The Magazine for Pump Users Worldwide December 2010

pump-zone.com
Critical Testing
Optimum Performance
In our continuing commitment to the pump industry, Hydro has designed
and built a new state of the art Test Lab dedicated to the needs and
requirements of the pump aftermarket.

Key features include:

• Designed in compliance with Hydraulic Institute Standards and API 610
• Capable of testing horizontal, vertical and submersible pumps
• Maximum of 5000 HP
• Variable Frequency Drive; 2300 - 4160 volts
• Flows of up to 21,000 GPM on the horizontal loop and 42,000 GPM
on the vertical loop
• State of the art data collection system

U.S. Service Centers

Hydro, Inc. l Chicago, IL HydroAire, Inc. Chicago, IL Hydro East, Inc. Hydro South, Inc. HydroTex Dynamics, Inc.
Headquarters Madison Street Facility Philadelphia, PA Atlanta, GA Houston, TX
800.223.7867 40th Street Facility 610.497.7867 770.475.3393 713.937.9001
www.hydroinc.com 312.738.3000
Evans Hydro, Inc. HydroTex Golden HydroTex Deer Park, Inc.
Los Angeles, CA Triangle, Inc. Deer Park, TX
310.608.5801 Beaumont, TX 713.937.9141
409.842.3619
 Being Independent Makes All the Difference
Because we are independent, we offer unbiased recommendations in
every test situation. We are committed to our customer – not our brand.

This new capability enables Hydro to work with our customers to develop
and implement engineering modifications for improving the performance
of your critical pumps and then to verify that performance in the lab. And
because the test lab is dedicated to the aftermarket we have the flexibility
to schedule tests to meet your needs.

The Test Lab, located in Hydro’s Service Center in Chicago, is

strategically located to service pump users throughout North America.

For additional information contact Jeff Johnson at

info@hydropumptesting.com or call 281.475.9680.

Companies

International Service Centers

CW Hydro, Inc. Hydro Australia, Inc. Safe-T Hydro, Inc. Hydro Scotford, Inc. Hydro Middle East, Inc.
Incheon Metropolitan, Korea Morwell, Australia Port Coquitlam, BC Canada Edmonton, AB Canada Dubai, United Arab Emirates
82.32.561.0971 61.3.5165.0390 604.941.1116 780.992.0100 971.50.5547129

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 PUBLISHER
Walter B. Evans, Jr.
Letter from the Editor
ASSOCIATE PUBLISHER

O
VP-SALES ne of the best parts of my were worthy of honorable mention.
George Lake
glake@pump-zone.com job is the opportunity to Please see page 18 for full Product
205-345-0477 learn about the newest tech- Innovation of the Year coverage, and
EDITOR nologies in the industry. To help us visit our Awards page on www.pump-
VP-EDITORIAL
Michelle Segrest stay aware of some of the industry’s zone.com for information and criteria
msegrest@pump-zone.com latest developments, the Pumps & Systems team about our 2011 awards.
205-314-8279
attends tradeshows and visits our advertisers’ Meanwhile, we wrap up another busy year
MANAGING EDITOR
Lori K. Ditoro manufacturing and testing facilities. of tradeshows when our team attends POWER-
lditoro@cahabamedia.com When we implemented our first awards GEN International in Orlando (Booth #2683).
205-314-8269
program two years ago, we were thrilled with We continue to maintain a presence at more
ASSOCIATE EDITOR—
WEB EDITOR
the response. As Pumps & Systems continues to tradeshows than any other industry publica-
Julie Smith be the expert source for pump users worldwide, tion, attending 23 shows in 2010 (distribut-
jsmith@cahabamedia.com
205-314-8265 we collaborate with our Editorial Advisory ing more than 6,900 additional copies of P&S
CONTRIBUTING EDITORS
Board to find the latest and greatest pump inno- and our new publication, Upstream Pumping
Laurel Donoho vations. Solutions). We will continue to stay at the fore-
Joe Evans, Ph.D. his month, we are pleased to announce front of industry trends, news and the latest
Dr. Lev Nelik, PE, APICS
the winners of our 2nd annual Product technologies in 2011.
SENIOR ART DIRECTOR Innovation of the Year award. First place is We will also explore new pumping mar-
Greg Ragsdale
PRODUCTION MANAGER
awarded to Warren Rupp’s AirVantage® Energy kets. In January, we will publish a supplement,
Lisa Freeman Saving Technology. It manages the amount of HVAC Pumping Solutions, which explores
lfreeman@pump-zone.com air volume required for AODD pumps to run motors, drives and packaged pumping systems
205-212-9402
at desired flow rates, and produces its own elec- in HVAC applications.
CIRCULATION
Tom Cory tricity to save energy and reduces air usage by Please send us your ideas and feedback for
TomCory@cirtecinc.com up to 50 percent. 2011 coverage.
630-482-3050
Other finalists are Active Water Sciences’
ACCOUNT EXECUTIVES Best Regards,
Charli K. Matthews portable water treatment system, SDT
cmatthews@pump-zone.com Ultrasound’s ultrasonic detector, LUDECA’s
205-345-2992
high-resolution processor, Mouvex’s sealless
Derrell Moody
dmoody@pump-zone.com positive displacement pumps and Wanner
205-345-0784 Engineering’s sealless, triplex diaphragm pump. Michelle Segrest
Mary-Kathryn Baker Products from A.W. Chesterton, Baldor Electric Editor
mkbaker@pump-zone.com
205-345-6036 Company, GF Piping Solutions and seepex msegrest@pump-zone.com
Mark Goins
mgoins@pump-zone.com Editorial Advisory Board
205-345-6414
William V. Adams, Director, New Business John Carter, President, Warren Rupp, Inc.
ADMINISTRATIVE ASSISTANT Development/Corp. Mktg., Flowserve
Ashley Morris David A. Doty, North American Sales Manager,
Corporation
amorris@pump-zone.com Moyno Industrial Pumps
205-561-2600 Thomas L. Angle, PE, Vice President, Product
Ralph P. Gabriel, Director of Product Development,
Engineering, Weir Specialty Pumps
John Crane
Robert K. Asdal, Executive Director, Hydraulic
A Publication of Institute William E. Neis, PE, President, NorthEast Industrial
Sales
Bryan S. Barrington, Machinery Engineer, Lyondell
Chemical Co. Dr. Lev Nelik, PE, Apics, President, Pumping
P.O. Box 530067 Machinery, LLC
Birmingham, AL 35253 Kerry Baskins, Vice President, Grundfos Pumps
Corporation Henry Peck, President, Geiger Pumps & Equipment/
Editorial & Production
1900 28th Avenue South, Suite 110 Smith-Koch, Inc.
R. Thomas Brown III, President, Advanced Sealing
Birmingham, AL 35209 Mike Pemberton, Manager, ITT Performance
Phone: 205-212-9402 International (ASI)
Services
Advertising Sales Chris Caldwell, Director of Advanced Collection
Technology, ABS, & President, SWPA Earl Rogalski, Sr. Product Manager, KLOZURE®,
2126 McFarland Blvd. East,. Suite A
Garlock Sealing Technologies
Tuscaloosa, AL 35404
Phone: 205-345-0477 or 205-561-2600

is a member of the following organizations:

PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Pumps & Systems, a member of the Cahaba Media Group, 1900 28th Avenue So., Suite 110, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the right to determine qualifications. Annual sub-
scriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call (630) 482-3050 inside or
outside the U.S. POSTMASTER: send change of address to Pumps & Systems, PO BOX 9, Batavia, IL 60510-0009. ©2010 Cahaba Media Group, Inc. No part of this publication may be reproduced
without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, articles or descriptions herein, nor does
the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily
represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained
in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media Group, Inc. permission
by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to
republish your submission. Submissions will not be returned.

2 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

2009 R&D 100
Award Winner
Synchrony Fusion®
Magnetic Bearing

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 Table of Contents
The Magazine for Pump Users Worldwide December 2010

pump-zone.com

Photo Courtesy of Warren Rupp

December 2010
Volume 18 • Number 12

PRODUCT INNOVATION OF THE

YEAR AWARD
p
18
In Pumps & Systems’ second annual
Product Innovation of the Year Award,
14 entries from 12 manufacturers
contended for top honors. The winners,
finalists and honorable mentions were
chosen by the magazine’s editorial
advisory board and editors.

48

SPECIAL SECTION:
PUMPS IN POWER GENERATION
DEPARTMENTS
p
25
New Solutions for Solving Coal Handling
Pumping Problems
Matt Vetter, Chicago Industrial Pump Company
P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Positive displacement technology helps solve maintenance headaches at a Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

power plant. Joe Evans, Ph.D.
The Benefits of Pump Restoration and Coating

p
30 Pumps in the Global Power Generation Industry
Rebecca Tucker and Laurel Donoho, Frost & Sullivan
Business of the Business
Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 16
Dr. Lev Nelik, P.E., P&S Editorial Advisory Board, &
Jerry Skelton, Pumping Machinery, LLC

p
33 Power-Gen Preview Improper Grease Lubrication Could Be Troublesome

PRACTICE & OPERATIONS
p Proactive Planning
48 Paul Boyadjis & Chris Hurrell, Mechanical Solutions, Inc.
Potential vibration problems were avoided through design-stage finite
Maintenance Minders. . . . . . . . . . . . . . . . . . . . . . . . . 34
Jerry Rigsby, Georgia Power Company, Plant Scherer &
Will Gates, Morrow Repair Services
11-Year-Old Source of Forced Outages Found
Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ted Ratcliff
The Importance of Transloading Efficiency

element analysis. FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 42

If stress analysis can ensure that piping loads are within ASME limits,

p Pump System Energy Assessment why are rubber expansion joints needed?
52 Greg Case, PD3
Improved reliability, performance and energy efficiency can result from pump HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
system assessment. What are the parameters for pump baseplate design, and why
must baseplates be grouted in place? What are mixed flow
impellers, and when are they used?

Pump Users Marketplace. . . . . . . . . . . . . . . . . . . . . . 69

ANNUAL PRODUCT SHOWCASE
Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . 69
p
56 Innovative products, technologies and solutions from
selected suppliers.
P&S Stats and Interesting Facts . . . . . . . . . . . . . . . . 72

4 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS


 
  

“ FW Murphy was our first choice when we decided to upgrade – we didn’t need to
look anywhere else. We were happy with our existing Murphy controller for pump
automation, but we wanted to expand our capabilities to include remote monitoring.
By upgrading to the EMS controller, our customers can reduce fuel and water usage,
cut emissions, and in turn save money.
Working with Murphy made the transition easy. We were able to write our own
specifications, and Murphy provided the firmware developed specifically to meet
our application needs. “
We received personal attention that most companies don’t provide. With direct access
to engineers, sales people, and technical support – their customer service cannot be
matched. That’s why we stick with Murphy for our electronic monitoring needs.
Kevin Connolly
Owner, KC Irrigation Automation
www.irrigationautomation.com

Murphy’s latest engine controller, the EMS PRO, is a compact,

flexible, all-in-one industrial pump controller. Its customization and
easy interface make it the perfect fit for engine-driven equipment.

