applications, Dr. Baum stresses three factors when selecting a pump for dangerous-chemical transfer. One important point is the compatibility of the material with the chemical, Dr. Baum said. he second factor is, if we use solvents, for example, we must use the appropriate pump that wont cause an ignition. his means using pumps with electric conductive material. he third factor is suction capability. One pump technology that meets all Baums criteria is ATEX-certiied, solid-body, air-operated double-diaphragm (AODD) pumps, which can be built using conductive plastic materials. his technology ofers the material
PUMPS & SYSTEMS www.pump-zone.com
s low F on ati v o Inn e r e Wh
Safe Solutions For Handling Dangerous

Chemicals
Award-winning Almatec E-Series Plastic AODD pumps provide safe and reliable performance when handling the most dangerous acids, solvents and caustics.
Solid block CNC machining Polyethylene and PTFE materials, conductive also available for explosionproof environments (ATEX) Ring design structure for improved product containment Optional features available (e.g., barrier chamber system) for further safety requirements Dry run ability, self-priming, gentle uid handling, no rotating parts, no shaft seals
Contact your local Almatec representative today.
PSG Euro-Center 22069 Van Buren Street Grand Terrace, CA 92313 USA O: +1 (909) 512-1224 miguel.blanca@psgdover.com World Headquarters Carl-Friedrich-Gau-Str. 5 47475 Kamp-Lintfort, Germany O: +49/2842/961-0 F: +49/2842/961-40 info@almatec.de
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EFFICIENCY MATTERS
compatibility and strong suction that other pump technologies cannot. he many factors to consider when selecting an AODD pump for a dangerous-chemicals application are discussed in this section. Material Compatibility Matching the proper pump to the materials being transferred starts with the housing. Pumps made of polyethylene (PE) have better wear resistance than pumps made of polypropylene (PP), enabling the units to transfer highly abrasive chemicals. Polytetraluoroethylene (PTFE) construction, on the other hand, provides the superior chemical resistance necessary in dangerous-chemical transfer. Operators should also focus on the materials of construction for a pumps internal components. Diaphragms made of ethylene propylene diene monomer (EPDM), PTFE/ EPDM-composite or nitrile rubber (NBR) feature large diameters and short strokes with low lexural loads, which ensure uniform delivery regardless of chemical properties.
Conductive Materials Pumps with non-conductive housing materials are susceptible to electrostatic discharge. Static can accumulate in liquid being moved or transferred through a non-conductive pump, leading to sparking in a lammable, vapor-air mixture. Pumps with conductive PE or PTFE housing are preferred in explosion-proof areas in which lammable liquids are present. hese conductive PE and PTFE housings enable pumps to meet ATEX requirements. Strong Suction (Self Priming) Totes or barrels of chemicals are oten placed at ground level in protective cabinets with pumps located on the top or to the side of these containers. Strong suction is imperative. AODD pumps, by their nature and design, provide suficient suction to draw luids from tanks regardless of location. Other technologies, such as centrifugal pumps, require luid pressure into the impeller to create suction and low. Operators should also consider that AODD pumps ofer superior containment, shear-sensitivity and rundry capabilities over other pump technologies. Solid-Body Construction Solid-plastic-block machining increases the pumps strength and life cycle while eliminating maintenance concerns. A computer numerical control (CNC) machined solid block of PTFE or PE allows the pump to deal with the harshest environments. Plastic injection-molded construction, by comparison, deforms in harsh environments, creating a potential leak path when the temperature variesregardless of how tight the bolts are torqued. However, with solidplastic-block machining, no crevices exist for a potential leak path. It is also more robust, and the integrity of the material is stronger. In addition, CNC technology enables tight tolerances, with reduced vibration and greater stability and durability. Containment Containment is another important consideration when selecting a pump that will efectively handle and transfer dangerous chemicals. Mechanical seals found in centrifugal pumps, progressive cavity pumps and gear pumps can be prone to failure. Seal failure can lead to bearing failure, which results in costly downtime
Figure 1. ATEX 94/9/EG directive requirements
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Robust AODD pump technology meets all the ATEX criteria.

and unscheduled maintenance. he safest way to avoid seal failure and avoid product contamination is by removing the seal from the equation. AODD pumps are free of mechanical seals and are designed so that the diaphragm acts like a seal. When matched with materials that are appropriate to the chemical being pumped, the diaphragm acts as a gasket, which is not subject to wear from shat friction. Run Dry Friction can lead to static discharge, which in turn creates a dangerous environment. When handling chemicals, operators will continue to operate the pumpeven ater the chemical has been depletedto more fully clear the lines. his is known as running dry. When certain pump technologies run dry, their components can burn and seize, creating a dangerous situation when hazardous chemicals are involved. AODD pumps are designed to run dry. When the luid is depleted, they pump air with no damage to the pump internals. Shear Sensitivity Pumps that have a propensity for shearing or damaging the product typically have meshing teeth or introduce the luid to multiple moving parts. When transferring chemicals, providing gentle handling to eliminate any change to the chemical properties is critical. AODD pumps are considered one of the gentlest pumping technologies available because the luid is simply drawn into a chamber and then pushed out without contacting moving parts. Deadheading Many chemical applications require accurate low rates to maintain the consistency and quality of the product. To maintain this consistency, valves on the discharge side of the pump close switly, interrupting the product low. his creates a jolt to the pump, also known as deadheading. AODD pumps are designed to handle such start-and-stop deadhead conditions without any adverse efects to the product or the pump. ROBUST AODD PUMP TECHNOLOGY One robust AODD pump technology meets all the ATEX criteria. his technology features housing constructed of PE, PTFE, PE-conductive material and PTFE-conductive material. he PE-conductive and PTFE-conductive pumps
PUMPS & SYSTEMS
meet the requirements of the ATEX 94/9/EG directive (see Figure 1). For use in device group IIC without additional protection measures, these plastic AODD pumps also feature electrically conductive PTFE diaphragms to provide safer transfer of chemicals while avoiding dangerous electrostatic discharge. hey continue to pump even ater the chemical has been depleted. By comparison, other pumps require operators to pump nitrogen, water or carbon dioxide ater the luid transfer has been completed to avoid potentially dangerous electrostatic discharge. hese plastic AODD pumps pump air with no damage to the pump internals. he pumps diaphragms have a large diameter and short stroke with low lexural load, ensuring uniform delivery regardless of the diaphragms material of construction. he EPDM diaphragms are conductive as standard. hey are available in seven sizes, from 6 to 76 millimeters ( inch to 3 inches), with maximum temperatures to 120 C (248 F). he pumps feature maximum lows to 800 liters per minute (210 gallons per minute); suction lit to 5 meters (16.4 feet), dry, 9.5 meters (31.2 feet), wet; and maximum solids sizes to 15 millimeters (916 inch). CONCLUSION Chemical plants have a great responsibility to take every necessary precaution to protect their employees and the surrounding communities. During the past half-century, legislation has been put in place because of a number of preventable chemical accidents. While adhering to these rules remains mandatory, chemical companies worldwide need to consider installing ATEX-conformed equipment as standard, despite it only being required in the EU. ATEX is widely considered the accepted symbol of safety, and using ATEX-rated pumping equipment can provide operators with the peace of mind they need to work in potentially dangerous environments. P&S
Edison Brito is the director, Global Segment Marketing, Chemical, with Pump Solutions Group (PSG). He can be reached at edison.brito@psgdover.com. Dover Corporations PSG is comprised of several pump brandsincluding Abaque, Almatec, Blackmer, Griswold, Neptune, Maag, Mouvex, Quattrolow and Wilden. For more information, visit www.psgdover.com.
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SEALING SENSE
Improved Torque Tension

