AU G U S T 2 0 19

SYSTEMS
PUMPSANDSYSTEMS.COM

The Leading Resource for Pump Users Worldwide

Strategies
to Strengthen
Your System
Managing risks and minimizing
environmental impact.

THE MIDDLE EAST’S

IIOT ADOPTION
CURVE

HOW BEP
AFFECTS RELIABILITY

PLUS: TPS
2019 PREVIEW
Thanks
for 50 years.

Independent. Experienced. Trusted.

Here’s to another 50 years of uptime.

Hydro's story began in a Chicago neighborhood in 1969. From the beginning, our vision was to be a full service pump
house supporting customers with new pumps, replacement parts and a broad range of repair, field service and
advanced engineering services. We began with a passion for improvement, and a commitment to our customers.

Today, with dedicated aftermarket pump service centers across the globe, Hydro maintains this vision and
continues to build a comprehensive knowledge base in applying, rebuilding, and improving pumps for better
performance and longer life.

Our passion for improvement and commitment to our customers is as strong today as it was in 1969.

Thank you for being part of Hydro's story.

 "Over the past 50 years, we have been very fortunate to have the support
of our customers, colleagues, and business partners whose talents,
counsel, and passion for the pump industry have supported our
accomplishments and continue to fuel our growth."

Ð George Harris, President and CEO

WORLDWIDE PUMP SERVICES

24/7 Emergency Services

Engineered Pump Repairs
Certified Performance Testing
Wireless Condition Monitoring
Engineering Services
Critical Parts Solutions
Customer Training
State-of-the-Art Technology
Watch Video
In-depth Knowledge of Major Brands
Field Service Support for Installation & Start-up

Circle 101 on card.

Worldwide Service Centers l 800.223.7867 l hydroinc.com/50

2 FROM THE EDITOR

P ump professionals in every

industry are looking for ways
to optimize their total systems,
EDITORIAL
EDITOR-IN-CHIEF: Alecia Archibald
aarchibald@cahabamedia.com • 205-278-2843
EDITOR: Jennifer King
to save money, time and energy
jdking@cahabamedia.com • 205-278-2826
consumption.
PRODUCTION MANAGER: Amy Cash
End users can get plenty of ideas acash@cahabamedia.com • 205-314-8274
about those potential savings at MANAGING EDITOR: Drew Champlin
the 2019 Turbomachinery & Pump dchamplin@cahabamedia.com • 205-314-8264
Symposia (TPS), scheduled for CONTRIBUTING EDITORS: Lev Nelik,
Dominik Fry, Jim Elsey, William Livoti
Sept. 9-12 in Houston, Texas, at the
George R. Brown Convention Center. CREATIVE SERVICES
Pumps & Systems’ Drew Champlin and Thomas Schardt DIGITAL PROJECT MANAGER &
TPS is a highly anticipated annual of Nidec Motor Corporation talk industry trends at the SENIOR ART DIRECTOR: Greg Ragsdale
event that is sponsored by Texas recent EASA show in Las Vegas.
ART DIRECTOR: Elizabeth Chick
A&M’s Turbomachinery Lab. The WEB DEVELOPER: Greg Caudle
show offers an exhibition and networking opportunities and a new event for the MANAGER OF EMAIL OPERATIONS:
Women of TPS. But the real draw is the technical sessions. Short courses, case studies, Brent Godwin
lectures and tutorials cover maintenance, reliability, troubleshooting and technology. CIRCULATION
So, a lot to learn. AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
With this in mind, the August issue of Pumps & Systems magazine focuses on ways end lmasaoay@cahabamedia.com • 205-278-2840
users can optimize their systems, impacting mean time between failure (MTBF), energy ADVERTISING
efficiency and total cost of ownership. NATIONAL SALES MANAGER:
The Pumps & Systems team looks forward to TPS every year because it gives us a Derrell Moody
chance to see new products, hear some really smart presentations, and—best of all— dmoody@pump-zone.com • 205-345-0784
talk to our readers. SENIOR ACCOUNT EXECUTIVES:
If you are at the event, please stop by and see us. We will be at Booth #1200. Mary-Kathryn Baker
Next, our attention will turn to WEFTEC, which is planned for Sept. 21-25 at mkbaker@pump-zone.com • 205-345-6036
Chicago’s McCormick Place. This water quality trade show is big—one of the biggest Mark Goins
mgoins@pump-zone.com • 205-345-6414
shows we attend.
Garrick Stone
I always look forward to seeing the chopper pumps in operation on the floor of the gstone@pump-zone.com • 205-212-9406
expo and the highly competitive operations challenge. SALES DEVELOPMENT REP:
Next month, the Pumps & Systems September issue (also big!) will provide articles and Gannon Greene
case studies on water and wastewater challenges in anticipation of the WEFTEC show. ggreene@pump-zone.com • 205-278-2876
If you have ideas for the magazine, or comments about how we are doing, please email CLIENT SERVICES COORDINATOR:
us at pumpeditors@cahabamedia.com. Carra Barnes
cbarnes@pump-zone.com • 205-561-2600
As always, thanks for reading!

PUBLISHER: Walter B. Evans Jr.

VP OF SALES: Greg Meineke
Editor-in-Chief, Alecia Archibald CREATIVE DIRECTOR: Terri Jackson
CONTROLLER: Brandon Whittemore
aarchibald@cahabamedia.com

P.O. Box 530067

Birmingham, AL 35253
EDITORIAL & PRODUCTION
Pumps & Systems 1900 28th Avenue South, Suite 200
is a member of the following organizations: Birmingham, AL 35209
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue S., Suite 200, Birmingham, AL 35209. Periodicals 205-212-9402
postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the
right to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and ADVERTISING SALES
possessions $5, all other countries $15 US funds (via air mail). Call 205-278-2840 inside or outside the U.S. POSTMASTER: Send changes of address and 1806 6th Street, Suite 200
form 3579 to Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253. ©2019 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 advertise- Tuscaloosa, AL 35401
ments, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descrip-
tions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media
205-345-0784
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 (with the right to license to third parties) to edit, reproduce, distribute, publish and adapt your submission
in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will
not be returned. Volume 27, Issue 8.

August 2019 | Pumps & Systems

Circle 112 on card.
4
This issue AUGUST Volume 27 • Number 8

COVER
SERIES PUMP SYSTEM OPTIMIZATION COLUMNS
54 HYDRAULIC RETROFIT MEETS PUMP SYSTEM IMPROVEMENT
INCREASED DEMAND 14 By Dominik Fry, P.E.
By Matt Kinney
Engineered Software, Inc.
Sulzer
Correcting a Common Pump Myth
Texas refinery achieves improved
performance from API barrel COMMON PUMPING MISTAKES
pump through major re-rate.
18 By Jim Elsey
58 PROPER CALCULATIONS Summit Pump Inc.
OPTIMIZE NORTHEAST Wishing & Hoping for
PUMP SYSTEM Pump Performance
By Kristo Naude
NRG Energy, Inc. PUMP SYSTEM STANDARDS
NPSH problem was corrected to 22 By William Livoti
generate additional power. Senior Engineer
General Scope Document:
40 60 SMART PUMPING HELPS AVOID
CAVITATION & COMMISSIONING
Project Constraints

ISSUES
By Tunji Asiwaju
40 ENHANCE FLARE GAS Armstrong Fluid Technology
RECOVERY WITH LIQUID Fluid management data monitoring AU G U S T 2 0 19

SYSTEMS
PUMPSANDSYSTEMS.COM

RING COMPRESSORS and analytics services can The Leading Resource for Pump Users Worldwide

By Stefan Lähn assist in preventing injuries and

Strategies
Flowserve system damage. to Strengthen
Your System
Managing risks and minimizing

These systems can reduce the environmental impact.

environmental and economic 64 TRENDS IN VARIABLE FLOW ON THE COVER

impacts of releasing flaring gas PUMPING FOR HYDRONIC Image courtesy
into the atmosphere. HEATING & COOLING THE MIDDLE EAST’S
IIOT ADOPTION
CURVE
of Flowserve
By Reece Robinson
HOW BEP
AFFECTS RELIABILITY

PLUS: TPS
2019 PREVIEW

44 ASSET MONITORING IMPROVES Grundfos

RELIABILITY & VISIBILITY
By Ares Panagoulias, Hydro, Inc. &
Ken Babusiak, HydroAire
Pipeline transmission company
achieved successful ROI from
wireless condition monitoring.
50 3 STRATEGIES FOR SUCCESSFUL
PUMP SYSTEM OPTIMIZATION
By Jordan Ruff
Xylem Inc.
Whole-system approach improves
overall performance.
Operators can increase efficiency with
packaged HVAC pump systems, inline
multistage pumps, and advanced
motors and controls. 2 FROM THE EDITOR
69 7 STEPS FOR HIGH-PRESSURE 8 NEWS
CENTRIFUGAL PUMP
EFFICIENCY 99 ADVERTISERS INDEX
By Tom Helmreich
Sundyne 100 PUMP USERS MARKETPLACE
Extend maintenance intervals
and reduce total cost of ownership 104 PUMP MARKET ANALYSIS
of pumps used in chemical and
petrochemical applications.

AFTERMARKET 73 HOW GLOBAL SOURCING HELPS

AFTERMARKET COMPANIES
73
By John D. Allen, JDA Global
Competitive pricing and rapid delivery fosters
successful service.

August 2019 | Pumps & Systems

Close and
responsive

Sulzer is the leading service provider for rotating equipment that

specializes in high quality, cost-effective, customized solutions for Visit us at Turbomachinery
maintenance and repairs of all makes and models of turbomachinery, & Pump Symposia,
electromechanical equipment and pumps. booth #1635.

We help you keep your operation at peak efficiency with unique

solutions that are tailored to the equipment needs of each application.
With continuous investment in state-of-the-art machine tools,
engineering and facilities, Sulzer’s global manufacturing and service
network combines the advantages of a global company with the
flexibility of a local partner.

Contact us to find your best service solution, www.sulzer.com

Circle 113 on card.
6
This issue
OTHER
REPORTS
24 5 THINGS TO CONSIDER
WHEN IMPLEMENTING IIOT
IN OIL & GAS
By Michael Kanellos
OSIsoft
Follow these best practices to navigate
common challenges.
26 IIOT SUCCESS DEPENDS ON END
USER PARTICIPATION
By Tor Jakob Ramsøy &
Martin Lundqvist
Arundo Analytics
Empowered operators should be
more active in the purchase and
implementation process.
28 5 WAYS REMOTE MONITORING
CAN EXTEND THE LIFE OF PUMPS
By Rob Fusco
Sensaphone
Catch problems early to avoid
pump failure.
34 UNDERSTANDING A
TURBINE GOVERNOR WITH
NEW DIGITAL TRICKS
By Brent T. Ward, Voith Digital
Solutions &
Gerhardt Maurer, Voith Turbo
The closed loop differential pump uses
linear drives that can offer accuracy in
control and reliability.
EDITORIAL ADVISORY BOARD
THOMAS L. ANGLE, P.E., MSC,
Geschaeftsleiter (CEO), Swiss Flow
Solutions GmbH
AXEL BOKIBA, Vice President of
Project Management, Pulsafeeder
R. THOMAS BROWN III, President,
Advanced Sealing International (ASI)
KEVIN CLARK, VP, Fluke Accelix
JACK CREAMER, Market Segment
Manager – Pumping Equipment,
Square D by Schneider Electric
BOB DOMKOWSKI, Business
Development Manager – Transport
Pumping and Amusement Markets/
Engineering Consultant, Xylem, Inc.,
Water Solutions USA – Flygt
August 2019 | Pumps & Systems
AUGUST
38 GROWTH OPPORTUNITIES & DEPARTMENTS
DISRUPTIONS IN THE MIDDLE
EAST PROCESS INDUSTRIES
By Arunkumar Janarthanan 85 SEALING SENSE
Frost & Sullivan What to Understand About
Expert explains the IIoT adoption curve Chemistry to Make
in the GCC nations. the Best Materials Choices
By Mark Freeman, FSA Member,
EGC Enterprises, Inc.
74 BEP: ITS IMPORTANCE & ITS
EFFECT ON RELIABILITY
By Amin Almasi 90 HI PUMP FAQS
Principal Machinery/ Bearing Wear Detection Methods
Mechanical Consultant & Monitoring Seal Leakage in
Submersible Pumps
Running far from the best efficiency
By Hydraulic Institute
point can be damaging.
92 EFFICIENCY MATTERS
76 TIPS FOR BEARINGS IN MACHINE Flexible AODD Pumps Can Improve
MAINTENANCE Priming, Startup Pressures &
By Gakuo Ndonga Retrofit Possibilities
SKF USA, Inc.
By Erik Solfelt
Basic training for selecting, installing Wilden
and maintaining bearings
94 MOTORS & DRIVES
79 HOW TO FIGHT LEAKAGE & Motor Efficiency in Municipal
BEARING CONTAMINATION WITH Applications Provides
THE RIGHT SEALING SOLUTION 3 Reliable Alternatives for Operators
By David Amory By Jeff Frank
AESSEAL Franklin Electric
Consider mechanical seals, gland packed
seals and lip seals.
82 A PUMP REBUILDER’S GUIDE
TO REPLACING CARBON
GRAPHITE BEARINGS
By Keith Hoge
Metallized Carbon Corporation
Installation techniques and tips for
choosing the best material grade.
34
JIM DRAGO, Principal Applications TODD LOUDIN, President/CEO SCOTT SORENSEN, Oil & Gas
Engineer, Garlock Sealing North American Operations, Automation Consultant & Market
Technologies Flowrox Inc. Developer, Siemens Industry Sector
WALT ERNDT, Vice President of JOHN MALINOWSKI, Industrial ADAM STOLBERG, Executive Director,
Business Development, Pump and Motor Consultant Submersible Wastewater Pump
Process Equipment, Inc. MICHAEL MICHAUD, Executive Association (SWPA)
JOE EVANS, Ph.D., Customer & Director, Hydraulic Institute JERRY TURNER, Founder/Senior
Employee Education, PumpTech, Inc. WILLIAM E. NEIS, P.E., President, Advisor, Pioneer Pump
GEORGE HARRIS, President & CEO, Northeast Industrial Sales DOUG VOLDEN, Global Engineering
Hydro LEV NELIK, Ph.D., P.E., APICS, Director, John Crane
ROB LAIRD, Engineering Manager, International Center for Pumps CHRIS WILDER, CEO, SEPCO
Sulzer Research and Development, Israel JAMES WONG, Associate Product
LARRY LEWIS, President, Vanton HENRY PECK, CEO, Geiger Manager – Bearing Isolator, Garlock
Pump and Equipment Corp. Pump & Equipment Company Sealing Technologies
WILLIAM LIVOTI, Senior Pump MICHELE SHAUGHNESSY,
System Engineer Vice President Marketing & Sales,
PSG Dover
Circle 106 on card.
8 NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
SCOTT SUMMERVILLE, MITSUBISHI ELECTRIC
VERNON HILLS, Ill. – Mitsubishi Electric Automation,
Inc. (MEAU) has named Scott Summerville as its new
president. Summerville fills the position formerly
held by Toshio Kawai.
Prior to joining Mitsubishi Electric, Summerville
was the chief executive officer of Omron Microscan
since October 2017, after successfully leading Scott
the sale of Microscan Systems, Inc. to Omron Summerville
Corporation. Summerville has more than 30 years of experience in the
automation industry, having spent most of his professional career at
Rockwell Automation where he held positions of increasing responsibility
including president of the Asia Pacific region 2003 to 2008.
Summerville is a former chairman of the Integrated Systems &
Controls council within the Material Handling Industry of America
and a former member of the board of governors of the American
Chamber of Commerce in Hong Kong, as well as a contributing author
to the book “Leadership Experiences in Asia” (2007). He has degrees in
environmental design from Miami University, Ohio, and an MBA from the
Kellogg School of Management at Northwestern University.
us.mitsubishielectric.com
MARYROSE SYLVESTER, ABB
CARY, N.C. – ABB has appointed Maryrose Sylvester
as country managing director (CMD) and head of
electrification for the United States. In the CMD
role, she will succeed Greg Scheu, who will retire on
Oct. 31.
Sylvester was most recently president and CEO
of “Current, powered by GE,” a GE startup business Maryrose
Sylvester
that was acquired in April by New York-based private
equity firm American Industrial Partners. Having spent her career at GE,
she held several positions, including president and CEO of GE Lighting, of
GE Intelligent Platforms/GE FANUC, which was GE’s longest-running joint
venture with a Japanese company, and of GE Quartz.
abb.com
GREGG CUMMINGS, HAZEN AND SAWYER
SAN FRANCISCO – Hazen and Sawyer has announced the appointment
of Gregg Cummings as senior associate and senior project manager.
Cummings has more than 30 years of experience in water, wastewater
and water reuse including program and facility planning, pilot testing,
studies, design and construction of water-related infrastructure.
Cummings earned a bachelor’s degree in civil engineering from the
University of California, Berkeley, a Master of Science in environmental
and structural engineering from San Jose State University, and
professional licenses in California and Oregon. He has led the local high
school outreach for the American Society of Civil Engineers for the last
25 years and has been a member of the Water Environment Federation
Food Processing Waste Literature Review Committee for more than 10
years. He is also a four-time Distinguished Toastmaster.
hazenandsawyer.com
August 2019 | Pumps & Systems
THOMAS MOUNTZ, LAN
HOUSTON – Thomas Mountz joined planning,
engineering and program management firm
Lockwood, Andrews & Newnam, Inc. (LAN) as a
senior project manager. Mountz will manage
flood control and drainage projects throughout
central Texas.
Mountz has more than 46 years of experience as Thomas
an engineer and project manager. He has expertise Mountz
in several areas, including water resources management, master
planning, floodplain and dam breach modeling, design, stormwater
quality analysis, stormwater management ordinance development,
best management practices, FEMA map revisions and studies,
fluvial geomorphology, stream restoration, grant applications and
management, and construction inspection and oversight.
lan-inc.com
TOM SUTER, ENGINEERED SOFTWARE
LACEY, Wash. – Engineered Software, Inc. (ESI)
named Tom Suter as the company’s next chief
executive officer. Suter, who recently moved to
the Pacific Northwest after a long career running
and managing technology companies across the
United States, succeeded Christy Bermensolo, ESI’s
CEO since 2014, effective June 17. Bermensolo will Tom
continue in her role as an owner and board member. Suter
eng-software.com
TIPHAINE HECKETSWEILER, SUEZ
PARIS – SUEZ announced the appointment of
Tiphaine Hecketsweiler as chief communications
officer (CCO). As a member of the executive
committee, Hecketsweiler started July 15.
A graduate of the Pantheon-Sorbonne University
and holder of a postgraduate diploma in corporate
finance and financial engineering from Paris Tiphaine
Dauphine University in 1990, Hecketsweiler began Hecketsweiler
her career at France Telecom Mobiles and then as strategy manager at
Experian in London.
Hecketsweiler will report to Bertrand Camus, CEO of SUEZ Group.
mysuezwater.com
OLLI ISOTALO, METSO
HELSINKI, Finland – Metso’s Board of Directors has
defined its view on the company’s portfolio strategy
and has decided that the businesses under the
Minerals and Flow Control segments will be further
developed separately from each other.
Olli Isotalo was named president, valves
business area. Isotalo will start his position Olli
July 15, and will become a member of the Metso Isotalo
executive team. Isotalo has previously served as
 9

EVENTS BOMB
PROOF
Turbomachinery & Pump
Symposia
Sept. 9-12
George R. Brown Convention Center
Houston, Texas
tps.tamu.edu

WEFTEC
LONG LIFE. PRECISION FIT. SEALS EFFECTIVELY.
Sept. 21-25
McCormick Place
Chicago, Illinois
weftec.org

Pack Expo
Sept. 23-25
Las Vegas Convention Center
Las Vegas, Nevada
packexpolasvegas.com

Chem Show Patented Product

Oct. 22-24
Javits Center
New York, New York
chemshow.com Increases Reliability in Aging Equipment
ADIPEC DRASTICALLY REDUCES FLUSH WATER TOO!
Nov. 11-14
Abu Dhabi National The PackRyt® Sealing System is a unique stuffing box sealing
Exhibition Centre
arrangement that incorporates a bearing and flush channel system
together. The one-piece ultra-durable polymer bearing and lantern ring,
Adnec, Abu Dhabi
made from the same material, ensures the lantern doesn’t spin, collapse,
adipec.com
or expand in the stuffing box which can result in failure.
Power Gen EASY TO MIMIC. IMPOSSIBLE TO MATCH.
Nov. 19-21
Morial Convention Center
New Orleans, Louisiana
power-gen.com
Circle 122 on card.

NGWA ROTATING SHAFT SEALING EXPERTS

Dec. 3-5
Las Vegas Convention Center Call us to find out why reliability and maintenance managers are moving to our patented solutions!

Las Vegas, Nevada

MADE IN THE U.S.A.
groundwaterweek.com Designed and
64 Servistar Industrial Way Phone: 413-564-5202 Manufactured
Westfield, MA 01085 Fax: 413-564-5203 in Westfield, MA

pumpsandsystems.com | August 2019

10 NEWS

CEO of Patria Oyj and has held various executive positions at Cargotec
Corporation. John Quinlivan, the current president of the valves business
area, will continue as senior adviser until the end of 2019 and will
support Isotalo during the transition period. Metso’s executive team
will otherwise remain unchanged.
metso.com
RICK WIEDEMANN,
TUTHILL TRANSFER SYSTEMS
FORT WAYNE, Ind. – Rick Wiedemann became
president at Tuthill Transfer Systems Aug. 1.
Wiedemann has been with Tuthill since 2015
when he joined Tuthill Vacuum & Blower Systems
in Springfield, Missouri, as director of global
business development & Americas sales. In 2017, Rick
Wiedemann transitioned to the commercial lead at Wiedemann
Tuthill Transfer Systems as vice president of sales and marketing. During
his time, Wiedemann lead Tuthill to launch e-commerce platforms on
Amazon, eBay and Zoro for the Fill-Rite and Sotera Systems brands.
tuthill.com
NORMAN ZOMBOR, SEEPEX
ENON, Ohio – Norman Zombor has been hired for
the position of SEEPEX territory manager for the
Northwest region of the United States and Canada.
He covers provinces British Columbia, Alberta,
Yukon and Saskatchewan, and states Oregon,
Washington and Alaska’s industrial market. Zombor
was previously employed with other industrial Norman
engineering and manufacturing firms for the past Zombor
20 years where he sold progressive cavity pumps.
seepex.com

To have a news item considered, please send the information to Drew Champlin, dchamplin@cahabamedia.com.

AROUND THE INDUSTRY

Weir Flow Control Has New Name
HOUSTON – Weir Flow Control has changed
its name to Trillium Flow Technologies. This
change follows the completion of the sale
of The Weir Group’s Flow Control division
to First Reserve. First announced last
year, The Weir Group sold the Flow Control
division to First Reserve, a global private
equity investment firm focused exclusively
on energy, for an enterprise value of 275
million pounds, according to a February
2019 press release. The plan to sell the
division was first announced on April 19,
2018, alongside the acquisition of ESCO.
Once the transaction was completed,
the earlier press release stated, more than
80 percent of Weir’s revenues will be from
aftermarket-intensive mining and upstream
oil and gas markets.
trilliumflow.com
PsiKick Changes Name to
Everactive, Raises Money for IIoT
SANTA CLARA, Calif. – PsiKick, which
creates wireless, batteryless internet of
things (IoT) systems, has changed its name
to Everactive and closed a $30 million
funding round, led by Future Fund and
joined by new investors Blue Bear Capital
and ABB Technology Ventures, alongside
existing investors New Enterprise Associates
(NEA) and Osage University Partners. The
company has raised $63 million to date.
Everactive’s initial target market is the
industrial sector, where collecting and
analyzing data on physical equipment and
infrastructure can have a profound and
measurable impact—serving to reduce
downtime, cut maintenance costs, improve
safety and environmental impact, as well as
boost overall efficiency.
everactive.net
CIRCOR Expands China Footprint
WEIHAI, China – CIRCOR has signed
an investment agreement to build a
new facility in the Weihai Economic &
Technological Development Zone (ETDZ).
CIRCOR Weihai manufactures centrifugal
and three-screw positive displacement
pumps for the industrial and commercial
marine markets.
The new facility is scheduled to open
in 2020 in the city of Weihai in Shandong
province, which is strategically accessible
by highway, air, rail and sea.
circor.com
MERGERS & ACQUISITIONS
Sulzer  Acquires  Hayward Tyler  Acquires  Munro  Acquires
Alba Power      Energy Steel
July 2, 2019 July 1, 2019
AxFlow Italy  Acquires  Ohio Transmission Corp.
EnPro Industries
Generalcontrol
Acquires The Aseptic Group
June 24, 2019
July 2, 2019
John Crane Opens Asia
Service Center
CHICAGO – John Crane announced the
opening of its super service center in
Pune, India.
Located in India’s second largest city,
the facility builds on the vast experience of
its local workforce and provides John Crane
with the capabilities necessary to offer
support for its customers within the region,
while also allowing them to deliver quick
turnaround service capabilities and reduce
downtime costs.
Differing from a traditional service center
designed only for repair services, the Pune
super service center serves as a Center
of Excellence for machining capabilities,
providing additional engineering
capabilities on top of its repair services.
johncrane.com
 
FloWater Irrigation 
June 18, 2019
   
Acquires Furey Filter & Pump 
and PSI Engineering
June 18, 2019

August 2019 | Pumps & Systems

 Control with Confidence

Smart Systems Need Smart Motor Control

As smart industry advances, the need for intelligent fan, pump
and compressor control with enhanced communications and
energy efficiency have become critical. Mitsubishi Electric
FR-F800-E drives are designed for tougher environments,
cleaner power, and higher efficiency. They feature easy to read
plain text display, PLC functions and Ethernet communications
for remote monitoring. FR-F800-E drives are connected to any
industrial process, building management system or remote
control center, so you don’t have to be.

Download our latest white paper to learn more.

AD-VH-00116 https://mitsubishisolutions.com/power-and-water/

Circle 119 on card.

