April 2014 PDF

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circle 100 on card or go to psfreeinfo.com
From the Editor
EDITORIAL
Editor
very month for 10 years, Pumps &

Systems has published Sealing Sense
with the support of the Fluid Sealing
Association (FSA). he column provides solutions for the most challenging
problems surrounding mechanical seals,
gaskets, pump and valve packing and
expansion joints. hese articles have been
coordinated by FSAs Technical Director
Pete Petrunich, who retires this year ater
serving the association for 17 years.
Pumps & Systems attended ConExpo-CON/AGG in
FSAs Administrative Director, Hope
Las Vegas and distributed more than 500 copies of
Silverman, has worked with Petrunich for
the March dewatering issue. Our friends at Griffin
13 years and credits him for many of the
Dewatering were proud to show off the cover.
associations greatest accomplishments.
Petes work on all our publications and standards was huge, Silverman says. And his
work in collaboration with the European Sealing Association was signiicant. We have several publications that are joint eforts between the two associations, and that is thanks to
Petes eforts. He has been the face of the FSA to other associations, at trade shows and on
our LinkedIn site.
Petes level of commitment to the FSA and his knowledge of the industry are impressive, and he has always been patient and willing to share that knowledge. He was a voice
of reason when things got busy, and his support has been invaluable. I have the utmost
respect for him and have enjoyed working with him, professionally and personally. I hope
he enjoys his well-deserved retirement, but I am going to miss him terribly.
It has been the pleasure of the entire Pumps & Systems team to work so closely with
Pete, and we wish him an enjoyable retirement. We pay tribute to his accomplishments on
page 74. Fortunately for our readers, we will continue to publish monthly Sealing Sense
articles with the support of the FSA.
his month, the Pumps & Systems team travels to Houston for the Ofshore Technology
Conference (OTC). See our coverage on page 59, and visit us at Booth 9631. his issue
covers several Oil & Gas Reinery Solutions (page 44), including a case study on coker
charge pump failures at BP Whiting Reinery, a submersible solids-handling pump solution in a petcoke sump service application and an update on valve fugitive emission regulations.
While at OTC, be sure to pick up a copy of Upstream Pumping Solutions. his publication is produced by the same team that brings you Pumps & Systems, but it focuses on
upstream oil & gas pumping technology. Visit the website at www.upstreampumping.com.
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
Assistant Editor
Savanna Lauderdale
slauderdale@cahabamedia.com
Contributing Editors
Laurel Donoho
Joe Evans, Ph.D.
Lev Nelik, Ph.D., PE, APICS
Ray Hardee
CREATIVE SERVICES
Senior Art Director
Greg Ragsdale
Art Director
Jaime DeArman
Web Content Editor & Web Advertising Traffic
Robert Ring
Print Advertising Traffic
Lisa Freeman
lfreeman@cahabamedia.com 205-212-9402
CIRCULATION
Jeff Heine
jheine@cds1976.com 630-739-0900
ADVERTISING
National Sales Manager
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
Administrative Assistants
Ashley Morris
amorris@cahabamedia.com 205-561-2600
Sonya Crocker
scrocker@cahabamedia.com 205-314-8276
Publisher
Walter B. Evans, Jr.

VP of Sales
Greg Meineke
VP of Editorial
Michelle Segrest
Creative Director
Terri Jackson
Controller
Tim Moore
P.O. Box 530067, Birmingham, AL 35253
Editorial & Production
1900 28th Avenue South, Suite 200
Birmingham, AL 35209
205-212-9402
Advertising Sales
2126 McFarland Blvd. East,. Suite A
Tuscaloosa, AL 35404
205-345-0784
Best regards,
is a member of the following organizations:

PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and
additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the right to determine qualifications. 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. 2014 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 22, Issue 4.
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
April 2014
Table of Contents
Volume 22 Number 4
Oil & Gas Refinery Solutions
52
45
COVER
SERIES
Refinery Repairs 20-Year Old Design Flaw

By Miguel Salgado, BP Whiting Refinery
Once recommissioned, a turbine-driven coker charge pump supplied the
highest capacity margins in its history.
52
Submersible Slurry Pump Provides Solution for

Petroleum Coke Sump Service
By Mike Bjorkman, BJM Pumps
With an agitator and a top-discharge design, these pumps prevent
clogging and successfully handle abrasive materials.
56
Valve Fugitive Emission Compliance Requirements

By Gobind Khiani, FLUOR CANADA, LTD.
End users must be aware of the valve emission standards to meet
industry requirements.
44
SPECIAL
SECTION
Bearings & Couplings

24
Active Magnetic Bearings Provide

Harsh Conditions Solution
By Richard Shultz, Waukesha Magnetic Bearings
A Russian oil & gas company produces a compressor
station to maximize pipeline capacity.
26
Prevent Bearing Misalignment

By Ryan Thomas, NSK
Properly aligned bearings can be critical to the life
and health of pumps.
32
32
Bearings & Seals Boost

Pump Performance
By Mark J. Cutler, SKF USA Inc.
Appropriate equipment selection and best-practice
maintenance procedures can make a difference in
reliability, service life and production.
36
Using Thermoplastic Composite

Bearings in Vertical Water Pumps
By Martin Swierczek, Greene, Tweed & Co.
A northeast Germany refinery increased its MTBF
and saved money by upgrading eight pumps.
24
4
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
Table of Contents
Sealing Technologies
SPECIAL
REPORT
74
FSA Celebrates 10 Years of Sealing Sense

By Michelle Segrest
Pete Petrunich retires as technical director after 17 years but leaves a legacy
of education and high quality standards.
78
From the Archives - The First Sealing Sense

How do you determine the primary cause(s) of mechanical seal failure?
Originally published September 2004
74
80
Sealing Sense
By FSA member Randy Wacker, P.E.
Prevent Gasket BlowoutWhats Most Important?
Practice & Operations

84
Sizing Pulsation Dampeners Is Critical to Effectiveness

By David McComb, Blacoh Fluid Control
Pressure variation is an important consideration when determining the
appropriate size pulsation dampener needed for an application.
Columns
16 Pump Ed 101
By Joe Evans, Ph.D.
Igor Karassik
the Pump Users Engineer
18 Pumping Prescriptions
By Lev Nelik, Ph.D., P.E.,
Pumping Machinery, LLC
Suction Valve Throttle Versus Vacuum
20 Pump System Improvement

By Ray Hardee,
Engineered Software, Inc.
Overcome Resistance to
Program Upgrade
84
Departments
2 From the Editor
8 Readers Respond
10 News
59 Trade Shows
60 Efficiency Matters
By Glenn Webb
Maximize Natural Gas Vapor Recovery
64 Maintenance Minders
By Jack Claxton, P.E.,
Patterson Pump Company,
A Gorman-Rupp Company
Analyze Top-of-Motor Vibration
70 Motors & Drives

By Josh Gross, Eaton
Modern Industrial Drives Redene
Motor Control
83 HI Pump FAQs
By Hydraulic Institute
Monitor Power in Rotary Pumps &
Submersible Air-Operated Pumps
89 Product Pipeline
91 Index of Advertisers
92 Pump Users Marketplace
96 Pump Market Analysis
Editorial Advisory Board

Thomas L. Angle, P.E., MSc, Vice President Engineering,
Hidrostal AG
Robert K. Asdal, Executive Director,
Hydraulic Institute
Bryan S. Barrington, Machinery Engineer,
Lyondell Chemical Co.
Kerry Baskins, VP/GM, Milton Roy Americas
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 Manager Pumping
Equipment, Square D by Schneider Electric
April 2014
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, VP/GM, Crane Pumps & Systems
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
www.pump-zone.com
William E. Neis, P.E., President, Northeast Industrial Sales

Lev Nelik, Ph.D, P.E., APICS, President, Pumping
Machinery, LLC
Henry Peck, President, Geiger Pump & Equipment Company
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)
Jerry Turner, Founder/Senior Advisor, Pioneer Pump
Kirk Wilson, President, Services & Solutions, Flowserve
Corporation
James Wong, Associate Product Manager - Bearing Isolator,
Garlock Sealing Technologies
PUMPS & SYSTEMS
P9 Pump Drive with
EQP Global Motor
ONE CALL. ONE SOLUTION.

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with the EQP Global motor, we have set new pump control
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READERS RESPOND
Using a Torque Wrench to Apply Stress to a Gasket,

December 2013 & Readers Respond, February 2014
In Readers Respond from the February 2014
issue of Pumps & Systems, someone commented
about an earlier Sealing Sense article, Using a
Torque Wrench to Apply Stress to a Gasket. The
commentary made reference to a point in the earlier article, Torque losses occur when using socket
extensions or crows foot attachments. The typical
Lee Ruiz
rule is to increase the torque by 10 percent to
account for these losses.
At irst, the notion of a torque loss and a compensating
increase didnt seem to make sense. However, the reasoning may
have been in the original authors response about The origin of
the increase was an auto mechanics rule-of-thumb for installations with awkward angles that prevented complete transmission of
torque. That is, a loss may be the result of a tilted torque wrench.
Therefore, the February response about no loss when using a
straight socket extension is correct if the centerline of the socket
coincides with the axis of the attachment. If the wrench and socket
are signiicantly tilted, a loss in applied torque can occur depending
on the tilt angle. Torque applied to

a fastener with a wrench that is not
held square to the work will act on
a longer moment arm than the fasteners normal width. Therefore, the
transmitted force will effectively act
on the fasteners shorter normal
width and transmit less torque than applied with a non-tilted
wrench. This same reasoning can also be applied to a tilted torque
wrench with a crows foot type extension. The auto mechanics may
have known a thing or two.
For a tilted torque wrench application, increasing the setting to
the desired fastener torque divided by the cosine of tilt angle might
be a better approximation than a lat 10 percent increase for any tilt
angle. Of course, torque setting reductions should be made when
using wrench extensions as addressed in the February commentary.
Lee Ruiz
Oceanside, Calif.
The Cost of PumpingPower Cost & Eficiency,

February 2014
The Pumps & Systems February 2014 article by Joe Evans, The
Cost of PumpingPower Cost & Eficiency, like so many others,
misuses the term power. The title should have been, The Cost of
PumpingEnergy Cost & Eficiency. There is no cost for power (think
horsepower); we only pay for energy (kilowatt-hours). These terms
are not interchangeable.
Russ Hulse, P.E.
Joe Evans responds:
I have to disagree with you that these terms are not interchangeable. he dictionary deinition for power is electrical or mechanical energy. Electric power is deined as
energy consumption per unit of

time. Although energy may be
the more precise term, power is
used commonly throughout the
industry. Power factor, reactive
power, apparent power, alternative power and power transmission are just a few examples. In fact, one of our local power
companies (Paciic Power) recently warned their customers
of potential power outages due to high winds. P&S
To have a letter considered for Readers Respond, please send it to Amanda Perry, aperry@cahabamedia.com.
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
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NEWS
NEW HIRES, PROMOTIONS & RECOGNITIONS

CARL-HENRIK BRAMSTNG,
Colfax Fluid Handling
MONROE, N.C. (March 10, 2014)
Colfax Fluid Handling named Carl-Henrik
Bramstng sales director, Shipowner Sales.
He has more than 30 years of experience and
Carl-Henrik
his responsibilities include sales of pumps and Bramstng
controllers to the maritime community.
Colfax Corporation provides gas- and luid-handling
and fabrication technology products and services. www.
colfaxcorp.com
TIMOTHY R. PIERCE, EXONE
NORTH HUNTINGDON, Pa. (March 3, 2014)
he ExOne Company announced that Timothy R. Pierce
joined the company as U.S. chief operating oicer. Pierce
brings extensive operational experience and will focus on
expanding and supporting production operations in the
U.S.
ExOne provides 3-D printing machines and printed
products, materials and other services. www.exone.com
PATRICK K. DECKER, Xylem Inc.
RYE BROOK, N.Y. (March 3, 2014)
Xylem Inc. announced that Patrick K. Decker
has been named president and chief executive
oicer and will be appointed to the board
of directors. Decker succeeds Steven R.
Patrick K. Decker
Loranger, who will remain a member of the
Xylem Board.
Xylem Inc. is a global water technology company. www.
xyleminc.com
WAYNE ROSE, Armstrong Fluid Technology
TORONTO (Feb. 28, 2014)
Armstrong Fluid Technology promoted
Wayne Rose to global marketing manager,
Pumps. His responsibilities include marketing of Armstrong pumps, suction guides and
Wayne Rose
valves on a worldwide basis. Rose has fulilled
a number of roles since joining Armstrong 15 years ago.
Armstrong Fluid Technology designs, engineers and
manufactures luid-low equipment. www.armstrongluidtechnology.com
10
April 2014
HYDRAULIC INSTITUTE Announces Board of Directors

and Oficers
PARSIPPANY, N.J.
(Feb. 25, 2014) he
Hydraulic Institute
(HI) announced the
2014 2015 board
of directors and
oicers at its annual
meeting. Dennis
Wierzbicki, presiHI Board
dent, Grundfos USA,
has been elected to serve as chairman of the board. George
Harris, president & CEO, Hydro, Inc. has been elected to
serve as HI president.
Other HI oicers are Michael S. Cropper, director,
Product Development, Sulzer Pumps (US) Inc. who
remains in his position as vice president, Technical Afairs;
John White, Jr., president & CEO, TACO, Inc. has been
elected to serve as HIs new vice president, Government &
Regulatory Afairs; Bob Hendricks, president, Industrial
Pump Operations, Flowserve, has been elected to serve
as HI vice president, Member Services; John Kahren,
president, SPP Pumps, Inc. remains in his position as HI
vice president, Knowledge & Education. Robert K. Asdal,
HI executive director, also continues to serve as secretary/
treasurer for the Hydraulic Institute.
Additional board members, serving terms of varying
lengths, include:
Jeremy Frank, president & CEO, KCF Technologies,
Inc.
Rich Heppe, president, Industrial Motors & Systems,
Nidec Motor Company
Allen Hobratschk, president, National Pump Company
Pat Morello, general manager, General Electric Power
Conversion
Robert Pagano, Jr., president, ITT - Industrial Process
Frank Rebori, president, Smith & Loveless, Inc.
Jef Wiemelt, president, Sundyne, LLC
HI also named Randy Bennett, vice president of Technology & Operations, Leistritz
Advanced Technologies Corporation, its
2013 Member of the Year.
HIs mission is to be a value-adding
resource to member companies, engineering
consulting irms and pump users worldwide.
www.pumps.org
www.pump-zone.com
Randy Bennett
PUMPS & SYSTEMS
GREGG C. SENGSTACK,
Franklin Electric
FORT WAYNE,
Ind. (Feb. 19, 2014)
Franklin Electric
announced that
Gregg Sengstack
Chairman and Chief
Executive Oicer R. Scott Trumbull
will retire as chief executive oicer
efective May 2, 2014 and that Gregg
C. Sengstack will succeed him in
that role.
Franklin Electric provides complete water and fueling systems.
www.franklin-electric.com
GARY BROWN,
BJM Pumps
OLD SAYBROOK,
Conn. (Feb. 18, 2014)
Ater more than 40
years in the pump
Gary Brown
industry, Chuck
Emmerling, Midwest regional manager, retired. Gary Brown joined the
BJM sales team as the new Midwest
regional sales manager.
BJM Pumps provides submersible
pumps for a variety of applications.
www.bjmpumps.com
AND
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Terminal Blocks
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Patented Tube
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Method for
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Non-invasive Clamp-on
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NEW Small Pipe Capacity
to 0.5".
Large Pipe Capacity
to 100".
Smart External
Communications.
Selectable Doppler or
Transit Time.
New T-Track
Mounting System
JON AMDURSKY,
U.S. Water
ST. MICHAEL, Minn.
(Feb. 24, 2014)
U.S. Water Services,
Inc., named Jon
Jon Amdursky
Amdursky to its
marketing team, focusing on media
relations. Amdursky comes to U.S.
Water from BWA Water Additives
where he had similar responsibilities.
U.S. Water provides solutions for
water treatment needs.
www.uswaterservices.com
Fast and Easy Sensor

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PUMPS & SYSTEMS
www.pump-zone.com
April 2014
11
NEWS
VICTOR KROTIKOV, Global Pump

DAVISON, Mich. (Feb. 17, 2014)
Global Pump appointed Victor Krotikov
as its European Union/Commonwealth of
Independent States business development
manager.
Victor Krotikov
Global Pump is a wholly-owned subsidiary
of the Mersino Group and a manufacturer of pumping
solutions. www.globalpump.com
CARRIE HALLE, PSG
OAKBROOK TERRACE, Ill. (Feb. 6,
2014) Pump Solutions Group, an operating company within Dover Corporation,
announced that Carrie Halle was appointed
director of marketing, Americas.
Carrie Halle
Dovers Pump Solutions Group manufactures positive displacement pump and supporting technologies. www.psgdover.com
AROUND THE INDUSTRY

REVERE CONTROL SYSTEMS Opens North Carolina Ofice
BIRMINGHAM, Ala. (March 12, 2014) Revere
Control Systems opened a new oice Charlotte, N.C. his
is the third remote oice opened in the past two years, with
others opened in Chattanooga, Tenn., and Lakeland, Fla.
he new oice will support Reveres growing customer base
in the Carolinas.
Revere Control Systems provides control systems for the
municipal and industrial markets and original equipment
manufacturers. www.reverecontrol.com
LEISTRITZ Restructure
ALLENDALE and SOMERVILLE, N.J. (Feb. 24, 2014)
Leistritz announced the reorganization of its pumps,
machine tools, turbine components and extrusion business
unites under the name Leistritz Advanced Technologies
Corp. efective immediately.
Leistritz Advanced Technologies Corp. is a fully owned
subsidiary of Leistritz AG. www.leistrizcorp.com
YOKOGAWA Receives Frost & Sullivan Award
NEWNAN, Ga. (Feb. 21, 2014) Yokogawa Electric
Corporation announced that it has received the Frost &
Sullivan 2014 Global Enabling Technology Leadership
12
April 2014
Award in the wireless solutions category. he Enabling

Technology Leadership Award is presented to companies around the world that are best-in-class in a speciic
category.
Field wireless systems enable a plants ield devices and
host-level monitoring and control systems to communicate
wirelessly with each other. his has numerous advantages
such as allowing the placement of ield instruments or
analytical sensors in diicult to wire locations, which eliminates the need for cables to connect devices and reduces
installation costs.
Yokogawa Corporation of America provides industrial
automation and test and measurement solutions. www.
yokogawa.com/us
XERIUM Breaks Ground on New Press Felt Plant in China
YOUNGSVILLE, N.C. (Feb. 19, 2014) Xerium
Technologies, Inc. held a groundbreaking ceremony for its
new press felt manufacturing facility in Kunshan, Jiangsu
Province, China.
he new plant will solidify the companys current and
future capacity to address the growing Asian market for
premium press felt product technology.
With an initial investment of approximately $35 to
$40 million, the facility will employ the industrys most
advanced press felt manufacturing technology. Once
MERGERS & ACQUISITIONS

HIGH PRESSURE EQUIPMENT COMPANY
acquired Stafordshire Hydraulics
Feb. 25, 2014
LYDALL, INC.
acquired Andrew Filtration
Feb. 20, 2014
NASMYTH GROUP
acquired Arden Precision
Feb. 20, 2014
FW MURPHY
was renamed Enovation Controls
Feb. 17, 2014
COLFAX CORPORATION
acquired Victor Technologies
Feb. 12, 2014
ARKEMA
created Sunke with Jurong Chemical
Jan. 23, 2014
For details about industry M&A activity, subscribe to

Pump Industry Insider and visit www.pump-zone.com.
www.pump-zone.com
PUMPS & SYSTEMS
operational, the project is expected to generate about 100

new jobs.
Xerium Technologies, Inc. provides industrial consumable products and services. www.xerium.com
FROST & SULLIVAN: Increased Demand for M2M
Communication
LONDON (Feb. 18, 2014) he manufacturing sector
has traditionally implemented a range of wired networks
to automate plant loor operations. However, emerging
machine-to-machine (M2M) systems such as short-range
wireless and long-range cellular networks are evolving into
choice solutions for factories of the future, Frost & Sullivan
reports.
M2M systems can supplement or replace wired networks
to enable advanced robotics and enterprise mobility on the
plant loor, enabling convenient connectivity in inaccessible areas, communication across barriers, and simpliied
installation based on wireless local area, wide area, and
sensor networks.
Frost & Sullivan, the Growth Partnership Company,
works in collaboration with clients to leverage visionary
innovation that addresses the global challenges and related
growth opportunities. www.frost.com
SIEMENS Provides Driving Gear for Truck in Guinness
Book of Records
MUNICH, Germany (Feb. 14, 2014) Siemens developed an AC traction drive system, MMT500 for the
BelAZ-75710. his truck was ield tested as the biggest
machine of its class, a performance worthy of an entry in
the Guinness Book of Records.
Siemens Industry Sector supplies products, solutions and
services. www.usa.siemens.com/industry
XYLEM Opens Third Dewatering Solutions Location
in Florida
BRIDGEPORT, N.J. (Feb. 10, 2014) Xylem announced
the opening of its newest dewatering solutions branch in
Pompano Beach, Fla. Managed by Florida branch manager,
Mike Sturgill, the 12,000 square-foot facility is equipped
with shop and oice space and sits on more than two acres.
Xylem is a global water technology provider, enabling
customers to transport, treat, test and eiciently use water
in public utility, residential and commercial building services, industrial and agricultural settings.
www.xyleminc.com
PUMPS & SYSTEMS
SIEMENS and ZOLO Expand Joint Activities

ERLANGEN, Germany (Feb. 5, 2014) Siemens Energy
and Zolo Technologies have expanded their previous
collaboration to a worldwide license agreement for fossilfueled steam generation boiler applications.
Under the terms of the agreement, Siemens and Zolo
will more closely integrate their combustion optimization
products and actively extend their market activities beyond
Europe into the U.S., China and other fossil markets in
Asia.
he Siemens Energy Sector supplies a broad spectrum
of products, services and solutions for power generation
in thermal power plants and using renewables, power
transmission in grids and for the extraction, processing and
transport of oil and gas. www.siemens.com/energy
EPA Awards Grants to Researchers Working to Improve
Water Quality
WASHINGTON ( Jan. 30, 2014) At the 14th National
Conference and Global Forum on Science, Policy and
the Environment, U.S. Environmental Protection Agency
(EPA) Administrator Gina McCarthy announced grants
to four research institutions for innovative and sustainable
water research to manage harmful nutrient pollution.
Nutrient pollution is one of Americas most widespread,
costly and challenging environmental problems, and is
caused by excess nitrogen and phosphorus in waterways.
he following institutions received grants:
Pennsylvania State University Center for Integrated
Multi-scale Nutrient Pollution Solutions, to focus on
nutrient flows in Pennsylvania and the Chesapeake
basin
University of South Florida Center for Reinventing
Aging Infrastructure for Nutrient Management, to
support Tampa Bay and similar coastal areas as they
face problems of aging wastewater collection and
treatment systems, and rapid population growth
Colorado State University, Center for Comprehensive,
Optimal, and Effective Abatement of Nutrients, for
linking physical, biological, legal, social and economic
aspects of nutrient management in the Western and
Eastern United States
Water Environment Research Foundation,
Alexandria, Va., National Center for Resource
Recovery and Nutrient Management, for innovative research in nutrient reduction through resource
recovery and behavioral factors affecting acceptance
and implementation
www.pump-zone.com
April 2014
13
NEWS
EPAs mission is to protect human health and the environment. www.epa.gov