How does lubrication affect fastener torque and resultant tension?
By FSA member Dave Hageman
any methods are used to tighten fasteners. he most common is using a hand or impact wrench and mechanics feel. he installer tightens the fastener until it feels tight. While this process is acceptable for noncritical applications, it is unacceptable when greater tension accuracy is required. In more critical situations, the irst thought may be to use a torque wrench. However, what torque should be used, and will the required tension be achieved? his Sealing Sense is intended to help end users choose the best torque to apply for their applications. It will demonstrate the importance of lubrication and describe procedures that provide the required compressive load on a gasket using torque. It will also identify other important considerations for proper assembly. A more comprehensive discussion of the entire assembly process for bolted lange joints can be found in ASME Standard PCC-1-2010. Information provided in this Sealing Sense is consistent with that documents guidelines. A word of caution, torque is not the most accurate way to tension a fastener. he amount of tension achieved from torque is afected by a number of variables. Friction is the most important, and it is diicult to control. High friction results in low tension, and low friction results in high tension. At best, torque tension results will vary in un-lubricated fasteners by +/-25 percent. Using a lubricant can improve this to about +/-15 to 20 percent. IMPORTANT STEPS To ensure the appropriate tightening of fasteners, certain steps should be followed: Determine the tension needed for each fastener. Choose a fastener size and grade with strength that can provide the required tension without being overloaded. Calculate the required torque. Use a calibrated torque wrench. Apply torque correctly to evenly load all the fasteners. Use only through hardened washers.
To determine the tension needed on each fastener, establish the total compressive load required for the application. Divide this by the number of fasteners to ind the tension needed for each. Next, choose the fastener size and grade. In most cases, end users already know the size since the application usually determines the required size. Keep in mind that a inethreaded fastener of a given diameter is able to tolerate a higher load than a coarse thread of the same size. If a load is needed that is higher than a coarse-threaded fastener has the ability to provide, a ine-threaded fastener of the same grade and size can provide more tension and may be able to meet the need. Tables 2 and 3 list common grades, stress areas and maximum loads permitted using U.S. customary and International System of Units (SI) bolts. Never exceed these loads. HOW TO CALCULATE REQUIRED TORQUE A common method of calculating the required target torque uses the formula below: T = (KDF) / 12 Where: T = Torque, foot pounds K = Nut factor (torque coeicient resulting from estimated coeicient of friction) D = Nominal diameter of the bolt, inches F = Tension, pounds
K Values Un-Lubricated Lubricated Un-plated steel fastener 0.2 0.17 Zinc-plated fastener 0.17 0.15 Cadmium-plated fastener 0.15 0.12 Stainless steel fastener 0.3 0.2
Table 1. Nut factors for molybdenum disulde lubricant
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Dividing by 12 gives foot pounds. If inch pounds units are required, do not divide by 12.
SAMPLE TORQUE CALCULATION his example assumes that four -16 bolts must provide a total load of 20,000 pounds. Each step for applying the corOnly K remains an unknown. Table 1 shows the values rect tightening should be followed: available. Keep in mind that K values are all best approxi Step 1Tension needed for each fastener: 20,000 / 4 mations. For a lubricated, un-plated steel fastener, K = fasteners = 5,000 pounds needed for each fastener. 0.17. Step 2he size is -16, which is a -inch nominal diameter fastener with 16 threads per inch. Using herefore: Table 2, a -16, Grade 5 fastener has a maximum T = (0.17 x 0.375 x 5000) / 12 = 27 foot pounds load capacity of 6,510 pounds. his fastener is appropriate for this application. For this example, assume it is an un-plated steel fastener. Step 3Calculate the SIZE DIA. Threads STRESS Grade 2 300 SS Grade 5 B7 Grade 8 Socket Per AREA Head Cap torque. his step can Inch Screws be tricky. Since friction Max Max Max Max Max Max variation will cause tension INCHES SQ INCH LOAD LBS LOAD LBS LOAD LBS LOAD LBS LOAD LBS LOAD LBS variation, controlling the 1/4 0.2500 28 0.0364 1886 1638 3058 3185 3822 4586 friction as much as possible 0.2500 20 0.0318 1647 1431 2671 2783 3339 4007 is important. Lubricants are 5/16 0.3125 24 0.0580 3004 2610 4872 5075 6090 7308 used to do this. hey must 0.3125 18 0.0524 2714 2358 4402 4585 5502 6602 be applied to the threaded 3/8 0.3750 24 0.0878 4548 3951 7375 7683 9219 11063 surfaces of the bolt, the nut 0.3750 16 0.0775 4015 3488 6510 6781 8138 9765 and under the bolt head. 7/16 0.4375 20 0.1187 6149 5342 9971 10386 12464 14956 Many lubricants are avail0.4375 14 0.1063 5506 4784 8929 9301 11162 13394 able, and they do not all 1/2 0.5000 20 0.1599 8283 7196 13432 13991 16790 20147 work the same. Typical 0.5000 13 0.1419 7350 6386 11920 12416 14900 17879 brush-on, thread lubricants are not always the best 9/16 0.5625 18 0.2030 10515 9135 17052 17763 21315 24157 choice. hey are intended 0.5625 12 0.1820 9428 8190 15288 15925 19110 21658 more for facilitating fastener 5/8 0.6250 18 0.2560 13261 11520 21504 22400 26880 30464 removal than controlling 0.6250 11 0.2260 11707 10170 18984 19775 23730 26894 tightening friction. One of 3/4 0.7500 16 0.3730 19321 16785 31332 32638 39165 44387 the lubricants often used 0.7500 10 0.3340 17301 15030 28056 29225 35070 39746 (when it is permitted) is 7/8 0.8750 14 0.5090 26366 22905 42756 44538 53445 60571 molybdenum disulde 0.8750 9 0.4620 23932 20790 38808 40425 48510 54978 grease with an extreme 1 1.0000 14 0.6800 35224 30600 57120 59500 71400 80920 pressure (EP) additive. his 1.0000 12 0.6630 34343 29835 55692 58013 69615 78897 lubricant is used in this 1.0000 8 0.6060 31391 27270 50904 53025 63630 72114 example. 1 1/8 1.1250 12 0.8560 44341 38520 71904 74900 89880 101864 Using the steps above: T = (K x 0.375 x 5,000)/12
1.1250 1 1/4 1.2500 1.2500 7 12 7 0.7630 1.0730 0.9690 39523 55581 50194 34335 48285 43605 64092 90132 81396 66763 93888 84788 80115 112665 101745 90797 127687 115311
Where: D = 0.375 (-inch) F = 5,000 pounds
Chart calculated based on industry standards (ISO, IFI, ASTM etc.)
Table 2. Bolt specications U.S. customary units
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OTHER CONSIDERATIONS Using the methods described so far, end users will know how much torque to apply, but they have more to consider. As they tighten the fasteners, each fasteners load afects the others as each is tightened. To help ensure uniform loading on all the fasteners, they must be brought up evenly by tightening in stages and in a staggered manner. Historically, the star pattern has been used for the tightening sequence. ASME PCC-1-2010 describes this procedure in detail as the Legacy Tightening Sequence/Pattern. As a brief overview, take each fastener to 25 percent, 50 percent, 75 percent and inally 100 percent of the required torque. In the example using the lubricated, un-plated fastener, the end users would take each fastener to 7 (6.75 calculated), 14 (13.7 calculated), 20 (20.25 calculated) and inally, to 27 foot pounds.
CONCLUSIONS Proper fastener loading depends on friction control. For torque to provide predictable and repeatable loading, friction must also be predictable and repeatable. Fastener lubrication is one of the most efective ways to accomplish this. Keep in mind that other factors can afect frictionsuch as corrosion and re-used components. he best practice for critical applications is to use only new, clean and lubricated fasteners and to calculate the torque using the information and formulas described in this article and described in more detail in ASME Standard PCC-1-2010. P&S NEXT MONTH: What should I do about lange face damage: accept, repair or replace?
We invite your suggestions for article topics as well as questions on sealing issues so we can better respond to the needs of the industry. Please direct your suggestions and questions to sealingsensequestions@luidsealing.com.
Metric Course NOMINAL SIZE AND THREAD DEC. PITCH STRESS AREA SQ INCH 0.75 0.5 1.00 0.75 1.25 1.00 1.5 1.25 1.75 1.25 2.0 1.5 2.0 1.5 2.5 1.5 2.5 3.0 2.0 3.0 3.5 0.022 0.025 0.031 0.035 0.057 0.061 0.09 0.095 0.131 0.143 0.178 0.194 0.243 0.259 0.38 0.422 0.447 0.547 0.595 0.711 0.87 METRIC 5.8 Max EQUIV. M5 M5 M6 M6 M8 M8 M10 M10 M12 M12 M14 M14 M16 M16 M20 M20 M22 M24 M24 M27 M30 0.197 0.197 0.236 0.236 0.315 0.315 0.394 0.394 0.472 0.472 0.551 0.551 0.63 0.63 0.787 0.787 0.8661 0.945 0.945 1.063 1.1811 Load Lbs 4634 4090 6265 5611 8440 7489 10714 9606 13512 11928 19687 17629 26865 24384 35890 34993 31985 45180 40271 56633 51144 METRIC 8.8 Max Load Lbs 7394 6526 9996 8952 13465 11949 17095 15326 21558 19031 31410 28126 42863 38905 57263 55831 51031 72084 64252 90357 81599 METRIC 9.8 Max Load Lbs 8021 7080 10843 9711 14607 12963 18544 16626 23386 20645 34074 30511 46497 42204 62118 60565 55358 78196 69700 98019 88518 METRIC 10.9 Max Load Lbs 9268 8181 12530 11221 16879 14979 21429 19212 27023 23857 39374 35257 53730 48769 71781 69986 63969 90359 80542 113266 102288
The following members of the Gasket division sponsored this Sealing Sense: American Falcon, Inc. A.W. Chesterton Co. Barrett Strip and Alloys Daikin America, Inc. Donit Tesnit d.d. EGC Enterprises, Inc. Empak Spirotallic Mexicana SA de CV Gasket Resources, Inc. GFL Americas - Gujarat Fluorochemicals W.L. Gore & Associates, Inc. GrafTech International Holdings, Inc. John Crane Nippon Pillar Corp. of America Sealing Corporation SGL Technic Polycarbon Division Slade, Inc. Teadit International Teijin Aramid USA, Inc. Thermoseal Inc. Triangle Fluid Controls, Ltd. YMT/Inertech, Inc.
Chart calculated based on industry standards (ISO, IFI, ASTM etc.)
Table 3. Bolt specications SI units
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BRINGING THE GLOBAL WATER COMMUNITY TOGETHER

