PM 6782

The Magazine for Pump Users Worldwide February 2012
pump-zone.com
The
Aftermarket
Rrviacrxrxr Panrs Rrvain
The
Aftermarket
Also Inside:
Pumps & Seals for
Harsh Conditions
Centrifugal Pump
Efciency
Repair Standards
for Vertical Pumps
Also Inside:
Pumps & Seals for
Harsh Conditions
Centrifugal Pump
Efciency
Repair Standards
for Vertical Pumps
The Magazine for Pump Users Worldwide
pump-zone.com
February 2012
Hydro, Inc. l Chicago, IL
Headquarters
800.223.7867
www.hydroinc.com
HydroAire, Inc. Chicago, IL
800.223.7867
40th Street Facility
Hydro Performance Test Lab
Madison Street Facility
Hydro South, Inc.
Atlanta, GA
770.475.3393
HydroTex Dynamics, Inc.
Houston, TX
713.937.9001
HydroTex Golden
Triangle, Inc.
Beaumont, TX
409.842.3619
HydroTex Deer Park, Inc.
Deer Park, TX
713.937.9141
U.S. Service Centers
Repair is an Opportunity
for Improvement
Evans Hydro, Inc.
Los Angeles, CA
310.608.5801
Hydro East, Inc.
Philadelphia, PA
610.497.7867
B
A
10
10
10
10
10
10
6.1 6.
10.5
14.9
C
B
A
1
222
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44
55
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15 5
X
Many of the pumps operating today were designed and manufactured several decades
ago. Since that time, operating requirements of the plant may have changed, and as a
result, the pump may no longer be running at its best efficiency point.
Taking the time to review the current operating conditions in relation to the pump's
original design specifications can lead to engineering recommendations for improving
the pump's performance and extending its life.
Hydraulic Modifications
Hydro's engineers analyze pump hydraulic performance and tailor new designs to meet
current requirements within a much shorter time period than previous methods allowed.
Repair is an Opportunity
for Improvement
CW Hydro, Inc.
Incheon Metropolitan, Korea
82.32.561.0971
Hydro Australia, Pty. Ltd.
Morwell, Australia
61.3.5165.0390
Hydro Vietnam, Co. Ltd.
Ho Chi Minh City, Vietnam
84.9.141.9914
Hydro Scotford, Inc.
Edmonton, AB Canada
780.992.0100
Safe-T Hydro, Inc.
Port Coquitlam, BC Canada
604.941.1116
Hydro Middle East, Inc.
Dubai, United Arab Emirates
Saudi Arabia
971.50.5547129
International Service Centers
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Our engineers review pump design, check the existing geometry and make
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Hydros engineering team will evaluate the metallurgy of your pump components
and recommend upgrades specific to your application which often translates into
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Performance Testing
Testing can be an important verification tool for not only ensuring proper performance
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rebuilt. With the ability to configure hundreds of different suction and discharge
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of pump users across the globe.
For information about Hydro's comprehensive pump aftermarket
capabilities, visit www.hydroinc.com or call 800-223-7867.
circle 100 on card or go to psfreeinfo.com
2 FEBRUARY 2012 www.pump-zone.com PUMPS & SYSTEMS
Letter from the Editor
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Pumps & Systems, a member of the Cahaba Media Group, 1900 28th Avenue So., Suite 110, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the right to determine qualications. Annual
subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call (630) 739-0900 inside
or outside the U.S. POSTMASTER: Send changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. 2012 Cahaba Media
Group, Inc. No part of this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of
any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed
are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or
appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us
your submission, you grant Cahaba Media Group, Inc. permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions.
You are free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.
is a member of the following organizations:
T
hanks for all the kind; productive; and
in some cases, critical feedback about
our January 2012 feature, he History
of Pumps. We knew our readers would come
through with additional information on the rich
history of this great industry, and you did not
disappoint us. As promised, we are incorporat-
ing all the relevant, new information on the
complete timeline on www.pump-zone.com.
Some of these additional highlights (and a few
interesting historical images) can be found on
Page 6.
In a way, Pumps & Systems is also making
history. We feel condent that our online
hrough the Years account is the ultimate
and most comprehensive record of the history
of pumps! With your help, we will continue to
update it.
Many of you sent glorious historical photos
that we did not have the space to include in the
print edition. We are creating an online slide-
show of Reader Favorites and welcome your
contributions. If you have a historical photo,
please send it to me with a detailed description.
his provides the perfect opportunity to
invite you to explore our freshly redesigned web-
site. In addition to the worlds largest collection
of pump-related technical articles and case stud-
ies, it now oers automatic twitter feeds, a more
easily searchable manufacturers directory, inter-
esting web-exclusive slideshows, in-depth White
Papers and daily pump industry news updates.
If you crave more news, subscribe to one or
both of our monthly e-newsletters. Pump Users
Digest delivers news about the industry, people
and products, web-exclusive articles and some of
the most interesting social media conversations.
Pump Industry Insider is the only industry
resource that pulls together the latest news about
M&A activity, contracts and orders, new proj-
ects for bid, industry buzz and also oers exclu-
sive insight into the pump market with analysis
from Jordan, Knau & Company.
In this issue of Pumps & Systems, check out
our cover series on he Aftermarket (Page 34),
which includes articles about pump replace-
ment part availability, inspection and repair,
replacement part options and genuine parts and
replacement kits.
his month also features a special section
on Pumps and Seals for Harsh Conditions (Page
18). his section includes the rst of a six-part
series on dry gas seal selection, a case study on
pumps exposed to extreme altitudes and an arti-
cle which details the benets of coating speci-
cation sheets.
Best Regards,
PUBLISHER
Walter B. Evans, Jr.
ASSOCIATE PUBLISHER
VP-SALES
George Lake
glake@pump-zone.com 205-345-0477
EDITOR/VP-EDITORIAL
Michelle Segrest
msegrest@pump-zone.com 205-314-8279
MANAGING EDITOR
Lori K. Ditoro
lditoro@cahabamedia.com 205-314-8269
CONTRIBUTING EDITORS
Laurel Donoho
Joe Evans, Ph.D.
Terry Henshaw
Dr. Lev Nelik, PE, APICS
SENIOR ART DIRECTOR
Greg Ragsdale
ART DIRECTOR
Terri Jackson
PRODUCTION MANAGER
Lisa Freeman
lfreeman@pump-zone.com 205-212-9402
CIRCULATION & MARKETING
MANAGER
Jaime DeArman
jdearman@cahabamedia.com
CIRCULATION
Jeff Heine
jheine@cds1976.com 630-739-0900
WEB EDITOR
Jane Longshore
jlongshore@cahabamedia.com
ACCOUNT EXECUTIVES
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 ASSISTANT
Ashley Morris
amorris@pump-zone.com 205-561-2600
EDITORIAL INTERNS
Grace McNair
Jeremy Salter
Courtney Woods
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Phone: 205-345-0477 or 205-561-2600

Editorial Advisory Board
Thomas L. Angle, PE, Vice President Engineering,
Hidrostal AG
Robert K. Asdal, Executive Director, Hydraulic Institute
Bryan S. Barrington, Machinery Engineer, Lyondell
Chemical Co.
Kerry Baskins, Vice President of Sales, Viking Pump
Walter Bonnett, Vice President Global Marketing, Pump
Solutions Group
R. Thomas Brown III, President, Advanced Sealing
International (ASI)
Chris Caldwell, Director of Advanced Collection
Technology, ABS, & President, SWPA
John Carter, President, Warren Rupp, Inc.
Jack Creamer, Market Segment Manager, Schneider
Electric
David A. Doty, North American Sales Manager, Moyno
Industrial Pumps
Joe Evans, Customer & Employee Education, PumpTech,
Inc.
Ralph P. Gabriel, Chief EngineerGlobal, John Crane
John Malinowski, Sr. Product Manager, AC Motors,
Baldor Electric Company, A Member of the ABB
Group
William E. Neis, PE, President, NorthEast Industrial Sales
Dr. Lev Nelik, PE, Apics, President, Pumping Machinery,
LLC
Henry Peck, President, Geiger Pumps & Equipment/
Smith-Koch, Inc.
Mike Pemberton, Manager, ITT Performance Services
Bruce Stratton, Product Manager, KLOZURE
, Garlock
Sealing Technologies
Kirk Wilson, Vice President/General Manager,
Integrated Solutions Group, & Vice President
Marketing, Engineering & Technology, Flowserve
Corporation
In the tradition of groundbreaking innovations comes
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result is Flygt Experior, a uniquely holistic experience that combines state-of-the-art
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Today, Flygt Experior combines N-technology hydraulics and its adaptive functionality,
premium efciency motors and SmartRun the all-new intelligent control. Flygt Experior
comes from years of listening to you and applying our knowledge and expertise, to
develop the most reliable and energy-efcient wastewater pumping. It is therefore the
ultimate in our commitment to you.
Flygt Experior. Inspired by you. Engineered by us.
ygt.com/FlygtExperior
Flygt is a brand of Xylem, whose 12,000 employees are dedicated to addressing
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SPECIAL SECTION:
PUMPS & SEALS FOR HARSH CONDITIONS
p
Dry Gas Seal Requirements
Glenn Schmidt, EagleBurgmann
Find a reliable dry gas seal system for any application.
p
High-Altitude Condensate Pumping
Kamran Mirza, seepex Inc.
A progressive cavity pump provides an ideal solution to a difcult pumping
application.
p
Choose the Right Coating
Ivan Ordaz, Belzona
Understand coating manufacturers specication sheets.
COVER SERIES: THE AFTERMARKET
p
Pump Replacement Part
Availability
Jeff Smith, Standard Alloys
Address this problem to avoid the possibility of future
crises.
p
Inspections and Repair Enhance
Pump Performance
Bob Bluse, Hydro, Inc.
Improvement can result from repair opportunities.
p
Specialty Replacement Parts
Sally Huynh, NOV Monoo
When stator wear was an issue, a custom-made replacement part was the
solution.
p
The Value of Industrial Pump Genuine Parts and
Repair Kits
Christine Gfrer, IDEX Corporation
Many options are available when pump repair is required.
Table of Contents
DEPARTMENTS
Readers Respond. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Joe Evans, Ph.D.
Centrifugal Pump EfciencyWhat Is Efciency?
Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 16
Lev Nelik, Contributing Editor, P&S Editorial Advisory Board
Repair Standard for Vertical Pumps
Maintenance Minders. . . . . . . . . . . . . . . . . . . . . . . . . 50
Peter Carlisle, John Crane
Smooth Equipment Operation
Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
F. Scott Jackson, Blackmer
The DEF Market
FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Why dont my PTFE gaskets seal FRP, plastic and other light load
anges?
HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
What guidelines should be followed regarding pump selection
based on good wear resistance? Besides the obvious nancial
benets derived from energy savings, what are the other
important economic benets of pump systems optimization
that affect the total cost of ownership? What different types of
couplings can be used on pumps, and what is are their functions?
Product Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Pump Users Marketplace. . . . . . . . . . . . . . . . . . . . . . 69
P&S Market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
February 2012
Volume 20 Number 2
The Magazine for Pump Users Worldwide February 2012
pump-zone.com
The
Aftermarket
Rrriacrxrxr Panrs Rrrain
The
Aftermarket
Rrriacrxrxr Panrs Rrrain
Also Inside:
Pumps & Seals for
Harsh Conditions
Centrifugal Pump
Efciency
Repair Standards
for Vertical Pumps
Also Inside:
Pumps & Seals for
Harsh Conditions
Centrifugal Pump
Efciency
Repair Standards
for Vertical Pumps
The Magazine for Pump Users Worldwide
pump-zone.com
February 2012
19
26
28
35
40
44
46
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Editors Note: In the January 2012 issue of
Pumps & Systems, we were proud to bring
you an in-depth look at some of the highlights
of ground-breaking achievements in pump
technology through the years. We suspected
that our readers would come through with
some information that we did not have. We
are happy to give you some of the additional
information provided by our readers on the
greatest moments in pump history. For the complete version of
this feature, continuous updates from our readers and entertain-
ing slideshows on the subject, please visit www.pump-zone.com.
In the Letter from the Editor in the January 2012 issue,
we referred to leather pump seals. A friend of the industry,
Inpro/Seal principal Dave Orlowski, let us know that the seals
were most likely bearing housing seals and not liquid end seals
and produced by the Chicago Rawhide Company. (Now CR
Industries, a division of SKF).
he following are a few interesting additions to our
History of Pumps timeline:
1874
Charles Barnes of New Brunswick invents the vane
pump.
1899
Robert Blackmer invents rotary vane pump tech-
nology, a pump design that was an important depar-
ture from the old gear principle and predecessor to todays
sliding vane pumps.
1900
Siemens les the rst German patent for liquid ring
vacuum pumps and compressors.
1908
Hayward Tyler creates its rst electric motor for
use under water and develops the wet stator motor
for use as a boiler circulation glandless motor-pump.
1910
Lewis H. Nash les the rst U.S. patent for liquid
ring vacuum pumps and compressors.
1923
Ruthman Companies designs the worlds rst seal-
less vertical pump.
1937-1939
Smith Precision Products Company
(Smith Pumps) designs three pumps, two
of which (models 300 and 200) were specically designed for
LP-gas transfer.
1939
Smith Pumps develops the rst liqueied gas trans-
fer pump for LP-gas.
1940
Reuben Smith, of Smith Precision Products
Company (Smith Pumps), receives the rst
approval for an LP-gas pump from the California Industrial
Accident Commission. his was for the model 4X pump and
the approval was a suitable for use certicate.
1948
Smith Precision Products Company receives the
patent for the rst mechanical seal supplied for
liqueied gas transfer pumps (production in 1947).
1950
Vanton develops the Flex-I-Liner sealless self-prim-
ing rotary pump which handles corrosive, abrasive
and viscous uids as well as those that must be transferred free
of product contamination.
1954
Smith Precision Products Company (Smith
Pumps) begins work with the Underwriters
Laboratories to develop their rst standard for liqueed gas
pumps, UL-51, which is still in use today.
1954
Worlds rst atomic-powered submarine is equipped
with Ingersoll-Rand boiler-feed pumps and
compressors.
1960
Development of GIW trademark GASITE hard
iron for longer wearing pumps and parts.
1960
GIW vice president and inventor, Danforth Hagler,
invents the Hydraulic Slide Rule.
1965
Warren Rupps heavy-duty, diverse AODD pump
is introduced to the industrial market to address the
vigorous demands of the steel mills.
1971
Gusher develops a purge hole system to enable
pumps to handle 30-40 percent entrained air.
MORE PUMP
HISTORY
The rst pump
designed speci-
cally for LP-gas, (the
model 300; which was
rst sold in 1939).
This is an under-
ground installation
using a Parkhill-Wade
dispenser in Los
Angeles, 1940. Photo
courtesy of Smith
Precision Products
Company (Smith
Pumps)
Nash Hytor #1 being loaded on a train for shipment, c. 1929.
Photo courtesy of Gardner Denver Nash
PUMPS & SYSTEMS www.pump-zone.com FEBRUARY 2012 7
1979
Gusher develops multistage pumps for higher
pressures required by the machine tool industry and
designs the rst top pull-out pump.
1980s
GIW develops wear modeling technology for
predicting pump performance.
1985
Sims manufactures the rst structural composite
pump, the Simsite Vertical Pit Pump, for which it
won the Innovative Product Award in 1990.
1990s
GIW develops a hard metal slurry pump for
hydraulic transport of oil sands tailings.
1994
Sims receives the U.S. Navys honor of approval for
composite centrifugal pump intervals.
1995
Sims manufactures the largest structural composite
pumps in the worldtwo Simsite vertical turbine
pumps for Potomac Electric Power Company.
2000s
GIW introduces computer designed LCC rubber-
lined pump to the market.
2000s
GIW develops an innovative slurry diverter to
improve wear.
2002
Siemens (Elmo Division, liquid ring pumps) merges
with Nash.
2002
Sims introduces the rst structural composite verti-
cal in-line pumps.
2006
Sims manufactures the largest structural composite
centrifugal impeller, installed in a cooling tower
pump for Puerto Rican Electrical Power Company.
Readers Respond to
The History of Pumps
I really enjoyed your article on the history of pumps. I am
sure a lot of research had to go into that. I was also surprised to
learn how much the Italians contributed to pumps in the early
years. I knew we were good for something! Great article!
Rich Greatti, Mechanical/Industrial Engineer
Knoxville, Tenn.
We have been receiving your magazine, Pumps & Systems,
for a good number of years, although we are not an advertiser.
We recently received your January 2012 issue and the segment
he History of Pumps caught my eye. My company shares a
very long history in the pump industry and my familys roots
go very deep. I found the history very fascinating, and give your
magazine a big thumbs up for the research required to put this
together. I know this is not an easy task.
Walter W. Smith, President
Smith Precision Products Company (Smith Pumps)
I always look forward to the new issue of P&S. he Jan.