EMERSON Opens Third Global Innovation Center
AUSTIN, Texas ( Jan. 30, 2014) Emerson Process
Management held the grand opening of its Emerson
Innovation Center - Process Systems and Solutions in
Round Rock, Texas, near Austin.
his 282,000 square-foot, nearly $70 million facility
will be the global headquarters for Emersons automation
systems and project services business.
Emerson brings technology and engineering together to
provide innovative solutions for customers in industrial,
commercial, and consumer markets around the world.
www.emerson.com
P&S
To have a news item considered, please send the information to Savanna

Lauderdale, slauderdale@cahabamedia.com.
CALENDAR
MAY
OFFSHORE TECHNOLOGY CONFERENCE
(OTC)
May 5 8, 2014
Reliant Park
Houston, Texas
301-694-5243
www.otcnet.org
IFAT
May 5 9, 2014
Munich Trade Fair Center
Munich, Germany
+49 89 949-11358
www.ifat.de
WINDPOWER CONFERENCE
May 5 8, 2014
Mandalay Bay Convention Center
Las Vegas, Nev.
202-383-2500
www.windpowerexpo.org
JUNE
ECWATECH
AWWA
WEFTEC
June 8 12, 2014

Boston Convention & Exhibition Center
Boston, Mass.
800-926-7337 / www.easa.com
Sept. 27 Oct. 1, 2014

New Orleans, La.
New Orleans Morial Convention Center
www.weftec.org
SIEMENS AUTOMATION SUMMIT

June 23 26, 2014
Walt Disney Worlds Contemporary Resort
Orlando, Fla.
www.usa.siemens.com
NOVEMBER
POWER-GEN INTERNATIONAL
EASA
Nov. 12 14, 2014

Orange County Convention Center
Orlando, Fla.
918-831-9161 / www.power-gen.com
June 29 July 1, 2014

Hynes Convention Center
Boston, Mass.
314-993-2220 / www.easa.com
INTERNATIONAL ASSOCIATION OF
AMUSEMENT PARKS AND ATTRACTIONS
(IAAPA)
SEPTEMBER
PUMP USERS SYMPOSIUM /
TURBOMACHINERY
Sept. 23 25, 2014
George R. Brown Convention Center
Houston, Texas
979-845-7417 / http://pumpturbo.tamu.edu
June 3 6, 2014
Moscow, Russia
+7 (495) 225 5986 / www.ecwatech.com
Nov. 18 21, 2014

Orange County Convention Center
Orlando, Fla.
703-836-4800 / www.iaapa.org
DECEMBER
NGWA
Dec. 9 12, 2014
Las Vegas, Nev.
www.ngwa.org
To have an event considered, please send the information to Savanna Lauderdale, slauderdale@cahabamedia.com.
14
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
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By Joe Evans, Ph.D.

PumpTech Inc.
P&S Editorial Advisory Board
PUMP ED 101
Igor Karassik
the Pump Users Engineer
D
uring the past few years, I have written articles about Users Symposium because of its objective to help pump
scientists who have contributed to our understanding users better understand pumps. At the 1988 symposium,
of hydraulics. hese included Daniel Bernoulli (Pumps he presented a paper entitled, An Open Letter to the
& Systems, August 2012 and September 2012) and Blas Pump Industry. his presentation stressed his belief that
Pascal (Pumps & Systems, February 2007). Several more manufacturers should exert a greater efort to educate
have made signiicant contributions that I have yet to cover. pump users.
Bernoullis theorem on energy conservation during
He was most concerned with something he called consteady-state low and Pascals work on hydrostatics are still troversial facts. he two that he mentioned were required
used daily in our industry. heir work dates back to the versus recommended net positive suction head and recom17th and 18th centuries. However, not long ago, a 20th mended minimum lows. One of his most quoted statecentury Russian immigrant also had a profound inluence ments from this presentation was, When the user hears
on the industry. Igor Karassik championed several engi- two or more statements that contradict each other but
neering breakthroughs and focused on
start with the same it has been proven he
Part of our ongoing series on
teaching pump users to apply their pumps
is completely confused. Remember, a man
correctly.
with one watch knows what time it is, but a
One of his frequent quotes was operaman with two watches does not.
tors deserve to sleep nights, too. During
For some of the younger readers who
his 50-year career, he became known as the
may not be familiar with mid-20th cenpump users engineer.
tury watches, they were not as accurate
www.pump-zone.com/tags/history-pumps
Karassik was born in Russia in 1911 and
as todays digital models. Seldom did two
passed away in 1995. He immigrated to the U.S. during display the same time. Several of his symposium papers,
the Russian revolution and was educated at the Carnegie including An Open Letter to the Pump Industry, A Map
Institute of Technology, where he received a B.S. and M.S. of the Forest and A Name Well Chosen, as well as all the
in engineering. Karassik joined Worthington Pump in annual proceedings are available online at http://turbolab.
1934 and spent much of his career there. In 1937, he and tamu.edu/proc/index.html.
fellow employees, George Wislicenus and R. M. Watson,
Karassiks forward-thinking ideas oten faced resistance
developed the concept of suction speciic speed, which from others in the industry who were reluctant to try someeventually replaced the homa-Moody constant.
thing new. His usual reply was, If you dont want probhe use of suction speciic speed provided a far more lems, then dont do anything. Progress is made by solving
reliable method for determining the low at which recir- the problems caused by progress.
culation could occur in the suction of a pump. Two of
As a follow-up, he also stated, here may be a light at
Karassiks other successes include the prevention of cata- the end of the tunnel, but once in a while, there could be
strophic boiler feed pump failures in open-cycle steam another tunnel at the end of the light.
power plants and the development of high-speed (9,000
In the end, he considered his most important role as that
rpm) boiler feed pumps. In the 1970s, he was an early advo- of a teacher. He was unique and, to date, I have yet to see his
cate for the development of variable frequency drives and replacement in the pump manufacturing industry.
the use of magnetic bearings in electric motors.
During his career, he authored several pump-related
In addition to his vast technical knowledge, Karassik had books including, Centrifugal Pump Selection, Operation
a keen business sense. He believed that the only way busi- and Maintenance; Engineers Guide to Centrifugal Pumps;
ness can prosper is by helping customers succeed in their and Centrifugal Pump Clinic. He was co-author of Pump
endeavors. A major goal was educating end users about Questions and Answers and co-editor of the industry bible,
pumps so they could apply them properly.
Pump Handbook. Some of the older editions of his books
He was a loyal supporter of the International Pump are available as a free download. He also authored more than
16
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
Karassiks forward-thinking ideas often faced resistance from others in

the industry who were reluctant to try something new. His usual reply was,
If you dont want problems, then dont do anything. Progress is made by
solving the problems caused by progress.
500 technical articles. One of the
most popular was a three-part series
on Centrifugal Pump Operation at
Of-Design Conditions. his series
is a must-read and is available on my
website, www.PumpEd101.com.
For the pump industry to excel, it
must follow Karassiks philosophy
because it is a proven roadmap to success. Invest in innovation and progress. Solve the problems caused by
progress. Work with customers and
help them succeed. Finally, use education to make the incomprehensible
comprehensible to all in the industry.
In closing, another Russian engineer who has been a major contributor to the proper application and
understanding of pumps is Dr. Lev
Nelik. Nelik immigrated to the U.S.
in 1979 and worked for several major
pump manufacturers before founding his own company, which ofers
training and consulting services.
Like Karassik, he is a major supporter of the International Pump
Users Symposium and serves on
the advisory committee. Nelik has
authored his own book on centrifugal and rotary pumps and has
published more than 50 technical papers. You probably know
him best for his educational
Pumping Prescriptions that are
published monthly in Pumps &
Systems. P&S
Joe Evans is responsible for customer and
employee education at PumpTech Inc., a pump
and packaged systems manufacturer and distributor with branches throughout the Paciic
Northwest. He can be reached via his website
www.PumpEd101.com. If there are topics that
you would like to see discussed in future columns, drop him an email.
PUMPS & SYSTEMS
WHEN QUALITY AND

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centrifugal API 610 pumps for oil
and gas exploration and production,
petroleum refining, gas processing,
oil processing, hydrocarbon and
crude oil pipeline and offshore
production platform applications.
We make the purchase of your API
610 pump an enjoyable process,
and we ensure that the finished
product meets or exceeds your exact
specifications.
OUR PUMPS ARE:
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Fully compliant with API 610 specs

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Selector Program - no registration
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For more information, call toll free at

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www.pumpworks610.com.
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www.pump-zone.com
April 2014
17
By Lev Nelik, Ph.D., P.E.

Pumping Machinery, LLC
P&S Editorial Advisory Board
PUMPING PRESCRIPTIONS
Suction Valve Throttle Versus Vacuum

First of Two Parts
avitation can severely damage pumps and is afected by

pump design and system issues. What afects it most?
Does the suction behavior from the discharge side (system)
of a pump afect pump cavitation? Cavitation is initiated
when the suction pressure drops below vapor pressure.
However, does it matter how this pressure is reduced, and
what is the system mechanism that can lead to the typical
detectable noise versus cases in which, even if pressure drops
substantially, no sound occurs? his column and Part Two
in May will cover this topic.
Part One breaks down a video of two cases that are seemingly similar, but under closer examination, have signiicant
diferences. Learning the diferences can help pump users
better understand the basics of cavitation mechanisms and
also how the system within which the pump operates can
contribute to it.
Diferences in low pressure initiation at the pump inlet
is not the only factor to consider for an in-depth understanding of suction valve throttle versus vacuum pumping.
A video of one of the live, hands-on exercises conducted
during Pump School sessions shows each example and can
be viewed at:
www.pump-magazine.com/pump_magazine/q&a/
faqq111-120/faqq111_120.htm (Question #120)
In this video, two tests are conducted. he irst, Case A,

involves dropping the suction pressure in front of a pump
by valve throttling. Case B introduces vacuum at the supply
tank. In Case B, water is recirculated to the supply tank
(dash line version), instead of a more common situation in
which it is pumped from one tank to another. Would you
expect the result shown in Figure 2in both cases?
Case A and B will be a test. he reader who answers correctly wins a ticket to the next Pump School. Make sure to
view the video to follow along.
As the suction valve (Vs) is throttled, the suction gauge
(Ps) reads less pressure and becomes below atmospheric.
What should happen when suction pressure begins to drop
is the low and head should remain constant for some time
until the suction pressure drops signiicantly, when net positive suction head available (NPSHA) reaches the net positive suction head required (NPSHR), and then the total
pump head drops quickly. However, as the video shows,
low drops immediately while the suction gauge needle
barely moves. However, no cavitation is observed.
Alternatively, when the suction valve is kept open and
vacuum is applied to the supply tank via the vacuum control
valve (Vvac), the low remains constant, as expected, until
a strong vacuum is reached. his results in fully developed
cavitation, which becomes obvious and strong. Only then
will low drop suddenly.
Vacuum
Vvac
Pd
Ps
P
Vs
Vd
Figure 1. System sketch illustrating the example on the video
18
April 2014
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PUMPS & SYSTEMS
Can you explain why?

Should the low behave similarly in both casesstaying
constant for a long time and
only becoming afected at low
values of NPSHA (low Ps)?
he best answer will be published in an upcoming issue of
Pumps & Systems.
A lot of bubbles
More bubbles
Incipient
Head, ft
Note: his test is one of the

standard exercises during Pump
School sessions. For the schedule, visit www.pumpingmachinery.com/pump_school/
pump_school.htm). P&S
Dr. Nelik (aka Dr. Pump) is president
of Pumping Machinery, LLC, an Atlantabased irm specializing in pump consulting, training, equipment troubleshooting
and pump repairs. Dr. Nelik has 30 years
of experience in pumps and pumping
equipment. He can be contacted at www.
pump-magazine.com.
3%
NPSHR3%
NPSHA, ft
Figure 2. Development of cavitation, starting from the incipient bubble formation and eventually
developing to highly unstable bubble activity, their collapse, and damage of the impeller blades

PUMPS & SYSTEMS
www.pump-zone.com
April 2014
19
By Ray Hardee
Engineered Software, Inc.
PUMP SYSTEM IMPROVEMENT
Overcome Resistance to
Program Upgrade
P
revious articles in this series explained how oversized

piping systems can have higher operating and
maintenance costs. Higher maintenance costs can adversely
afect the reliability and uptime of piping systems. All these
factors have a detrimental efect on plant proitability.
My last column (Pumps & Systems, March 2014) explained
how the plants inancial management team could estimate
the magnitude of potential savings using readily available
plant operating data. Once team members feel that the risk/
reward is suicient, they may choose to proceed with a pilot
pump system improvement program.
he most diicult step is implementing the inancial management teams goals and objectives into plant operations.
he inancial managers may think the program is valuable,
but the plants operation and maintenance staf still must be
convinced. his article discusses how to overcome the resistance to setting up a pump system improvement program.
he irst step is selecting the team leader. For the program
to be successful, the team leader must be dynamic and able
to involve the major players in overall plant operations to
see the programs value for their workgroup or department.
OVERCOME RESISTANCE TO CHANGE

When beginning any new program, the team leader
will oten experience resistance to change. his must be
addressed. he value of the program must be sold to the
key individuals who will run the program. In most cases,
reluctance to implementing a pump system improvement
program exists for three primary reasons:
Pump systems are designed to meet future needs, and
most people do not want to lose the extra capacity.
Many people at a plant do not have a clear picture of
how the dierent elements in pumping systems interact. As a result, they may feel these systems are difcult to understand and do not want to make changes
to something they do not fully understand.
he process systems that are being evaluated generate
the plants revenue, so many people are reluctant to
change the process unless they are assured of a positive
nancial outcome.
RECOGNIZE WHY SYSTEMS ARE OVER BUILT
Systems are over-designed to account for unknown conditions. For example, the system may be designed to meet
future needs versus the expected current market needs.
20
April 2014
During the equipment sizing process, additional design

margins are added to accommodate unknown factors before
the system is built.
Using these margins in the design process is similar to
purchasing insurance to protect against lifes unknowns.
Just like insurance, a cost is associated with over-designing
systems, speciically an increase in capital cost, as well as
operating and maintenance costs.
I would never recommend designing a system without
considering potential unknown factors, but plant owners
need to realize that once the pumping system is in operation, many of the unknown factors become apparent.
For example, if the system was sized for a design low rate
of 500 gallons per minute (gpm), but it has been running for
the last four years at 250 gpm, a major cost reduction is possible. he goal of the pump system improvement program
is to evaluate the actual operation of pumped systems and
improve the total system eiciency to meet current plant
operation requirements.
UNDERSTAND THE SYSTEM

Pump systems span many departments within an operating
plant, and diferent groups must work together to ind a
common solution (see Figure 1). A pump is powered by an
electric motor that converts electrical energy to mechanical
energy. he rotating impeller in the pump converts mechanical energy to hydraulic energy in the luid.
he hydraulic energy provides the low and pressure
required to make a product. To meet the product quality
Figure 1. Deionized water system
www.pump-zone.com
PUMPS & SYSTEMS
requirements, the process must be controlled by instrumentation and controls. he control valve removes excess energy
from the system and turns it into heat, noise and vibration.
In addition, the process system must be safely operated
and maintained. If the personnel in each efected department do not have a system-wide view, identifying and
correcting problems that afect the whole system can be
diicult.
Because pumping systems consume
25 to 50 percent of all electrical power
in process plants, it is important to
gain a better understanding of how
the various elements work together as
a total system. his is a crucial step in
an efective program in reducing cost
and improving system uptime.
RELUCTANCE IN CHANGING
PROCESS SYSTEMS
Because the process system generates
plant revenue, people can be reluctant
to make changes to an existing process
system unless the changes will increase
plant output. Most plants will gladly
modify a system to increase system
output, even if the changes require
additional equipment that must be
purchased, operated and maintained.
If market conditions warrant and
the increased capacity and return
on investment can be justiied, the
changes are oten made.
With a system that is not operating
eiciently, plant managers are likely
not aware of how ineicient their
pumping systems are.
If a system is operating ineiciently
(because of an oversized pump) and
system improvements are made without a reduction in system capacity,
the systems proitability is increased.
Oten, improvements to system eiciency can occur without purchasing
new equipment.
Increased proitability is possible
either by increasing the systems capacity or removing the systems ineiciencies. Any change that can improve
proitability should be considered if
the risk/reward ratio is suicient.
ADDITIONAL ITEMS TO ADDRESS

Additional items needed for implementing a pump system
improvement program include:
Identifying systems that have significant savings
potential
Developing a method for evaluating the existing
system
Personnel required to run the program
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PUMPS & SYSTEMS
www.pump-zone.com
April 2014
21
PUMP SYSTEM IMPROVEMENT

Instrumentation requirements
Method of presenting the results
A means of evaluating proposed system improvements
he standard discusses the items that must be addressed

when starting a pump system improvement program.
FOCUS ON QUALITY IMPROVEMENTS

Personnel oten push back when beginning a new program
within a plant, and a pump system improvement program
is no exception. Once again, the team leader must demonstrate the value of the program and ease of implementation
to plant personnel.
Most industrial plants use a quality
programsuch as Quality Assurance,
Zero Defects, Total Quality Management (TQM), Six Sigma, Toyota
Production System (TPS), or Lean
Six Sigma. he goal of programs such
as these is to continuously improve
the quality of products and processes.
his is accomplished through a group
efort to improve product quality and
proitability. he objectives of a pump
system improvement program coincide with all plant quality programs.
Rather than create yet another program, simply roll the pump system
improvement program into the existing quality program. he only additional task is educating the diferent
members of the pump system improvement team on how to conduct a system
assessment as outlined in the ASME
EA-2-2009 Energy Assessment for
Pumping System standard.
Because gaining a clear picture of
total system operation is such an integral part of a pump system improvement program, the May 2014 column
will focus on total system operation.
A pump system will be broken down
into its basic elements to see how they
work together, how the system operNSK High Performance Series (HPSTM) Angular Contact Ball Bearings
ates, how the energy is used and how
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Designed for the rigorous demands of pump and compressor applications, this
At irst glance, this looks like a major efort, but these items
and more are covered in an American National Standard
American Society of Mechanical Engineers (ASME) EA-22009 Energy Assessment for Pumping System.
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Ray Hardee is a principal founder of Engineered

Software, creators of PIPE-FLO and PUMP-FLO
software. At Engineered Software, he helped
develop two training courses. He is a member of
the ASME ES-2 Energy Assessment for Pumping
Systems standards committee and the ISO
Technical Committee 115/Working Group 07
Pumping System Energy Assessment. He may be
reached at ray.hardee@eng-software.com.
22
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
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SPECIAL SECTION
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Active Magnetic Bearings Provide
Harsh Conditions Solution
A Russian oil & gas company produces a compressor station to maximize pipeline capacity.
By Richard Shultz, Waukesha Magnetic Bearings
ith more than 20 years of experience in the oil and gas

industry, Lukoil, a Russian oil and gas business, aspired
to expand its oil and gas ields. For the expansion, Lukoil
selected the Bolshekhetskaya depression in West Siberia,
where large deposits of ceromanian gas lay.
Developing and constructing a compressor station to
connect the ields would increase the total capacity of the
pipeline. he compressor design had to produce a high discharge pressure. In addition to the pressure gain required
to compensate for the piping frictional losses, the discharge
pressure of the compressor also supports a refrigeration process applied to the gas at the plant outlet.
his refrigeration process, based on a throttling principle, is
required to cool the gas suiciently to keep the buried piping
24
April 2014
temperatures from thawing the permafrost. he permafrost

helps maintain a stable support for the buried piping.
THE CHALLENGE
Lukoil partnered with Sumy Frunze, an oil and gas equipment manufacturer, to develop centrifugal compressors that
could withstand the frigid Siberian conditions. he compressors would allow the station to pump 12 billion cubic
meters of gas per year to another station, furthering the central gas pipeline of Russia. Providing such high compressor
discharge pressures with reasonable drive power requires
compressors with high eiciency.
he high eiciency was achieved with a compressor rotor
shat with a high slenderness ratio. his high slenderness
www.pump-zone.com
PUMPS & SYSTEMS

ratio allows high eiciencies but results in a lexible compressor rotor shat. he Lukoil compressors have the most
lexible rotors ever equipped with magnetic bearings. he
processing power and advanced control algorithms provided by the bearing manufacturers electronic controller
were required to make these machines a success.
he bearing manufacturer provided its multiple coordinate control (MCC) algorithm to stabilize all compressor
rotor natural frequencies, with robust stability margins.
Ater installation, the technology performed successfully.
Within the centrifugal compressor, the magnetic bearing
technology provided savings in energy, ecology and the
total cost of ownership for Lukoil.
he active magnetic bearing (AMB) system has an
expected life of 25 years. he primary advantage for the end
user throughout this time period is lower maintenance and
operating costs and improved reliability compared to luid
ilm bearing solutions.
he compressors equipped with the magnetic bearing
technology allowed Lukoil to continue with its nine-year
development strategy, which started in 2005. Prior to this
installation, Sumy Frunze had used AMB systems from
other manufacturers. his equipment included analog
components within the controller tuning circuitry. he
bearing manufacturer supplied its digital controller, which
eliminated the physical act of connecting and disconnecting
analog electronic components with its standard digital technology that is adjusted and calibrated by quickly changing
sotware parameters.
PERFORMANCE COUNTS
he Lukoil site is located in western Siberia and is isolated
from all public utilities. All electric power must be generated on site, and losing all power is not unusual. During
these outages, conventional equipment, such as lube oil
skids, required for luid ilm bearings will drop well below
operable temperatures.
he time required to heat this equipment and the oil
reservoirs back to operable temperatures can be four hours
or more. his downtime risk was completely eliminated by
using magnetic bearings for the compressors. he magnetic
bearings can be re-activated within minutes ater site power
outages. his greatly increases the availability of the compressors. Following the 2013 installation, gas production
and the total production of hydrocarbons were on track to
increase by 42 billion cubic meters and 25 percent, respectively, by 2014. It is now possible for 12 billion cubic meters
of gas to be transported from the newly constructed compressor station to the main station and ultimately to the central gas pipeline in Russia.
VERSATILITY
Similar magnetic bearings may be used in other applications.
In fact, the success of the six-stage centrifugal compressors
led Lukoil to implement the magnetic bearing technology
on a booster compressor station in the same gas ield. Other
applications include turbo expanders, motors, generators,
pumps, steam turbines, gas turbines and blowers. P&S
Richard Shultz is the chief engineer for bearing systems at
Waukesha Magnetic Bearings with 20 years of industrial
experience designing magnetic bearing systems and auxiliary bearing systems. He received his rotordynamic and control system education at Texas A&M University, and there, he
co-invented the TAMSeal damping seal with Dr. John Vance.
Shultz can be reached at rshultz@waukbearing.com.
Top of facing page: Natural gas compressor at the Lukoil