THE LARGEST ANNUAL WATER QUALITY CONFERENCE AND EXHIBITION ON THE PLANET
Covering the full water cycle, WEFTEC is your leading source for research, design, and operation of collection systems, stormwater management, wastewater treatment plants, water reuse and supply, watershed management, and much more. Through the largest annual water quality exhibition, WEFTEC connects operators, managers, consultants, and buyers with more than 900 leading manufacturers and service providers. WEFTEC is the greatest opportunity for the international water community by creating business opportunities for individuals and organizations with global perspectives.
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SAVE THE DATES 30 August Phone, fax, and mail registration deadline 30 August Cancelation/ substitution deadline
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HI PUMP FAQs
Outdoor Installations, Rotodynamic Vertical Pumps & Drooping Head

By The Hydraulic Institute
Q. What is a rotodynamic vertical pump? What pumps are classied in this way? A.
Rotodynamic pumps are kinetic machines in which energy is continuously imparted to the pumped luid by using a rotating impeller, propeller or rotor. he most common types of rotodynamic pumps are centrifugal (radial low), modiied radial low (turbine pumps), mixed low and axial low (propeller pumps). hese pumps, particularly the radial low and modiied radial low types, are usually designed for multistage operation, by bolting or threading individual bowls together. he pumping element (bowl assembly) is usually suspended by a column pipe, which also carries the liquid from the bowl (assembly) to the discharge opening. Figure 2.1.3. Vertical pump typesvertically suspended, single & multistage Rotodynamic vertical pumps (see Figure 2.1.3) are normally classiied as deep well, short set or submersconiguration, such as an electrical motor or engine, driving ible motor-driven. he driver for these pump conigurations through a right-angle gear. is mounted either on the discharge head (lineshat pumps); For more information about rotodynamic vertical directly to the bowl assembly, either above or below (for pumps, see ANSI 2.1-2.2 Rotodynamic (Vertical) Pumps for pumps with submersible motors); or in a horizontal Nomenclature and Deinitions. P&S
Q. What considerations should be made for outdoor rotodynamic pump installations? A. For outdoor installations, the pump components
should be covered with rainproof tarps during installation to protect them from the elements. his is particularly important during freezing conditions to prevent water from collecting in pump cavities and causing freezing damage. he pump and equipment, as shipped, have adequate protection for short-term storage (up to three months) in a covered, dry and ventilated location at the jobsite prior to installation. However, if the equipment will be subjected to extended storage (more than three months), then the standard warranty of the equipment may be afected. In this case, the equipment manufacturer should be advised about the extended storage duration when the pump is speciied and/or ordered so that special, long-term storage protection can be provided before shipment to the jobsite. For pumps that require onsite assembly, a clean, drained area should be provided next to the point of installation. he area should be of adequate size for placing the pump components and driver in the sequence in which they will be installed. Protective covers should be let on all pump
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PUMPS & SYSTEMS
openings until actual installation to prevent dirt and foreign objects from entering the pump. Protective coatings should likewise be let on machined surfaces to prevent rusting. All pumps require regular maintenance. herefore, the location of all pump discharge piping (and suction piping when applicable), auxiliary equipment, and control and starting panels should provide adequate access for maintenance. Suitable loor space and working room should also be provided for repair, including parts placement. To minimize frictional head loss, the pump should be located where it can be installed with a short and direct discharge pipe and with the least number of elbows and
ittings. If practical, it should be placed so that it will be accessible for inspection during operation. In addition, the equipment selected should be compatible with the environment. Pumps and drivers (other than submersible types) and controls should be protected against looding. If ever in doubt, end users should refer to the manufacturers installation, operation and maintenance (IOM) manuals for IOM information speciic to their equipment. For more information on installation considerations for rotodynamic pumps, see ANSI/HI 1.4 Rotodynamic (Centrifugal) Pumps for Manuals Describing Installation, Operation, and Maintenance. P&S
Q. What is droop, and does it affect rotodynamic pump operation? A. Some rotodynamic pump head versus rate-of-low
curves exhibit a characteristic commonly referred to as droop (see Figure 9.6.3.3.8a). A drooping head versus rateof-low curve is one in which the zero rate of low head (shutof head) is lower than the maximum head on the curve. his phenomenon oten occurs in low- to medium-speciic-speed pumps: Speciic speed (Ns) < 68 (Ns < 3,500)
FOOD PROCESSING PUMPS

Cornell Hydro-Transport Food Process pumps are designed and manufactured with the sole purpose of pumping delicate food products. Cornell food pumps have the lowest product damage rates in the industry, are the pump of choice for food processors around the world and were the original Hydro-Transport pump manufacturer.
" ppqxcvkxg"ukping"rqtv"korgnngt"ykvj"q "ugv"xqnwvg " Quality and reliability " Available in sizes ranging from 4 to 12 discharge " Ductile iron, all stainless steel or iron w/ stainless steel impellers " Optional Cycloseal upgrade
COPYRIGHT CORNELL PUMP COMPANY, 2012, ALL RIGHTS RESERVED www.cornellpump.com
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HI PUMP FAQs
hese pumps have been designed to optimize eiciency. Droop does not present an application problem unless one or more of the following conditions exist: he system head curve intersects the pump curve at two or more rates of ow. he pump is operated in parallel with one or more other pumps at a system head that is greater than the pump shuto head. A continuously rising curve is required for control purposes. For example, systems that require pressure control. Applying pumps with drooping head curves in these conditions may cause the pump to be pushed back to shutof or to hunt between two operating points. Neither condition is desirable. In these cases, the allowable operating region may require further limitation and/or appropriate system controls may be implemented. In the absence of any of the above conditions, pumps with drooping head curves can perform as well as pumps with continually rising curves.
Figure 9.6.3.3.8a. Pump head versus rate-of-ow curve illustrating a droop
For more information about rotodynamic pump operating conditions, see ANSI/HI 9.6.3 Rotodynamic (Centrifugal and Vertical) Pumps Guideline for Allowable Operating Region. P&S
Pump FAQs is produced by the Hydraulic Institute (HI) as a service to pump users, contractors, distributors, reps and OEMs. For more information, visit www.pumps.org.
Comprehensive Industry Coverage

Positive Displacement Pumps Centrifugal Pumps Specialty & Other Pumps Industrial Valves Pneumatic & Hydraulic Valves Industrial Automation & Process Control Electric Motors & Drives Actuators Compressors Custom Research White Papers
Frost & Sullivan evaluates and implements effective growth strategies. We employ 50 years of experience in partnering with Global 1000 companies, emerging businesses and the investment community from more than 40 offices on six continents. Visit us at www.frost.com For more information, contact Britni Myers at 210-477-8481 or britni.myers@frost.com
circle 155 on card or go to psfreeinfo.com www.pump-zone.com PUMPS & SYSTEMS
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BUSINESS OF THE BUSINESS
Food & Beverage Industry Pump Market