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FW Murphy
P.O. Box 470248 Tulsa, Oklahoma 74147 • Phone: 1.918.317.2610 • www.fwmurphy.com/EMSPRO-PAS
1010642-EMSPRO-PAS
P&S News
PEOPLE
GODWIN PUMPS (BRIDGEPORT, N.J.)
announced the loss of Joseph L. Abbott,
Jr., the company’s national sales manager.
Abbott joined the Godwin Pumps team in
1989 and brought sales and manufactur-
ing expertise to the company from the
sewer rehabilitation industry. In addition,
Joseph L.
he helped build Godwin’s distribution Abbott, Jr.
network throughout the U.S. and Canada,
managed product pricing and oversaw bids. Abbott is sur-
vived by his wife and their three children.
Godwin Pumps is a direct, wholly-owned subsidiary of
ITT Corporation and the manufacturer and supplier of the
Dri-Prime automatic self-priming pump.
www.godwinpumps.com
FREEWAVE TECHNOLOGIES (BOULDER,
COLO.) added Blair Harness to its engi-
neering department. Harness, who has
worked as an engineering contractor for
FreeWave since 1999 will continue to act
as the engineer responsible for wireless
radio products and technical development
Blair Harness
of the FreeWave product line.
FreeWave also added Ralph Oriscello,
a seasoned sales professional with more
than 25 years of sales management experi-
ence, to its business development team. He
will deliver wireless radio data solutions to
global OEM accounts.
FreeWave Technologies manufactures Ralph Oriscello
spread spectrum and licensed radios for
mission-critical data transmission. www.freewave.com.
KOCH MEMBRANE SYSTEMS (WILM-
INGTON, MASS.) promoted Dr. Hamid
R. Rabie to the newly created role of chief
operating officer responsible for all aspects
of KMS’s technology, product develop-
ment, manufacturing, process engineering,
supply chain and purchasing. He joined
Dr. Hamid R.
KMS in early 2010 as senior vice president
Rabie
of technology.
Koch Membrane Systems, Inc., offers membrane filtra-
tion technology and engineering support.
www.kochmembrane.com
JDA GLOBAL (REDLANDS, CALIF.) announced the addition
of two key pump veterans to its team. Tom Brown, whose
most recent position was director of Global Sourcing for the
Dover Corporation, has more than 25 years experience in the
pump industry. He will serve as president and partner of JDA
6 DECEMBER 2010 www.pump-zone.com
Global, LLC. He will oversee the Redlands, Calif., facility as
well as the Chinese and Indian base of operations.
Sam Featherston will serve as acting managing director
of JDA Global’s Wholly-Owned Foreign Enterprise (WOFE)
in Shanghai, China. Featherston will assume full managing
director status once legal proceedings are concluded and the
Chinese business entity is official. His most recent position
as director of procurement for the Pump Solutions Group
provided Featherston with an extensive skill set in castings
and injection molding.
JDA Global, LLC, is a pump holding company that
creates start-up pump companies and/or acquires small to
mid-size pump manufacturers that serve fluid transfer needs.
www.jdaglobal.com
EAGLEBURGMANN (HOUSTON, TEXAS) announced that
Rick Page, managing director of EagleBurgmann Canada,
Inc., has been recognized with an Award of Merit from the
Fluid Sealing Association (FSA). Page was recognized for his
distinguished and exceptional
contribution and leadership
to the FSA Mechanical Seal
Division and the association,
as well as his service as a mem-
ber of the board of directors
since 2007.
EagleBurgmann manu-
factures mechanical seals,
systems, packing and expan- Rick Page and FSA President
sion joints. Ed Marchese
www.eagleburgmann.com
AROUND THE INDUSTRY
HYDROAIRE (CHICAGO, ILL.), on September 29 and 30,
unveiled its new service center and test lab at an open house
attended by hundreds of customers, dignitaries, neighbors
and friends. his new facility has 46,000 square feet dedi-
cated to pump aftermarket services. In addition to new
machining equipment and 82 tons of crane capacity, the new
facility also has a unique test lab.
HydroAire is a subsidiary of Hydro Inc., a Chicago-
based organization formed in 1969, and is an independent
pump rebuilder. www.hydroinc.com
NATIONAL PUMP COMPANY (GLENDALE, ARIZ.)
announced that it has been acquired by the Gorman-Rupp
Company. Gorman-Rupp, headquartered in Mansfield,
Ohio, has been manufacturing and designing centrifugal
pumps and pumping systems for more than 77 years.
National Pump Company manufactures pumps and
pump systems for irrigation, municipal, power, industrial,
mining and oil and gas applications.
www.nationalpumpcompany.com
PUMPS & SYSTEMS
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 P&S News

BEST PUMPWORKS (HOUSTON, TEXAS) acquired Centrifugal distributor and service provider.
Technologies (CTI), a manufacturer of horizontal multistage www.pumpworks610.com
pumps (API configuration BB3, Model HSM) and service pro-
vider to the oil and gas market, based in Shreveport, La. CTI’s NATIONAL HIRE GROUP, LTD., (LANDSDALE, WA, AUSTRA-
operation and products will be aligned and marketed with Best LIA) will acquire Sykes Group, an Australian pump company.
PumpWorks OEM pump brand PumpWorks 610. he completion of the acquisition will take place in the near
Best PumpWorks is a pump manufacturer, remanufacturer, future.
National Hire Group, Ltd.’s indus-
tries include many equipment busi-
nesses. www.nationalhire.com.au

MEGGITT (GERMANTOWN, M.D.)

Meggitt added a new partner—Trans-
ducers, Measurements & Instruments,
Inc., (TMI). TMI focuses on transduc-
ers and data acquisition systems and test
instrumentation.
Meggitt has also added a Spanish-
language page to the www.wilcoxon.
com website, which focuses on vibration
sensors for industrial machinery health
monitoring.
1967 Nova Pro Street Meggitt PLC is an international
group operating in North America,
Europe and Asia and offers aerospace
equipment, sensing systems, defense
training and combat support products
and systems. www.meggitt.com
Do you have flows up to
1,400 US GPM (320 m3/hr), RS Series PUMP-FLO™ SOLUTIONS (LACEY,
heads up to 3,400 feet WASH.) announced that Met-Pro
(1,000 m), pressures up to Global Pump Solutions, part of the
1,500 psig (100 bar),
temperatures from 20˚F to 300˚F (-30˚C to 149˚C), and speeds
Met-Pro Corporation, has awarded
up to 3,500 RPM? Then you need Carver Pump RS Series muscle! PUMP-FLO Solutions a contract for
Designed for moderate to high pressure pumping applications, the RS is its ePUMP-FLO™ web-based selection
available in five basic sizes with overall performance to 1,000HP. As a software for its Sethco® product line. he
standard, with a product lubricated radial sleeve bearing and two matched Sethco Division will license the full-fea-
angular contact ball bearings for thrust, it only takes a mechanical seal on tured ePUMP-FLO software including
the low pressure, suction side to seal the pump. Optional features include a hosted online pump selection solution
ball bearings on both ends with an outboard mechanical seal, various seal
flushing arrangements and bearing frame cooling. These features make
and lead generation and management
the RS ideally suited for Industrial and Process applications including tools.
Pressure Boost Systems, Boiler Feed, Reverse Osmosis, Desalination PUMP-FLO Solutions is an engi-
and Mine Dewatering. Whatever your application, neered software business. www.pump-
let us build the muscle you need! flo.com

ABB (ZURICH, SWITZERLAND) experi-

enced accelerated order growth and rev-
Creating Value. enues rose in the third quarter. Orders
Carver Pump Company rose 18 percent and revenues 2 percent
2415 Park Avenue in local currencies, including an 11-per-
Muscatine, IA 52761
563.263.3410 cent increase in service revenues.
Fax: 563.262.0510 ABB offers power and automation
www.carverpump.com
technologies. www.abb.com

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8 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS



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 P&S News

RUHRPUMPEN (TULSA, OKLA.) opened a new manufacturing mining, and water industries and heavy industry applications.
facility in Orland, Calif. his new Ruhrpumpen facility adds www.ruhrpumpen.com
another full manufacturing location to the already existing ones
in Witten, Germany; Tulsa, Okla.; Monterrey, Mexico; Cairo, GE (ATLANTA, GA.) announced that it has signed a contract to
Egypt and Buenos Aires, Argentina. acquire Dresser, Inc., a global energy infrastructure technology
Ruhrpumpen is a centrifugal pump technology company and service provider. he $3 billion deal is the latest in a series
and offers a range of pumps to support petrochemical, power, of acquisitions over the last 10 years. Headquartered in Addi-
son, Texas, Dresser operates in more
than 100 countries, delivering compres-
sion, flow technology, measurement and
distribution infrastructure and services.
Pumps "Valves Systems
̈ ̈
GE is an infrastructure, finance and
media company and operates in more
than 100 countries. www.ge.com.

GRUNDFOS PUMPS CORP. (OLATHE,

KAN.) announced the launch of its cor-
porate Facebook fan page to promote its
products, programs, services and events.
One partner for valves and pumps. Grundfos manufactures pumps,
motors and pumping systems for HVAC,
liquid transfer, boiler feeding, water and
All around the world, KSB gate, globe, and check wastewater treatment, groundwater and
valves ensure that fluids stay where they have to, or digital dosing applications.
go where they should. Whether it’s a SICCA gate, www.grundfos.com
globe or check valve for power stations or industrial
processes, KSB customers know they can rely on one
partner for their valve and pump applications,
particularly on large-scale projects.
KSB, Inc. · 4415 Sarellen Road · Henrico, Virginia 23231
Stay Connected With
Tel./Fax: (804) 565-8330 · E-mail: slindgren@ksbusa.com · www.ksbusa.com

on

Globe

Gate

@PumpsSystemsMag
Check and at
www.pump-zone.com

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10 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
WÄRTSILÄ (HELSINKI, FINLAND) signed three operations and Colfax will design and manufacture a variety of fluid-handling
maintenance (O&M) contracts for power plants with Bor- systems at the expansion.
borema Energética S.A. in Paraiba, Brazil; Maracanaú Gera- Colfax Corporation manufactures fluid-handling products
dora de Energia in Ceará, Brazil; and Linhares Geração S.A. in and technologies. www.colfaxcorp.com
Linhares, Espirito Santo, Southwest of Brazil. With these con- P&S
tracts, Wärtsilä now operates and maintains 15 power plants in
the country.
Wärtsilä offers lifecycle power solu-
tions for the marine and energy markets.
www.wartsila.com

CONTROL MICROSYSTEMS (OTTAWA,

ONTARIO), announced the manufactur-
ing expansion of its Accutech wireless
instrumentation product offering.
Control Microsystems, a Schneider
Electric company, is a supplier of auto-
mation products for SCADA systems.
www.controlmicrosystems.com

IMI SENSORS (DEPEW, N.Y.), a division

of PCB Piezotronics, Inc., announced
Answers.
ATEX approval of the company’s Series
686B USB Programmable Smart Vibra-
tion Switch, designed for 24/7, continu-
ous protection of cooling towers, fin
fans, pumps, HVAC systems and other
critical machinery operated in hazardous
areas.
IMI Sensors offers vibration sensing
products for condition monitoring, pre-
dictive maintenance and process control
requirements. www.imi-sensors.com.