12 NEWS

SPOTLIGHT stored in bonded tanks close to refining

locations on the coast of China. The Chinese
The Success of China’s see the Shanghai contract as a path to
reignite international interest in the yuan,
Crude Oil Futures which has fallen amid the currency’s $100 a barrel
Seventy percent of China’s oil demand is slump against the dollar and government
met by imports. interventions in the market since 2015. While 90
most Chinese commodity markets are open 80
By Jordan Knauff & Company only to domestic investors, foreign investors
have been allowed to trade the INE contract 70
since its launch, with the Chinese Ministry of

C hina launched yuan-denominated crude 60

oil futures contracts on the Shanghai
International Energy Exchange (INE) in
March 2018. There are signs that the new
Finance granting a three-year tax exemption
on trading profits. 50
According to the INE, 52 overseas agencies
have registered with the exchange. They are
40

contracts are being accepted into a market
dominated by West Texas Intermediate
crude oil (WTI) traded in New York and
Brent crude oil (Brent) traded in London.
Designed specifically to attract international
participants, China hopes the Shanghai crude
futures will create a new China-based global
pricing point for crude oil alongside the
incumbent international crude benchmarks
like Brent and WTI. The creation of the
Shanghai oil futures followed years of
planning by the Chinese and are a key part
of Beijing’s broader strategy to gain clout
in global oil trade and turn the yuan into a
credible challenger to the dollar.
The value of Shanghai crude futures
reflects the price of medium sour crudes
mainly from Hong Kong, Singapore, Britain,
the Republic of Korea and Japan. These
agencies are serving customers from Britain,
Australia, Switzerland, Singapore, Cyprus,
Seychelles, as well as Hong Kong and Taiwan.
The success of any new futures contract
and market is typically measured by its
liquidity, depth and open interest. With a
physically settled contract, the delivery
mechanism of the new contract is also
scrutinized by the market. Over the past
year, China’s yuan-denominated crude oil
futures’ trading volume has grown strongly
while prices have closely tracked global
benchmarks. In January, daily trading
volume of front-month crude oil futures on
the INE averaged 248.5 million barrels of oil.
Apr Jul Oct Jan Mar
2018 2018 2018 2019 2019
*Converted from yuan at March 26, 2019 exchange rate.
This made up roughly 20 percent of global
trading in similar contracts and was close
to trading volumes in Brent front-month
oil contracts in London, according to The
Wall Street Journal. At the end of March,
the benchmark Shanghai contract’s trading
volume made up about 14 percent of the
global activity in similar futures, or about
half of Brent’s volume. The bulk of crude oil
trading still takes place in the United States,
where the benchmark is the WTI contract.
Read this full report from Jordan Knauff &
Company at pumpsandsystems.com.

Preview: TURBOMACHINERY & PUMP SYMPOSIA

Sept. 9-12, 2019
George R. Brown Convention Center Exhibition
Houston, Texas Hours
Tuesday, Sept. 10
Noon – 7 p.m.
T he Turbomachinery & Pump Symposia (TPS) is the
conference for rotating equipment engineers and
technicians worldwide, spanning oil and gas, petrochemical,
TPS 2018 attracted 4,750
delegates from 45 countries and
365 exhibiting companies.
Wednesday, Sept. 11
Noon – 6:30 p.m.
chemical, power, aerospace and water industries. The expert- New to TPS this year is
selected technical program combined with an international the Women of TPS luncheon, Thursday, Sept. 12
exhibition is the perfect platform for networking with, and a forum for women of TPS 9:30 a.m. – Noon
learning from, colleagues, OEMs and end users. to share experiences and
TPS, founded in 1972, is organized by the Turbomachinery challenges in the industry. It
Laboratory, a center of the Texas A&M Engineering is also an avenue in which those experiences and challenges
Experiment Station (TEES) and member of the Texas can be heard and understood by others, including upper
A&M University System. management. The lunch is on Wednesday, Sept. 11, from noon
This year marks the 35th anniversary of the pump to 1:30 p.m. and costs $50.
symposium. The annual TPS promotes professional Short courses will be held along with the symposia Monday,
development, technology transfer, peer networking and Sept. 9. For more information on registration, the Women of
information exchange among industry professionals. TPS lunch and a daily schedule, visit tps.turbolab.tamu.

August 2019 | Pumps & Systems

Circle 114 on card.
14 PUMP SYSTEM IMPROVEMENT

By Dominik Fry, P.E.

Engineered Software, Inc.

Correcting a Common Pump Myth

O
ne common misconception I
hear is that a pump is rated for a
certain flow rate and the pump
is bad if it does not deliver. While this
may be true when you are discharging to
a spillway and there is little resistance,
most pumping systems are much more
complicated. I was recently dealing with
a situation where multiple pumps in
parallel and the operators and engineers
were confused as to why they were
not getting the flow or pressure they
thought they should. In fact, they were
only operating with one of the two
cooling towers available due to the lack
of flow. The system had been expanded
many times, and they were considering
expensive repairs to the pump manifold
that would total more than $100,000.
Since the system had been in operation
for many years, there were not many
places to collect data. There was a
pressure gauge on the pump manifold. It
was known that the cooling tower would
overflow at 2,200 gallons per minute
(gpm), so a flow rate of around 2,000
gpm was assumed. While we looked at
modeling the entire system, the crux of
the problem can be seen in just the model
of the pump manifold. There were two
larger pumps on the ends (Pump 4070)
with three slightly smaller pumps (Pump
830) in the middle (Image 1). The pumps
were operating at just over 82 pounds per
square inch (psi).
Normally, all of these pumps were

Image 1 (top). Pump manifold under normal operation

Image 2 (bottom). Pump manifold with one pump shutdown (Images courtesy of the author)

August 2019 | Pumps & Systems

—
The sign of reliability

For more than 100 years, ABB has developed a reputation for marketing, designing and
manufacturing the most reliable industrial electric motors available. Azima, Inc. confirmed
this in their Reliability Rating Report in which they stated that “ABB produces the majority
of models scoring highest for reliability in 2018.”

When reliability counts, look for the sign of reliability from ABB.

479.646.4711
baldor.abb.com Circle 117 on card.
16 PUMP SYSTEM IMPROVEMENT
Image 3 (top). Pump 830 under normal operation. Image 4 (bottom). Pump 830 with one pump shut down
in operation. The end users thought
something was wrong because they could
not see a difference in discharge pressure
when one of the smaller pumps was off.
When the system was modeled with
shutting down the middle pump, it
resulted in a pressure drop at the gauge of
less than 2 psi (Image 2). This drop could
easily be missed. It also shows that it
may not be the rest of the system at fault,
or even the manifold itself, but how the
pumps were interacting with each other.
Pump professionals agree it is generally
not a good idea to have different sized
pumps operating in parallel. At one point
during an expansion, the plant decided
they needed more flow and installed the
third small pump expecting to get the
rated flow. It appears the efforts were
largely wasted. So why is it that the extra
pump did not deliver the desired results?
We need to look at the pump curves.
The larger pumps may have
overpowered the smaller pumps, but
there is another aspect to observe.
Normally, the smaller pumps put out
just over 177 feet of head (Image 3). The
impeller has been trimmed to 7.125 and
August 2019 | Pumps & Systems
the pump is operating far to the left of
its best efficiency point (BEP). While the
desired output was around 600 gpm,
the pump was only putting out just over
half this amount. We can also see that
the pump curve is flat, so we should not
expect a large change in pressure with a
change in flow rate.
When we see how the pump is
operating while one of the pumps is
shut down, it confirms that there is a
small change in pressure due to the flow
change. While the total system flow is
the same, the pressure barely drops. The
small pump’s flow rate changes from
around 350 gpm to almost 400 gpm.
Because it is operating at an almost flat
section of its curve, barely any change
at the pressure gauge is observed. If we
repeat this process with the larger 4070
pumps, we would see the same thing.
This scenario demonstrates why more
attention needs to be paid to pump
curves. To be clear, there is no issue with
the specific pumps, just how they were
applied. Here, I ran the simulation with
all five pumps the same.
Where the pump was operating
shifted, but the manifold exit pressure
did not change much. If all the pumps
were the larger model, the exit pressure
would only increase by about 1 psi
total to 83.5 psi. This would lead to a
power increase, and the pump would be
almost outside of the manufacturer’s
recommended operating range. Even
with all five pumps at the smaller Pump
830 model, the pressure would only drop
about 2 psi to 80.4 psi.
While it may seem a new pump is
needed, there may be an easier, less
expensive solution. Remember that the
impellers were trimmed, so there is the
potential of ordering larger impellers.
When modeled, this could significantly
increase the pressure and flow rate.
Dominik Fry, P.E., is Engineered
Software, Inc.’s business development
engineer and has nearly a decade of
experience in the energy industry while
working on some of the nation’s largest
energy projects. Fry earned a Bachelor
of Science at Montana State University.
For more information, visit
eng-software.com.
 17

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18 COMMON PUMPING MISTAKES

By Jim Elsey
Summit Pump Inc.

Wishing & Hoping for Pump Performance

W
ishin’ and Hopin’”—both Dionne Warwick and Dusty
Springfield had hit versions of this pop song in the
early ’60s. The lyrical message is that you will not get System Curve
want you want if you just sit around wishing and hoping; instead New / Larger / Faster
you need to take action to achieve the desired outcome.
Worn / Smaller / Slower
The same advice holds true for pump performance. I witness an
alarming number of people who unwittingly wish and hope their
pump would perform in the proper manner, but they are wishing
and hoping with total disregard of the system curve, pump Worn / Smaller / Slower New / Larger / Faster
capabilities, the laws of physics and the fluid properties. Time
to take action.
I start my pump training courses with the simple System Curve
personification that “pumps are stupid.” Put a centrifugal pump
Head for fluid like water
in any system, and it does not know where to operate. It is the
Head for increased
system, not the pump, that dictates where the pump will operate viscosity
on its performance curve—if the pump is even capable of
operating at that point.
Flow for Normal flow
Further, and intended only as a comedic anecdote to help Increased and head
Viscosity for water
my students learn, I refer to the pump as the “husband” in this
marriage with the system curve, aka the “wife.” Perhaps, and with
ostensible apologies to the “PC Police,” I suggest that the marriage
System Curve
works best if the husband (pump) listens and obeys the wife
(system). If there is a mismatch in the two, then divorce (pump Normal Ops Head
and system failure) is imminent.
Cavitation Head
The pump will operate where its performance curve intersects
the system curve, but we don’t always know where that point
is—and just to complicate matters, it can change quickly because
of many variables. Two roadblocks that make this determination
difficult are:
1. We frequently have no idea of the system curve geometry
2. The pump is often forced off its published curve by
No air
outside factors Entrainment
2% to 4%
5% to 6%
We will address the system curve calculation in a future article. 10% to 12%
For now, the system curve is the absolute summation of the 13% to 15%
system’s static head, pressure head, velocity head and friction
head. The geometry of the system curve is directly related to the
flow rate, pipe size, elevation changes and losses due to friction
Image 1 (top to bottom). Effect on pump performance with
of all the components in the system. Note the system curve is wear, speed, impeller size
dynamic and will change with tank elevation and system pressure Image 2. Performance effect with increased viscosity
changes. It will also change with valve position, system age, Image 3. Insufficient NPSH—pump will cavitate at higher
flow rates (compare to Image 5 restricted flow, page 20)
fouling and corrosion. This month’s article will address No. 2: How Image 4. Effect on pump performance with increased air
pumps can operate off their published curves, and we will look at a entrainment (Images courtesy of author)
few common examples.

August 2019 | Pumps & Systems


Causes for Operating Off Curve
Here are some of the common issues:
1. worn clearances
2. different or incorrect size impeller
3. different or incorrect speed
4. viscosity not corrected or accurate
5. net positive suction head (NPSH)
margin insufficient
6. air entrainment and/or dual phase
liquids beyond 3 percent
7. inadequate submergence (also see
air entrainment)
8. partial or restricted blockage of the
suction line
9. operating the pump in the
wrong direction
First Things First
To determine where your pump is really
operating, you will need to calculate
the pump performance curve in the field
“as is.”
First, obtain a copy of your pump
performance curve as published or
purchased. Then, using the pump’s
discharge valve position, create a series of
several different flow rates (recommend
at least six points including shutoff
head), determine and record the suction
and discharge pressures for each flow
condition, convert these pressures to
differential head and plot them on
your curve. Be careful to correct for
gauge elevations, temperatures and
specific gravities.
Does your curve match the published
curve? If it does within 5 to 10 percent,
then there is likely no problem.
Let’s look at a few cases where the
curve does not agree with the published
curve. Each case tells a critical story to
help understand what is happening with
your pump and the system.
Worn Clearances
As a pump wears, the hydraulic
performance deteriorates. Most people
understand the pump efficiency will
drop due to wear, causing the power to
increase, but not all users realize that the
head and flow will also deteriorate.
Note the revised pump curve still
intersects the system curve, but the
meeting point is at a lower flow rate and
a lower head. See my Pumps & Systems
articles from January 2016 and July 2017
for more details on this subject (Image 1).
It is important to understand if you
are also plotting power on the curve: if
the wear is simply the impeller or casing
wear rings, the power will increase
noticeably. But if the wear is in other
areas such as internal passages, cutwater
or the impeller vanes, the power will only
increase a small amount.
A special note for ANSI pump
designs that use the critical clearances
between the impeller and the casing
or stuffing box: the effect on power will
be as the aforementioned pump with
wear rings—that is, the power will
increase noticeably.
Different Impeller Size or Speed
Often, one of the reasons for poor
pump performance is that the wrong
size impeller is in the pump. This could
be caused by several different reasons,
mostly human error. Another common
reason is that the speed is different
than perceived. This is common with
systems that are controlled with variable
frequency drives (VFDs) as part of the
system control process. I mention both
of these issues (speed and diameter)
here because the performance manifests
almost exactly the same as worn
clearances.
See Image 1 to see the performance of
smaller impellers or lower speeds.
Viscosity—the Kryptonite of
Centrifugal Pumps
Viscosity has a direct and negative
effect on centrifugal pump performance.
The pump efficiency is affected the
most, but head and flow are not far
behind. Of course, all of these negative
factors will contribute to increase the
power required to pump the fluid at the
same flow rate and head as if based on
water performance.
19
Note that viscosity is directly
proportional to temperature, so be
cognizant of the fluid temperature. Also,
smaller pumps are more affected by
viscosity due to the smaller passage size.
See Image 2 for how viscosity will
affect the pump performance, and also
refer to my article on this subject from
the November 2017 issue.
Insufficient NPSH Margin
Pumps require a certain amount of NPSH
to operate satisfactorily at a given point
of head and flow on the curve to prevent
cavitation. The points are empirically
determined by the manufacturer and
are denoted as net positive suction head
required (NPSHr).
The suction system itself must in
return provide a certain amount of
NPSH, and that is referred to as net
positive suction head available (NPSHa).
There must be more NPSHa than NPSHr
for the pump to operate satisfactorily.
The difference is referred to as the margin
or ratio.
Refer to Hydraulic Institute 9.6.1-2017
for details.
NPSHa ÷ NPSHr = margin ratio
NPSHa – NPSHr = margin
Equation 1
A frequent field issue is that the
margin calculations were not done, not
done correctly or there were changes in
the pump and/or system that have not
been accounted for. A common issue in
the field is that the pump has sufficient
margin at lower flows, but as the flow rate
increases the pump will begin to cavitate.
See Image 3 to see how insufficient NPSH
margins affects pump performance.
Inadequate Submergence &
Air Entrainment
The pumped fluid could have air
entrainment from different sources for
many reasons, but a common cause is
insufficient submergence.
pumpsandsystems.com | August 2019
20 COMMON PUMPING MISTAKES

Image 5. (left to right). Effects of suction line restriction. Actual performance will vary with the magnitude of the restriction.
Image 6. Effects of running the pump in the wrong direction. Assumes low- to mid-range specific speed. Do not confuse with pumps
running as turbines.

The pump curve is not always where you think it is and neither is the system
curve. You will not get the performance you need and want just by wishing
and hoping—you need to measure the parameters and manage the system.

No matter the source of the air,
standard centrifugal pumps cannot
handle it well. At about 3 to 4 percent air
entrainment, the pump performance will
drop off as if the impeller was trimmed to
a smaller diameter or the pump is being
operated at a lower speed.
Please refer to my April 2016 and
December 2017 articles for details on air
entrainment and pump performance.
Also note that at low flow rates the
fluid velocity is insufficient to “sweep
away” the air that collects in the impeller
eye. Consequently, the pump will
become blocked (air bound) and will stop
pumping or it will surge in a destructive
and alternating cycle of air blockage and
subsequent flow passage.
See Image 4 to see how air entrainment
de-rates the pump performance.
Restricted Pump Suction
This issue typically manifests on new
construction, post repair startups and
when there is equipment installed in the As a general rule, the flow rate in a
suction line like a fi lter press, foot valve reverse operating pump will be about 50
or strainer. As flow increases the head
will drop off. This is similar, but different, near 60 percent. The higher the impeller
than an NPSH margin issue.
See Image 5 to see how a suction
restriction affects the pump curve.
Wrong Direction
I have written about pumps operating in
the wrong direction many times because
it is unfortunately an all too common
issue. In the case of ANSI pumps (with
impellers that thread on the shaft),
the pump will, 99 percent of the time,
pronounce in a millisecond that the
direction is incorrect as the impeller
grinds into the casing creating expensive
and extensive damage and yet hopefully
tripping out the motor.
For pumps that have impellers keyed
to the shaft it may or may not be obvious.
Pumps running backwards will typically
be a little noisier and exhibit higher
vibrations than a similar pump operating
in the correct direction. But this is not
always easy to determine in an operating
plant due to background noises and other
field interference.
Performance will depend on the pump
design and is mostly, but not always, a
function of the impellers’ specific speed.
percent, and the head will be somewhere
specific speed, the lower the head will
be. Concentric casing designs will yield
different results.
Please see Image 6 to see how reverse
rotation may affect pump performance.
Conclusion
Pumps will operate where the system
curve dictates, but the pump curve is not
always where you think it is and neither
is the system curve. You will not get
the performance you need and want by
just wishing and hoping—you need to
measure the parameters and manage
the system.
Jim Elsey is a mechanical engineer
with more than 48 years of design
and operating experience, primarily
focused on rotating equipment
reliability in most all industrial
applications and markets around the
world. Elsey is an active member of
the American Society of Mechanical
Engineers, the American Society
of Metals, the National Association
of Corrosion Engineers and the
Naval Submarine League. Elsey
is the principal of MaDDog Pump
Consultants LLC and may be reached
at jim.elsey@spiohio.com.

August 2019 | Pumps & Systems

Circle 111 on card.
22 PUMP SYSTEM STANDARDS
General Scope Document:
Project Constraints
W
e are moving along with the
steps that comprise a general
scope document (GSD).
This month, we will discuss project
constraints, the next step in the scope
development process.
What do we mean by project
constraints? Project constraints are
limitations that the project may be
faced with due to funding, scheduling
or time, technology or resources.
These constraints may also be
physical, such as logistics or perhaps
equipment availability.
Identifying Project
Constraints (Limitations)
Prior to developing the GSD, identifying
project constraints may influence how
the project is managed and may even
determine whether you decide to proceed
with the project.
Relative to the GSD, constraints or
limitations may include:
• Results: project may be cost
prohibitive
• Time frames: limited amount of
time to complete project (outage
or turnaround)
• Resources: limited resources, people,
funding, materials, etc.
• Activity performance: may need to
use site personnel
• Logistics: equipment placement,
movement within the site
Once the team has determined that the
project is viable, the constraints must be
identified in more detail. Look at each of
the items listed individually.
Results: Identify the anticipated results
of the completed project. This may seem
August 2019 | Pumps & Systems
By William Livoti
Senior Engineer
redundant relative to the owners’
acceptance criteria (OAC), but it is
more about clearly stating the absolute
minimum that you would expect as
a result. This would include input
from all team members with a vested
interest in the project.
Time frames: Define start dates
and completion dates of the project
as well as incremental timelines
throughout the project. Be specific
when developing the timeline by
taking into consideration equipment Image 1. Components of a general scope
or component deliveries, resources, document (Image courtesy of the author)
activity performance and logistics.
limited to—the placement of contractor
Resources: Identify and state the type,
equipment, power availability, staging of
amount and availability of resources
project materials, warehouse availability
needed to perform the project. Resources
for equipment (such as a crane or
may include people (in-house personnel),
forklift) that must be undercover, and
funds, equipment (cranes, compressors,
third-party construction equipment
power sources, etc.), facilities (office
movement within the plant. Logistical
space, workshop, machine shop, etc.),
planning and identification of
and information (drawings, location of
constraints may sound like a no-brainer,
piping and power lines, testing, etc.).
but I have seen where this fell through
the cracks and wound up creating havoc
Activity performance: Activity
within the plant and significant delays in
performance identifies strategies for
the completion of the project.
performing the different tasks. An
There you have it. Project constraints
example would be scheduling overhead
or limitations are another important
crane availability so as not to interrupt
step in preparation of the GSD.
plant production. Other examples
Next month: project assumptions.
include power disruption, compressor
Only three more steps to discuss.
usage and blocking thoroughfare or
Until next month remember:
plant access. These strategies must be
teamwork—the devil’s in the details.
carefully thought out and documented in
the scope document.
William Livoti is retired after more
than 40 years in the industry. Livoti
Logistics: Logistics is covered to
is a member of the Pumps & Systems
some extent in the activity segment;
Editorial Advisory Board. He may be
however, it does require a bit more detail.
reached at wlivoti@outlook.com.
Logistics would include—but are not
Stray Electric Current:
Meet Your Match

The problem: Damage caused by electrical current passing through

bearings in electric motors.

The solution: Current-insulated bearings from Schaeffler — including

hybrid ceramic or ceramic-coated versions featuring our proprietary
Insutect™ coating — that have been engineered to stop stray electric
current in its tracks.

Now that’s electrifying!

www.schaeffler.us Circle 107 on card.
©2019
24 IIOT
5 Things to Consider When 
Implementing IIoT in Oil & Gas 
Follow these best practices to navigate common challenges.
BY MICHAEL KANELLOS 
OSISOFT
O
il and gas is one of the driving forces in industrial
internet of things (IIoT). But it is also challenging
to separate the reality from the hype. Below are
five questions and a set of best practices to help
navigate the challenges.
It is often necessary to install artificial lift systems in
early production depending on the producing formation
and expected reduction of the natural reservoir pressure.
In unconventional production, including shale and tight
formations, artificial lift is needed right at production start
to compensate for rapid decrease of the flowing pressure. The
well bore architecture is also complicated with deeper wells,
deviated and long horizontal legs and multi-well entries.
1 How is IIoT different than IoT?
To people in the information technology (IT) industry
or in IT departments, “IoT” and “IIoT” often mean collecting
and analyzing machine data to achieve a business goal such as
reduced energy consumption. To people in operations, that is
business as usual. To them, IoT means putting in a secondary
network on top of the so-called IoT network that is already
reducing energy.
Yes, this sounds like a word game, but it is an important
distinction because it will help avoid confusion and
redundant or overlapping efforts. Users need to bring IT and
operational technology (OT) onto the same page. The first
step is a common vocabulary.
2 Where are potential data silos?
Simply put, it costs less and takes less time to link new
or stranded assets through wireless technologies and IoT
gateways than to retrofit existing supervisory control and
data acquisition (SCADA) or distributed control systems
(DCS). Connecting untethered devices with IoT gateways and
stick-on sensors can cost a few thousand dollars. Upgrading a
SCADA system to do the same might cost $250,000 or more.
August 2019 | Pumps & Systems
These stick-on sensors will feed data into something other
than SCADA, and that can result in data silos, which then
means headaches and an incomplete picture of operations.
Whatever the architecture in use, merge data sources.
3 What is the business case?
IoT typically can deliver three macro benefits: cutting
costs, increasing revenue or reducing regulatory risk. Or, as
analyst James Brehm likes to call it, save money, make money
and stay out of jail. Those are all worthy goals, and the best
bet is to knock them out in order.
Start with predictive maintenance and reducing uptime.
Then look at ways IoT can increase the productivity of existing
capital. Natural gas processing company DCP Midstream has
created an interesting program that gives plant operators
visibility into current production, potential production and
market pricing. The idea is to show employees how they can
squeeze more out of the plant. Once those are established,
many move onto things like emissions monitoring. If users
try to implement them all at once, they are just increasing the
chance of failure.
4 Who is accessing the data?
With IIoT, not only are users collecting more data,
they are also creating a system that will encourage more
people to use the data. That requires thinking about the
user experience. Having mobile access to contextualized
operational data coming from all data sources is an absolute
necessity. Operational data will be accessed by operators
and maintenance technicians in the field responding to
emergencies as well as executives at the airport who want to
compare current production with pricing forecasts.
If people cannot start quickly using this data in their daily
routines, the project will likely fail. Providing easy-to-use,
contextualized data in a mobile, self-serve environment
is fundamental.
 25

Who is performing analytics?

5 When someone says “analytics,”
people often envision data scientists
leveraging algorithms to sift through
mountains of data in the cloud. And users
will see gigantic problems solved with the
IoT data in the cloud.
For example, MOL, a large refinery
in Hungary, is conducting analytics on
its machine data to determine how and
when it can use less expensive, higher
sulfur “opportunity” crudes in one of its
refineries without introducing risk to its
operating parameters.
Still, many analytics problems are
performed directly by people looking at
a few finite data streams, which could be
viewed as human analytics. For example,
a sudden drop in oil pressure on a truck
working in the tar sands of Canada
can be a leading indicator that a major
malfunction may be in the offing.
Companies should think about taking a
“layered” approach to analytics that will
take into consideration edge versus cloud
capabilities and costs, whether human
or algorithms might work better and the
feedback loop between these systems to
ensure insights are operationalized.
Users cannot anticipate every use
case they will have in the future, but
if they take a broader view of what
“analytics” means, they can create an
analytical framework that can take care
of the unknowns.