The total pump market within this segment is steadily growing in the U.S.
By Sakthi Pandian & Anand Gnanamoorthy, Frost & Sullivan
rom increasing raw material costs to changing food consumption patterns, the food and beverage industry has faced a number of changes during the past couple years. he U.S. food and beverage market is one of the largest in the world and contributes more than 14 percent to the countrys total manufacturing output. Additionally, the demand for food products is less susceptible to changes in the economic landscape and was one of the industries least afected by the 2009 economic recession. he manufacturing of processed foods increased as the demand for ready-to-eat home foods rose versus eating at restaurants. An increased sale of frozen food and private labels occurred during the recession because these helped consumers cut down on their household expenses. Although inlation, supply chain management and quality control are some of the major challenges faced by the industry, demand for processed foods continues to drive the food and beverage industry. his increasing processed food industry faces pressure from public agencies and consumers to produce healthy products while maintaining right margins. Nutritious and
organic foods are expected to have a large impact on the industry. To remain competitive, food manufacturers are making headway by taking several positive steps toward the health and wellness trend. Reformulation of products to have high nutritional value, partnering with organizations for health accreditations and adhering to government regulations proactively are a few of the steps being taken. Also, growing concerns about obesity and other heartrelated diseases increased awareness of diet-related food segments. Most manufacturers are revamping their product oferings with a special focus on nutritional content. For example, the salt and sugar content is being reduced in a number of products to become healthy snack options. Increased consumer demand because of these changes is likely to accelerate the growth of this segment into one of the largest in the food and beverage industry. Rising costs have an impact on the industry, but with consumers increasing demand for good food and beverages, they are willing to pay a premium. he food and beverage industry is highly fragmented in the U.S., with an increasing number of mergers and acquisitions taking place. Consolidation, rising costs, changing consumer Prevention Comprehensive, science-based preventive control across the food supply preferences and increasing regu Preventive Controls lations are dramatically chang Safety Standards ing the landscape of the indus Avoid Intentional Contamination try. Innovations and technology Inspection, Compliance and Response will play a key role in successful Necessary for FDA to provide an oversight of facilities, ensure compliance with strategies. As a result, a proactive requirements and respond effectively when needed approach to addressing regula Suspensions of registration Mandatory recall tory issuespaving the path Product Tracing Record Access toward a risk-free businessis Import Safety most important.
FDA has authority to ensure imported foods meet U.S. standards and to deny entry Importers can obtain third party certification from FDA recognized organizations
Enhanced Partnership
FDAs collaboration with other domestic and foreign agencies can facilitate effective work towards achieving public health goals
The four elements of the FSMA
FDAS FOOD SAFETY MODERNIZATION ACT AND ITS INFLUENCE Food manufacturing is complexincluding the equipment design, manufacturing processes,
PUMPS & SYSTEMS
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The total pump market in the U.S. food and beverage industry was estimated at $604.5 million in 2012, which is steadily growing at a compound annual growth rate (CAGR) of 5.9 percent.
packaging and distribution. With numerous concerns from several public bodies regarding food safety, the U.S. Food and Drug Administration (FDA) designed the Food Safety Modernization Act (FSMA) to fortify the existing system. he FSMA is divided into four main elements: Prevention Inspection, compliance and response Import safety Enhanced partnership and actively participating in the FDAs upcoming activities. hese factors hold good for the equipment manufacturers and for those who must adhere to these requirements during product design. he food properties are impacted by the conditions inside the equipmentsuch as shear rate, residence time, temperature history and moisture levelswhich can impact food quality. Some examples in design consideration include the requirement of surfaces in contact with food to be stainless steel, because stainless steel ofers excellent corrosion protection and is not afected by the pH of the food. he hygienic designs should be maintained by minimizing the dead spots and supporting cleaning-in-place/sterilizationin-place (CIP/SIP) requirements.
he ultimate goal is to achieve an impeccably clean and disinfected result under a tight control of costs. he FSMAs primary focus is prevention. To implement preventive controls, the processors are required to evaluate the hazards in their operations and implement and monitor measures to prevent accidental and deliberate contami- PUMP MARKET OUTLOOK nation. hey are also required to have a corrective plan in he total pump market in the U.S. food and beverage induscase of a breach. he FDA ensures the adequacy and proper try was estimated at $604.5 million in 2012, which is steadily implementation of these plans, called Hazard Analysis and growing at a compound annual growth rate (CAGR) of 5.9 Risk-Based Preventive Controls (HARPC), along with a percent. With increasing investment in new expansions and mandatory recall to switly remove contaminated products the revamping of older facilities, pump manufacturers expefrom the market. To maintain an eicient inspection system, rience a constant growth in demand for pumps with sanithe FDA will strengthen its collaboration with many food tary requirements. safety agencies. 7.0 1,000.0 Total Pump Market in Food and Beverage he FSMA has been North America, 2010-2019 CAGR = 5.9% acclaimed as the most com900.0 prehensive food safety law in the last three decades. It places the responsibility on 800.0 manufacturers to enforce its provisions within the speciied 6.0 700.0 compliance dates, which vary from one year to three years based on the size of the facil600.0 ity. Fierce competition and the need to optimize costs require 500.0 manufacturers to take a proactive stand in implementing the system by documenting hazard 5.0 400.0 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 plans for prevention and corNote: All figures are rounded. The base year is 2012. Source: Frost & Sullivan analysis. rective measures, evaluating Pump market overview traceability and recall plans,
Market Size ($ Millions)
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Growth Rate (%)
BUSINESS OF THE BUSINESS
he total pump market for sanitary applications in the food and beverage industry in the U.S. is projected to reach $657 million in 2019. Positive displacement pumps will experience a higher growth rate because of their functional advantages in food processing. hese pumps are beneicial to the shear-sensitive nature of these products because the
low rates can be uniformly controlled and product loss is minimized. Diaphragm and peristaltic pumps are gaining popularity because the pumped product does not contact their metal surfaces. he tubing in these pumps can be regularly replaced to adhere to sanitary requirements, maximizing production up-time. With changes in regulations, food manufacturers are becoming proactive to ensure maximum safety in production. he FSMA has provisions making a number of mandatory changes in the Current Good Manufacturing Practices (cGMPs) and Sanitation Standard Operating Procedures (SSOPs). As a result, the demand for pumps fulilling sanitary requirements is expected to increase further. he expectations from pumps catering to diferent segmentsfor instance, the juice and seafood segments that have already been covered by hazard analysis and critical control points (HACCPs)vary according to the extensiveness of the regulations. Pump manufacturers have many opportunities to increase their growth in the future. Innovation in handling the regulatory changes and extending services to facilities to help them prepare safety plans are some strategies for pump manufacturers to move to the next level. Also, smart pumps are creating interest in the regulatory and eiciency fronts and play a promising role in the pump market. P&S
Sakthi Pandian an is a resear research rch analyst for rch Frost & Sullivans Industrial Automation and Process Control practice. Senior Analyst Anand Gnanamoorthy also works on this team. Both can be reached at britni.myers@frost.com.
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PRACTICE & OPERATIONS
Rotary Lobe Pumps in Sugar Processing