ULTRA-CHEM, INC., (NEW CASTLE,

DEL.) updated its online synthetic lubri-
cant resource guide to include new infor-
mation on food grade, high pressure and
gas compression lubricants. A synthetic
lubricants cross-reference allows profes-
sionals to select the proper oil for a par-
ticular application.
Think Cole-Parmer
Ultra-Chem, Inc., manufactures
products designed to meet the cleaning
Unique products combined with
and maintenance needs of today’s busi- exceptional service and tech support.
ness. www.ultracheminc.com

COLFAX CORPORATION (RICHMOND,

VA.) has added a 17,000-square-foot
expansion to its factory in Monroe, N.C.
he $3 million space opened in October
2010 and includes a 6,000-square-foot
Call, click, or chat live!
laboratory for high-tech pump testing. 800-323-4340 ColeParmer.com/8167
3202

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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 11
 P&S News

UPCOMING EVENTS EVERYTHINGABOUTWATER

INTERNATIONAL EXHIBITION
CENTRIFUGAL COMPRESSORS: POWER-GEN January 6 – 8, 2011
OPERATIONS FOR THE 21ST CENTURY December 14 – 16 Bombay Exhibition Centre / Mumbai, India
USER SHORT COURSE Orange County Convention Center +91-11-430 0519 / www.eawater.com/expo
December 7 – 10 Orlando, Fla.
South Shore Harbor Resort & Conference 918-831-9160 / www.power-gen.com INTERNATIONAL POULTRY EXPO
Center / League City, Texas January 26 – 28
979-845-8943 / engrevent.tamu.edu Georgia World Congress Center
Atlanta, Ga.
770-493-9401
www.internationalpoultryexposition.com
A “DESIGNATED DRIVER” AHR EXPO
FOR YOUR ROTATING EQUIPMENT January 31 – February 2
Las Vegas Convention Center
Las Vegas, Nev.
203-221-9232 / www.ahrexpo.com

RENEWABLE ENERGY WORLD

March 8 – 10
Tampa Convention Center / Tampa Fla.
1-888-299-8016
www.renewableenergyworld.com

WQA AQUATECH USA

March 8 – 11
Henry B. Gonzalez Convention Center
San Antonio, Texas
210-201-8500 / www.wqa.org

INTERPHEX
March 29 – 31
Jacob K. Javits Center / New York, N.Y.
Choose a Skinner steam turbine to do 203-840-5324 / www.interphex.com
your driving. You can always count on
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April 5 – 8
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eqortguuqtu»vq"pcog"lwuv"c" WINDPOWER CONFERENCE &
hgy"crrnkecvkqpu0""Pqy"cxckncdng" EXHIBITION
kp"oqfgnu"wr"vq"5222"JR"ykvj"unggxg"dgctkpiu"qt"dcnn"dgctkpiu"cpf"oqfgnu" May 22 – 25
Anaheim Convention Center
oggvkpi"CRK"833"uvcpfctfu0""Yg"ockpvckp"cp"kpxgpvqt{"qh"322'"igpwkpg"
Anaheim, Calif.
Umkppgt"rctvu"vq"jgnr"mggr"{qwt"qrgtcvkqp"twppkpi"cv"vqr"ghhkekgpe{"cv"cnn"vkogu0 202-383-2500 / www.windpowerexpo.org
Hqt"swkem"fgnkxgt{"cv"c"nqy"equv."ecnn"wu"Vqnn/Htgg"cv":99/:8:/:799"qt"xkukv"qwt"
SOCIETY OF MANUFACTURING
ygdukvg"yyy0umkppgtrqygtu{uvgou0pgv"vq"ngctp"oqtg"cdqwv"qwt"ecrcdknkvkgu"vq" ENGINEERS ANNUAL CONFERENCE
ugtxg"cu"{qwt" fgukipcvgf"ftkxgt 0 June 5 – 7
Hyatt Regency Bellevue / Bellevue, Wash.
Skinner Power Systems, LLC 1-800-733-4763 / www.sme.org/conference
8214 Edinboro Road To have an event considered for Upcoming
Erie, Pennsylvania 16509 U.S.A. Events, please send information to Lori Ditoro
at Pumps & Systems, P.O. Box 530067,
Visit us at Booth #337 at Power Gen International Birmingham, AL 35253, 205-314-8269,
lditoro@cahabamedia.com.
circle 118 on card or go to psfreeinfo.com
P&S

12 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

Pump Ed 101
Joe Evans, Ph.D.

The Beneits of Pump Restoration

and Coating
Second of Two Parts

The Restoration Process—

Before and After

I
n the November 2010 issue of Pumps & Systems, this
column began a two-part series to analyze a study
conducted on the Monroe County Water Authority
(MCWA) in Rochester, N.Y., pump restoration project.
As discussed in Part One, the restoration consisted of the
mechanical refurbishment (replacement of wear rings, bear-
ings and shaft sleeves), sandblasting, application of a metal
filler (if required) and two coats of epoxy coating.
Figure 1. The pump’s internal condition before sandblasting
Several types of coatings were considered for the project,
but brushable, ceramic-filled epoxy coatings were the final
choice for several reasons. he MCWA wanted coatings that
could be applied in-house without sophisticated tools. hey
also wanted coatings with good adhesion and abrasion char-
acteristics. Finally, the coatings had to be NSF-61 approved
and available at a reasonable cost. he coatings selected for
the study were Henkel / Loctite Brushable Ceramic Grey,
Belzona 1341 Supermetalglide and Enecon Chemclad XC.
Figure 1 shows a typical pump’s internal condition prior
to sandblasting. his particular pump is a 600 horsepower
model that was installed in the mid 1980’s. As shown, the Figure 2. The pump casing after sandblasting
interior exhibits both surface corrosion and tuberculation. In
certain areas of the casing and cover, tubers were larger than
one-half inch.
Figure 2 shows the interior of the pump following
sandblasting. After sandblasting, the surface was evaluated
to determine if application of the metal filler was required
prior to coating. his particular pump exhibited a significant
amount of surface pitting, and those pits were filled prior
to the coating process. Figure 3 shows the same pump after
application of the metal filler and two coats of ceramic-filled,
epoxy coating. Figure 3. The interior after pit filling and two applications of
epoxy coating
Brush-On Coating Durability monitoring continues to provide the information necessary
As the project progressed, one of the most frequently asked to fully answer that question.
questions was “how long will the coating last?” hat ques- Figure 4 is an example of information gained by peri-
tion may not be fully answered for many years, but a greater odic visual inspection. It shows the interior of a pump cover
understanding is achieved as time goes on. after four years of operation. At first glance, it appeared that
MCWA tests all the pumps every six months to look the coating was beginning to fail. However, upon closer
for performance changes that could indicate premature examination, the discoloration was due to “rust staining.”
coating failure. hey also remove the upper casings annu- he staining was caused by the rusting of a small part of
ally and inspect the coating’s integrity. his detailed uncoated machined surface between the upper and lower

14 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS


Restoration cost, energy savings and payback period
Figure 4. Rust staining initially thought the result of
coating failure
Figure 5. Coating after four years of operation and rust stain
removal
casing of the pump.
he coating remained smooth to the touch and did not
flake off at its edges. After cleaning with a steel wool pad (Figure
5), the coating returned to its original, post-coating appearance.
Cost vs. Payback
Table 1 summarizes the restoration costs, energy savings and
payback periods for all the pumps in the study. It assumes that
the pumps operated nearly continuously prior to restoration.
he energy savings are based on a demand charge of $10 per
kilowatt and an energy charge of $0.085 per kilowatt hour.
As shown, the estimated total post restoration annual
energy savings for all 16 pumps is $122,190 versus a total resto-
ration cost of $101,461. he payback period ranges from 0.47
to 2.84 years, while the average for all pumps is 0.83 years. he
total power reduction exceeded 1.3 million kilowatt hours.
Relationship of Specific Speed
and Efficiency Increase
A European study published in 2001 suggested that lower
specific speed (Ns) pumps would show a greater increase in
WEFTEC presentation authors:
Paul Maier (can be reached at paul.maier@mcwa.
com); Randy White; Steve Connell; Chris King, PE
and Richard Metzger, PE
Monroe County Water Authority, Rochester, N.Y.
PUMPS & SYSTEMS www.pump-zone.com
Table 1.
efficiency after coating than higher Ns pumps. MCWA’s results
showed a similar pattern. Pumps with an Ns between 1,000 and
1,200 saw an increase of about 12 percent while those between
2,000 and 2,500 increased by about 8 percent.
As the Ns approached 2,800, the increase dropped to
about 5 percent, and at 3,900, the efficiency increase reached a
low point of 2 percent. hese results may be somewhat skewed
since some of the pumps did not exhibit the same degree of
roughness prior to restoration, and a roughness variable was not
developed for the efficiency comparisons.
Project Conclusions
and Recommendations
he MCWA’s goal was to prevent or significantly delay the
inevitable decline of pump performance due to internal cor-
rosion. MCWA believes that it achieved its goal, and the con-
clusion is that restoration and coating offers multiple benefits
including increased efficiency, head and flow. he study showed
that sandblasting and coating resulted in higher initial and
long-term efficiencies than sandblasting alone, and to date, the
coatings have shown no signs of failure. MCWA recommends
that new pumps be coated by the manufacturer or a coating
vendor selected by the manufacturer prior to pump delivery.
Internal coating is now part of its specifications for new and
replacement pumps.
his study involves much more than space allows. If you
have questions or would like a copy of the complete WEFTEC
presentation, please contact Paul Maier by email.
P&S
Joe Evans is responsible for customer and employee educa-
tion at PumpTech, Inc., a pumps and packaged systems
manufacturer and distributor with branches throughout the
Pacific Northwest. He can be reached via his website, www.
PumpEd101.com. If there are topics that you would like to
see discussed in future columns, drop him an email.
DECEMBER 2010 15
Pumping Prescriptions
Dr. Lev Nelik, P.E., P&S Editorial Advisory Board, &
Jerry Skelton, Pumping Machinery, LLC

Improper Grease Lubrication

Could Be Troublesome

J
erry, my repair shop manager, called me
for advice on a recent problem he had with
an end-suction, vertically-mounted, raw
sewage intake pump. He was troubleshoot-
ing the problem at the lift station of a major
municipal water treatment plant.

The Problem
“Lev, the bearings are running hot, and the
plant maintenance guys are concerned,” Jerry
tells me. “hey say they follow the IOM proce-
dures by the book, but the temperature is going
above 200 degrees F, and the pump shuts down
at these temperatures. hey wonder if my guys
should pull the pump and inspect it at our shop,
but I would first like to do some checking in the
field to see if we can find something obvious.”
“Can you send me some photos of the
installation and a sectional drawing?” I ask.
“Also, tell me more about this problem. Is the
pump running continuously or with leads/
lags?”
I asked this question because influent lift
station pumps typically run in sequence. he first pump may
run for 20 to 30 minutes drawing down the wet well and
then shuts off, and the station idles until the well builds up.
hen the second pump takes the lead, runs and shuts off,
and then the third, and so on. In this mode, a pump would
hardly get its bearings higher than 130 to 150 degrees F for
the short time it operates.
“No problem. I’ll email the photos to you right away,”
Jerry says. “But call me back as soon as possible. I am run-
ning out of ideas, and the grease plugs at this housing do not
look right.”
Jerry was timing the pumps
between runs and measuring the tem-
perature climb. he 200 degrees F, after
20 minutes of run time, did not sound
right to him, nor to me. Something was
wrong.
After examining the images
(Figures 1 & 2) that he emailed me,
I called him back. “he lower hous-
ing seems to have a double-row, radial
load bearing. he upper housing has
two bearings: a tandem arrangement, Figure 3. Excess grease on the housing
Figure 1 (above). End-
suction, vertically-mounted,
raw sewage intake pump
Figure 2 (left). Drawing of
the pump
40-degree angular contact to take the main thrust, and a
bumper single row bearing to take a start-up, transient up-
thrust. I am confused about the greasing arrangement. he
lower housing has a grease fitting [Figure 2 (B)] on the top,
and a pop-up relief plug at the bottom. he top housing has
two grease injection fittings (one at the top chamber and
another between the bearings) and a pop-up relief plug at the
bottom. Is that right?”
“hat’s right,” Jerry says. “hat is what’s bothering me.
How do they make sure the bearings are not over-greased?
he relief plugs are supposed to pop open and relieve the
pressure if the chambers are full of grease. However, as soon
as the pressure relieves, the pop-up
relief closes, and the chambers remain
mostly filled. his would make the
bearings run hot. I also see clear signs
of that because the whole housing is a
mess—mostly at the top, but it’s OK at
the bottom.”
“hey say the IOM procedure
manual tells them to pump two strokes
of the grease gun,” Jerry continues.
“hey showed me where they inject the
grease: into A at the top housing and B