Nahodkaskaya site in Western Siberia
Above: Gas pumping station process equipment
Right: Compressor building at the Lukoil Nahodkaskaya site
in Western Siberia
PUMPS & SYSTEMS
www.pump-zone.com
April 2014
25
SPECIAL SECTION
Prevent Bearing Misalignment

Properly aligned bearings can be critical to the life and health of pumps.
By Ryan Thomas, NSK
isalignment is a frequent cause of rolling

bearing failure. It can cause cage fracture,
which will result in seizure of the bearing, pump
failure and costly downtime. It can also cause
edge loading, which will result in early bearing
failure.
Typical bearing-life calculation tools assume
that the bearings inner and outer rings are well
aligned. A general acceptable alignment is better
than 0.003 radian (10 arcminutes) for ball bearings and 0.0012 radian (4 arcminutes) for cylindrical roller bearings.
Rolling bearings are manufactured with great
accuracy. Great care must be taken with machin- Figure 1. Typical running paths of deep groove ball bearings
ing practices and assembly accuracies of the
Non-lat mounting surface
mating shat and housing to maintain this accuracy. In prac Insuicient rigidity of the mounting surface
tice, however, the machining accuracy of parts surrounding
the bearing must be considered. Sources of misalignment
DIAGNOSE MISALIGNMENT
include:
Misalignment in a failed bearing can typically be diagnosed
Nonconcentric housing bores
by examining the rolling element path inside the bearing.
Non-perpendicular shoulders on mating components
As bearings rotate, the rolling elements generate a wear path
Bent shating
on the inner and outer raceways. A well-aligned bearing will
Errors during installation
exhibit a running path down the center of the inner and
Baseplate irregularities
outer rings, while a misaligned bearing will exhibit
Item
Class of
Shaft
Housing
uneven running paths (see Figure 1).
Bearings
Bore
IT3 IT4 IT4 IT5
AVOID MISALIGNMENT
to
to
2
2
2
2
Tolerance for
Normal, Class 6
Misalignment can be avoided by being attentive
out-of-roundness
Class 5, Class 4 IT2 to IT3 IT2 to IT3
during the bearing installation process. he irst step
2
2
2
2
is the proper design and machining of the mating
housing and shat components. Housings should
IT3 IT4 IT4 IT5
to
to
be rigid to provide irm bearing support. In cases
2
2
2
2
Tolerance for
Normal, Class 6
in which two bearings are mounted in one housIT2
IT3
IT2
IT3
cylindricity
Class 5, Class 4
to
to
ing, the itting surfaces of the housing bore should
2
2
2
2
be designed so both bearing seats may be inished
Tolerance for
Normal, Class 6
IT3
IT3 to IT4
together with one operation, such as in-line boring.
shoulder runout
Class 5, Class 4
IT3
IT3
he recommended accuracy and surface inish of
1.6
0.8
Roughness of itting Small bearings
shats and housings are listed in Table 1 for normal
3.2
1.6
Large bearings
surfaces, Ra ((
operating conditions (IT values are International
Table 1. Recommended accuracy and roughness of the shaft and housing
Tolerances Grades as per the International
26
April 2014
www.pump-zone.com
PUMPS & SYSTEMS

Organization for Standardization 286). he shoulders of his allows the axis of the inner ring, balls and cage to
the shat or housing that contact the face of a bearing must delect to some extent around the bearing center. However,
be orthogonal to the shat center line.
this design can create a smaller contact angle between the
he illets of the shat and housing should not contact the ball and the raceway, which results in a lower load capacity
bearing chamfer, while the supporting shoulder diameter compared to a similar sized, deep-groove ball bearing.
still must be large enough to fully support the face of the
he permissible static misalignment in this bearing type
bearing.
During installation, all mating
surfaces should be cleaned, and all
shat and shoulder abutting surface
edges should be free of burrs. Bearing
mounting methods will vary depending on the bearing type and the type
of it. Because bearings are usually
used with rotating shats, the inner
rings require a tight it.
MAKE THE CONNECTION
Bearings with cylindrical bores are
usually mounted by pressing through
the inner ring on the shats (press it)
or heating them to expand their diameter (shrink it). Bearings with tapered
bores can be mounted directly on
tapered shats or on cylindrical shats
by using tapered sleeves.
Bearings are usually mounted in
housings with a loose it. However, if
Tje glodal leader in ezidle eourlings
the outer ring has an interference it,
hor rumr ( eomrressor arrlieations.
a press may be used. End users should
Trust the innovator-trust CENTA.
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of the bearing. When pressing onto a
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MITIGATE THE EFFECTS ON
BEARING LIFE
Several bearing solutions are available
to help mitigate the efects of misalignment. For example, nylon cages
are more lexible than steel cages
and can accommodate misalignment
better than steel cages. Increasing the
internal clearance of the bearing will
increase its misalignment capacity.
Self-aligning ball bearings can also
be used. hese bearings have a spherical raceway with a center of curvature
that coincides with that of a bearing.
PUMPS & SYSTEMS
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www.pump-zone.com
April 2014
27
SPECIAL SECTION
is approximately 0.07 to 0.12 radian (4 to 7 degrees) under
normal loads. Depending on the surrounding structure, this
angle may not always be possible.
Because standard L10 calculations assume that the bearing is well-aligned, additional calculations must be made
to determine the efect of misalignment on the bearings
fatigue life. he maximum allowable misalignment of a

bearing varies depending on the size and type of bearing,
internal clearance during operation, and the load.
Assume the fatigue life without misalignment as L 0, and
the fatigue life with misalignment as L. he efect of the
misalignment on the fatigue life can be found by calculating L/L0. Figures 2 and 3 show the
efect of misalignment on the life ratio
for a deep groove ball and roller bearing, respectively. In these igures, the
horizontal axis shows the misalignment of inner/outer rings (rad), while
the vertical axis shows the fatigue life
ratio L/L.
As an example of ordinary running conditions, the radial load Fr (N)
{kgf } for both igures was assumed to
be approximately 10 percent of the
dynamic load rating Cr (N) {kgf },
and the shat it was machined to the
recommended value. he decrease of
the internal clearance because of the
expansion of the inner ring was also
considered.
Figure 2 was generated using the
normal radial clearance for the deep
groove ball bearing. he three separate plots represent maximum, minimum and mean efective clearance.
he reduction of the fatigue life is
limited to 5 to 10 percent up to 0.004
radian of misalignment, therefore,
not signiicantly reducing the bearing
life. However, when the misalignment
exceeds this limit, life is reduced considerably. In this scenario, an increase
of 111 internal clearance results in
~0.0015 radian increase in misalignment capacity.
Figure 3 plots three separate clearance classes for a cylindrical roller
bearing: normal, C3 and C4 clearFOR EXTREME DUTY POWER TRANSMISSION:
ance. In comparison to Figure 2, the
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life ratio is reduced by more than 10
percent with only 0.001 radian of misalignment. Little variation between
the diferent clearance classes exists,
RW-AMERICA.COM
THE COUPLING.
despite a total diference of 500.
Clearly, the roller bearing is more
THE SURVIVOR
28
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
SPECIAL SECTION
Figure 2. Life ratio for 6200 deep-groove ball bearing
Figure 3. Life ratio for NU315 cylindrical roller bearing
completely avoided, additional calculations are required to

determine the efect it will have on the bearing life. Contact
a bearing manufacturer for assistance with these calculations and additional application analyses. P&S
sensitive to the efects of misalignment than the ball bearing, and this should be considered when selecting a bearing
type in a new pump design. hese igures were generated
for typical operating conditions but are not applicable to all
pump applications.
Reducing or eliminating misalignment is critical to long
bearing and pump life. Catalog-recommended assembly
tolerances and installation processes must be followed to
prevent bearing misalignment. If misalignment cannot be
Ryan Thomas is the Pump and Compressor market segment

manager at NSK Corporation. He has a BSME from the
University of Michigan and more than 10 years of motion
control experience.
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April 2014
www.pump-zone.com
PUMPS & SYSTEMS
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SPECIAL SECTION
Bearings & Seals Boost Pump Performance

Appropriate equipment selection and best-practice maintenance procedures can make a
difference in reliability, service life and production.
By Mark J. Cutler, SKF USA Inc.
earings in centrifugal pumps support hydraulic loads

imposed on the impeller, the mass of the impeller and
shat, and loads caused by couplings and drive systems. hey
also keep axial and radial shat delections within acceptable
limits for the impeller and shat seal.
Handling all these functionsoten in diicult process
conditionsbearings are subjected to adverse forces that
can potentially reduce their service life and reliability.
Radial shat seals serve as critical elements within a
pumps bearing and sealing system. Seals will efectively ofer
a irst line of defense for bearings in pump applications.
hey retain lubricants or liquids, exclude
contaminants, separate luids and conine
pressure.
With pump bearings and shat seals
continually tested as an integrated system,
the industry responded to the many challenges with solutions engineered to withstand even the most diicult operating
conditions.
BEARING OPERATING CONDITIONS
Centrifugal pump bearings are typically
subjected to high axial loads, marginal
lubrication and high operating temperatures and vibrationall while attempting
to minimize friction. Friction, if uncontrolled, can result in power loss, excessive
heat generation, increased noise and/or
wear, and premature bearing failure.
hese inluences can dramatically
impact the service life and reliability of
bearings and pumps. Bearings (types,
designs and arrangements) should be evaluated in the context of their anticipated
operating environment.
For example, angular contact ball bearings are usually speciied as pump thrust
bearings to support axial loads created by
32
April 2014
the hydraulic forces in a pump. Each variation will carry particular beneits for an application.
ANGULAR CONTACT BALL BEARINGS
Single-row, 40-degree angular contact ball bearings represent the most popular American Petroleum Institute (API)
pump thrust bearings currently in service. hey are generally used in moderate-speed centrifugal pumps in which
high thrust loads can be anticipated.
he bearings are normally mounted in back-to-back
paired arrangements to accommodate reversing thrust loads
Single-row angular contact ball bearings are used in moderate-speed centrifugal pumps in
which high thrust loads can be anticipated.
www.pump-zone.com
PUMPS & SYSTEMS

and to provide adequate shat support. his promotes long
mechanical seal life.
Versions designed with robust, machined brass cages can
run particularly well in applications in which thrust loads
vary greatly during operation and periods of ball skidding
are likely.
hese bearings also resist destructive vibration forces
when cavitation occurs. Double-row, angular contact ball
bearing arrangements are used extensively as the primary
thrust bearing in American National Standards Institute
standard centrifugal pumps and some older API-style
pumps.
he most efective types feature a Conrad-design;
Annular Bearing Engineers (ABEC) 3 (P6) precision tolerances; 30-degree contact angle per row; one-piece, heattreated pressed steel cages; and multiple sealing options.
Because their contact angles diverge outwardly, the bearings exhibit greater rigidity and increased resistance to
misalignment.
Design variations of these types are increasing, including:
Steeper 40-degree contact angles to deliver increased
thrust capacity
Machined brass cages to impart robust performance in

heavy-duty and poor lubrication conditions
Reduced axial internal clearances to promote load
sharing between the two rows of balls and a reduced
possibility of skidding in the inactive ball set
Double-row angular contact ball bearings. These bearing arrangements

are used extensively as the primary thrust bearing in ANSI standard
centrifugal pumps, among others.
Progressive Cavity Pump Solutions

for the oil and gas industry.
The oil and gas industry places some of the
Low shear gentle pumping action
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Flow rate is proportional to the pump speed
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PUMPS & SYSTEMS
www.pump-zone.com
April 2014
33
SPECIAL SECTION
ABEC-3 (P6) tolerances to gain better control of the
bearings mounted condition and promote smoother
bearing operation
Specialized angular contact ball bearing sets are designed
for centrifugal pumps with heavy thrust loads that are not
reversing or those that only reverse periodically. Highperformance matched sets of 40-degree and 15-degree
angular contact ball bearings can provide improved robustness in high thrust load conditions by reducing the susceptibility of ball skidding in the inactive bearing.
For pumps with minimal thrust, an alternative arrangement of paired 15-degree angular contact bearings would
be appropriate.
he primary advantage of these sets is that the 15-degree
bearing ofers considerably less internal clearance compared with a 40-degree bearing, making it less susceptible
to centrifugal and gyroscopic forces producing ball sliding
and shuttling, while delivering additional radial stifness to
maintain the integrity of a pumps shat and seals.
Split inner-ring angular contact ball bearing arrangements are commonly used in vertical pumps to handle the
primary thrust load. hey can also be used in horizontal
arrangements if the loading is such that the split inner ring
bearing does not support radial load on its own.
his bearing set integrates a split inner-ring ball bearing
or four-point contact ball bearing to accommodate thrust
loads in either direction, matched with
a single row 40-degree angular contact ball bearing. Because two bearings
acting in tandem share the thrust load,
this arrangement provides an extremely
high thrust-carrying capacity. Reversing
thrust load can be accommodated on the
backside of the split inner-ring bearing.
with resistance to high temperature, chemicals and wear.

PEEK cages are ideal for pumps in which the bearings are
lubricated with light hydrocarbons, liqueied gases (cryogenic) or ire-safe hydraulic luids and will oten be integrated with hybrid bearings or with super-tough stainless
steel rings. he combination ofers protection from damage
caused by poor lubrication and exposure to chemicals, creating reliable, robust and low-energy pump designs.
SEALING THE SYSTEM
Bearing seals in centrifugal pumps must prevent potential
contamination and loss of efective lubrication or lubricant
properties. Without efective sealing, contaminants (solid
or otherwise) may iniltrate the area of a bearing, invade the
lubricant and bearing, and shorten bearing life.
Solid contaminants (depending on the particle size,
hardness and brittleness) will produce either indentations
or wear on bearing surfaces, while the ingress of water can
adversely afect the lubricant eiciency. In addition, if a
bearing loses lubrication because of seal failure, dry-running
operation can ultimately lead to bearing failure.
Diferent seal designs and materials are available to
accomplish speciic tasks and functions in centrifugal pump
applications. While the proper sealing choice for centrifugal
pumps will depend on the applications demands and operating conditions, dynamic radial shat seals will typically
be applied to create the necessary barrier between surfaces
ADVANCED MATERIALS
Other bearing solutions for pumps beneit from advanced materials. Hybrid
bearings are equipped with balls or rollers made of silicon nitride, a ceramic
material with characteristics that make
it a good choice for pump applications
requiring high speed, high stifness and
electrical insulation.
Bearings with injection-molded,
glass-reinforced polyetheretherketone
(PEEK) combine strength and lexibility
34
April 2014
A group of hybrid bearings
www.pump-zone.com
PUMPS & SYSTEMS

in relative motion (one usually stationary while the other
rotates). hese seals usually incorporate a steel or elastomer
shell, which is bonded to the sealing material. his enables
the requisite interference it of the seal in the housing bore
to be maintained (as well as facilitating proper installation).
An elastomer sealing lip installed against the shat can help
exclude contaminants without increasing friction.
he lip provides dynamic and static shat sealing and features a sealing edge formed by pressing, cutting or grinding.
Most oil-based sealing lips are made from a formulation of
nitrile rubber. Other materials have been introduced for
use with fuels, industrial luids and highly-compounded
lubricants.
When constant pressure diferentials are encountered in
pump applications, pressure proile sealsin which the seal
cavity is pressurizedcan counterbalance the conditions.
When a seal is exposed to pressure, the radial load of the
sealing lip increases, which increases the sealing lip/shat
contact area, resulting in additional friction and elevated
underlip temperatures. Some pressure proile seals have
been designed to withstand pressure diferentials of 50 psi
at speeds up to 1,000 feet per minute.
As an added precaution when a pressure diferential

occurs across a seal, a shoulder or retaining ring should be
used at the low-pressure side of the seal to prevent it from
being pressed out of the housing bore.
Because of their design and oten harsh operating conditions, seals will routinely experience a shorter life than the
components they protect. When seals require replacement,
users should not automatically replace them with the same
design. For example, if an oil analysis shows a higher than
anticipated ingress of contaminants, upgrading the entire
sealing arrangement (perhaps using a more chemically resistant material or adding elements to bolster the system) may
be needed. In cases of excessive wear, non-contact labyrinthtype seal designs may be appropriate.
Viewed as a system, optimized bearings and sealsand
the implementation of best-practice maintenance procep p perforp
durescan make a diference in boosting pump
mance, reliability, service life and production.
P&S
Mark J. Cutler is applications engineering manager for SKF

USA Inc. Cutler may be reached at mark.j.cutler@skf.com or
267-436-6695. For more information, visit www.skfusa.com.
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PUMPS & SYSTEMS
www.pump-zone.com
April 2014
35
SPECIAL SECTION
Using Thermoplastic Composite Bearings in

Vertical Water Pumps
A northeast Germany reinery increased its MTBF and saved money by upgrading eight pumps.
By Martin Swierczek, Greene, Tweed & Co.
hen pumping river or well water, abrasive particles

such as sand and other debriserode hardware quickly.
his leads to poor performance and costly, frequent repairs.
Historically, sacriicial bronze components have been
used as wear materials in these applications. However, the
poor tribological nature of bronze requires generous running clearances between dynamic components, decreasing
reliability from lack of rotor support. he lack of resistance
to particulates in the media stream signiicantly shortens
component life.
A reinery in northeast Germany struggled with this
problem in the water pumps of its collector wells. Designed
and built in the early 1970s, the pumps had to be removed
from service every two years because of bearing failures.
To overcome this, the reinery elected to upgrade the
bearings to a polyetheretherketone (PEEK)-based solution. Mean time between failure (MTBF) increased from
two to more than ive years as a result of the upgrade. his
saved more than $135,000 (100,000) in repairs. his case
study discusses how this was achieved and the design process involved.
THE PROBLEM
Sand, shells and other abrasive materials have been a problem for pump users for many years. hese particles wear line
shat bearings, increasing clearances and leading to greater
vibration and premature pump failure.
In this application, water pumps designed and built in the
Pump Removal Repair Steps
Open the roof of pump station
2 cranes + truck for dismantling
Refurbishing of pump
2 cranes + truck for assembly
Close the roof of pump station
Total
Cost
$540 ( 400)
$1,485 ( 1,100)
$9,454 ( 7,000)
$1,485 ( 1,100)
$540 ( 400)
$13,500 ( 10,000)
Table 1. Itemized estimate of maintenance costs per pump
36
April 2014
1970s were installed in reinery collector wells. Every two

years, the pumps had to be removed from service because of
bearing failures caused by erosion. he total costs were up
to $13,500 (10,000) per episode (see Table 1).
THE PUMPS & BEARINGS
he vertical water pumps operated at 75 to 90 kilowatts
(kW), 1,480 rpm and pumped river water at a low rate
of 250 to 400 cubic meters per hour (m3/h) (see Table 2).
Each pump had six line shat bearings with inside diameters
ranging from 60 to 65 millimeters (mm) (see Image 1).
NEW BEARING MATERIAL
Based on the failures, a new bearing material was required
that could withstand of-curve and dry-run conditions,
startup, high-impact vibration, and abrasive luids. Low
friction was also desired to prevent product lashing during
upset.
Because of these requirements, a chopped carbon iberreinforced, PEEK-based thermoplastic composite was
selected. his material is thermally stable and can be used
in temperatures up to 121 C (250 F) with a coeicient
of thermal expansion 2.5 times that of steel. It is recommended for stationary componentssuch as bushings, line
shat bearings and bowl wear ringsin sump or river water
pumps containing sand and other abrasives (see Table 3).
his material ofered many advantages when compared
to the incumbent bronze. Critically, it showed signiicantly
Media
Flow rate
Pressure
Impeller
Speed
Motor power
Water with abrasive particles

such as sand, shell and other debris
250 to 400 m3/h
4 bar
257 to 335 mm
1,480 rpm
75 to 90 kW
Table 2. Technical description of the pump conditions
www.pump-zone.com
PUMPS & SYSTEMS

less wear ater undergoing testing at 900 rpm
in media containing 5 percent silica sand (see
Images 1 and 2).
In addition, thermoplastic composites provide non-galling, non-seizing properties and
a low coeicient of friction, enabling them
to withstand of-curve conditionssuch as
dry run or excessive vibration. When pump
failure is unavoidable, thermoplastic composites minimize damage to surrounding metal
components.
Base
Material
Fiberreinforced
PEEK
Temperature Range
F
C
Min
Max
Min
Max
-100
+250
-73
+121
General capabilities
Moderate loads and

pressures in abrasivecontaining service, avoid
coke ines, stationary
Table 3. Typical properties of fiber-reinforced PEEK material
DESIGN CONSIDERATIONS
At the German reinery, bearings were mechanically secured and designed with interference of
0.0015 mm/housing diameter with a minimum
of 0.102 mm interference it. For retroit applications like this, the radial (or wall) thickness
of the thermoplastic composite is generally dictated by existing hardware.
For new equipment, however, standard practice is to
design with a minimum radial wall thickness of 3 mm.
Image 1. The wear of a leaded tin bronze bearing on a 304 stainless

steel shaft after eight hours of operation at 900 rpm and 25 psi
(0.172 MPa) in 95 percent water with 5 percent silica sand
If the part has internal grooves, radial thickness is measured at the thinnest portion of the cross-section. Use of a
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www.pump-zone.com
April 2014
37
SPECIAL SECTION
Image 2. The wear of a thermoplastic composite bearing on
a 304 stainless steel shaft after eight hours of operation at
900 rpm and 25 psi (0.172 MPa) in 95 percent water with 5
percent silica sand
metal casing may be considered with a radial wall

thicker than 6.35 mm.
he thermoplastic composite bearing will generally have a surface inish
between 1.6 and 3.2 Ra m. A surface
inish of between 0.4 and 0.8 Ra m
is recommended to be maintained on
the mating metallic component.
Typically, rounded axial grooves
are recommended to help lush media
through the bearing when abrasives
are present. Spiral and circumferential grooves are an alternative to slow
the low of media through the bearing and assist with lubrication.
Soter metals can show a high rate
of wear when operating in low lubrication environments against this
composite material. To maximize the
life of the composite and mating components, a surface hardness minimum
of 40 Rockwell C is recommended.
For applications containing suspended solids, a higher hardness
will maximize shat life by reducing damage caused by hard particles
scratching the surface. In these cases,
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38
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
EXPERIENCE
TODAY
1990
We recently came across a two decades old photo of some young up and coming engineers that were
part of our drive engineering team at the time.
Guess what? All those people are still with us. In fact, they are among our company leaders today.
Imagine. Twenty years of experience from each of them going to work for you every day.
Incredible knowledge. Penetrating insights. Real results.
Yaskawa puts all of that to work for you every day. Think of what you can do with a partner like that.
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A
YA S K A W A . C O M
Follow us:
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2014 Yaskawa America Inc.
SPECIAL SECTION
and heat dissipation. Despite these considerations, housing-to-shat clearances are signiicantly reduced by using
thermoplastic composites. Reduced clearances create a
higher luid ilm pressure, which leads to a more stable shat
with lower vibration. his creates a more reliable pump
and reduces unplanned shutdowns resulting from process
upset.
Year 1
Year 2
Year 3
Year 4
Year 5
Year 6
Pump 1 retroitted with PEEK-based composite