This pump type manages the temperature and viscosity challenges of handling this dificult product.
By Marino Curati, Vogelsang ugar processing requires pumping heavy and sometimes abrasive liquids such as molasses, black liquor, magma and tailings. he liquids are oten hot and tend to quickly crystallize if the product remains inside pumps and lines and then cools. A heavy, industrial positive displacement pump is required to handle such applications. Because of advancements in wet-end and overall pump design, rotary lobe pumps ofer signiicant advantages to sugar processorssuch as improved product handling, lower lifecycle costs and reduced maintenance. Rotary lobe pumps are part of the positive displacement group. hey create low by trapping liquid from the suction side, carrying it through the pump and expelling it out the discharge side. During operation, two rotors mesh together and rotate in opposite directions (see Figure 1). he rotation forms cavities between the rotors and wet-end housing. he liquid that ills the cavities is carried through the pump and expelled out the discharge side. MOLASSES he major hurdles when dealing with molasses (the mother liquor in sugar processing) are viscosity, temperature and crystallization. Molasses is available in many varieties. Each type difers in viscosity and solids content depending on its sourcecane, sugar beets or another source. During processing, molasses can be hotat times approaching 150 F. All factors combined, molasses can be a tough application for pumps. Viscosity Rotary lobe pumps are designed to operate with diferent
levels of slip. he slip is induced because the rotor tips do not touch the pump housing. As viscosity increases, the slip drastically decreases, and the overall eiciency of the pump increases as a result. his also applies to other positive displacement pumps commonly used for molasses, such as gear pumps. hey too become more eicient as viscosity increases. he rotary lobe pump is advantageous for processes involving molasses. Although slip is a factor, it is not as detrimental to the overall eiciency as some other positive displacement pump designs. hese pumps are well-suited to handle thinner irst molasses up to heavy, black strap molasses without a major change in performance. Temperature Temperature afects rotary lobe pumps diferently depending on the wet-end materials chosen by the manufacturer for each application. Material options vary among brands. Some manufacturers ofer elastomer-coated rotors that use materials such as nitrile rubber (NBR) or ethylene propylene diene monomer (EPDM). hese materials are great solutions for molasses pumping as long as the liquid never surpasses 165 F. he elastomer can handle these temperatures, but they tend to swell, which leads to damage to the rotors if the pump seizes. he other caveat to using elastomers is an understanding of how the facilitys maintenance staf cleans the equipment. If steam is used to clean inside the lines, pumps and other devices, then using elastomers is not an option. he high temperature of the cleaning process can cause catastrophic damage to elastomer-coated rotors. Many manufacturers also ofer solid metal rotors. Metal rotors are available in materials from mild steel, hardened steel, coated steel (such as tungsten carbide) and stainless steel. Brands that ofer elastomer-coated and solid metal rotors typically specify the coated version if possible. Elastomer-coated rotors
Figure 1. Rotary lobe pump operation
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Rotary lobe pumps offer signiicant advantages to sugar processors such as improved product handling, lower life-cycle costs and reduced maintenance.
are less expensive and better if solids are present in the pumped luid. Solid metal rotors require precision machining. hey also have the added cost of simply needing more metal compared to a rough casted core. Added costs aside, molasses applications oten require solid metal rotors. An advantage is that solid metals handle high temperature and high abrasives exceptionally well. he pump will be well-suited for operation in a process with unpredictable viscosity and temperature conditions. In addition, the pump would be unafected if steam cleaning of the system is required. Crystallization he natural hardening process that occurs as molasses cools requires thorough cleaning of the system ater a run of product to prevent build-up and clogging. his afects many aspects of the overall system but can be particularly hard on pumps if they are not conigured properly for the application. Seals are particularly vulnerable to crystallized molasses build-up. Manufacturers ofer many sealing systems from basic packing-style seals to split-face mechanical seals and water-lush mechanical sealing systems. Each seal system design has its advantages and disadvantages. Even with adequate system cleaning, pump seals will experience some degree of crystallized molasses. he ideal seal choice will handle a reasonable degree of build-up and prevent product leakage. Sometimes seal choice is simply a matter of factoring cost and maintenance against performance. Pumps that use lowcost and low-maintenance packing-style seals oten allow gallons of molasses to leak out of the pump and onto the loor. Conversely, pumps with complex water lush systems to maintain seal lubrication ensure that the product remains in the pump, but complex systems can add cost and maintenance time. A happy medium in terms of maintenance and performance can be found in brands that use a cartridge mechanical seal that is back-pressurized and compatible with hightemperature and abrasive liquids. he back pressure comes from adding positive pressure to a bufer chamber behind the seals. his neutralizes the combined pressure in the wet-end and prevents the seals from experiencing excess pressure. MUD CLARIFIER/THICKENER UNDERFLOW Depending on the size of the clariier, underlow mud removal applications are oten high volume and involve multiple pumps. Single-acting diaphragm pumps are oten used to move the luid and solid mixture from mud clariiers. Typically, up to six diaphragms may work to empty one clariier. One crank arm is oten running three diaphragms each. Although the diaphragms are well-suited for handling the thick mud, they consume a great deal of electric power to run the compressor(s). In terms of the application itself, the major issues are capacity, abrasives, solids and sometimes temperature. he waste tailings contain heavy amounts of sand and other damaging solids. Rotary lobe pumps have advantages when handling clariier underlow. Capacity he delivery rates of rotary lobe pumps vary by brand. hey are oten available in capacities well over 4,000 gallons per minute. Installing one large pump can eliminate the need for multiple pumps while maintaining the required low. In the same step, when choosing an assembly type that is either direct-coupled or V-belt-driven, the compressor can be eliminated. Depending on the compressor system in use, an electric motor drive can reduce the required horsepower by as much as 75 percent. Added beneits include reduced maintenance and a smaller footprint. Abrasives Rotary lobe pumps can safely handle the sand and other abrasives found in the waste tailings of the clariier. In addition to solid metal rotors, some brands ofer rotors with lame spray coatings. hese coatings, such as tungsten carbide, are extremely wear-resistant and hold up well against heavy grit. When the application requires high-wear coatings, end users should specify that the other wet-end components have the same or compatible coating. Components and wet-end design vary widely by brand. However, most major brands feature some type of adjustable and replaceable upper and lower housings as well as front and rear lat wear plates. In high-wear applications, choosing a brand that ofers diverse wet-end material options and a wet-end design that allows for easy maintenance will reduce spare parts cost and maintenance time.
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MAGMA/MASSECUITE Magma/massecuite is a mixture of liquids, juices and crystals that result from the crystallization process. Metal lobe lapper valve pumps that are almost always found in magma and massecuite pumping applications are purpose built and have been used in this application for decades. Many of these pumps have been in operation for more than 30 years. Even with the established use of this single rotor pump, the modern, two-rotor lobe pump ofers distinct advantages. Pulsation Magma and massecuite should be pumped with as little pulsation as possible. Pulsation is bad for the product and constant hammering of the liquid is bad for the facilitys infrastructure, equipment and work environment. By design, the single rotor hinged lapper pump creates pulsation. he rotor hits the lap, which expels trapped liquid from the pump. By comparison, the two-rotor lobe pump meshes the rotors to create the positive displacement. However, rotary lobe pumps vary in performance when measuring pulsation. Pulsation, when applied to rotary lobe pumps, is directly related to rotor design. Although many styles of rotors have been developed, the rotor design that most major brands would use for a sugar process application would be some variation of the examples shown in Figures 2, 3 and 4. hese pumps can have two basic types of rotors: straight and balanced. A straight rotor (see Figures 2 & 3) can have two, three or more lobes. hey are straight from front to back and could be elastomer coated, solid metal or lame spray coated. he second type is the balanced rotor (see Figure 4). A
balanced rotor can have two, three or six lobes. his design is also available in elastomer-coated, solid metal or lamespray-coated versions. A properly balanced rotor produces a smooth, steady low of liquid that is free of pulsation. A properly balanced rotor is also much more diicult to design and machine than a straight lobe design. If pulsation is a factor in the application, reviewing the performance characteristics of each brand is important. Maintenance & Spare Parts Many of the advantages in the other sugar process applications also apply to magma and massecuite. he sealing systems on the major brands prevent product leakage and contamination. Many brands also ofer capacities beyond those of a typical, one-rotor design. An advantage in this particular application pertains to the construction of the two-rotor lobe pump. Some major brands have learned that using common parts between pump models decreases the cost and maintenance time for the end user. For example, switching to one pump design for multiple processes provides a signiicant cost savings in terms of stocking spare parts. A good manufacturer can ofer multiple products, conigured for diferent low-rates and capacities, which use common wear parts that could be swapped out should a failure occur. P&S
Marino Curati is the director of marketing for North America at Vogelsang. He can be reached at marinoc@vogelsangusa.com. Vogelsang designs and manufactures rotary lobe pumps, inline macerators and twin-shaft grinders for wastewater, food processing and industrial applications. Vogelsang also produces a line of biogas process products for sludge lysing, conferment premixing and digester feeding.
Figure 2. A straight rotor
Figure 3. An example of a straight rotor
Figure 4. A balanced rotor
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Peristaltic Pump Speed Considerations