16 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

at the bottom. hey do this monthly
per work order request. hey have
been doing it for about seven months,
since the pump was installed.”
Two strokes are barely a fraction
of an ounce. hrough seven months,
the number of strokes would be 14,
which would perhaps be an ounce or
two, not enough to even be close to
over-greasing. his assumes that they
did what they said and did not add a
few more strokes just to be safe.
“What else do you see?” I ask.
“Is the pump pumping OK? Is it
vibrating?”
“It pumps fine. he operators
are happy, and vibrations are low. I
just took measurements myself. he
issue is that the housing definitely
looks over-greased but only at the top
side of the housing.”
Jerry pauses thinking, “It would
make sense according to the fittings. Grease cannot be injected
into the bottom portion of the upper or lower housings, other
than relying on the dripping of grease through the entire row
of bearings.”
“You’ve said enough,” I say, now worried too. “Pull the
pump, and get it to the shop. I will see you there when the
pump is opened.”
The Answer
Grease arrangements are many.1 Sealed-for-life, open, shield-
on-one-side, dead-headed arrangement, thru-flow arrange-
ment and cross-lubrication are some of the numerous tech-
niques used. Improper lubrication—too much, or not enough,
grease—could mean trouble.2
In practice, perfection is almost impossible.3 Bearings are
initially greased at the OEM manufacturer or after repairs. he
amount of grease is usually 50 percent (half the space within the
bearing is filled), plus some grease is added within the cham-
ber itself. hat is all that the bearings actually need, and they
will run cool, about 100 to 130 degrees F, or 10 to 20 degrees
F higher for a roller bearings case. Going over 150 degrees F,
approaching 180 degrees F and certainly going beyond 200
degrees F is a sign of too much grease or other bearing-related
issues.
he real challenge is not when the bearings are greased at
the shop but when they are re-greased in the field. Not know-
ing what is inside, how much grease should a mechanic add?
Manuals vary on recommendations, but the simplest, and per-
haps most reliable, is to inject new grease until the old grease is
purged and is followed by the new fresh grease coming from the
relief port (which must be open completely).
he pump may or may not have pop-up plugs. If it does
PUMPS & SYSTEMS www.pump-zone.com
have them, they should serve as
a precautionary measure, and the
relief plugs should also be present.
Sometimes if relief plugs are not pres-
ent, the pop-ups should be entirely
removed during re-greasing, and the
pump allowed to run for 15 to 30
minutes, while watching the fresh
grease leak out, being pumped out by
the bearings.
After that time, the plugs would
be put back in to keep the remaining
grease inside. his procedure would
result with roughly 50 to 70 percent
of the grease left inside the housings,
without the bearings being over-
packed with grease and, therefore,
running cool.
Figure 4. The pump
Jerry’s next action was to modify
with injection ports
the housings to make sure each
labeled
chamber had its own way in (grease
fitting) and its own way out (pop-up
plugs). he pop-up, plugs would need to be removed at each
re-greasing and replaced after 15 to 30 minutes of the pump
running.
In Figure 4, Ctop, Cmid and Cbot are cavities on top of the
top bearing at the upper bearing housing. Gt, Gm and Gb are
injection ports (grease fittings), and Pt, Pm and Pb are pop-up
relief plugs (also served as relief plugs to be opened during
relube). Similar designations are shown for the lower housing
(G = grease in and P = pop-ups).
he logic made too much sense, and the plant mainte-
nance did not completely buy it. Why waste so much grease
every month? “Is there a simple method?” they had asked Jerry.
here is indeed—perhaps not perfect but a compromise.
hat is how the final procedure was modified. Can you
guess how? he person with the winning answer gets a free
ticket to our Pump School session: www.pumpingmachinery.
com/pump_school/pump_school.htm. Email me, and let me
know what you think. he solution will be included in the
January 2011 issue of Pumps & Systems.
P&S
References
1. Nelik, L., “To Grease or Not to Grease,” Pumps & Systems, August 2005.
2. SCOPETM Reliability Program, www.pumpingmachinery.com/pump_
magazine/pump_articles/articles_summary.htm (Article #33).
3. Nelik, L., “Reliability of Grease Lubrication Methods,” www.pumpingma-
chinery.com/pump_magazine/pump_articles/article_07/article_07.htm.
Dr. Nelik (aka “Dr. Pump”) is president of Pumping
Machinery, LLC, an Atlanta-based firm specializing in
pump consulting, training, equipment troubleshooting and
pump repairs. Dr. Nelik has 30 years of experience in pumps
and pumping equipment. He can be contacted at www.
PumpingMachinery.com.
DECEMBER 2010 17
 Product Innovation of the Year Award
Product Innovation Year
Lori K. Ditoro
I
n Pumps & Systems’ second annual Product Innovation
of the Year Award, 14 entries from 12 manufacturers
contended for top honors. he contest examined prod-
ucts that entered the market between September 1, 2009 and
August 31, 2010. he winners, finalists and honorable men-
tions were chosen by the magazine’s editorial advisory board
and editors. he editors extend a special thank you to the
board members for their much-valued help in making this
decision.
he winner of this year’s award is Warren Rupp’s
AirVantage Energy Saving Technology, which is used on air-
operated double diaphragm (AODD) pumps. he AirVantage
technology continuously manages the amount of air volume
required to operate the pump at desired flow rates and pro-
duces its own electricity, ultimately saving energy and cutting
air usage by up to 50 percent.
he second place finisher is Active Water Sciences (AWS),
a newcomer to the pump industry. AWS’s Water Phoenix is a
portable water treatment system that can provide clean water
within 24 hours of setup. It is currently in use by the U.S.
military in Afghanistan.
Warren Rupp
AirVantage Energy Saving Technology
2010 WINNER
Innovation
Coming to market in August 2010, AirVantage® Energy Saving
Technology is used on air-operated double diaphragm pumps
(AODD), which are industrial pumps that employ the use of
a twin diaphragm system for positive displacement to move
liquids. Important specifications for diaphragm pumps include
maximum discharge flow, maximum pressure discharge, inlet
size, discharge size and media temperature. Power sources are
primarily pneumatic or hydraulic and incorporate the use of
compressed air or natural gas.
AODD pumps with AirVantage Energy Saving Technology
are equipped with a microprocessor that is adaptive and contin-
uously manages the amount of air volume required to operate
the pump at the desired flow rates. his technology determines
the optimal diaphragm rod velocity and relays the informa-
tion to an air distribution valve at the pump’s air inlet location.
18 DECEMBER 2010 www.pump-zone.com
of
the
SDT Ultrasound’s SDT270 Ultrasonic Detector receives
third-place honors. he SDT270 provides early indication of
bearing re-lubrication requirements, bearing failure and pump
cavitation.
Fourth place goes to LUDECA’s VIBXPERT II, which
has the best resolution on the market at 102,400 lines of
resolution FFT and a new, fast processor that provides rapid
operation and high-speed data collection.
In a two-way tie for fifth place are Mouvex’s SLP pump
range and Wanner Engineering’s T8030 Pump. he SLP
pump range is the first positive displacement pump that is
sealless without using a magnetic drive system. he T8030
Pump has a patented valve system that maintains the correct
volume of hydraulic fluid in the pumping chamber behind
the diaphragm.
AW Chesterton, Baldor Electric, GF Piping Solutions
and seepex receive honorable mentions.
Congratulations to our winner, finalists and honorable
mentions! We appreciate your participation in the contest this
year. For information about next year’s competition, please go
to the Awards section of www.pump-zone.com.
he valve acts as a gated air management system, allowing only
enough air to enter each inner pump chamber. Diaphragms
perform at their optimal operating point with less air consump-
tion. As the pump experiences air inlet fluctuations or other
changes that affect air flow, the system adapts to optimize the
pump’s performance.
PUMPS & SYSTEMS
 AirVantage uses existing air flow to provide its own elec-
tricity and power to the device. his eliminates the need for
batteries or hard wiring. No training or special setup is required
to operate the energy saving technology, which installs in the
same way as traditional AODD pumps.
Statistical Data
his product was tested at 20 manufacturing facilities during
an 18-month period. During these tests, Warren Rupp vali-
dated that AirVantage saves up to 50 percent air consumption
over competitive pumps when applied to heavy flow applica-
tions. his information was validated by standard cubic feet per
minute (SCFM) meters and recorded on data-loggers within
these facilities.
Warren Rupp has published comparison charts show-
ing greater than 50 percent energy consumption versus major
pump brands on a 3-inch pump comparison point, 150 gal-
lons per minute and 40-psi head. his information is based on
published performance curves. At 150 gallons per minute/40-
psi head, Versa-Matic AirVantage air consumption is 67 stan-
dard cubic feet per minute (SCFM), where other manufactur-
ers’ AODD pumps measured 155 SCFM, 150 SCFM and
117 SCFM (manufacturers’ names were removed by Pumps &
Systems’ editors for the purposes of this article). hese compari-
sons are indisputable when comparing published data sheets.
AirVantage has also qualified under the Iowa Custom
Energy Rebate Program as an energy saving technology where
Advanced Water Sciences
The Water Phoenix
2nd Place
Innovation
Introduced in September 2009, the Water Phoenix from
Advanced Water Sciences (AWS) was recently recognized by the
Wall Street Journal in its 2010 Technology Innovation Awards.
It is a patented wastewater treatment system that can be used
in any situation in which clean water is a priority—including
disaster relief, nation building, agricultural applications and
industrial and municipal wastewater cleanup efforts
Based on a continuous flow technology, the Water Phoenix
uses special bacteria to convert wastewater into EPA standard
water, producing little to no sludge. Portable and scalable, it
can be fully functional within a matter of hours, can provide
clean water within 24 hours after set up, can operate virtually
autonomously and can be monitored remotely.
he Water Phoenix provides an energy-efficient, cost-effec-
tive and ecologically proven wastewater cleanup solution across
PUMPS & SYSTEMS www.pump-zone.com
the utility (MidAmerican Energy) has committed project fund-
ing to install the equipment.
End-User Testimony
Rick Klok, plant manager, Grains and Powders manufactur-
ing facility, Saint Gobain, Niagara Falls, N.Y.
he Saint-Gobain Grains and Powders manufacturing facility
took on a 30-day energy savings challenge. he facility reduced
its energy costs by 23 percent at its fluid separation points, the
most process-critical applications within the facility, according
to Rick Klok. hey perform several functions and run 24 hours
per day, seven days per week.
“Over this period of time, AirVantage reduced our air con-
sumption by 23 percent while maintaining our desired flow
rates,” Klok says. “It was simple. All we did was install the trial
AirVantage pump, and it did the rest, optimizing our energy
consumption without special handling or monitoring.
At the end of the product trial, the test results showed
the amount of compressed air that the pump consumed with
AirVantage versus data points collected before the product trial
began.
“We were surprised to learn that we can save as much as
$1,200 in energy costs and increase our air compressor capacity
by 2.5 horsepower per pump,” Klok says. “We were very satis-
fied with the performance of the new system, and we plan to
use AirVantage on all [our] AODD pumps in the future.”
a broad range of applications in diverse locations throughout
the world. he Water Phoenix’s ability to clean water is indi-
cated below:
DECEMBER 2010 19
 Product Innovation of the Year Award

Parameter Influent Effluent Reduction improved’ technologies for all of my 35 plus years in the busi-
(avg. value) (mg/L) (mg/L) (percent) ness and have rarely, if ever, been impressed. Typically, I would
BOD 272 15 95 percent
have and did consider this just another pipe dream being mar-
keted by another ‘snake oil’ sales person. I was wrong.
TSS 166 13 92 percent “I believe this technology will change our industry. [It]
will simplify operation/maintenance and reduce overall cost for
End-User Testimony
an ongoing necessity (wastewater treatment) for many years to
Six Water Phoenix systems are in use by the U.S. Army in
come. I see this technology growing exponentially. I am excited
Afghanistan. Sonny H. K. Van-Skyhawk, environmental con-
that our industry is really taking a leap forward with this tech-
sultant for the U.S. Army, was doubtful at first but has since
nological development in helping manage our environmental
become impressed with the Water Phoenix.
resources as good stewards of our planet. I have been around for
“When I first heard about this and was asked by our…
quite awhile, and believe it or not, I had actually envisioned our
project manager to evaluate this system firsthand, I was skep-
industry getting to this point. I just honestly did not believe it
tical,” Van-Skyhawk says. “I have heard of these ‘new and
would happen during my watch. It has.”