Michael Kanellos is a technology analyst

at OSIsoft where he helps customers
understand how data is changing some
of the biggest businesses in the world.
He has worked as a reporter, analyst and
marketing executive in Silicon Valley for
over 20 years. His work has appeared
Circle 123 on card.

in the New York Times, CNET, Forbes,

Newsweek, Newsday,
the Chicago Tribune and
National Geographic. For
more information, visit
osisoft.com.

pumpsandsystems.com | August 2019

26 IIOT
IIoT Success 
Depends on 
End User
Participation 
Empowered operators should be  creating the tools to resolve those problems and gather all
more active in the purchase and  will be finished, and leadership continues to fund an ongoing
implementation process.
BY TOR JAKOB RAMSØY & MARTIN LUNDQVIST 
ARUNDO ANALYTICS
M
any end users have been through it more than
once. The executive suite announces a new
industrial internet of things (IIoT) investment to
the tune of millions of dollars. Instead of sharing
the enthusiasm, operators cringe. What represents promise to
the C-suite often smells of chaos to operators.
Tired of experiments and prototypes that interrupt critical
workflows, operators on the ground level often ignore IIoT
investments. This resistance—understandable in the face of
alert fatigue—defines the next phase of what was previously
defined as the DevOps dilemma. In tech companies,
development teams (programmers) and operations teams
(the folks responsible for keeping systems up and running)
suddenly found worlds collided by disruptions of the cloud
and big data analytics. Confl icting interests and confused
responsibilities meant the teams did not work together
naturally and new protocols were needed.
The same is true for executives, the information technology
(IT) team and end users in industrial companies. The IIoT is
here to stay, but its implementation often plateaus at the end
user level. No data innovation, however powerful or robust,
can function successfully unless it positively and reliably
makes operators’ day-to-day lives more efficient and more
expedient. End users have a powerful voice to add to the IT
and chief information officer (CIO) decision-making process,
and it is time to use it.
August 2019 | Pumps & Systems
How Chaos Happens
In many environments, the process to address technology
solutions typically follows a precarious path. At the
start, someone recognizes there is a problem and wants
a technology solution. Not everyone is convinced it is the
correct path to take, so a consultant is hired to analyze the
solution and provide recommendations (as well as validate
the original assessment). Many meetings, slideshows and
discussions later, an investment is made in minimally viable
products and point solutions that work well on laptops. The
executive committee is amazed and greenlights a plan to
implement the solution companywide, launching an ongoing
investment in research and development.
The final result? The engineers build a growing
infrastructure that aims to address every problem while
necessary data. But no one can say exactly when the project
technology initiative. In the meantime, the solution put in
place is so complex and cumbersome that no one really knows
how to use it. The team must monitor, manage and respond to
the chaos that ensues.
IIoT Has a People Problem
While executives see IIoT investments—the bigger, the
better—as competitive promises, end users too often
experience them as complications. Their days (and often,
evenings and weekends) are spent in reactive mode,
brainstorming solutions and addressing safety hazards.
Many struggle with “alert fatigue,” constantly moving from
one issue to the next and forever solving one problem only to
identify two others.
The end result is that unworkable—and sometimes
unwanted and uninformed—solutions are thrown at teams. A
cycle of implementations ensues, as does endemic frustration
and finger-pointing. But there can be empowerment in the
role of technology, if operators can persuade organizations to
put it to use.
End Users Are the Keys to the IIoT Kingdom
In the age of machine learning and big data, companies need
a better way forward, and end users on the floor should be
integral to the solution.
Rather than run around fire-fighting every pitfall in an
implemented tech solution, users should push to be invited
to the party during the development process. They are,
after all, on the ground floor of enhanced intelligence—the
subject matter experts who can add context and experience to
machine learning. Users witness firsthand how infrastructure
investments can become overly complex, can fail to serve
internal or external customers and can ultimately become a
cost center rather than a profit-maker.

The involvement of the operations team can quickly
remedy some of the most fundamental obstacles that arise
in IIoT development—namely the urge to rely on existing
systems to solve every problem and the failure to recognize
the limitations of those systems. Because they are intimately
familiar with how things actually run, industrial users can
provide detailed context, and therefore are invaluable to
identifying which data points are most important to consider.
Operators are also more easily apt to recognize the cause-
and-effect relation between suggested tech approaches and
potential outcomes. Putting this knowledge to use should
become a key part of any end user’s job in the future.
Bring Operations Into the Strategic Fold
Today, it is no longer necessary to build a complete solution
only to later recognize it falls short of expectations. And there
is no guarantee that “if you build it, productivity will come.”
The old way no longer works, and users can help lead the
way to smarter IIoT solutions. End users understand how
to problem solve and are accustomed to trying different
approaches. The capabilities of the cloud and ability to create
application programming interfaces (APIs) for problem-
solving recommendations enable experimentation without
impacting the bigger system and with fewer complexities.
Choose better technology
Accurate, versatile chemical pumps
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Circle 142 on card.
27
Smart companies place the data science and analytics
teams, IT or information sciences (IS) workers, operators
and business leaders in the same room—often with
dedicated experts in solution architecture, business process
management and data science deployment—to discuss
solutions, practical limitations on those solutions and the
interdependence between functions throughout the company.
By breaking down the silos of departments and perspectives,
a solution that focuses on identifying the right data is
required to solve the right problems.
No data innovation will ever have the desired impact
unless it positively and reliably makes end users’ day-to-day
lives more convenient and more time-efficient. Innovation
must enable techs to spend more time doing the work they
were hired to do, so that they can optimize the equipment
and plant production processes. Only when end users help
lead the innovation process, rather than merely be required to
implement uninformed solutions, will the IIoT finally realize
its return on investment promise.
Tor Jakob Ramsøy is founder and CEO of Arundo Analytics.
Martin Lundqvist is vice president of Strategic Partnerships of
Arundo Analytics. For more information, visit arundo.com.
pumpsandsystems.com | August 2019
28 IIOT

5 Ways Remote Monitoring 
Can Extend the Life of Pumps 
Catch problems early to avoid pump failure. 

BY ROB FUSCO 
SENSAPHONE

M
odern pumping systems typically include alarms pump and impeller jams
that alert operators when a malfunction occurs. can all cause premature
However, by practicing predictive maintenance, motor and pump failure,
potential problems can be caught before they which can lead to
become major issues. Integrate a remote monitoring system overflows and station
with the right sensors and data logging functionality to shutdown.
prevent high-level equipment failure, extend pump life and Using sensors and
minimize station downtime. data logging are keys to
performing predictive
Advantages of Remote Monitoring maintenance, preventing
Managing a stormwater or sewer pump station can be unscheduled shutdowns
challenging. Unexpected events such as fast-moving storms, and optimizing the
heavy rains, lightning and power outages are unpredictable. pumps’ BEP. Here are
During these times, an unexpected pump failure can make five ways to get more out
it difficult to take fast enough action to avoid a spill. Remote of the pumps and water/
monitoring of pumping stations provides operators with wastewater equipment
real-time alerts on failures, which maximizes pumps’ best by using sensors and remote monitoring technology.
efficiency points (BEP) and reduces overflows and spills.
Monitoring systems also safeguard from costs associated
with fines from overflow and flooded wells, cleanup and
downtime. If a pump fails, the callout system immediately
1 Monitor Vibration
Fortunately, critical and auxiliary pumping systems
usually give hints they are damaged and about to fail. Every
sends an alert, so personnel can diagnose the pump failure rotating machine has its own vibration characteristics, and
and take corrective action to get the well back online before a when a part starts going bad, those characteristics change.
spill occurs. In addition, having a remote monitoring system
reduces maintenance and travel costs because it prevents the
need to regularly drive to remote sites to check if pumps are
functioning properly.

Predicting Equipment Failures

In theory, a well-designed pumping system should continue
performing effectively for years. However, the reality is
that many different operating conditions can cut a system’s
life short.
A pump laboring under the handicap of a clogged intake,
suction loss or cavitation stresses parts of the system and
can cause it to fail prematurely. Bearing wear, dead head, dry

August 2019 | Pumps & Systems

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Circle 109 on card.

30 IIOT

When a pump is not running at BEP, motor

temperature rises, and bearings, seals and
impellers have more stress, reducing service life.
This can lead to premature failure of the pumping
system. It is also useful to have a pressure sensor
on the suction side: the difference in pressure is
proportional to the total head. It is ideal to have
pressure sensors on both sides of the pump.
Pressure sensors also monitor pump discharge,
so they can alert if a pump shuts down for a
long period of time or pressure drops from lack
of suction. Pressure alarms allow users to take
action to prevent the pumps from running dry if
suction is lost for any reason.
Image 1. Remote monitoring systems monitor the pressure on the discharge and If the pumps are water-cooled by an externally
intake sides of the pump. (Images courtesy of Sensaphone)
fed supply line, pressure sensors can monitor
these lines for adequate pressure. Water-cooled
If the seals or bearings on a pump begin to fail or if an pumps will go into a thermal overload if the temperature
impeller breaks, vibration increases. Although this change reaches unsafe levels, causing permanent damage to the
would not be noticeable to the human eye or ear, it is easily motor, shaft and impeller. Cost-efficient sensors can prevent
detected by a vibration sensor installed on the pump. The expensive repairs and unexpected downtime at the station.
sensor “listens” to the pump’s acoustics to detect imbalances, Remote monitoring devices can interface with pressure
providing early warning of issues arising within the pump. sensors. For example, 4 to 20 mA inputs work with an
Vibration sensors measure the vibration velocity array of sensors and provide real-time data acquisition, so
(severity of vibration) of a machine from 0 to 25 millimeters well pressure data can be logged and accessible via the web
per second (mm/s) root mean square amplitude (rms) over interface at any time. Th is allows end users to easily run
the frequency range 10 to 1,000 hertz (Hz). An output of reports and analyze accurate data.
4 milliamps (mA) will correspond to 0 mm/sec (no vibration) In wastewater applications, submersible pumps are
and an output of 20 mA corresponds to 25 mm/sec typically placed at the bottom of lift station storage tanks to
(intense vibration). pump suspended solids, sewage and refuse. Pressure sensors
Each vibration sensor communicates its frequency readings can identify blockages and flooding so that operators can
in real time to the remote monitoring system. The system turn on additional pumps during flooding, equalize wear on
can be set to “alarm” when an out-of-limit value is detected. pumps and turn pumps off when tanks are low.
This allows for time to take the action required to prevent
Monitor Current Amperage & Voltage
catastrophic failure, secondary damage and downtime.
Many remote monitoring systems function as data
loggers because they record and store all sensor data, which
3
power
Remote monitoring systems can easily monitor for
failures, which stop pumps and other equipment
personnel can access and view at any time. When vibration from running altogether. But you can go a step further by
sensors are integrated, they capture vibration readings at set continually monitoring the pump’s motor current and using
time intervals, which can be viewed in real time and analyzed the results to determine if there is a looming problem. A
for trends that indicate a failure is imminent. pump running at overcurrent for a long time, even by small
amounts of 5 to 10 percent of their rating, will ultimately
Monitor Pressure
2 If a pump is running, it has pressure. Monitoring this
pressure is a key way to understand the characteristics
overheat, damaging internals and causing premature failure.
Bad or failing bearings, clogged lines or material jammed
within the pump can also cause an overcurrent problem.
of the pump and increase its life cycle. The more flow, the Reduced flow caused by a blockage can also cause an
less pressure on the discharge, whereas low flow will show undercurrent situation. In an overvoltage situation, current
a higher pressure on the discharge. Pressure sensors help can increase and cause motor temperatures to run higher
identify key problems that can prevent the pump from when the load decreases, causing a surge in voltage to the
running within its BEP. pump’s motor. Similarly, if the voltage sags under heavier
Ideally, a pump should not operate at flows ±10 percent loads, the motor can suff er from a low-voltage state, which
of its BEP. will increase the motor’s current.

August 2019 | Pumps & Systems

EXPERIENCE, EXPERTISE AND
A STAINLESS REPUTATION
Count on Ashcroft to ensure you have
the right materials to resist corrosion
Corrosion is a nasty business.
It can damage your instruments,
sometimes to the point of cata-
strophic failure. Acids, chemicals
or even water can aggressively
attack incompatible metals. The
good news is that you can avoid
this costly problem by choosing
the correct instrument right from
the start.
Ashcroft offers a wide variety
of pressure gauges, switches,
transducers, transmitters and
accessories with stainless steel
wetted parts that are specifically
Circle 110 on card.
designed to stand-up to harsh
pressure media. Are you measur-
ing more aggressive fluids?
We’ll match diaphragm seals
constructed with even more
impervious materials to ensure
safety and durability.
Understanding your application
and helping you select the best
instruments is what we do every
day. Please contact us by calling
203-385-0635 or through our
website at:
www.ashcroft.com/contact_us.
tel: 203-378-8281
www.ashcroft.com/contact_us
www.ashcroft.com
32 IIOT
Image 2. A remote monitoring system’s dashboard shows total flow output from the
pump in gallons from a pulse count flow meter.
Image 3. Remote monitoring systems can provide alerts to end users.
In any pump installation, the amount of current
(amperage) the motor draws correlates directly to the size of
the load. Adding a current transformer (CT) on the pump’s
incoming power will monitor the pump’s current draw. A
severe increase or decrease as described above indicates a
pump problem that requires immediate attention.
In pump installations, problems like suction loss and jams
can cause serious damage to the motor or pump long before
the thermal overloads trip.
These problems can be detected within milliseconds of the
occurrence by monitoring the drive motor current with a
current transformer.
August 2019 | Pumps & Systems
Wastewater treatment plants also use
current transformers to monitor motor
conditions at remote lift stations. Operators
analyze current data from each motor to
predict potential failures. Current monitoring
can extend the life of any pump system.
Pulse Counts, Run Times & Alarms
4 Monitoring systems should be equipped
with data acquisitioning functionality to
automatically provide operating statistics
and historical information on the pumps that
indicate how well the station is performing.
Personnel can collect and record precise
data, including flow rates, run times and all
the operational principles involved in pump
monitoring. This data is available via a web
interface and can display in real time as the
pump operates.
Flow meters with multipliers can be
configured to determine how much flow a
station is outputting. These values can be
recorded and archived, so operators can create
monthly and yearly reports. Important run
times to include for data measurements include
total hours a pump has worked, how much
accumulated time the station has operated per
day, and work cycles on pumps. So, when an
inspector requires data, run time reports can
be easily produced and exported.
Other reports like alarm logs can be crucial
tools to determine how much time the site
was offl ine and when it came back online.
Depending on the length of the downtime,
penalties and fines occur most often when
authorities determine that you didn’t take fast
corrective action to get the site back online.
Switch to Cellular Service
5 Cellular-based remote monitoring systems
can have a higher initial cost, but that cost is easily recovered
with lower monthly rates. Cellular service costs far less than
dialers using copper phone lines. For each remote site added,
the recurring monthly cost on the landline can be cut in half.
In addition, cellular systems are supervised. These systems
will generate an offl ine alarm if the device unexpectedly
stops communicating, which can be caused by a weather-
related event, power surge, mass outage or human error. With
unsupervised landline-based systems, users can call in to
verify the lines are operational. But a line can go down at any
time after that check, rendering the pump station’s alarm
monitoring system useless.
 33

Multi-Tube
Delivers
4X LONGER
Tube Life
Image 4. Monthly savings is $400 by is
eliminating the landlines at 10 remote ISO 9001:2015
locations and getting cellular service. Certified

Look for cellular systems that are cloud-

based because they provide the greatest
flexibility, redundant servers, real-time
monitoring and data acquisition.
Cloud-based cellular systems give a full
view of all the sites from a user-friendly
dashboard, as well as free phone apps to
monitor on the go.

Final Thoughts
It is vital to keep pumping systems
and stations running as efficiently as
possible. A remote monitoring system
with integrated sensors can provide all
the protection needed to avoid high-level
events and also enable users to conduct
predictive care and maintenance.
When production depends on early
fault detection, sensor selection becomes
critical. Sensors help monitor vibration,
pressure, current, pulse counts and run IP66
time. The right system provides a clear NEMA 4X
WASH DOWN
picture of energy use, equipment life
cycle and pump performance. It also
uncovers fault trends to predict and

ProSeries Flex-Pro A3
diagnose pump failure, breakdowns and
® ®
performance loss.
PERISTALTIC METERING PUMP
Rob Fusco is director of business
Circle 125 on card.

development with Sensaphone, a

developer and manufacturer of remote S
ND PO
D IA MO

NS R

monitoring and alerting systems. He can

O

be reached at rfusco@sensaphone.com or Visit us at

BOOTH
877-373-2700. For more information, visit 3425
sensaphone.com. 714-893-8529 • sales@blue-white.com • www.blue-white.com

pumpsandsystems.com | August 2019

34 IIOT

Understanding a Turbine 
Governor with New 
Digital Tricks 
The closed loop diff erential pump uses linear drives that can off er 
accuracy in control and reliability. 

BY BRENT T. WARD,  VOITH DIGITAL SOLUTIONS &
GERHARDT MAURER,  VOITH TURBO  

H
ydraulics have long been the go-to solution where
mechanical advantage is needed and where an
appropriate amount of space is available. However,
hydraulics pose a number of challenges that users
have historically accepted as a trade-off for the relative
simplicity of operation and servicing.
Some of these challenges have to do with the nature of the
hydraulic fluids, the required supporting system components
and setup, and the failure modes associated with the systems.
To address these issues as well as the growing need to
decrease size, improve accuracy and deliver high reliability, Image 1. CLDP servo drive (Images courtesy of Voith)
a new approach has been created.
The technology uses linear drives that can offer the the electronics but not
mechanical advantage of hydraulics, along with accuracy plug-and-play with regard
in control and reliability. Solutions are relatively wear-free, to the system, making
pose little to no environmental issues and provide compact the installation and
solutions for applications with small footprints. These factors commissioning more time-
make the closed loop differential pump (CLDP) solution a consuming and complex.
choice for both retrofit and new installations. The CLDP Using a CLDP, a turbine
has the ability to remotely notify an operator when it or governor can regulate
associated equipment may need attention, as well as the water flow by adjusting the
Image 2. Traditional
capability of providing insight into the specifics of what turbine guide vanes. This hydraulic-based turbine
attention the equipment requires. design results in a more governor control
compact unit. The hydraulic
Configurations regulation is largely
Traditionally, turbine governors regulate water on the environmentally friendly and energy efficient. The drive unit
principle of interconnected valves, and they require large leverages the principles of a servo-hydraulic linear drive
systems that take up valuable plant floor space. Today, a CLDP, which can be successful in a wide range of applications.
hydraulic axis control typically consists of a cylinder, a Due to low wear and long service life in continuous-use
servo valve, electronics and a separate hydraulic unit. These applications, this design is also used in sectors such as the
components may be considered plug-and-play in terms of food industry, test rigs and laboratory machines.

August 2019 | Pumps & Systems

 35

Some of the demonstrated benefits of

the CLDP approach include:
• power density
• flexibility and configurability
• compact size
• energy efficiency
• resiliency

The linear drive with the servo pump

and servo inverter can provide pressure
and position control when operating the
linear axis. The control loop is closed using
an integrated or external travel measuring
system or a pressure sensor. A separate
hydraulic drive unit is unnecessary for
axis operation. Eliminating the valves
reduces system complexity and with
closed loop systems, the fi ltration and
cooling systems are eliminated.
Same Look. Same Installation.
Operation, Safety & Reliability
Depending on the space and configuration New Technology.
of equipment, the CLDP-based equipment
can be arranged in a number of ways, as
It’s all about efficiency. The MagForce™
depicted in Image 5 on page 37. High Efficiency Motor System offers a
One hydropower station on a remote 90% motor efficiency rating, which
island that has a CLDP-based turbine is up to 12% higher than traditional
governor installed offers a capacity of
submersible motor designs. With
approximately 2 megawatts (MW) and is
equipped with two turbines. permanent magnet technology,
As part of an extensive upgrade, the you can now offer an investment
power plant installed two new turbines, payback of less than 2 years
each fitted with a control unit. The
in most long- or continuous-
CLDP-based equipment allowed it to be
readily integrated into existing systems, run applications*. They get a
even where space was tight. The self- trusted product, you become
contained system of the autonomous their solution provider.
compact drive did not require additional
*Results based on field trial data.
piping, the control unit did not require
an additional accumulator and it works
with a low volume of hydraulic fluid. These
factors allow for safer operation without
fluid losses, making it environmentally
friendly. Regular checks and inspections
could be discontinued.
Circle 124 on card.

In remote facilities, these features

represented cost savings along with
enhanced service. The system was
preassembled at the manufacturer, so the
installation and commissioning at the site franklinengineered.com
was kept to a minimum.

pumpsandsystems.com | August 2019

36 IIOT
Image 3 (left). CLDP configuration diagram. Image 4 (right). Functional block diagram of CLDP control
Connectivity, Monitoring & Optimization
As part of the CLDP equipment, controllers and sensors are
provided for position, pressure and other parameters that
provide feedback for proper, accurate and responsive control.
Additionally, other sensing equipment can be combined to
provide a holistic view of the operation of the equipment both
on-site and off-site. This information can provide real-time
information, alerts and alarms should any of the equipment
August 2019 | Pumps & Systems
begin to trend outside of normal operating condition—
indicating a potential issue.
When connected for remote monitoring, computing
capabilities—such as those in the cloud—can perform
advanced analytics, machine learning, predictive algorithms
and anomaly detection, providing information about the
current operation and potential set points or remedies for
improved efficiencies or to avert catastrophic failures.
Circle 136 on card.
 37

Linear Conclusion
Some possible additional benefits of the CLDP-based
approach include:
Orthogonal
(Option) • flexibility for conversion ratios
• functionality like a wear-free gearbox
• precision-improved accuracy and control
• overload protection
• integration of the volume compensator
Parallel
(Option) This type of design provides availability in remote sites
that need to run for long periods of time without service. In
addition, remote monitoring technology provides real-time
information with ongoing insights and indications should
there be a change in operations—thus ensuring notifications
Movement direction when or if needed and information provided about the source
of piston rod of any issues.
Image 5. Configuration options for CLDP equipment
Brent T. Ward is part of Global IIoT/4.0 Solutions at Voith
Digital Solutions Inc. Ward may be reached at brent.ward@
Ultimately, information from the turbine governor and voith.com.
other systems can provide a comprehensive operational
picture for the facility or enterprise and enable options to Gerhardt Maurer is head of sales, Voith Turbo in Germany. He
more automatically shift loads, adjust to market demands and may be reached at 49-7152-992-421 or gerhard.maurer@
provide greater insights. voith.com. For more information, visit voith.com.

V E R T I CA L S
VERTICAL & SUBMERSIBLE
TURBINE PUMPS

WE HAVE A STATE OF THE ART

TESTING FACILITY TO ENSURE PUMP
AND MOTOR PERFORMANCE.

We can test up to 800HP and 6,000gpm

vertical and submersible turbines and test
up to 1,500gpm centrifugal pumps. We
also do dynamic balancing up to 6,500lbs.

I N T E G R I T Y P U M PA N D M O T O R . C O M 615.544.7072
Circle 139 on card.

pumpsandsystems.com | August 2019

38 IIOT
Growth Opportunities & 
Disruptions in the Middle East 
Process Industries
Expert explains the IIoT adoption curve in the GCC nations. 
BY ARUNKUMAR JANARTHANAN
FROST & SULLIVAN
Editor’s Note: This overview of industrial internet of things (IIoT) trends
in the Middle East, with focus on the Gulf Corporation Council (GCC), is
provided by global research firm Frost & Sullivan.
GCC’s IIoT Adoption Curve
The GCC has been undergoing a significant transformation
with respect to its role in the global industrial market. There
has been a push toward construction of assets that are best-
in-class and in a manner that will enable GCC nations to
enhance their export focus and deliver exceptional customer
experience globally. Additionally, the smart facilities are
also expected to ensure better return on investments
(ROI). Considering this scenario and the expected wave of
industrialization, adoption of IIoT can be expected to take off
with a strong thrust in the near future.
Process majors in GCC are keying in on next generation
practices and want to be the front-runners in adoption, but
there exists a key question on the need for IIoT while the
advanced automation can handle the current duties. This
situation is fast-changing with aging assets, the increasing
need to minimize costs while ensuring long-term asset
reliability as well as manage the data explosion for achieving
life cycle optimization.
The success of ongoing pilots and proof of value
demonstrations by solution providers is expected to encourage
the users to start accepting IIoT as a complementing solution
to the existing automation solutions.
A case in point is adoption of smarter and more digital oil
field technology. The oil producers in the region have already
been using automation, but they are increasingly turning
to digital technology to not only enhance recovery but also
produce economically.
August 2019 | Pumps & Systems
Trends on the Global IIoT Landscape
There is a significant shift in global customer perception
toward IIoT as IIoT adoption is expected to drive efficiencies
across the enterprise such as safety, security, sustainability
and operational efficiency.
The key trends are:
• The convergence of operational technology (OT) and
information technology (IT) is driving new business and
unlocking previously unseen levels of efficiencies.
• Customers prefer long-term service contracts/outcomes-
based instead of capital expenditure (capex) based.
• Complexity and industry-specific challenges have
necessitated solution providers to develop asset and
function specific apps to address user requirements.
• 5G will become critical to accelerate adoption and efficient
implementation of edge computing.
• Cross-industry collaborations will occur, and mergers and
acquisitions (M&A) will become indispensable.
• There will be enhanced field force effectiveness through
use of wearable devices such as augmented-reality systems.
Digitization, Digitalization & Digital Disruption
The process majors in the GCC are expected to spend money
on IIoT adoption in order to enhance capital, asset and process
efficiencies. The organizations are working on a focused digital
transformation journey.
The adoption of digitalization is focused on addressing the:
• shift from periodic inspection to real-time monitoring of
assets or processes.
• better use of sensors and real-time data to enable life cycle
cost savings.
• enhancement of energy efficiency and cybersecurity.
• emergence of “as a service model.” This enables customers
 39

to pay only for the service they

receive instead of upfront capital Arunkumar Janarthanan is the associate director, Industrial Practice for
expenditure and other life cycle Frost & Sullivan. He has more than 14 years of experience in monitoring and
costs. For example, instead of buying analyzing global growth opportunities and trends in the security,
a compressor, customers prefer to manufacturing and process control segments. For more information,
visit frost.com.
opt for “air as a service.” Customers
prefer to focus on their core activities,
reduce total expenditure and also
ensure asset uptime for critical assets.
Even in scenarios where customers
have an existing installed base, they
are willing to work with solution
providers on a subscription fee-based
asset management model to enhance
efficiency and critical asset uptime.
• management of human capital/skills.

The region is still evolving from the

perspective of full-fledged adoption and
implementation. Users are confused
about different solutions or solution
providers that are approaching them with
ways to approach different challenges.
The legacy systems and processes may
not always be supportive of the new
solutions, and the available budgets are
highly targeted.
In addition, research shows the end
users prefer to deal with fewer suppliers
to increase project execution consistency
and flawless implementation.
Considering the above, there is a
clear need for solution providers to
offer industry-specific solutions and
offer the possibility of co-creation
with customers.
In order to facilitate industry-specific
solutions, the systems integrator
ecosystem or focused application
developer ecosystem is critical, and this
has to evolve further in Middle East.
The solution providers should adopt a
consultative approach—understand
the users’ technology maturity, their
existing peripheral process and the
spend threshold. The solution providers
should also play a role of facilitators
enabling futuristic planning and
answering ROI questions.
The above factors are crucial to
accelerate the adoption of IIoT in the
GCC region.
Circle 135 on card.

pumpsandsystems.com | August 2019

40
PUMP SYSTEM OPTIMIZATION

Enhance 
Flare Gas 
Recovery with 
Liquid Ring 
Compressors 
These systems can reduce the 
environmental and economic 
impacts of releasing fl aring gas 
into the atmosphere. 

BY STEFAN LÄHN  
FLOWSERVE

G
as flaring—the process of burning off associated
gas from wells, hydrocarbon processing plants or
refineries, either as a means of disposal or as a
safety measure to relieve pressure—has extensive
ecological and economic impacts. Managing the risks of flare
gas is one of the leading challenges facing the oil and gas
industry today.
While the composition of flare gas varies by application
and facility, more than 250 hazardous substances have been
identified in flare gas. These include carcinogenic substances
such as benzopyrene, benzene, carbon disulphide, carbonyl
sulphide and toluene. Dangerous metals, such as mercury,
arsenic and chromium, as well as poisonous gases like
hydrogen sulfide and sulfur dioxide, are also present.
Flare gas is one of the major factors contributing to
climate change. Oil production facilities around the world
burn off approximately 140 billion cubic meters of natural
gas annually, causing more than 300 million tons of carbon
dioxide (CO2) to be emitted to the atmosphere.1
These chemicals can have devastating impacts on local
populations because they contribute to serious health
conditions, especially in newly industrializing countries with
significant oil production levels.
Flare gas also contributes to billions in lost revenue for oil
and gas companies. The World Bank estimates the 140 billion
cubic meters being flared every year would be worth around
$20 billion. If the amount of gas flared off in a year was
recaptured for energy production, it could provide about
Gas flaring is the
process of burning off
associated gas from wells,
hydrocarbon processing
plants or refineries, either
as a means of disposal
or as a safety measure to
relieve pressure.