2012 issue is unique not only for the usual informative and
interesting articles but for all the good information of the
World Pump History. Congratulations! his issue is a keeper. I
always recommend P&S to my friends and clients in the chemi-
cal process industry. his issue is a ne example of the high
quality of your magazine. What a way to start the year!
Keep up the good work,
Jose M. Sentmanat, Consultant
Liquid Filtration Specialist, LLC, Conroe, Texas
In 1965 the AODD was introduced to the industrial
market. It wasnt until this time when Mr. Warren Rupps con-
cepts of having a heavy duty diverse AODD pump to better
address the vigorous demands of the steel mills and the indus-
trial markets applications lead the way to industrial distribution.
Never to be forgotten!
Mike Weed, Application Engineering
Warren Rupp, Inc., Units of IDEX Corporation
I always look forward to receiving my copy of Pumps &
Systems. he January 2012 edition was of particular interest
with the inclusion of the History of Pumps article. Having
been in the pump design business for more than 40 years, it was
very interesting reading.
For over 50 years, our company has manufactured a vari-
ety of fuel transfer pumps with the majority being positive dis-
placement vane pumps. I have taught many courses within the
company on vane pump technology over the years and have
always presented Charles Barnes of New Brunswick as the
inventor of the vane pump, citing his patent issued in June of
1874. I was surprised that your list credits Robert Blackmer
with that achievement in 1899.
I cant remember where I got my information about Barnes,
but Wikipedia lists Barnes as the inventor also citing the fol-
lowing reference: Marlo heriault, Great Maritime Inventions
1833-1950, Goose Lane Editions, 2001, p. 53.
hanks for all of the great articles each month and all of
the work that goes into them.
Tim Hoehn, Sr. Mechanical Engineer,Tuthill Transfer Systems
Pumps & Systems Editor Michelle Segrest responds:
he reference to Blackmer inventing vane pump technol-
ogy was a mistake that I made. Blackmer had sent me the cor-
rect information. It should have read that Blackmer invented
rotary vane pump technology. I have corrected this on our
website version and added the 1874 item citing Charles Barnes
and the inventor of the vane pump. hank you very much for
bringing this to my attention. his was a huge undertaking and
I want to get it right!
Please check www.pump-zone.com often for
continuous updates on he History of Pumps.
Nash Engineering exhibits at the 1922 Chem Show at Grand
Central Palace. Photo courtesy of Gardner Denver Nash
P&S News
NEW HIRES, PROMOTIONS &
RECOGNITIONS
EAGLEBURGMANN (HOUSTON, TEXAS)
announced that Paul van Wyk is the new
head of the Americas Region. He joined
EagleBurgmann South Africa in 1997.
EagleBurgmann is a sealing technology
provider. www.eagleburgmann.com
MEGGITT SENSING SYSTEMS (SAN JUAN CAPISTRANO,
CALIF.), a Meggitt group division, announced the promotion
of Sharon Nelson to vice president, Contract Management.
In this role, Nelson is responsible for the overall management
of a newly established, fully dedicated contract management
function, to include customers, partners and supplier rela-
tionships across all development sites of Meggitt Sensing Sys-
tems. Also, Meggitt announced that it now oers a lifetime
warranty on its products that serve a range of applications.
Meggitt Sensing Systems, is a supplier of sensing and
monitoring systems for physical parameter measurements in
extreme environments. www.meggitt.com
OPW FLUID TRANSFER GROUP (MASON, OHIO)
announced that it has named Ross Pliska vice president of
its transportation business unit. Pliska assumed his new
responsibilities January 1, 2012, and will report directly to
OPWFTG president, Tim Warning.
OPW Fluid Transfer Group, organized in 1998, is part
of Dover Corporation and is comprised of two business
units: OPWFTG Global Transportation Business Unit and
OPWFTG Global Chemical & Industrial Business Unit.
www.opwftg.com.
THE WATER ENVIRONMENT FEDERATION (ALEXANDRIA,
VA.) awarded seepex the Innovative Technology Award.
he Innovative Technology Awards are presented annu-
ally to WEF associate members who have introduced new,
innovative products or services related to the construction,
operation, or maintenance of treatment facilities. seepex was
recognized in the solids handling & disposal category for its
Smart Conveying Technology.
WEF is a not-for-prot technical and educational orga-
nization that works to preserve and enhance the global water
environment. www.wef.org
AESSEAL (MILLCLOSE, ROTHERHAM, U.K.) was named the
International Trade Company of the Year in a ceremony at
the House of Lords. his follows being named as the overall
winner at the 2010/2011 International Trade Awards, which
honored the U.K.s leading exporters. AESSEAL manufac-
tures mechanical seals. www.aesseal.co.uk
MOTION INDUSTRIES, INC., (BIRMINGHAM, ALA.) recog-
nized 62 of its key suppliers as participants in its Operational
Excellence Supplier Partnership program at the North Amer-
ican 2011 meeting in Atlanta, Ga. Suppliers were recognized
for making signicant contributions in the area of supply
chain integration and process improvement. his program
has spanned seven years and has resulted in more than 1,000
individual implementations to improve supply chain e -
ciency. Suppliers achieving the highest level of improvement
for 2011 are Climax Metal, ITW Devcon, General Bearings
and RBC Bearings.
Motion Industries is a wholly-owned subsidiary of
Genuine Parts Company and is a distributor of industrial
maintenance, repair and operation (MRO) replacement
parts. www.motionindustries.com
SIEMENS INDUSTRY (ATLANTA, GA.) was recognized by
the city of West Chicago, Ill., with its Brilliance in Business
Green Initiatives award during a ceremony at city hall. he
Brilliance in Business program features six categories, includ-
ing green initiatives, economic development, outstanding
not-for-prot, community service, community image and
small business of the year. Siemens invested approximately
$10 million upgrading two buildings at the location. Siemens
West Chicago manufacturing facilities comprises 200,000
square-feet in two buildings.
Siemens Industry is a supplier of products, solutions and
services for industrial customers. www.usa.siemens.com
PURALYTICS (BEAVERTON, ORE.) announced that it was
named in the prestigious 2011 Global Cleantech 100, pro-
duced by Cleantech Group, a leading research rm focused
on global clean technology innovation. Puralytics is a water
purication equipment company. www.puralytics.com
AROUND THE INDUSTRY
DRESSER-RAND GROUP INC. (HOUSTON,TEXAS)
announced that it closed the previously announced acquisi-
tion of Synchrony, Inc., for approximately $50 million net
of cash acquired. Synchrony is a technology development
company with a portfolio of technologies and products for
clean, e cient and reliable rotating machinery.
Dresser-Rand is a supplier of rotating equipment to the
oil, gas, petrochemical and process industries. www.dresser-
rand.com
GODWIN PUMPS OF AMERICA, INC., (BRIDGEPORT, N.J.),
eective January 1, 2012, changed its name to Xylem Dewa-
tering Solutions, Inc. Also, the company announced a dona-
tion to the National Coalition Against Domestic Violence
(NCADV). NCADV works to eliminate domestic violence,
empower battered adults and children, promote and unify
direct service programs, alert and educate the public and pro-
Paul van Wyk
mote partnerships.
Godwin is
a direct, wholly-
owned subsidiary
of Xylem, Inc.
Godwin maintains
a eet of more
than 6,000
portable rental pumps and 3,200 pieces of related equipment for
dewatering in construction, mining and quarrying; in drinking
water supply; and in wastewater bypasses in municipal, indus-
trial and environmental markets. www.godwinpumps.com
THE ENVIRONMENTAL PROTECTION AGENCYEPA
(WASHINGTON, D.C.) marked 25 years since the passage of the
federal Emergency Planning and Community Right-to-Know
Act (EPCRA). he act was passed in 1986 as a part of the reau-
thorization for Superfund. EPCRA has played a signicant role
in protecting peoples health and the environment by providing
communities and emergency planners with area-specic infor-
mation on toxic chemical releases. he EPA issued the Mercury
and Air Toxics Standards, the rst national standards to protect
American families from power plant emissions of mercury and
toxic air pollutionsuch as arsenic, acid gas, nickel, selenium
and cyanide. he standards will slash emissions of these pollut-
ants by relying on widely available, proven pollution controls
that are already in use at more than half of the nations coal-
red power plants.
he EPA protects human health and safeguards the natural
environmentair, water and land. www.epa.gov
SINCLAIR GROUP (THE WOODLANDS, TEXAS) and Allied
Reliability Groupa global maintenance and reliability con-
sulting, services and training companyhave formed a strategic
partnership to support clients needs for sustainable operating
performance improvements. he partnership is the result of a
need for integrated solutions in operational and organizational
best practices, work processes, operating procedures and tools.
Sinclair Group is a global operations management consul-
tancy. www.sinclairgroup.com
DAMALINI AB/EASY-LASER (GOTEBORG, SWEDEN)
announced that Cascade Machinery Vibration Solutions of
Houston, Texas, will become the authorized U.S. distributor
for Easy-Laser products. Damalini AB develops, manufactures
and markets Easy-Laser measurement and alignment solutions.
www.damalini.se
ITT GOULDS PUMPS (SENECA FALLS, N.Y.), in celebration
of the new changes company-wide, has launched a fun way to
Yg"tgfwegf"qwt"rwor"ukvg"xkukvu"cpf"kpetgcugf"qwt"
rwor"wr/vkog"ykvj"cwvqocvgf"eqpvtqnu"htqo"Owtrj{0
To get the best yields from the vineyard it is extremely important to get
all the water allowed to us. Without automated controls there were times
when our pumps wouldnt run fast enough or would even run dry.
The Ranch Systems monitor with FW Murphys EMS PRO controller helps
us maintain engine and pump up-time by instantly notifying us of engine
performance and potential breakdowns. The new control system can stop
and start the engine, vary the speed and smooth out the peaks and valleys
of water levels in the canal.
Thanks to the remote monitoring capabilities, we can check the water
level and monitor engine performance all through a cell phone. I no longer
have to start and end my day at the pump site, which saves valuable time
and increases the up-time of our sites.
- Eugenio Figueroa
Vineyard Manager, Shannon Ranches
Ranch Systems www.ranchsystems.com
Murphy has introduced its new EMS PRO Lite controller -
perfect for irrigation and dewatering applications.
918-317-2638 www.fwmurphy.com/EMS-PAS
1
1
1
0
9
1
8
P&S News
show how much pump users know about the world of pumps
and to celebrate pumps as the heart of industry.
Every other week through April 1, 2012, pump users have
a chance to answer a question about industrial pump applica-
tions around the world. For each question answered correctly,
ITT Goulds will make a donation to support International
CPR and First Aid Training.
1. Visit www.gouldspumps.com.
2. Answer the current question correctly and a donation
will be sent to the global Emergency Cardiovascular Care
(ECC) Program of the American Heart Association.
Donations will be made on April 10, 2012, during Pump
Appreciation Day.
3. Watch e-mail for the next question and another opportu-
nity to help keep the world pumping.
ITT Corporation is an engineering
and manufacturing company operating
in three markets: water and uids man-
agement, global defense and security and
motion and ow control. www.itt.com
BENTLEY SYSTEMS, INC., (AMSTER-
DAM, NETHERLANDS) announced the
acquisition of FormSys, based in Perth,
Australia. his software development
company has a 20-year track record in
3D design, analysis and construction
software for structural engineering, o-
shore engineering and naval architec-
ture. he acquisition will expand Bent-
leys SACS oerings for the design and
analysis of oating structures, further
extending the companys reach in the
oshore energy market. Bentley is dedi-
cated to providing architects, engineers,
geospatial professionals, constructors
and owner-operators with comprehen-
sive software solutions for sustaining
infrastructure. www.bentley.com
GE (LEWISTOWN, PA.) is investing
more than $10 million to expand its
Inspection Technologies headquarters
site in Lewistown, Pa. Key features of
the project include a new global cus-
tomer applications center and a nonde-
structive testing(NDT) academy. his
52,000-square-foot expansion project
will increase the facilitys oor space by
more than 63 percent and is scheduled
to be completedin 2012. GE is a tech-
nology, services and nance company
www.ge.com.
P&S
To have a news item considered for P&S
News, please send information to Lori
Ditoro at Pumps & Systems, P.O. Box
530067, Birmingham, AL 35253, 205-
314-8269, lditoro@cahabamedia.com.
See how to reduce your water and energy
consumption, increase equipment
reliability and improve your
bottom line with SEPCO
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UPCOMING EVENTS
TURBOMACHINERY LABORATORY
CONTINUING EDUCATION SHORT
COURSES
March 6 9
Hilton Westchase Hotel
Houston, Texas
979-845-7417
www.turbolabtamu.edu/articles/
short_courses
WQA AQUATECH USA
March 6 9
Las Vegas Convention Center
Las Vegas, Nev.
630-505-0160
www.wqa.org
PUMPS AND MOTORS
April 10 12
University of Wisconsin Pyle Center
Madison, Wis.
800-462-0876
http:epd.engr.wisc.edu/webM792
TEXAS WATER
April 10 13
San Antonio, Texas
512-251-8010
www.texas-water.com

WORLD FILTRATION CONFERENCE
April 16 20
Messe Center Graz / Graz, Austria
+49 (0)2132 93 57 60 / www.wfc11.at
OFFSHORE TECHNOLOGY CONFERENCE
(OTC)
April 30 May 3
Reliant Park / Houston, Texas
972-952-9494 / www.otcnet.org
INTERPHEX
May 1 3
Jacob K. Javits Convention Center
New York, N.Y.
203-840-5897 / www.interphex.com
WINDPOWER CONFERENCE &
EXHIBITION
June 3 6
Georgia World Congress Center
Atlanta, Ga.
202-383-2500 / www.windpowerexpo.org
ECWATECH: INTERNATIONAL WATER
FORUM
June 5 8
International Exhibition Centre Crocus
Expo / Moscow, Russia
+7 (495) 225 5986 / www.ecwatech.com
AMERICAN WATER WORKS ASSOCIATION
CONFERENCE & EXHIBITION (AWWA)
June 10 14
Dallas Convention Center
Dallas, Texas
800-926-7337
www.awwa.org/ACE12
EASA
June 24 26
Gaylord Opryland Resort and Convention
Center / Nashville, Tenn. 314-993-2220
www.easa.com/convention
Send event information to Lori Ditoro at
lditoro@cahabamedia.com. P&S
Creating Value.
Carver Pump Company
2415 Park Avenue
Muscatine, IA 52761
563.263.3410
Fax: 563.262.0510
www.carverpump.com
Designed specifically to meet the
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I
n this multi-part series, we will investigate several
aspects of centrifugal pump e ciency. First, I will dene
e ciency and give some examples. Next, I will examine
some of the design criteria that ultimately dictate the e -
ciency exhibited by a particular pump.
I will also try to make that somewhat nebulous quan-
tity, known as specic speed, more meaningful. I will illus-
trate its eect on the shape of a pumps performance curve
and overall pump e ciency.
Next, I will explain the contributions of individual
pump components to a pumps overall e ciency and show
why the combined e ciency of a pump and its driver is the
product, not the average, of the two e ciencies.
How pump e ciency can be preserved by changing
impeller speed rather than reducing it diameter will also be
examined. hen I will compare the value of peak e ciency
versus the breadth of e ciency over a range of ow. he dis-
cussion will end with the importance, or sometimes unim-
portance, of e ciency as it relates to a particular application
or process.
What Is Pump Efciency?
When we speak of the e ciency of any machine, we are
simply referring to how well it can convert one form of
energy to another. If one unit of energy is supplied to a
machine and its output, in the same units of measure, is
one-half unit, its e ciency is 50 percent.
As simple as this may seem, it can still get a bit com-
plex because the units used by our English system of mea-
surement can be quite dierent for each form of energy.
Fortunately, the use of constants brings equivalency to these
otherwise diverse quantities.
A common example of such a machine is the heat
engine, which uses energy in the form of heat to produce
mechanical energy. his family includes many members, but
the internal combustion engine is one with which we are all
familiar. Although this machine is an integral part of our
everyday lives, its eectiveness in converting energy is far
less than we might expect.
he e ciency of the typical automobile engine is
around 20 percent. To put it another way, 80 percent of
the heat energy in a gallon of gasoline does no useful work.
Although gas mileage has increased somewhat over the years,
that increase has as much to do with increased mechanical
e ciency as increased engine e ciency itself.
Diesel engines do a better job but still max out around
40 percent. his increase is due, primarily, to its higher com-
pression ratio and the fact that the fuel, under high pressure,
is injected directly into the cylinder.
In the pump industry, much of the work involves two
extremely simple, yet e cient, machinesthe centrifugal
pump and the AC induction motor. he centrifugal pump
converts mechanical energy into hydraulic energy (ow,
velocity and pressure), and the AC motor converts electrical
energy into mechanical energy.