Pumps 2 and 3 retroitted with PEEK-based composite
Note: Pump 1 with bronze bearings would normally be
serviced
Note: Pumps 2 and 3 with bronze bearings would
normally be serviced
Pump 8 retroitted with PEEK-based composite
Note: Pumps 1, 4 and 5 with bronze bearings would
Note: Pumps 2, 3, 6 and 7 with bronze bearings would
Table 4. Illustration of pump retrofit dates with past service schedule.
CALCULATIONS
To determine ambient clearance (machine dimensions) for
thermoplastic composites, values should be adjusted for
the application temperature. his adjustment is based on
the following calculation:
Ambient Clearance = C + (ABD)(GHD)+(EFD)
A = ambient shat diameter
B = coeicient of thermal expansion (CTE ) for the
shat
C = clearance according to American Petroleum
Institute (API) 610 or equivalent standard
D = change in temperature
E = 2 radial thicknessor
outside diameter (OD) inside diameter (ID)
F = CTE for the PEEK-based material
G = housing/carrier ID
H = CTE for the housing/carrier
When properly designed, thermoplastic composites can
be installed directly into pump housings or into metallic
carriers.
Proven Performance with Flowrox Pumps

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

B^[[X]VSTbXV]_a^SdRTbWXVWTbcR^]cX]d^dbU[^faPcTbÛP]h_TaXbcP[cXR_d\_
@d\_d]SX[dcTScWXRZT]TSb[daahfXcWcWTWXVWTbcb^[XSb
8XVWTbcPRRdaPRhX]U[^RRd[P]cST[XeTah
>^bTP[fPcTa>^WXVWR^bcX\_T[[Tab>^fTPa[X]Tab
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
40
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
Rexnords new Thomas XTSR52 and

XTSR71 Disc Couplings provide the
highest value solution for rotating
equipment, including higher torque,
lower mass and an all-metric design.
Combining compact size and powerful
performance, the Thomas XTSR Disc
Couplings feature simple installation
and maintenance, and strengthened
operation and safety.
And, you can find Rexnords Thomas

Disc Couplings at your local Motion
Industries location. Our local sales
and service specialists are experts
in application and technical support,
providing the parts and the know-how
you need to stay up and running.
Scan this code with your smartphone for
more information.
http://esp.to/w48NK2
Call. 800-526-9328
Click. www.motionindustries.com
Visit. Over 550 Locations
SPECIAL SECTION
Thermoplastic composites provide non-galling, non-seizing properties
and a low coeficient of friction, enabling them to withstand off-curve
conditionssuch as dry run or excessive vibration.
RELIABLE
CentriPump Lubricants
New CentriPump PPO & SPO Series ...
Problem Solving Centrigual Pump Lubricants
Improve your pump reliability, extend MTBF*, reduce downtime and
energy consumption with Summits New CentriPump lubricants. These
newly formulated lubricants are resistant to rust, oxidation, corrosion
and improve wear protection. CentriPump lubricants have excellent
low temperature fluidity and high temperature stability. They are
compatible with most process fluids being pumped and commonly
used seal materials. Call Summit today for a distributor near you.
RESULTS
In the ive years since the German
reinery upgraded eight pumps to
thermoplastic composite components, none of the upgraded pumps
have been removed from service
because of bearing issues.
MTBF increased, leading to a cost
savings of approximately $135,000
(100,000) during the past six years
(see Table 4).
Historically, virgin polymer materials have been used in pumps with
limited results.
his has changed in recent years
with the development of materials
that combine the non-seizing, nongalling properties of thermoplastics
with the mechanical and wear properties of composites.
Because of their strong performance, thermoplastic composites
have now been recognized by API
Standard 610 as suitable wear materials. P&S
Martin Swierczek is senior ield
applications engineer with
Greene, Tweed & Co. GmbH and
has 15 years of industry experience in design and development
of innovative sealing solutions.
Currently working to advance sealing and llow
ow
technology for Greene, Tweeds Petrochem &
Power group, Martin was previously a design
engineer for hydraulic power units and a project engineer for water puriication systems. He
is a graduate in mechanical engineering from
Fachhochschule Wiesbaden (Rsselsheim).
Swierczek may be reached at mswierczek@
gtweed.com or +49 6192 9299-693.
*mean time between failure
Summit
Industrial Products
9010 CR 2120
Tyler, TX 75707
For more information, visit www.gtweed.com.
800.749.5823
Made in USA
www.klsummit.com
42
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PUMPS & SYSTEMS
COVER
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44
AApril
priill 22014
pr
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01
www.pump-zone.com
www.
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w.ppuump
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PPU
PUMPS
UM
MPPS & SSY
SYSTEMS
YST
STEEM
MS
Oil & Gas Reinery Solutions
Reinery Repairs 20-Year Old Design Flaw

Once recommissioned, a turbine-driven coker charge pump supplied the highest capacity
margins in its history.
By Miguel Salgado, BP Whiting Reinery
oker units thermally crack the residual oil (or bottoms)

from an oil reinerys vacuum distillation tower into
smaller, low molecular weight hydrocarbons that are further
processed or sold. he excess or residual hydrocarbons from
this process are heated and then sold as petroleum coke,
which is usually a high economic margin product.
Coking heater charge pumps transfer a continuous low
of process prior to the product stage, so any interruption
would have a high economic impact on the unit
margins and the reinery because other units will
need to reduce the process to shit production.
he coker charge pumps at an Indiana reinery had a history of repeated failures from the
1990s through the end of 2011. Two pumps
were in servicea turbine-driven pump and an
electric-motor-driven pump.
he turbine-driven pump typically exhibited
a longer time between repairs because it was
used less oten. he perception was that the
turbine-driven pump also had a lower capacity
threshold because it operated at a lower
speed. hese pumps normally have a pumping
temperature of 560 F. hey use an American
Petroleum Institute (API) Plan 32 seal lush
in which a lighter gas oil is used to cool the
mechanical seals.
hese high-temperature, two-stage difuser
pumps had mean time between repairs ranging
between six and 12 months and failure modes
almost equally divided between seal leaks and
thrust bearing overload. During every rebuild,
the pump cases regularly exhibited heavy erosion at speciic points insidethe suction eye
to vane edge, the vane end to difuser end and
around the divider plate between stages.
hroughout their history, numerous mitigation plans were completed that included
modifying the impeller sizes and hardening
both impellers and difusers with diferent
PUMPS & SYSTEMS
methodsincluding tungsten carbide coating treatment

and boron difusion. horough root cause failure analyses
and multiple modiications were previously completed, but
the pumps had already developed a reputation based on
their performance and reliability. hey were also known for
inherent thrust issues with the equipment, which had never
been addressed.
In early 2011, soon ater undergoing a major rebuild, the
www.pump-zone.com
First-stage diffuser
Diffuser tip erosion
April 2014
45
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motor-driven pump was commissioned and developed an
outboard seal leak only two weeks later. his prompted an
immediate shutdown. It triggered a ield repair, and replacement seals were required.
During the seal change, the outboard bearing (thrust bearing) showed signs of skidding damage. he thrust bearing
was a back-to-back pair of 40-degree angular contact bearings, which are susceptible to skidding on the unloaded
bearing. he decision was made to install two 15-degree
angular contact bearings back-to-back, which cannot tolerate as much thrust but do not have skidding issues.
he pump operated with these bearings for three months
until a motor failure occurred. When
the motor was removed, the pump
shat was hard to turn, and it was
later determined that both inboard
and outboard pump bearings were
destroyed (melted, blackened and in
pieces). hese two subsequent failures and the future need for reliable
crude units prompted an emergency
deep-dive team to meet and deine a
true root cause for all the historical
failures.
A cross-functional team comprised
of members from engineering, operations, maintenance, reining technologies and process began meeting
weekly to establish root causes of the
continual failures. he team was also
tasked with devising a plan that would
allow for reliable operation of the
motor-driven pump so that the turbine pump could undergo its scheduled rebuild without interrupting the
units process.
FINDINGS
he team determined that the thrust
issue was an inherent design problem
and could not be addressed with ield
modiications. hey also tackled the
issues of erosion wear inside the case.
hey found discrepancies in pump
operations and the actual design of
the pump.
It was determined that the low
meters used to measure pump
throughput had a low correction
factor that required adjustment for
temperature. Once this was completed, it was discovered that the
pump had been operating at 25
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April 2014
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PUMPS & SYSTEMS

percent above its best eiciency point (BEP) instead of the ACTION PLAN
he team members implemented an action plan to mitigate
expected 4 percent.
Rotating equipment experts determined that an operat- the issues based on their indings. First, they addressed the
ing point at this capacity coupled with the composition of thrust and erosion issues by procuring a new pump that
the process and temperature would lead to the extensive would have a more balanced design. his new pump would
abrasive wear that was found during every rebuild. he cur- also have a revised low pattern design and coating of the
rent geometry of the impeller and diffuser design coupled with the highspeed luid and temperatures led to
aggressive luid directional changes
that facilitated the abrasive wear.
Sealing Equipment Produ
Products
ucts Co., In
Inc.
nc.
c.
A pump that operates high above
its BEP may experience cavitation,
resulting in the formation of gas
pockets that can lead to erosion. he
luid had also experienced an increase
,
in catalyst carryover and other solids
throughout the years that accelerated
the pumps erosion rate. Operating
beyond the BEP had created luid

recirculation pockets in areas of
.
drastic velocity and direction change
where the high erosion was found.
A World Class Provider of

Fluid Sealing Solutions
SEPCO CAN SAVE YOU MORE THAN OUR PRODUCTS COST.
Bearing failure in July 2011
800-633-4770 -- www.sepcoUSA.com
GFO is a registered trademark of W. L. Gore and Associates.
PUMPS & SYSTEMS
www.pump-zone.com
April 2014
47
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Casing erosion wear found during the rebuild
Inter-stage plate erosion wear
internals with wear-resistant boron that would lessen the

abrasion wear.
his option, however, was not pursued immediately
because the equipment would have a lead time of six
months. As an immediate resolution, the team rebuilt the
existing motor-driven pump with the following modiications. First, the internals were furnished with an ion-nitride
hardening process, suggested by the parts manufacturer,
which would help mitigate the expected erosion wear. In
addition, the bearings and impellers were sized to match

the original design condition. his would help mitigate
any thrust concerns and help the pump operate within its
expected performance.
he team also implemented a weekly performance monitoring report in which the pump operating points were
imposed against the pump curve to capture any gradual
drop in performance and raise alarms to operations. his
last recommendation proved helpful in determining the
48
April 2014
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PUMPS & SYSTEMS
TM
The new
Double-Row
Angular Contact Ball Bearing from FAG
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to its hardened, black oxide-coated steel cage and 30
contact angle.
Pump more efficiently, thanks to Schaeffler-exclusive X-life
features that deliver the lowest friction levels in the industry.
Pump with less downtime, thanks to industry-leading load
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Need more details?

Contact us at 803-396-3638 or
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2014

Superior-quality products.
Comprehensive reliable solutions.
COVER
SERIES
maintenance schedule and establishing a priority for the
operational efectiveness on the coker unit. Additional lesser
modiications included the seal lush piping, process warmup lines, air cooled outer bearing and vibration monitoring.
With these steps implemented, the maintenance team
could pull both pump and turbine driver for a rebuild
without causing any operational constraints. he turbine

system received some modiications during the overhaul
that would eventually allow higher throughput with what
was previously considered lower capacity equipment.
he turbine low-pressure exhaust piping was relocated
from a closed condensate return system to an atmospheric
vent muler. his would help decrease
back pressure and improve the power
rating of the turbine. During the
turbine rebuild, which was its irst
in more than 20 years, the blades on
the rotor assembly were repaired and
replaced ater they showed signiicant damage and bends, which would
explain the limited amount of power
output that was being received from
the turbine. On the pump, additional seal lush piping and warm-up
line changes were made that would
improve seal life and overall maintenance frequency.
RESULTS
Considering an opportunity with the
market margins, the coker unit experienced its most proitable months in
its history, without process upsets or
interruptions. he reinery reached
its most proitable year in its 120-year
history, and once recommissioned,
the turbine-driven pump supplied the
highest capacity margins in its history.
Following this success, the only maintenance instances completed on these
pumps until their decommissioning in
December 2013 were the replacement
of the newly ordered motor-driven
pump ( June 2012) and a radial bearing replacement on the turbine pump
executed around the same time. P&S
NATIONAL PUMP COMPANY
Proud Member of the

American Petroleum Institute
7706 N. 71st Avenue | Glendale, AZ 85303

800-966-5240 | 623-979-3560
Miguel Salgado is a pump maintenance and reliability engineer

at the BP Whiting Reinery in
Indiana and has more than ive
years of experience in rotating
equipment and diversity and
inclusion initiatives. Salgado
may be reached at miguel.salgado@bp.com.
o@bp com
www.nationalpumpcompany.com
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PUMPS & SYSTEMS
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Submersible Slurry Pump Provides Solution

for Petroleum Coke Sump Service
With an agitator and a top-discharge design, these pumps prevent clogging and successfully
handle abrasive materials.
By Mike Bjorkman, BJM Pumps
ith the high price of petroleum, U.S. producers must

maximize every dollar from a barrel of crude oil. Every
42-gallon barrel produces 45 gallons of petroleum products.
Most of the petroleum is reined into gasoline (47 percent)
followed by heating oil/diesel fuel (20 percent) and jet fuel
(8 percent). Ater that, the percentages decrease signiicantly
as reiners produce liquid and gas distillates for industry and
construction. One of these is petroleum coke.
During the petroleum reining process, distillates are
separated from residual oil ater it goes through a vacuum
distillation unit. hese lighter grade petroleum products
such as hydrocarbon gases, naphtha and light and heavy gas
oilsare separated from the oil in a coker unit. Ater distilling the desired petroleum byproducts, the remaining carbonaceous solid residue is petroleum coke, which has to be cut
out of the coker unit with high-pressure water.
Petroleum coke (oten abbreviated as petcoke), is more
than 90 percent carbon and releases 5 to 10 percent more
carbon dioxide than coal when burned. Petcoke, depending
upon the gradeeither high or low in sulfur
and metalsis used as inexpensive fuel in ofshore power generation, coal ired boilers or in
the steel and aluminum industries. U.S. reineries produced more than 61.5 million tons of
petcoke in 2011enough to fuel 50 average
coal plants each year.
CASE STUDY
Oil reineries usually store petcoke onsite awaiting pending sales or ship it to other companies
that store and sell it. PABTEX, L.P., an ailiate
of Kansas City Southern Industries, located in
Port Arthur, Texas, is a major bulk-commodity
handling facility and vessel-loading terminal.
It specializes in exporting petroleum coke and
receives petroleum coke by train from one of
several reineries in the area. On its 29 acres of
outside storage, PABTEX can store 500,000
52
April 2014
tons of petcoke before transferring it to shipping terminals

for transport to global end users.
When the raw petcoke is transported to PABTEXs terminal in bottom dump railcars, a system of shakers breaks
the petcoke into smaller chunks that are easier to transport
on a conveyer system. Below the shakers is the open conveyer shat that is 70 to 80 feet below the ground.
Because rainwater oten ills the conveyer shat, a large
sump was sunk into the bottom of the shat to ensure that
water could be pumped into an existing retention pond.
With the shakers directly above the bottom of the conveyer
shat, pieces of petroleum coke fall into the shat and eventually wash into the sump.
Todd Wilkes, the maintenance supervisor of Savage Gulf
Services, which operates PABTEXs Port Arthur terminal, had tried several submersible pumps in the conveyer
shat sump. However, coke is similar to coal ines when
pumpedvery abrasive and easily separates into a slurry.
Because most submersible pumps are cast iron, they cannot
The conveyor system carries small chunks of coke from the shakers to the storage site.
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PUMPS & SYSTEMS
The sump is 80 feet below the shakers.
hold up in this demanding service. Petcoke is too abrasive, and without an

integral agitator, solids settle-out and clog the pump.
A 15-horsepower, high-head, hard metal agitator submersible slurry pump
was suggested by Tim Weber, sales manager of industrial luid handling distributor, Saladin Pump, as a solution for Wilkes problematic sump application.
Heavy-duty submersible slurry pumps with agitators have been applied to
many similar abrasive applicationssuch as lime slurries, mill scale coal runof
sumps, wash-down sumps and ash transfer. Its success can be attributed to two
important features:
Optimum wear resistanceall wetted parts are constructed of abrasiveresistant, 28-percent chrome iron (600 Brinell, 57 Rockwell C) for maximum wear life. In addition, a replaceable hardened wear plate is located on
the suction side, where erosion would cause a loss of pump performance.
Maximum solids-handling capabilityan integral agitator luidizes
settled solids into a slurry, making them easier to pump with less chance of
clogging. he semi-open impeller handles abrasive solid concentrations as
high as 70 percent by weight.
he submersible slurry pump achieves maximum service life because of
numerous design features, such as:
Class H motor insulation and built-in amperage (full load amp) and temperature overload protection
PUMPS & SYSTEMS
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Double silicon carbide mechanical seals in a separate oil
illed seal chamber
Heavy-duty lip sealadditional protection for the
mechanical seals
Stainless steel shat and shat sleeve, which provides
maximum wear and corrosion protection
Pump volutes cast from hardened ductile iron (300

Brinnell hardness), which is twice as abrasive resistant
as standard ductile iron with extra thick walls where
pumped slurry enters the discharge
Another key feature of the submersible slurry pump is its

top-discharge design. Slurry pumps
are considered utility pumps, and
they are frequently dragged from one
site to another. Other pumps have
side-discharge connections that can
break of or be damaged as it is pulled
and pushed into place.
Top-discharge pumps are cooled by
the pumped liquid. hey can pump a
sump or pit down to within inches of
the bottom. A side-discharge pump,
without a cooling jacket, must stay
submerged to avoid overheating, leaving as much as 3 feet of unpumped
slurry.
The submersible pump is positioned in the sump below the shakers to handle runoff water laden
Top discharge also equates to
with coke chunks and fines.
slimeven the largest model, with
a 22.75-inch waistline, will it down
a manhole with a hose attached.
Saladin Pump installed a 10-horsepower, submersible slurry pump in
the sump at Salvage Gulf Service for
a 60-day trial. he trial was successful with no clogs or wearing issues.
Savage Gulf bought the pump, and
60 days later bought a backup pump.
Pumping reliability is critical to the
overall reining process. P&S
Mike Bjorkman is vice president of BJM Corp. and has more
than 30 years of experience in
the pump industry. He serves
as director of marketing and IT
for BJM Pumps, LLC, and ALLTEST Pro, LLC. Both companies
are subsidiaries of BJM Corp.
Bjorkman may be reached at 860-399-5937.
BJM Pumps, established in 1983, supplies electrical submersible pumps to industrial and municipal
markets throughout the U.S., Canada and South
America. ALL-TEST Pro, LLC provides electric motor
testing equipment to markets throughout the
world. For more information, visit www.bjmpumps.
com.
54
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PUMPS & SYSTEMS
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Valve Fugitive Emission

Compliance Requirements
End users must be aware of the valve emission standards to meet industry requirements.
By Gobind Khiani, FLUOR CANADA, LTD.
n article in the October 2013 issue of Pumps & Systems

discussed how to minimize leaks by applying proper
design and material-selection standards. his article
details new codes that have been established because the
International Organization for Standardization (ISO) is
currently updating certain standards, including ISO 15848
Parts 1 and 2.
American Petroleum Institute (API) 624 was updated in
February 2014. A summary of the standards and their test
methods are shown in Table 1.
he standards are strong. However, the community has
hesitated to apply them across all businesses. While the
change in the Environmental Protection Agencys (EPA)
policy is in review, business is moving forward in the rest of
the world, except North America, which is actively pushing
toward green and clean air pacts.
Valve emissions have been reduced in North America.
However, they have increased or have been minimally
changed in the rest of the world.
Current EPA guidelines have helped reduce valve emissions by handling issues such as:
Leaks greater than 10,000 parts per million (ppm) are
being eliminated.
Leakage to 500 ppm maximum is being limited.