August 2019 | Pumps & Systems

 41

Image 1. A flare gas recovery system in action (Images courtesy

of Flowserve)

250
750 billion kilowatt hours (kWh) of electricity, or more than
Africa’s current annual electricity consumption.2
More than
Oil and gas companies should consider how to optimize 250 hazardous
flare gas recovery process—not only for the environmental substances
impact, but also to recoup economic losses. have been
identified in
Flare Gas Recovery Systems flare gas.
While the flaring of gas plays a vital role in plant safety and
excess gas disposal, oil and gas operations need to reassess
how they recapture these materials. system, must be reliable and able to withstand the aggressive
One way to prevent toxic substances from entering the conditions typically found in oil and gas production, including
atmosphere is to use a flare gas recovery system. These below freezing temperatures, hot and humid climates,
systems can recapture up to 98 percent of emissions for use sandstorms and intensive sun radiation.
in other plant processes, such as the heating gas system. Flare
gas recovery systems reduce noise and thermal radiation, Liquid Ring Compressors
operating and maintenance costs, air pollution and gas While there are many compressors available for flare gas
emissions, the risk of harming human health, and fuel gas applications, liquid ring compressors are attracting a lot of
and steam consumption. attention because of their design and reliability that make
The compressor, a vital component of a gas recovery them ideal for use in aggressive environments.

pumpsandsystems.com | August 2019

42 COVER SERIES PUMP SYSTEM OPTIMIZATION
140
Image 2. These compressors use a double-shaft seal design.
Worldwide oil
production
facilities burn off
approximately
140 billion cubic
meters of natural
billion cubic meters gas annually.
One reason for the liquid ring compressors’ reliability is
that it uses a liquid ring formed from the operating liquid,
instead of a mechanical piston, as an energy carrier to
compress gases and vapors. Liquid ring compressors can
compress nearly all gases and vapors without any metallic
parts contacting one another, which is advantageous because
sliding parts are subject to vibration and wear, which impacts
efficiency and leads to increased maintenance, downtime and
possibly mechanical failure.
These compressors also use a double-shaft seal design,
which creates a safer environment for the compression of
flammable mixtures as well as toxic and environmentally
hazardous materials. Liquid ring compressors use an impeller
located within a cylindrical casing, which is fi lled with
operating liquid (typically water). As the impeller rotates, the
resulting centrifugal force forms a moving cylindrical ring
against the inside wall of the casing.
This results in a volumetric expansion in the section of
the outflowing liquid ring, which causes the medium to be
drawn in via the inlet port in the guide plate. In the area of
the inflowing liquid ring, the volume is reduced, causing the
medium to be compressed. After compression, the medium is
discharged via the outlet port in the guide plate.
August 2019 | Pumps & Systems
300
The burn off
natural gas
causes more than
300 million tons
of carbon dioxide
(CO2) to be emitted
to the atmosphere
million tons annually.
Three-Stage Compression
New liquid ring compressor designs use two impellers,
which compress the medium in three stages, rather than
one- or two-stage compression as with previous designs.
This three-stage compression can result in lower internal
losses, optimized intermediate pressures, higher isothermal
efficiency and lower volume flow loss at high-discharge
pressures. The three-stage design also can require less power
and water consumption.
These compressors may be a viable alternative for those
operations looking to optimize current flare gas recovery
system and reduce costs.
With a smaller footprint, these compressors can have lower
installation labor and expenses.
Modern liquid ring compressors employ an easy access
pullout design. Since the bearings and axial face seals are
arranged outside the pump, they can be replaced without
having to dismantle the complete compressor. This design can
make it simple to perform routine maintenance on seals and
bearings and can reduce associated maintenance costs.
Reliability, Efficiency & Maintenance
Flare gas recovery systems can reduce the environmental
and economic impacts of flaring gas into the atmosphere. As
more oil and gas operations contend with larger volume flows,
they need to leverage compressors that are reliable, efficient
and easy to maintain. Using liquid ring compressors that
employ modern hydraulic and mechanical designs that create
thermodynamic advantages is a significant way to optimize
flare gas recovery, recoup lost revenue and guarantee a safe
compressing process.
References
1. The World Bank. “Zero Routine Flaring by 2030.”
2. Ibid.
Stefan Lähn is the global product portfolio leader, liquid ring
vacuum pumps, compressors and systems for Flowserve. For
more information, visit flowserve.com.
 FREE

Energy savings –
what’s the next step? August 15, 2019
2 p.m. Eastern

In this webinar we will discuss how to translate your energy management

to money in your pocket. Move beyond the improvements you have already
made. Learn how to identify the biggest culprits of your energy waste and
how to translate your power management to energy savings.

Learning objectives Who Should Attend:

• Reliability Engineers
• Methods to measure and track • Maintenance Technicians
your energy usage • General Managers
• New technologies to identify
energy loss
• How to make simple changes
to reduce your energy usage

Presenters

Han Tran Sat Sandhu

Tran has a master of science in electrical and
computer engineering from Georgia Institute
of Technology. She was previously at GE where
she worked on complex embedded systems
for condition monitoring systems and obtained
three patents. She is an application engineer
for Fluke collaborating with end users to better
understand their workflow, ultimately uncovering ways to
alleviate their pain points.
Sandhu is the Thermography Services Support
Manger for the Fluke Corporation with over 20
years of experience in the infrared technology.
He provides application support on all Fluke
thermography products. Sat also conducts
seminars, webinars and thermography training.
Sat is a Qualified Level III thermographer, certified
in compliance with ASNT standards. He has authored over 20
papers in infrared and electronics.

educational webinar sponsored by

REGISTER NOW!
PUMPSANDSYSTEMS.COM/WEBINARS
44 COVER SERIES PUMP SYSTEM OPTIMIZATION

Asset Monitoring Improves 
Reliability & Visibility  
Pipeline transmission company achieved successful ROI from 
wireless condition monitoring.

BY ARES PANAGOULIAS, HYDRO, INC. &
KEN BABUSIAK, HYDROAIRE

A
major pipeline transmission company found itself
reconsidering the effectiveness of its maintenance
strategy. The company faced a challenge:
optimizing asset visibility and implementing
remote condition monitoring of equipment health while
avoiding a high-cost investment and installation disruptions.
This particular pipeline transfers a variety of products,
ranging from gasoline to jet fuel, serving customers via pump
stations and storage tanks across the United States. For this
customer, it is imperative to ensure that pumping assets
are efficient, reliable and safely maintained consistently.
The pipeline supports the needs of more than 50 cities, thus
making the pumping assets critical to the availability and
overall operation.
Technology plays a vital role in day-to-day operations
in supporting end user activities, ensuring strict safety
regulations, optimizing maintenance and providing data
on equipment health. In this case, the pipeline company
wanted to significantly improve and innovate upon its current
maintenance approach in two ways: by monitoring asset
visibility in real-time and trending data for their critical
pumping equipment. Image 1. IIoT has brought connection infrastructure to machines that
previously operated in an analog world, isolated from the end user.
Today, there are various options available on the market (Images courtesy of Hydro, Inc.)
for machine sensor instrumentation, data analysis and
methods of installation. The industrial application of With this data acquisition strategy, users may be vulnerable
modern technology has led to a significant rise in the to intermittent issues between site visits. With interval
industrial internet of things (IIoT). This brought connection route-based monitoring, users also may be unable to address
infrastructure to machines that previously operated in an recurring equipment issues.
analog world, isolated from the end user.
Like many practitioners of condition-based maintenance, From Route-Based to Remote Monitoring
the pipeline company had relied on set interval route-based To transition from route-based, condition-based maintenance
monitoring to trend and manage its assets. For some remote to remote-based, the company focused on machine vibration
locations, this may look like a monthly or quarterly check-in. and temperature as primary early condition indicators.

August 2019 | Pumps & Systems

 USING IIoT/
DIGITIALIZATION TO
IMPROVE PROCESS
PERFORMANCE
Reduce downtime and
maintenance costs.

FREE

ABOUT THE EVENT

In the webinar, participants will learn how
today’s digital technology provided by the
Industrial Internet of Things (IIoT) can make a AUGUST 29, 2019
difference in how facilities operate, including: 1 P.M. EASTERN
• Improving mean time between failure
(MTBF) Ideal for:
• Introducing real-time analytics to predict • Maintenance and operations personnel
maintenance issues • Reliability engineers
• Reducing total cost of ownership • Design engineers
on assets • Facilities/plant managers
• Increase energy efficiency • Anyone interested in the possibilities
• Reduce safety incidents offered by IIoT

Todd Loudin is President

of North American
Operations and Vice
ABOUT THE President of global sales
for Flowrox. Loudin has
PRESENTER been with Flowrox for 23
years. He has a BS and
MBA from Loyola.

Educational Webinar Sponsored By

REGISTER NOW!
PUMPSANDSYSTEMS.COM/WEBINARS
46 COVER SERIES PUMP SYSTEM OPTIMIZATION

The real-time data allows for users to make educated decisions regarding asset
maintenance and associated schedules. It also allows decision-makers to identify
issues before escalating and leading to unplanned equipment shutdowns.

In partnering with an aftermarket pump

service provider with domain expertise in
pumps, the pipeline company can extract
maximum value from the collected data with
confidence in support for their pumping assets.
An IIoT-based solution gave the company a
real-time measurement of machine vibration
and temperature, as well as increased sampling
or trending of machine health. The real-time
data allows for users to make educated decisions
regarding asset maintenance and associated
schedules. It also allows decision-makers to
identify issues before escalating and leading to
unplanned equipment shutdowns.

Real-Time Vibration & Temperature Data

Image 2. The aftermarket pump service provider installed wireless sensors on four
machine trains at two pumping stations.
The cost to procure sensors, perform the installation
(including power, conduit and data acquisition (DAQ) system)
and implement a data analysis platform for those sensors
proved to be exorbitant in the past, as compared to a state-of-
the-art wireless system.
In this case, the aftermarket pump service
provider supplied a total solution by using
wireless condition monitoring for the pumping
assets while also offering pump repair,
engineering and upgrades as opportunities
for improvement.
This newly executed system included
wireless sensors mounted on pumps, motors
and other critical machinery. Collection gateways
were then provided to communicate with the
sensors, collect data and transmit data to a
cloud-based server.
Once data is transmitted to a cloud
platform, reliability engineers can access it
from web-based software, regardless of their
device or operating system. Access to the web-
based predictive maintenance (PdM) platform
allowed engineers to view data from anywhere,
anytime—creating the flexibility required for
their day-to-day operations.
The specialized software allows users to monitor and trend
condition indicators that are customizable for each sensor
and machine.
The main features include overall vibration amplitude and
temperature trend data.

August 2019 | Pumps & Systems

Circle 121 on card.
 PUMP SYSTEM
48 COVER SERIES
OPTIMIZATION

THE PROVEN BLUELINE

ROTARY LOBE PUMP

THE CASING
PROTECTION

QUICK-
CARRIER AND RELEASE
TIMING GEAR COVER

LARGE INTERMEDIATE
QUENCH AND THE ROTORS
SEAL CHAMBER
UNIQUE BLOCK DESIGN
Image 3. The time waveform analysis, fast fourier transforms
(FFT) spectrum analysis and cross-phase analysis are part
the vibration analysis tools and as data is collected, algorithms
develop baseline levels of vibration.
THE BLUELINE BENEFITS:
+ Self-priming
The software also offers tools to perform time waveform
+ Flows up to 7,500 gpm
analysis, FFT spectrum analysis and cross-phase analysis as
+ Pressures up to 180 psi part of a full suite of vibration analysis tools (Image 3).
+ Low shear handling As machine data is collected, algorithms develop baseline
+ Reversible operation levels of vibration and determine alarm threshold levels for
each asset. Alternatively, user-determined alarm thresholds
+ Dry-running capability
may be used based on historical data.
If a sensor collects data that crosses a specified alarm
UNIQUE FEATURES: threshold, an automatic notification is triggered by the
+ Patented rotor tips software via email or text message.
+ MIP radial liners
Benefits of Wireless Condition Monitoring:
+ Casing BLOCK construction • real-time data—not dependent on next route cycle
+ Proven seal solutions • high-frequency data collection (no missed events
+ Customized construction
or issues)
• increased resources for data analysis and reduced
+ Compact design
data collection time
• customized alerts and alarms
• optimized maintenance schedules based on
Wetted parts can be inspected or machine condition
replaced at the installation site without
the removal of pipe or drive systems.
The pipeline company customized alarm thresholds based
on historical alarm amplitudes used during route-based
Circle 132 on card.

data collection. By doing so, the evaluation of vibration flowed

seamlessly into the process and general maintenance approach.
VISIT US AT WEFTEC | BOOTH #1014 The aftermarket pump service provider’s monitoring software
was programmed to automatically report on any alarm or
emergent issue to engineering experts, as well as the pipeline
company’s reliability engineers.

August 2019 | Pumps & Systems

 49

As machine data is collected,

algorithms develop baseline levels of
WE CAN
HELP
vibration and determine alarm threshold
levels for each asset.

The pipeline company chose to initially focus on several

bad actor pumps within the pipeline’s network of assets. The
aftermarket pump service provider installed wireless sensors
on four machine trains at two different pumping stations Our high performance solutions
(Image 2). Significant reliability improvements were achieved, make us your source for everything
ensuring a faster return on investment (ROI) due to the
wireless condition monitoring products and services.
sealing, including mechanical seals,
pump and valve packing, air seals
Expanded Remote Monitoring and bearing isolators.
For the pipeline company’s pumping assets, the aftermarket
pump service provider met the customer’s needs while also
increasing the reliability, maintainability and availability of
critical assets for years to come.
The reliability improvements implemented via wireless
condition monitoring include real-time machine health
trends, machine vibration frequency excitation, and
optimization of operation and maintenance strategies.
When the initial investment achieved its goals, the
pipeline company expanded its application of sensors to eight
additional stations. The company decided to take the same
approach with the new stations, choosing the stations with
the most substantial potential for reliability improvements
and the highest need for remote monitoring.
Often, players in the marketplace focus on a single
aspect of the broader IIoT process such as the sensors,
software, connection infrastructure or machines undergoing
monitoring. In this case, the aftermarket pump service
provider was able to offer an integrated package/product that
included the wireless condition monitoring solution and total GFO is a registered trademark of WL Gore and Assoc.

support for critical assets.

Ares Panagoulias has overseen Hydro, Inc.’s

pump test lab for the past eight years and
serves as the sales and engineering manager
for its wireless condition monitoring system.
Circle 130 on card.

Ken Babusiak has held various positions in

the pump industry for more than 40 years.
For the past 16 years, Babusiak has served
VISIT US 800-633-4770
www.sepco.com
as the vice president of industrial sales for AT TPS 2019
HydroAire, Inc. For more information, visit
hydroinc.com/IIoT. BOOTH 1201

pumpsandsystems.com | August 2019

50 COVER SERIES PUMP SYSTEM OPTIMIZATION
3 Strategies 
for Successful 
Pump System 
Optimization
Whole‑system approach improves  Switch to Smart Pumping
overall performance.
BY JORDAN RUFF
XYLEM INC.  management and pump system optimization.
S
ystem optimization is the process of evaluating
pump systems to identify opportunities for
improvements that will reduce energy consumption
and increase reliability. Improving a single
component—like installing a more efficient motor—will do
little to improve overall system efficiency. Engineers seeking
to design mechanical systems for commercial buildings that
lower energy consumption, reduce maintenance and extend
the life of system components must evaluate how all pump
components work together to ensure they are selecting the
most efficient pumps for the application.
Greater pump system efficiency achieved through system
optimization will improve reliability and lower operating
costs by reducing wear and tear. It will also decrease
downtime and costs associated with lost production,
maintenance and repairs, while extending equipment life.
Here are three ways to boost pump system optimization.
Use Multiple Pumps
1 When multiple pumps operate as part of a parallel
pumping system, there can be opportunities for significant
energy savings.
Multiple pumps in parallel are well suited for systems
with high static head. Some advantages of multiple pump
arrangements are flexibility and the ability to meet changing
flow needs efficiently in systems with high static head.
August 2019 | Pumps & Systems
Another advantage is system redundancy. One pump can
fail or be taken offline for maintenance while the other pumps
support system operation. When identical parallel pumps are
used, the pump curves should remain matched. Therefore,
operating hours should be the same for each pump, and
reconditioning should be done at the same time for all pumps.
With a series of identical pumps placed in parallel, the
number of operating pumps can be changed according to
system demands. Because the pumps are the same size, they
can operate together, serving the same discharge header. If
the proper pumps are selected, each pump can operate closer
to its highest efficiency point. An added flow control benefit
of parallel pumps is that a system curve remains the same
whether one or several pumps are operating. What changes is
the operating point along this system curve.
2 While installing drives and controls on existing pump
systems can deliver improvements in efficiency and reliability,
the emergence of pumps with embedded intelligence is
a critical step forward in the evolution of performance
Intelligent pump controllers can automatically configure a
system with the optimal settings for the application, taking
the guesswork out of the process. Systems can be customized
with pump protections and for multiple pump operation.
Curve control technology relies on pump-specific
algorithms, which can accurately predict where a pump
operates on its curve. Using speed, torque and power data to
know where the pump operates on the curve, sensorless pump
controllers can be set up to take action based on those factors.
Area control uses physical sensors to embed the actual
pump curves into controllers, giving the controller an
unprecedented view of the pumps and the system and how it
is performing. Now, the controller is not just responding to
the need for additional flow, but it can also look at that the
pumps in the arrangement to decide the most efficient way to
get that extra flow.
Embedded electronic drives expand the efficiency island
of the pump, which is the area where the pump is operating
within its preferred operating range. This maximizes
flexibility and enhances system performance as the pump
system adapts to user needs in real time, ensuring optimum
performance at all times. The drive also enables the size of the
motor to be reduced, resulting in a more compact footprint.
Electronically commutated motors (ECMs) are another
variable to consider for pump system optimization. ECMs can
reduce energy consumption by as much as 80 percent without
sacrificing performance.
Today’s ECM circulators use a permanent magnet motor
design and variable speed technology to adapt automatically
 51

to system demand. Infinitely variable However, with the traditional When combining efficient pumps
speeds means optimized system pump selection approach, industry with selections based on PLEV, system
performance while drawing the least professionals select pumps at 100 percent designers can maximize operational
amount of energy possible. load conditions, although a pump only performance while realizing energy
When paired with technologically operates there 1 percent of the year. cost savings.
advanced drives and controls, pumps
with ECM technology enable designers to
optimize hydronic systems for the lowest
total energy use.

3 Access Advanced Selection Tools

Proper system design is critical to
minimizing life-cycle costs and reducing
a system’s power consumption. Online
selection tools that enable designers to
choose all system components within a
single integrated tool ensure the most
efficient hydronic system design. SAME-
Advanced selection tools include SHIPM DAY
intuitive features to assist in system E
AVAILA NTS
design. One market feature allows users
BLE
to search pumps by constant or variable
speed to discover and select products
that will deliver optimal performance

within a hydronic heating, ventilation
and air conditioning (HVAC) or plumbing
system. Variable speed technology allows
the pump to adjust operating speed and
respond smoothly and efficiently to
fluctuations in demand.
The online system selection tool is also
the only one available that includes part
load efficiency value (PLEV) selection
criteria, a calculation that helps system
designers gauge true pump performance
by measuring the efficiency of the pump
at partial flow rates.
Flow requirements fluctuate constantly
based on the heating and cooling needs of
a building at any given time.
Jordan Ruff is product line manager,
Monitoring and Controls for Xylem
Inc. He holds a Bachelor of Science
degree in mechanical engineering from
Duke University and completed the
Advancing Business Acumen Program
at the University of Pennsylvania – The
Wharton School. For more information,
visit bellgossett.com.
PERMANENT BEARING
PROTECTION
THAT’S WHAT WE DO...
At Inpro/Seal®, we are dedicated to providing increased equipment reliability through
engineering excellence, superior sealing technology and unmatched customer support.
The new IP66 rated VB45 Bearing Isolators are the next generation of Bearing Isolator
technology. The VB45-S™ Bearing Isolator’s compact design, with only a 0.625 in.
(15.88 mm) overall length, provides premium contamination protection and lube
retention to maximize rotating equipment reliability. The VB45-U™ Bearing Isolator offers
superior bearing protection for both oil and grease lubed equipment. Its unique, unitized
rotor design accommodates axial movement.
To learn more about increasing equipment reliability with permanent bearing
protection, visit www.inpro-seal.com.
Visit Us At:
Turbomachinery & Pump Symposium
Booth 2427
Sept. 10 - Sept. 12 Houston, TX
Circle 127 on card.

pumpsandsystems.com | August 2019

Innovative Communication.
Enhanced Reliability.
Introducing SIDRIVE IQ™
now with Veros ForeSight™
Get more out of your drive systems with
digitalization

Digitally enhanced drive components are an important step

toward digitalized automation. With SIDRIVE IQ, you can now
benefit from an IoT digitalization solution for drive systems.
Take advantage of digitalization to enter a new dimension of
availability, serviceability, productivity, and efficiency.

In addition, Siemens is excited to announce its expanded

relationship with Veros Systems. The companies interfaced Veros
ForeSight technology with Siemens variable frequency drives to
provide new performance and health monitoring of motors and
the assets they drive, all without installing any sensors on the
rotating assets themselves.

Listen to Shell discuss how their organization has utilized Veros

ForeSight and the benefits they have seen with this technology
during the Turbomachinery & Pump Symposia. Visit
Siemens
at Booth
usa.siemens.com #1835
Circle 102 on card.
54 COVER SERIES PUMP SYSTEM OPTIMIZATION

Hydraulic Retrofi t Meets 
Increased Demand
Texas refi nery achieves improved performance from API barrel 
pump through major re‑rate.

BY MATT KINNEY
SULZER

P
roductivity targets are a key performance
measure in any process industry and the refining
business is no exception. Increasing output from
a large refinery to meet market demand presents
challenges. However, dealing with the pumps does not need
to be one of them.
Due to changes in government regulations over the past
Image 1. Cross section of pump barrel and internals, showing
several years, the demand for ultra-low sulfur diesel (ULSD)
reduction from 10/9 stages (Images courtesy of Sulzer)
has increased. As a result, refineries across the country have
been forced to adapt and find innovative solutions to meet
increasing capacity. A refinery in Texas found itself in this
situation and began investigating possible solutions with the the API BB5 can be suitable for applications such as water
help of a service center. injection, oil export, boiler feed and charge service.
The two pumps of interest were 6 x 8 x 10.5 BB5 10 stage
units in diesel charge service. The American Petroleum The Challenge
Institute (API) BB5 is a barrel pump that encloses a The subject pumps were originally sold in 2006 at a rated
multistage axial split inner bundle with an opposed impeller point of 1,110 gallons per minute (gpm) at 4,014 feet. With
configuration (Image 1). Being that the pressure boundary is the change in ULSD demand, the reliability engineers at
radially split, these pumps are typically designed for high- the refinery wanted to increase the capacity to 1,628 gpm at
temperature and/or high-pressure applications. With the 3,450 feet (Image 2). The goal was to find the most economical
capability of handling pressures and temperatures up to and timely solution to meet the needs of the refinery.
6,250 pounds per square inch (psi) and 800 F respectively,
The Design Review
When in this situation, there are three possible options:
• Purchase a new pump that is designed to deliver the
It was important that the proposed desired capacity.
upgrade was supported by internal • Hydraulically modify or “re-rate” the existing pumps.
• Operate the two existing 100 percent pumps in parallel
empirical data and experience to (depending on system curve).
provide confidence in the accuracy of
Each of these options have advantages and disadvantages.
the proposed design changes. For example, parallel operation would be the least costly to
achieve the increase in flow.