Many medium and larger centrifugal pumps oer e -
ciencies of 75 to 93 percent and even the smaller ones usu-
ally fall into the 50 to 70 percent range. Large AC motors,
on the other hand, approach an e ciency of 97 percent, and
any motorten horsepower and abovecan be designed to
break the 90 percent barrier.
he overall e ciency of a centrifugal pump is simply
the ratio of the water (output) power to the shaft (input)
power and is illustrated by the equation below:
E
f
= P
W
/ P
S
Where:
E
f
= e ciency
P
w
= the water power
P
s
= the shaft power.
In the U.S., P
s
is the power provided to the pump shaft
in brake horsepower (BHP) and P
w
is:
P
w
= (Q x H) / 3960
Where:
Q = Flow (gallons per minuteGPM)
H = Head (feet)
he constant (3,960) converts the product of ow and
head (GPM-feet) into BHP. hese equations predict that
a pump that produces 100 GPM at 30 feet of head and
requires 1 BHP will have an overall e ciency is 75.7 percent
at that ow point. An extension of the second equation also
Joe Evans, Ph.D.
Centrifugal Pump Eficiency
What Is Eficiency?
First of Five Parts
Pump Ed 101
allows the computation of the BHP required at any point on a
pumps performance curve if we know its hydraulic e ciency.
I will show some examples of this later in this series.
How Is Pump Efciency Attained?
he overall e ciency of a centrifugal pump is the product
of three individual e cienciesmechanical, volumetric and
hydraulic. Mechanical e ciency includes losses in the bearing
frame, stu ng box and mechanical seals. Volumetric e ciency
includes losses due to leakage through the wear rings, balanc-
ing holes and vane clearances in the case of semi-open impel-
lers. Hydraulic e ciency includes liquid friction and other
losses in the volute and impeller.
Although mechanical and volumetric losses are impor-
tant components, hydraulic e ciency is the largest factor. he
centrifugal pump has a lot in common with the induction
motor when it comes to the design phase. he commonality is
that both have only two major components that can be modi-
ed by the designer. In the case of the motor, it is the rotor and
the stator. For the centrifugal pump, it is the impeller and the
volute (or diuser). Lets start our investigation of centrifugal
pump e ciency with the impeller.
he a nity laws tell us quite a bit about the inner work-
ings of an impeller. We know that, for any given impeller, the
head it produces varies as the square of a change in speed.
Double the speed and the head increases by a factor of four.
If you keep speed constant, the same rule holds true for small
changes in its diameter.
he ow through an impeller follows a similar rule, but
in this case, its change is directly proportional to the speed
A change in rotational speed or impeller diameter
refers to its peripheral speed or the speed, in feet
per second, of a point at its periphery.
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FROM YOUR RELIABILITY EXPERTS
Pump Ed 101
or diameter changedouble the speed or diameter, and the
ow doubles. Actually, a change in rotational speed or impeller
diameter refers to its peripheral speed or the speed, in feet per
second, of a point at its periphery. It is this speed that deter-
mines the maximum head and ow attainable by any impeller.
he head produced by an impeller is almost entirely
dependent upon its peripheral velocity, but ow is inuenced
by several other factors. Obviously, the width and depth (cross
sectional area) of the ow passages (vanes) and the diameter
of the impeller eye are important considerations as they deter-
mine the ease with which some volume of water can pass
through the impeller.
Other factors such as vane shape also inuence an impel-
lers performance. But where do you start if you want to design
an impeller from scratch? Do you take a
wild guess about dimensions and shapes,
make some samples and then test them?
In the early days, that is exactly
what pump designers did. Today, how-
ever, they can draw on years of experi-
ence and, at a minimum, nd a suitable
starting point for the design. hat start-
ing point is specic speed. Next month,
we will investigate specic speed and
how it can predict the performance of a
particular impeller.
Where Can You
Learn More?
here are many great pump books
available today, but one of the classics
is now available as a free download at
Google Books. Pumping Machinery
was authored by Arthur M. Green, a
professor of mechanical engineering at
Rensselaer Polytechnic Institute and was
published by John Wiley & Sons over
100 years ago. It begins with a compre-
hensive history of pumps and ends with
a detailed review of centrifugal pumps
and their advances over the previous
twenty years. You will be impressed at
the level of knowledge possessed by the
author. he number of illustrations is
amazing and accounts for a signicant
portion of its 725 pages. his one gets
an A+ rating from me.
P&S
Joe Evans is responsible for cus-
tomer and employee education at
PumpTech, Inc., a pump & packaged
system manufacturer & distributor
with branches throughout the Pacic
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.
W W W. S A ND P I P E R P UMP. C O M
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S
ince the original publication of this draft standard in the
January 2008 issue of Pumps & Systems, I have received
feedback, encouragement, numerous questions and
criticism. he draft listed three basic levels of repair:
Level 1: Basic repair
Level 2: Extended repair
Level 3: Complete overhaul
Each adds increasingly extensive machining work and
cost. While most of the comments strongly encouraged a
need for such a standard, many wondered how a specic level
(1, 2 or 3) can be prescribed and quoted before the pump is
pulled, reassembled and examined at the shop.
Determine the Need for Repair
Commercial considerations and the logistics of the quotation
process further complicate this issue. With vertical pumps, a
need for a repair is usually determined by the plant operating
and maintenance personnel and is based on increased vibra-
tions. Most of the vertical pump body is below the soleplate,
making assessing the pumps condition di cult.
Spectral vibration analysis can reveal some potential
problemsa bent shaft, worn bushings, etc. However, prac-
tically speaking, the extent of the repair cannot be deter-
mined without the pump being removed and examined. he
dilemma for a repair shop is what level of repair to quote?
Example
One example involves mid-size, single-stage vertical pump.
Assume that a Level 1 repair costs $20,000, including pull-
ing the pump, cleaning/blasting, replacing a few bushings,
reassembling, painting and other standard maintenance and
repair. A Level 2 repair might cost $50,000, and a Level 3
repair it might be $120,000. Obviously, the cost of each level
will also depend on the pump length, metallurgy, number of
stages and other factors.
If the pump had already been removed and repair shops
were asked to inspect it and provide competing quotes, then
the quotation process would be simple and straightforward.
he quoted numbers, provided by several (usually at least
three) repair shops, would be relatively close: $20,000 (Shop
A), $22,000 (Shop B) and $24,000 (Shop C). In this case,
Shop A with the lowest quote would get the job (assuming
that all three bidders are technically capable and qualied
to handle the repairs). he problem is, however, that the
pump had not been removed. his makes the quotation pro-
cess more di cult. he repair shops are now faced with the
dilemma of which level to quote?
One Quote
Shop A assumes that the repair will be completed at a mini-
mum extent and quotes $20,000 (Level 1). Shop B assumes
an extended repair and quotes $50,000 (Level 2). To do
things right, Shop C decides that a full restoration of ts,
clearances, the replacement of worn rings and other measures
will be needed and quotes $120,000 (Level 3).
he purchasing department of the plant will likely
award the job to the lowest bidder (Shop A). Once shop A
pulls the pump, reassembles and examines it, its personnel
may discover that the extent of damage is actually at a Level
2 requirement ($50,000). However, the committed quote of
$20,000 prevents them from conducting that level of work.
Presenting a new quote to the pump owner would seem
reasonable, but with shops B and C by now out of the pic-
ture, such an approach may, in the long run, raise the eye-
brows of purchasing.
Three Quotes
Requesting to prepare three dierent quotes based on each
level also presents a dilemma. For example:
Level 1 Level 2 Level 3
Shop A $20,000 $50,000 $120,000
Shop B $22,000 $52,000 $122,000
Shop C $10,000 $100,000 $300,000
What would be the basis for the purchasing decision?
If awarding the job based on the Basic Level ($10,000) but
afterward having to pay $300,000 for the full repair (by
which time the award is made), then plant would end up
paying almost three times more compared to what the other
two shops would have charged.
Only Quote for Level Three
Because of such dilemma, there are two main approached
taken by the plants when soliciting the quotations. he rst
is to specify the full blown overhaul (Level 3), which guaran-
tees the pump will be done perfectly and, as rightly hoped,
last a long time, - but knowingly paying more regardless if
Dr. Lev Nelik, P.E., P&S Editorial Advisory Board
Repair Standard for Vertical Pumps
Pumping Prescriptions
the inspection conrms the need to such full repair (repair shop
making modest prot), or just a minor damage in which case
a repair shop makes very good prot.
Only Quote Simple Work
he second strategy is to specify just a bare bone work (clean/
blast, change bushings, reassemble and paint), with any addi-
tional work to be found during inspec-
tion to be quoted then allowing the
repair shop charge a very high premium,
as it is usually not practical to shop the
reassembled pump to another shop for
a new quotation of the extended repair
need.
Weighted Average
Another strategy is to consider a bid
award decision based on a weighted
average of variety of factors, besides the
cost, such as technical competency, past
experience, eld support, and other fac-
tors. Finding root cause of failure is one
of the factors (P&S April 2009 article),
as repeated repairs without pinning
down the root cause, are likely.
Rening the Standard
Other types of pumps (Repair and
Upgrades of Multistage Centrifugal
Pumps, December 2007) have similar
considerations as far as purchasing deci-
sions. However, since assessing the extent
of damage for pumps operating on the
surface is usually easier, such variations
in quotes are usually less signicant.
he dierent quote processes of
course pose more questions, and many
other variables, both technical and
commercial, that need to be consid-
ered. Reviewing such variations and
parameters and expanding and rening
the draft Vertical Turbine Pump (VTP)
Repair Standard would be desirable.
he standard could be rened by pump
sizes, materials, number of stages, etc., to help end users make
better estimates of the quality of repair that is needed and to
receive these repairs at an aordable price.
he original draft was reviewed by the committee. he
second draft is targeted for release by next September. Let us
know your input.
P&S
Dr. Nelik (aka Dr. Pump) is presi-
dent of Pumping Machinery, LLC,
an Atlanta-based rm specializing
in pump consulting, training, equip-
ment troubleshooting and pump
repairs. Dr. Nelik has 30 years of
experience in pumps and pumping
equipment. He can be contacted at
www.PumpingMachinery.com.
MUNICIPAL
For Large & Small Treatment Systems or L
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PUMPS & SEALS
FOR
HARSH CONDITIONS
A Special Section of
February 2012
A
s manufacturers continue to increase production capa-
bilities to meet customer orders, the demand for com-
pressors with higher speeds, higher pressures, lower and
higher temperatures and larger sizes is also growing. A properly
functioning compressor is critical to optimal plant operation.
Compressor failure can bring down an entire plant or bring
production to a halt, costing a company $250,000 an hour or
destroying millions of dollars of catalyst. herefore, a reliable,
well-designed dry gas seal system included with a compressor
can make a dierence to a plants bottom line.
Typically, compressors with dry gas seals are used in appli-
cations in which they are critical parts of the entire process. A
well-designed dry gas seal system will prevent extensive damage
to the dry gas seal, compressor and process. Compared to pump
operations, dry gas seals and compressors usually operate at
higher speeds and pressures. Every component of a dry gas seal
must be designed to manage exposure to extreme conditions.
Five factors inuence the reliability of dry gas seals:
he seal
Separation and process seals
Seal selection
he dry gas seal panel
Auxiliary systems
Each factor must be analyzed to identify what is required
for the application. When selected correctly, they will provide
the best dry gas seal system and deliver the highest reliability
achievable from dry gas seals. Not only will this provide reliable
dry gas seals with a minimum of six years mean time between
repairs (MTBR), it will also reduce utility, maintenance and
repair costs.
Improvements Increase Reliability
Over the years, features in dry gas seals have changed, improv-
ing the technology. Many small adaptations have taken place
to correct the aws or deciencies of past dry gas seal systems.
hese changes range from adjusting the hardness/durometer
of an o-ring for handling high-pressure dry gas seals to using
polymer gaskets, which have no depressurization limits and will
not take a set such as elastomers do. he question is, Although
these are small improvements, how do they aect the reliability
of dry gas seals?
Since the rst dry gas seal was developed, tested and
installed 32-years ago, the knowledge gained from upgrading
oil seals to dry gas seals, analyses of dry gas seal failures and
troubleshooting dry gas seal failures at site have identied the
need for auxiliary systems and the necessity for improvements
in the dry gas seal.
hrough all this, many dry gas seal designs were identied
as unsuited for the applications in which they were installed
including the use of improper materials of selection that
resulted in seal failures, incorrectly installed seals that limited
Dry Gas Seal
Requirements
Glenn Schmidt, EagleBurgmann
Find a reliable dry gas seal system for any application.
First of Six Parts
Figure 1. Basic components and ow illustrating the operation
of a dry gas seal
Special Section: Pumps & Seals for Harsh Conditions
seal life and poor dry-gas-seal panel designs that caused unnec-
essary compressor shutdowns. In many instances, when design-
ing dry gas seal panels, little consideration has been given to
piping congurations, auxiliary systems and utility costs even
though all these aect the reliability of dry gas seals.
Choosing Seal Features
Because dry gas seals operate under extreme conditions, choos-
ing the right seal features can substantially increase the reliabil-
ity by ensuring that they maintain a gap between the rotating
seat and the stationary face. To understand this, lets start with
the basic principles of a dry gas seal (Figure 1).
A dry gas seal creates a lm of gas (3) between a rotat-
ing seat (1) and a stationary face (2). his lm of gas (or gap)
between the seal faces must be generated and maintained at
150 to 200 micro-inches so the seal faces do not touch and the
smallest amount of gas is allowed to leak through the seal.
his gap can be generated in two ways
When applying pressure to the seal
When the rotating seat is turned fast enough to pump gas
between the rotating seat and the stationary face
he rotating seat is xed to the compressor rotor, and
the stationary face is connected to the compressor case. he
stationary face must adjust axially to maintain the gap as the
rotating face/compressor rotor moves and as the compressor
case expands and contracts from changes in heat
and pressure. To manage axial movement, the sta-
tionary face must move freely when required, and
as a result, the dynamic secondary sealing design is
key to attaining a response to axial changes without
resistance or delay. herefore, a reliable dry gas seal
will have a parallel gap of 150 to 200 micro-inches
between the rotating seat and the stationary face
even when axial movement occurs.
Because the gap is so small between the faces, a
clean dry gas is required with particles less than 150
micro-inches because larger particles will expand the
gap. With smaller particles, if the groove does not
have a feature to ensure that particles pass through
the seal faces, even ner ltration will be required to
minimize build-up of contamination in the grooves.
Do not be mislead when people say: he gas
being supplied is clean. Everyone has a dierent
denition of clean gas, and almost no piping or
process has a gas quality with debris of 150-micro-
inches or less. How can end users ensure that their
dry gas seal will only encounter clean dry gas?
Essentially, a clean dry gas environment must be cre-
ated for the seal. When this is done correctly, the seal
will provide a long and protable life.
Process and Separation Seals
To create the right environment for the seal, con-
tamination must be prevented from entering the
Figure 2. Separation seal
A coaxial barrier seal prevents
lubrication oil from contaminating the dry gas seal.
Figure 3. Seal congurations are available to t every application.
seal. From the process side, a process seal is required to prevent
process gas from contaminating the dry gas seal environment.
On the atmospheric side, where lubrication oil is present, the
oil must be stopped from entering the dry gas seal environment.
To prevent a dangerous condition, process gas cannot
leak into the bearing cavity, which could cause an explosion
or expose operators or the environment to hazardous or toxic
gas. To eliminate this danger, a separa-
tion seal (Figure 2) is used on the atmo-
spheric side of the dry gas seal. Since a
number of separation seals are available,
selecting the correct seal for the applica-
tion is important.
Choosing a Seal
Conguration
Next, a seal conguration must be
chosen (Figure 3). here are single seals,
double seals, tandem seals, and tandem
with intermediate labyrinth seals. So
how do you know which seal to use for
your application? To assess what seal
conguration will meet the require-
ments for the application, it is impor-
tant to know: the operating conditions
of the seal and the process gas; what seal
supply gas is available; and if a back-up
seal is required.
Available utilities can aect which
seal conguration is used. Other aspects
to consider include:
Safety
How to manage a primary seal failure
he length of space available and
how it aects the compressors rotor
dynamics
All these factors must be identied
when selecting the dry gas seal congu-
ration, process seal and separation seal to
assemble the best dry gas seal cartridge
for the application.
Dry Gas Seal Panels
Once a seal conguration has been
selected, a panel (Figure 4) must be
designed to support the dry gas seal car-
tridge. he panel design must deliver
su cient, quality seal supply gas to the
dry gas seal. his will prevent liquid from
forming in the seal gas when subject to
changes in temperature or pressure. he
panel will monitor the leakage rate of
the dry gas seal and provide alarms and
shutdowns to prevent process gas from leaking should a pri-
mary seal failure occur. It will also verify that the secondary seal
or back-up seal is intact and provide process gas containment in
the event of a primary seal failure.
If an intermediate labyrinth is part of the cartridge, a
secondary seal supply will be provided to ush all the process
gas to the vent system. A system to control the secondary seal
supply ow will then be needed. Some applications require that
the compressor to continue to operate on the secondary seal
when the primary seal has failed. Continued operation allows
for a controlled shutdown of the process and prevents the loss
of millions of dollars of catalyst. In this case, the secondary vent
must be monitored.