New API 624 (released February 2014) has moved
toward allowable leakages of 100 ppm or lower.
Awareness of environmental initiatives in North
America has grown tremendously, and such initiatives
have given visibility to projects such as the Keystone
XL Pipeline.
Hydraulic fracturing is being examined more closely
and codes and regulations in this space have been
updated.
Policy makers are becoming strict and inspectors are
imposing ines when necessary.
End users are working closely with the standards organizations to develop mandatory requirements on API 622
and API 624, such as the following:
Maximum stem to seal tolerance allowance (inishing)
Criteria on leakage rates
Maximum temperatures
Minimum temperatures
Leakage class
Cycles
PARAMETERS
ISO 15848
API 622
API 624
ISA 93
Chevron
Shell
Medium
Helium
Methane
Methane
Methane
Methane
Helium
Method
Vacuum
Snifing
Snifing
Snifing
Snifing
Snifing
Units
Atm.cc/sec
ppm
ppm
ppm
ppm
Atm.cc/sec
Leakage
Class A/B/C
<500
<100
User deined <100
Class A/B
Mechanical
500 to 2,500 1,510
310
1,500
5,000
200
Thermal
2 to 4
10
2 to 3
Max Temp
User deined
260
260
260
260
User deined
Max SSA
1 to 3
User deined Not permitted 1
Table 1. International standards and test methods
56
April 2014
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PUMPS & SYSTEMS
End users are requesting consistent

research and improvement on current
practices, including testing and approvals.
In fugitive emission testing, braided packing has been successful, which is

cost efective for retroitting existing and stock valves. Braided packing can be
installed during shutdown or replaced during a valve refurbishment program.
hese packings have been in use since the 1990s. he testing of fugitive emissions on braided packings is achievable on higher temperatures and longer test
duration compared to standard packing materials (resulting in loss of binders
at temperatures higher than 200 C).
he use of braided packings for new valves is not commercially viable or
practical compared to traditional die-formed graphite lantern rings. he alternative packings (specially engineered) for new valves are limited to API 602
forged steel valves (valves less than 2 inches).
With regulation requirements, users must now determine the costs and the
best way to be compliant. It requires additional cost to provide an engineered
solution (such as special braided packing) in combination with managing production requirements because the cost impact is about 25 percent on special
braided packing valves.
he majority of users have accepted these costs because of:
he total cost of the valve
Maintenance, shutdown and reliability costs
he manpower required
Meeting corporate safety and regulations
heir industry image to be green and a clean producer
Figure 1. Sources of fugitive emissions
PUMPS & SYSTEMS
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57
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With regulation requirements, users must now determine the
costs and the best way to be compliant.
Because the requirements may be interpreted diferently

depending on the end users locations, the industry is still
in partial acceptance of fugitive emission requirements and
the use of braided packings for controlling these emissions.
THE FUTURE
he debate continues about the development of fugitive emissions regulations from the EPA, API, ISO,
International Society of Automation (ISA), National
Association of Corrosion Engineers (NACE), American
Society of Mechanical Engineers (ASME) and many other
organizations. End users are also requesting consistent
research and improvement on current practices, including
testing and approvals.
One way to ensure compliance is for the industry to conduct a survey of all valve manufacturers across the globe to
validate that they have met the fugitive emissions requirements during the design phase with proper allowable code
dimensions and the use of braided packing. P&S
Gobind Khiani is a professional engineer with FLUOR CANADA LTD. He has
been in the energy and power business for more than 18 years and has worked
in three countries (the U.K., United Arab Emirates and Canada) with more
than 10 years in the Western Canadian oil and gas industry based in Calgary,
Alberta.
He graduated from the University of Poona in India and completed his masters
in materials and mechanical engineering from Schulich School of Engineering
at the University of Calgary, Alberta, Canada. He is a registered professional
engineer in the provinces of Alberta and Saskatchewan. Khiani can be reached
at gobindkhiani@gmail.com.
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April 2014
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PUMPS & SYSTEMS
TRADE SHOW COVERAGE
Offshore Technology Conference (OTC) 2014

May 5 8, 2014
Reliant Park
Houston, Texas
Exhibition
Monday, May 5
9 a.m. - 5:30 p.m.
Tuesday, May 6
9 a.m. - 5:30 p.m.
Wednesday, May 7
9 a.m. - 5:30 p.m.
Thursday, May 8
9 a.m. - 2 p.m.
he Ofshore Technology Conference (OTC) is an annual

event for the development of ofshore resources in the
OTC will host two events for teachers and students in the
ields of drilling, exploration, production and environmental
Houston
area as a part of the Energy Education Institute.
protection. hirteen industry organizations and societies
On
May
8,
100 teachers will have the opportunity to attend
sponsor the conference and develop the technical program.
a
one-day
energy
education workshop where they will learn
More than 80,000 attendees travel from 120 countries to
about
the
scientii
c concepts of energy and the world of oil
attend the event.
and
natural
gas
exploration
and production.
Attendees have the opportunity to network with other
Also
on
May
8,
200
high
school students will have the
professionals, see new innovations, meet providers of prodopportunity
to
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professionals
and
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2014 technical program will cover issues related to the ofparticipate
in
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shore energy industry. Experts will ofer information about
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lessons
provided by the
the efect of unconventional plays on the industry, developNational
Energy
Education
Development
Project.
For more
ing standards and curriculum for subsea engineering educaP&S
information
or
to
register,
visit
www.otcnet.org/2014/.
tion and industry economics. he discussions on economics will focus on oil economics, gas monetization, energy
forecasts, and changes in Mexicos
oil sector. New topics for the 2014
conference will be new applications
and solutions for underwater monitoring networks and sensing, process
safety in ofshore operations and
results from the irst marine methane
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he schedule will also include
daily topical breakfasts and luncheons, technical sessions, opportunities to visit the exhibition halls,
and the University R&D showcase.
In addition, the conference will
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PUMPS & SYSTEMS
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April 2014
59
EFFICIENCY MATTERS
Maximize Natural Gas Vapor Recovery

New regulations challenge oil and gas producers to optimize operations, and oil-free
reciprocating gas compressors can help.
By Glenn Webb
il and natural gas producers have always had an economic

rationale to capture or recover as much product as
possible in the oilield. Any vapors that were vented to the
atmosphere or lared of during the production process were
no longer saleable, or not worth the time and labor needed
to reclaim them. Now, an even more compelling reason
for producers to optimize their operations vapor-recovery
capabilities exists.
In August 2011, the U.S. Environmental Protection
Agency (EPA) introduced New Source Performance
Standard 40 CFR, Part 60, Subpart OOOO, or the Quad
O regulation. In October 2012, Quad O became law and
began afecting oil and gas storage facilities, natural gas processing plants and gas wells across the country.
Quad O establishes emission standards and compliance
schedules for the control of volatile organic compounds
(VOC) and sulfur dioxide (SO2) emissions from storage
tanks in tank batteries that are used to temporarily hold liquids produced during oil and natural gas production.
More speciically, Quad O includes a requirement that
VOC emissions be limited to less than 6 tons per year
(tpy)a daily equivalent of 33 poundsfrom storage
tanks that contain crude oil, condensate, produced water
and other unreined petroleum liquids.
Per the edicts of the Quad O regulation, storage tanks
were divided into two distinct groups:
Group 1Any storage vessel constructed, reconstructed or modiied ater Aug. 23, 2011, but before
April 12, 2013
Group 2Any storage vessel constructed, reconstructed or modiied ater April 12, 2013, or within 60
days ater startup, whichever is later
On April 15, 2014, all Group 2 storage tanks must be
fully compliant with Quad O, while all Group 1 tanks have
until April 15, 2015, to attain Quad O compliance.
his has led to a rush by oil and natural gas producers to
upgrade their vapor-recovery abilities so that their tank batteries will emit less than the allowable 6 tpy of VOCs and SO2.
60
April 2014
his article will demonstrate how a speciic type of compressor technologyoil-free reciprocating gas compressioncan be used to maximize the performance of vaporrecovery units at storage facilities, all with the ultimate goal of
satisfying the emission limits of the EPAs Quad O regulation.
THE CHALLENGE
Crude oil storage tanks oten have issues with gas vapors
escaping, even though most tanks have various types of
door hatches, gaskets and low-pressure pop-of vent valves
that have been designed to control and limit the amount of
escaped product vapors.
Without any strong environmental regulations restricting this venting, many tanks were, and are, in poor shape,
with faulty hatches and safety valves that leak badly. In some
cases, operators do not even close the hatches, or the tanks
have faulty gaskets that allow vapors to leak uncontrollably.
In many instances, releases would occur simply because of
the buildup of vapor pressure in the tanks, which would
cause the tanks relief valves to open and release the excess
vapor pressure.
he Quad O mandate requires that 95 percent of vapor
releases now be contained, lared or reclaimed. Several types
Oil-free reciprocating gas compressors help oil and gas producers and
handlers meet the Quad O requirements.
www.pump-zone.com
PUMPS & SYSTEMS
s
low
F
n
THE SOLUTION
Recognizing the untapped potential for an improved vapor-recovery technology in the oilield, a Michigan pump manufacturer provides compressor
products that cover a broad range of markets, including oilield vapor-recovery
applications.
Several of the pump manufacturers series of oil-free reciprocating
gas compressors were designed to
handle hazardous, toxic or lammable gases. heir oil-free design provides unique features that were once
considered unnecessary and unimportant in the natural gas market.
hese features have strong environmental appeal while ofering the
best vapor-recovery mechanics and
sealing technology. he beneits of
these features include:
Oil-free designs do not add
additional contamination to the
gas being handled or recovered.
A vapor-recovery unit featuring an oil-free
Maximum control of gas
reciprocating gas compressor is a reliable way
leakage from the compresto control the amount of vapors that are lost to
sor is achieved because of the
the atmosphere at a crude oil tank battery.
PUMPS & SYSTEMS
www.pump-zone.com
ere
Wh
The EPAs Quad O regulation

mandates that uncontrolled gas
releases from storage tanks be
reduced by 95%. To maximize vapor
recovery, demand Blackmer Oil-Free
Reciprocating Gas Compressors.
Distance-piece design controls vapor leakage
and emissions
Ductile-iron construction reduces thermal
and mechanical shock
PEEK valves deliver superior sealing,
efficiency and durability
Precision-ground crankshaft ensures smooth,
quiet operation
Contact your authorized Blackmer distributor.
WORLD HEADQUARTERS
1809 Century Ave SW
Grand Rapids, MI 49503-1530
USA
+1 (616) 241-1611
www.blackmer.com
April 2014
61
of compressors have been popular for the reclaiming process. Rotary vane,
rotary screw and reciprocating piston compressors are all used. Depending on
the overall operating conditions (required low rate and discharge pressure) a
particular compressor technology would be selected.
However, oil-free reciprocating gas compressors are ideal for applications in
which discharge pressures are around 50 psig (3.4 barg), and in some extreme
cases can be more than 500 psig (34.4 barg). Typical discharge pressures from
crude oil storage tanks are usually less than 200 psig (13.8 barg).
he challenge for the compression equipment is that traditional lubricated
piston compressors and some rotary designs do not have leak-tight sealing or
the ability to handle small amounts of condensed liquids (condensate) that
can form in the compressor. his condensate collects in the crankcases on
some reciprocating compressors and contaminates lubricating oils, causing
extremely frequent oil changes and, in many cases, signiicant power-frame
damage to the bearings and shats. In many cases, frequent complete compressor replacement is considered acceptable when the damage is considerable.
Oil-free reciprocating gas compressor technology with a distance-piece
design is a unique feature that allows the condensate to be collected and controlled at the compressors distance piece, keeping it out of the critical powerframe area in which damage can occur. he added beneit of the oil-free design
is that it has two sets of rod seals that seal the gas at the distance piece, reducing the amount of gas vapors that can escape to the environment through the
crankcase. his is typical in most styles of reciprocating machines.
ati
ov
n
In
EFFICIENCY MATTERS
compressors full distance-piece compartment and

piston-rod seals. he two sets of rod seals create a compartment between the process gas and the lubricated
crankcase, which provides leakage control and minimizes any leakage to the crankcase or the atmosphere.
he ductile-iron construction of all pressure parts
results in greater resistance to harmful thermal and
mechanical shock.
High-eiciency valves made of polyether ether ketone
are self-lubricating and provide high-quality sealing
characteristics and durability.
A heavy-duty, precision-ground crankshat features
roller bearings and integral counterweights to ensure
smooth, quiet operation.
hese design advances make these compressors environmentally friendly and a safe method to move and recover
gas vapors. In highly regulated tank vapor-recovery applications, these important features help deliver peace of mind to
the oilield operator and producer.
he distance-piece design feature of the oil-free reciprocating gas compressors is critical because condensate can
form inside the compressor because of the wide mix of

hydrocarbons that can oten be found in the gas stream.
Formation of condensate inside the compressor is never
good. When the gas is compressed, heavier hydrocarbons
and small amounts of water vapor can form. Compressors
that do not have a distance piece allow the condensate to
leak directly into the crankcase. It can damage the quality of
the lubricating oil and lead to signiicant bearing damage or
a complete failure of the power frame.
he oil-free reciprocating gas compressors help control
condensate that may form. heir design helps control small
amounts of condensate by collecting it in the distance-piece
compartment.
Easy operator access to this compartment allows the
end user to empty it regularly. he distance piece can also
be vented to a safe disposal area when available. While
single-compartment, distance-piece designs will generally
satisfy most design requirements, the pump manufacturer
also provides triple-packed (two-compartment distancepiece) models for applications in which leakage control is
extremely critical. hese designs have been used in industrial
and chemical plant applications for many years.
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62
April 2014
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PUMPS & SYSTEMS
Single-stage models, which are recommended for use on

low-to-moderate compression-ratio applications, are available in seven sizes with piston displacements up to 125
cubic feet per minute (212 cubic meters per hour) at working pressures up to 1,000 psia (69 bara). he three, two-stage
models, which are available for higher compression-ratio
requirements, provide piston displacement up to 53.7 cubic
feet per minute (91.2 cubic meters per hour) at a working
pressure up to 615 psia (42.4 bara).
CONCLUSION
In January, the North Dakota Petroleum Councils Flaring
Task Force reported to the North Dakota Industrial
Commission that it believed that the states oil and gas
industry can increase natural gas capture to 85 percent of
the total volume produced within two years, to 90 percent by 2020 and up to 95 percent within the next decade.
Reaching these levels, however, will require full buy-in from
a number of entities, most notably the oil and gas companies operating in the state.
Process-system designers and environmental-compliance
managers at those oil and gas companiesand at others
around the countrywill improve their chances of 95 percent capture of natural gas by continuing to incorporate
improved vapor-control technology that minimizes the
amount of vapors and VOCs that are released to the atmosphere at tank battery locations.
Oil-free reciprocating gas compressor designs provide
a safe and efective method to control potentially dangerous vapor emissions. In addition to their environmentallyfriendly beneits, they provide economic advantages to
operators because of their ability to eiciently recover gas
from diferent types of storage tanks. his leads to a higher
amount of saleable end-product while simultaneously protecting the atmosphere. When used in many tank battery
applications, the vapor recover unit equipment will have a
lucrative payback period. P&S
Glenn Webb is a senior product specialist for Blackmer and can be reached
at glenn.webb@psgdover.com or 616-475-9354. For more information on
Blackmers full line of pumps and compressors, visit www.blackmer.com.
Blackmer is a member of Pump Solutions Group (PSG), which is comprised of
several brands, including Abaque, Almatec, Blackmer, Ebsray, Finder, Griswold,
Maag, Mouvex, Neptune, Quattrolow and Wilden. For more information on PSG,
visit www.psgdover.com.
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PUMPS & SYSTEMS
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April 2014
63
MAINTENANCE MINDERS
Analyze Top-of-Motor Vibration

Guidelines for reduced vibration and information on how a pumps foundation and operating
speed affect the vibration response
Last of Two Parts
By Jack Claxton, Patterson Pump Company, a Gorman-Rupp Company
art One of this series in the March 2014 issue of Pumps

& Systems discussed insights that may be gained by
analyzing the mathematical model featured in Top-ofMotor Vibration (Pumps & Systems, September 2012).
Part Two expands on these insights and provides guidelines
for reduced top-of-motor vibration, how the pumps
foundation inluences vibration and discusses the impact
of a pumps operating speed.
GUIDANCE FOR OBTAINING REDUCED
TOP-OF-MOTOR VIBRATION
Readers are reminded of the limitations imposed by the
simplifying the assumptions discussed in Part One (irst
mode only considered, no other modes, no excitation
sources other than imbalance). he information presented
is provided as tools for insight and does not present
a inished comprehensive work. It will assist in better
understanding of vertical, wet-pit, column type pump
vibration and help develop standard vibration acceptance
criteria for the top-motor bearing. General guidance for
achieving lower vibration levels includes the following:
To achieve reduced top-of-motor vibration measurements, an improved motor balance grade beyond
standard is recommended. Motor manufacturers
typically have a default standard balance grade but can
ofer a special balance with little additional cost. Pump
manufacturers can assist speciiers regarding the level
of motor balance grade that can be practically supplied
for inclusion in the speciications.
To achieve reduced top-of-motor vibration measurements for an installation, adequate frequency separation margins in the ield are needed. To help assure
lower vibration response for installations in the preconstruction stage, the most diicult challenge is predicting the expected structure reed frequency because
this is not easily accomplished to the required accuracy. A simple method of calculating the structure reed
64
April 2014
frequency was discussed in the September 2012 article.

An additional resource, the Hydraulic Institutes
ANSI/HI 9.6.8 Guideline for Dynamics of Pumping
Machinery (soon to be published), also provides guidance on this topic. In ANSI/HI 9.6.8, the calculation
method for the structure reed frequency presented is
considered a Level 1 analysis, whereas more accurate
methods are discussed in ANSI/HI 9.6.8 for use when
these methods are justiied (guidance for making this
determination is also discussed in ANSI/HI 9.6.8).
Because accurate prediction of the structure reed frequency is so important to achieving reduced vibration,
speciiers desiring a high degree of certainty of reduced
vibration values may need to specify a higher level
(more accurate) dynamic analysis to precisely predict
the expected structure reed frequency. ANSI/HI 9.6.8
includes a discussion of the analysis methods available
and sample speciication templates that can be used in
contract speciications to request the desired analyses.
Figure 1. The structure reed frequency versus motor reed

frequencyadapted from Figure C.2 of ANSI/HI 9.6.8, Dynamics of
Pumping Machinery
Courtesy of Hydraulic Institute, Parsippany, N.J., www.pumps.org
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PUMPS & SYSTEMS
MAINTENANCE MINDERS
ANSI/HI 9.6.8 discusses motor reed frequencies and

the efect they have on vertical structures. Sample
speciication templates are provided that can be used
for contract speciications to request an impact test to
determine the actual motor reed frequency prior to
shipment.
FOUNDATION EFFECTS
For an installation with known ield structure reed frequency characteristics based on tests, these test results will
include foundation rigidity efects and no calculation of
foundation efects is necessary. he ratio of the pump operating speed versus the actual structure reed frequency has a
major impact on the vibration response.
For pre-construction phase applications in which the
actual structure reed frequency characteristics based on
tests are unknown and must be calculated, the following
approach may be used to apply the foundation efects to
the mathematical model being discussed.
Equation 1 is used to determine the structure reed
frequency.

frequency at 600 rpm
1
n = fn = 2
g
w(L3 a3)
(s)Motor +
3 E1 I1
Equation 1
66
April 2014
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PUMPS & SYSTEMS
Where:
he denominator (also shown in Equation 2)
= the static delection of the structure
at the motors center of gravity (CG)
(s)Motor and W = motor properties
L and a
= dimensions
= properties of the pump head (from
E1 and I1
the September 2012 article)
(s)Motor +
w(L3 a3)
3 E1 I1
Equation 2
Adapting the deinition for a rigid foundation as one that

increases the static delection of the structure at the motors
CG by 5 percent or less produces the structure reed frequency shown in Equation 3 (an efect of 5 percent or a
factor of 1.05 is used).
1
n = fn = 2
g
w(L3 a3)
(1.05) (s)Motor +
3 E1 I1
Equation 3

Introducing the factor of 1.05 to account for the foundation efects reduces the structure reed frequency to
97.6 percent of what would otherwise be obtained with
no foundation efects included. Factors of greater than
1.05 for non-rigid foundation efects may be handled in

PUMPS & SYSTEMS
www.pump-zone.com
April 2014
67
MAINTENANCE MINDERS
a similar way, and the resulting structure reed frequency

will be input into Equation 1 (from Part One). Using this
information, the foundations rigidity impacts vibration
indirectly through the frequency ratio (/n) in this rotating imbalance model.
DESIGN OPERATING SPEED CONSIDERATIONS
Satisfactory frequency separation margins are not easily
achieved in applications that have certain design operating speeds (or motor speeds). hese applications are more
vulnerable to resonance and increased vibration because of
typical structure characteristics and available motor reed
frequencies. Conversely, avoiding resonance and experiencing lower vibration with some design operating speeds is
easier when compared to others.
Consider Figure 1. It shows the structure reed frequency

versus motor reed frequency, with plots of diferent values
of structure characteristics as deined in ANSI/HI 9.6.8.
Figure 1 enables the structure reed frequency to be determined graphically using the motor reed frequency and
structure characteristics.
For each design operating speed, maintaining a frequency
separation ( to n) of 10 percent in ield conditions is
desired. Figures 2 through 7 depict Figure 1 with the 10
percent margin envelope for design operating speeds of 600
rpm to 3,600 rpm. Synchronous speeds are used for simplicity, with the 10 percent range to be avoided shown
in red. Constant speed operation is assumed in each case.
In Figures 2 through 7, the structure reed frequency
required to achieve a minimum 10 percent separation from


frequency at 1,800 rpm


68
April 2014
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PUMPS & SYSTEMS
the motor speed must be outside the red bands. he structure reed frequency
avoidance band is wider for the higher speeds than the lower speeds, because of
mathematics (3,600 x 20 percent = 720, where 600 x 20 percent = 120).
In addition, some speeds (such as 1,800 rpm) seem to have a greater probability of intersecting the plots of structure characteristics for the range of
motor reed frequencies available. Lower design operating speeds appear to be
less vulnerable to problems than higher motor speeds. hese characteristics have
implications concerning the units of vibration to use for the purpose of standard acceptance criteria. his topic will be covered in detail in the next section.
Another concern is that, oten, a speciier will want the structure reed frequency to be above the maximum pump operating speed. However, as shown in
these igures, this may not always be achievable, especially for the higher speeds.
Pump manufacturers can provide pre-contract guidance.
UNITS OF VIBRATION FOR THE PURPOSE OF STANDARD
ACCEPTANCE CRITERIA
Units of vibration in terms of velocity are best used as the basis of standard
vibration acceptance criteria, with velocity root mean square (RMS) being the
industry accepted format. However, at some point, the design operating speed
begins to move away from the typical structure reed frequencies encountered,
with frequency separation margins increasing as the design operating speed
decreases. his phenomenon can be understood from Figures 2 through 7 that
illustrate the design operating speed considerations.
At lower speeds, the frequency separation margins are far greater than the
minimum recommended 10 percent, and the resulting vibration is very low
well below the velocity acceptance criterion that is useful at the higher speeds.
herefore, at some speed, introduction of an additional criterion of displacement (Mils, peak-to-peak) that applies a proper sensitivity to the lower speeds
becomes desirable. his criterion should be based on empirical data speciic to
top-of-motor vibration that considers typical frequency separation margins
encountered (not height).
VARIABLE SPEED CONSIDERATIONS

he proliferation of variable speed drives has added a challenge for the vertical
pump industry pertaining to vibration. Space does not allow a discussion of this
topic in this article series.
However, ANSI/HI 9.6.8, Dynamics of Pumping Machinery, provides useful
guidance for dealing with structure reed frequencies in variable speed applications. Coordination with the pump manufacturer is also recommended. P&S
References
1. Claxton, J., Top-of-Motor Vibration, Pumps and Systems, September 2012.
2. ANSI/HI 9.6.8, Dynamics of Pumping Machinery, Hydraulic Institute (HI), Parsippany, N.J.,
www.pumps.org.
Jack Claxton, P.E., served as chairman of the HI Vibration Committee from 1995 to
2012 and has been chairman of the HI Dynamics of Pumping Machinery Committee
since its inception in 2005. He has worked for Patterson Pump Company in Toccoa,
Ga., since graduating from the Georgia Institute of Technology in 1975. He is vice president of Engineering and has worked as the Engineering Department head for 33 years.
Patterson Pump is a Gorman-Rupp Company. Claxton may be reached at
jclaxton@pattersonpumps.com.
The author would like to thank Fred Buse for providing helpful comments during the development of
this article.
PUMPS & SYSTEMS
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April 2014
69
MOTORS & DRIVES
Modern Industrial Drives Redeine