Operating speed requirements must be a factor when selecting a pump.
By Todd Loudin, Flowrox Inc.
f someone is being chased by a lion in the Serengeti, he deinitely wants to run fast. A world-class sprinters ability to run fast is a positive attribute that may help her win a gold medal. However, a peristaltic pump running fast may be detrimental to an end users operation. Many types of peristaltic pumps are available, and some of the designs include shoe, double roller and single roller.
SHOE DESIGN A shoe-design peristaltic pump typically has two shoes that drag across the rubber hose to create the occlusion of the hose. his is one of the earliest types of designs available. Unfortunately, the dragging action creates a signiicant amount of friction, resulting in heat build-up within the pump casing and the rubber hose. his type pump typically requires a signiicant amount of lubricant (usually glycerin) to dissipate the heat and lubricate the dragging action of the shoe against the rubber hose. Even with the glycerin lubricant cooling the pump and its internals, the pump is limited to how fast it can run. If it is a large diameter (2.5-inch to 4-inch) peristaltic pump, the speed limit may be because of the heat generated during operation. Most large diameter, shoe-design peristaltic pumps are limited to approximately 40 rpm.
Figure 1. The limitation of shoe-design pumps for varied ow rates
If an end user needs the pump to run faster than 40 rpm, then the pump can only be run intermittently. For instance, an end user could run the pump at 60 rpm for one hour, but it would need to cool for two hours. If an end user chose to run the pump faster for longer than one hour, then the hoses mean time between failure (MTBF) would likely decrease to an unacceptable level. Also, the amount of glycerin required for these pumps is extreme. A 3-inch pump may require 10 gallons of glycerin. he glycerin may cost approximately $100 per gallon or higher. With each repair that results from running the pump too fast, an end user will have to dispose of 10 gallons of contaminated glycerin, which can cost up to $1,000 per hose to change. Since the shoes drag across the hose, signiicant starting torque is required to get the shoes moving. If running at low rpm with this type pump, end users may trip the variable frequency drive (VFD) because of the high load on the motor. Figure 1 depicts a shoe-design pumps limitation for running at diferent low rates. he faster the pump runs, the more it moves outside continuous duty and must run at intermittent duty. he pump could run for a period of time and then would need to be shut down for an equal period of time or longer to cool. Also, the temperature of the pumped luid can move this type pump into the intermittent duty area of the pump. One might suggest running the pump slower to remain in the continuous low range. Unfortunately, the end user would have to compromise the pumps low rate or increase the pump size by one to two sizes to remain in the continuous low area to do this. Also, the torque would increase to a high starting torque area. his is common for shoe designs because of the drag of the shoes against the rubber hose on start-up. If an operator runs the pump slowly, the VFD may be tripped frequently. In many cases, the motor size must be larger compared to singleroller pumps.
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Figure 2 is an example of a shoe-design peristaltic pump. he two shoes rub the hose as it revolves and compresses the hose two times every single revolution. SINGLE-ROLLER DESIGN Figure 3 is an example of a single-compression, roller-design pump. his type pump can be run up to its maximum rpm and run continuously without signiicant heat generation or destruction of the hose. he only efect of running at up to its maximum speed will be an increased number of compressions on the hose. However, this type of device has half the number of compressions per revolution compared to dual-shoe or dual-roller designs. Even running at twice the speed of other designs, a single-compression design will, in most cases, provide better hose life. Since a single-roller pump can be operated continuously at almost twice the speed, it can typically be one size smaller than other designs and provide the same low rate. For example, a dual-shoe pump manufacturer may recommend a 4-inch (100-millimeter) pump to move 150 gallons per minute (gpm). However, a single-roller design at 3 inches (80 millimeters) can pump up to 176 gpm continuously providing a much smaller footprint, lower spare parts consumption, less expensive spare parts and lower energy consumption. Also, a 4-inch (100-millimeter) shoe-design pump will have a maximum continuous low rate of about 200 gpm. However, a 4-inch (100 mm) single-compression, roller-
design will have a maximum continuous low rate of 440 gpmmore than double the low rate can be accomplished with larger diameter, single-roller designs. Figure 4 shows the low for a single-compression roller designa 1.5-inch (40-millimeter) pump. It indicates continuous duty. he pump, hose and glycerin do not experience heat at any signiicant level, so the pump can be run at high rpms continuously. When calculating the lifetime cost of a pump, the purchase price and the seven-year operational costs are used. he maintenance costs of a dual-shoe design or multipleroller design peristaltic pump are signiicant. Using a singleroller design instead can save up to 70 percent per year. Table 1 compares the operating costs of a 2.5-inch (65-millimeter), single-compression roller pump that replaced a 4-inch (100-millimeter), shoe-design pump at a
Figure 3. Shoe design or multiple-roller design peristaltic pumps will experience half the hose life compared to single-roller designs.
Figure 2. Dual-shoe design pump
Figure 4. Flow for a single-compression roller design
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power plant. he two pumps moved lime slurry. he savings were so signiicant that the power plant was able to replace a second dual-shoe design with a single-compression roller design with the savings in maintenance costs within nine months. Users of peristaltic pumps have been accustomed to making sure their pumps rotate slowly to ensure the longest hose life. his is wise if the ultimate goal is to maximize the uptime of your pumps. However, if an end user must run the pumps continuously at high rpms, then a smaller, single-compression roller design is the better choice. Many customers are shocked to see a peristaltic pump rotating at higher rpms. In this case, the consumer should be shown how the faster rotation is normal with the new generation of peristaltic pump technology. HOSE COMPRESSION With multiple-shoe and multiple-roller designs, the rubber hose is compressed two or more times with every revolution. In most peristaltic pump applications, the No. 1 determining factor of how long the hose will last is the number of times that the hose is compressed. he pumped mediums make up
Update Basic parameters in example process Reguired flow, gpm Use hour/a Utililzation rate, % Use hours@ min ut.rate,h Hose life, revolutions Speed, rpm Revolutions/hour Power consumption, kW/h Total down time/ hose Glycerine need/hose, gallons Maintenance time/hose brake Revolutions/a Number of spare hoses/a Maintenance time/a Utilization rate Operating costs Lubricant Hoses Electricity Maintenance Total Difference to LPP, $
or abrasiveness is usually not a signiicant factor in hose life. herefore, shoe designs and two or more roller designs will experience a minimum of two times shorter hose life than single-roller designs. Because of the increased heat caused by friction, the hose life of dual-shoe or dual-roller designs is even more diminished. In many cases, the hose life of a single-roller design will be three to ive times longer than dual-shoe or multiple roller designs. CONCLUSION Faster is not always better. Running a peristaltic pump slower to maximize hose lifetime is recommended. However, when faced with the price tag of a 4-inch (100-millimeter) shoe design compared to a 2.5-inch (65-millimeter) single-compression roller design and calculating that both pumps will provide the same low rates, end users will likely select a single-compression roller design for extended run time and minimized wear. Users experience less energy consumption, lower spare parts cost, decreased glycerin consumption, and greater uptime or pumping availability. Some customers using continuous duty, 4-inch (100-millimeter) dualshoe designs have the unfortunate distinction of purchasing $15,000 to $20,000 of 7/29/2008 glycerin per year for their Unit price, Unit price, pumps. his huge amount conventional 4" LPP-T2.5" of glycerin consumption is $96.00 not required with a single$0.06 $2,300.00 $1,200.00 compression roller design. $43.75 herefore, with new sinCompetitor 4" gle-roller technology, it 518,400 is acceptable to allow the 6 pumps to run faster. P&S 360
12 30 15.8 4 2,995,920 6.0 180 97.8 % $9,100.80 $13,800.00 $5,792.11 $525.00 $29,217.91 $20,148.11
30 8,322 99% 8,239 LPP-T2.5" 2,721,600 21 1,260 7.4 15 0.75 2 10,485,720 4.0 60 99.3 % $348.00 $4,800.00 $3,571.80 $350.00 $9,069.80 $0.00
lubricant, gallon Electricity, kWh Hose, psc work hour
Difference to LPP-T %
0%
69%
Table 1. The operating costs of a 2.5-inch (65-millimeter) single-compression roller design pump versus the costs of a 4-inch (100-millimeter) shoe-design pump at a power plant
Todd Loudin is president and CEO of North American Operations for Flowrox. He is also a member of Pumps & Systems Editorial Advisory Board. He has a Bachelor of Science in marketing and an Executive MBA from Loyola University. Loudin joined Flowrox in 1994 as a sales manager and became general manager after six months. In 2002, he became president and CEO. From 1998 to 2001, he sat on the board of directors at Larox Flowsys (later renamed to Flowrox) and held a dual position from 2008 to 2011 as SBU manager of Energy and Environment globally. He can be reached at todd.loudin@lowrox.com.
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PRODUCT PIPELINE
Submersible Motor
Xylem Inc. introduced the CentriPro Xtreme Duty 4-inch submersible motor. Designed for sandy wells and coal bed methane applications, it combines sand ighting and coal bed methane motor capabilities into one unit. A silicon carbide mechanical seal and felt diaphragm ilter prevent coal ines and other abrasives from entering the motor. All sizes feature a 17-4PH stainless steel shat and 1,500-pound thrust bearings.
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Washers
Nord-Lock introduced its X-Series washersa new evolution in bolt security. X-Series combines NordLocks wedge-locking protection against spontaneous bolt lusive spring efect loosening with an exclusive efect that protects against slackening because of settlement and relaxation. his combination makes X-Series the irst, true multifunctional solutionofering the highest security for critical joints, without compromise.
Check Valves
Val-Matic introduced the dual disc check valve in 14 inches and larger and the silent check valve with lead-free bronze and stainless steel trim, now certiied to NSF/ANSI 61 for drinking water system components. he dual disc check valves have a compact design and features non-slam, spring-assisted closure. he silent check valve features a short linear stroke and spring return action to close the valve before low reversal can occur, eliminating surges and water hammer.
Remote Monitor
Global Monitoring reintroduced its Messenger GMU 8100 Remote Monitor. he remote monitoring units are designed to track and react to conditions at remote, unattended or inaccessible locations. heir land-line-based communications reduce or eliminate ongoing communication costs by sharing existing phone or fax lines. he units are conigurable to many sensor types and are expandable to 16 inputs.
Twin Screw Pumps

Maag Industrial Pumps introduced its S Series line of twin screw pumps. Maag S Series pumps are ATEX-certiied for use in explosive or dangerous environments in the oil and gas, process and marine industries. he S Series features three pump models: WTG, NTG and Multi-phase. Maag S Series pumps can provide solutions for the toughest application challenges regardless of temperature, viscosity or pressure.
Sump/Efluent Pumps
Franklin Electric introduced Little Giant 6EN and 10EN sump/eluent pumps. hey feature permanent, split capacitor motors, providing low current draw, energy eiciency, improved performance and cool running. he -horsepower 6EN consumes six amps and produces fh d he 50 gallons per minute (gpm) at 5 f feet of head. horsepower 10EN has a full-load rating of eight amps producing 67 gpm at 5 feet of head.
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PRODUCT PIPELINE
Grinder Pump
JWC Environmental introduced the Monster Industrial 7 SHRED grinder, built to fulill the demands of product reduction for industrial applications such as petroleum, agriculture, food processing and municipal solid waste. Stronger shats allow for greater torque and through put. he grinder pump has a maximum of 100 horsepower and is designed to stand up to applications requiring product reduction of up to 1,500 cubic feet per hour (42 cubic meters per hour).
Ethernet Switch
Siemens Industry Automation Division introduced the Ruggedcom RSG2488 compact rack switch designed for electric power, transportation and defense applications. his high-density layer two switch supports up to 28 copper or iber ports in a compact 1U chassis. he switch is the irst product under the Siemens Ruggedcom brand. Designed to operate from -40 C to +85 C and with high immunity, it is ideally suited for use in almost any harsh environment.
Shaft Alignment System Metering Pump