SDT Ultrasound
SDT270 Ultrasonic Detector
3rd Place
Innovation
Released in January 2010, the SDT270 Ultrasonic Detector,
in conjunction with its powerful database software, gives the
earliest indication of bearing re-lubrication requirements, bear-
ing failure and pump cavitation. In addition, it is useful as a
total product data management tool for finding compressed air
leaks, vacuum leaks, checking steam trap conditions, finding
leaks in condensers, inspecting electrical systems for possible
arc flash and inspecting non-rotating and rotating equipment
for fault. It is useful on slow speed bearing monitoring where
other technologies such as vibration analysis can struggle.
he SDT270 is the first ultrasound instrument to
incorporate:
• An onboard SQL database for PC/instrument • Building blocks platform that allows the user to define the
synchronization instrument with only the needed features, but the user has
• True amplitude for collecting accurate and comparable the flexibility to unlock other features in the future if the
wave files facility’s needs change
• A USB or Ethernet IP addressable connection for remote
support/training
• Two channel inputs End-User Testimony
• Multi-functional data collection including (dBμV, rpm, Mike Chesson, reliability engineer, General Mills, Inc.
degrees C/F, SCFM, dBA, and acceleration) Mike Chesson felt that using the SDT270 hardware and soft-
• Onboard messaging ware to standardize the ultrasonic monitoring program at
• Independent amplification and headphone volume General Mills, Inc., in Murfreesboro, Tenn., was an easy deci-
adjustment sion. “We are going to begin approaching reliability engineers
• Sensor recognition in survey mode to prevent data collec- in our other facilities to inform them of our decision and
tion with the wrong sensor recommend that they contact SDT for further information,”
• Powerful database software that is both simple and Chesson says.
sophisticated

20 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

 LUDECA
VIBXPERT II
4th Place
Innovation
Introduced in June 2010, the VIBXPERT II
(VXP II) has many different uses and func-
tions. Its primary use is to extend the lifespan
of equipment within a plant or facility using
vibration signatures. One of its many appli-
cations is detecting bearing faults, either early
or pre-existing within the machinery. It can
also detect cavitation within pumps.
he VXP II was designed with the end
user in mind—faster, tougher and sleeker and
intuitive to operate. It is a true, two-channel
data collector and signal analyzer. It offers 102,400 lines of res-
olution FFT. A new fast processor provides rapid operation and
high-speed data collection. he screen is a full VGA (480 x 640
pixels), 18-bit, TFT LCD non-reflective color display.
he greatest improvement is at lower lines of resolution,
where the VXP II is almost 20 percent faster than the VXP I.
his means that data can be collected quicker than ever before.
he VXP II uses between 9 and 13 percent of its battery life per
hour. he variation depends on the data acquisition method
being used. his allows the VXP II to provide eight hours of
continuous use.
Mouvex
SLP Pump Range
5th Place
Innovation
Introduced in April 2010, the SLP25i is a positive displace-
ment vane pump that can be used on a variety of industrial
and chemical fluids. his pump is sealless, which means that
packing or a mechanical seal is not used. It features an all 316L
stainless steel construction with PTFE encapsulated FKM
O-rings. It provides a maximum flow rate of 110 gallons per
minute, can stand a maximum 174-psi differential pressure and
can handle viscosities up to 278000 SSU.
his pump is the first rotary, positive displacement pump
that is sealless without using a magnetic drive system. Shaft
PUMPS & SYSTEMS www.pump-zone.com
End-User Testimony
Ray Wonderly, Advanced Maintenance
Technologies, Germantown, Ohio
After using an evaluation unit of the VXP
II, Ray Wonderly was anxious for his own
model. “I recently had the chance to borrow
and use an evaluation unit which proved
to be faster than my current VIBXPERT,”
Wonderly says. “Speed is important when
working with big routes since it cuts down in
data collection time. I was also impressed by
its crisp and bright color display and record-
ing functionality.”
Besides the acquisition of accurate and consistent vibration
measurements, other features stood out to Wonderly, including:
• he unit’s light weight
• Long battery life
• Route storage capacity
• he ability to download past measurements and history
trends into data collector.
• he ease to edit or customize instrument setup in the field
when needed
sealing is provided by a double, stainless bellows that houses
an eccentric shaft. By rotating, the shaft drives the bellows
end in a rotating movement. his rotation is transmitted to
the pump rotor shaft by a crank system. Sealless drive system
cooling is provided by the whole flow rate crossing the bellows
DECEMBER 2010 21
 Product Innovation of the Year Award
chamber and then driven to the pumping chamber by the side
tube. Cooling does not require the diversion of part of the flow,
which would reduce pump efficiency, or a separate cooling
system, which would make the pump more complex to operate
and maintain.
When comparing the SLP25i to mechanical seals, it pro-
vides the following advantages:
• Suppresses leakages
• Reduces or even suppresses maintenance
• Suppresses flushing system, which is often necessary with
mechanical seals
• Accepts pump dry running up to 10 minutes
Compared to a pump with a magnetic drive, it provides
these advantages:
• Reduces power consumption up to 40 percent
• Increases pump global efficiency up to 20 percent
• Simplifies maintenance
• Suppresses all side precautions due to magnetic field
• Needs much less monitoring when used in potentially
explosive atmosphere
• Accepts pump dry running up to 10 minutes without
damages
Wanner Engineering
T8030 Pump
5th Place
Innovation
Introduced in August 2010, the Hydra-Cell T8030 is a sealless,
triplex diaphragm pump that reduces maintenance and down-
time by eliminating packing, has zero leakage of production
fluid, has the ability to pump abrasives and can run dry without
damage. he T8030 high-pressure pump employs asynchro-
nous, hydraulically-balanced diaphragms with a patented valv-
ing system. his asynchronous design allows the diaphragms
to be hydraulically coupled to the displacing plungers with no
mechanical coupling required. It is capable of flow rates to 926
barrels per day (27 gallons per minute) and pressures to 4,500
psi.
he heart of the Hydra-Cell T8030 is a patented valve
system that maintains the correct volume of hydraulic fluid
in the pumping chamber behind the diaphragm. his valve
system uses a spool valve combined with one-way hydraulic
check valves to maintain the proper diaphragm position. his
breakthrough in diaphragm pump design enables diaphragm
pumps to have much higher flow rates and pressures than
22 DECEMBER 2010 www.pump-zone.com
In addition, the SLP25i is self priming. he wear parts
(vanes) can be replaced while the pump is online and without
total dismantling. he bearing lubrication is made by synthetic
oil needing replacement only every 12,000 to 17,000 hours,
and pump dismantling and reassembly is simple and requires
neither specific tooling nor accurate clearance settings.
End-User Testimony
A methyl di-p isocyanates plant in Hungary has been using an
SLP25i for the past four months. he pump is used at its maxi-
mum speed, 24 hours per day. According to the plant main-
tenance manager (name not provided), the pump has allowed
significant process improvement:
• Pump monitoring was reduced. he previous installation
of magnetic driven pumps required constant monitoring of
flow, power and temperature (ATEX Zone 1). he Mouvex
SLP pump only requires temperature monitoring to comply
with ATEX.
• he crystallization that was occurring inside the magnets
cooling channels was suppressed.
• his pump was more accepting of accidental dry running
without damage and keeping inside ATEX certification
field.
• It is a “start and forget” pump.
previous diaphragm pumps.
he improvement over current technology comes through
the elimination of plunger pump packing, and the diaphragm
in the T8030 does not wear.
End-User Testimony
Matt James, J & J Technical Services, Shreveport, La.
J & J Technical Services (JJ Tech) is convinced that the Hydra-
Cell T8030 is the pump of choice for its oil and gas applica-
tions. JJ Tech manufactures artificial lift jet pump systems that
increase the flow of liquids such as crude oil or water from a
PUMPS & SYSTEMS
production well. For decades, oil wells throughout the world
have been produced by beam pumps (also referred to as pump
jacks or sucker rod pumps). With numerous downhole moving
parts, beam pumps have regular costly maintenance. JJ Tech’s
jet pump system has zero moving parts downhole thereby
reducing maintenance and avoiding costly shutdowns.
Jet pump systems needed a positive displacement surface
pump to power the jet pump downhole. To avoid the regu-
lar maintenance of the packed plunger pump family, JJ Tech
has been testing the Hydra-Cell T8030 for their high pressure
well applications since February and is convinced of the pump’s
superior performance over the competition.

A.W. Chesterton
170 Slurry Seal
Honorable Mention
Released for testing in July 2009, the 170 Slurry Seal has springs entirely outside the seal to prevent clogging. he seal faces are
loaded through an innovative loading mechanism called the pressure plate. he springs are viewed externally and can be cleaned if
required. Chesterton also incorporated larger springs into the design to minimize clogging.

Baldor Electric
Super E Motor with
Honorable Mention AEGIS Shaft Grounding Ring
Introduced in June 2010, Super-E Motors with AEGIS Shaft Grounding Ring are used in commercial and industrial applications
to drive pumps and provides a path to ground for circulating currents, preventing bearing fluting.

GF Piping Solutions
Type 514 High Flow
Honorable Mention Diaphragm Valve Series
Introduced in May 2010, the type 514 High Flow Diaphragm Valve is suitable for extremely contaminated media, media con-
taining solids and high purity liquids for a variety of applications such as the chemical process industry to microelectronics, water
treatment, cooling and control. he valve’s innovative flow geometry and bolt-less design are the two significant features that make
it a true break-through.

seepex
Smart Conveying Technology
Honorable Mention
Introduced in September 2010, seepex’s Smart Conveying Technology allows the stator to be readjusted giving longer stator and
rotor life compared to conventional designs. It makes maintenance easier, has low life cycle costs, requires less space for installation
and is eco-friendly because the stator is not bonded to a tube, and only the rubber components are replaced when worn.
P&S

PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 23

Pumps in Power Generation

PUMPS IN POWER
GENERATION

A Special
ecial Section
Specia ection of
Section of
Top:
Top: Freighter
Freighter Unloading
Unloading to
to Coal
Coal Pile
Pile
Bottom:
Bottom: Transfer
Transfer Belt
Belt Area
Area Sump
Sump
December
D 2010b 22010
24 DECEMBER 010
010 www.pump-zone.com PUMPS & SYSTEMS
New Solutions for
Solving Coal Handling
Pumping Problems
Matt Vetter, Chicago Industrial Pump Company

Positive displacement technology helps solve

maintenance headaches at a power plant.