August 2019 | Pumps & Systems

 55

40

NPSH IN FEET
NPSHR AT IMPLR CL
30

20
RED DASHED LINES REPRESENT ORIGINAL 100 10
PUMP PERFORMANCE
BLUE SOLID LINES REPRESENT PUMP
5500 90

EFFICIENCY PERCENT
PERFORMANCE POST RETROFIT
5000 80
EFF %
HEAD IN FEET

4500 70

4000 60

3500 50
MIN FLOW

HEAD

3000 40

30 1500
BHP AT 0.770 SP GR
20 1000

BHP
10 500
EFFICIENCY PERCENTAGE EXCLUDES
SPECIAL MECHANICAL SEAL LOSSES!
0 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
GALLONS PER MINUTE

Image 2 (left). The predicted pump performance curve achieved by the retrofitted pump pushed the best efficiency point (BEP) to achieve
higher flows. Image 3 (right). Pump inner case shown with volute lips that have angled cutback

However, the lack of system The approach was to keep it simple: • Ensure that case modifications could
redundancy in the event of a failure is • Select an existing standard impeller be made to fit the new impeller.
risky and can often be costly in terms hydraulic design that was suitable for • Confirm the nozzle area could be
of lost production. the desired performance and had been increased enough to mimic the
A new pump selection to fit the proven by at least two factory tests. reference pump performance.
application could be advantageous
with regards to efficiency. But long lead
times, the cost to reroute pipework, and
baseplate or foundation modifications
may make this option less attractive. PUMP MOTOR
BEARING
If re-rating pumps, the desired
performance may not be achievable in
the given frame size. But if feasible,
re-rating can often be quicker and
more economical.
Based on the criticality of this service
PROTECTION
for the overall success of the refinery
operations, the possibility of re-rating
was of great interest.
• Reduce downtime
Engineers conducted a thorough
• Save money
feasibility study both hydraulically and
• Easy installation
mechanically to determine whether the
• Superior
goal was possible. A specific speed (Ns) performance
based search revealed an existing proven
design that would meet the refinery’s
needs—provided the impellers were able
to physically fit, and the inner-case You can extend the life
volute nozzle areas could be increased of your motors and
enough to allow the impeller to meet prevent costly damage
as-designed performance. A review of to bearings! 1-800-962-4851
the volute development drawings
provided confidence that both items helwigcarbon.com
could be fulfi lled.
Circle 146 on card.

pumpsandsystems.com | August 2019

56 COVER SERIES PUMP SYSTEM OPTIMIZATION
Image 4. Exterior of completed pump at Odessa Service Center
Ideally, a factory test would have been performed after
completing this work, but unfortunately, the project’s
timeline did not make this possible. It was important that the
proposed upgrade was supported by internal empirical data
and experience to provide confidence in the accuracy of the
proposed design changes. It was necessary that the predicted
impeller trim was calculated correctly on the first attempt.
The Optimized Solution
With an array of impeller hydraulic designs available,
engineers were able to select an existing design that would
meet the new desired head and capacity of the application.
A mechanical cutback was done (see Image 3) to achieve
both an increase in nozzle area and lip diameter. Based on
empirical data, the increase in nozzle area would allow the
new impeller selection to run out in flow to the new design
point. The increase in volute lip diameter enabled sufficient
lip clearance. This, and the fact that the cutback was angled,
helped with the reduction of vane pass pulsations and overall
vibration amplitudes. The outlet vanes of the impeller were
underfi led to increase the outlet area between vanes (OABV)
and help flatten the performance curve. This also pushed the
best efficiency point (BEP) to achieve higher flows.
The new performance level did not require all 10 stages.
One stage was removed so that the impeller trim could be
near full diameter. This benefitted both the efficiency and
the BEP location for the pump. With the stage reduction, the
effect on axial thrust direction and magnitude was analyzed.
The internal bushings were resized to ensure the axial load
was acceptable for the thrust bearing.
The Obstacles & Drawbacks
With a major re-rate such as this, it can be difficult to fit
a new, relatively large, high-capacity impeller within the
existing volute.
August 2019 | Pumps & Systems
This is because multistage pumps are designed with the
shortest possible stage spacing to limit overall pump length.
Fortunately, the pumps in this example were originally
equipped with a relatively low-flow rotor compared to
its frame size, which offered more room to work. To
accommodate the increased impeller outlet width, the volute
side walls required widening or “slabbing” to ensure adequate
side-room clearance, which is critical to centrifugal pumps.
In addition, the inner-case line bore diameter was
increased to accommodate the larger impeller eye
diameter. The bore was increased to the maximum allowable
value while maintaining enough wall thickness between it
and the waterways and maintaining structural integrity of
the inner bundle.
The increased pump performance required more power
than the original 1,250-horsepower (hp) motor could deliver,
so a new motor was acquired to meet this demand. However,
no baseplate modifications were required as the frame size
for the higher rated motor remained the same.
The net positive suction head required (NPSHr) had
increased with the new selected suction impeller. However,
this was not a problem as the net positive suction head
available (NPSHa) was adequate.
The Advantages
The decision to re-rate the existing pumps rather than
buying new was highly advantageous for the refinery. The
re-rating project was more economical, especially since the
outer barrel alone can be a high-priced component.
The re-rate required no changes to the footprint of
the existing pump, saving valuable time in completing
the project. If a new pump had been specified, baseplate
modifications and rerouting of suction and discharge
pipework may have been required.
The hydraulic modifications were all confined to the
inner bundle, allowing the outer barrel to remain piped up
in the refinery. This improved the overall delivery time for
the project.
The Outcome
Once complete (Image 4), the pump was reinstalled and ran
well. In fact, the pump had slightly outperformed what was
proposed. Both the vibration levels and bearing temperatures
were well within the acceptable limits.
The final benefit: The payback period for the cost of this
project was achieved in 35 days.
Matt Kinney is a hydraulic retrofit specialist at Sulzer. For
more information, visit sulzer.com.
BUY American.
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www.pumpworks.com | 1-800-405-0209
pumpsandsystems.com
Circle 120 on card. | August 2019
58 COVER SERIES PUMP SYSTEM OPTIMIZATION
Proper Calculations Optimize 
Northeast Pump System
NPSH problem was corrected to generate additional power.
BY KRISTO NAUDE
NRG ENERGY, INC.
Editor’s Note: This case study is provided by a pump advisor for Turbomachinery Lab at Texas A&M where students are exposed to hands-on experiences,
providing them pump training in the field. In this article, students learn the importance of doing the math.
A
call came from a regional engineering manager
in a Connecticut-based facility two winters ago,
inquiring about an operational issue with a No. 2
fuel oil pump feeding a power generation boiler. It
would not pump like it should.
The problem had a sudden onset, which coincided with a
dramatic flow rate drop, increased vibration, loud noises and
overheated pump case. This was all amid a cold spell, when it
was necessary to generate additional power.
After some discussion about the layout and the symptoms,
the “why” became clear. The cold weather caused the viscosity
of the fuel oil in the long, outdoor suction line to increase
until the net positive suction head required (NPSHr) by the
pump could no longer be met. It was an NPSH problem.
Image 1. Long suction piping from horizontal tank in background
(Images courtesy of NRG Energy, Inc.)
August 2019 | Pumps & Systems
A site visit was required to assess what to do about this
NPSH inadequacy. The problem was evident. Whereas best
practices guidelines would contain wording such as “keep
the distance between the suction tank and pump as short
as possible,” this layout was different. Compounding the
problem, no source for heat tracing of the 260-foot suction
line (electrical or steam) was readily available.
The only practical solution was to either replace the entire
suction line with a larger diameter line or to install a second,
parallel suction line to reduce the friction head loss. Both
options would carry a price tag of more than $100,000. There
was no easy solution. More research was needed.
To determine the appropriate diameters required for
each option, the system was modeled using pump and pipe
hydraulic modeling software. An unexpected problem arose—
despite the increased viscosity and the long suction line, the
impact on NPSH available (NPSHa) was still such that the
margin (NPSH3) required by the pump could not be met.
Clearly, this was not correct. The team thought a computer
error had to be responsible. The calculation was run by
hand, and the software output result was confirmed. Then,
in researching the behavior of No. 2 fuel oil further, the
tendency of the fuel oil to wax, or gel, in extremely cold
conditions was discovered.
And that was the real problem. The viscosity did not
only increase to the point that friction head losses became
excessive, but the exposed pipe wall temperature had dropped
low enough to allow the fuel oil to develop wax against the
inner pipe wall and propagate radially inward. The slow-
flowing liquid in the pipe had lost enough heat to reduce the
active hydraulic diameter of the pipe further, to the extent
that NPSH3 could no longer be met.

Image 2. Lower half of a double suction, two-stage pump
The plan was to increase the suction line capacity to reduce
friction losses, which would slow the linear velocity in this
line down even further. This would increase fluid residence
time even more, and thereby further increase the tendency
and opportunity to wax.
A double suction, two-stage pump was used to provide
No. 2 fuel oil to the boiler (see Image 2 and 3). Since the
flow rate required by the boiler was low, yet the pump
dynamic head required high, the boiler flow rate constitutes
an uncomfortable duty for a centrifugal pump—even for
pumps with low specific speeds. It was found that the boiler
flow rate was the only flow through the pump, at 25 percent
best efficiency point (BEP). The minimum flow recirculation
(routed back to the fuel oil tank) was essentially inoperative,
because a pressure relief valve was ineffective in a flat part of
the curve and the activation pressure had been set too high.
The preferred option (an in-line flow meter) was not available.
With the pump operating at only 25 percent BEP and
the minimum flow recirculation line inactive, the optimal
solution also became apparent.
Contrary to first instinct, the solution here was not to
increase the suction line diameter and capacity to decrease
friction head losses, but the exact opposite: increase the flow
rate and linear velocity.
A small modification would be required to activate the
minimum flow recirculation by opening a bypass valve to
an appropriate setting on a permanent basis to act as a
minimum flow orifice. The residence time would be reduced
and heat loss to the environment reduced, such that waxing
would be delayed.
System modifications in this scenario are not too difficult
to implement. The solution would have two-fold benefits:
59
Image 3. Pump design; two stages
NPSHa will be improved and the operating point on the
pump performance curve will improve, and reliability of the
centrifugal pump improved as a direct consequence.
Once the math was calculated and the optimal solution
determined, a win-win solution was determined:
1. Residence time in the suction pipe exposed to the cold was
reduced, thereby reducing the risk of waxing.
2. The pump minimum flow recirculation was now activated
and functional, such that the pump would run closer to 65
percent BEP. This was a significant improvement over the
former 25 percent.
3. Major reliability improvements were made possible for
minimal investment.
It is important to note not only the technical details of
this problem and its solution, but also to realize how easy
it is to make inaccurate assumptions and to draw incorrect
conclusions. Use facts to draw conclusions. In this case, initial
assumptions would have caused the implementation of a
modification that would have guaranteed failure.
The major lesson learned here is to do the math. It is less
expensive than the results of a mistake, and easier on future
career aspirations.
Kristo Naude is a senior engineer for NRG Energy, Inc., and a
pump advisor for the Texas A&M Turbomachinery Laboratory.
Naude obtained a Bachelor of Science in mechanical
engineering from the University of Pretoria in 1986 and an
MBA through the University of Stellenbosch Business School
in 1998. He may be reached at kristo.naude@nrg.com. For
more information, visit nrg.com or turbolab.tamu.edu.
pumpsandsystems.com | August 2019
60 COVER SERIES PUMP SYSTEM OPTIMIZATION

Smart Pumping Helps 
Avoid Cavitation & 
Commissioning Issues
Fluid management data monitoring and analytics services can 
assist in preventing injuries and system damage.

BY TUNJI ASIWAJU
ARMSTRONG FLUID TECHNOLOGY

T
here are many stories of expensive pump repairs and
performance problems brought on by cavitation.
In one case, a municipal water department was
replacing impellers for its reservoir feed valve every
18 months, for years, until engineering efforts produced an
accurate diagnosis and resolution.
In another instance, a power plant was regularly forced
to spend millions of dollars to shut down, dismantle,
transport, repair and re-install cooling water pumps before
it understood the root problem and an effective remedy.
If high cost is not a serious enough issue, there have also
been reports of pumps exploding and motors flying through
concrete walls, which suggests that someone could be
seriously injured or even killed by the effects of cavitation.

System Performance
Well before equipment runs to failure, cavitation can
quietly ravage an operating budget. Cavitation reduces
flow performance, which can lead to increased power
consumption, and can cause serious wear on seals and
bearings. Associated noise can create occupant reactions and
even minor leaks can cause unwanted cleanup expenses.
Writing in Pumps & Systems a year ago, Jim Elsey noted
that, “When the bubbles collapse near or at the metal
surface, they collapse asymmetrically and cause a small
microjet. This collapse occurs on a nanoscale (1.0 x 10-9 or
billionth). Local pressure forces involved can be higher than
Image 1. Impeller damage shown with a pump performance map
10,000 pounds per square inch gauge (psig) (689 bar) or (Images courtesy of Armstrong Fluid Technology)
more, plus there is heat generated.

August 2019 | Pumps & Systems

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62 COVER SERIES PUMP SYSTEM OPTIMIZATION
Image 2. Fluid management data monitoring and analytics can
predict pump problems
“This phenomenon can occur at frequencies up to 300 times
per second and at speeds near the speed of sound.”
It Is Complicated
Occasionally, journal articles from a variety of experts
appear, presenting structured breakdowns of the types of
cavitation damage, their causes and solutions. Meanwhile,
the average engineer acknowledges that cavitation is not
simple to diagnose, and often even more difficult to correct.
In the “Centrifugal Pump User’s Guidebook: Problems
and Solutions,” published in 2012, Appendix A contains a
checklist of pump problems and their causes. Under “Pump
is operating with noise or vibrations, or both” it mentions
cavitation, plus 41 other possible explanations.
It is true that symptoms indicating cavitation might also
signal air entrapment, suction recirculation or discharge
recirculation. It can be expensive to determine the problem,
before any consideration is given to the cost of solving it via
shutdown, draining the system, service personnel, redesign,
new components, downtime and more. The good news is that
technology has evolved to provide more precise information.
August 2019 | Pumps & Systems
Connected Systems & Data Analysis
Intelligent fluid management systems now include internet
connectivity and the capability to gather existing data of
operating occurrences. It is also possible to capture and
store patterns and trend lines in the cloud. Contemporary
algorithms can analyze the data and provide insight into the
workings of mechanical systems and components with a level
of statistical accuracy that was previously unavailable.
Fluid management engineers with major technology
manufacturing firms now rely on a wider variety of analytic
processes aimed at reviewing history and predicting the
future. Vibration, performance data, operating pressure and
temperature variations are all analyzed to develop models
that will lead to reliable diagnoses of fluid management
challenges and recommendations on preventive measures.
Failures of different types, including issues with shafts,
bearings, seals or cavitation, exhibit a unique signature.
Even within a given type of failure, there are different
signatures. Examples include early onset cavitation, moderate
cavitation, critical cavitation or complete failure caused by
cavitation. If pumps are cavitating, the pumps are likely not
the problem. The actual causes can be numerous, including
suction pressure below normal, clogged strainers or leaking
valves. It will soon be possible for data analytics teams to
suggest which of these is the likely culprit.
Smart Commissioning
The same departments making a science out of diagnosing
and preventing catastrophic failures are learning with
more precision about system performance and ongoing
commissioning. When purchasing intelligent pumps and
controls for a mechanical room, the pumps can now be
installed and commissioned, and then ongoing performance
tracking can be added along with tweaking for continuous
performance improvements. As best practices are more
precisely defined, based on systems around the world, fluid
management can improve in real time.
This is valuable in almost any situation involving intelligent
engineered systems, and even more so when the facilities
teams are large and the assets expansive. Big complexes and
campuses can experience personnel turnover that can disrupt
performance and the dissemination of learning. Ongoing
performance tracking and data collection can provide
data succession and commissioning continuity to support
the efforts of incoming engineering personnel and ensure
organizational goals are met.
Data Does Not Have an Opinion
Another valuable dimension of this technological
advancement is that it allows an enterprise to welcome the
new data-driven world.
 63

There are stories of the stereotypical curmudgeonly

engineer who has been in residence forever and is convinced
of his own wisdom regarding long-standing systems problems

We’ve got
and how nothing can be done to fi x them. Although this
character is fictional, there may be some individuals who
struggle to keep an open mind. Sometimes narrow thinking
is a contributing factor in poor system performance or the right
continued inordinate maintenance costs.
motor
for your
Here is where data can save the day. Accurate data can
provide an unbiased assessment of what is really happening.
As the databases and analytics continue to develop, solutions
will be identified with increasing precision and, in some cases, application
dramatic results.

Anomalies & Alerts Case Study

In one example, an integrated pumping system had been
installed and a subscription data gathering function was
enabled. Everything was fine until alerts regarding an
anomaly were received, and the user was advised.
The team helped the user focus on the possible scenarios.
Following a physical investigation, it was determined that the
facilities team had recently replaced the valves and drained
the system, but the system had not been properly refi lled.
There were still pockets of air in it. Thankfully, the issue could
be corrected quickly. Running a pump intermittently dry
could have resulted in burned-out motors or a greatly reduced
life span for the motors—five years rather than 20.

Manual Settings
Fluid management data labs have discovered that one habit of
some facility managers and engineers is the unnecessary use
of pump-in-hand, also known as manual settings. Manually
selected speeds and sequences may or may not be a good idea NovaMAX ¨

with properly commissioned intelligent control systems.

Algorithms have already been developed that can calculate
The award-winning line of SyMAX®
the efficiency differences between manual selections and
and NovaMAX® motors delivers high
optimum settings determined by modern controls. Still, torque performance meeting IE4 and
technicians routinely find one or more pumps set to “Hand even proposed IE5 efficiency standards
Mode,” underserving the system (not delivering enough in a variety of applications including:
data centers, ventilation, pump,
pressure) or wasting energy (creating too much pressure).
compressors and more.
For smarter commissioning, extended performance
efficiency, anomaly alerts, adding new best practices or Try our savings calculator at
predicting failures, an intelligent, connected system with www.novamaxmotor.com.
ECM made Easy™
analytics capability offers compelling advantages.
Circle 133 on card.

Tunji Asiwaju is global manager of Performance
Management Services at Armstrong Fluid Technology. He can
be reached at tasiwaju@armstrongfluidtechnology.com.
For more information, visit armstrongfluidtechnology.com.
www.regalbeloit.com
Creating a better tomorrow™...
Regal, Creating a better tomorrow, ECM
Made Easy, Marathon, NovaMAX and SyMAX
are trademarks of Regal Beloit Corporation or
one of its affiliated companies.
©2018, 2019 Regal Beloit Corporation, All
Rights Reserved. MCAD18067E • SB0196E

pumpsandsystems.com | August 2019

64 COVER SERIES PUMP SYSTEM OPTIMIZATION

Trends in Variable Flow 
Pumping for Hydronic 
Heating & Cooling 
Operators can increase effi  ciency with packaged HVAC pump systems, 
inline multistage pumps, and advanced motors and controls. 

BY REECE ROBINSON  
GRUNDFOS

B
efore talking about pumps, take a look
at another piece of equipment used to
maintain comfort in a building: chillers. A
chiller consists of a compressor, condenser,
evaporator, expansion valve, power and controls unit,
and many other ancillary items. When chillers were
first introduced to the market, they were supplied
as separate components, bringing many challenges
during installation and commissioning. This is why
manufacturers started manufacturing chillers as
complete packages.
Why should pump systems be any different?
Pumping systems are comprised of pumps, motors,
isolation valves, check valves, a power and control unit,
and other ancillary items such as gauges and sensors.
One could argue that pumps should be supplied as
packages for the same reasons as chillers and boilers.

HVAC Design Requirements &

Pumping Guidelines
The principal role of the pumping system is simple:
provide enough flow so the building can be adequately
heated or cooled. The pumping capacity, namely
flow and head, is determined based on the building’s
peak demand requirements. Since the building will rarely
reach these peak design requirements—or if it does, it is
only for a short period—the pumping system should be
optimized for part-load conditions. Today, the most common
approach to ensure good pumping efficiency at part load is
Image 1. Cost savings on NEMA Premium motors (Tables & images courtesy
of Grundfos)
the use of variable frequency drives (VFDs). The increased
use of variable speed is also being driven by the building
construction codes, which now include energy.
The American Society of Heating and Air-Conditioning
Engineers (ASHRAE) has included hydronic variable flow
pumps in the Energy Standard for Buildings (ANSI/ASHRAE/

August 2019 | Pumps & Systems

66 COVER SERIES PUMP SYSTEM OPTIMIZATION

Table 1. Chilled water demand based on

IES 90.1, section
building cooling loads 6.5.4.2). This
section of the code
% Design Flow Hours / Year
requires pumps to
7.2% 2,663 have controls that
20.9% 281 will result in pump
34.3% 816 motor demand of
53.7% 805 no more than 30
percent of design
86.6% 75
wattage at 50
Total 4,640 percent of design
water flow.
HVAC Pumping Design Practices
A common approach is to select one pump to handle the total
flow and specify a second pump as a backup, resulting in
what is considered “100 percent redundancy.” With the use
of VFDs, this has been an acceptable approach and, in most
cases, can meet the building energy code requirements.
When looking at actual building cooling or heating
requirements, this can result in pumps operating at below 20
percent of the rated capacity, and even with variable speed
drive (VSD) control this can result in less than optimum
pumping efficiency.
Engineers should look at actual cooling and heating water
demands over time when selecting which pump configuration
to go with. This can result in multiple smaller pumps being
more efficient than larger counterparts. Software can help
determine building loads, which can help calculate flow rate
data for each hour of the day for a full year. This information
can be summarized to help select the optimal number of
pumps. Table 1 shows the chilled water flow demand for a
variable flow system.
If chilled water flow peak demand was 1,000 gallons per
minute (gpm), this pumping system would be operating at
around 72 gpm for over half of the pump system’s duty cycle.
This low flow demand brings up questions when considering
pump selection. Is this below the pump’s preferred operating
region (POR)? And more importantly, is it below the pump’s
allowable operating region (AOR)? What is the pump
efficiency at this low flow range? Is this flow below the
chiller’s minimum flow capacity? Would it be better to use
three or four smaller pumps coupled in parallel?
When multiple pumps are to be considered, this is where
providing them as a package can be beneficial.
Field-Built Multipump Systems
Specifying pumps is more than addressing hydraulic
considerations. Specifications must include motors, drives,
controls, valves and any other equipment necessary for the
successful installation and operation of the pump system.
Engineers and building operators need the assurance that
the pumps, motors and drives will work in harmony for many
years. What sets the stage for this is proper installation—
which requires planning—and that starts in the design phase.
See Table 2 on page 67 for design phase considerations.
Users should examine the details closely for the multipump
field-assembled system to be designed, purchased, installed
and commissioned successfully. It is common for a
miscommunication and/or details to be left out. Examples
include: motors need to be 208 volt, but controls and drives
were ordered at 460 volt; a missing gauge here, a sensor there;
where a sensor should be located along with drive and control
settings; the wrong type of valve; and so on. Oversights like
these can delay the installation and commissioning process.
Multipump Packaged Pumping Systems
Looking back at the chiller example, it should be clearer why a
packaged system can be a good idea.
A packaged system supplier normally has complete
specification packages that cover all the included equipment,
such as pumps, motors, drives, controls, valves, and other
ancillary items such as sensors and gauges. If the project has
special requirements, the engineer can modify a standard
specification into something more specific.
HVAC Pumping: Pump Types
One decision engineers face is the type of pump to specify.
The most common type of pumps found in hydronic heating
and cooling applications are end-suction pumps.
They are relatively inexpensive and offer pumping efficiency
at the rated condition, making them a practical choice for
this application.
Inline vertical multistage pumps have been under-used in
these applications. This is commonly used in more demanding
applications such as boiler feed systems for steam generating
plants and pressure boosting systems for multistory
buildings. The modern version of this pump has been used
since the late 1970s and has grown in size and versatility.
Vertical multistage pumps have flow capacities that reach
over 1,000 gpm and efficiency reaching 80 percent and higher.
There are many reasons to consider this style of pump for
hydronic heating and cooling systems. A key benefit is the
small footprint. On average, the floor space required for
the inline multistage pump is 25 percent of the floor space
required for alternative technologies.
These pumps can be prone to fewer problems because of
the hydraulic design and use of smaller diameter impellers.
Inline multistage pumps also have a wider AOR due to this
hydraulic design. Because most of the loading on an inline
multistage impeller is axial (parallel with the pump shaft),
shaft deflection is typically not present.

August 2019 | Pumps & Systems

 67

HIGH
Table 2. Design phase considerations
Considerations PERFORMANCE.
STANDARD.
Pump type, End-suction frame-mounted, end-suction close-
configuration coupled, inline, split case, vertical, horizontal,
inline multistage
Pump motors, Pump motor: Inverter capability,
controls motor-drive cabling
Controls: Pump sequencing, BMS Integration
Equipment room Adequate floor space, pump housekeeping pads,
layout, space vibration isolation, suction diffusers
Maintenance Pump service: Shaft seal access, impeller access,
considerations bearing lubrication, motor bearing lubrication

Advancement in chiller designs and controls have resulted

in more variable primary-based designs and a wide range of
flow rates. Chillers have minimum flow requirements that
often result in pumps operating at low flow, often below the
minimum continuous stable flow.
Because of the wider AOR for multistage pumps, especially
at low flow, this makes them a solution to variable primary-
based designs. Using parallel connected pumps also allows
for better low flow operation.
There are further design features that can make
installation of inline multistage pumps easier. For instance,
installation steps such as grouting and pump shaft to motor
shaft alignment are not required. Due to the low inertia
design and the lack of radial loading on the pump shaft,
inline multistage pumps have low vibration levels, which can
NSK rolling bearings promote
negate the need for vibration isolation. Another benefit to smooth and energy-efficient operation
the inline multistage pumps is that the pump bearings are in high heat, at highspeeds, with high
lubricated by the pumped liquid.
loads for a wide array of pumps and
This results in elimination of a routine maintenance step
(greasing pump bearings). compressors. Featuring optimized
From a service and repair standpoint, inline multistage internal design, high strength / high-
pumps are some of the easiest pumps to work on. Most have yield cage options and superior steel
single piece cartridge mechanical seals that can be replaced
without removing any part of the pump casing from the
composition, NSK delivers advanced
piping. Many of the larger sizes—typically 15 horsepower product solutions that deliver extended,
(hp) or 11 kilowatt (kW) and greater—have spacer couplings maintenance-free performance.
that allow for seal replacement without motor removal. In
the event of a major repair, the entire rotating assembly is
offered as a kit and can be replaced on-site while the bottom
volute casing remains in place. ROLLING BEARINGS FOR PUMPS
With these inline multistage pumps, end users can provide AND COMPRESSORS
Circle 137 on card.

pump repair on-site and, in many cases, avoid a possibly

costly field service call.

Advances in Pump & Motor Controls

Buildings account for nearly 40 percent of global energy
consumption. There are opportunities for efficiency gains in
the operation of pump systems and other HVAC equipment. www.nskamericas.com

pumpsandsystems.com | August 2019

68 COVER SERIES PUMP SYSTEM OPTIMIZATION

Using smarter pump controls and efficient motors is easier
than ever and will not only reduce pump energy usage, but
also provides greater efficiencies for larger HVAC systems.
The highest motor efficiency level recognized by the
U.S. Department of Energy is NEMA Premium. The
equivalent efficiency level to NEMA Premium in the European
Union is IE3. The EU recognizes efficiency levels of IE4 and
IE5. These efficiency levels have not yet made their way
into the NEMA standard for motors in North America.
However, motors in the IE4 and IE5 range are produced and
sold worldwide, including in North America. These efficient,
“above NEMA Premium” motors are typically of a permanent
magnet design and are available in ratings that range up to 15
hp (11 kW). Using these motors on packaged pump systems
can typically reduce energy consumption by 8 to 10 percent
over NEMA Premium designs on a typical hydronic heating or
cooling system.
One other area of improvement is advanced pump
control logic, mainly originating from pump manufacturers.
With the increased use of variable speed controls, this
has resulted in pump manufacturers taking a harder
look at how parallel-connected pumps are controlled.
Traditionally, the most common pump sequencing
method is based on pump speed (when an operating pump
reaches 95 percent of full speed, an additional pump is
started, etc.). In today’s world, efficiency-based pump
sequencing is possible given that pump curve information
can be loaded into the controls and sensors can be used to
continuously monitor efficiency.
There are many installations where two parallel-connected
pumps running at a slower speed can be more efficient
than a single pump running at a higher speed. Or three
pumps operating even more efficiently than two pumps,
and so on.
Reece Robinson is Grundfos’ building services technical
content manager. He has been with Grundfos since 1997
and has held positions in product engineering, product
management and technical training. Robinson received a
bachelor’s degree in mechanical engineering from
California State University, Fresno. For more information,
visit grundfos.com.

COMPACT. POWERFUL.
CONSISTENT RESULTS.
Milton Roy Mixing side entry mixers provide the most efficient
and cost effective fluid motion for storage tank operations.

Our side entry mixers mount quickly and easily

on the tank flange. The proprietary, small diameter
SABRE ¨ impeller allows for reduced energy
consumption, improved hydraulic efficiency,
and easy installation.

Learn more about the most efficient side

entry mixers for all of your crude oil and
derivatives storage and blending tanks,
visit miltonroy.com or contact
your local representative.