Lastly, a system to control ow to the separation seal is
required. All these components are needed to provide an
e cient system for controlling the supply and quality of gases
to the dry gas seal and to monitor the seals health.
Identifying Auxiliary Systems
he nal factor that inuences the reliability of a dry gas seal
is the auxiliary system. Typically, auxiliary systems (Figure 5)
Figure 4. Dry gas seal panelSeal management systems control
supply gases and monitor seal health.
Figure 5. Auxiliary systems condition seal gas and ensure continu-
ous seal gas ow.
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are chosen when the seal and seal supply are selected, as these
choices have major inuences on what is included in the aux-
iliary system. When identifying what to include in an auxil-
iary system, the reliability of the seal gas supply ow must be
assessed to determine if it will provide a ow during all condi-
tions, such as start-up and recycle. If an alternate gas is used,
can pressure build up in the compressor be managed?
he quality of the seal supply gas must also be assessed to
ensure that no liquids are formed during changes in gas pres-
sure and temperature. he seal gas will drop in pressure from
the supply pressure all the way to the atmospheric side as it
leaks through the dry gas seal. Factors that can inuence seal
gas temperature are process gas temperature or environmental
conditions, which can drop the temperature of pipes or the
compressor to the point that liquid will
form in the seal gas supply. All these con-
ditions must be identied to ensure that
no liquids form that will aect the oper-
ation of the dry gas seal during dynamic
as well as static conditions.
Conclusion
All these factorsseal design, process
and separation seal, seal congurations,
dry gas seal panels and auxiliary sys-
temsmust be reviewed, assessed and
designed for the seals intended appli-
cation. With strict adherence to these
guidelines, a dry gas seal system can
be designed that oers the highest e -
ciency and reliability, preventing unnec-
essary plant shutdowns and subsequent
loss of production and catalysts.
he next article, in the March 2012 issue,
will focus on selecting the proper seal fea-
turesface materials, groove geometries,
secondary sealing elements and gasket
extrusion/explosive decompressionto pro-
vide a reliable dry gas seal system.
P&S
Glenn Schmidt is
Eag l e Bur g mann s
regional compressor
seal specialist sup-
porting the American
region with techni-
cal and sales support
for designing, servicing, repairing,
troubleshooting and upgrades of dry
gas seals and systems. His 16 years of
experience with dry gas seals includes
instructing a Texas A&M dry gas seal
systems course and providing input as
a member of the API 692 committee
developing the standards for dry gas
seals and systems. He can be reached
at glenn.schmidt@us.eagleburgmann.
com or 713-939-9515.
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P
umping applications come in vary-
ing degrees of di culty and com-
plexity. It is not unique to any one
industry or pump type. his makes select-
ing the right pump for a set of operating
conditions an interesting challenge.
Shear-Sensitive, Abrasive &
Mixed Fluids
Progressive cavity pumps (PCP), due to
their inherent design and performance
are suitable for di cult applications. he
handling of shear sensitive uids; highly
abrasive slurries; or a mixture of solids,
liquids and gases can be e ciently han-
dled by this type positive
displacement pump.
Unlike many industries, applications
in oil and gas are more di cult since the
incoming ow can be non-uniform and
is almost always a mixture of solids, liq-
uids and gasesthe percentage of which
is not constant. Further complication results from gases being
dissolved in the oil and water mixtures and the presence
of condensates.
Gas Condensates
Even slight changes in temperature and pressure can cause
condensates to vaporize resulting in major damage to pumps.
Gas condensates can also lead to the formation of waxes, which
alters the ow characteristics signicantly from Newtonian to
non-Newtonian. Related problems result in increased
operating costs.
Condensates at High Altitudes
he handling of gas condensates is a di cult problem and draws
upon the challenges of all pump technology. One such prob-
lem was extraordinarily di cult because the location, Evanston
Wyo., was at an altitude of approximately 7,000 feet above sea
level. he Net Positive Suction Head Required (NPSHR) in
this case was extreme due to the altitude. At higher altitude, the
density of the air is much thinner than at sea-level. herefore
the equipment, pumps and motors, have to be adjusted to work
e ciently in a less air-dense environment. his made every-
thing much more di cult, and restricted the pump choices.
he PCP was the only pump that could handle the
High-Altitude
Condensate Pumping
Kamran Mirza, seepex Inc.
A progressive cavity pump provides an ideal solution to a difcult pumping application.
operating conditions and also the low NPSHR. In addition to
the performance, it also oered the most economical alternative.
he selection of the PCP to solve the condensate pumping
problem was based on several advantages:
It is able to handle very high gas fractions, in excess of 99
percent, and was able to handle the condensate stream.
he PCP was not aected by changes in the proportion of
condensates or liquids, so the performance of the pump was
not aected by variability in condensation or vaporization
of the pumped medium.
It was able to function in a low NPSHR situation with a
high vapor pressure and a low atmospheric pressure.
Any other type of pump used in this well-site-to-storage-
pumping application would have required a much higher
NPSHR, which would have meant expensive methods to
place the pump at a lower altitude. he overall cost of such an
arrangement would have been prohibitive.
he PCP operated with ease at the higher altitude even
with the motor de-rated, resulting in savings to the customer.
It had a compact design, with all wetted parts made of duplex
stainless steel. he Duktil coated rotor and uoropolymer
stator were selected for service life longevity with minimum
maintenance. A 100-horsepower motor operated the pumps at
225 rpm for a ow rate of 350 gallons per minute. he pump
was equipped with special dry running protection device.
A Long-Term Solution
he PCPs have been operating trouble free for more than
eight years. here are many di cult applications, but this one
was unique because every parameter was extreme in its scope,
and the collective conditions imposed additional restrictions.
However, the carefully engineered PCP provided a long-term
solution that continues to operate successfully.
P&S
Kamran Mirza is director of business
development, at seepex, Inc. in Enon,
Ohio. He has 34 years of experience in
progressive cavity pumps. Mirza developed
the progressive cavity multiphase pump for
Robbins & Myers and served as director
of engineering and manufacturing for the
Dyna-Drill Division of Smith International and director
of manufacturing for Baker Hughes Drilling Systems. He
has authored several technical papers and holds two pat-
ents in multiphase pump technology. Mirza has an M.S.
in Mechanical Engineering from the University of New
Mexico.
C
hoosing a coating for a pump
can be a challenging task. A good
coating can extend the life cycle
of a pump, providing cost and downtime
reductions. Alternatively, a poor coating
can do the opposite. It could jeopardize the
pump and increase costs and downtime.
Information for comparing the coat-
ing options is generally limited to three
possible sources: anecdotal evidence, a
salesman pitch or a manufacturers speci-
cation sheets. he rst two can be judged
by impression or level of trust and are
somewhat subjective. he third is possibly
the most misunderstood and di cult to
judge. his article provides insight into the
general makeup and applicability of the
typical manufacturers coating specica-
tion in hopes of making the decision easier
and increasing the odds of choosing what
is best for each pump.
Standards
Most reputable coating manufacturers
carry out their performance testing as
per industry recognized testing standards.
Standards have one purpose, to make a
test as repeatable as possible. It does not
guarantee that the results have real world
meaning, although many make an attempt
at doing so. his is important to under-
stand when choosing a material based on
a specication sheet.
A common mistake is to compare
values side-by-side and make the assump-
tion that the higher the better. Without a
basic understanding of the true meaning
of the numbers, an objective comparison
is impossible. End users must resist the
basic human instinct to compare the quick
and obvious number and make a swift
Choose the Right
Coating
Ivan Ordaz, Belzona
Understand coating manufacturers specication sheets.
Figure 1. High-tech coatings lab
Figure 2. VICAT heat distortion temperature
judgment when, in reality, the not so obvious is many times
more meaningful and rarely represented by a single numerical
value.
Reading the standard itself oers much insight. Never take
the number simply for what it is and understand that not all
standards are created equal. Some are specic and detailed while
others might be broad with wiggle room. Some standards are
also much more representative of desir-
able properties for a specic application.
For example, compressive strength is a
value, which for a pump coating appli-
cation, does not have much signicance.
However, for a machine shop oor coat-
ing with heavy machinery and tra c, it
could be more relevant.
General Data
When analyzing a product specica-
tion sheet, keep in mind that thousands
of possible tests could be listed for a
polymeric coating. What is listed is,
therefore, carefully chosen by the manu-
facturer for a specic reason. Perhaps
the manufacturer feels that the data is
important for a specic market that it is
targeting. Maybe it is limited by testing
capabilities, but it could also be limited
to the strong points only of the product
and intended to make the best impres-
sion possible.
Regardless of the reason or intent,
what matters is that the end user identi-
es the data that is most critical to the
success of the application. If dealing
with coatings that will see chemicals,
end users should focus on chemical
testing, and identify how the products
are tested and how rigorous the testing
procedures are. If the pump moves uid
with entrained solids, then abrasion
resistance and heat distortion tempera-
ture are absolutely critical.
Some basic data that should be
present on a specication sheet are:
Physical propertiesdensity, appear-
ance, consistency, viscosity, slump
resistance, peak exotherm, time to
peak exotherm, working life, percent
solids and shelf life. he more details
the better because these physical
properties allow for proper applica-
tion planning.
Strength and hardnesscompressive
strength, exural strength, tensile
strength and hardness are values that could be considered
performance data but because they are so generic in nature,
they seldom become a critical focal point during coating
selection.
Polymer materials could also be formulated in ways that
amplify these basic mechanical characteristics but serve little
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purpose as far as performance in the
intended environment or in some cases
could be detrimental to the coatings real
world performance.
Performance Data
At a minimum, the general performance
data in this section should be present in a
manufacturers coating specication sheet.
Adhesion
Cross hatch for thin coatings, direct ten-
sion and lap shear adhesion for thick coat-
ings. Adhesion is critical to the success of
any coating. A coating that is unable to
maintain a tight bond with the substrate
stands little chance of successfully protect-
ing that substrate. Adhesion of coatings is
highly dependent on methods of surface
preparation.
Some coatings are designed speci-
cally to adhere to poorly prepared or con-
taminated surfaces. If your application has
restrictions on surface preparations, these are important char-
acteristics that could benet your application. Such coatings
should have appropriate data to prove the claims.
Dry Heat Resistance
he thermal stability of a coating is dependent on the formula-
tion of the resin systems. Heat resistance is generally subdivided
into dry heat resistance and wet (immersion) heat resistance.
he temperature at which a coating will begin to break down is
dened as the dry heat resistance of the material. Exposures to
temperatures above this value will cause permanent irreversible
damage to the coating eventually leading to its destruction.
Immersion Heat Resistance
Immersion heat resistance is almost always lower than dry heat
resistance. When immersed in a liquid, a polymeric coating will
generally experience a lower heat resistance due to increased
permeation of the liquid as the temperature increases. he per-
meation can lead to blistering, chemical attack, under coating
corrosion and other detrimental eects.
Coatings chosen for immersion service
should be tested by a rigorous method to
determine the immersion heat resistance.
Atlas cell testing is among the most
widely accepted and most scrupulous
methods available. Atlas cell testing will
not only expose the coating to the hot
uid but also incorporates the eects of
a cold wall. A cold wall will make condi-
tions much more aggressive to the coating
by introducing a strong thermal gradient
across the coating. he strength of the cold
wall depends on the thickness of the coated
metal panel. hicker panels will dampen
the cold wall eect since they will contain
a larger thermal mass.
Heat Distortion Temperature
he heat distortion temperature of a mate-
rial denes a temperature at which the
material begins to soften. When a material
Figure 3. Performance testing equipment
Figure 4. Lab based accelerated UV chamber
exceeds its heat distortion temperature, it will lose most of its
physical strength and soften. It is important to note that this
is not a permanent eect. Once the temperature has decreased
below the heat distortion temperature, the material will regain
its rigidity, returning to normal.
he heat distortion temperature is extremely important in
situations and meaningless in others. Any coating that will be
subject to mechanical stress or chemical
exposure should never be put in service
above its heat distortion temperature.
For pumps, I this is a critical property
since high velocity uids and possible
abrasion are the norm.
Abrasion Resistance
Abrasion is di cult to simulate and
generalize in a test due to the nature
of the eect. Abrasion of a coating can
occur by dierent means such as uid
impingement, impact abrasion and ero-
sion by entrained solids. Sliding abrasion
is often tested by the Taber method in
which abrasive wheels slide over a rotat-
ing sample for a given number of cycles.
he mass loss is then determined. his
method is eective for comparing slid-
ing abrasion of coatings. Several param-
eters need to be established and quoted
along with the results.
When using Taber abrasion for
comparison of coatings, all these param-
eters need to be the same. he param-
eters are mass of weights, wheel used,
number of cycles and abrasive condition
(wet or dry). Only when all these are the
same can two test results be compared
side by side. Taber results are determined
by measuring the mass of the sample
before and after the test. he mass loss
represents the degree of abrasion.
Considering the density of the coat-
ing when comparing values is impor-
tant. Because coatings have dierent
densities, mass alone is a poor tool for
comparison. Many coatings manufac-
turers will convert mass loss to volume
loss. However, one should never com-
pare dierent material by mass loss.
Comparison by volume is the only
accurate way to compare two coatings
abrasion resistance. A gram of coating
A does not necessarily equate a gram of
coating B if their densities are dierent.
A cubic millimeter of coating A and a
cubic millimeter of coating B will always be the same quantity.
After all, the interest is in how quickly the coating will wear
down not how much mass is being lost as it wears.
Cathodic Disbondment
Coatings that will work alongside cathodic protection sys-
tems should be tested for cathodic disbondment resistance.
he presence of a polarizing potential on exposed sections of a
cathode will produce an aggressive environment for a coating,
which could lead to disbondment and corrosion creep.
Corrosion Resistance
Accelerated corrosion testing generally performed in a salt
spray cabinet to demonstrate the coatings ability to provide
protection in corrosive environments reveals how well the coat-
ing withstands this eect.
Accelerated Weathering
Testing for discoloration, loss of gloss, blistering, aking, rust-
ing or other break down when exposed to harsh environments.
his test can be performed in a test chamber designed to simu-
late such environments or in outdoor
exposures.
Outdoor exposure should be in
geographical areas of harsh weather con-
ditions such as Florida or Arizona.

Key Steps
As this article shows, choosing a pump
coating is no easy feat. It consists of sev-
eral steps in which the decision maker
must have extensive knowledge of the
structure or equipment that will be
coated, as well as the coatings them-
selves. Otherwise, a signicant number
of coating failures can result.
he key steps to choosing the right
coating is rst to understand what key
properties are required of the coating.
Once this is accomplished, end
users can start looking at specications
sheets to determine if the standards
quoted accurately simulate the expected
real-world conditions.
his should lead to an educated and
correct decision. In essence, a properly
chosen coating will prolong pump life
by repairing it, reduce downtime by pro-
tecting it and possibly even improve its
e ciency.
P&S
Ivan Ordaz is an
accomplished engi-
neer in the eld of
industrial coatings
and corrosion protec-
tion. A graduate from
Georgia Institute of
Technologys school of chemical engi-
neering, he has focused his career on
high performance coatings. He man-
ages a product development depart-
ment Belzona. Additionally, he is
a certied NACE Level 3 coating
inspector, having presented in NACE
International coating symposium
and prides himself in being immersed
in the coatings community.
No matter which pump type you have, KSB can handle the diagnostics, repair or
casting and machining of aftermarket parts regardless of the manufacturer. KSB offers
you full service repair shops, with skilled technicians to service or repair your pump.
Contact KSB, a leading aftermarket solution provider for your next repair job.
Locations throughout North America and the world!
KSB, Inc.
.
Mid-Atlantic
.
Phone: (804) 565-8373
.
repair@ksbusa.com
.
www.ksbusa.com
Standard Alloys Inc.
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Gulf Coast
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Phone: (800) 231-8240
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sales@standardalloys.com
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www.standardalloys.com
Precision Pump & Machine
.
West Coast
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Phone: (661) 633-5520
.
info@precisionpump.com . www.precisionpump.com
KSB Aftermarket Solution Provider
Pumps
Valves
Systems
Replacement part cast
and machined
Cover Series: The Aftermarket
The
Aftermarket
The
Aftermarket
Cover Series
Inside this Section:
Pump Replacement Part Availability. . . . . . . . . . . . . . 35
Inspections and Repair Can Enhance Pump Performance. . . 40
Specialty Replacement Parts . . . . . . . . . . . . . . . . . 44
The Value of Industrial Pump Genuine Parts and Repair Kits . 46
Inside this Section:
Pump Replacement Part Availability. . . . . . . . . . . . . . 35
Inspections and Repair Can Enhance Pump Performance. . . 40
Specialty Replacement Parts . . . . . . . . . . . . . . . . . 44
The Value of Industrial Pump Genuine Parts and Repair Kits . 46
Photo courtesy of KSB
T
he crumbling infrastructure of
our roads and bridges is the hot
topic in todays political discourse.