Motor Control
Ease of installation, improved algorithms, enhanced displays, onboard communication and other
technology make VFDs an ideal and cost-effective solution.
By Josh Gross, Eaton
proven tool to reduce energy consumption, variable

frequency drives (VFDs) became increasingly used
during the 1970s energy crisis. Today, VFDs remain a
critical component to control motor speedimproving
eiciency, reducing wear and tear on valuable mechanical
components, and improving system performance. However,
modern drives are more efective and easier to use.
Fundamentally, VFDs control the frequency and voltage supply so the motor closely matches the speed requirements for an application. However, the latest generation of
VFDs is more eicient, intelligent and user friendlyultimately leading to increased energy savings for industrial
applications.
Technology advancements in capacitors, direct current (DC) link reactors, insulated-gate bipolar transistors
(IGBTs), heat management, processing power, graphical
interfaces, communications and monitoring technology
enable the development of solutions to problems that were
not recognized in the past. Additionally, new and advanced
performance algorithms enhance energy eiciency.
Drives can deliver energy savings while optimizing process reliability and protecting valuable assets by controlling
the motor or pump and themselves.
ADVANCED PERFORMANCE ALGORITHMS

New algorithms can deliver signiicant energy savings and
stabilityestablishing a new level of eiciency. A novel
control algorithm for VFDs reduces the input power of an
induction motor that is used to drive a variable torque load,
such as a fan or pump. he algorithm dynamically adjusts
the volts per hertz (V/Hz) relationship supplied to the
motor while maintaining optimum magnetization current
to provide improved energy eiciency and reduced electrical costs. his algorithm can also be applied to constant
torque applications that would not typically realize energy
savings by using a VFD.
70
April 2014
he energy-optimizing algorithm begins when the drive

commands the motor to follow a reference frequency or
when the user enters a new reference frequency. To assure
motor stability, the algorithm initially sets the drive output
voltage at the same level as the voltage based on the linear
V/Hz method for the same reference frequency. It then
reduces the voltage incrementally to optimize energy use.
Meanwhile, the algorithm monitors several real-time
motor parameters to prevent the motor from experiencing
conditions that may lead to instability. When the motor
enters the optimal zone of operation, the drive output voltage remains at the same level until a change triggered by
commands to the drive occurssuch as a change in the reference frequency or a change in real-time parameters. Ater
the output voltage stabilizes, the drive monitors the motors
real-time parameters to prevent instability conditions and
motor current rise.
Experimental results demonstrate that these algorithms
are capable of assuring motor stability and achieving superior energy savings compared with other static or dynamic
V/Hz control methods. By using VFDs with this technology, users can go beyond drive eiciency and ultimately
improve the eiciencies of the motor and the application
for superior energy savings.
FROM LINE REACTORS TO DC CHOKES
In the latest generation of VFDs, the internal line reactor
is replaced with a built-in DC link choke with input surge
protection. he internal line reactor provided protection for
the alternate current (AC) diode and harmonic mitigation
to the line, preventing harmonic distortion from returning
to the distribution channel. he line reactor is most efective
at the highest order of the harmonic spectrum.
he DC link choke performs the same task as the line
reactorpreventing harmonic distortion from returning
on the line and acting as a ilter to smooth the ripple on a
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PUMPS & SYSTEMS
Onboard communicationwhich enables communication between the

drive and other devices within the system and reduces the software
coniguration setup timeis also quickly becoming standard in
modern VFDs.
DC bus. While it reduces harmonics similarly to the AC
line reactor, the DC link choke reduces harmonics across
the entire harmonic spectrum.
In turn, this allows end users to meet the more rigid
requirements of International Electrotechnical Commission
(IEC) 61800, which looks at individual harmonics, not just
the total harmonics of the system. he built-in DC link
choke complies with the C2 category for both radiated and
conducted emissions speciied in European Norm (EN)/
IEC 61800-3.2 for commercial and industry environments.
In other words, all drive manufacturers will need to use a
DC link choke to meet this emissions standard in the next
generation of drives.
Further, the DC link choke has the added beneit of a
lower voltage drop than the equivalent AC line reactor,
translating into overall increased eiciency for the drive.
Speciically, the AC line reactor typically results in a 2 to 4 percent voltage drop, whereas the DC link choke
has a voltage drop of less than 1 percent. his translates into an overall
increased drive eiciency.
ENHANCED GRAPHICAL DISPLAYS
& MONITORING
he next generation of drives also
has enhanced graphical displays and
monitoring capabilities that support
a shit to user-friendly interfaces. he
days of referencing keypad-displayed
codes in user manuals are ending with
scrolling text descriptions of parameters, monitoring values, fault codes
and menu structures.
In addition, users are shiting to
threshold functionality, which provide the ability to customize text or
units displayed for their speciic application. Drive keypads are also starting
to provide the ability to deine user
conigurable sot keys on the keypad
to create speciic functions that
enhance diagnostics or convert a process from complex to

simple with the press of a button.
CONFORMAL-COATED CONTROL BOARDS
Optional features, such as conformal-coated drive control
boards, are becoming standardprotecting equipment
from dust, corrosion and other environmental conditions.
his clear material is applied directly over the electronic circuitry of the control boards and can greatly extend drive life.
ONBOARD COMMUNICATION
Onboard communicationwhich enables communication between the drive and other devices within the system
and reduces the sotware coniguration setup timeis also
quickly becoming standard in modern VFDs.
Ethernet IP, Modbus transmission control protocol
Simple, Reliable
Efficient
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money on power and maintenance costs.
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Carbon ber vanes last longer than traditional blades
Variable ows with VFD and/or bypass
Single stage to 3000 SCFM, two-stage to 1800 SCFM
Discharge pressures to 250 PSIG
Made in the USA for over 80 years
Find out more at www.flsmidth.com/compressors

PUMPS & SYSTEMS
www.pump-zone.com
April 2014
71
MOTORS & DRIVES
Technology advancements in capacitors, DC link reactors, IGBTs, heat

management, processing power, graphical interfaces, communications
and monitoring technology enable the development of solutions to
problems that were not recognized in the past.
(TCP)/remote terminal unit (RTU) and building automation and control network (BACnet) are becoming the
default communication protocols included in industrial
VFD products.
hese communication protocols reduce wiring time
when compared to traditional input/output designs and
also provide more control and monitoring capabilities. he
pre-programmed irmware is conigured for ease of setup
and the ability to easily interface with other manufacturers
components and programmable logic controllers.
CONCLUSION
A proven technology, the modern capabilities of VFDs are
redeining motor control. VFD technology available today
continues to generate more economic and lexible motor
control solutions which can result in less expensive electric bills and more reliable operations. Additionally, these
solutions are engineered with the end user in mind to make
system installation, setup and commissioning easier and
more cost-efective. P&S
Josh Gross is product manager at Eaton. He can be reached at joshuabgross@
eaton.com. For more information, visit www.eaton.com/drives.
O\ulz"Jvu}lu{pvu"Jlu{ly
June 29 - July 1
Boston, Massachusetts
Featuring Exceptional Education
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72
April 2014
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PUMPS & SYSTEMS
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SPECIAL REPORT
FSA Celebrates 10 Years of "Sealing Sense"

Pete Petrunich retires as technical director after 17 years but leaves a legacy of education
and high quality standards.
By Michelle Segrest
or 17 years, Pete Petrunich has been

the authoritative expert on sealing
technology.
Every month for the past decade, the
Fluid Sealing Associations technical
director has coordinated the Sealing
Sense articles for Pumps & Systems.
hese articles have provided detailed
insight to the most common sealing challenges surrounding rotating equipment.
hey have also helped raise the proile of
FSAs educational mission.
his year, Petrunich retires from his
post. He leaves a wealth of technical
knowledge and a worldwide legacy of
good will.
he impact Petrunich has made on the
pumping and sealing industries is welldocumented. However, his impact on the people of the sealing industry leaves the most notable impression.
Pete is one of the most modest, yet well-respected, technical experts Ive had the pleasure to know, said Joseph
Boylan, marketing and sales manager for Morgan Advanced
Materials. His ability to network and motivate those
around him has been a huge beneit for FSA. His retirement
will leave large shoes for any successor to ill. I wish him an
ininite and enjoyable retirement.
Petrunichs European colleagues also speak highly of him.
I have worked with Pete Petrunich since he joined
the FSA as technical director, and we have become great
friends, said Dr. Brian S. Ellis, technical director of the
European Sealing Association. In fact, we are oten referred
to as the twins because we face identical challenges in our
two organizations.
74
April 2014
Henri Azibert, FSA Vice President, A.W. Chesterton Co.

Pete Petrunich, FSA Technical Director
Greg Raty, FSA President, Slade, Inc.
Brian Ellis, ESA Technical Director
In the early days, we would spend long hours on joint,

technical publications just to make sure the language used
in the documents was correct in both British English and
American English. Pete would say, two nations, divided by
a common language. You can see how important it is to get
the text in a format which is correct and unambiguous.
his was just the beginning of the importance of collaboration between the two associations.
In aiming to show that together we could do much more
than either association could do on their own, Pete would
say, One plus one equals three. In my view, these ive words
represent the key phrase by which everyone will know and
remember him. I want to thank Pete for all the fantastic
things we achieved together.
Professor Elmar Baur of Baur & Company consultants in
Munich is the former CEO and president of EagleBurgmann
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PUMPS & SYSTEMS
and served on the executive committee of

the European Sealing Association and is
an honorary member of FSA.
Pete was, for meand probably many
members of the ESAthe face of FSA,
Baur said. Presidents, committee members and other oicers changed. But Pete
remained. He was busy attending all
division meetings and always available
to inform and comment on U.S. aspects
and views in the sealing industry.
With his enormous knowledge, he
could answer nearly all questions and
helped us reach a much better
In aiming to show that together we could
understanding of the sometimes diferent positions on
do much more than either association could do on
both sides of the Atlantic. In
their own, Pete would say, One plus one equals three.
addition to these technical
aspects, Pete is a great guy.
In my view, these ive words represent the key phrase
He certainly has made a lot
by which everyone will know and remember him."
of friends in the U.S. and in
Brian Ellis, ESA
Europe. We all will miss him
when he retires.
he purpose was to discuss partnering opportunities
Pumps & Systems had the opportunity to speak with
Petrunich about a decade of Sealing Sense articles, his focused on sealing education to the pump industry using
retirement from FSA and the signiicant accomplishments Pumps & Systems as the vehicle. Wally presented several
of the Fluid Sealing Association during his 17-year tenure. options at the division meeting. One of the six options was
his Q&A is followed by the irst-ever "Sealing Sense" arti- regular contribution of FSA-branded editorial material
cle, published by Pumps & Systems in the September 2004 entitled Sealing Sense. he concept was to provide practical education on real sealing issues facing the readers and to
issue.
demonstrate FSAs ongoing commitment to sealing educaP&S: Sealing Sense celebrates its 10th anniversary of tion that is useful to the readers.
To use an old clich; the rest is history.
publication in Pumps & Systems this year. Can you tell us
how this idea originated?
P&S: What have been some of the major developments
PP: Early in 2004, the FSA Mechanical Seal Division was with FSA and with Sealing Sense in the past 10 years?
looking to further its key education mission, along with
FSAs mission. A number of the division members had PP: First and foremost, it has been the readers response
established relationships with Pumps & Systems, including to the articles. Consistently, since publication began, the
membership in the Editorial Advisory Board. One of the greatest number of hits on the FSA website has been
division members, Bill Adams, who was with Flowserve Sealing Sense articles. his is one relection of the relevance
at the time, invited Wally Evans (publisher of Pumps & and interest in the practical topics covered on a monthly
Systems) and the Pumps & Systems editor to the April basis. hese topics included a wide range of important
2004 Mechanical Seal Technical Committee and Division pumping system issues on mechanical seals and compression
packing, as well as gaskets and expansion joints.
meetings in Key Largo.
PUMPS & SYSTEMS
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April 2014
75
SPECIAL REPORT
The completion of the Sealing Systems

Matter initiative was a signiicant
accomplishment. This effort focused
on raising awareness of the important
role sealing systems play in energy
conservation and has led to inclusion
of sealing systems in important
pump energy assessment standards.
Pete Petrunich
Major developments included articles focused on energy
eiciency, sealing systems reliability and total cost of ownership. hese were, and still are, all timely and important
issues to the pump industry. he readers response has also
catalyzed interest in a similar efort on educational publications by the European Sealing Association (ESA).
P&S: What are some of your favorite memories from the
past 10 years with Sealing Sense and with FSA?
PP: As I search my memories, I ind it diicult to provide
favorites, but a number of thoughts occur. As with most
things in life, change is constant. When I look back over the
last 10 years, there have been plenty of changes related to
the Sealing Sense articlesboth at the FSA and Pumps
& Systems.
Many of these have to do with personnel changes. One
experience that remained constant throughout these
changes has been the professional working relationship by
all those involved in the process of creating and publishing
the articles. hat experience stands out as my favorite during
these 10 years of publication.
P&S: What would you consider your most signiicant
accomplishments during your tenure with FSA?
PP: I have been technical director for the FSA since 1997
when that position was irst introduced. he dynamics of
what efectively is a staf position means facilitating is the
key role of the technical director.
Eliciting and supporting consensus has been a key
responsibility.
76
April 2014
Taking that into consideration, the completion of

the Sealing Systems Matter initiative was a signiicant
accomplishment.
his efort focused on raising awareness of the important role sealing systems play in energy conservation and
has led to inclusion of sealing systems in important pump
energy assessment standardssuch as the already published
ASME EA-2-2009 and EA-2-2010, and the soon to be published ISO 14414.
Beyond that, I will leave it to others to make judgments
about my key accomplishments. Certainly my contribution
for delivering Sealing Sense articles over the last 10 years
can be considered one of them.
P&S: What do you foresee for the future of FSA?
PP: As the needs of the sealing industry change, the FSA
is faced with the challenge of responding to those needs by
providing compelling value to its members and the industry.
he current leadership of the FSA is working hard on
initiatives that respond to those challenges, which are not
unlike those faced by other groups.
Further collaboration with related associations will certainly be one of the future considerations, as it is to some
extent currently with the ESA and the Hydraulic Institute
(HI), for example.
I believe the FSA recognizes and is poised to address these
challenges and create a bright future for the Association.
P&S
Michelle Segrest is the editor of Pumps & Systems.
www.pump-zone.com
PUMPS & SYSTEMS
Pete Petrunich is the technical director of the Fluid Sealing Association

(FSA), a North American-based international trade association established in
1933. Membership is comprised of irms who manufacture and market virtually
every type of luid sealing device or material and represent the majority of the
manufacturing capacity for luid sealing devices in the Americas market.
Close ailiation is maintained with the European Sealing Association.
Petrunich has more than 30 years of functional and administrative experience with the technology and marketing of luid
sealing materials employed in the worldwide gas, oil, petrochemical, chemical and power industries. He served as both the
vice presidents of marketing and technology for a subsidiary of
Morgan Crucible, Plc.
During his tenure with Union Carbide he held various positions in technology, marketing and manufacturing. He was a
key member of the team that successfully promoted the application of lexible graphite-based sealing products to the gas, oil and petrochemical industries. Petrunich holds a bachelors degree in chemical engineering from
Purdue University and a Master of Science from the University of Toledo.
Programs and course work in marketing, technology and motivational management have supplemented his formal education. He has authored several papers
on topics related to the luid sealing industry and was a contributor to the hird
Edition of Technology Management: Case Studies in Innovation.
Petrunich has also been ailiated with a number of related trade, standards
and technical associations. hese include the American Society of Mechanical
Engineers (ASME), American Petroleum Institute (API), the American Society of Testing & Materials (ASTM), the
Pressure Vessel Research Council Sealing Reliability Council (PVRC-SRC), and 3A Sanitary Standards.
FSAThe Voice of The Fluid Sealing Industry
n 1933, 36 American and Canadian companies attended

the inaugural meeting of the Mechanical Packing
Association in New York. After changing its name to the
Fluid Sealing Association (FSA) in 1970, the organization
has grown to represent more than 85 percent of the manufacturing capacity for North America.
he FSA has six divisions with a specic product technology focus: Mechanical Seal, Gasket, Compression
Packing, Piping Systems Non-Metallic Expansion Joint,
Ducting Systems Non-Metallic Expansion Joint and the
Heavy Industry Process Damper Division.
he initiatives of the Mechanical Seal Division include
Sealing Systems Matter, which is based on an energydriven total life cycle cost approach to sealing systems. he
Life Cycle Cost Estimator software tool, part of Sealing
Systems Matter, is a web-based tool for calculating and
comparing pump seal life cycle costs. he software is available for download from the FSAs website (www.uidsealing.com) or under the Seals topic at www.pump-zone.
PUMPS & SYSTEMS
com. Publications from the Mechanical Seal Division

include the Mechanical Seal Handbook and Mechanical
Seals for Pumps: Application Guidelines. Joint FSA/
European Sealing Association (ESA) publications from
the Mechanical Seal Division include the Seal Forum, a
series of case studies in pump seal performance.
Other FSA publications include the joint ESA/FSA
Guidelines for Safe Seal Usage Flanges and Gaskets and the
pamphlet Gasket Installation Procedures; the Compression
Packing Technical Manual; the Non-Metallic Expansion
Joints and Flexible Piping Connectors Technical Handbook;
and the Ducting Systems Non-Metallic Expansion Joints
Technical Handbook, 4th edition.
he FSA collaborates with several other organizations.
Since 1999, the FSA has collaborated with the ESA on
several technical documents and completed a joint strategic planning session that calls for additional joint ventures.
he FSA has also partnered with the Hydraulic Institute
(HI) since 2007.
www.pump-zone.com
April 2014
77
Fr
The om the P
irst
FSA umps &
in th "Sealin System
e Se
s
ptem g Sense archive
s:
ber 2 " as p
ublis
004
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issue
.
SPECIAL REPORT
From the voice of the fluid sealing industry
SEALING SENSE
Q. How do you determine the primary cause(s)
of mechanical seal failure?
A. A systematic method, based on failure analysis,

to investigate and correct the performance of
mechanical seals provides the means to attain longer
service lives and reduced life cycle costs.
Failures occur when a product ceases to perform its

intended purposeseither prematurely or after satisfactory life cycles have passed. Since downtime
usually is even more expensive than maintenance
costs, the efforts we expend on failure analysis frequently pay for themselves many times over when
corrective actions are taken. To understand the primary causes of failure, we must first understand the
basic features of a mechanical seal system.
The function of every mechanical seal is to prevent
the escape of a fluid past the clearance between a
rotating shaft and the passageway through the wall
of a housing or pressurized vessel. End face mechanical seals can incorporate many designs and configurations to accomplish this. As shown in the accompanying figure, typical mechanical seals have three
basic components: (1) primary seal elements,
78
April 2014
(2) secondary seals; and (3) hardware for attaching,

positioning, and maintaining face-to-face contact.
The primary seal is formed by two materials with
lapped faces that create a very restrictive leakage
path from rubbing contact between them. In all
such seals, one face is held stationary, and the other
is fixed to and rotates with the shaft.
The phrase restrictive leakage path is used because
all mechanical seals leak through these faces, even
though one does not see leakage from most of them
or any leakage is controlled to environmentally
acceptable levels via ancillary systems. The leakage
rates, however, are normally small; and environmentally acceptable, non-hazardous or nontoxic fluids may be allowed to evaporate or dissipate to the
atmosphere in a short time period. For controlled,
hazardous and toxic fluids, other means are required
for containment.
Secondary seals made from various fluoroelastomers
usually close leakage paths around the stationary face
and the rotating face. For pusher-type seals, the secondary seal must move forward along the shaft to
compensate for wear and vibration at the seal faces.
For non-pusher-types, such as metal bellows units,
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PUMPS & SYSTEMS
vibration and wear are taken up internally in the bellows, and here the secondary seals are truly static.
The mechanical hardware supplied with and integral to the seal is used to:
Improper startup and operating procedures,

including failing to pressurize a double seal
before starting a pump or inadvertently running
a seal dry.
1. Adapt seals to various pieces of equipment. This

hardware may consist of a sleeve or housing for
ease and precision of seal setting.
Fluid contamination, which might be the presence of harmful solid particles in the seal cavity
fluid.
2. Provide mechanical preloads to the seal faces

until hydraulic pressures take over. This normally is accomplished by a large single-coil
spring, or by a set of small coil springs.
Poor equipment conditions, such as excessive

shaft runout, deflection or vibration.
Worn-out seals that may have completed a satisfactory life cycle.
3. Transmit torque to both stationary and rotating

faces. This normally is accomplished by a series
of drive pins, dents, notches or screws integral
with the seal design.
The objective of failure analysis, naturally, is to learn

from failures. We should carefully look at worn and
damaged seal parts, the condition of the equipment,
and the operating conditions, to establish a list of
ways to improve seal life. For worn parts, this consists of identifying damage as chemical, mechanical,
or thermal and taking steps to ensure it does not
recur. Skills in mechanical seal failure analysis can be
improved by looking at the basic forms of damage
that occur to determine:
No matter how complicated a design might appear

the first step in seal failure analysis is to identify
which of the basic seal components show damage
that might indicate the cause of leakage. A mechanical seal has failed when leakage becomes excessive.
Common causes include:
I
Allowing the seals components to become

chipped, scratched or damaged prior to or during assembly.
Incorrect seal assembly, including the incorrect

setting or misplacing of seal components in the
seal cavity.
Selecting the wrong materials of construction or

an incorrect design for the combination of pressures, temperatures, speeds and fluid properties
required for a given application.
1. What the damage looks like.