At the heart of mixing miltonroymixing.com

Circle 128 on card.

August 2019 | Pumps & Systems

 PUMP SYSTEM OPTIMIZATION COVER SERIES 69

7 Steps for High‑Pressure 
Centrifugal Pump Effi   ciency
Extend maintenance intervals and reduce total cost of ownership of 
pumps used in chemical and petrochemical applications.   

BY TOM HELMREICH
SUNDYNE Sundyne Multistage Pumps

C
hemical, petrochemical and refining applications
such as pipeline transfer services, waxy oil charge,
polyethylene terephthalic acid (PTA) reactor feed
or water injection require American Petroleum
Institute (API)-compliant pumps that can deliver typical
flow rates of 300 to 1,500 gallons per minute (gpm) (68 cubic
meters per hour [m3/h] to 340 m3/h) and heads up to 15,000
feet (4,572 meters).
The pumps commonly used for these applications include
API multistage, integrally geared pumps and BB3- or BB5-
style pumps. They achieve higher pressures by connecting
multiple liquid chambers in a series, sometimes at higher
speeds. Increased final discharge pressure is accomplished
through increased rotational speed, impeller trim size,
number of stages (impellers) and diff usion pressure recovery.
The plants using these pumps run operations around the
clock, so unplanned downtime should be avoided at all costs,
as the value of a lost day of production vastly exceeds the cost
of the pump. How do plants ensure pumps are optimized to
run at peak efficiency, in a manner that extends the mean
time between maintenance and reduces maintenance costs?
Proper Selection & Design
It starts with proper selection and process design. Two stage
pumps that use the addition of a speed increasing gearbox can
replace up to 12 stages, which offers a significant reduction
in material costs. It minimizes the complexity of setting
clearances and takes up about 25 percent as much space in the
plant. Sizing the pump properly at the outset is critical. This
is accomplished by advanced analytics and computer-tailored
hydraulics, which place the best efficiency point (BEP) at or
slightly below the rated point, resulting in optimum efficiency
and reduced end-of-curve horsepower (hp).
Image 1. Users should monitor pump performance to identify when
pumps need to be re-rated. (Images courtesy of Sundyne)
This enables smaller drive sizes to be used, which can still
deliver the required output while saving energy. Because
process conditions change over time, it is important for users
to monitor pump performance and identify when pumps
need to be re-rated to ensure the most efficient and reliable
operations (Image 1).
Keeping the pump operating within the API limits for high-
energy pumps—ideally between 70 and 100 percent of BEP—
is critical. Running at flows above or below design can result
in cavitation, bearing damage, seal failures, excessive shaft
deflection, high vibration and motor overloads.
Pump failures of any kind result in poor mean time
between repair (MTBR), plant downtime and increased
maintenance costs. Maintenance and operational costs can
make up as much as 80 percent of a pump’s total life cycle
costs (Image 2).
Many multistage centrifugal pumps used in chemical
and petrochemical plants have been in service since the
late 1980s. This longevity can be attributed to proper

pumpsandsystems.com | August 2019

70 COVER SERIES PUMP SYSTEM OPTIMIZATION

and mechanical designs. Coupled with improved materials,

increased reliability is readily achieved, particularly if
upgrades are coupled with re-rates to match pump flows to
the required process conditions.
Enhancements in manufacturing, combined with extensive
customer feedback from dozens of chemical, refining,
fertilizer and PTA manufacturers, have identified seven
key areas for optimizing pump performance, extending
maintenance intervals and reducing total cost of ownership.

Image 2. Maintenance and operational costs can make up 80 percent

of a pump’s total life cycle costs.
manufacturing, quality materials and diligent maintenance.
But there is another factor—a modular design that makes it
easy to swap out parts when necessary.
The adage, “if it isn’t broke, don’t fi x it,” often applies
to pumps and other equipment. But this does not mean
that pump companies are not seeking (and making)
improvements. Advances in analytics such as finite element
analysis (FEA), computational fluid dynamics (CFD) and
multiphase modeling have greatly improved both hydraulic
7 Upgrades on Multistage Integrally Geared Pumps
1. Process seals—Many new materials have been developed
that improve seal performance and life.
2. Process seal rotating face—Today’s “soft-mount” design
creates a more stable sealing surface. Removing old hard-
mount hardware allows the rotating face to better handle
fluctuations in temperature and pressure while improving
the running flatness of sealing surfaces.
3. Seal housing—Modifications are needed to accommodate
the newer and more reliable rotating face, and also to
improve fluid flow through the seal housing and remove
high-point vapor pockets, which improves seal life.

ELIMINATE SHAFT
MISALIGNMENT

Shaft misalignment is a common challenge

that now can easily be eliminated.
Blackmer® GNX Series sliding vane pumps
are the only alignment free reduced speed
positive displacement pumps on the market
today. GNX pumps combine gearbox, motor
and baseplate all in one perfectly aligned
compact system that eliminates the costly
process of shaft alignment common with
traditional pump installations.

Learn how to eliminate misalignment:

blackmer.com/PS

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Circle 134 on card.

August 2019 | Pumps & Systems

 71

4. Gearbox seal—Today’s latest gearbox seal designs offer

better sealing capabilities and reduce leakage of gearbox
oil, reducing process fluid entry into the gearbox.
5. Shaft sleeves—These are machined to extremely tight
tolerances. They maintain proper parallelism and
flatness for optimal seal life and low vibration. This type
of upgrade specifically complements the new seals and
rotating faces.
6. Inboard bearings (motor side) and outboard bearings
(pump side)—The latest generation of inboard bearings
offers better rotor stability over a wider operating range Image 3. Extending a pump’s life cycle can save installation costs.
and improves bearing stability, while enhanced outboard
deflection pad bearings improve rotor stability, damping Upgrading these elements can double the service life of the
and reduced vibration and enable improved seal longevity. bearings and seals at a fraction of the cost of replacing the
7. Instrumentation—Updated instrumentation for entire pump.
monitoring vibration and temperature accommodates the In most cases, this eliminates the need to make any
new bearing designs. changes to piping and foundations. Because of the modular
design, upgrades to key components can refresh an aging
Upgrades Offer Better ROI pump in a manner that delivers longer service life.
Upgrading these key elements reduces MTBR and provides Upgrading eliminates the cost of installing a new pump,
operational flexibility while leveraging improvements in which in refineries or fertilizer plants involves a customized
materials and design technology. process defined by nonstandard piping, different foundations,

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pumpsandsystems.com | August 2019

72 COVER SERIES PUMP SYSTEM OPTIMIZATION
space limitations and steel structures. A re-rate of the
pump with an upgrade to the key components can be
easily accomplished in a matter of days, during a standard
turnaround, at a fraction of the cost.
Benefits of an Upgrade
Operating costs—These costs can be minimized by reducing
energy costs, vibration, eliminating leakage and ensuring
that pumps are operating at their BEP.
Maintenance costs—Upgrading the key components such
as the seals, bearings, seal housings and shaft sleeves with
newer and warrantied parts extends maintenance intervals
and reduces overall maintenance costs.
Improved seals specifically limit environmental leaks
and reduce the risk of process fluid entering the gearbox,
which could result in corrosion and damage. In this case, an
ounce of prevention is truly worth a pound of cure, because
this upgrade hardens and protects a critical area that helps
maintenance professionals avoid unplanned maintenance
down the road.
Extending a pump’s service life by up to 30 years eliminates
Standard Alloys Engineered Services
Complete BB3 Pump Package
Standard Alloys, Inc. is proud to announce its engineered replacement bare shaft pump or pump package program. Our operations are
certified to ISO-9001:2015 by DNV to assure we meet the customer’s needs and expectations. Our designs will maintain all of the critical
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August 2019 | Pumps & Systems
replacement costs, avoids the need to incur installation
costs, and saves time for plant operators and maintenance
personnel (Image 3).
Plant uptime—For refineries using multistage integrally
geared pumps in a variety of applications, such as
reactor-charge, liquefied petroleum gas (LPG) injection or
pipeline transfers, plant uptime is the true measure of all
optimization efforts. Specialized applications such as PTA
dissolver feed pumps and fertilizer plants using these pumps
for applications such as carbamate recycling or ammonia
injection benefit equally from these upgrades.
Pump re-rates and upgrades to key components can extend
the life of the initial investment and reduce maintenance
costs by extending MTBR.
Tom Helmreich is Sundyne’s global product line
director. He has worked in operating units, plant
design and construction, and pump design and
manufacturing for 33 years. For more information,
visit sundyne.com.
Our Services:
API Upgrades
Drop-In Replacements
Field Service (Push, Pull, Start-Up & Commissioning)
Gearbox Repairs (all makes & models)
Hydraulic Re-Rates (including CFC Analysis)
Metallurgical Upgrades
Pump Repairs (all makes & models)
Replacement Parts
Reverse Engineering (Parts & Pumps)
System Efficiency Service (Field Testing & Troubleshooting)
Standard Alloys, Inc. · P.O. Box 969 · Port Arthur, TX 77641
www.standardalloys.com · sales@standardalloys.com
Visit us at Turbo/Pump Symposia 2019
Booth #1221
Circle 141 on card.

How Global Sourcing Helps
Aftermarket Companies
Competitive pricing and rapid delivery
fosters successful service.
By John D. Allen
JDA Global
T
he worldwide pump industry is
covered with large multinational
firms that have acquired privately
held pump companies, with specialized
products from the original inventors.
As pressure mounted to grow profits,
prices usually increased. This practice
opened the door to fast-growing
aftermarket business, in which the air
diaphragm pump segment participates
with vigor.
Here are three drivers that are
expected to further launch aftermarket
pump companies into prominence.
1 Tribal Knowledge
Aftermarket parts and services
companies are often led by veteran
industry professionals, whom possess
valuable “tribal knowledge” about
distributor patterns and supply-
chain interface. They know the key
procurement specialists who can rapidly
create new products, tooling, etc. Those
who create startup aftermarket ventures
have often absorbed industry expertise
based on longevity or time in a position.
Image 2. Tooling for a stainless steel part
The aftermarket company that
succeeds will likely specialize in rapid
delivery and competitive prices.
2 Global Sourcing
Prior to the practice of global
sourcing, most manufacturers obtained
raw materials within a tight geographic
radius around their facilities. Global
sourcing and the internet have evened
the playing field. Fast and flexible
aftermarket experts can move tools,
change procurement geographically and
rapidly respond to economic trends.
For example, U.S. firms looking to
escape Chinese tariff issues (ongoing as
of this publication’s print time) can more
rapidly move tooling, molding, etc., to
countries such as Vietnam and India,
thus escaping unwanted costs that drive
up final pricing to the end user.
3 Reshoring
This concept serves as the opposite
of offshoring: the global sourcing
phenomenon whereby the lowest labor
rate and low cost producer are pursued.
In some cases, the aftermarket specialist
can use the same supply chain as the
OEM, since raw material suppliers do not
work with exclusive agreements. Most
supply chain providers are happy to add a
second-tier buyer.
Further, they have the tooling
expertise, reverse engineering talent
and drawing capability.
AFTERMARKET 73
Image 1. Aftermarket parts can offer a lower
cost without sacrificing quality. (Images
courtesy of JDA Global)
In the end, the legitimacy of the
aftermarket provider will be determined
by the end user, whose constant search
for the highest quality, lowest cost
provider will separate those who will
grow and prosper and those who will fall
aside in the aftermarket space.
The aftermarket specialist also
understands that its market position
signals a “one chance” protocol for
market capture. Therefore, fit and
function must be of the highest
standards to survive.
This formula can create a win-win for
the customer.
Having a lower cost option, without
sacrificing quality, drives the end user’s
enhanced bottom line.
John D. Allen is CEO of JDA Global, a
pump holding company that features
aftermarket diaphragm pumps and
parts. He holds a bachelor’s degree
in international affairs from Ohio
University, and a master’s degree
from Arizona State
University’s Thunderbird
School of International
Management. For
more information, visit
jdaglobal.com.
pumpsandsystems.com | August 2019
74 BEST EFFICIENCY POINT
BEP: Its 
Importance & 
Its Eff ect on 
Reliability 
Running far from the best  inside a pump.
effi
  ciency point can be damaging.
BY AMIN ALMASI  A large portion of wasted energy when a pump is operated
PRINCIPAL MACHINERY/MECHANICAL CONSULTANT
T
he best efficiency point (BEP) of a pump is the
operating point, flow rate (capacity) and head
where the pump offers the peak of efficiency.
However, the importance of BEP is more than
efficiency and best performance. This is the operating point
where the possibility of energy waste and unwanted force,
vibration, noises, etc., are at the lowest. Therefore, BEP is
closely related to the highest theoretical reliability and lowest
possible risk or maintenance.
Image 1. An example of a large, critical pump during installation.
This variable speed pump is designed to operate most of the time
around its BEP. (Image courtesy of the author)
August 2019 | Pumps & Systems
Working Far From BEP
A centrifugal pump might be operated far from its BEP for
many reasons. The most common causes have been wrong
selection of the pump, an error in operation or a misjudgment
of operators. Unfortunately, there are still operators who
think operation far from BEP is just a matter of lower
efficiency and higher energy waste. However, it could heavily
affect reliability. Many pumps cannot be operated safely and
reliably far from BEP for long durations of time.
The complex liquid pattern inside a centrifugal pump
operates in 3D with many complicated effects such as
recirculation flows at suction and discharge sections, flow
separation, etc. The curvature of the blades, the rotation
of impeller assembly and separation of flow at different
places have great influence on this complicated flow field
Even when a centrifugal pump is operated at BEP, there is
some energy waste and loss, and there could be issues and
challenges. When a pump is operated far from its BEP, these
problems would be intensified and new issues would arise.
far from BEP is converted to unwanted heat, vibration or
noises. Another effect of such an operation is high forces or
loads on bearings and seals, which can reduce their life. The
rise of liquid temperature and internal circulation (within the
pump) are other damaging effects of such a poor operation.
These effects can be minimized with the use of a variable
speed drive or other suitable methods to keep the operating
point close to BEP.
Higher forces and loads on bearings experienced for
operation far from BEP can be a major issue, particularly for
constant-speed pumps using rolling-element bearings. This
can be partially rectified by specifying certain types of heavy-
duty and long-life rolling-element bearings. For small- and
medium-size pumps, only rolling-element bearings would be
used and other more reliable bearings such as sleeve bearings
cannot be used.
Left Side of BEP
The impeller passage flow for operating points around BEP is
smooth and follows the curvature of the impeller blades. As
flow rate is reduced and the operation point is moved to the
far left side of BEP, this situation changes.
When a pump is operating at low flow rates, different
sets of unsteady flows and unwanted effects are developed
in the impeller passage and volute casing. In addition, flow
separations at impellers can be intensified as the flow rate
is reduced. As an example of unwanted effects, a strong flow
recirculation can be developed at the center of the passage of
the impeller.
The stall region can be developed due to the recirculation,
which is blocking the flow passing through the passage.
 75

Right Side of BEP Amin Almasi is a principal machinery/mechanical consultant in

When a pump is operating at the far
Australia. He is chartered professional engineer of Engineers Australia
right side of BEP, this leads to high flow
and IMechE. He has authored more than 200 papers and articles
in liquid passages, which causes high
dealing with pumps, rotating equipment, mechanical equipment,
velocities and turbulences. The passages
condition monitoring and reliability. Almasi can be reached at
were not designed for this high flow.
amin.almasi@ymail.com.
Therefore, there are high losses, local
turbulences and localized stall and
blockage in bottlenecks.
The high momentum of main flow
tends to follow the curvature of the pump
parts as flow in some sections might
be blocked or stalled. At higher flow
rates (right side of BEP), a twin vortex
structure may be formed downstream of
the impeller passage. The recirculation
and twin vortex structure are attributed
to the increase of total pressure loss and
energy waste. As a result, both efficiency
and head would be low when operating at
the far right side of BEP.

Pump Selection
The rated operating point should be
close to BEP. It is usually difficult to
note a general guideline, since the limits
depend on the pump details, pump curve
and application. As a rough indication,
the rated capacity should preferably be
located in the range of 75 to 110 of the
BEP flow.
There is usually more concern about
the overload region to prevent the
selection of an undersized pump. For
operation around BEP, the internal
flow is smooth along the internal
curvatures. Even for this preferred range
of operation, there have been some
inefficiencies and challenges.
When operating far from BEP, the
mentioned problems would be intensified
and also flow patterns can be changed
significantly from the well-behaved and
well-guided flows at BEP to unstable
flows with vortices, recirculation,
secondary flows, turbulences, etc.
Operation of a pump far from its BEP
can affect the performance, the
efficiency, and the patterns and flow of
liquid inside the pump.
This can dramatically affect the
reliability, safety and life of the pump.
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pumpsandsystems.com | August 2019

76 SEALS & BEARINGS

Tips for Bearings in 
Machine Maintenance
Basic training for selecting, installing and maintaining bearings.

BY GAKUO NDONGA
SKF USA, INC.

M
aintenance technicians handle a
wide range of responsibilities to
ensure rotating equipment and
machine components operate at peak
performance levels. With a generation of seasoned
technicians soon ready for retirement, it is
imperative to close the knowledge gap. A new crop
of up-and-coming employees needs to understand
the basics of maintaining rotating equipment
and the new technology available to help them
troubleshoot machine performance.
Bearings play a vital role in rotating equipment
performance. Bearing failure can compromise machine
health and lead to unexpected downtime and production
delays. Fortunately, there are numerous tips for preventative
measures that technicians can follow as they gain more
on-the-job experience in machine maintenance. As with any
maintenance project, the No. 1 tip is to follow the company’s
safety procedures when inspecting, maintaining or replacing
a bearing.
Understanding Product Designation
One main factor in bearing performance is ensuring the
proper bearing is specified for the given application. Each
bearing has a unique set of design characteristics and options
that may not necessarily be determined simply by looking
at, or even handling, the old bearing. Sometimes the right
bearing is not used to begin with, further complicating the
choice moving forward.
In many cases, the best way to identify the critical
specifications is by understanding the bearing’s product
designation marked on the side faces of the bearing.
For example, if a technician only looks at a numeral
designation—without the additional suffi xes—the selected
bearing may be provided with the incorrect design feature
such as the improper level of internal clearance.
Image 1. The new generation of employees needs to understand the
basics of maintaining rotating equipment and the new technology
available to help them. (Image courtesy of SKF USA, Inc.)
Proper Bearing Installation
Manufacturing facilities collect dust and other contaminants.
Despite the surroundings, it is crucial to establish a clean
workspace prior to bearing installation. This prevents
harmful elements from contacting the bearing before it is
commissioned. An oft-forgotten but common-sense tip is
to keep the box containing the new bearing closed until it is
ready for mounting to avoid any ingress of contaminants.
Additionally, technicians should closely monitor the
orientation of the bearings during both removal and
installation. Bearings that are asymmetrical and mistakenly
installed in reverse will not perform as intended, leading to
bearing damage and possible machine failure.
Seals Are a Bearing’s Best Friend
To achieve maximum service life, bearings require a
sealing solution to retain lubricant and prevent the entry
of contaminants. Anytime a bearing is replaced, a new seal
should also be installed. And, like bearings, there is a wide
range of seals for a variety of applications, so it is important
to specify the proper seal design.

August 2019 | Pumps & Systems

 77

Sometimes, the rotating shaft has

deteriorated to a point where the seal is
no longer effective. This can be caused
by an inadequate surface finish, surface
roughness or hardness. Instead of
replacing the shaft, consider installing
a sleeve over the worn shaft to provide
a smoother surface for the seal, giving
new life to an older but still productive
machine. Some sleeves are designed to
slide over the worn area, providing a
counter-face surface that is optimized for
radial shaft seals.

Precision Lubrication
It is critical to use the right amount of
lubricant during bearing installation
and operation. Not enough lubricant can
lead to metal-on-metal contact, which
can cause premature wear and reduce
the life of the bearing. Conversely, too
much lubrication can generate additional
friction, causing the machine to overheat.
It is also important for machine
Circle 144 on card.
technicians to use the proper type
of lubricant. Oil and grease are most
commonly used to lubricate rotating
equipment. These lubricants are applied

100%
100 %
differently and also perform differently.
As a liquid, oil is ideal for carrying heat
away from bearings in machines that
generate a lot of heat.

smart
Oil requires routine maintenance
through fi ltration, temperature control,
flow rate monitoring and replenishment.

clean
After the initial fi ll, however, grease only
requires replenishment after a small
amount has left the bearing, has aged
or deteriorated. Properly calculating the
intervals for replenishment is something
many newer technicians overlook.
Bearing companies can provide tools to
help technicians calculate the proper
relubrication intervals for optimal For venting the electrical gear motors in a clean and
machine health. HN LÜ-OR | VENT VALVE
reliable manner. Unique construction against mois-

Working With Sensors

ture and dirt. Opening pressure 0.15 - 0.25 bar. 100% Our solution for
Today’s machinery and digital tools often tested thanks to a fully automated assembly. Assem- reliable venting
involve a variety of sensors to collect data. bled transportation lock and dust cap possible.
However, it is important to remember
the context of the data may not paint a
complete picture of machine health. It’s our turn. heinrichs-usa.com

Circle 145 on card.

pumpsandsystems.com | August 2019

78 SEALS & BEARINGS

GRAPHALLOY’S® Bushings and

Wear Rings for Water Depending on the situation, data reported from a vibration
and Wastewater Pumps. sensor mounted on a bearing housing may be misleading and
result in a technician troubleshooting the wrong problem.
For example, a service tech might notice a pump is displaying
NSF & WRAS Pump
Grades Available a higher than normal vibration velocity reading and may contact
the manufacturer to help diagnose the problem. Those readings
• Will not swell when submerged can be misleading if the fluctuation in vibration is attributed to
• No lubricant wash out changes in equipment, such as the pump being recently serviced.
• Corrosion resistant
If the condition of the bearing housing is not up to
• Works in hostile liquids
• Run wet, run dry
specification, the vibration sensor may also pick up the
difference. Therefore, it is imperative for technicians to access all
the necessary machine data and history—including service and
maintenance schedules—to accurately assess machine heath.

Incorporating Predictive Maintenance

Maximizing operational productivity should go beyond routine
bearing maintenance. Implementing a predictive maintenance
(PdM) program allows service technicians to proactively detect
issues with machine performance and take corrective action
Yonkers, NY USA
prior to failure. The best time to begin a PdM program is when a
+1.914.968.8400 piece of equipment is first commissioned. This gives technicians
www.GRAPHALLOY.com the ability to establish baseline limits for performance and
to understand changes that occur during the life cycle of the
equipment using historical data.
Circle 156 on card.
With a proactive PdM program, personnel can have
replacement parts ordered and on standby to prevent
Visit us at Booth 3246
at the Turbomachinery &
EFFICIENCY & unnecessary downtime. A PdM program can also be used to
Pump Symposia 2019
PERFORMANCE mitigate unnecessary repairs or premature replacement of
machine components due to a misdiagnosis.
We design and manufacture rugged, heavy-duty service
pumps. Our precision and advanced design significantly Digital Tools
enhance bearing and seal life insuring excellent pump Today, there are numerous mobile apps available for service
performance and full satisfaction. technicians to support PdM development, equipment
troubleshooting and bearing maintenance. These digital tools
Internal Gear
can assist in everything from predicting bearing performance
Pumps
EI-Series to establishing relubrication levels. There are mobile apps
124A and 4195 that help identify counterfeit bearings, which may cause more
maintenance hassles in the long run.
In addition to self-diagnostic tools, some companies offer
ANSI Pumps expert monitoring and analysis for service technicians who
DPUMPS encounter more challenging problems. As today’s digital-savvy
RV Impellers ANSI /ASME
B73.1 yet less-experienced technicians enter the workplace, these
tools make it easier to quickly learn about bearing and machine
maintenance, while still providing access to industry experts
who can offer technical support when needed.

Gakuo Ndonga is an applications engineer

with SKF USA, Inc., based in Pennsylvania. Gakuo
WE ARE specializes in bearing applications for the fluid
CURRENTLY
LOOKING FOR machinery industry. He may be reached at gakuo.
DISTRIBUTORS.
ndonga@skf.com. For more information, visit
internationalsales@d-pumps.com +52 55 57 15 16 82 www.d-pumps.com skfusa.com.
Circle 158 on card.

August 2019 | Pumps & Systems

 SEALS & BEARINGS 79

How to Fight Leakage & 
Bearing Contamination with
the Right Sealing Solution 
Consider mechanical seals, gland packed seals and lip seals.

BY DAVID AMORY 
AESSEAL

T
he drive for operational efficiency, optimization
of assets and adherence to the International
Standards Organization (ISO) 14001 Standard for
environmental management systems and ISO-50001
standard for energy management systems must always be
balanced against the bottom line.
However, it is fair to say in some cases this can lead
to short-sightedness when it comes to selecting sealing
solutions, with lower cost at point of purchase taking
precedence over total cost of ownership.
Mechanical seals have been on the market for around
80 years, and while pump design has remained largely
unaltered, sealing technology has evolved over time. This has
resulted in advances in reliability, operational efficiency and
environmental sustainability.
Traditional sealing options like gland packed seals and
lip seals are traditional for a reason. These products are
comparatively inexpensive when taking the purchase price
into account, and work well in many applications. This article
will take a look at the differences between mechanical seals,
gland packed seals and lip seals.

Excessive Wear
Leakage, product loss and bearing contamination that
leads to premature failure are three common issues with
traditional seals.
There is no reason why bearings should not last for their Image 1. Pump showing perished gland packing (Images courtesy
full predicted lifespan, which is typically calculated at roughly of AESSEAL)
15,250 operational hours. Leakage caused by inefficient
sealing is the simple reason why they do not last. With is one of the most frequent causes of pump malfunction.
research showing that water contamination of just 0.002 The cost of regularly replacing damaged seals and bearings
percent—a single drop—in a bearings chamber can reduce accumulates over time and can escalate if the pump shaft
bearing life by almost half, it is easy to see why bearing failure suffers wear damage and must be repaired or replaced.

pumpsandsystems.com | August 2019

80 SEALS & BEARINGS

Monitoring, Datalogging & alarMing

with CELLULAR DAtA tRAnsmission
Another key cost, which is often
Integrate Remote Monitoring into your PLC overlooked, is the number of hours
demanded to maintain, repair and replace
via Cloud–Based Monitoring and Convenient these components.

Web–Based Management Guaranteed ROI

A shrewd purchaser wishing to guarantee
a good return on investment (ROI)
• Monitor up to 64 Modbus registers
compares different types of seals to
determine what is best for their system
• Receive alarms via e-mail, phone call, and application. Dual mechanical seals
or texts are one choice. Mechanical seals operate
best with a seal support system, which
• Store an unlimited number of recycles the flush water required to
datalogged records keep seal faces cool and lubricated via a
continuous loop system.
• Program & view real time The initial outlay will be higher but
status online or in the app
this will be offset by a number of cost-
saving benefits:
• No direct contact with the pump shaft
tel: 877.373.2700 means it is not exposed to possible
sales@sensaphone.com
www.sensaphone.com
damage. Leakage beyond accepted
industry norms is virtually eliminated
and so is the premature seal failure
Circle 152 on card.
that leads to product loss, bearing
contamination, equipment breakdown
and repeat repurchasing of parts.
• Mean time between failure (MTBF) is
improved and unscheduled downtime
is less likely.
• Dual mechanical seals can be
retrofitted onto assets and require
virtually no ongoing maintenance.