However, an even bigger problem may be
the pump infrastructure in our nations
industrial base.
Pumps are the heartbeat that enables
most industries to run the processes that
create products. Untold thousands of
pumps are now in the 25-to-75-year-old
age group and must continue running even
though the original life was probably pre-
dicted to be 20 years. his is because of the
extremely high cost of replacing the pumps
with newer model pumps.
he manufacturers of many of these
pumps are either out of business or have
moved on to selling new models and no
longer support the older models with
replacement parts. he question becomes
what are the strategies for continuing to
maintain sources for these old pump parts
in the coming years?
In 1973, I was involved in an expan-
sion project at a large renery in St. Croix,
U.S. Virgin Islands. hirty-nine years later,
that plant is still there, and many of those
pumps are probably still in service. I can
remember that we manually set up spare
parts inventory, minimums and maxi-
mums, based on the list sent to us by the
vendors.
Millions of dollars of spare parts
inventory were kept in the warehouse to
support the pumps and other equipmentunlike today when
inventories are kept at a minimum at both the plants and by
the original equipment manufacturers ( OEM). In those days,
we would set up the parts in our system and purchase inventory
for the warehouse except for the cases, which were a non-wear
item. Now, almost 40 years later, I can say with certainty that
pump cases are wear itemsthey just wear very slowly.
Pump Cases
Older pumps still in operation are creating major problems
for their owners. One example is a large pump case that was
Pump Replacement
Part Availability
Jeff Smith, Standard Alloys
Address this problem to avoid the possibility of future crises.
This decades old (but critical) power plant pump case was no longer supported by the OEM.
As a short term solution, it has been built up using a synthetic polymer product. Before the
power plant puts it back in service for its nal run, it is being reverse engineered so that it
can be replaced with an identical case during the next maintenance cycle, ensuring that the
pump design can continue to be used.
worked on for a major customer. he case had come into the shop for a minor
repair. It looked great, but during the repair process, the mechanic checked the wall
thickness and found that the wall had worn to only 1/8 inch thick. When informed,
the customer immediately ordered a replacement case and paid a premium to get
an expedited delivery.
Another example regarding cases happened recently. We received an email from
a salesman that read, he customer called and said that the case currently being
manufactured on overtime is now an emergency. he sister pump is failing. Again,
this was an older pump still being used in a key operation.
One last example is truly amazing. A replacement case for a reciprocating pump
still in operation was requested. A case had last been made for it 37 years ago.and
the pump was not new then. he old pattern was located and a replacement case was
produced. Hopefully, it will last another 37 years.
The Current Problem
Many stories like this exist in the business, which leads to the conclusion that the
current problem with replacement parts may become a crisis in the future. In most
industries, pumps move products. he industry cannot exist without its pumps. he
pumps are old, and they are starting to need more spares, including pump cases.
Sources for spare parts are becoming di cult to nd, and few companies have a
strategy to keep their old pumps running long-term. his problem is only going to
increase at an accelerated rate.
Proactive Analysis
People at the appropriate management level must determine if this is a problem in
their plant. here are many plants in which the pumps in service are relatively new
and are still supported with available spare parts. A recent informal survey indicated
this to be true for 36 percent of those surveyed.
However, a majority (64 percent) of the plants have older pump populations.
his group needs to study their pumps:
heir age
How critical they are to the process
he availability of spares
hey should also determine whether a problem exists today or, if not, when
it may exist. At some point a problem with parts availability will exist with older
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Applications
pumps. he survey indicated that 90
percent of plants with older pumps have
either a minor problem or a growing
problem with their pump spare parts
sources today.
Awareness is always the rst step of
the problem-solving process. Once the
problem is acknowledged, it should be
further dened. Each pump should be
identied, and a determination made
as to whether spares are readily avail-
able. Some parts that may be considered
obsolete may still be available from after-
market sources.
Other parts that may not techni-
cally be obsolete may not be available
because no one is making them and put-
ting them in inventory. When needed,
the lead time may be many months
even if a delay of many months is not
acceptable.
Alternative Strategies
Numerous reasons exist as to why a
pump part may not be readily avail-
able. For example, the pump cannot
be repaired due to the unavailability of
critical spares because they are no longer
manufactured. In this case, a couple
options are available. First is that some
pre-engineering of currently available
models should be conducted so that
when the pump does end its useful life,
a known replacement model can be
ordered with minimal delay.
Another option is to determine if
the pump part can be reverse engineered.
Reverse engineering during downtime
for normal maintenance might be a
good strategy.
Some pump parts are still manufac-
tured but are not stocked in inventory.
In this case, lead times for manufactur-
ing can be very long. For these parts,
a strategy may be that the plant or the
OEM should decide to maintain an
inventory to prevent an interruption to
operations.
hese alternatives are some of the
strategies that must be developed and
implemented rather than ignoring the
growing problem. In the survey we
found that 64 percent had no plan in
place. he ones that had a plan were
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divided into the two groups: Replace old pumps and use repli-
cators, although none of the plans were formalized.
hese strategies should be aimed at making sure that the
older pumps can be supported for some period of known time,
and the related costs are considered in both maintenance bud-
gets and capital budgets. If this problem is ignored, a signicant
future operating expense due to downtime is probable.
Responsible Parties
he responsibility of maintaining sources for older pump parts
rests with the owners of the pumps. Maintenance is typically
charged with keeping the pumps running and rarely has time
or budget resources to plan for future problems.
Purchasing is typically only charged with buying what is
currently needed and does not know what will be needed in the
future. Reliability is typically charged
with making equipment last longer but
would normally not have visibility as to
whether replacement parts will be avail-
able when needed. Regardless of who
within the organization has responsibil-
ity, someone should be challenged with
addressing this problem.
Implementation
he last step is to implement the newly
developed strategies to keep equipment
operational for years to come. his chal-
lenge will grow as plants continue to
age and pumps that are currently sup-
ported by spare parts sources move into
the obsolete or unavailable categories.
A continual review of pumps and parts
availability must be conducted to keep
plants operational.
In addition, a closer involvement
between the plants and their spare parts
sources (whether OEM or aftermar-
ket) must be maintained. hese sources
should not be seen simply as vendors
but as partners in the challenge of keep-
ing pumps and plants operating long
term. Proper planning and investment
are needed to keep industries, and the
pumps that support them, operational
now and in the future.
P&S
Je Smith is the executive vice
president and managing director of
Standard Alloys, a KSB company.
He has directed the operations of
Standard Alloys since 1996. Prior to
arriving at Standard Alloys, Smith
worked with four OEM companies
in the energy and process indus-
tries. For more information about
Standard Alloys, contact
sales@standardalloys.com, or visit the
website at www.standardalloys.com.
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O
ften all that is needed to improve a pumps depend-
ability and performance is a high quality inspec-
tion and repair. Over time, a pump may have been
repaired by more than one service provider with varying levels
of engineering and technical experience.
Tolerances may have been opened, ts and concentricities
may have been lost and materials may have been changed, all
of which contribute to reduced performance, loss of reliability
and more frequent repairs.
his article highlights the opportunity seized by a coal-
red power generating facility located in Western Pennsylvania,
to upgrade a Westinghouse vertical pump.
Background
he Power Plants Unit 4 Alpha circulating water pump was
scheduled for repair. In the process of removal, the sister pump
4 Bravo, exhibited severe vibration and failed in a manner
that was believed to have been a result of a broken shaft. he
Alpha pump was put back into service and the Bravo pump
removed and sent to the repair facility for inspection and emer-
gency repair.
his circulating water pump performs a critical function in
the power plant, by cooling the low-pressure steam in the con-
denser to use as feedwater for the boiler. A loss of one of these
pumps in the summer means that the plant will not be able to
produce to its maximum capacity until the pump returns to
service.
Observed Pump Condition
he general condition of the Bravo pump when received at the
repair facility was much worse than anticipated with the top
column ange broken about half way around. he entire pump
had been hanging from this broken joint leaving a gap of
inch to inch at the opening.
he keyed coupling (internal to the pump) used to join
its two shafts was broken in several pieces. he shaft journals
were severely worn to one side, and the impeller vanes and
suction bell liner surface were also severely worn as expected,
Inspections and
Repair Enhance Pump
Performance
Bob Bluse, Hydro, Inc.
Improvement can result from repair opportunities.
Column pipe upper ange as-received
Close-up of the broken pipe
considering the signicant pump damage.
After disassembly of the pump, the repair engineers also
observed that the shaft enclosing tubes had spun in their ts
because they were not tted with any anti-rotation mechanism.
his rotation caused damage to the O-ring t areas at both ends
of the enclosing tube assembly, which resulted in the loss of
a proper ush water supply to the pump bearings below the
packing box.
Another issue observed during the inspection was that
part-to-part alignment of major pump components used dowel
pins, which are very di cult, if not impossible, to verify.
Opportunity for Improvement
While the typical repair scope of bearing, wear ring and small
Close-up of the broken pipe ange
Destroyed shaft coupling and hardware
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part replacement was employed, several issues identied during
the inspection were corrected with improvement to the design:
he column pipe repair included replacing the entire upper
ange, adding reinforcing gussets to the anges on both
ends, excavating defective ange and pipe seams and full-
welding to restore integrity and improve the overall strength
of the column.
Register ts were machined into each component as part of
the repair process with minimum clearance to assure proper
alignment.
he impeller vanes were re-established to the proper and
consistent vane lengths. his was done instead of merely
de-burring the worn edges to restore pump performance
and to eliminate hydraulic imbalance. It required an
extensive amount of welding to the sealing surface of the
vanes and precision machining of the impeller and suction
bell because this t has a signicant eect on the pumps
e ciency. NDE of the impeller during inspection revealed
minor cracks, which were also repaired.
he repair plan required the replacement of both shafts,
which presented another opportunity for improvement. he
service center upgraded the shafts by manufacturing them
in a stronger, more durable material to match the pumps
application. he improvements also included maintaining
full-size shaft diameter through the coupling (the existing
shafts were turned-down) and machining proper radii into
all corners and keyways. A new upgraded coupling assembly
was also designed and manufactured by the service center.
he new coupling consisted of a larger outside diameter,
heavier thrust rings (instead of the existing thin-walled
clam-shell type), improved bolting and two keys, 180
degrees apart on opposite ends for balance and strength.
Enclosing tube O-ring t areas on both ends were restored,
and the enclosing tube assembly was tted with an anti-
rotation device.
Pump fasteners were replaced, upgraded to a more durable
material to resist corrosion and fatigue.
Follow-Up and Proof of Design
Repairs and modications discussed in this article were com-
pleted on the Unit 4 Bravo circulating water pump in
February 2010. Modication and repair of the sister Alpha
pump was completed in December 2010, which outtted the
design of both pumps equally.
Soon after the completion of the Alpha pump, a travel-
ing screen failure forced the
removal of the Bravo pump
once again.
Inspection revealed
severe damage to the impel-
ler by a piece of wood debris
that was allowed to pass
through the failed screens.
his permitted an oppor-
tunity to inspect the repairs
and modications from the
previous year.
he customers com-
ments were: In retrospect,
Gusset added to the column pipe anges Typical register ts added throughout the pump
New shafts and shaft coupling components during and after assembly
after our most recent repair on this pump in January 2011,
replacing the shafts was typically part of the repair scope. his is
the rst time I can remember not replacing the shafts due to the
new robust shaft and coupling upgrade that was performed.
After the Bravo pump was repaired again and returned to ser-
vice, he commented that: he pump is currently operating as
expectedquiet and smooth, ready for a long service life.
Lessons Learned
While there are typical repair items such as bearing and wear
ring replacement, shaft journal repair and impeller balancing,
the unexpected issues are what really cause the most frustration.
Proper inspection will reveal other issues that may not be
so obvious, and coordination with a qualied service provider
can present real opportunities for improvement of your pumps.
Improvement of pump reliability, durability and performance,
provides greater mean time between repairs (MTBR), which is
becoming the main focus of most pump users. he technical
manager at the power station reports that working with his ser-
vice provider has been a very positive experience to the power
generating facility because the repairs are done right, pump
inspection as-found and as-left measurements are documented
and reported, and solutions to problems are identied quickly.
At the power plant, we are good at burning coal and
making electricity in a safe, reliable and environmentally
responsible manner, says the manager. Hydro helps us do
that by providing high quality pump repairs and delivering
solutions on time. We are not experts at the plant in repairing
pumps, but we know who to call, so we can get back to doing
the things we are good at.
Make sure to work with a qualied pump service provider
who can oer a thorough inspection, engineering support and
review and an experienced work force dedicated to providing a
quality product.
Taking the time to review the current operating conditions
in relation to the pumps original design specications can lead
to engineering recommendations for improving the pumps
performance and extending its life.
P&S
Bob Bluse is the general manager at Hydro
East located in Aston, Pa. With more than
40 years in the pump aftermarket services
business, his experience has proven valu-
able in helping companies provide a higher
level of operational performance and reli-
ability for their pumping assets.
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W
hen a global adhesive
and sealant manufac-
turer needed a main-
tenance and equipment solution
for frequent and premature stator
wear, a specialty rubber stator was
the solution. Collaboration with
a distributor and pump company
helped the manufacturer save
money and reduce downtime due
to maintenance operations.
The Company
Based in Ohio, the adhesive
manufacturer is among the worlds
largest, privately held manufactur-
ers of adhesives and sealants.
he company integrates its
core competency, emulsion polym-
erization, oering a broad portfolio
of products, including: adhesives,
glues, hot melts, binders and sizing
compounds for use in construction,
wood furniture manufacturing,
millwork, paper converting, pres-
sure-sensitive paper products and
berglass reinforcement. he man-
ufacturer markets an array of products to customers worldwide.
Customer Challenge
he Ohio-based manufacturing facility operates a eet of pro-
gressing cavity (PC) pumps. hese PC pumps are applied in
the transfer of raw materials and shear-sensitive adhesive uids
to dierent parts of its manufacturing process throughout the
facility. One of the companys agship global products is a
pure-white adhesive that requires very gentle, low-shear pump-
ing action.
In addition, the manufacturer had two additional critical
objectives:
he companys process requires a high cleanliness standard
to ensure the exceptional quality of the end product.
he company required high reliability and low operating
costs to improve nancial performance.
A Need for a New Stator
he adhesive manufacturer was experiencing problems with
premature stator wear. On average, its original PC pump sta-
tors would wear out within three months.
hat meant that it had to replace hundreds of stators every
Specialty Replacement
Parts
Sally Huynh, NOV Monoo
When stator wear was an issue, a custom-made replacement part was the solution.
The white stators improved life and maintained the pure-white color of the adhesives.
year. With the downturn in the global market for adhesives and tight budgets, the
Ohio manufacturer needed a way to cut its maintenance and operating costs.
In search of a solution, the company looked to a technical distributor to collab-
orate on its critical needs. he sales manager from the distributor partnered with a
PC pump solutions company to oer special rubber compounded stators to address
these challenges.
To meet the customers needs, this pump company developed and tested its
own rubber formulation in its Manchester, U.K., research and development facility.
he solution was a special white stator for all the manufacturers PC pumps, instead
of the traditional black, which also helped maintain the adhesives pure-white color.
Results
he rst shipment of pure-white stators was delivered to the adhesive manufacturer
from the pump company at approximately 50 percent of the cost of the original
OEM supplier. In addition, the stator life has been twice the life of the OEM sup-
plied stators. his additional stator life saved the company more than 200 stator
change-outs during the year and approximately 1,600 hours of maintenance upkeep
for the same period.
Future Changes
With a change in global demand for adhesives and a shrinking maintenance budget,
the manufacturer needed a signicant cost savings solution within its manufactur-
ing facility.
As a result of the distributors and pump companys eorts in designing, sup-
plying and stocking white stators, the company has been able to realize quick lead
times and competitive pricing for its pumping needs.
Moving forward, the manufacturer is considering a change to a transfer pump
with white stators in the future expansion of its facility. With the transfer pump
technology, the manufacturer will be able to maintain a PC pump in place without
removing the pump from the pipe work.
P&S
Sally Huynh graduated with a degree in marketing from he University of Texas
at Austin. She was hired into a rotational program at National Oilwell Varco
to gain experience in all areas of the company. Currently, Huynh is responsible
for the planning and implementation of marketing communication activity that
supports North and South Americas business strategies and objectives at NOV
Monoo, the industrial sector of National Oilwell Varco. She can be reached at
monoo@nov.com or 281-854-0300.
The stator life has been twice the life
of the OEM-supplied stators,
and the special white material
helped maintain the adhesives
pure-white color.
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T
he word genuine denes something that is
real and authentic. In and of itself, the word
represents reliability and something worthy
of being trusted. Combine genuine with parts, and
you have a winning solution in the pump industry.