2. How the damage affects seal performance.
3. What the types of damage indicate about a seals
past history.
4. What corrective steps can be taken to eliminate
various types of damage from recurring under
the same operating conditions.
Next Month: A discussion of the symptoms, examination of the causes, and review of the corrective actions
for failures of mechanical seals by chemical action.
Sealing Sense is produced by the Fluid Sealing

Association (FSA) as part of our commitment to
The following Mechanical Seal Division members

sponsor this initial series:
industry-consensus technical education for pump

users, contractors, distributors and manufacturers. As
a source of technical information on sealing systems
and devices, and in cooperation with the European
Sealing Association (ESA), the FSA also supports
development of harmonized standards in all areas of
fluid sealing technology. The education is provided in
the public interest to enable a balanced assessment of
the most effective solutions to pump technology issues
on rational Total Life Cycle Cost principles.
The Mechanical Seal Division of the FSA is one
of six divisions with a specific product technology
focus. As part of its mission, it develops fundamental
technology publications such as the Mechanical Seal
Handbook, to complement more detailed manufacturers documents produced by its member companies.
Advanced Sealing International (ASI)

A.W. Chesterton
DuPont Dow
Eagle Burgmann
Flowserve FSD
Garlock Sealing Technologies
Greene Tweed
Industrias Vago de Mexico
John Crane
PPC Mechanical Seals
Robco
Sealing Equipment Products Co.
Simrit Div., Freudenberg-NOK
For additional information on FSA and the pub-
PUMPS & SYSTEMS
lications and services it offers to industry, log on to

www.fluidsealing.com
www.pump-zone.com
April 2014
79
SPECIAL REPORT
Prevent Gasket Blowout

Whats Most Important?
SEALING SENSE
First of Two Parts

By FSA member Randy Wacker, P.E.
asket blowout is the most catastrophic of gasket failures.

It usually occurs with no discernable warning and
causes a sudden and signiicant release of internal pressure,
usually accompanied with loud popping sound or whistle.
Depending on the process being contained and/or the
amount of stored energy at the time, the result can be fatal.
Part One of this two-part Sealing Sense series brings
attention to the balance of forces present at the potential
moment of gasket blowout and provides guidance on how
to protect against this type of gasket failure. Equations are
provided to assist with evaluating these forces and results are
presented to show that to protect against blowout, clamping force can be signiicantly more important than gasket
tensile strength.
BLOWOUT FORCES
For the purpose of this article, Figure 1 identiies the general condition of potential blowout. It shows an axial cut
across the thickness of the gasket and the three general forces
afecting blowout. Equation 1 provides the force balance in
the radial direction. he potential condition of blowout
is taken when the sum of these forces is equally balanced.
hat is, the forces holding the gasket in place and together is
equal to the outward force trying to dislodge or damage it.
Equation 1
FGten + FClamping = FBlowout
hese are deined as follows:
= Force supplied by the (resisting) tensile
FGten
strength of gasket
FClamping = Frictional force on gasket from combined
axial forces
FBlowout = Outward radial force trying to separate gasket
from langes
hese three forces give a general descriptive condition
of blowout, but do little to identify the components upon
80
April 2014
which they are dependent. Equation 2 provides greater

detail to draw attention to these components.
Equation 2
(FGten) + (FBtot) - (FGrelax) (Fhyd) ( Fother) = FBlowout
FClamping has been subdivided into four components. hese
components are deined as follows:
FBtot = he total initial force on the gasket created
from tightening the fasteners to a prescribed
target torque
FGrelax = Loss of compressive gasket stress because of
time, temperature and load efects
FHyd = Force resulting from hydraulic load being
contained
FOther = General collection of other efects that reduce
or increase the clamping force
Fhyd and FOther, though normally negative, can be positive
and help prevent blowout.
Table 1 lists common conditions that should be considered when evaluating each force. he reader is cautioned
that this is only a partial listing. he intent is to bring attention to the type and number of factors that can afect the
force balance.
Equation 3 provides a further redeinition and rearrangement of terms that allow the potential blowout pressure
to be evaluated directly. Example values are supplied for a
Figure 1. Forces on a gasket
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PUMPS & SYSTEMS
2-inch, Class 150, ASME B16.21 ring gasket.

Equation 3
[ A
+ (FBtotal gRF Ag FOther)]
PBO = tg blowout
Di2
t Di +
4
he added terms are deined as follows:
= Tensile strength of gasket, 2,700 pound-force per square inch
tg
(lbf/in2)
Ablowout = 2 x gasket width x gasket thickness in compressed condition, in2
= Friction factor, gasket on lange face, 0.2

FBtotal = Total bolt load at original tightening torque, 32,914 pound force
(lbf )
gRF = Loss of gasket stress to time, temperature and loading history,
2,050 lbf/in2
= Axial area of gasket, 5.84 in2
Ag
Di
= Inner diameter of gasket, 2.38 inches
t
= hickness of gasket in compressed condition (0.0625 inch)
FOther = as above, 10,000 lbf
PBO = Blowout pressure, lbf/in2
ANALYSIS OF BLOWOUT FACTORS

A way to trial diferent values to inspect their potential efect on PBO is available. It will be used to test the general belief that gasket tensile strength is
always a major factor in preventing gasket blowout. To investigate, two series
of calculations are evaluated to the resulting value of PBO.
FBtot
Nut factor
FGrelax
Softening
of gasket
modulus
at design
temperature
Coeficient of
friction, gasket
on lange
Flange
misalignment
Cyclic
temperature
loading of
gasket
Cyclic pressure
loading of
gasket
Tightening
procedure
Flange
analysis
Torque wrench
precision
FHyd
Internal
pressure being
contained
(positive or
negative)
FOther
Differential
thermal
expansion of
components
(bolt, lange,
gasket)
Piping/
equipment
loads
FGten
Gasket tensile
strength
Vibration
Flange rotation
Relative
stiffness
of lange
components
Bolt condition
Table 1. Common conditions to evaluate
PUMPS & SYSTEMS
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April 2014
81
SPECIAL REPORT
he irst series is performed by holding all
values ixed, except tg. Its value is progressively
reduced in 5 percent increments. In the second
series, all values are held ixed except, FOther. his
shows the potential efect of an axial piping
load or axial lange misalignment that tends to
separate the langes. Its value is progressively
increased in 5 percent increments. he results
are plotted in Figure 2.
he plot of gasket tensile strength is relatively
lat. his shows PBO to have a low sensitivity to
changes in gasket tensile strength. On the other
hand, PBO shows a signiicant sensitivity to the
efect of the change in axial piping load. During
the range considered, the overall change in PBO
for tensile strength and the piping load are approximately 4 percent and 41 percent, respectively. In
Figure 2. Effect of piping load and gasket tensile strength on blowout pressure
fact, a 5 percent drop in clamping force produces
larger drop in blowout pressure than a 50 percent
drop in tensile strength. Clearly, the clamping force can play a CONCLUSION
much larger role in protecting against blowout. his is equally In this example, the total value of clamping force was
true for any efect that reduces the clamping force.
adjusted by considering a single factor such as piping load
or lange misalignment. In reality, the
ultimate value of clamping force will
be the result of the combined efects
of several factors. Unless the value of
gasket tensile strength is very high, the
clamping force will be most responsible for protecting against blowout.
A review of Table 1 shows a signiicant number of conditions that can
negatively impact blowout pressure.
Developing values for these factors
can oten be a challenge. Next month,
Part Two of this Sealing Sense series
will investigate two strategies to help
make this challenge manageable. P&S
NEXT MONTH:
Part Two: Prevent Gasket Blowout
Whats Most Important?
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.
82
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
HI PUMP FAQs
Monitor Power in Rotary Pumps &

Submersible Air-Operated Pumps
By Hydraulic Institute
Q. What are some ways to monitor the power used by a rotary pump?
A. Instrumentation and systems can be used, such as:
which alter voltage and current characteristics.
Torque meterhe most direct way to monitor
power is a torque meter with integral speed pickup
between the driver and pump. his system directly
senses the pump speed and torque required. Some
torque meter readouts calculate the actual power
transmitted. Under controlled operating conditions,
torque measurement can sometimes detect internal
component rubbing and wear in rotary pumps.
Power meterhis device is useful if the pump is
driven by an electrical motor, either directly coupled
to the pump or through a gearbox, belt or hydraulic
coupling. Electrical transducers are typically installed
in the electrical motor starter to measure voltage,
current and phase angle. he product of these values
results in the power supplied to the motor. his
approach monitors the power increase or decrease
pump parts deteriorate or drag. It also indicates the
general health of the electrical motor and/or the
gearbox, belts or hydraulic coupling. his device may
not be suitable for use with variable frequency drives,
Electrical current monitorSimilar to a power meter,

it only monitors the motor current. he line voltage
and power factor are assumed to remain constant,
calculating the power supplied to the motor. While
this method monitors the pump and motor condition, it is susceptible to error caused by variations in
the electrical supply grid and motors with a low load.
Strain gaugesStrain gauges installed on the pump
shaft near the coupling or the drive output shaft with
proper telemetry or slip ring equipment will indicate
the torque required to drive the pump. his approach
is similar to using a torque shaft except that a longer
baseplate is not required to accommodate the length
of the torque shaft. However, some accuracy is sacriced. If the pump speed is constant or known, the
power required by the pump can be calculated.
With positive displacement pumps, a power monitoring
device must not be used for overpressure protection. he
pump must be protected by a pressure relief valve. P&S
Q. Is it possible for air-operated pumps to be submerged

during operation?
A. Some air-operated pumps are designed to be submerged. Before submerging a

pump, check the chemical compatibility of the material of the wetted and nonwetted parts of the pump with the liquid in which the pump is to be submerged. Check
the manufacturers operation manual for each pump before attempting to use it in a
submersible application. When submerging a pump, a hose should be attached to the
pump air exhaust with the exhaust piped above the liquid level to prevent the liquid
from entering the pump (see Figure 10.4.1.6). To learn more about air-operated pumps,
see ANSI/HI 10.1-10.5 Air Operated Pumps for Nomenclature, Deinitions, Application,
and Operation. P&S
Figure 10.4.1.6 Suggested submerged

installation
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.
PUMPS & SYSTEMS
www.pump-zone.com
April 2014
83
PRACTICE & OPERATIONS
Sizing Pulsation Dampeners Is Critical

to Effectiveness
Pressure variation is an important consideration when determining the appropriate size pulsation
dampener needed for an application.
By David McComb, Blacoh Fluid Control
ositive displacement pumps efectively pump luid at

a constant average low rate. However, because the
individual pumping elements of these pumps discharge
discrete quantities of luid, the instantaneous low rate
varies in a cyclic fashion.
Pulsations are observed in the system as pressure spikes.
In the positive displacement pump family, single-shoe peristaltic pumps generally create the largest pulse, followed by
two-shoe peristaltic pumps. Triplex and quintuplex pumps
have smooth output curves because of piston overlap. Gear
pumps can have extremely small pulses, but pulsations still
exist. his pulsating low can cause operational problems
and shorten equipments service life.
To alleviate the problem, pulsation dampeners can be
added to the pumping system to absorb pressure spikes and
smooth luid low. Figure 1 shows the undampened pressure
spikes from a triplex pump in green. he dampened pressure
curve from the same pump with the same system settings are
indicated in blue. Six pulses per revolution occur instead of
the expected three. his is a result of piston overlap.
DETERMINE ADEQUATE SIZE
he most common type of pulsation dampener
is a hydro-pneumatic pressure vessel containing
compressed air or nitrogen and a bladderor
bellowsthat separate the process luid from
the gas charge. To maximize the dampening
efect, pulsation dampeners should be installed
as close as possible to the pump discharge with
a gas charge that is slightly below the normal
system pressure. More important, pulsation
dampeners must be properly sized for the
system.
A dampener that is undersized cannot adequately compensate for pressure and low luctuations. An oversized dampener will act as an
accumulator, storing too much luid. his will
cause slow stabilization and a delayed response
84
April 2014
to system changes. he irst step in sizing a dampener is to

quantitatively deine the acceptable performance.
DETERMINE THE AMOUNT OF TOLERABLE
PRESSURE VARIATION
he speciic requirements of the application and the components that make up the system are all factors that need
to be considered. Once an acceptable pressure variation is
deined, the unit size required for the desired performance
should be determined. Engineers and designers are interested in making accurate predictions. Avoiding a problem is
better than inding a way to ix it.
CALCULATE PRESSURE FLUCTUATIONS
Sizing pulsation dampeners is straightforward. However,
calculating the system pressure luctuations is more complex. Fluid discharge rates from pumps are diicult to mathematically model. For example, in Figure 1, the spikes are
not even. heoretically, they should be equal. Mathematical
models must be physically tested to verify their accuracy.
Figure 1. Triplex pump output pressure curves
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PUMPS & SYSTEMS
Pumps with multiple heads and higher pulse frequencies

can make the calculations more diicult. he distance from
one output port to the next is generally not constant. his
creates a shit in the piston overlap with intermittent larger
and smaller pulses. Calculating the magnitude or frequency
of noise pulses that can develop or resonate in a system is
diicult.
Piping arrangementsuch as bends, reducers and
valvescombined with the opening and closing of pump
discharge check valves can create noise in the luid called
pressure pulses. Because many variables must be considered,
each pump type should be tested with and without a dampener. he pressure curve data can be recorded and used to
ind the pumps formula constant. his constant can be
used in future calculations. As long as other pump models
are similar to the test unit, accurately predicting the magnitude of line pressure variation with a given size dampener is
possible.
MINIMIZE ACCELERATION HEAD
he pressure in a piping system will rise sharply when a
volume of luid is added to the line. It accelerates the mass of
the luid in the piping system. his is acceleration head, and

it needs to be minimized with a dampener. he efect and
its impact must be considered on both the inlets and outlets
of positive displacement pumps. On the inlet side, cavitation and partial illing of pump cavities can damage pump
components and make the pump much louder than normal.
A non-snubbed pressure transducer can accurately measure the systems pressure spikes. A pressure transducer can
react much faster than a bourdon tube gauge, and it can
measure noise if the sample rate is high enough.
Bourdon tube gauges require time to equalize and can
undershoot and overshoot the actual pressure depending
on the magnitude and frequency of the pressure pulse. Even
if the gauge could read accurately, reading a quickly moving
dial is diicult. Electronically measured and recorded data
can determine how the system is operating.
System noise must be considered when taking measurements because it can give higher-than-expected results.
Noise in the pumping liquid can generally be ignored, but
in some situations, system noise needs to be controlled.
Noise can cause pressure relief valves to leak, damage sensitive components and create occupational safety hazards.
PUMPS & SYSTEMS
www.pump-zone.com
April 2014
85
Dampeners typically reduce noise, and some are speciically

designed for this purpose.
PULSATION DAMPENER STYLES
Several diferent styles of dampeners are available, and each
has advantages and disadvantages. his article focuses on
reducing the pressure pulses caused by pulsing low. he
principles and the method for calculating the appropriate
size dampener for this application are the same for most
dampeners.
A dampener absorbs a luid pulse and then allows the
luid to low back into the system between pulses. Most
dampeners use a gas charge that is set slightly below the
normal system pressure and is compressed by the pulse of
luid. he gas then expands when luid is released.
DETERMINE THE PUMP CONSTANT

To determine the pump constant, the volume from a single
pulse of the pump must irst be determined. hen an initial
estimate of dampener size is made, and the corresponding
value of dampener volume is applied. he amount of gas in
the dampener will be less than the total dampener volume,
which needs to be factored into the calculation. A typical
range of 80 to 90 percent of the dampener volume should
be gas if the dampener is properly charged. hese give an
initial gas volume:
(Vp = pulse volume)
(Vd = dampener volume)
(Vpr = percent ill)
V1 = Vd Vpr
CALCULATE PRESSURE CHANGES

Two formulas should be considered when calculating pressure changes in the gas:
If the pressure changes happen slowly, the gas temperature will have time to equalize. his is an isothermal
V P
process. he equation is: P2 = 1 1 , where P1 and V1
V2
are the initial states, and P2 and V2 are the inal states.
he other formula assumes no heat transfer from the
gas to its surroundings. his is an isentropic process,
V
and the equation is: P2 = ( 1 )n P1. In this formula,
V2
n is a constant that is speciic to the gas being used. For
example, for air at room temperature,
n 1.4, and for nitrogen, n 1.399.
Some heat transfer almost always occurs. he process is
rarely slow enough for the gas temperature to equalize, so
the actual answer will be between these two calculations.
In most cases, the luctuations are fast enough that the
actual value is signiicantly closer to the isentropic formula.
he isentropic formula gives the most conservative result.
herefore, it is the more accurate formula in most cases.
In actual practice, either formula would probably work
if the pressure luctuations are small relative to the system
pressure. he pump constant that is developed would cover
the inaccuracies in the formula as long as the pressure variations are similar. In this article, the isentropic formula is
used.
86
April 2014
he inal volume is the initial gas volume minus the pulse

volume:
V2 = V1 Vp
he constant reduces the pulse volume to account for
low leaving the dampener while the pulse is entering. It also
accounts for piston overlap, which changes the efective size
of the pulse. Adding the factor to the isentropic formula and
solving for the pump factor gives us the following equation:
V1 1 (
fd =
P1 n1
Pa )
Vp
Where:
fd = pump factor constant
Pa = measured maximum absolute pressure
P1 = minimum absolute line pressure
he pressure formula can be rearranged to give the desired
dampener volume with given minimum and maximum
pressures:
P 1
Vp fd( 2 ) n
P1
Vd =
P2 n1
Vpr ( ) 1
P1
he formula can also be rearranged to give pressure variation with the pump factor and with a known dampener
volume:
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PUMPS & SYSTEMS
n
Vd Vpr
P2 = (V V V f ) P1
d
pr
p
d
the pressure luctuation is calculated using the isentropic

pressure formula, the result is:
Note: he formula does not account for pressure spikes

that result from rapidly changing the low rate in the piping
system. hese pressure spikes, also known as water hammer,
can travel throughout the entire piping system and may
damage pumps, piping and other ixtures. If this type of pressure transient occurs in the system, a larger dampener at the
pump may be needed. Alternatively, an additional dampener at the source of the transient spike may be required.
For example, the pressure curve from an undampened,
two-shoe, 2.5-inch peristaltic hose pump shows a sharp
increase in low, followed by a no-low or negative low
zone. In this instance, the line has a ball valve that is creating
the low restriction for back pressure. he blue line shows
the undampened pressure spikes (see Figure 2). he red line
shows the pressure changes of the same pump with the same
back pressure valve setting but now using a dampener. his
sample dampener has an actual gas volume of 415 cubic
inches, and the dampener is 90-percent gas illed. he base
pressure is 14.15 psig, and the pulse is 76.9 cubic inches. If
(415 0.9) 1.4

P2 = [( 415 0.9 76.9 ) (14.15 + 14.7)] 14.7
= 25.62 psig
It is important to remember to add 14.7 psi to convert
from gauge to absolute pressure, then subtract 14.7 psi again
to get the inal result in gauge pressure. his pump setup was
tested, and the actual pressure variation was determined to
be 7.38 psi. herefore, the result is:
Pa = 7.38 + 14.15 = 21.53 psig
Inserting the numbers into the factor formula gives:
14.15 + 14.7 1.41

21.52 + 14.7 )
= 0.73
76.9
415 0.9 1 (
fd =
If the example above is used and it is decided that a pressure luctuation of 15 psi would be acceptable, the formula
U N M AT C H A B L E E X P E R I E N C E
I N F L OW C O N T RO L
TRANSACTIONS
Jordan, Knauff & Company is a knowledgeable and

experienced provider of a comprehensive line of
investment banking services to the pump, valve and
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Our lines of business include: selling companies,
raising debt and equity capital, and assistance
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To learn more about Jordan, Knauff & Company,
contact any member of our Flow Control
XIEQ %GGIWW SYV *PS[ 'SRXVSP VIWIEVGL EX
[[[NSVHEROREYJJGSQS[GSRXVSP
+'SSO.SVHER.V
(EZMH%/EOEVIOE
Managing Principal
GN$NSVHEROREYJJGSQ