Environmental & Cost Advantages

The pressure on companies to reduce
the impact of their operations on the
environment has never been greater.
The advantages of including a seal
support system that recycles flush water
are significant both financially and
environmentally.
Most seals require cool, clean liquid
to provide lubrication and prevent
overheating and dry running.
This is often injected from an external
source, and the majority of it can go to
waste, either flowing down the drain or
evaporating off at the end of the cycle.
In a typical application, where water is
measured for one minute, around 1.6 to
3.17 gallons of flush water is required. In
Circle 154 on card.

August 2019 | Pumps & Systems


Image 2. Packing vs. seals
Mechanical seals operate best with a
seal support system, which recycles the flush
water required to keep seal faces cool and
lubricated via a continuous loop system.
continuous operation, that amounts to
roughly 0.8 to 1.6 million gallons per
year for each seal (or pump). Add up the
number of pumps involved to calculate
the scale of waste.
Continuous loop water management
systems employ a thermosiphon
process to supply flush water to the
barrier space between the double seals
at a pressure higher than the product
pressure, ensuring a consistent, stable
and clean fluid film. As mechanical
seals generate heat, the hot water in
the barrier space rises to the tank and
the heat is radiated to the atmosphere,
allowing the cooler, denser water
to sink back down to provide cool
lubrication to the seal faces.
While a typical flush-to-drain system
used to flush gland or single seals
consumes 1.6 to 3.2 gallons of water
per minute, this constantly recycled
flow of water can reduce water loss to
roughly one teaspoonful a day, in the
form of vapor.
The energy savings that result
from not having to heat and cool the
flush water, as required in traditional
flush to drain systems, deserve closer
consideration.
For example, one paper mill reduced
energy use by 50,000 British thermal
81
units (MMBtu) per year, leading to
savings of more than $500,000 and an
ROI of less than four months, simply
by reducing the amount of water that
needed to be evaporated off.
A sugar refinery saved more than
5,944 cubic meters (m³) per year of
water and reduced gas usage by 594,432
m³, saving $230,000 over that period.
Other savings to bear in mind include
effluent charges for discarded water.
Conclusion
The swift ROI and ongoing savings
offered by mechanical seals and
their support systems are a powerful
argument for purchasers. And when the
environmental benefits are also taken
into account, both fiscal wisdom and
commitment to sustainable practices
are accounted for.
David Amory is global head of
marketing at AESSEAL.
Circle 143 on card.
He may be reached at
david.amory@aesseal.
co.uk. For more
information visit
aesseal.com.
pumpsandsystems.com | August 2019
82 SEALS & BEARINGS

A Pump Rebuilderʼs 
Guide to Replacing 
Carbon Graphite Bearings
Installation techniques and tips for choosing the best material grade.

BY KEITH HOGE
METALLIZED CARBON CORPORATION

P
ump repair and rebuild shops are
integral to the pumping world.
Industrial pumps are not a cheap
commodity, so the ability to
refurbish an old pump to extend its working
life is immensely beneficial.
Pump rebuilders may come across a wide
variety of pumps, from centrifugal slurry
pumps to vertical submersible pumps.
These pumps are used in many applications,
including pulp and paper production,
municipal water distribution and boiler feed
applications. Despite the variety of pumps
that rebuilders may encounter, they are often
tasked with the same thing for each rebuild
job they come across—bearing replacement.
The function of a bearing is to support a
moving shaft. As such, there will inevitably
be some rubbing that occurs during operation
and, consequently, some bearing wear. This
means bearings are often one of the first Image 1. The pump cross section shows the locations in which
components in a pump that need to be replaced, regardless of carbon graphite bearings are often used. (Images courtesy of
Metallized Carbon Corporation)
what type of bearing is used. This is why it is important for
pump rebuilders to become familiar with the different types
of bearing materials used in pumps, especially more common Carbon graphite bearings also have thermal and chemical
ones like carbon graphite. resistance, which is crucial when pumping hot fluids or
Carbon graphite bearings are used in pumps for many caustic chemicals.
reasons. Since there is no metallic attraction between
carbon graphite and the shaft, these bearings are not prone Choosing the Base Carbon
to galling or seizing, which is a known failure mode of other The base carbon graphite of most bearing-grade carbons is
types of bearings. Carbon graphite is self-lubricating, so it coarse-grained carbon graphite rod. Coarse-grained carbon
can run dry in certain conditions without the need for grease graphite rod is formed by extruding raw carbon graphite
or oil lubrication. powders through a die of a set outer diameter (OD).

August 2019 | Pumps & Systems

 83

These “green” (or unbaked) extruded

rods are then sent through a baking
process, which carbonizes the binder to
form what is referred to as mechanical
carbon graphite.
After the baking process, the material
should have sufficient strength and
hardness to be used as a bearing in certain
pumping applications.
Relative to compaction molded carbon
graphite, which is a more fine-grained
material, extruded carbon graphite is
softer and is often a better choice for
press fitting into a housing. This is one
of the reasons why extruded grades have
been historically specified in many pump
designs and are often the material of
choice for pump rebuilders.

Optimizing Dry Running &

High Temperature Capabilities
For certain dry running or high
temperature applications, carbon graphite
may not have sufficient lubricity or
Circle 148 on card.
oxidation resistance to operate.
In these situations, carbon graphite
manufacturers can re-bake the material
at high temperatures, causing the carbon
graphite to graphitize and form plain
graphite. This process increases the ratio
NEW PT2020
of graphite grains to amorphous carbon Automated Pump Controller System
within the carbon matrix.
The layered structure of the graphite for Air-Driven High Pressure Hydraulic Pumps
grains causes the material to become
much more lubricious, which enhances
its dry running capability. Graphite also • Automated pressure control
has less “active sites” that are prone for hydrostatic testing
to oxidation, allowing it to withstand • PT2020 will run pressure test,
exposure to higher temperatures for
give pass/fail and generate
longer durations.
test certification report
Proper Impregnation Type • Plug’n play upgrade for any
Depending on the application, the manufacture high pressure
base carbon/graphite can be used as
manual pump – to 75,000 psi
the bearing material alone, or it can be
impregnated with metals, resins, salts,
etc. The type of impregnation used affects
the ultimate material properties of the
carbon graphite, so choosing the proper
impregnation grade is essential.
The type of impregnation depends
www.HighPressure.com • 800-289-7447
on the type of pump and the physical
Circle 147 on card.

pumpsandsystems.com | August 2019

84 SEALS & BEARINGS
Image 2. A standard metallized carbon graphite bearing—a
component in many pump rebuilds that is frequently replaced
The type of impregnation used
affects the ultimate material
properties of the carbon graphite,
so choosing the proper impregnation
grade is essential.
conditions the bearings will be exposed to. Although different
types of impregnations exist, three in particular have proven
to perform the best in a wide range of pump applications:
babbitt, nickel and resin.
• Babbitt is a soft metal with strong lubricating properties.
This is best for low temperature water applications where
the bearing is running submerged.
• Nickel-impregnated carbon graphite is strong and has the
best corrosion resistance. It is commonly used in boiler
feed pumps and high load applications.
• Resin-impregnated carbon graphite provides chemical
resistance and is usually used in lower-duty applications.
Although the properties of each impregnation type vary
significantly, the primary function of each is to fi ll carbon
graphite’s porosity. This is critical, because an impervious
material is necessary for the formation of a hydrodynamic
fluid layer between the bearing and the shaft needed in
submerged applications.
This layer serves to extend the life cycle of the bearing,
since it acts as a protective boundary between the two
rubbing surfaces.
August 2019 | Pumps & Systems
Installation Tips
Once the proper material grade is selected, pump rebuilders
are tasked with installation of the bearing.
Carbon graphite is a brittle and soft material, so it is
important that bearings are handled with care during the
installation process. Most carbon graphite bearings are
press-fit into a housing, but may require some other means of
installation in certain cases.
It is also important to use the correct interference. The
interference depends on a number of factors, including
application temperature, housing material, bearing material
and other considerations. The manufacturer can assist with
this calculation.
1. For tight interference fits, heat the housing to decrease
the interference during installation and allow the bearing
to press-fit more easily.
2. For tight interference fits, the carbon graphite bearing
can also be cooled with liquid nitrogen to further reduce
the interference.
3. Guide the bearing into place with lead-in chamfers on
both the bearing outer diameter and the housing
inner diameter.
4. Press fit bearings in a single motion at a constant rate.
Machining the ID:
Running Clearance Properly
After the press fit, it is common that the ID may need to be
machined to account for any “close-in” that occurred during
installation as a result of the press fit.
It is possible to predict this “close-in” and design the
bearing accordingly to avoid having to machine the ID.
However, this may not be manageable if the tolerances and/or
clearances are too tight.
When machining the ID, keep in mind that a proper
running clearance must be maintained between the shaft and
the bearing.
For most submerged applications, it is recommended that
this running clearance is 0.1 to 0.3 percent of the shaft
diameter. This allows for sufficient space for a hydrodynamic
fluid layer to form, while preventing excess space that could
cause rattling or increased localized wear.
Once the bearing is press fit and the ID is machined to size,
the bearing installation is complete.
Keith Hoge has been an applications engineer for Metallized
Carbon Corporation since May 2017. He works
with pump rebuilders to ensure proper use
of carbon graphite bearings throughout the
rebuild process. He may be reached at
khoge@metcar.com. For more information,
visit metcar.com.
 SEALING SENSE 85

What to Understand About Chemistry

to Make the Best Materials Choices
Strong oxidizers can damage metal, causing pitting or rust and creating possible safety concerns.

By Mark Freeman
FSA member, EGC Enterprises, Inc..

I
n chemistry, a strong oxidizer is a
substance (like chromic acid) that
can cause other substances (like
seals and gaskets) to lose electrons. So,
an oxidizer is a chemical species that
undergoes a reaction that removes one
or more electrons from another atom.
This causes a change in mass. Metals
will turn into their respective heavier
oxides, and the carbon in graphite will
oxidize into carbon dioxide—which,
although molecularly heavier, is a gas at
room temperature.
This happens in pumps, valves,
pipelines or any other equipment that
have seals and gaskets carrying a
strong oxidizer. It will cause pitting or
rust and, depending on your choice of
seal material, may require shorter
service intervals.
Ultimately, you may have to look Image 1. Powder resin graphite (Courtesy of author)
for a more suitable material that can
handle strong oxidizers.
More importantly, an oxidizing
agent can cause or contribute to the
combustion of another material.
The U.S. Department of Transportation
defines oxidizing agents specifically.
DOT’s Division 5.1(a)1 means that a
material may enhance combustion or
quickly raise pressure causing a rapid
chemical reaction. A fire may start or,
even worse, create or facilitate
an explosion.
There have been instances of fires or
explosions in mining, chemical process
and even fertilizer factories where strong
oxidizers were used. Image 2. Thermabraid braided gasket packing

pumpsandsystems.com | August 2019

86 SEALING SENSE

Image 3. Laminated graphite

The U.S. Department of Transportation defines oxidizing

agents as materials that may enhance combustion or
quickly raise pressure causing a rapid chemical reaction.
A fire may start or, even worse, create or facilitate an explosion.

The following example shows how
an ammonium nitrate explosion can
affect not only the plant but also the
surrounding area.
Deadly Force
A West Texas fertilizer company storage
and distribution facility caught fire on
April 17, 2013. As firefighters attempted
to extinguish the blaze, the plant
exploded with the force of 10 tons of
TNT, killing 15 people and injuring
200. It destroyed 60 nearby homes and
left a 93-foot-wide crater where the
plant once stood.
All said, it is important to choose
the right sealing material for strong
oxidizers. There are multiple products
on the market for the chemical
processing, oil and gas, mining and
aerospace industries.
A fluoropolymer, such as
polytetrafluoroethylene (PTFE), can
handle most strong oxidizers, as long
as the temperature is below 260 C
(500 F). This is also true with a modified
PTFE because they are chemically inert
and stable.
Strong oxidizers will weaken most
other material to various degrees. Much
of a material’s capability to withstand
a strong oxidizer depends on the used
concentration, the service temperature
and the service pressure. Therefore,
consult with the sealing material
manufacturer to ensure compatibility.
How Graphite Handles Strong
Oxidizing Environments
Graphite starts as natural mineral flake
and is mined in various parts of the
world. The flakes form a layered structure
of completely crystalline graphite,
which is essentially elemental carbon.
In this form, it is used for products like
powdered lubricant and lead in pencils. It
has excellent lubricity in this form.
Expanded graphite is produced with
the use of strong oxidizing agents such
as sulfuric and nitric acids. The acids
weaken the bonds between the graphite

August 2019 | Pumps & Systems

 87

layers, the flakes are then rinsed, dried Some flexible graphite compositions The class of organic chemicals
and exposed to high heat. include oxidation inhibitors or are that should not be used are those
The heat causes the layers to separate physically structured to extend that are highly oxidizing like nitrates,
and expand dramatically to form temperature capability when exposed to persulfates, perbenzoates and
expanded worm-like macro structures. these extra strong oxidizers. peroxides. Unacceptable compatibility
The structures can then be recompressed
into flexible graphite forms.
Flexible graphite is a soft material
that is resistant to many strong
chemicals and high heat. It has a low
coefficient of friction and is proven to
be advantageous over braided carbon
or graphite fiber packings mainly as it
is a better conductor of heat—a plus on
moving shafts.
Flexible graphite is also naturally
lubricious, conformable and resilient.
It has good corrosion resistance and is
compressible, allowing it to conform to
most mating surfaces or valve cavities.
The chemical compatibility of flexible
graphite can be enhanced with a blocking
agent like PTFE. However, flexible
graphite’s temperature limit will be
restricted by PTFE’s limit of 260 C
(500 F). If high temperature is an issue,
this configuration will not work.
Flexible graphite, in combination with
PTFE, is an extremely effective material
in sealing fugitive emissions or volatile
organic compounds (VOCs). VOCs have
been targeted by several government
agencies as a source of air pollution.
Although, flexible graphite alone has a
long way to go in stopping all fugitive
emissions, it is a trusted sealing material
for valves, flanges and stems in the
chemical process, power generation, and
oil and gas industries.

Flexible Graphite Pitfalls

Flexible graphite may be susceptible
to chemical attack in the presence of
strong oxidizing fluids, including air Proud Member of the
at extremely high temperatures. These American Petroleum Institute NATIONAL PUMP COMPANY
include liquids such as 20 percent 7706 N. 71st Avenue | Glendale, AZ 85303
concentration of nitric acid or a 800-966-5240 | 623-979-3560
98 percent concentration sulfuric acid,
the same chemicals that are used to break
down mined graphite into expanded www.nationalpumpcompany.com
graphite flake.
Circle 129 on card.

pumpsandsystems.com | August 2019

88 SEALING SENSE

for inorganic chemicals includes molten
sodium, potassium hydroxide and
chlorine dioxide.
However, many of the chemicals
depend on the concentration, and
some engineering groups can create
an inhibitor that is right for a specific
oxidizer. For instance, a 704 stainless
steel cladding provides the user with
protection against strong oxidizers
while still providing the benefits of
flexible graphite.
When in doubt, do a test loop
using a pump to pressurize the
strong oxidizer exposing it to flexible
graphite. The pressure, temperature and
concentration of the oxidizer must be
exact as used in service, as to provide
some idea of how the material will react
to a given chemical.
Image 4. Thermacord flexible graphite It is easier to list the chemicals that
packing yarn
are not compatible with flexible graphite
(about 50) than those that are (more
than 600 tested). A list of incompatible
materials are listed on the next page.
Next Month: Flushing Arrangements
We invite your
suggestions for article
topics as well as
questions on sealing
issues so we can better respond to the needs of the
industry. Please direct your suggestions and questions
to sealingsensequestions@fluidsealing.com.
Mark Freeman is the marketing
director for EGC Enterprises, Inc. For
more than 25 years, he was CEO of the
nationally recognized Mark Freeman
Advertising. He may be reached at
440-285-5835. For more information,
visit egcgraphite.com.

SHREDDING
THE COMPETITION

AGPR AGP300/500/750 AGP-HC200

Single Seal Grinder Dual Seal Grinder Dual Seal Grinder

Your solution for: • Wipes • Swiffer Pads • Hygiene

Products • Dental Floss • Rags

P U M P
Honest, Professional, Dependable
1899 Cottage St. n Ashland, OH 44805 n 855 281-6830 n ashlandpump.com

Circle 157 on card. Circle 159 on card.

August 2019 | Pumps & Systems

 89

STRONG OXIDIZERS FOR FLEXIBLE GRAPHITE

Aqua Regia Chromium Nitromuriatic Acid Potassium Chlorate

Bromine (dry) Chromium Trioxide* Norge Niter Potassium Chromate
Calcium Chlorate Dichloropropionic Acid* Norwegian Saltpeter
Potassium Dichromate
Calcium Hypochlorite* Dichromates Oleum (Fuming
Calcium Nitrate Hydrogen Dioxide Sulfuric Acid) Potassium Nitrate

Chlorazotic Acid Hydrogen Peroxide Oxygen*(above +600 F) Sodium Chlorite*(over 4%)

Chlorine Dioxide* Lime Nitrate Ozone Sodium Hypochlorite*
Chlorine Trifluoride Lime Saltpeter Perchloric Acid
Sodium Peroxide
Chloric Acid Molten Alkaline Permanganate Solutions
Sulfuric Acid
Chloroazotic Acid Nitrates Persulfates
Chloronitrous Acid Nitric Acid* Perbenzoates Sulfur Trioxide*
Chromates Nitric Oxide Perborates
*Flexible graphite may be
Chromic Acid Nitrocalcite Peroxide Potassium acceptable in specific temperature
Chromic Anhydride Nitrohydrochloric Acid Bichromate or concentration ranges.

No Part Number? No Problem.

Call us : 800-523-3382
If you have our phone number, you don’t need a part number

Call Bartlett Bearing for identification &

EXPERT BEARING KNOWLEDGE
Call us : 800-523-3382
visit us on the web at
www.bartlettbearing.com

Circle 131 on card.

pumpsandsystems.com | August 2019

90 HI PUMP FAQS

Bearing Wear Detection Methods &

Monitoring Seal Leakage in Submersible Pumps
By Hydraulic Institute

What are methods for Table 1. Failure modes for pumps with sleeve bearings (Courtesy of Hydraulic Institute)
detecting bearing wear in
Failure Mode Causes Indicators
sealless pumps?
Insufficient lubrication Containment shell temperature
Sealless pumps (canned motor Containment shell liquid
temperature
pumps or magnetic driven) generally
Bearing wear detector
have sleeve bearings that are cooled Power monitor
and lubricated by the process fluid. Worn-out bearing Temperature monitor
As the name suggests, sealless pumps Cavitation Vibration
do not have dynamic shaft seals and Bearing wear detector
are designed with the rotor within a Power monitor
containment shell. Abrasives in lubricant Bearing wear detector
Excessive wear or failure of the Insufficient lubrication Containment shell temperature
bearings due to insufficient lubrication, Pumped liquid temperature
abrasives in the lubricant, or Bearing wear detector
cavitation could cause contact between Power monitor
the rotor and the containment device. Overload Power monitor
Broken bearing
This could result in equipment failure Cavitation Vibration
and leakage of the process liquid. Bearing wear detector
Therefore, providing some means to Power monitor
monitor the condition of these bearings Thermal shock Power monitor
is desirable. Image 1 provides some Vibration
common failure methods for Overload Power monitor
sleeve-type (journal) bearings, their Trapped solids Containment shell liquid
causes and indicators. temperature
Seized bearing
The detection method to monitor Containment shell temperature
wear of the bearing depends on the Failed antirotation device Vibration
material of the bearings. For instance, Power monitor
silicon carbide bearings are more prone
to sudden failure, so a progressive wear This method allows wear to be vibration sensor, containment shell
monitoring device might not be suitable. detected prior to contact between the temperature probe, continuity
Carbon bearings, on the other hand, rotor and the containment device. The probe or contact switch.
may exhibit progressive wear, and a sensing devices should be configured to
progressive wear monitoring device may detect axial and radial changes in the How can seal leakage be
be beneficial. rotor position. monitored in submersible
With progressive wear monitoring, Since bearing wear will cause contact pumps?
proximity sensing devices can be used between the rotor and the containment
to monitor the position of the rotor device due to positional changes in the The two principal places for
within the containment device. rotor, use of a contact detection device leakage monitoring are at the bottom
Positional changes to the rotor are may be useful. of the motor (for vertical shaft
used to determine the direction and Contact can be detected using an motors) or in the seal barrier fluid
amount of bearing wear. acoustic detection device, power monitor, containment volume.

August 2019 | Pumps & Systems

 91

Two sensor types dominate the

market: the conductivity probe and the
float switch.
In order to detect liquid intrusion from
all possible areas, it is beneficial to install
the leakage sensor in the bottom of the
dry motor compartment.
The float switch contains a small
floating element. Under normal
conditions, it remains at rest at the
bottom, but when liquid enters, it rises.
This rise can be detected by several
electrical methods.
While reliable, float switches are
position sensitive, so they are usually
not used in submersible equipment that
is subject to incline, such as in portable
pumps. The conductivity probe senses
the conductance of an oil-water mixture,
beyond a threshold limit, that reaches
the sensor.
In an inner seal of a dual unpressurized
seal arrangement, change in the seal Circle 151 on card.
reservoir pressure can be detected by
either blocking off the reservoir from

50 YEARS AND RUNNING STRONG

the vent and noting the increase in
pressure or using a pressure transmitter
or switch. In an inner seal of a dual
pressurized seal arrangement, change in
the seal support system pressure can be
detected by using a pressure transmitter
or switch.
For more information about bearing
wear detection and seal leakage
monitoring, refer to ANSI/HI 9.6.5-2016
Rotodynamic Pumps – Guideline for
Condition Monitoring at pumps.org.
Cat Pumps produces the longest-lasting, most durable high-pressure
triplex pumps on the market. With over half a century of field-proven
reliability, the surest way to maintain production is to specify Cat Pumps.
A Wide Range of Pressure and Flow:
100 to10,000 psi (6.9 to 689 bar) | 0.13 to 240 gpm (0.49 to 908 lpm)
Whatever your specs and application, Cat Pumps has the right pump.
Take the next step to more dependable pumps today.
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Visit pumpsandsystems.com/
training/HI/training
to register for classes, or to
purchase guidebooks or
standards.

HI Pump FAQs® is produced by the Hydraulic

Institute as a service to pump users,
contractors, distributors, reps and OEMs. For
more information, visit pumps.org.

© 2019 Cat Pumps 19037 1/19

Circle 150 on card.

pumpsandsystems.com | August 2019

92 EFFICIENCY MATTERS
Flexible AODD Pumps Can Improve Priming, Startup
Pressures & Retrofit Possibilities
Certain designs of skid systems can reduce leaks and system size
while maintaining reliability.
By Erik Solfelt
Wilden
I
n these days of tightened capital and
operating budgets, one thing that is
always a front-of-mind concern for
OEMs as they design and fabricate an air-
operated double diaphram (AODD) skid
system is how to streamline operating
costs for end users. A cost-effective
pump is one way to get their attention.
This requires a balancing act from the
pump manufacturer: finding a way to
offer equipment at an attractive price
point while still producing competitive
products that reliably do everything
they need to do.
This is where a pump’s operational
flexibility enters the picture. Flexible
pumps can be valuable since they allow
OEMs to design system costs effectively.
With that in mind, the versatility
and flexibility of a multiport and
multiposition AODD pump allows OEMs
to design skid systems so that costs can
be reduced or eliminated through:
• reduction in the amount and size of
piping needed
• reduction in fabrication costs
• reduction in the overall size of the
pumping system
• ability to be fitted into existing
systems in multiple orientations
• ability to operate without fail
when required
• elimination of product leaks
• ability to meet all regulatory
standards
August 2019 | Pumps & Systems
Due to the space constraints that
many OEMs face, the pump must
easily fit into the system’s existing
infrastructure with minimal repiping
or remodeling. Here, the pump must
be flexible enough to work within
the system’s requirements, rather
than the system being forced to
work around the new pump.
Simply put, adding a new pump
that requires a system redesign with
its inherent costs is difficult for the
OEM to swallow.
Reliability Required
When the pump has been selected
and installed, the next demand
is an obvious one: it must work
when needed, every time and without
exception. When plant operators turn
the air “on” for AODD pumps, they
expect the pump to begin delivering
fluid immediately. However, there may
be certain limitations in the pump’s
operational capabilities that make
this difficult.
These may include:
• Startup pressures. This is an issue
because AODD pumps require high
inlet air pressure to begin operation,
but often there may only be a small
amount of air available in the system.
Another concern at startup is an
application that may require low
but accurate flow, which can only be
Air Line
Product In
Product Out
Air Line Vertical
Product Out
Air Line
Product Out
Air Line Product Out Product In Horizontal
Horizontal Product In
Vertical
Product In
Air Line
Horizontal
Product Out
Product In
Image 1. The compact size and multiple
mounting options of some AODD pumps provide
the flexibility to meet the user’s system or skid
space requirements no matter the configuration
of the application. (Images courtesy of Wilden)
achieved with low air pressure. In
these cases, an AODD pump with
inconsistent startup pressures may
not begin operating when needed, or
it may start up adequately when the
pump is newer, but experience startup
difficulties as it ages. In any case,
these inconsistent and unreliable
startup capabilities are unacceptable.
• Failure to prime. Typically, AODD
pumps have different suction-lift
capabilities that are determined
by the amount of air pressure that
is provided to the pump. In many
instances, the pump’s suction lift
is best when it is running slowly
but degrades as it operates faster
at higher air pressures. So, if the

system’s air pressure is not at the
optimum point on the suction-lift
curve, it may fail to prime. To combat
this, a system designer can add a
three-way valve or design into the
programmable logic controller (PLC)
“soft start” capabilities that will
allow the pump to prime properly.
Both options will add cost and
complexity to the system. Systems
with large amounts of valving and
piping require a pump capable of
pulling liquids through multiple
tight piping runs. Here, a pump
that can create high suction-lift
capabilities is needed to overcome
the restrictive piping.
Living Without Leaks
One thing OEMs and their customers will parallel surfaces kept consistent to
not tolerate is a pump that leaks. While
most pump models will not leak when
they are taken out of the box,
over time they can become susceptible to
liquid loss as seals wear and the
pump absorbs the abuse of hundreds
of thousands of operating cycles. This is
true for users that handle thin liquids,
such as surfactants. Also, in many cases
the liquids that are being transferred are
potentially hazardous if not contained
properly, in which case leak-free
operation is nonnegotiable.
Most diaphragm pumps are developed
to use a face-seal design that relies on
two parallel surfaces to be held in tension
by a fastener that compresses a seal
between them. This design works well
and is used in many pump technologies,
including a majority of legacy AODD
pump designs. However, as the pump
operates, there is the potential for the
effectiveness of the seals to be affected
by torque decay on the fasteners. This
Erik Solfelt is the diaphragm pump
product manager for Wilden. He may be
reached at 909-422-1741 or erik.solfelt@
psgdover.com. For more information,
visit wildenpump.com.
93
While most pump models will not leak when
they are taken out of the box, over time they can
become susceptible to liquid loss as seals wear and the
pump absorbs the abuse of hundreds of thousands
of operating cycles. This is true for users that handle
thin liquids, such as surfactants.
can be caused by the normal operation hold the two surface faces in a consistent
of the pump, or by outside factors, such position, if any torque decay occurs it will
as environmental temperature swings or not compromise the integrity of the seals.
the composition of process fluids. The advantages are that the fasteners
Bore-seal design in newer AODD play no role in maintaining the seal.
pumping models relies on fastener force Any mild to moderate torque decay
that is perpendicular to the seal face should not adversely affect the pump’s
with the distance between the two leak-prevention abilities. This should
result in improved sealing over time,
optimize sealing. which is significant when thin or
Since the fasteners are only required to hazardous liquids are being transferred.
ONE PUMP, MULTIPLE
MOUNTING OPTIONS
COMPLETE CONTROL
Velocity Series
OVER DESIGN AND COMPACT PUMPS
PERFORMANCE
FEATURES AND BENEFITS
• Multiple mounting options
• 1/4": 4.3 m (14.2') of dry suction lift
for better priming
• 1/2": 5.1 m (16.9') of dry suction lift
for better priming
• Startup pressures as low as 1.03 bar
(15 psig)
• Bore-seal design eliminates leaks
that result from torque decay
PSG | 22069 Van Buren Street
Grand Terrace, CA 92313-5651 USA
P: +1 (909) 422-1730 | F: +1 (909) 783-3440
wildenpump.com
Circle 149 on card.
pumpsandsystems.com | August 2019
94 MOTORS & DRIVES

Motor Efficiency in Municipal Applications Provides

3 Reliable Alternatives for Operators
Permanent magnet motor technology gives users an option beyond surface and submersible choices.