Watson-Marlow Pumps Group launched its Qdos 30 pump range. Developed in response to extensive industrial customer feedback for improved chemical metering, the Qdos 30 eliminates ancillary equipment, enhances productivity and reduces chemical waste through more i than h typical i l solel accurate, linear and repeatable metering noid or stepper-driven diaphragm metering pumps.
VibrAlign introduced the Fixturlaser NXA Pro Laser Shat Alignment System featuring innovations for greater ease of use and accuracy. he shat alignment system features new screen a re engineered power sensors, a new display touchscreen, re-engineered management system, new reporting, and the addition of MEMS Inertial Motion Sensors (gyroscopes) in both sensors and in the display unit.
Drive+Motors AC Drive
ABB introduced the ACS880 model. he AC drive portfolio presented a new era in control panel design, featuring an intuitive, high-contrast and high-resolution control display, enabling easy navigation. Many lexible data visualizations r m and nd tr nd graphshelp r ph h lp including bar charts, histograms trend users analyze processes. he menus and messages are customizable for speciic terminology for applications.
Applied Motion Products announced the addition of ive IP65 rated integrated drive+motors to its line of motion control products. he SWM24 fuses a high-performance motion controller to a high-torque i mounts t NEMA24 step motor. he NEMA24 f frame size like the popular NEMA23 motor, but has a 15 percent larger cross section, allowing it to deliver more torque in the same length. he entire package is engineered to resist the ingress of water and dust to IP65 standards.
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Vibration Sensors
Meggitt released radiation-resistant vibration sensors for condition monitoring applications in nuclear power plants. Wilcoxon accelerometers are designed to perform continuously in harsh environments without degradation. Wilcoxon radiation-hardened sensors can tolerate a cumulative radiation exposure of 1 x 107 radiation absorbed doses (RADs) and are operable up to 248 F (120 C). Model 797R is a side-exit, low-proile IsoRing accelerometer with tight sensitivity tolerance.
Inventory Tracking Software

Wasp Barcode Technologies announced the release InventoryControl Version 7, a complete inventory tracking solution for small and medium-sized businesses. Wasp developed the QuickBooks Connector bilit to t reconcile il i Module for this version. he ability inventory and accounting systems with this integrated platform allows small businesses to more efectively plan, execute and optimize their operations.
Coolers and Harnesses

Volvo Penta introduced a heavy-duty cooling package and cabling harness for industrial engines in harsh working environments. he side-byih d cleaning l i side, heavy-duty cooling packages withstand with high-pressure water and will be ofered as suctionand pusher-type cooling systems. he heavy-duty cable harnesses are based on a manufacturing technique that uses a split, synthetic polyester tubing as cable protection.
To have a product considered for Product Pipeline, please send the information to Amanda Perry, aperry@cahabamedia.com.
New: Pump Intake Design Standard

Standard for Rotodynamic Pumps
The 2012 version of the Pump Intake Design Standard is a completely updated expanded version of the widely respected Intake Design standard issued in 1998. This standard addresses specic phenomena that can adversely affect the performance of pumps, including:
Submerged vortices Free surface vortices Preswirl magnitude & uctuation with time Nonuniform distribution of velocity in space & time at the impeller eye Entrained air or gas bubbles
U N M AT C H A B L E E X P E R I E N C E I N P R I VAT E C O M PA N Y TRANSACTIONS
Jordan, Knauff & Company is a knowledgeable and experienced provider of a comprehensive line of investment banking services to the pump, valve and ltration industries (Flow Control). Our lines of business include: selling companies, raising debt and equity capital, and assistance on acquisitions. To learn more about Jordan, Knauff & Company, contact any member of our Flow Control team. Access our Flow Control research at www.jordanknauff.com/owcontrol.
G. Cook Jordan, Jr.
Managing Principal cj@jordanknauff.com 312.254.5901
Visit the HI eStore at: eStore.Pumps.org for more information about this new standard.
David A. Kakareka
Associate dkakareka@jordanknauff.com 312.254.5907
MEMBER FINRA, SIPC
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PUMP USERS MARKETPLACE EMPLOYMENT EXECUTIVE SEARCH/RECRUITING

Pump Manufacturer seeks U.S. territorial representation for the following markets, Sugar & Ethanol Industry, Distilleries, Mining & Steel, Sewage, Water & Waste Water, Pulp & Paper, Chemical & Petrochemical, Irrigation, Air Conditioning HVAC, Food, Boiler Feed & Heat Transfer, Naval and Fire Fighting & Booster Systems. For more information, please email lyndonsmith@rogers.com.
Serving the Pump & Rotating Equipment, Valve, and Industrial Equipment Industry since 1969
Domestic & International
Specializing in placing: General Management Engineering Sales & Marketing Manufacturing

DAN BOLEN JASON SWANSON CHRIS OSBORN DAN MARSHALL 9741 North 90th Place, Suite 200 Scottsdale, Arizona 85258-5065 (480) 767-9000 Fax (480) 767-0100 Email: danbolen@mindspring.com
www.danbolenassoc.com
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INDEX OF ADVERTISERS
Advertiser Name
Advanced Engineered Pump, Inc. Alpha Grainger Manufacturing, Inc. Baldor Electric Company Bartlett Bearing Company Benshaw Incorporated BLACOH Fluid Control, Inc. Blue-White Industries Conhagen Continental Pump Company Cornell Pump Company Dan Bolen & Associates, LLC Denmar Pump Services, Inc. Environmental Gasket Co., Ltd. Equipump Flowrox Inc. Frost & Sullivan Graphite Metallizing Corp. Grundfos Pump Corp. Houston Dynamic Service, Inc. Hydraulic Institute Hydro, Inc. Hydro, Inc. Hyundai Heavy Industries Co. Ltd. ICR Water Technologies Inc. InfoSight InfoSight John Crane Jordan, Knauff & Company Junty International, Ltd. KB Electronics, Inc. KSB, Inc. LE LE Load Controls, Inc. Load Controls, Inc. LobePro Maag Automatik Inc. Magnatex Pumps, Inc. Master Bond Inc. Meltric Corporation Motion Industries
Page
92 8 27 51 33 41 11 53 94 77 92 54 59 95 7 78 58 BC 93 91 92 IFC 31 92 30 94 55 91 95 35 63 12 93 26 95 94 58 94 94 93 37
RS#
158 120 101 121 122 139 124 154 159 140 160 142 143 161 125 156 149 102 163 150 181 100 104 164 144 157 118 151 165 145 126 127 167 128 168 162 152 169 170 171 105
Advertiser Name
Mouvex National Pump Company NETZSCH, Group Nidec Motor Corporation NSK ODrill MCM/Titan Pumps Orion Seals Phoenix Contact Pioneer Pump Pump Solutions Group PumpWorks 610 Scenic Precise Element Inc. Schenck Trebel Corp. Schlumberger Schneider Electric Webinar SEPCO SEPCO Sims Pump Co. Sims Pump Co. Singer Valve, Inc. SJE-Rhombus Skinner Power Systems, LLC TECO-Westinghouse ThinQk Ltd. Toshiba Trachte, USA Tuf-Lok International United Rentals, Inc. Varisco USA Inc. Vaughan Vertilo Pump Company Vesco Viking Vogelsang USA WEFTEC WEG Electric Corporation Wilden Xylem USA Yaskawa America, Inc.
Page
14 19 23 47 25 53 46 15 17 69 13 95 21 5 79 61 94 65 95 78 34 18 67 93 49 93 93 9 93 3 93 95 45 36 75 39 22 IBC 43
RS#
129 130 131 106 132 153 141 107 133 146 123 172 134 108 109 135 173 110 174 155 147 136 119 175 117 176 177 111 178 112 179 180 138 148 113 114 137 115 116
* The Index of Advertisers is furnished as a courtesy, and no responsibility is assumed for incorrect information.
circle 158 on card or go to psfreeinfo.com PUMPS & SYSTEMS
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PUMP
PLUGS
QUICKLY CONNECT & DISCONNECT POWER
OFF Button
AFTERMARKET PARTS WKDW W AIR OPERATED DIAPHRAGM PUMPS
Safety Shutter
(on receptacle)
YOUR
AVERAGE
SAVINGS
25%
Rated up to 200A, 60hp

Connector + Switch in 1 device Maximizes Arc Flash Protection Minimizes PPE Requirements
meltric.com 800.433.7642
www.thinqk.com
Rotating Equipment Repair Specialists