Senior Associate
HOEOEVIOE$NSVHEROREYJJGSQ

MEMBER FINRA, SIPC

PUMPS & SYSTEMS

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April 2014
87
with the previously calculated pump factor can be used to

determine what size of dampener is needed.
14.15 + 14.7 + 15 1.41
76.9 0.73 (
14.15 + 14.7 )
= 222 cu in
Vd =
14.15 + 14.7 + 15 1.41
1
0.9 (
14.15 + 14.7 )
Table 1 lists some approximate pump constant factors

that can be used when sizing dampeners for diferent pump
types. hese factors are approximate, and the results may
vary signiicantly with the many variables involved.
Type of pump
pump must stay full of luid with no voids. Any voids or

pockets can cause seal leakage, pump vibration and excess
pump noise.
he solution was to install a pulsation dampener at the
pump discharge to smooth the low and remove pressure
pulsations. his allowed the dosing to be more accurate. An
inlet stabilizer (suction dampener) was also installed on the
inlet side of the pump to act as an accumulator to keep the
pump chambers illed. he inlet stabilizer also removed pulsations created by the pump on its inlet stroke. Both devices
were sized based on the pump type, low rate and operating
pressure.
Factor
Single-shoe/roller hose pump
0.87
Two-shoe hose pump
0.73
Air-operated double diaphragm pump
0.19
Simplex single acting
0.60
Triplex single acting
0.13
Quadruplex single acting
0.10
Quintuplex single acting
0.06
Table 1. Pump constants
Application 1
A triplex plunger pump doses methanol, which is metered
on the discharge side. Without a dampener to control pulsations and smooth out the low, the installed low meters
were giving inaccurate readings.
When using a triplex pump, all three chambers of the
Application 2
During the illing of a drum with a lexible hose, an automatic valve would close and cause a water hammer efect.
All the pipes leading into the system would shake until they
broke loose from their supports. he solution was to install
a pulsation dampener at the beginning of the lexible hose
connection.
he pulsation dampener was sized based on the low
parameters and installed at the beginning of the lexible
hose. When the automatic valve closed, the hose and pulsation dampener efectively absorbed a portion of the water
hammer, eliminating pipe shake and improving operational
safety.
CONCLUSION
he sizing of a pulsation dampener is critical to achieving
the desired result. Finding and using the correct constant
pump factor in dampener sizing is a key
part of the solution. As long as the pulsation dampener is properly sized, positioned and charged, it will efectively
dampen pulsations to protect equipment and keep the pressure pulses within
design parameters. P&S
David McComb is the engineering
manager at Blacoh Fluid Control, a
manufacturer of pulsation dampeners, surge suppressors, inlet stabilizers and other luid control products.
McComb obtained a B.S. in mechanical engineering from University of
California, Riverside, and has extensive
ive experience in
project and product line management.
For more information, contact Blacoh at 951-3423100 (800-603-7867), or visit www.blacoh.com.
Figure 2. Peristaltic pump pressure curves
88
April 2014
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PUMPS & SYSTEMS
PRODUCT PIPELINE
Diaphragm Pumps
Wireless Monitoring
JDA Global introduced

its HARD HAT series
of aluminum NOMAD
TRANS-FLO GOLD
pumps. Featuring a screen
base design, this stand-up
base section has strainerlike vertical slots that
capture large particulatessuch as stone, heavy sand and
dirtpreventing clogging of connection points, manifolds or chambers.
Phoenix Contacts Radioline

wireless platform ofers wire
replacement for simple I/O and
serial communication. Radioline
ofers a cost-efective wireless solution when running a wire is impossible or too costly. It features I/O
to I/O communication without
the need for programming sotware and is ideal for simple
wire replacement; pump control; sensor, low and temperature monitoring; and PC/PLC/RTU applications.
Submersible Cistern Pump
Couplings
Franklin Electric Co. introduced

its C1 Series stainless steel submersible cistern pumps. Designed for use
in gray water/iltered eluent service
applications, these pumps can pass
solids up to 1/8-inch diameter during
normal operation without impacting
pump life. hey are constructed of a
304 stainless steel motor and outer
shell with engineered polymer hydraulics, providing corrosion resistance and abrasive handling.
Zero-Max, Inc.
ServoClass Couplings
ofer a smooth, quiet
operation because of
their consistent assembly. A solid ilm lubrih socket
k head
h d cap screws
cant treatment is used on allll the
to ensure correct assembly and precise shat grip. hey are
ideal for precise positioning requirements and high-speed
reversing loads common in many alternating-current and
direct-current servo motor systems.
Drives
AODD Pump
ABB ofers its

ACS250 drive, which
is designed for the
requirements of end
users in applications
such as augers, mixers
h wiring allows
ll
h IP20 chash
and pumps. Its feed-through
the
sis drive to replace motor starters, improve energy eiciency, reduce mechanical stresses and enhance process
control. For demanding environmental conditions, the
IP66/UL type 4x drive is an ideal solution.
Flotronic Pumps Limited introduced its H series air-operated

double diaphragm pump. he
ONE-NUT design allows rapid
pump disassembly and straightforward cleaning in place. It also
features an electronic rupture proh ffood,
d beverage
b
tection system and ease of cleaning ffor the
and pharmaceutical industries. he pump has the ability
to shut down immediately to avoid contamination in the
event of a problem.
Circle 201 on card or go to psfreeinfo.com
Trash Pump
Rain for Rent ofers the sound attenuated 12x8-inch DV200c pump, built by PowerPrime Pumps. his
pump reduces operating and maintenance costs during bypass pumping and dewatering jobs because of
its excellent fuel and hydraulic eiciencies. hey feature lows up to 4,600 gallons per minute and heads
up to 260 feet, solids handling up to 3.375 inches and superior suction lit performance.
PUMPS & SYSTEMS
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April 2014
89
PRODUCT PIPELINE
Positive Displacement Pumpp
Motors
Mouvex ofers its A Series

Eccentric Disc Pumps,
which are ideal for use in
oil transfer applications.
he positive displacement
pumps are available in
ductile iron construction
and have maximum speeds
b
up to 600 rpm and maximum low rates up to 55 cubic
meters per hour. Its maximum diferential pressure is 10
bar, allowing safe transfer of viscous, non-lubricating,
volatile or delicate luids.
Grundfos introduced its

line of MGE and MLE
pump motors. hese models
are energy eicient and are
available with integrated
frequency converters.
Frequency converters can
automatically control motor
speeds based on actual demand, whereas standard pumps
run at either full speed or of. Users can customize the
advanced control system with several input/output possibilities and added functions.
Electric Submersible Pumps

Atlas Copco ofers its WEDA electric submersible pumps for the American market. hey are available in 1-horsepower or less, c-UL-us approved, 60-hertz single-phase drainage, sludge and residual
pumps. Each model is equipped with motor protection that automatically stops the pump in case
of overheating or overload/over-current. he pump automatically restarts ater cooling down. To
ensure easy service, the pumps can be disassembled by removing only three bolts.
Newly Published Pump Guideline

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A one-of-a-kind guide exclusively for

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Identiies the styles of pumps

used in combined-cycle power
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Describes the basic operation
of combined-cycle plants
Provides recommendations for
operating pumps at the highest
eiciency & greatest reliability
Places an emphasis on boiler
feed, boiler feed boosting, condensate, condenser circulating,
boiler circulating, & heater
drain pump applications.
Positive Displacement Pumps

Centrifugal Pumps
Specialty & Other Pumps
Industrial Valves
Pneumatic & Hydraulic Valves
Industrial Automation & Process Control
Electric Motors & Drives
Actuators
Compressors
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90
April 2014

www.pump-zone.com
PUMPS & SYSTEMS
Lubricant
Remote Monitoring System
Royal Purple ofers Synergy, its

high-performance, extreme-pressure gear oil. Ideal for service in
pressure pumping and designed to
operate under the stresses pumps
are subjected to when injecting
drilling luid into boreholes on
drilling rigs, it lubricates machinery gears, providing protection
under virtually all pumping conditions. his includes heavily loaded, slow-speed operations and/or shock load conditions.
PRIMEX ofers its Pump

Watch web-based cellular
remote monitoring system.
he system allows for the
management of lit stations
and wastewater collection
systems remotely via a secure
cellular network from a web
browser on a PC, tablet or smart phone. It visually tracks
system performance through data logging and critical
information trending. Alarms are monitored and personnel is notiied via email or text message.
Compressors
Danfoss ofers its inverter scroll compressor range VZH in three models. he variable
speed VZH compressors provide eiciency at part-load conditions, can improve eiciency
by more than 30 percent and ofer precise cooling capabilities. Designed for small rootop
and process cooling applications, the inverter scroll compressor range VZH will introduce
cooling capacities between 4 and 6.5 tons of refrigerant with a single compressor.
To have a product considered for Product Pipeline, please send the information to Amanda Perry, aperry@cahabamedia.com.
INDEX OF ADVERTISERS
Advertiser Name
Page
RS#
Advertiser Name
Page
RS#
Advertiser Name
Page
RS#
A. W. Chesterton Company . . . . . . . . . . . 73
AE Pumps . . . . . . . . . . . . . . . . . . . . . . . . . 95
American Water Works
Association (AWWA) . . . . . . . . . . . . . . 62
Bal Seal Engineering Inc. . . . . . . . . . . . . . 95
Baldor Electric Company . . . . . . . . . . . . . 15
Blackmer . . . . . . . . . . . . . . . . . . . . . . . . . . 35
BLACOH Fluid Control, Inc. . . . . . . . . . . . 81
Blue Ribbon Corp. . . . . . . . . . . . . . . . . . . 54
Blue-White Industries . . . . . . . . . . . . . . . . 11
Burns Dewatering Service, Inc. . . . . . . . . 95
Carver Pump Company . . . . . . . . . . . . . . 21
CAT Pumps . . . . . . . . . . . . . . . . . . . . . . . . 37
CENTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Continental Pump Company . . . . . . . . . . 94
Convergent Science . . . . . . . . . . . . . . . . . 53
Corrosion Fluid Products . . . . . . . . . . . . . 94
Dan Bolen & Associates, LLC. . . . . . . . . . 95
Dreisilker Electric Motors, Inc. . . . . . . . . . 94
DSI Dynamatic . . . . . . . . . . . . . . . . . . . . . 43
Electrical Apparatus Service
Association (EASA) . . . . . . . . . . . . . . . 72
Environmental Gasket Co., Ltd. . . . . . . . . 19
FCX/Pump Pros . . . . . . . . . . . . . . . . . . . . . 5
Flowrox Inc. . . . . . . . . . . . . . . . . . . . . . . . . 40
FLSmidth . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 90
Fullo Specialties Co. . . . . . . . . . . . . . . . . 66
Global Valves Marketplace. . . . . . . . . . . . 95
101
158
Godwin, a Xylem Brand . . . . . . . . . . . . . . 38

Gorman-Rupp Company . . . . . . . . . . . . . . 3
General Pump . . . . . . . . . . . . . . . . . . . . . . 48
Graphite Metallizing Corp. . . . . . . . . . . . . 85
Greene, Tweed . . . . . . . . . . . . . . . . . . . . . . 9
Houston Dynamic Service, Inc. . . . . . . . . 94
Hydraulic Institute . . . . . . . . . . . . . . . . . . . 90
Hydro, Inc. . . . . . . . . . . . . . . . . . . . . . . . . IFC
Hyundai Heavy Industries . . . . . . . . . . . . 23
JDA Global . . . . . . . . . . . . . . . . . . . . . . . . 95
Jordan, Knauff & Company . . . . . . . . . . . 87
KTR Corporation. . . . . . . . . . . . . . . . . . . . 69
Load Controls, Inc. . . . . . . . . . . . . . . . . . . 30
Load Controls, Inc. . . . . . . . . . . . . . . . . . . 93
Lobe Pro . . . . . . . . . . . . . . . . . . . . . . . . . . 93
LOFA Industries, Inc. . . . . . . . . . . . . . . . . 67
Magnatex Pumps, Inc. . . . . . . . . . . . . . . . 94
MasterBond Inc. . . . . . . . . . . . . . . . . . . . . 94
Mazdak . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Meltric Corporation. . . . . . . . . . . . . . . . . . 93
Motion Industries . . . . . . . . . . . . . . . . . . . 41
National Pump Company . . . . . . . . . . . . . 50
Nidec Motor Corporation . . . . . . . . . . . . . 46
NSK Americas. . . . . . . . . . . . . . . . . . . . . . 22
Proco Products, Inc.. . . . . . . . . . . . . . . . . 58
Pump Solutions Group . . . . . . . . . . . . . . . 61
Pumpworks 610 . . . . . . . . . . . . . . . . . . . . 17
Quadrant . . . . . . . . . . . . . . . . . . . . . . . . . . 63
R + W Coupling Technology . . . . . . . . . . 28
129
106
130
153
107
166
154
100
108
167
155
145
131
168
169
146
170
171
172
173
109
133
134
135
147
148
121
132
136
Royal Purple . . . . . . . . . . . . . . . . . . . . . . . 29
Ruthman Companies . . . . . . . . . . . . . . . . 82
Scalewatcher. . . . . . . . . . . . . . . . . . . . . . . 87
Scenic Precise Element Inc. . . . . . . . . . . 93
Schaefler Group USA Inc.. . . . . . . . . . . . 49
seepex, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 33
SEPCO. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SERO Pump Systems. . . . . . . . . . . . . . . . 92
Sims Pump Co. . . . . . . . . . . . . . . . . . . . . . 65
Sims Pump Co. . . . . . . . . . . . . . . . . . . . . . 92
Solcon USA . . . . . . . . . . . . . . . . . . . . . . . . 57
St. Marys Foundry . . . . . . . . . . . . . . . . . . 93
Summit Industrial Products
Dorsey Advertising. . . . . . . . . . . . . . . . 42
Summit Pump, Inc. . . . . . . . . . . . . . . . . . . 92
Superbolt. . . . . . . . . . . . . . . . . . . . . . . . . . 59
Titan Manufacturing, Inc. . . . . . . . . . . . . . 85
Topog-E Gasket . . . . . . . . . . . . . . . . . . . . 92
Toshiba . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Trachte, USA . . . . . . . . . . . . . . . . . . . . . . . 95
Tuf-Lok International. . . . . . . . . . . . . . . . . 95
United Rentals, Inc. . . . . . . . . . . . . . . . . . 31
Varisco USA Inc. . . . . . . . . . . . . . . . . . . . . 92
Vaughan. . . . . . . . . . . . . . . . . . . . . . . . . . IBC
Vertilo Pump Company . . . . . . . . . . . . . . 95
Vesco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
WEG Electric Motors . . . . . . . . . . . . . . . .BC
Yaskawa America Inc . . . . . . . . . . . . . . . . 39
110
149
157
174
111
137
138
175
112
176
150
177
PUMPS & SYSTEMS
120
159
102
122
140
141
119
160
123
124
125
162
142
161
163
164
104
126
127
105
128
143
152
144
165
www.pump-zone.com
139
178
151
156
179
113
180
181
114
182
115
183
184
116
118
* The Index of Advertisers is furnished as a courtesy, and no

responsibility is assumed for incorrect information.
April 2014
91
PUMP USERS MARKETPLACE
Solve
dry start
problems with
Vesconite Hilube
bushings
G
G
G
G
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
Your Best Value in

ANSI Centrifugal Pumps
Model 2196
Green Bay, WI
www.SUMMITPUMP.com

92
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
MAZDAK SLURRY & FROTH PUMPS

Excellent service and
engineering support
sales@mazdakpumps.com
www.mazdakpumps.com
(360) 988 6058
Splitvane Impellers for improved
multi-phase pumping
Distributors needed
MONITOR PUMP PERFORMANCE
OFF
Button
Easy
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Dead
Front
GO WITH THE PROS!! LOBEPRO ROTARY PUMPS
Protects from electrical hazards

Simplifies NFPA 70E compliance
Qualified technicians can quickly
OFF
disconnect and connect power
Button
up to 200A, 60hp, 600V.
Important Properties of
LobePro Rotary Lobe Pumps

FREE Samples Available
Low shear
Capacities 0- 2, 656
Measured Flow
GPM (0-604 m/hr)
Self priming to 25 wet Low pulsation
Discharge pressure to Space-saving,
175 psi (12 bar)
compact design
800.433.7642 meltric.com
To learn more or get a custom quote, email PumpSales@lobepro.com

912-466-0304
www.LOBEPRO.com
Made in USA

PUMPS & SYSTEMS
www.pump-zone.com
April 2014
93
PUMP USERS MARKETPLACE
Rotating Equipment Repair Specialists
6LOLFRQH
&DUELGH
)LOOHG
(SR[\
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
Two Component EP21SC-1

([FHSWLRQDODEUDVLRQUHVLVWDQFH
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3DVWHYLVFRVLW\
&RQYHQLHQWRQHWRRQHPL[UDWLR
+DFNHQVDFN1-86$
PDLQPDVWHUERQGFRP
ZZZPDVWHUERQGFRP

94
April 2014
www.pump-zone.com
PUMPS & SYSTEMS
Less downtime.
Longer seal life.
More predictability.
U-iv>}}Eiv
}`}
U}ii
x*-
U>V
>i`
UV
U}i`
The Bal Seal Spring-energized Seal

for critical upstream & downstream applications.
800.366.1006
/vi>>
*i\ n{n U www.tuflok.com
www.balseal.com
pump.com
EMPLOYMENT
EXECUTIVE SEARCH/RECRUITING
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 DEBORAH SHAW
9741 North 90th Place, Suite 200
Scottsdale, Arizona 85258-5065
(480) 767-9000 Fax (480) 767-0100
Email: dan@danbolenassoc.com
PUMPS & SYSTEMS
www.danbolenassoc.com
www.pump-zone.com
April 2014
95
PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

By Jordan, Knauff & Company
he Jordan, Knauf & Company (JKC) Valve Stock
Index was up 14.7 percent during the last 12 months,
while the broader S&P 500 Index was up 22.5 percent. he
JKC Pump Stock Index was up 36.1 percent for the same
time period.1
he Institute for Supply Managements Purchasing
Managers Index (PMI) increased 1.9 percentage points in
February to 53.2 percent from Januarys 51.3 percent. he Source: Capital IQ and JKC research. Local currency converted to USD using historical
PMIs average during the past 12 months is 53.8 percent. spot rates. he JKC Pump and Valve Stock Indices include a select list of publicly-traded
he New Orders Index was up 3.3 percentage points in companies involved in the pump and valve industries weighted by market capitalization.
January, 54.5 percent in February. he Production Index Figure 1. Stock indices from March 1, 2013, to Feb. 28, 2014
contracted for the irst time since May 2013down from
and parts), miscellaneous nondurable goods and machinery.
54.8 percent in January to 48.2 percent in February.
According to the U.S. Energy Information Administration
he U.S. economy added 175,000 jobs in February according to the Department of Labor. During the past three (EIA), U.S. total liquid fuels consumption grew by approximonths, job growth has averaged 129,333 jobs per month, mately 2.1 percent in 2013. Use of hydrocarbon gas liquids
well below the average of 194,250 seen in 2013. Professional registered the largest increase at 6.2 percent. Gasoline conand business services added 79,000. he manufacturing sumption grew by 1.1 percent, the largest increase since 2004
sector added 6,000 new jobs in February, with the largest because of growth in highway travel during the second half of
gains in transportation equipment (mostly motor vehicles 2013. he EIA projects that total liquid fuels consumption
in the U.S. will increase 0.2 percent in 2014 and 0.3 percent
in 2015, because of increasing transportation demand for
distillate fuel oil and industrial demand for hydrocarbon gas
liquids.
Driven by rising prosperity in China and India, the EIA
projects that world energy consumption will increase by 56
percent during the next three decades. hese two countries
combined will account for half the increase in the worlds
total energy consumption through 2040. Although fossil
fuels will continue to supply almost 80 percent of the worlds
energy use through 2040, renewable energy and nuclear
Source: U.S. Energy Information Administration and Baker Hughes Inc.
power are expected to grow faster than fossil fuels, with each
Figure 2. U.S. energy consumption and rig counts
increasing by 2.5 percent per year during this period. he
liquid fuels share of world consumption is anticipated to fall
from 34 percent in 2010 to 28 percent in 2040.
On Wall Street, the Dow Jones Industrial Average was up
4.0 percent in February, the S&P 500 Index rose 4.3 percent
and the NASDAQ Composite Index increased 5.0 percent.
P&S
Reference
1
he S&P Return igures are provided by Capital IQ.
Source: Institute for Supply Management Manufacturing Report on Business and

U.S. Census Bureau.
Figure 3. U.S. PMI index and manufacturing shipments
96
April 2014
Jordan, Knauff & Company 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 & Company is a member of FINRA.
www.pump-zone.com
PUMPS & SYSTEMS
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.
Motors | Automation | Energy | Transmission & Distribution | Coatings
WEG Rolled Steel Line

Great WEG quality and flexibility in a new LIGHTER frame
Investing over 2.5% of our revenue in R&D for electric motors every year, WEG takes pride in engineering and
manufacturing motors that run cooler, last longer, and are easy to install and maintain.
Available in Open Drip and Totally Enclosed designs our WEG Rolled Steel line is the perfect example of these efforts.
A product line with superior features that make a big difference for our customers.
Features that make a difference:

"Dual
rated for 60 Hz and 50 Hz @ 190-220/380-415 V
"Optimized
ventilation system for cooler operation
"Robust
feet design for the toughest applications
"Frames
182/4T and larger have two eyebolts for easy mounting in any position
"Oversized
diagonally split aluminum terminal box that exceeds IP55 requirements. (Ideal for easy
installation and tough environments).
"Terminal
"AEGIS
"IP55
box is rotatable in 90 degrees increments for easy installation
ring inside (optional) to extend bearing life when used with VFDs
ingress protection is standard
"Suitable
"Color
"Motor
for VFD operation per NEMA MG1 part 31.4.4.2
coded leads for easy installation

paint resistance exceeds 500 hours of salt spray test
Please contact your authorized WEG distributor or go to weg.net/us for further

information or additional specifications.
1-800-ASK-4WEG
Transforming Energy into Solutions
www.weg.net/us

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Repair is an Opportunity

only ensuring proper performance

circle 100 on card or go to psfreeinfo.com

From the Editor

very month for 10 years, Pumps &

Walter B. Evans, Jr.

is a member of the following organizations:

PUMPS & SYSTEMS

circle 106 on card or go to psfreeinfo.com

Oil & Gas Refinery Solutions

Refinery Repairs 20-Year Old Design Flaw

Submersible Slurry Pump Provides Solution for

Valve Fugitive Emission Compliance Requirements

Bearings & Couplings

Active Magnetic Bearings Provide

Prevent Bearing Misalignment

Bearings & Seals Boost

Using Thermoplastic Composite

PUMPS & SYSTEMS

circle 105 on card or go to psfreeinfo.com

FSA Celebrates 10 Years of Sealing Sense

From the Archives - The First Sealing Sense

Practice & Operations

Sizing Pulsation Dampeners Is Critical to Effectiveness

Suction Valve Throttle Versus Vacuum

20 Pump System Improvement

70 Motors & Drives

Editorial Advisory Board

Bob Domkowski, Business Development Manager

William E. Neis, P.E., President, Northeast Industrial Sales

PUMPS & SYSTEMS

P9 Pump Drive with

EQP Global Motor

ONE CALL. ONE SOLUTION.

circle 113 on card or go to psfreeinfo.com

Using a Torque Wrench to Apply Stress to a Gasket,

on the tilt angle. Torque applied to

The Cost of PumpingPower Cost & Eficiency,

energy consumption per unit of

PUMPS & SYSTEMS

Need a quick fix?

*Shipping and delivery dependant on customer location and order quantity.

When your equipment fails, every second

WR & AR Wear-Resistant Thermoplastic Composites

circle 107 on card or go to psfreeinfo.com

NEW HIRES, PROMOTIONS & RECOGNITIONS

HYDRAULIC INSTITUTE Announces Board of Directors

PUMPS & SYSTEMS

FLEX-PRO Peristaltic Metering Pump

SONIC-PRO Ultrasonic Flowmeter

Works with clean or

circle 119 on card or go to psfreeinfo.com

Fast and Easy Sensor

5300 Business Drive, Huntington Beach, CA 92649 USA

VICTOR KROTIKOV, Global Pump

AROUND THE INDUSTRY

Award in the wireless solutions category. he Enabling

MERGERS & ACQUISITIONS

Feb. 20, 2014

Feb. 20, 2014

Feb. 17, 2014

Feb. 12, 2014