A
large amount of fuel is needed
to generate 2,100 megawatts of
power. A boiler’s appetite for coal
is as relentless as a customer’s demand
for power. In the case of the power plant
discussed in this article (corporate policy
prevents name disclosure), the generating
station provides enough electricity to serve
1.3 million people.
hose familiar coal piles (black mini-
mountains) are the result of a constant,
supply-and-consume process that requires
substantial conveyor belt systems includ-
ing dumping stations, transfer points,
sloped belts and outside bulldozers.
Millions of tons of coal arrive each
year at the Midwestern plant, either by Coal Pile Unloading
rail car or freighter, and must be unloaded. be pumped up and out together. he conditions cause difficult
Rail cars are dumped, and the dumper infrastructure and belt pumping situations.
systems are located about 80 feet below ground. his coal is However, coal handling applications have ever-changing
conveyed over and up onto the coal piles via underground and variables. Under upset conditions, solids can be dumped so
sloped belts. Eventually, it is fed to the boilers again through a quickly that they literally bury the pumps. Water flow is gen-
conveyor belt system. Coal from freighters is offloaded to the erally low and intermittent with variable sources such as rain,
coal pile and fed to the plants using the same conveyor systems. snow melt, groundwater seepage, automatic flush and dust sup-
pression systems. In addition, operators manually wash down
Coal Handling Pump Problems these areas to control dust and build-up. he sumps are often
Two key factors cause problems when handling coal. First, coal small and sized for lower flows. his dirty, dusty environment
sinks in water. Second, water collects in low spots. Combine is, in most cases, rated as Class II, requiring explosion-proof
this with a conveyor system, which operates below ground and motors and controls.
has dust, fine particles and chunks falling from the belt. With he net result is a variable, medium-to-low flow slurry
nowhere to drain, water collects, and whatever is with it must

PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 25

 Pumps in Power Generation

application that is critical to plant operation. Flooding the con- One example is a 30-inch square sump with fines draining
veyor equipment and stopping the flow of fuel are not options. in at a normal rate of 10 gallons per minute. his is followed
by 2-inch chunks pushed in with a pile of solids as an operator
Typical Solutions and Limitations washes the area down with a 70-gallons-per-minute hose. he
he common approach is to use vertical and submersible slurry 10-gallons-per-minute inflow, which carries the quick-settling
pumps, but this is often a poor matchup for the flow rates, solids fines, can easily silt-in a typical centrifugal pump as it waits for
concentrations and solids sizes involved in this type application. a sump high-level indicator to activate it.
In addition, the 3-inch solids capac-
ity (needed to pass the chunks) requires
a much larger pump and higher flows
to function properly. he small sump is
drained in seconds, bumping the pump
on and off too quickly, assuming that
|
INNOVATION FUNCTIONALITY DEPENDABILITY | it was not silted-in during the low-flow

NEW! BHAT*LNK
Peristaltic Metering Pumps
É
Û
conditions.
he final problem can come from
the slug of solids pushed in all at once
during the wash-down process, creating
TKS
KS
SG":G :^
G":^
slurry too thick to be pumped.
]GY
GYN
GY N JU]
N"J U]T All these factors can create excess
maintenance, pump failure and expense.
he financial costs involve:
• he labor to pull the pumps, clear
the area and unplug the piping
• he erosive damage from abrasive
solids
• Motor and seal failures from running
dry

Coal Sump Issues

BHAT*LNK ÉÛÙ1 BHAT*LNK ÉÛÙ0
Addressed
FLEX-PRO® Benefi ts Include:
At the power plant, the maintenance
Feed Rates to 171 GPH pressures to supervisor for fuel handling is responsi-
125 PSI. ble for keeping the coal handling equip-
2500:1 turndown ratio.
ment up and running to feed the plant.
NEW!
Tube Failure Detection (Patented).
Brushless DC motor. Downtime is critical, and eliminating
problems, as well as the maintenance
?DAI*BAA@
OGE@ÛOUOPAI
Û É that accompanies them, is essential to
keeping the plant running at capacity.
Benefi ts Include: he coal handling sumps at this
Single and Dual plant were a continuous source of prob-
Pump Systems.
Tough, lightweight,
lems and expense for the supervisor’s
powder-coated, welded maintenance team.
aluminum Structure
Construction. Submersible and vertical centrifugal
Stainless Steel slurry pumps with grinders were used to
mounting pads.
Drip Containment Tray handle the coal slurries. he average time
for easy removal and between rebuilds and/or replacements
cleaning.
Flow Indicator. was about six months. In addition,
Compact design for downtime due to plugging, silt-in issues,
small footprint.
Can be shipped via UPS. unintentional debris and float controls
?DAI*BAA@ ÉÛ@KQ>HAÛ
OGE@ÛOUOPAI
hanging up was substantial, requiring
considerable labor.
714-893-8529 5300 Business Drive sales@blue-white.com “It was nothing to spend a whole
www.bluwhite.com Huntington Beach, CA 92649 USA fax: 714.894.9492 shift just to get a pump to work,” the
circle 108 on card or go to psfreeinfo.com supervisor noted.

26 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

A New Solution Using Different air-operated pumps such as single and double diaphragm
Technology pumps, this PD pump had an extensive tolerance to solids con-
Tired of fighting the same problems with the same technology, centrations. It also had the option of increasing discharge pres-
about four years ago, the supervisor looked for new solutions. sure to handle different slurry densities and discharge heads.
A local area pump and sealing specialist, Todd Sherwood
of Dubric Packing and Seals, was aware of the supervisor’s The Results
maintenance issues and suggested going in a new direction. He he results have been successful. “he original pump is still in
proposed using a different type of pump
to address these maintenance issues. he
supervisor took the risk of trying a new
approach and selected a 3-inch sub-
mersible pump for one of the problem
sumps. his test sump handled primar-
ily coal fines, grit and ground run-off as
is called the de-ionized (DI) water treat- Never ask for less –
ment equipment area pit.
®
his positive displacement (PD),
air-operated pump used two check
New LEWA
valves as the only wetted, moving parts.
It is similar conceptually to a diaphragm Protect your process
or piston pump but without the dia-
phragm, piston or any sort of mem-
with LEWA’s Double-
brane. he design employed full pipe Diaphragm design
diameter passages and check valve ports
to route fluid into and out of the pump-
ing chamber.
Compressed air was used to directly
push the surface of the fluid, eliminating Extreme
the need for dynamic seals while allow- operational safety
ing for a large stroke-to-volume ratio.
his design kept cycles to a minimum
for a given flow rate and the internal
API 675 Compliance
velocities low, reducing wear in abrasive
slurries and difficult fluids.
When used in an application such Simple installation
as a coal handling sump, this PD pump Highest and start-up
metering precision
is filled by vacuum. his allows the
pump to operate in just a few inches
of liquid, minimizing both the volume
and the amount of time that solids have
to settle out because the sump does not
have to reach a high level for this pump
to function.
Probably the most important dif- Compact design Double Diaphragm with
ference under these conditions is that monitoring system
the PD pumping technology does not
require the relationship of solids diam-
eter to flow capacity and discharge head Suction pressure
that centrifugal pumps need. his allows down to 1 psi a
large diameter solids to pass through the
pump at both low- and high-flow rates. LEWA, Inc. · 132 Hopping Brook Road
At this plant, the 2-inch chunks Holliston, MA 01746 · Phone +1 508 429-7403 www.lewa-inc.com
would be able to pass through the pump
under the 10-gallons-per-minute, low-
flow condition. Consistent with other circle 112 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 27
 Pumps in Power Generation

service in the DI area sump and

has been untouched these last
four years,” says the supervisor.
Given the prior six-month
replacement/rebuild intervals
the return on investment has
been dramatic on the purchase
costs alone. he eight-fold (and
still growing) service life also
reduces the overhead of spare
parts inventory, purchasing and
the substantial labor to switch
out pumps.
Most beneficial for this
supervisor has been the savings
in manpower, allowing him to
apply his personnel to other
pressing problems.
hree years ago, after the
initial success, he installed a
second 3-inch PD pump in
his transfer conveyor sump.
his sump is next to the belt
and receives solids, chunks and
fines along with welding rods DI Area Test Sump

circle 116 on card or go to psfreeinfo.com

28 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
 In the meantime, the crews have learned to take advan-
tage of the new ability to handle solids and now stir the sump
bottom after wash-downs to eliminate solids build up.
“Downtime was the issue,” says the supervisor, “and that
has been greatly reduced.”
Based on the successes and savings in both manpower
and repairs, this PD pumping technology was specified for an
upgrade project on the plant’s longest underground conveyors.
he project included new dust suppression and wash-down
systems resulting in higher flow requirements, and this time,
larger 6-inch inlet by 4-inch discharge pumps were selected.
hese have been installed during 2010 and are performing up
to expectations.
he supervisor stated that based on the field experiences at
his plant, he would consider this pump technology first as the
way to solve future difficult sump applications.
Conveyor Upgrade Sumps
P&S
and other materials that find their way into the sump during
wash-downs. Matt Vetter is currently the president of Chicago Industrial
he transfer conveyor sump is considered a difficult appli- Pump Company and was the inventor/designer of the
cation at the plant and required high maintenance. A long, CIPC (Pitbull®) pump line. He can be reached at
convoluted discharge run further complicated problems and mvetter@pitbullpumps.com or 847-214-8988. For more
plugging. Again, the PD pumping technology was able to information about Chicago Industrial Pump Company, go
greatly reduce maintenance with the original pump still in to www.pitbullpumps.com.
place without rebuilding.

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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 29
 Pumps in Power Generation: Business of the Business

Pumps in the Global

Power Generation
Industry
Rebecca Tucker and Laurel Donoho, Frost & Sullivan

T
he global, growing demand for power has softened the dealing with the crippling aftereffects of the worldwide reces-
impact of the recent recession on the power generation sion. Investments in plant infrastructure and retrofit needs
sector. Going forward, this growth is expected to reach were put on hold for the duration of the downturn. As the gen-
significant proportions, as evidenced by some key projected eral economic environment improves in North America and
metrics and trends, including: Europe, pump revenues in this industry are expected to gradu-
• A 60-percent increase in global demand for electricity by ally return to moderate growth rates.
2030, led by growth in India and China In 2009, the power generation segment accounted for
• he literally trillions of dollars expected in infrastructure about 6.7 percent of the total revenues in the PD pumps
investment in the industry to 2030 market. In the same year, as shown in Figure 1, revenues for
• Projected growth in nuclear power, with China, Russia, PD pumps within this industry totaled $484.7 million, with a
India and the rest of Asia leading the way in future planned steady growth rate expected to occur over the next few years. By
or proposed plants 2013, the revenue growth rate for PD pumps within the power
generation sector is forecast to meet or exceed pre-recession
hese trends promise notable revenue opportunities for rates, at about a 6 percent revenue growth rate by 2016.
pumps suppliers in both new plants and existing plant upgrades he power generation segment, in 2009, accounted for
and refurbishments. about 9.9 percent of revenues in the centrifugal pumps market.
Figure 2 shows a forecast for this industry. In the same year,
Global Pump Forecast revenue for centrifugal pumps within the power generation
he world’s positive displacement (PD) and centrifugal pumps market totaled $1.72 billion.
markets witnessed flat to negative growth in 2009, as end- Revenue growth for this product type within the power
user segments across the board experienced
the impact of global recession. he expected
strength of pump revenue growth within the
power generation industry depends on regional
trends.
Emerging economies, such as the BRIC
(Brazil, Russia, India and China) nations, are
expected to witness considerable growth over
the short term of the forecast period, mainly
due to infrastructure developments in these
countries. Population growth, urbanization and
the resulting increase in power demand will
help fuel growth in the Asia Pacific.
Pump demand is also expected to increase
within the power generation sector in northern
Africa and the Middle East, although recovery
in southern Africa is expected to be slower.
Mature economies, on the other hand, are Figure 1. PD pumps revenue forecasts

30 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

generation industry is expected to be slightly
more sluggish than revenue growth for PD
pumps over the next few years. However, by
2016, the revenue growth rate is expected to
return to a pre-recession level of 5.7 percent.