A genuine part is a warranted replacement part
made by the original pump manufacturer. In most
cases, genuine parts are the most reliable and high-
est quality parts available in the marketplace. When
a pump needs to be repaired, purchasing genuine
parts from the original pump manufacturer is a logi-
cal solution.
When drivers need to make a repair to their
vehicle, they are presented with two options com-
monly used in the automotive industry: purchase
genuine parts, or purchase aftermarket parts.
Although the automotive industry has had much
success with their genuine parts programs, many
consumers choose aftermarket parts because of the
lower cost. When an end users invest in an air oper-
ated double diaphragm (AODD) pump or a rotary
positive displacement pump (PD), they are pre-
sented with the same option of selecting genuine
parts or aftermarket parts.
By going directly to the manufacturer to get the genuine
parts and service kits, end users will know they are an exact
match to the parts with which the pump was built. Genuine
parts also oer peace of mind by providing quality assurance
and performance guarantees. his option ensures that the
pump remains covered by the manufacturers warranty (the
length of warranty will vary per manufacturer), which is not
the case if the repair is made with an aftermarket part.
A viable alternative to genuine parts is aftermarket parts.
What exactly is an aftermarket part? Aftermarket parts are made
by companies other than the original manufacturer. he quality
can range anywhere from good to poor. Aftermarket parts can
be more aordable, and some companies, have a wide product
oering. A word of warning, some aftermarket parts may void
the manufacturers warranty.
Genuine parts or aftermarket parts? he choice is yours,
and it will be based on the current circumstances. he bottom
line is that all aftermarket parts are not created equal, but all
genuine parts are.
The Value of Industrial
Pump Genuine Parts and
Repair Kits
Christine Gfrer, IDEX Corporation
Many options are available when pump repair is required.
Figure 1. Companies that replace pumps if repair costs exceed a
certain amount
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Repair Versus Replace
Should an end users AODD or PD pump fail, he may be
inclined to simply replace the unit all together. However, if not
nancially prepared to do that, the end user could consider a
repair versus replace options.
Because a pump is old does not mean it needs to be
replaced. Many pumps are designed to be easily repairable by
experienced pump maintenance personnel. Many pumps have
a functional life of thirty or more years, but pump life is totally
dependent on the application, the pump system and how it is
operated and maintained.
he decision to repair or replace is based primarily on a
cost comparison between the two alternatives, but other fac-
tors also need to be consideredsuch as budgets, maintenance
workload, the application duty and the need for spares on the
shelf. Does an end user include the cost of maintenance labor in
the evaluation? Do end users rebuild on-site, or send pumps out
to be repaired? Do they sell scrap, or have to pay for disposal?
Each facility is dierent. Figures 1, 2 and 3 are results of a
survey of more than 100 industrial pump users, asking at what
level of cost do they repair a pump versus replace it (Figure
1); how they normally do pump repairs, in-house versus out-
side (Figure 2); and their preferences on individual parts versus
repair kits (Figure 3).
Do a facilitys pump maintenance practices and prefer-
ences look like those shown in Figures 1 through 3? he deci-
sion to repair or replace is made on a case-by-case basis, but
with the tools, parts, kits and expertise available from original
manufacturers and local stocking distributors, end users will
nd rebuilding pumps is normally a cost-eective way to keep
processes operating e ciently.
Conveniently Packaged Service Kits
Should an end user make the decision to repair, it is good to
know that some manufacturers now have complete service kits
to save money and time. he kits include all the parts needed to
make a typical pump repair, conveniently packaged. End users
order one part number and receive all the parts for the repair.
hese kits oer the exibility to use one or all of the compo-
nents at the same time. Some companies are making it easy to
quickly identify the specic kits needed by putting this informa-
tion directly on
the pump name
plate.
Wh e t h e r
a genuine part
is needed, an
a f t e r ma r k e t
part is searched
for or perhaps
a conveniently
packaged service
kit to make a
pump repair is
required, many
ma nuf a c t ur -
ers are making
it easier to nd
exactly what is
needed. For more information, end users should contact their
preferred manufacturer or local Distributor.
P&S
Christine Gfrer has been with IDEX
Corporation for four years. She is the global
marketing communications manager for
the Chemical, Food and Pharma group
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O
il and gas industry customers are increasingly
asking original equipment manufacturers (OEMs)
to balance their couplings to ensure that their
equipment runs smoothly. While balancing is intended to
reduce machine vibration, it can be an unnecessary and
costly expense. Manufacturing methods and design toler-
ances usually result in su cient balance so that couplings
meet industry standards without additional balancing
procedures.
API Balance Standards
he oil and gas industry relies on the American Petroleum
Institutes (API) 610 standard as the internationally accepted
set of standards for pumps and associated equipment, such
as couplings, in rotating equipment. he standard, which is
now in its 11th edition, has three key clauses that address
balancing couplings:
OEMs must provide all-metal, exible element, spacer-
type couplings that meet American National Standards
Institute/American Gear Manufacturers Association
(ANSI/AGMA) 9000 Class 9 requirements. (API 610
6.2.2)
Couplings that operate faster than 3,800 revolutions
per minute must meet the International Standards
Organization (ISO) 10441 or API 671 requirements for
component balancing and assembly balance check. (API
610 6.2.2 e)
OEMs must balance couplings to ISO 1940-1 Grade G
6.3 if the customer requests it. (API 610 6.2.3)
he rst clause requires couplings to meet ANSI/
AGMA 9000 Class 9, which states that the couplings center
of rotation must not deviate more than 0.05 millimeters
(0.002 inches) from the rotating axis of the machine to
which it is connected. While OEMs must produce couplings
accurately to achieve this standard, couplings that meet this
specication typically do not require additional balancing.
he second clause states that OEMs must balance
the components in higher-speed applications in compli-
ance with API 671, a mandatory specication that leaves
little room for error. OEMs can use a balancing machine to
achieve this specication. For a standard coupling, the trans-
mission unit and each hub normally have to be balanced to
ISO 1940-1 Grade G 0.66, and the assembly check should
be balanced to ISO 1940-1 Grade G 6.6. High-speed appli-
cations that require this level of balance are often tted with
keyless or two-key precision shaft ends. If the hubs have
standard single keys, balancing the transmission unit should
su ce.
Smooth Equipment
Operation
Peter Carlisle, John Crane
Balancing couplings may not be the ultimate solution for vibration issues.
Maintenance Minders
Couplings you can count on
ENDtoEND Solutions
Our couplings are the irst choice of the majority of the worlds energy suppliers.
For couplings that allow your equipment to perform at its peak, count on John Crane.
he third clause requires
OEMs to balance couplings to
ISO 1940-1 Grade G 6.3 if the
customer species it. Balancing
the transmission unit to ISO
1940-1 Grade G 2.5 results in a
better level of installed balance,
however, particularly with stan-
dard bore and keyed shafts.
Some projects rely on ear-
lier editions of the API 610
standard, particularly the 8th
edition. hat edition includes
a requirement for balancing
all components to ISO 1940-1
Grade G 1.0, which, in prac-
tice, means balancing the trans-
mission unit and both hubs.
his requires that OEMs bal-
ance the hubs before machin-
ing the keyway, wasting time
and resources. Furthermore,
the ANSI/AGMA 9000 Class
9 coupling standard is the only
mandatory requirement in the
latest API standard.
Balancing Hubs with Standard Keyways
he standard steps for balancing hubs with keyways are:
Bore the hub to the correct size
Balance the hub as a component
Machine a keyway into the bore
Because of the key and keyways tolerances, the volume
of material removed above the key varies signicantly, which
also aects the balance of the hub in an average-sized coupling.
As a result, hubs with keyways that technically meet balanc-
ing standards may still cause vibration in the equipment, even
though the goal of balancing is to eliminate vibration. his
means that customers who request coupling balancing accord-
ing to API standards often do not realize any benet.
As an example, the 8th edition of API 610 requires a
14.8-kilogram hub with a 100-millimeter bore installed in a
machine that operates at 3,600 rpm to be balanced in two
planes so that the maximum residual imbalance is less than
19.6 grams-millimeter/plane. he standard then requires a
single keyway to be machined into the coupling hub and for
the hub to be tted to the shaft with a key. Keyway standards
specify a certain amount of clearance over the key. In this
example, the standard key is a 28-millimeter by 16-millime-
ter key, and the permitted mean clearance is 0.65 millimeter.
hus, the missing mass caused by this clearance is 7.76 gm.
he hub is located at a radius of 56.5 millimeter, creating a
potential imbalance of 438 gram-millimeter, or 22 times the
hub balance limit.
his example demonstrates that API balancing standards
ignore the imbalance caused by the key extending beyond the
end of the hub boss, or the eect of the keys rounded ends.
While customers may meet generally accepted API standards by
Figure 1. The keyway has a clearance over the top of the key with a relatively large tolerance.
1.800.SEALING | www.johncrane.com
Packing Support Systems Filtration Systems Bearings Gas Seals Production Solutions Mechanical Seals
Couplings
Maintenance Minders
balancing their couplings, they often do not reduce vibration.
In addition, slip ts can disrupt the balance of a piece
of machinery. Taking the example above, a typical H7/g6 slip
t could result in a total clearance of 0.069 millimeter or an
axis displacement of 0.034 millimeter when the set screws are
tightened. his introduces an imbalance of 500 gram-millime-
ter in a 14.8-kilogram hub. While this is a worst case scenario,
customers could certainly expect an average imbalance of 250
to 300 gram-millimeters, more than 10 times the ISO 1940-1
Grade G 1.0 limit.
If we take this case a step further, here are the potential
repercussions:
Imbalance caused by keyway: 438 gram-millimeters
Imbalance caused by slip t: 500 gram-millimeters
ISO 1940-1 Grade G 1.0 residual imbalance: 39.2 gram-
millimeters (19.6 gram-millimeters x 2)
ANSI/AGMA root mean square (RMS) imbalance: 666
gram-millimeters
If the hub was balanced to ISO 1940-1 Grade G 6.3 (247
gram-millimeter), then the ANSI/AGMA RMS balance would
be 709 gram-millimeters, an increase of 6 percent.
It is evident from the example above that balancing a cou-
pling and then machining in a keyway can cause huge issues
since the clearance over the key has an inevitable eect on the
couplings overall balance. Note that this example also does
not take into account other assembly errors or shaft balancing,
which can create additional balance issues. If equipment has
vibration problems, end users should tackle the true causes of
imbalance by specifying the ANSI/AGMA class and consider-
ing all causes of installed vibration.

Balancing Can Cause Production Delays
In addition to the vibration issues that balancing can cause,
balancing coupling components is an involved and time-con-
suming process. As a result, the balancing process delays the
nal assembly of equipment while providing no added value to
the customer, who is paying for the balancing service.
herefore, customers should consider their couplings spec-
ications carefully before requesting balancing. Specications
are particularly important when couplings operate slower than
3,800 rpm to avoid paying for services
that have no benet.
P&S
Peter Carlisle is
John Crane EAAs
product line director
for couplings. His
work with the com-
pany has included
design, application
and research on the fundamentals
of power transmission couplings,
and he served as group engineering
manager for many years and has also
held roles in sales management and
operations management positions.
He can be reached at +44 161 886
6290 or peter.carlisle@johncrane.
co.uk.
John Crane is a provider of engi-
neered products and services for
major process industries, including
oil and gas extraction and rening,
power generation, chemical produc-
tion, pharmaceutical manufactur-
ing, pulp and paper production and
mining. For more information, visit
www.johncrane.com.
Slip fits can disrupt the
balance of a piece of
machinery.
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TOLL FREE 888-405-0209 Fax 713-956-2141
www.pumpworks610.com
When Quality and Delivery Matter
PumpWorks 610 manufactures centrifugal API 610
pumps for oil and gas exploration and production,
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We make the purchase of your API 610 pump an
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Our pumps are:
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G
rowth and innovation in
industrial pump design and
operation are often driven by
outside forces. A common force is the
creation of a new market. A recent
example relating to new opportuni-
ties for transfer pumps was the U.S.
Environmental Protection Agencys
(EPA) announcement of tougher
emission-control standards for on-
road vehicles would be phased in
from 2007 to 2010.
Specically, all new, on-road
vehicles must meet a tailpipe-emis-
sion standard of 0.2 grams of nitro-
gen oxide (NOx) per brake horse-
power-hour (g/bhp-hr). his is a huge reduction in NOx
and particulate matter that can be legally emitted into the
atmosphere, especially considering that the standard in 1994
was 5.0 g/bhp-hr in 1994 and remained at 1.2 g/bhp-hr as
recently as 2007.
When the manufacturers of diesel-powered vehicles
looked for ways to make their vehicles compliant with these
new regulations, they turned to Europe, where similar mea-
sures had been in place since the early 1990s. One of the
most popular ways to control NOx emissions on European
diesel vehicles was through the use of diesel exhaust uid
(DEF), originally known in Europe as aqueous urea solu-
tion 32 (AUS 32), which is a urea-based chemical reactant
consisting of 32.5 percent urea and 67.5 percent deionized
water that is injected into the vehicles exhaust stream. he
most common process for this injection is called selective
catalytic reduction (SCR), in which the exhaust is turned
into harmless nitrogen and water vapor.
his commitment to the injection of DEFwhich has
been called the largest addition to the motor-vehicle liquids
marketplace in decadesand its role in the SCR process as
the main way for diesel-powered vehicles to meet the EPAs
regulations has opened a new market in the U.S. hough
estimates vary, it is safe to say that the amount of DEF
that will be consumed in the U.S. by the year 2014 will be
between 300 million and 600 million gallons annually.
With the advent of this new market comes the creation
of a new supply chain, one that must be populated with
enough DEF to keep every diesel-powered vehicle on the
road compliant with the EPAs mandate. his article dis-
cusses how advances in DEF-handling pumping technology
and its use at critical points along the supply chain will help
optimize the availability of DEF to end users who rely on it
to keep their diesel-powered eets compliant.
The Challenges of Moving DEF
When new motor-vehicle liquid enters the marketplace, the
companies that develop equipment to produce and handle it
must identify the liquids characteristics. DEF has a number
of unique characteristics to consider:
Because of its water content, DEF freezes below 12
degrees F (-11 degrees C), meaning it must be protected
from extreme cold during storage.
When DEF freezes, it goes from a liquid state directly to
a solid with no intermediate slushiness stage.
DEF can freeze and thaw with no resulting degradation
of the urea solution.
Efciency Matters
The DEF Market
F. Scott Jackson, Blackmer
The diesel exhaust uid market creates opportunities for pump manufacturers.
It is stable at storage temperatures up to 84 degrees F (29 degrees C). Exposing
DEF to heat above 90 degrees F (32 degrees C) will decrease its useable shelf
life.
When exposed to air, the water in DEF evaporates and produces crystal-
lized urea, which can harm the vehicles SCR unit and any transfer or pump
components.
DEF must not become contaminated during its handling. If it does, the SCR
system can be compromised, which could lead to problems such as engine
failure.
For pump manufacturers, the most important of DEFs characteristics is its
incompatibility with a number of materials that are commonly used in the auto-
motive liquid supply chainsuch as aluminum, bronze, carbon steel, copper, iron,
nickel and zinc. However, stainless steel, polytetrauoroethylene (PTFE), uoro-
carbon and composite plastics such as polyethylene or PVC are compatible with
DEFs corrosive properties.
Selective Catalytic Reduction Dened
S
elective catalytic reduction (SCR) was originally developed in Europe as a
way to reduce emissions in power plants and utilities. In the 1990s, German
automotive giant Daimler AG became the rst automotive company to use
SCR technology in mobile applications for the control of emissions from light-,
medium- and heavy-duty diesel vehicles.
In an SCR system, diesel exhaust uid (DEF)urea and puried water
combines with engine exhaust in the presence of a catalyst to convert nitrous
oxide (NOx) to harmless nitrogen and water vapor.
he actual SCR process begins when hot diesel exhaust from the engine
ows through a diesel particulate lter toward the SCR system. At this point, the
DEF is injected into the exhaust stream, which enters the SCR chamber. In the
presence of the SCR catalyst, the exhaust and DEF solution react to convert the
NOx into nitrogen and water vapor. his process has been shown to reduce NOx
emissions by up to 90 percent, while lowering particulate emissions by more than
95 percent.
Since even small amounts of impurities can severely damage the performance
of a vehicles SCR system, high-purity water must be used, which will make the
DEF in compliance with its ISO 22241 production standards. DEF impurities
must also be avoided at all points along the supply chain, which necessitates the
need for pumping technology that can adequately clear lines, an advantage of
sliding vane pumps.
1461 Ford Street, Suite 205
Redlands, CA 92373
Tel: 909-512-1257
Fax: 909-798-1879
info@pumpsg.com
pumpsg.com
Constructed of 316 stainless
steel and ISO 22241-3 compliant,
Blackmer sliding vane pumps
for DEF are fast, reliable
and high-performance.
www.blackmer.com
+1 (616) 241-1611
STX Series
DEF-Compliant
Transfer Pumps
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Efciency Matters
Another major consideration for the DEF-handling pump
manufacturers is becoming familiar with the points along the
supply chain at which pumping equipment is necessary. As
the U.S. DEF market grows and matures, the production and
supply processes and the roles of pumps in them, are becoming
more well-dened:
Tanker trucks and railcars deliver urea and deionzied water
to chemical plants where the components are blended to
create DEF.
he newly produced DEF is transported by truck or railcar
to a terminal storage facility.