By Jeff Frank
Franklin Electric

M
unicipal groundwater pumping
operation choices can come
from many pumping brands
and technologies. When looking for an
efficient pumping system to move high
volumes of water in continuous- or long-
run applications, where should one start?
Ultimately, there are two choices:
surface or submersible systems. Surface
pumping solutions consist of vertical
line shaft turbine systems (VLSTs), while
submersible pumping solutions include a
turbine-style pump powered by either a
classic electrical induction design motor
system or the newer permanent magnet
motor technology.
In the past, VLSTs were thought
by some to be more efficient than
submersible motor systems and even
outperformed them in some cases.
However, with the permanent magnet
motor technology, the playing field has
changed, and an advanced solution now
offers its own set of advantages.

Surface vs. Submersible:

How do they differ?
The question is: Which solution is best for
the application? There are advantages and
disadvantages to both choices mentioned
above. Take VLSTs, for example. VLSTs
use an aboveground motor connected to
a submerged pump with a drive shaft.
Although these high-flow pumps operate
fairly efficiently, they generally require a
substantial and costly motor housing to
protect the motor and drive shaft from
harsh weather and vandalism.
Image 1. Submersible systems offer a smaller overall footprint
with no motor housing, line shaft, bearings and drive shaft.
(Images courtesy of Franklin Electric)
VLSTs tend to be extremely noisy example, extends the length of the well
due to line shaft vibration and the and must be stabilized with bearings
aboveground motor, whereas submersible throughout. If it is oil lubricated, the
systems are silent. VLSTs also have more shaft must rotate within a bearing tube,
moving parts that wear out and require stabilized by retainers, that is mounted
untimely maintenance. The shaft, for inside the water delivery pipe.

August 2019 | Pumps & Systems

 95

These factors place a substantial
increase on both installation and
maintenance costs.
There are, however, some advantages.
VLSTs tend to be more versatile than
submersible induction motor systems as
they can operate with a variety of energy
supply sources including electricity,
diesel fuel and gasoline.
Furthermore, because VLSTs operate
above ground, there is no need to pull
the motor for replacement or repair.
However, those that choose VLSTs
typically do so because of the VLSTs’
motor efficiency gains.
Submersible Induction
Motor Systems
These systems tend to have lower
installation costs, smaller well diameter
requirements and strong hydraulic
performance from a compact package.
Where submersible induction motor
systems fall short is in motor efficiency.
Because of the bearing system and
electrical design, a submersible induction
motor generally averages about 10
percent less efficiency than the surface
motor found on the VLST. Because the
submersible induction motor system
is operated underground, it uses a fi ll
solution to cool and lubricate the motor.
This creates drag, which ultimately leads
to hydraulic performance losses and a
lower efficiency.
Because a VLST is designed to operate
above ground, with a greater diameter,
the rotor can be cooled using air without
the hydraulic losses.
Submersible induction motor systems
are a good option because of the lower
overall cost, lower maintenance needs,
better installation aesthetics and flexible
performance range.
The primary ongoing cost savings
of submersible systems can be due to
operating underwater with little annual
maintenance, whereas VLSTs require
regular lubrication, packing and impeller
adjustments. Because the submersible
systems do not require routine
maintenance, there is no need to keep
an inventory of spare parts.
Additionally, because the submersible
system does not include the additional
moving parts, it can be installed as a
complete unit. It can be lighter and easier
to handle, and maintenance jobs may be
accomplished at a more affordable rate,
when or if needed.
Permanent Magnet Technology
Permanent magnet motor technology
is an efficient submersible pumping
solution that can be an alternative to
VLSTs and submersible systems.

When splines or keys fail prematurely,

Polygons are your Solution!

The Ultimate Shaft-To-Hub Connection

• Transmit nearly twice the torque of involute splines in the same shaft
diameter.
• Minimum backlash, even Zero Backlash with taper polygons, or press
fit connections.
• Excellent concentricity, provide balance at high speeds.
• Polygons are self centering even on
sliding fits.
• Can be ground after hardening, avoiding heat treatment distortion.
914.961.2000 • Polygons high strength makes it possible to reduce connection size
when space limitation is required.
Stoffel Polygon Systems, Inc. • Increase connection life on violent torque reversals.
199 Marbledale Road, Tuckahoe, NY 10707
Fax (914) 961-7231 • Easy to assemble, easy to clean.
• Peak Stress, half as high as in a spline, thus fatigue life is 10x greater
www.stoffelpolygon.com
Circle 153 on card.

pumpsandsystems.com | August 2019

96 MOTORS & DRIVES

Image 2. Permanent magnet motor systems can offer operation cost savings each time the motor is used.
The more you use it, the more you can save.
*Based on electric costs of $.010 USD/kWh running at 100 percent duty **Efficiencies generated by Franklin Electric lab tested data

Because the submersible induction motor system is operated underground,

it uses a fill solution to cool and lubricate the motor.

Image 3. A high-efficiency
motor provides an
electrical cost savings
via a 90 percent motor
efficiency rating.
With a similar look, feel and installation
process to the submersible induction motor
system, the permanent magnet motor system’s
construction is smaller and lighter, which can
simplify the handling and installation.
Permanent magnet motor systems also offer
maintenance advantages and noise-reduction
benefits that municipal operations prefer,
along with cost savings in both installation
and maintenance.
The primary difference is that the rotor in a
permanent magnet motor system does not use
input power to become magnetized. Permanent
magnet motors use rare earth magnets to
magnetize the rotor.
No energy is lost due to magnetization of
the rotor, concentrating more power into motor
shaft rotation.
Because of this power concentration,
permanent magnet motor systems can be run
at a synchronous speed, providing improved
hydraulic performance.
Packaged with a variable frequency drive
(VFD), permanent magnet motor systems run
with an efficiency rate of about 90 percent.
A permanent magnet motor system may hold
a higher initial price point than a submersible
induction motor system, but offers operational
cost and efficiency savings.
Conclusion
Moving forward, there are now multiple
efficient choices, including VLSTs, submersible
induction motor systems and permanent magnet
motor systems. The latter offers the familiarity
and benefits of submersible systems with the
efficiency of VLSTs.
Jeff Frank is senior portfolio
manager at Franklin Electric.
For more information, visit
franklinengineered.com.

August 2019 | Pumps & Systems


New & Notable Technology
Products selected by the Pumps & Systems editors
1
3 minimal energy for maximum efficiency, pumping
1 BEARING ISOLATOR
The ISOMAG MD V8 magnetic bearing isolator
is the result of a dedicated mission to increase
bearing life. Magnetically controlled lapped
flat faces create a bi-directional seal, ensuring
no leakage of lubricant and no ingress of
contaminants. The V8 features an atmospheric
expulsion port to expel contaminants back
into the atmosphere. It performs equally well
dynamically, statically and is rated to ingress
protection rating IP67.
isomag.com
Check 301 on index.
To have a product considered for this section, please send the information to Drew Champlin, dchamplin@cahabamedia.com.
2
4
2 MULTIFUNCTION TIMER AND COUNTER
The TMM1 NFC multifunction timer and counter
from LOVATO is now available with wireless NFC
programming. No front controls makes time
adjustments easy to set and accurate with optional
tamperproof password protection. Functions
include: on delay, off delay, flasher, pulse
generator, ON-OFF trigger, watchdog and analog
filter. Settings can be stored and shared across
multiple devices for ultra-fast programming or file
sharing with the free Lovato app.
lovatousa.com
Check 302 on index.
3 PERISTALTIC PUMPS
GRACO’s SoloTech line of peristaltic pumps are
ideal for applications where accurate metering of
the toughest materials is critical to the process.
Using an innovative single roller design that
compresses an engineered hose through a full 360
degrees of rotation means superior hose life when
pumping caustic, abrasive or sensitive materials.
motionindustries.com/pumpsandsystems
Check 303 on index.
PRODUCTS 97
4 SUMP PUMP
With a continuous-duty 115-volt PSC motor, the
ECO-FLO cast iron sump pump from ZORO uses
up to 5,100 gallons per hour. Its motor housing
offers efficient cooling, while the impeller passes
up to 1/2-inch solids. The ECO-FLO has a reliable
vertical switch and is submersible for quiet
operation. This pump features a 1 1/2-inch FNPT
discharge and an 8-foot cord.
zoro.com
Check 304 on index.
5 PRESSURE TRANSMITTER
Processes are twice as safe with the VEGADIF
85, a universal differential pressure transmitter
by VEGA for measurement of liquids, gases and
vapors. This instrument comes standard with an
additional absolute pressure sensor on the low
pressure side, providing the option to measure
differential and static pressure simultaneously
with a single device. Having both available as
digital or 4 to 20mA outputs provides more
information for all applications. vega.com
Check 305 on index.
6 BALL VALVE ASSEMBLY
BELIMO AMERICAS released new ball valve
assemblies with fail-safe and non-fail-
safe actuators (PKR and PR series). These
technologically advanced assemblies offer
energy efficiency, easy installation, application
flexibility, longevity and reliability for aggressive
applications. The modulating, multifunction
technology (MFT) actuator models can be field
customized to match the needs of the application.
belimo.us
Check 306 on index.
pumpsandsystems.com | August 2019
98 INDEX & SUBSCRIBER SERVICES

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RS1908

s i
t
s a ium
t u pos !
Vi Sym 242
Your PC Pump
mp th 1
Pu Boo Alternative

LobePro pumps do the same jobs as well as or

better than PC pumps up to 150 psi of pressure while
using 1/3 the space, 1/3 the repair time, 1/3 the part costs
AND Fast Delivery of Pumps & Standard Wear Parts.
Visit http://www.lobepro.com/fund-why-choose-lobepro-over-pc-pumps.php
to learn more about LobePro pumps vs PC Pumps.

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

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August 2019 | Pumps & Systems


REQUIRED for READER SERVICE
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Title
Company
Check the box(s) below to
READER SERVICE receive free information from
companies listed in this issue.
Advertisers
Advertiser Name RS# Page
ABB Motors & Mechanical, Inc .......❑ 117........15
Advanced Ceramics and Carbon......❑ 174......102
ADIPEC ..................................................................61
AE Pumps .......................................... ❑ 183......103
AMCO Pumps ................................... ❑ 165......100
Ashcroft ............................................. ❑ 110........31
Ashland Pump .................................. ❑ 157........88
Automationdirect.com .................... ❑ 118....... BC
Av-Tek, Inc. ........................................ ❑ 161......100
Bartlett Bearing Company .............. ❑ 131........89
Benshaw Advanced Controls
& Drives........................................ ❑ 114........13
Blackmer Pumps............................... ❑ 134........70
Blue-White Industries Ltd .............. ❑ 125........33
Boerger Pumps LLC.......................... ❑ 132........48
CAT Pumps ........................................ ❑ 150........91
Comercializadora FEOC
S.A. de C.V. .................................. ❑ 158........78
Continental Electric Motors ........... ❑ 162......100
Crane Pumps & Systems.................. ❑ 105........ 17
Dan Bolen & Associates LLC ............❑ 175......100
Dekker Vacuum Technologies, Inc. ❑ 166......100
Dickow Pump Company .................. ❑ 135........39
Equipump, Inc....................................❑ 176......102
Farrar Company................................ ❑ 184......103
Flowrox ..................................................................45
Fluke Corporation ................................................43
Franklin Electric............................... ❑ 124........35
Gator Pump, Inc................................ ❑ 177......103
Graphite Metallizing
Corporation ................................. ❑ 156........78
Heinrichs USA LLC .......................... ❑ 145........77
Helwig Carbon Products.................. ❑ 146........55
Products
Company Name RS# Page
Belimo Americas...............................❑ 306 ........ 97
Isomag Corporation .........................❑ 301 ........ 97
Address
City/State/Country/Zip/Post
*Phone
*Email
ONLINE FAX
For fastest service, Complete, tear out and
visit psfreeinfo.com fax to 630-739-9700
(U.S. only)
Advertiser Name RS# Page
High Pressure
Equipment Co.(HiP).....................❑ 147........83
Homa Pump Technology ................. ❑ 111........21
Hydro, Inc. ......................................... ❑ 101...... IFC
Inpro/Seal .......................................... ❑ 127........51
Integrity Pump & Motor ................. ❑ 139........37
Invertek Drives, USA ....................... ❑ 167......100
Isomag Corporation ......................... ❑ 106.......... 7
JDA Global......................................... ❑ 140........75
John Crane ....................................... ❑ 121........47
Jordan, Knauff & Company ............ ❑ 155........98
Kiris System .......................................❑ 178......102
Load Controls Inc ............................. ❑ 136........36
Load Controls Inc ............................. ❑ 171......102
Lobe Pro Rotary Pumps................... ❑ 160........98
Magnatex .......................................... ❑ 154........80
Magnatex .......................................... ❑ 180......101
MasterBond Inc. ............................... ❑ 163......101
METCAR
(Metallized Carbon Corp) .......... ❑ 151........91
Metrix Instrument Company ......... ❑ 143........81
Milton Roy Industrial ...................... ❑ 128........68
Mitsubishi Electric
Automation, Inc. ......................... ❑ 119........11
Moving Water Industries
Corporation (MWI) .......................... ❑ 181......103
National Pump Company ................ ❑ 129........87
NSK Americas ................................... ❑ 137........67
Pinnacle-Flo Inc................................ ❑ 172......101
Praxair Surface Technologies ......... ❑ 159........88
Pumpworks Industrial .................... ❑ 120........57
Regal Beloit........................................ ❑ 133........63
Rotech Pumps & Systems, Inc. ....... ❑ 182......103
Company Name RS# Page
Lovato USA ........................................❑ 302 ........ 97
Motion Industries ............................❑ 303 ........ 97
99
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Advertiser Name RS# Page
RWN Pump & Fabrication............... ❑ 144........77
Schaeffler Group USA Inc. ............... ❑ 107........23
SealRyt Corporation ........................ ❑ 122.......... 9
Sensaphone, Inc. ............................... ❑ 152........80
SEPCO ................................................ ❑ 130........49
Shin Nippon Machinery .................. ❑ 123........25
Siemens Industry ............................. ❑ 102........53
Smith & Loveless, Inc. ..................... ❑ 112.......... 3
St. Marys Foundry............................ ❑ 168......101
KSB SupremeServe by
Standard Alloys ........................... ❑ 141........72
Stoffel Polygon .................................. ❑ 153........95
Sulzer Management Ltd Rotating
Equipment Services .................... ❑ 113.......... 5
Titan Manufacturing, Inc. .............. ❑ 169......101
Topog-E Gasket ................................. ❑ 164......103
Torishima Service Solutions ........... ❑ 148........83
Tuf-Lok International ...................... ❑ 185......103
Universal Flow Monitors, Inc. .........❑ 170......101
Vaughan Company ........................... ❑ 115......IBC
Vertiflo ............................................... ❑ 173......102
Vesco Plastics Sales ...........................❑ 179......102
Watson Marlow Pumps ................... ❑ 142........27
WEFTEC ................................................................65
Wilden Pump & Engineering .......... ❑ 149........93
Worldwide Electric Corp.................. ❑ 109........29
Zoeller Pump Co. .............................. ❑ 138........71
The Index of Advertisers is furnished as a courtesy, and no
responsibility is assumed for incorrect information.
Company Name RS# Page
Vega Americas...................................❑ 305 ........ 97
Zoro US ..............................................❑ 304 ........ 97
pumpsandsystems.com | August 2019
100 MARKETPLACE

Check 165 on index. Check 161 on index. Check 162 on index.

EXECUTIVE SEARCH/RECRUITING

“Serving the Pump &

Rotating Equipment, Valve,
and Industrial Equipment
Industry since 1969”
Domestic & International
Specializing in placing:
• General Management • Engineering
• Sales & Marketing • Manufacturing
JASON SWANSON • JULIAN MUELLER
DAN BOLEN
UNIQUE CHALLENGES,
CUSTOM SOLUTIONS
LIQUID RING VACUUM PUMPS
& COMPRESSORS
COMPREHENSIVE INVENTORY
BOLT-IN REPLACEMENT PUMPS
TURNKEY SYSTEM SOLUTIONS
AFTER SALES SUPPORT & FIELD SERVICE
TM

120 N. 44th Street, Suite 325

Phoenix, Arizona 85034
(480) 767-9000 The Experts in Vacuum Solutions
Email: jason@danbolenassoc.com
www.danbolenassoc.com dekkervacuum.com | 888.925.5444

Check 175 on index. Check 166 on index. Check 167 on index.

August 2019 | Pumps & Systems

 101

SOLVENT RESISTANT
Sub ANSI magnetic drive pumps EPOXY ADHESIVE
IN STOCK, READY TO QUICK SHIP. EP41S-5
Two Component System
Exceptional resistance to
METHYLENE CHLORIDE
Also withstands acids,
bases & solvents
PINNACLE-FLO, Inc.
PUMPS & PARTS
INDUSTRIES: Chemical Process
Refinery • Oil & Gas Municipal
Food Process Markets
PRODUCTS: ANSI Process
API 610 • Centrifugal Solids-
handling Self-prime • Centrifugal
MUD • Air Operated Double
Diaphragm Pumps

Phone: 713.972.8666 | Toll Free: 866.624.7867

FAX: 713.972.8665 154 Hobart St., Hackensack, NJ USA
3575 West 12th Street, Houston, TX 77008 +1.201.343.8983 ∙ main@masterbond.com
PINNACLE-FLO.COM
www.magnatexpumps.com www.masterbond.com Houston, Texas • 832-303-1245 • sales@Pinnacle-Flo.com
Check 180 on index. Check 163 on index. Check 172 on index.

Monitor
Oil Flow

Options: HART,
mechanical switch

888-569-3090
Universal Flow Monitors, Inc.
www.flowmeters.com
STMFOUNDRY.COM 419-394-3346
Check 168 on index. Check 169 on index. Check 170 on index.

pumpsandsystems.com | August 2019

102 MARKETPLACE

www.ceramicscarbon.com

Products
Seal Faces
Bushings / Bearings
Steam Joints
Rotors and Vanes
Resin and Antimony Carbon Blanks
Hot Glass Fixtures
Industrial Brushes
Electrical Components
ADVANCED CERAMICS & CARBON, INC.
Materials
Graphite
Carbon Graphite
Resin Bonded Carbon
Reaction Bonded, Sintered and Slip
Cast Silicon Carbide
Tungsten Carbide Adding various impregnations such
Zirconia as resins and metals can enhance the
Alumina Ceramic strength and temperature capabilities.
808 South Michael Road | Saint Marys, PA 15857 | 814-834-0060
Check 174 on index.

REPLACEMENT • REPAIR • RECOVERING

• Aftermarket pump parts for most models of
Lobeflo®, Muniflo®, Lobeline®, Vogelsang®,
:

and Borger® Pumps

• Repair of Rotary Lobe Pumps
• Manufacturer of the Muniflo Rotary Lobe Pump
(originally manufactured by Wemco since 1985)

Are you looking for obsolete LobeFlo® (SSP/MGI) Pump Parts?

We are the answer!
www.equipump.com | www.muniflopump.com Check 173 on index.
800-783-5623 | fax 800-693-5623 | info@equipump.com

Check 176 on index.

KIRIS SYSTEM
Finally The Proper Tools to
disassemble and assemble
your open and closed
impeller ANSI Pumps. An • Safer, more economical
Ergonomically Safer way
• The correct tool for the job.
to work on your equipment.
Protect Your Craftsman as well • No more slapping or jarring
of critical components by using
Solve as the critical components of
your equipment by using the
other inferior tools
dry start correct tool for the job.
WWW.KIRISSYSTEM.COM
problems with Check 178 on index.
Vesconite Hilube
bushings MONITOR PUMP PERFORMANCE
● Increase MTBR
● No swell • Flow Rate univeRsal PoweR Cell
• One Size Adjusts for
● Low friction = reduced • PumP Condition All Motors, From Small
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● Quick supply. Drives, 3 Phase, DC and
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• BeaRing FailuRe just sensing amps
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vesconite@vesconite.com Call now FoR youR FRee 30-day tRail
www.vesconite.com
888-600-3247
Check 179 on index.
Check 171 on index.

August 2019 | Pumps & Systems

 103

• Self-aligning & self

grounding
• High pressure
rated
• Stainless or
mild steel
• Low cost
• High end pull
Tuf-Lok International
Phone: 608.270.9478 • www.tuflok.com
Check 185 on index.

Check 183 on index. Check 184 on index.

OUR EXPERTS CAN HELP

Every job is different. Our experienced,
licensed engineers will work with you
to design a cost-effective solution that
is the right fit for your application - FLOWS
potentially saving millions of dollars. TO 18,000
When you need to move large volumes
of water quickly and efficiently - call MWI.
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project review:
NO PRIMING-NO SUCTION LINES
954-426-1500 NO CHECK VALVES
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www.GATORPUMP.com 1-800-735-9811
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104 PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch
By Jordan, Knauff & Company
T
he Jordan, Knauff &
Company (JKC) Valve Stock
Index was down 2.5 percent
over the last 12 months, while the
broader S&P 500 Index was up
7.9 percent. The JKC Pump Stock
Index rose 2.3 percent for the same
time period.1
The Institute for Supply
Management’s purchasing
managers’ index (PMI) registered
51.7 percent in June, a decrease
of 0.4 percentage points from the
May reading of 52.1 percent. June
was the third straight month with
slowing PMI expansion. New orders
hit a 3.5-year low, at 50 percent, a
decrease of 2.7 percentage points
from May. Production improved
over the month, with the index up
nearly three points to 54.1 percent.
The employment index also edged
higher for a second straight month.
At 54.5 percent, it represents only
modest additions to factory jobs.
Respondents expressed concern
about United States and China
trade issues, potential Mexico trade
actions and the global economy.
According to the Bureau of Labor
Statistics, the U.S. economy added
224,000 nonfarm payrolls during
June. May’s figures were revised
to 72,000 positions, down from
the previously reported 75,000.
Image 2. U.S. energy consumption and rig counts
Source: U.S. Energy Information Administration and Baker Hughes Inc.
August 2019 | Pumps & Systems
Employment growth
has averaged 172,000
jobs per month this
year. The transportation
and warehousing sector
gained 24,000 jobs, while
manufacturing added
17,000 positions.
U.S. imports of crude Figure 1. Stock Indices from July 1, 2018 to June 30, 2019
oil from members of
Local currency converted to USD using historical spot rates. The JKC Pump and Valve
the Organization of the Stock Indices include a select list of publicly traded companies involved in the pump and
Petroleum Exporting valve industries, weighted by market capitalization. Source: Capital IQ and JKC research.
Countries (OPEC) in
March 2019 totaled 1.5 million averaged 26 percent and 28 percent Reference
barrels per day, their lowest below their 2018 average levels. 1. The S&P Return
level since March 1986. From On Wall Street, the market figures are provided
by Capital IQ.
the early 1980s through the late had a record-breaking first half
2000s, OPEC member countries of 2019, with the Dow Jones
were the source of about half of Industrial Average, the S&P 500 Jordan, Knauff
all U.S. crude oil imports. In the Index and the NASDAQ Composite & Company is an
investment bank
past decade, however, total U.S. rising 14 percent, 17.4 percent based in Chicago that
crude oil imports have fallen and and 20.7 percent, respectively. provides merger and
OPEC’s share of those imports has The S&P 500 had its best first half acquisition advisory
services to the
decreased. Non-OPEC countries performance since 1997. Positive pump, valve and
such as Canada, Mexico, Brazil developments in the trade war with filtration industries.
and Colombia have made up larger China, a softer monetary stance Please visit
jordanknauff.com for
shares of U.S. crude oil imports. In by the Federal Reserve Bank and further information.
each of the past four years, Canada a rebound of crude oil prices due Jordan, Knauff &
alone has supplied more crude oil to supply cuts by OPEC and Russia Company is a member
of FINRA.
to the U.S. than all OPEC members are major reasons for the rally. For
combined. In the first three months June, the Dow Jones Industrial
of the year, the volume of U.S. crude Average, the S&P 500 Index and
oil imports from Saudi Arabia and the NASDAQ Composite gained These materials were
prepared for informational
Iraq—the two largest sources of 7.2 percent, 6.9 percent and 7.4 purposes from sources that
are believed to be reliable
imports from OPEC in 2018—have percent, respectively. but which could change
without notice. Jordan,
Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or com-
pleteness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
Image 3. U.S. PMI and manufacturing shipments any investment offering or
deployment of capital.
Source: Institute for Supply Management Manufacturing
Report on Business and U.S. Census Bureau
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