Key Trends and Issues

A number of top-level trends are expected to
affect pump demand in this industry through-
out the forecast period, including the following
positive trends:
• End-user need for environmental compli-
ance with increasingly stringent regulations
has significant impact on the market. his
will continue to be a strong market driver
for pumps used within the power genera-
tion industry, as well as in other industries. Figure 2. Centrifugal pumps revenue forecast
In addition, growing interest in alternative suited for applications emphasizing more efficiency, this
energy sources to counter greenhouse gas (GHG) emissions is expected to offer a great potential for suppliers of these
is likely to contribute to the growth. pumps.
• he focus on energy efficiency offers a considerable poten- • Replacement/retrofit demand will increase. Increasing
tial for growth, mainly due to rising energy costs and the investments in the water and power generation sectors over
intense focus on driving costs out of process/production. the next decade, coupled with the rising trend of PD pumps
End users are increasingly seeking the optimization of their replacing centrifugal pumps in applications focused on
processes to reduce energy consumption. As PD pumps are energy efficiency, are expected to fuel the growth of the PD

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circle 115 on card or go to psfreeinfo.com

PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 31
 Pumps in Power Generation
pumps market
• Rising demand from the utility sector will continue to fuel
the growth for centrifugal pumps.
Of course, challenges also exist in the industry that can
impede growth, such as:
• Price pressure from low-cost participants has intensified the
circle 114 on card or go to psfreeinfo.com
32 DECEMBER 2010 www.pump-zone.com
competition, which can push suppliers to offer higher qual-
ity, more reliable and advanced technology at competitive
prices. However, the price pressure is a restraining factor on
the overall revenue growth potential of the pumps market.
• Although the impact of the global recession has been some-
what mitigated for the power generation sector as a result of
the rising global need for power, a short-term impact from
the economic slowdown will occur as
production slowly ramps up, capital
expenditure resumes and excess pump
inventory is sold.
• Maturity of the market: both PD
pumps and centrifugal pumps are
commonly used pieces of equipment
for power generation, as well as many
other industrial process/production
areas. In mature markets, demand
for such products typically flattens
out over a period of time owing to
consistent supply, few technologi-
cal innovations and the presence of
supply-side competition.
he power generation sector is
a critical industry that cannot afford
downtime. As such, the industry pro-
vides a consistent, if not stellar, rate of
growth for the pumps industry.
In addition, the aftermarket busi-
ness for pumps within the power gen-
eration sector will continue to generate
growth as plants undergo retrofits and
upgrades. he opportunities for growth
exist. he challenge will be identifying
the fastest growing regions for the power
generation sector, such as in the BRIC
countries, while also taking advantage of
the aftermarket opportunities in mature
economies.
P&S
Rebecca Tucker is a research analyst
for Frost & Sullivan. She has over
a decade of marketing research and
communications expertise, which
includes marketing communications,
industrial research reports and techni-
cal writing.
Laurel Donoho is the global program
manager, Industrial Automation &
Process Control, for Frost & Sullivan.
She has 19 years of strategy, analysis
and consulting expertice in the indus-
trial space. She can be reached at
laurel.donoho@frost.com.
PUMPS & SYSTEMS
 PREVIEW

Exhibit Hall Hours

Tuesday, December 14: 11:30 a.m. – 6 p.m.
Wednesday, December 15: 9 a.m. – 5 p.m.
Thursday, December 16: 9 a.m. – 2 p.m.

A
long with more than 1,200 exhibitors and 18,000 attend-
ees, Pumps & Systems will attend this year’s Power-Gen
International at the Orange County Convention Center in
Orlando, Fla. his year, attendees can participate in 12 conference
tracks, mega sessions, and networking breakfasts. Preconference
activities, beginning Sunday, December 12, include technical tours
and Competitive Power College (CPC) workshops.
While at the show, stop by and visit us at Booth 2683. For
more information about Power-Gen International visit
www.power-gen.com.
P&S
Photo Credit Barchfeld Photography

PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 33

Maintenance Minders
11-Year-Old Source of
Forced Outages Found
Jerry Rigsby, Georgia Power Company, Plant Scherer &
Will Gates, Morrow Repair Services
Main oil pump hydraulic geometry was the root cause
of numerous false turbine/generator overspeed trips.
T
roubleshooting rotating equipment failures and
improving reliability is a process of elimination. he
process of elimination should strip away the layers
of possible contributors until the true root cause can be
identified and corrected. Rarely does an opportunity arise
that allows for taking incremental steps to solve a problem.
In the case study below, the symptom was addressed,
and the solution provided manageable results, which meant
that forced plant outages were stopped. However, it still
required a plant shutdown every 12 to 18 months to replace
the unreliable but improved component.
his was a manageable process until five years later,
when forced outages began to recur. his recurrence required
a re-examination of the failures and, ultimately, led to find-
ing the root cause of the problem.
The Initial Solution
A Southern Company plant has four 818-megawatt electri-
cal plants with identical General Electric (GE) turbine gen-
erator units. In November 1990, Unit 1 had a forced outage
due to a false trip of the overspeed governor during normal
operation. he same failure and forced outage occurred on
Unit 4 in August 1993 and again on Unit 1 in November
1993. In October 1993 and April 1994, the overspeed trip
mechanisms were inspected on Unit 2 and 3 respectively. In
each case, severe wear was detected in the bushing and spin-
dle areas, and the overspeed trip mechanisms were replaced.
he original failures seemed to be related to excessive
overspeed guide bushing wear. It was thought that either the
overspeed guide bushings wore and placed undue stresses
on the spindle threads causing them to fail, or the trip ring
34 DECEMBER 2010 www.pump-zone.com
became unsupported and allowed contact with the mechan-
ical trip linkage.
While the source, or root cause, for the wear was not
identified, GE addressed the excessive bushing wear by
upgrading the material to a more durable “Chemloy,” a
Teflon-based material with 5 percent Mo52 and 15 percent
glass fiber. he material upgrade was made on all four units
in 1994 and provided some improved life of the overspeed
trip device, but significant bushing wear still occurred.
he overspeed trip devices were placed on a schedule to be
inspected/replaced every 12 to 18 months, and the forced
outages were eliminated until January 1997.
Recurrence of the Problem
In January 1997, Unit 4 had a forced outage due to a false
overspeed trip. his occurred three months after a scheduled
maintenance outage in which the turbine overspeed trip
device had been replaced. he failed overspeed device had
been rebuilt by a company other than GE, and the quality
of that rebuild was brought into question.
A new overspeed trip device rebuilt by GE was installed
and carefully inspected for quality. hen 13 months later,
another false overspeed trip occurred on Unit 4. After this
failure, the decision was made to measure Unit 4’s and Unit
1’s control rotor vibration and compare the results. he
vibration data revealed 10 times greater vibration ampli-
tudes at six times the running speed on Unit 4’s control
rotor than on Unit 1’s.
The Investigation
he overspeed trip device was located on the end of the
PUMPS & SYSTEMS
 For the
price of this

ProSmart®
gives you these,
plus 17 more.
Figure 1. New design after Unit 4’s detailed analysis

control rotor stub shaft. he supporting sleeve was screwed on the end of the con-
trol rotor stub shaft and was encircled by the ring assembly. he ring ran concentric
with the shaft but was dynamically unbalanced, and the weight of the moving
parts was distributed so that their center of gravity lay about 0.220 inches from the
center of rotation in the tripping direction of the ring.
he centrifugal force of the ring assembly, due to this unbalance, was counter-
acted by the force of a compressed helical spring. When the speed increased, this
centrifugal force overcame the spring’s force. he ring moved out and struck the
trip finger of the mechanical trip linkage.
Attached to the front of the overspeed trip device was the spur gear, which
Think about ITT.
served three functions:
• A coupling for the quill shaft to the permanent magnet generator (PMG) ITT ProSmart condition monitoring
• A balance point for the control rotor checks and analyzes not one
• An oil channel for the oil trip test feature but up to 22 critical conditions
of your rotating equipment.
In an effort to determine the cause of the vibration, a detailed review of the Including vibration, temperature,
Unit 4 1996 outage report was performed. he review revealed that the steady pressure, and rpm, every five
bearing and overspeed governor had been replaced without the necessary testing to seconds. It’s the kind of data that circle 122 on card or go to psfreeinfo.com
determine if the components were assembled within specifications. can make the difference between
As a result of the 1998 failure, a detailed analysis of the Unit 4 front standard catching a problem early—
was performed during the subsequent outage to determine the cause of the high and catastrophic failure. Visit
vibration. he outage investigation resulted in the following findings, modifica- ittmc.com/ProSmart_Overview.html,
tions and corrective actions: or call 1-800-734-7867.
• he spur gear was bent and prevented centering on the overspeed trip device.
• he insulated spacer between the overspeed and spur gear was 0.008 thicker on
one side than the other and caused the spur gear to be cocked on the overspeed
trip device.
• he spur gear’s soft-fit design allowed movement, which changed the balance
point of the control rotor and caused vibration.
• he overspeed governor was not tight enough on the control rotor and was

PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 35

 Maintenance Minders
seated against the uneven surface of the
locking ring, causing it to be cocked on the
control rotor.
• he steady bearing had sealant on the face
preventing slip.
• he steady bearing force movement check was
not completed, and no policy was in place to
require that one be performed.
• Runout checks were not completed, and no
policy was in place to require that one be
performed.
• Policies and procedures were put in place
requiring that a steady bearing force move-
ment check, runout checks and alignment
should be performed after all front standard
work is completed.
• he PMG, quill shaft and spur gear were
removed. he spur gear was replaced by an oil Figure 2. Clearance for the impeller was improved by removing additional metal.
collector with a rabbet to prevent movement.
• he control rotor was balanced with the gov-
ernor assembly attached.
• Final runout checks were completed, and personnel verified
that all the checks were within specifications.
• A force movement check was completed, and personnel
verified that both were within specifications.
• Proximity probes were installed on the control rotors and
a monthly vibration monitoring program for the front
standard control shaft was established.
• he overspeed trip point was reduced from 113 percent of
rated speed to 110 percent.
After the outage, vibration readings were taken on the
control rotor to verify that the revisions made solved the six-
times vibration problem. However, the vibration readings
showed it was four times greater than before the outage work
was performed. A reasonable conclusion was that the vibra-
tion change was in response to a natural frequency. hen the
search began to find a structural, natural frequency. However,
after extensive tests, a structural natural frequency could not
be found.
he control rotor in question was the turbine/generator
oil pump shaft being driven on the end of the turbine/gen-
erator shaft. he oil pump impeller had six vanes, and it was
discovered that the pump casing had been welded and repaired
during the outage due to erosion damage on the visible side of
the volute tongue.
A primary source for high vane pass vibration in a pump
would be a tight or insufficient Gap B. Gap B refers to the
distance between the impeller vane exit and the diffuser/volute
vane inlet and is normally expressed as the percent of the impel-
ler’s diameter. A tight Gap B results in shock waves or pressure
pulses that are generated each time an impeller vane passes the
volute tongue. hese shock waves can cause cavitation/erosion
36 DECEMBER 2010 www.pump-zone.com
damage typical of the ones weld-repaired during the outage.
he shock waves and pressure pulsations can be so great
that the volute tongue and/or shafts can fail in fatigue, the
impeller-side plates can break, or the pump flow control sys-
tems may become unstable. A typical Gap B ranges from 6 to 8
percent in volute-style pumps, and many installations require
12 to 15 percent to reduce the vane pass vibration amplitudes
to acceptable levels.
he case and impeller were measured, and the measure-
ments revealed that the Unit 4 oil pump Gap B was only 3.5
percent. Unit 4’s Gap B was opened to 8.5 percent, and the
vibration dropped from 1.6 inches per second to 0.43 inches
per second.
After final opening, Unit 4’s Gap B was 12 percent
with resultant vibration amplitudes of less than 0.14 inches
per second. All the oil pumps on the four units were modi-
fied by the end of 2001. Since that date, no forced outages
have occurred due to a false overspeed governor trip during
normal operation, and none of the overspeed trip devices have
required replacement.
As the pump cases on each unit were examined and modi-
fied, it was apparent that the equipment manufacturer for the
pump case placed no control on the final configuration of the
volute vane. he configurations were not the same in any of
the pump cases. Several of the cases had the volute vanes cut to
a diameter but not finished to provide a proper and consistent
profile.
Conclusion
he initial focus on the overspeed trip device, installation
procedures and practices resulted in a robust unit. However,
increasing Gap B to 12 percent minimized the vibration
amplitudes that were having the most significant effect on the
PUMPS & SYSTEMS
reliability of the overspeed trip device.
Millions have been saved as a result of this solution,
including:
• An average cost of $15,000 per trip device
• $50,000 labor per replacement
• No lost electrical generation
he solution may have taken 11 years to accomplish, but
today, only a few remember the weekends and nights required
to get a unit back online following a false trip of the overspeed
governor.
P&S