At the storage terminal, the DEF is pumped into packages,
generally some combination of 330-gallon intermediate
bulk container (IBC) tote, 55-gallon drums and two-gallon
bottles.
hese packages are delivered to retail fueling centers, auto-
motive-product retailers and maintenance-repair shops.
In some cases, DEF is transported via tanker truck to retail
fueling sites (most commonly at large truck stops) where
it is transferred into DEF dispensers that are similar to
gasoline/diesel pumps and is available for purchase by the
public.
Optimizing DEF Handling
Two crucial pressure points in the supply chain for transfer
pumps are from the production plant to the storage terminal
and when the DEF is transferred at the terminal location into
packages. To aid the DEF producer, transporter and packager,
a series of positive displacement sliding vane pumps has been
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created that not only meets DEFs product-handling needs but
has also been designed to be materially compatible with its cor-
rosive nature. Additionally, they oer energy-e cient opera-
tion that will help keep energy costs under control.
hese pumps are also designed and manufactured to meet
ISO standard 22241-3:2008, Diesel Engines: NOx reduction
agent AUS32. hey will meet or exceed that specication,
which includes recommended and not recommended materi-
als of construction. he 22241-3:2008 standard also commu-
nicates the level of cleanliness for wetted surfaces that contact
DEF during the transfer process to avoid contamination.
When DEF is taken from the production plant to the
storage terminal, it is generally by railcar, which can transport
from 10,000 to 15,000 gallons (37,854-56,781
liters) of DEF, or transport truck, which can
carry loads ranging from 6,000 to 8,000 gal-
lons (22,713-30,283 liters). At the terminal,
the DEF must be o oaded quickly, at rates
up to 250 gallons per minute (947 liters per
minute).
he 3-inch pump can deliver ow rates up
to 250 gallons per minute at speeds of 800 rpm
and dierential pressures up to 125 psi (8.6
bar). his means that a 6,000-gallon transport
truck can be unloaded in as little as 24 min-
utes. he pumps sliding-vane operation also
makes it better for these types of applications than centrifugal-
pump technology because the design allows it to easily prime
and pull a vacuum, which centrifugal pumps have a harder
time doing, especially when dealing with piping congura-
tions that have a restricted inlet or long runs. he pump is also
constructed of stainless steel.
When considering DEF transfer from storage tanks into
IBC totes, drums and jugs, one series of sliding vane pumps
with no pushrods can run at speeds up to 1,200 rpm and can
deliver ow rates from 49 to 92 gallons per minute (186-348
liters per minute). Some diesel haulers are also dedicating a
storage compartment on their straight delivery trucks for DEF
Stay Connected with
on
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Efciency Matters
and mounting pumps on them so that they can deliver a load
of DEF to a fueling site when they make a fuel delivery.
Another pump for the DEF-handling market is a 2-inch
pump that will be similar to the 3-inch, with one notable
exception: it is designed with pushrods so that it can run at
slower speeds, making it ideal for package-lling operations
that require ow rates between 25 and 30 gallons per minute
(95 to 114 liters per minute). he design of the pump also
means that it can be used with higher-viscosity uids, which
opens it up for use in other non-DEF markets.
All the DEF pump models can be powered by a base-
mounted electric drive, diesel motor, truck-mounted power
take-o (PTO) or hydraulic drive, and they are equipped with
a double-ended, straight-keyed drive shaft that allows either
clockwise or counterclockwise rotation.
A Look to the Future
hough the exact size of the DEF market in the U.S. in
future years is impossible to predict, theres no question that
the EPAs emission-control regulations, combined with most
diesel-vehicle manufacturers choosing SCR as the best way to
satisfy those regulations, leave no doubt that the DEF market
will continue to grow. Playing a pivotal role in this growth are
the pumps that will be used to deliver raw materials, transfer
nished products to storage locations and ll packages for
eventual use by the end user.
Recognizing the potential in this new market, pumps that
are needed at all points in the DEF production-and-supply
chain. he qualities of the sliding-vane operating principle
help create transfer pumps that are not only compatible with
DEFs unique characteristics but able to operate in a way that
is both energy-e cient and cost-eective for the end user.
P&S
F. Scott Jackson is the product manager,
Americas, for Blackmer. He can be reached
at scott.jackson@blackmer.com or 616-248-
9218. For more information on Blackmer,
please go to www.blackmer.com. Blackmer
is a member of Dover Corporations Pump
Solutions Group (PSG) which is comprised
of several pump companiesAlmatec, Blackmer, EnviroGear,
Griswold, Mouvex, Neptune, RedScrew and Wilden. For more
information go to PSG at www.pumpsg.com.
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M
anufacturers and distributors of PTFE gaskets are
being asked more frequently why PTFE gaskets
do not seal berglass reinforced plastic (FRP),
plastic and other light load anges. he answer is simple, but
the solution is complex. In a majority of cases, the answer is
that too little load is applied to the gasket. Unfortunately,
and as is the case in many such instances, the gasket is usually
considered the problem (see Sealing Sense, January 2008).
However, when other contributing factors are consid-
ered, the gasket carries little blame. his problem must be
considered at two stages. First is the original design of the
equipment, and the second is how to deal with the equip-
ment during installation and maintenance.
Legacy Gaskets
Originally, FRP and plastic piping evolved in the process
industry due to their low cost and excellent chemical resis-
tance. However, neither material approaches the strength of
metallic piping. herefore, ange strength limits the amount
of bolt torque that can be applied, which then limits the
gasket stress. Primarily, the gasket materials used then and
now are elastomers, which have good recovery properties and
seal at relatively low loads, often with as little as 15 percent
compression. However, due to the limited chemical compat-
ibility of each elastomer, the selection of the proper elasto-
mer must be made carefully. When this problem was com-
pounded with the dierent elastomers often being the same
color, improper gasket installations were all too frequent.
Current Gasket Concerns
In todays chemical process plants, more exotic chemicals
used at higher temperatures and pressures sometimes demand
a shift from elastomers to a more chemically inert gasket.
PTFE is the logical next choice as it is chemically compatible
with all common aggressive chemicals within the pH range
of 0 to 14except molten alkali metals and elemental uo-
rine (especially at higher temperatures and pressures).
Prevailing Standard
As with metallic piping, most FRP and plastic piping manufac-
turers follow ASME standards. ASMEs updated Reinforced
hermoset Plastic Corrosion-Resistant Equipment Standard
RTP-1-2011 for vessels operating at pressures not exceed-
ing 15 psig teaches the proper practices for design. Non-
mandatory Appendix NM-9 Installation of RTP Vessels
gives guidelines for gaskets, fasteners, torque, lubrication and
other factors related to the success of a bolted ange connec-
tion. While not mandatory, most in the industry use these
guidelines when discussing gaskets for equipment.
Load Requirements
While some gasket designs seal at lower loads, most PTFE
gasket manufacturers set minimum loads (from 2,500 psi to
3,000 psi) for their materials. However, the lower application
pressures and temperatures typical of FRP and plastic piping
may lower such requirements. Figure NM9-3 from Standard
RTP-1-2011 provides the recommended torque and bolt-up
procedure for standard RTP anges and manways.
Table 1 shows the resultant gasket stress when the
Why dont my PTFE gaskets seal FRP, plastic and other light load anges?
This months Sealing Sense was prepared by FSA member Charlie Miskell
From the voice of the uid sealing industry
SEALING SENSE
Figure NM9-3. Flange Bolt Tightening
Reprinted from ASME RTP-1-2011, by permission of The American Society of
Mechanical Engineers. All rights reserved.
suggested torque (Figure NM9-3) is used. Obviously, the
resulting gasket loads are well below the minimum threshold
necessary to seal with a PTFE-based gasket.
Table 2 shows additional specic RTP details that may
aect the load delivered to a gasket material in these anges.
he third column (added for this article) indicates some sug-
gested improvements needed for better PTFE gasket results.
However, at this time, no suitable answer is available for
Table 1. Flange Conguration and Achievable Gasket Stress for Class 150 Bolting per ASME RTP-1-2011
NPS (in.) ID (in.) OD (in.) BCD (in.) BHD (in.) BD (in.) Number
of Bolts
Torque
(ft.-lb.)
Gasket
Area (in
2
)
Nut
Factor
Gasket
Stress (psi)
2 2.00 6.00 4.75 0.750 0.625 4 25 23.37 0.15 548
3 3.00 7.50 6.00 0.750 0.625 4 25 35.34 0.15 362
4 4.00 9.00 7.50 0.750 0.625 8 25 47.52 0.15 539
6 6.00 11.00 9.50 0.875 0.750 8 25 61.95 0.15 344
8 8.00 13.50 11.75 0.875 0.750 8 25 88.06 0.15 242
10 10.00 16.00 14.25 1.000 0.875 12 25 113.10 0.15 243
12 12.00 19.00 17.00 1.000 0.875 12 25 161.01 0.15 170
14 14.00 21.00 18.75 1.125 1.000 12 30 180.49 0.15 160
16 16.00 23.50 21.25 1.125 1.000 16 30 216.77 0.15 177
18 18.00 25.00 22.75 1.250 1.125 16 35 216.77 0.15 184
20 20.00 27.50 25.00 1.250 1.125 20 35 255.26 0.15 195
24 24.00 32.00 29.50 1.375 1.250 20 40 322.16 0.15 159
Manways
24 24.00 32.50 29.50 0.750 0.625 20 25 368.35 0.15 174
Reprinted from ASME RTP-1-2011, by permission of he American Society of Mechanical Engineers. All rights reserved.
HN 8-WD: Leak-tightness is critical for hydraulic
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leak-tightness with long-term benets!
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FSA Sealing Sense
this dilemma. If the vessel or piping will use PTFE gaskets
instead of elastomers, these gaskets have little chance of work-
ing unless the recommended guidelines are changed. his is the
main reason that end users experience gasket problems. here
are two stages of this issue. In defense of the equipment manu-
facturers, they are able to increase the ange load capability of
equipment to allow torques that provide the required stress.
However, they have to make these changes in the design stages
before quoting the equipment. Most manufacturers will make
the appropriate adjustments to lessen this complaint.
Even when torque is increased to a level that should pro-
vide the proper gasket load, many additional issues may prevent
the proper load. Since end users deal with very low loads, any
factor that minimizes the required load on the gasket is signi-
cant. Factors that can aect load include:
Misalignment, both axial and angular
Lubrication and a correct value of the lubrication friction
factor (nut factor)
Quality and grade of the fasteners
Use of used fasteners
Accuracy of the torque wrench used
Any of these factors can determine if the end user will have
a successfully sealed bolted ange connection. herefore, end
users and their installers must understand these factors and
eliminate inuences that may prevent a true, target gasket.
Suggestions and Solutions
When leakage is experienced, the usual rst response in the
eld is applying more torque until the leak is reduced. Usually,
this does not cause immediate or catastrophic cracking of the
anges but puts high stresses on the anged connection, but it
could cause cracking. FRP piping is extremely alive and with
its constant motion, vibration, contraction and expansion, the
probable result of overstressing the ange is to cause premature
joint failure and shortened equipment life.
Table 2. ASME RTP-1-2011 Non-Mandatory Installation Guidelines
ASME RTP-1-2011 Non-Mandatory Appendix NM-9 Installation of RTP Vessels Gasket Related Details
(for vessels operating at pressures under 15 psig (approximately 30 psi)
Gasket Related Issue RTP Call-Out What is missing? What is the problem created for
PTFE gaskets?
Recommended bolt torques for hand
lay-up anges
See the list in Figure NM9-3 Recommended torque results in gasket loads well below
material requirements.
Gasket conguration Full faced, in cases where a raised face ange
mates with a at faced ange, a machined at
ller ring for the OD is required to provide a
quasi-full faced gasket surface.
Flat faced anges have large surface areas over which
limited gasket load is applied. Non-standard anges (top
lids, column segments) tend to have extremely wide
contact areas that increase the required torque even
more.
Gasket thickness Minimum 1/8 in. thickness Good feature, no problem. Some non-standard anges
may require thicker material to compensate for surface
deection problems.
Gasket material hardness Not to exceed 65 durometer (Shore A).
Generally, in PTFE gasket materials, this is not
a property of interest. Specic gravity or den-
sity in grams per cubic centimeter is frequently
called out instead.
PTFE materials are much harder even when they feel
soft.
Use of washers Metal washers to be used under all bolt heads
and nuts to avoid fastener contact with FRP
surfaces.
Washers should be dened as hardened through to
prevent cupping and poor surface contact and to more
evenly distribute the load to the gasket.
Bolt and washer seating area Spot facing, this is a slight countersink area
into the FRP contact surface to assure parallel-
ism to the ange face.
Good feature, no problem.
Lubrication Nut and bolt threads should be lubricated
before tightening.
All bearing surfaces should also be lubricated (under
the bolt head and washer contact area), and nut factor
should be dened. The problem created with poor or
incomplete lubrication is that not all the intended torque
is transmitted to gasket stress.
Installation bolting practice Bolt up torque to be applied uniformly per
cross torque patterns shown in Figure NM9-3
and in 5 foot pound increments.
Good Feature, no problem. Lower load requirements may
need to designate increments lower than 5 foot pounds.
Maximum gasket stress Resulting stresses are far too low to effectively
seal the anges.
Depending on the exibility of the vessel/piping manu-
facturer to allow higher torques, these may be suitable.
Reprinted from ASME RTP-1-2011, by permission of he American Society of Mechanical Engineers. All rights reserved.
If an end user experiences problems, the best advice is to
do everything possible to improve the delivered torque and
the alignment of the ange so that the intended gasket stress
is achieved. Use new bolts each time the joint is broken apart.
Lubricate all the bearing surfaces including the washers, under
the head of the bolt, the bolt face and the threads themselves.
Use an accurate and calibrated torque wrench, and follow the
torque steps recommended in RTP-1-2011 in 5 foot-pound
increments. In the case of very low torques, use 25 percent, 50
percent, 75 percent and 100 percent of target torque as a guide-
line. After the nal circumferential torque, wait at least four
hours, and do one more circumferential torque to 100 percent.
Think Ahead
An equipment manufacturer should think about the gasket
before completing the design of the equipment! If the gasket
will be PTFE or if the equipment may require PTFE, manufac-
turers must compensate beyond the recommendations of RTP-
1-2011. Not doing so may result in bolted ange connection
failure or premature stress fatigue due to a frustrated end user
applying more torque than necessary. FSA gasket manufactur-
ers can help resolve these and other gasket problems.
Next Month: What properties are most important when select-
ing an expansion joint or exible connector?
We invite your questions on sealing issues and will provide best
eort answers based on FSA publications. Please direct your ques-
tions to: sealingsensequestions@uidsealing.com.
P&S
he following members of the Gasket division sponsor this
Sealing Sense:
American Falcon, Inc.
John Crane
he Asbury Graphite Mills, Inc.
Latty International S.A.
Chicago-Wilcox Mfg. Co.
Leader Global Technologies
A.W. Chesterton
Lamons
Daikin America, Inc.
Nippon Pillar Corp. of America
Nippon Pillar Corp. of
America
Donit Tesnit d.d.
SGL Technic Polycarbon
Division SGL Technic
Polycarbon Division
EGC Enterprises, Inc.
Slade, Inc.
Empak Spirotallic Mexicana SA
de CV
Teadit International Simrit -
Div. of Freudenberg-NOK
EGC Enterprises, Inc.he
Flexitallic Group
Teijin Aramid USA, Inc.
he Flexitallic Group
Slade, Inc.
Garlock Sealing Technologies
hermoseal Inc.
Teadit International
W.L. Gore & Associates, Inc.
Triangle Fluid Controls, Ltd.
GrafTech International
Holdings, Inc.
YMT/Inertech, Inc.Teijin
Aramid USA, Inc.
Q. We plan to purchase several slurry pumps and understand
that this service is considered severe duty. What guide-
lines should be followed regarding pump selection based
on good wear resistance?
A. Pump wear is aected by the pump design, the abrasive
nature of the slurry, the specics of the application or duty con-
ditions, the way in which the pump is applied or selected for
the duty and the actual conditions of service. Wear inside the
pump varies signicantly depending on the velocity, concentra-
tion and impact angle of the particles. It is normally most severe
in the impeller seal face area of the suction liner, followed by
the vane inlet and exit. he casing wear amount and location
also vary with the shape of the collector and as a percentage of
the actual operating conditions compared to the best e ciency
point ow.