Rotating/Centrifugal Pumps | Turbines | Compressors Fan & Blowers | Gears/Gear Boxes | Centrifuges
www.houstondynamic.com
P 713.928.6200 | F 713.928.9203 | 8150 Lawndale, Houston, TX 77021 circle 176 on card or go to psfreeinfo.com circle 163 on card or go to psfreeinfo.com
XEMC VERTICAL HOLLOW-SHAFT MOTORS

Primarily designed for deep well turbine pump applications. Unmatched reliability Cost-efective 30% more eicient Easy to install
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93
PUMP USERS MARKETPLACE
ROTARY LOBE SLUDGE PUMPS MPS FOR SLUDGES/SLURRIES/CORROSIVES

Self Priming to 25. Reversible operation.
In Place wear part replacement at 1/3 the cost and time for equivalent screw (PC) pump.
To learn more or get a custom quote, email PumpSales@lobepro.com 912-466-0304 www.LOBEPRO.com
Cartridge seals for quick replacement. No pressure bottle needed below 100 psi.
Made in USA
E FL
X I B LE
Epoxy Polysulfide
EP21TP-2
Chemically resistant Withstands thermal cycling Excellent sealant
Hackensack, NJ 07601 USA +1.201.343.8983 main@masterbond.com
www.masterbond.com
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PUMPS & SYSTEMS
MONITOR PUMP PERFORMANCE

s &,/7 2!4% s 05-0 #/.$)4)/. s $29 25..).' s #!6)4!4)/. s "%!2).' &!),52%
5.)6%23!, 0/7%2 #%,,
s /NE 3IZE !DJUSTS FOR !LL -OTORS &ROM 3MALL UP TO (0 s 7ORKS ON 6ARIABLE &REQUENCY $RIVES 0HASE $# AND 3INGLE 0HASE s TIMES MORE SENSITIVE THAN JUST SENSING AMPS s -ILLIAMP 6OLT
Solve dry start problems with Vesconite Hilube bushings

G G G G
#!,, ./7 &/2 9/52 &2%% $!9 42!),

Increase MTBR No swell Low friction = reduced electricity costs Quick supply. No quantity too small
Tollfree 1-866-635-7596 vesconite@vesconite.com www.vesconite.com

PUMPS & SYSTEMS
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June 2013
95
PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

By Jordan, Knauff & Company he Jordan, Knauf & Company ( JKC) Valve Stock Index was up 16.9 percent during the last twelve months, above the broader S&P 500 Index which was up 13.6 percent. he JKC Pump Stock Index was up 14.4 percent for the same time period.1 In April, the Institute for Supply Managements Purchasing Managers Index (PMI) registered 50.7 per- 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 cent, a decrease of 0.6 percentage points from Marchs companies involved in the pump and valve industries weighted by market capitalization. 51.3 percent. his relects expansion in manufacturing for Figure 1. Stock indices from May 1, 2012, to April 30, 2013 the ith consecutive month but at the lowest rate of the Only Japan, South Korea, Indonesia and Vietnam reported year. When the PMI is more than 42.2 percent during an extended period of time, it generally indicates that the over- a faster rate of improvement in operating conditions during all economy is expanding. he April PMI represents over- April. With the Euro area contracting at the fastest pace all economic growth for the 47th consecutive month. he year-to-date and the U.K. stagnating, Europe remained a Employment Index fell from 54.2 to 50.2 percent suggesting drag on the global aggregate. U.S. PMI showed the slowest growth in six months, and neighboring Mexico expanded at that job growth is essentially lat. its weakest pace in 20 months. Manufacturing growth also he JPMorgan Global Manufacturing PMI showed slowed to near-stagnation in Russia, China, India and Brazil, expansion for the fourth straight month with a reading of while expansion rates fell in Taiwan and Turkey. 50.5 percent in April. However, the rate of expansion decelh e U.S. Energy Administration (EIA) projects that world erated, meaning that growth in 2013 has been marginal. liquid fuels consumption will be higher during the next two years because of a moderate recovery in global economic growth. As new reining capacity continues to grow and investment in the property market and infrastructure sectors expand, Chinas reinery crude oil inputs are expected to increase. he EIA estimates that liquid fuels consumption in China increased by 380,000 barrels per day (bpd) in 2012, will increase by 450,000 bpd in 2013 and 470,000 bpd in 2014. his is still lower than the average annual growth of about 520,000 bpd from 2004 through 2012. On Wall Street, the three major indices gained almost Source: U.S. Energy Information Administration and Baker Hughes Inc. two percent each in April based on better-than-expected Figure 2. U.S. Energy Consumption and Rig Counts domestic economy news. he S&P/Case-Shiller Home Price Index 20-City Composite, the leading measure of U.S. home prices, showed the average home price increased 9.3 percent during the 12-month period ending in February 2013. he Conference Board reported that its consumer conidence survey spiked to 68.1 percent in April, following an upwardly revised 61.9 percent in March. P&S
Reference 1 he S&P Return igures are provided by Capital IQ. Jordan, Knauff & Co. is an investment bank based in Chicago, Ill., that provides merger and acquisition advisory services to the pump, valve and iltration industries. Please visit www.jordanknauff.com for further information on the irm. Jordan Knauff & Co. is a member of FINRA. PUMPS & SYSTEMS
Source: Institute for Supply Management Manufacturing Report on Business and U.S. Census Bureau.
Figure 3. U.S. PMI Index and Manufacturing Shipments
96
June 2013
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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 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 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.
TotalCare services
For secure, optimal operations
Xylem TotalCare is a comprehensive, integrated portfolio of services that ensures your business keeps running at its best. Our portfolio comes backed by deep systems knowledge and expertise in water and wastewater applications. Which gives you the operational security and more time to focus on your core business.
What can Xylem do for you?
Call 1 704 4099700 or visit www.xylemtotalcare.com
For more information visit booth #6000 at ACE13 -XQHLQERRWK'HQYHU&2

Simplify Integrate Optimize
Hydro MPC: Perfecting your energy responsibility
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b.com/GrundfosPumpUSA twitter.com/GrundfosUSA youtube.com/GrundfosUSA www.grundfos.us circle 102 on card or go to psfreeinfo.com

June 2013

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From the Editor

Walter B. Evans, Jr.

George Lake glake@pump-zone.com 205-345-0477

Michelle Segrest msegrest@pump-zone.com 205-314-8279

Terri Jackson tjackson@cahabamedia.com

Michelle Segrest msegrest@pump-zone.com 205-314-8279

Lisa Freeman lfreeman@pump-zone.com 205-212-9402

Editorial Advisory Board

is a member of the following organizations:

PUMPS & SYSTEMS

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Internal Clearance & Its Effect on Bearing Fatigue Life

Long-Term Motor Reliability

Electric Motor Repair and Reliability

VFDs Save Energy in Pump Applications

Practice & Operations

Pump Repair & Maintenance

Peristaltic Pump Speed Considerations

Maintenance Minders: Root Cause Analysis & Problem Solving

10 News 68 Efciency Matters By Edison Brito

Outdoor Installations, Rotodynamic Vertical Pumps & Drooping Head

72 Sealing Sense By The Fluid Sealing Association

89 Product Pipeline 96 Pump Market Analysis By Jordan, Knauff & Company

PUMPS & SYSTEMS

Reliable, cost-effective surface pumping with no daily maintenance.

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Top 20 Pump Industry Trade Shows

NACS/PEI Show ConExpo

PUMPS & SYSTEMS

Oil Sands Trade Show and Conference

Proven Performance with Flowrox Pumps

With a range of sizes, we have a pump to accommodate every application.

Wasser Berlin International

TOP 20 TRADE SHOWS

For more information, see the slideshow on www.pump-zone.com.

Need to create or duplicate a critical part?

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PUMPS & SYSTEMS

BECAUSE THERES NO TIME FOR DOWNTIME.

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NEW HIRES, PROMOTIONS & RECOGNITIONS

MERGERS & ACQUISITIONS

ELGIN FASTENER GROUP acquires Vegas Fastener Manufacturing April 2, 2013

PUMPS & SYSTEMS

INNOVATION INNOVATI TION | ENGI ENGINEERING GINEE ERING | PE P PERFORMANCE ERFORMANC CE

PUMPS & SYSTEMS

AROUND THE INDUSTRY

THE ENGINEERED PERFORMANCE RUNS DEEP

FOR ADDITIONAL PRODUCT DETAILS, VISIT www.lt-eng.com/products/vertical-hollow-shaft

PUMPS & SYSTEMS

Tired of snails pace lead times?

When Quality & Delivery Matter

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WORLD ENERGY CONGRESS

PACK EXPO INTERNATIONAL ELECTRICAL APPARATUS SERVICE ASSOCIATION CONVENTION (EASA)

INTERNATIONAL PUMP USERS SYMPOSIUM & TURBO MACHINERY SYMPOSIUM

s low F on ati v o Inn

E ciency to the Next Level

Mouvex SLC Series, C Series and Micro C Series Seal-less

Contact your local Mouvex representative today.

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PUMPS & SYSTEMS

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