With only routine maintenance, many slurry pump
wear parts may last for years. Services, such as transportation
of high concentrations and very abrasive or large solids, can
sometimes reduce a parts life to several months. Larger pumps
with thicker sections, more wear material and slower operating
speeds can improve life in all applications, although the signi-
cant associated product cost increase may not be warranted in
certain cases.
Analytical and numerical models are available for making
qualitative predictions of wear. heir limitations and the vari-
ability of slurry service are such that wetted component life
prediction is still only good for estimation and should not be
used for guarantees. hese estimates are normally based on the
specied operating condition of the pump and may vary greatly
if the pump is operated under signicantly dierent conditions.
Using such an analysis, a life-cycle cost (LCC) evaluation of the
capital, power, wear and other costs associated with the pump
operation can be used to estimate the best balance between dif-
ferent pump designs. Such analysis is largely theoretical, how-
ever, as wear can be unpredictable in actual service.
Ranking the slurry into light (class 1), medium (class
2), heavy (class 3) and very heavy (class 4) services, as
shown in Figure 12.3.4.2a, provides a practical tool for
pump selection and, in conjunction with Table 12.3.5a, a
means of recommending limiting pump operating heads.
he boundary lines between the service class areas
in the chart approximate limits of constant wear modi-
ed for practical considerations and experience. Capital
and operating cost considerations are such that dierent
(higher specic speed) designs may be employed for the
lighter service classes.
he slurry service ranking shown in Figure 12.3.4.2a
is based on aqueous slurries of silica-based solids pump-
ing (Ss = 2.65). It can also be used to provide guidance
for mineral slurries if an equivalent specic gravity for the
mineral slurry is used to determine the service class.
Additional information regarding slurry pumps
can be found in ANSI/HI 12.1-12.6, Rotodynamic
(Centrifugal) Slurry Pumps for Nomenclature, Denitions,
Applications, and Operation, which is available at www.
Pumps.org.
Q. Besides the obvious nancial benets derived from energy
savings, what are the other important economic benets
of pump system optimization that aect the total cost of
ownership?
A. When conducting a pump system optimization analysis, it
is essential to look beyond the energy savings to capture the less
apparent economic factors that can have a positive eect on the
bottom line. Plant and corporate managers incentives are typi-
PUMP
FAQs
Figure 12.3.4.2a Service class chart for slurry pump erosive wear
cally to minimize initial costs as a means to increase company
prots when considering the investment of capital funds.
Decision makers historically have been more attuned to
investing in projects that translate directly to the bottom line,
such as capacity expansion versus lowering energy demand.
Most energy e ciency projects have additional economic ben-
ets that are overlooked, including the following:
Higher productivity and product quality
Higher reliability and lower maintenance
Better environmental compliance
Reduced waste byproducts
Increased capacity and throughput
Improved worker safety
It is widely recognized that energy e ciency projects
stand a better chance of being funded if their ancillary benets
have been taken into consideration. Another way of looking at
these projects is to consider the energy savings, which are often
easier to identify, as nancial justication for more appealing
improvements, such as increased equipment reliability or better
process management. herefore, it is important to identify the
savings opportunities associated with all LCC elements to help
decision makers move forward with projects classied as energy
e ciency.
Q. What dierent types of couplings can be used on pumps,
and what are their functions?
A. he main function of pump couplings is to provide a
mechanically exible connection between two in-line shaft
ends. Essentially, couplings join two pieces of rotating equip-
ment. heir function is to transmit power while allowing some
degree of misalignment or end movement.
hree basic types of couplings are: mechanical, elastomeric
and metallic. he mechanical element types generally obtain
their exibility from a combination of loose-tting parts and
the rolling or sliding of mating parts. hey typically require
lubrication unless one moving part is made of a material that
provides its own lubrication.
he elastomeric element types obtain their exibility from
the stretching or compression of the material. Metallic element
types obtain their ability to withstand misalignment and expan-
sion from the exing of thin metallic discs or diaphragms.
he type of pump couplings that should be used is related
to the power required by the pump. A small pump can be
considered a pump under 100 horsepower. Since these pumps
require a relatively low power input, they are able to use cou-
plings where the exible element can easily be inspected and
replaced when necessary.
If there is a coupling failure due to high-torque loads
or excessive misalignment, the ex element of the coupling
normally is replaced. However, typically no damage occurs
to other components. Types of couplings for smaller pumps
include exible grid, disc and elastomeric. In some small gear
coupling designs, no lubrication is need because the outer
sleeve is made of nylon or plastic.
Medium-power pumps use exible grid, gear, disc and
elastomeric type couplings. hese couplings will exhibit
good longevity, with premature failure occurring only when
improper application or installation, lack of proper lubrication
or excessive misalignment is a factor. Elastomeric couplings are
used frequently for applications in which very high cyclic peaks
occur since they minimize torsional loads on the equipment.
High-horsepower pumps are essential to ensure continu-
ous operation at most facilities, and therefore, the selection and
installation of their couplings are critical. For high-speed, high-
torque applications, high-performance gear, disc or diaphragm
couplings are frequently specied by the user.
he couplings are highly engineered designs that are man-
ufactured and balanced specically for the application. Many of
these couplings use special alloy materials and fasteners.
P&S
Pump FAQs is produced by the Hydraulic Institute as
a service to pump users, contractors, distributors, reps and
OEMs as a means of ensuring a healthy dialogue on subjects
of common technical concern.
HI standards are adopted in the public interest and are
designed to help eliminate misunderstandings between the
manufacturer, the purchaser and/or the user and to assist the
purchaser in selecting and obtaining the proper product for
a particular need.
As an ANSI approved standards developing organiza-
tion, the Hydraulic Institute, process of developing new stan-
dards or updating current standards requires balanced input
from all members of the pump community.
We invite questions and will endeavor to pro-
vide answers based on existing HI standards and
technical guidelines. Please direct your inquiries to:
pumpquestions@pumps.org.
For more information about HI, its publications,
Pump LCC Guide, Energy Saving Video-based educa-
tion program and standards, please visit: www.pumps.
org. Also, visit the new e-learning portal with a compre-
hensive course on Centrifugal Pumps: Fundamentals,
Design and Applications, which can be found at:
www.pumplearning.org.
On pump-zone.com
Read our archive of HI Pump FAQs articles.
Regenerative Turbine Pump
Corken introduces the model 060
regenerative turbine Coro-Flo
pump. It is a continuous-duty
design and is available with two
mounting optionsframe mount for
direct, belt drive congurations or a
direct mount that bolts to a standard
C-Face 60 Hz (3450 rpm) motor. he
ow range is 7 to 22 gallons per minute
(26.5 to 83.3 liters per minute) with a maximum dieren-
tial pressure of 150 psig (10.3 bar) at 60 Hz.
Circle 201 or go to psfreeinfo.com
Snap-In I/O
Known for its programmable logic con-
trollers with integrated HMIs, Unitronics
introduces the latest member of its
Snap-in I/O Module series: the V200-18-
E46B. his new module brings more ex-
ibility to the Vision series controllers by
supporting more I/O, all in one low cost unit. he PLC +
HMI package exempts machine manufacturers from setting
up Panel-PLC communication.
Immersible Wastewater Pumps
Smith & Loveless introduces its
I-Series Immersible Wastewater
Pumps with premium e ciency
motors, oering wastewater pump-
ing with emergency ood protec-
tion. Available for new and retrot
applications in lift stations and
treatment plant operations, these heavy-duty pumps can be
immersed for up to two weeks in ooding conditions and
have capacities up to 5,000 gallons per minute.
Actuator Control System
Rotork Fluid Systems oers a
new actuator package designed
for dependable actuator control
of pump control valves. he
system protects discharge pumps and piping systems from
reverse ow and water hammer. It has a specially designed
hydraulic manifold, which eliminates control circuit piping
and potential leak points. he manifold block includes
speed controls for open, close and emergency shutdown and
a hydraulic solenoid control valve.
Product Pipeline
Pump Systems Optimization:
Energy Efciency & Bottom-Line Savings
PumpSystemsMatter.org/Training 973.267.9700 x200
TRAIN: your customers, distributors and staff by hosting a one-day
course at your desired location and date. Hosting provides opportuni-
ties for suppliers and users to learn and network together for systems
savings. Turnkey package includes instructor and up to 25 sets of par-
ticipant guides, text books and more. Please call to learn more about
pricing and participant reimbursement programs.
Knowledge = Savings
2
Average Pump Systems
Efciency of 1,690 Pumps
31 Pumping
System Assessments
Professional Development
$5 Million Savings
Participants Earn
7 PDH Credits
Less than 40%
UNMATCHAB L E E XP E RI E NCE
I N P RI VATE COMPANY
TRANS ACTI ONS
MEMBER FINRA, SIPC
Jordan, Knauff & Company is a knowledgeable and
experienced provider of a comprehensive line of
investment banking services to the pump, valve and
ltration industries (Flow Control).
Our lines of business include: selling companies,
raising debt and equity capital, and assistance
on acquisitions.
To learn more about Jordan, Knauff & Company,
contact any member of our Flow Control
team. Access our Flow Control research at
www.jordanknauff.com/owcontrol.
G. Cook Jordan, Jr.
Managing Principal
cj@jordanknauff.com
312.254.5901
David A. Kakareka
Associate
dkakareka@jordanknauff.com
312.254.5907
[ MOTOR TRUTH #3 ]
The savings
dont add up!
Putting a premium efcient motor
onto a single stage worm gear unit
does not compute! Its because
the motor is only one part of the
equation.
Why gain 3% energy with a
premium efcient motor and then
lose up to 50% or more through the
worm gear?
Visit sewmotortruth.com to get
the whole story on energy-efcient
drivetrains.
sewmotortruth.com
?
Product Pipeline
Pressure Sensor with New TERPS
Technology
GEs Trench Etched
Resonant Pressure
(TERPS) technology is
now available for the rst time in a range of new pressure sen-
sors from the sensing business of GE Energy, Measurement &
Control Solutions. he RPS 8000 and the DPS 8000 resonant
silicon pressure sensors oer accuracy and stability greater by
a factor of ten over existing piezoresistive pressure sensors and
signicantly extend the pressure range capability conventionally
associated with resonating pressure technology (RPT) sensors.
Thermostatic Expansion Valves
Danfoss announces that the
universal TR6 thermostatic
expansion valve is available in
seven models that cover original
equipment manufacturer (OEM)
air-conditioner and heat pump
designs in a wide range of applica-
tions, from 1.5 to six tons in R-22 and R-410A systems. All
aftermarket TR6 valves have -inch by -inch connections and
come with Aeroquip and Chatle ttings, meaning they easily
install into almost any residential air conditioning system.
Heavy-Duty Air Cylinder
Air Engineering and
Supply announces the
manufacture and national
distribution of the widely
used 1.12-inch bore and
up to 20-inch standard
stroke with longer strokes available upon request. hese are
the popular and widely used double acting 18D and 18SD
models available in both stud and universal mounts. Both are
1.12-inch bore models and feature nitrile seals rated for 180
degrees F and 150 psi max.
To have a product considered for Product Pipeline, please send
information to Lori Ditoro at Pumps & Systems, P.O. Box
530067, Birmingham, AL 35253, 205-314-8269, lditoro@
cahabamedia.com.
P&S
Advanced Engineered Pump, Inc. 148 70
Advanced Sealing International (ASI) 114 27
Amtech Drives 115 29
Baldor Electric Company 101 49
Blue-White Industries 116 17
Carver Pump Company 117 11
Conhagen 138 58
Dan Bolen & Associates, LLC 149 70
Dickow Pump Company 118 21
Flexitallic 102 47
Flexitallic 150 69
Frost & Sullivan 139 63
FW Murphy 119 9
Garlock Sealing Technologies 103 5
General Polygon Systems Inc. 140 63
Global Pump 104 53
Graco, Inc. 131 37
Graphite Metallizing Corp. 141 56
Heinrichs USA LLC 142 61
Hitachi America Ltd. 132 36
Hydraulic Institute 143 66
Hydro, Inc. 100 IFC-1
Inpro/Seal 121 13
International Products Corporation 152 70
ITT Process 105 23
John Crane 122 50-51
Jordan, Knauff & Company 144 66
Junty Industries, Ltd. 153 71
KSB, Inc. 106 33
Liquid Controls Group 133 45
Liquilo 107 59
Littelfuse 108 BC
Load Controls, Inc. 123 43
LobePro 151 71
LUDECA Inc. 145 61
Magnatex Pumps, Inc. 154 69
MasterBond Inc. 155 69
Meltric Corporation 156 71
Munilo 163 69
NETZSCH 146 56
NOC 157 68
PCM USA, Inc. 134 37
PPC Mechanical Seals 124 32
Pump Pros 135 57
Pump Solutions Group 136 55
Pumping Machinery 158 71
PumpWorks 610 137 52
R+W Coupling Technology 125 31
Ruthman Companies/Gusher Pumps 160 15
Scenic Precise Element Inc. 159 71
seepex, Inc. 126 22
SEPCO 127 10
SEPCO 164 70
SERFILCO, Ltd. 147 58
SEW EURODRIVE 109 67
Sims Pump Co. 110 25
Sims Pump Co. 110 69
Smith & Loveless 128 41
Summit Pump, Inc. 161 69
TECO-Westinghouse 111 39
Trachte, USA 162 70
Tuf-Lok International 166 70
Varisco 167 71
Vaughan 112 IBC
Vertilo 165 70
Vesco 168 70
Viking Pump 120 24
Warren Rupp, Inc. 129 14
Waukesha Bearings 130 38
Xylem 113 3
* Ad index is furnished as a courtesy and no responsibility
is assumed for incorrect information.
Advertiser Name R.S. # Page Advertiser Name R.S. # Page Advertiser Name R.S. # Page
INDEX OF ADVERTISERS
PUMP USE RS MARKETPL ACE
Hackensack, NJ 07601 USA
+1.201.343.8983 main@masterbond.com
www.masterbond.com
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P&S Market
P&S Market
T
he Jordan, Knau & Company (JKC) Valve
Stock Index was down 12.5 percent for 2011,
well below the broader S&P 500 Index, down
only 1.1 percent. he JKC Pump Stock Index was also
down 19.2 percent. Both indices kept pace with the
S&P 500 during the beginning of the year and then fell
behind during the last ve months of 2011.
he U.S. manufacturing sector continues to record
modest gains. he Institute for Supply Managements
Purchasing Managers Index (PMI) rose to 53.9 in
December from 52.7 in November. Production and
employment came in at 59.9 and 55.1, respectively. Ten
industries reported production gains in Decemberincluding
primary metals, machinery, electrical equipment and comput-
ers. Export orders were up, suggesting less risk due to European
debt worries. he New Orders Index increased 0.9 points to
57.6, a third month of growth after three months of contrac-
tion. Raw material prices decreased for the third month.
he latest National Association of Manufacturers (NAM)/
IndustryWeek Survey of Manufacturers suggests that manu-
facturers are more condent in the economy80.2 percent
recorded a positive outlook, up from Septembers 65.4 percent.
More than 72 percent of NAM members expect sales to increase
over the next 12 months. About half expect 5 percent growth,
and one out of ve predicts growth will exceed 10 percent.
he Conference Boards Consumer Condence Index
jumped to its highest level since April 2011, from 55.2 in
November to 64.5 in December. Of the components that make
up this index, perceptions about the current and future eco-
nomic environment improved.
he Bureau of Labor Statistics reported that the economy
added 200,000 jobs in December. he unemployment rate
dropped to 8.5 percent, its lowest level since February 2009.
Job gains occurred in transportation and warehousing, retail
trade, manufacturing, health care and mining. Manufacturing
employment expanded by 23,000.
Absent a signicant oil supply disruption, the U.S. Energy
Information Administration expects the recent tightening of
world oil markets to moderate in 2012 then resume in 2013.
World oil consumption grew an estimated 1 million barrels
per day (BPD) in 2011 to 88.1 million BPD. his growth is
expected to accelerate during the next two years with consump-
tion reaching 89.4 million BPD in 2012 and 90.9 million BPD
in 2013. U.S. rig counts increased during 2011, with 2,003 rigs
in operation in December. Worldwide rig counts were 3,612 in
December with an average of 3,466 rigs in operation in 2011.
P&S
Wall Street Pump and
Valve Industry Watch
Jordan, Knauff & Company
Jordan, Knau & Company is an investment bank based in
Chicago, Ill., that provides merger and acquisition advisory
services to the pump, valve and ltration industries. Please
visit www.jordanknau.com for further information.
Figure 2. U.S. Energy Consumption and Rig Counts
Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates. he
JKC Pump and Valve Stock Indices include a select list of publicly-traded companies involved in the pump
and valve industries weighted by market capitalization.
Source: U.S. Energy Information Administration and Baker Hughes Inc.
Figure 3. U.S. PMI Index and Manufacturing Shipments
Source: Institute for Supply Management Manufacturing Report on Business and U.S.
Census Bureau.
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Figure 1. Stock Indices from January 1 to December 31, 2011
0
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The Magazine for Pump Users Worldwide February 2012

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