Jerry Rigsby is the startup manager for

the Southern Company Plant Scherer
environmental projects to add bag
houses, SCR’s and scrubbers on all HIGH PERFORMANCE PRODUCTS,
four units. Rigsby was supervisor of
the reliability and root cause analysis world class solutions.
group during the investigation of the
false generator overspeed trips.

Will Gates has been president

of Morrow Repair Services in
Birmingham, Ala., since January 1,
2008. He had over 20 years of expe-
rience in pump repairs and trouble-
shooting as a Southern Company
employee. He has a BS in Mechanical
Engineering from the University of
Alabama, an MS in Engineering
from the University of Alabama
Birmingham and is a Registered PE
in the Alabama. He can be reached
at wgates@morrowrepairs.com or
205-408-6651.

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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 37
Efficiency Matters
The Importance of
Transloading Efficiency
Ted Ratcliff
As the popularity of transloading continues to grow, operators may
consider sliding vane pump and gas compressor technology
for low maintenance costs and high energy efficiency.
T
ransloading is the practice of transferring products
between modes of transport, whether from refinery
to terminal, terminal to supplier, supplier to storage
facility or supplier to end user. he products that are typi-
cally transloaded can run the gamut from liquid chemicals
and petroleum products, to animal fats and vegetable oils,
to raw and semi-finished commodities such as grains and
dairy products.
he modes of transport include marine, pipeline, rail,
air and truck. Goods, whether raw or finished, rarely travel
directly from their source to the end user.
he focus of this article will be the transloading of
products or raw materials from railcar to truck. Transloading
allows shippers and their customers to enjoy many of the
cost benefits of rail transportation without having a rail
siding at their door, which can be an expensive proposition,
and for many companies, a physical impossibility.
In most instances, a transload facility operator, third-
party logistics company or transportation broker facilitates
the transloading for both the shipper and the consignee.
hese companies coordinate truck and rail connections and
frequently offer inventory management and facilitate stor-
age and delivery.
he main objective of transloading is to place the goods
as close as economically possible to the point of final pro-
cessing, packaging and consumption. herefore, transload-
ing can occur at any location at which a truck can pull up to
another truck or a train.
In a typical transaction, a bulk shipment moves by rail
to a transload facility where it is offloaded with specialized
pumping equipment that has the necessary operational char-
acteristics to handle the specific product or material. he
bulk product can then be scheduled for delivery in smaller
38 DECEMBER 2010 www.pump-zone.com
quantities to the consignee for further processing or delivery
directly to an end-user.
Some advantages of transloading are:
• Quick response to replenish inventories
• Transportation costs kept to a minimum
• Accelerated turnover and reduced inventory costs
Since transloading requires the handling of the goods
at different points in the supply chain, there is an inherent
risk of damage or the loss of expensive materials that could
potentially harm the environment or personnel. Shipping
vessels must also be completely cleared of product during
the transloading process.
With all these factors considered, it is imperative that
the proper equipment be used during the transloading pro-
cess. Proper pumps and compressors are needed, especially
for the transfer of chemicals, petroleum products, animal
fats, vegetable oils and other liquid commodities.
The Challenge
Transloading has grown rapidly in recent years, so much so
that it now has its own trade association. he Transloading
Distribution Association—TDA (www.transload.org)—
West Linn, Ore., represents the interests of the transloading
industry as it relates to business and political leaders, while
positioning transloading as the preferred method for effi-
cient distribution of product in the 21st century. Currently,
the TDA has more than 200 members throughout the U.S.,
Canada and Mexico.
As mentioned, the main challenge for shippers is
moving their products in the safest manner while also mini-
mizing the risk of costly and environmentally damaging
product spills. Recently, however, economics have played an
PUMPS & SYSTEMS
Operators at this chemical distribution/storage terminal facility transload hydrogen per-
oxide from a railcar to a transport via a sliding vane pump.
increasingly important role in a shipper’s decision to move product via a transload-
ing operation. hese economic pressures have come to bear in the form of driver
and equipment shortages, record high fuel costs found in long haul trucking and
increased demand for shipping capacity.
A producer relying on long-distance trucking to service a set of customers
faces many difficulties. he most significant is the likelihood of empty cargo holds
on return trips, in addition to the need for a large fleet of trucks to ensure service
frequency.
Adopting a transloading operation can allow these shippers to rely on a
smaller fleet of trucks that travel shorter distances, which may also allow them to
make several deliveries per day. A transloading facility can also offer a large number
of value-added incentives for the shipper, including storage, blending, packaging,
consolidated invoicing, combined product shipments, bar-coding and labeling.
For shippers who are considering a switch from a single transportation mode
to transloading, some useful benchmarks can help guide the decision. A main con-
sideration is whether the product’s travel distance is great enough to make the cost
of transloading worthwhile.
As a transloading general rule, 300 miles is the differentiation breakpoint for Energy-efficient by design,
transloading. his is about the distance that a long-haul trucker can safely and
circle 123 on card or go to psfreeinfo.com
Blackmer
Blackmer sliding vane pumps
efficiently travel in one day. Another thing that should be taken into consideration could reduce your electric
is the transportation and handling costs associated with trucking and transloading. consumption by up to 40%.
In a true bulk-transport transloading operation, a shipper can often ship four
truckloads of product on a railcar while paying about the equivalent of only two- www.blackmer.com
and-a-half truckloads.
Currently, according to the TDA, approximately 650 transloading terminals (616) 241-1611
are in the U.S., with more planned for the future. he TDA forecasts double-digit
growth in throughput by its members through 2015. he average number of avail-
1461 Ford Street, Suite 205
able railcar positions per transloading facility is 50. Redlands, CA 92373
If these estimates are correct, then more than 32,000 tank cars can be unloaded Tel: 909-512-1257
Fax: 909-798-1879
at any one time. Granted, that full capacity will probably never happen, but these info@pumpsg.com
numbers do offer an idea of the potential size of the market. pumpsg.com

PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 39

 Efficiency Matters

Using these estimates and assuming

only a 60 percent use factor, each facil-
ity would require three to five pieces of
off-loading equipment to keep up with
demand. At the lowest level, that would
be almost 2,000 units on the ground.
While transloading may make sense
for a shipper, both economically and
logistically, the world’s most efficient
transloading operation will not function
successfully if the pumping and compres-
sor equipment for the transloading process
does not work effectively.

The Solution
Fortunately for shippers who are imple-
menting transloading operations, an easy
solution is available for their product-
transfer needs—sliding vane pumps and
reciprocating-gas compressors. Sliding This transloading application features compressors transferring LPG from railcars to
vane pumps and compressors used in trans-transports.
loading operations must be highly energy
efficient and eliminate many of the maintenance concerns that
are inherent in these pumps and compressors.
he sliding vane technology makes these pumps ideal
for transloading applications. hese pumps are self-priming,
designed to run dry for short periods and their high suction
makes them ideal for line-stripping. hey are available in cast
iron, ductile iron and stainless steel models with special elasto- • Corrosive or caustic fluids
mers that make them compatible with the handling of many
products.
For self-loading trucks, the pumps come with port sizes
to 4 inches and have maximum working pressures up to 175
psi (12.1 bar). hey can reach speeds of 1,200 rpm with both
PTO and hydraulic drive capabilities.
For transloading applications that involve stationary and
portable onsite pumps, by manifolding the railcars, the flow
rates are limited to the receiving capacity of the system. Some
sliding vane pumps are also available in sealless designs for
applications that require zero shaft leakage.
he vanes in a sliding vane pump move freely into or out
of slots in the pump rotor. When the pump driver turns the
rotor, centrifugal force, rods and/or pressurized fluid causes the piston rod seals and other robust features.
vanes to move outward in their slots and bear against the inner
bore of the pump casing, forming pumping chambers.
As the rotor revolves, fluid flows into the area between the
vanes when they pass the suction port. his fluid is transported
around the pump casing until the discharge port is reached. At
this point, the fluid is squeezed out into the discharge piping.
his simple pumping principle, which has been an indus-
try standard for more than a century, allows sliding vane
pumps to handle numerous products safely and efficiently.
Among these are:
• Clean, non-corrosive industrial liquids and petroleum
products
• Liquids ranging in viscosity from thin solvents to heavy oils
• Hazardous fluids
• Biofuels
• Non-lubricating solvents to highly viscous liquids or abra-
sive slurries
• Inks, paints and adhesives
Like the sliding vane pump, some reciprocating-gas com-
pressors have been designed with liquefied gas transloading
operations in mind. A compressor draws vapor from the stor-
age vessel and boosts the pressure into the top of the railcar.
he increased pressure in the railcar and slightly decreased
pressure in the storage vessel results in a pressure differential
between the two tanks that will easily push the liquid from the
railcar to storage.
he result is fast and quiet liquid transfer with no NPSH
or cavitation problems. hese compressors are equipped with
high efficiency valves, ductile-iron cylinders, self-adjusting
Some specialty compressors not only evacuate a railcar or
truck tank, but they can also recover vapors, which is similar
to adding 3 percent capacity to every load. hey are designed
to handle transfer and recovery of propane, butane, liquefied
petroleum gas (LPG) and anhydrous ammonia. Compressors
can handle the transfer and recovery of carbon dioxide, refrig-
erants, sulfur dioxide, chlorine, vinyl chlorine, natural gas,
nitrogen and other gases.
If the sliding vane pumps and compressors are portable,
the option may be available for shippers and operators of

40 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

storage facilities to create moveable skids that allow the pumps
and compressors to be moved around a facility to perform
transloading operations.
hese transloaders can be placed between two railcars on
a siding if product needs to be pumped out of one and into
another or positioned between a truck and railcar to facilitate
the transloading process.
For an example of how effective a transloading operation
can be, consider the case of Seeler Industries. Seeler operates
the 3 Rivers Terminal in Joliet, Ill. his 100-acre facility fea-
tures 17 storage tanks and 15 blend tanks. It has become one
of the Midwest’s leading storage facilities, handlers and pack-
agers of hydrogen peroxide, along with other industrial liquids
such as caustics, amines, glycerin propylene, glycol and chemi-
cal de-icers.
he 3 Rivers Terminal is served by seven truck-loading
racks and 42 railcar-unloading positions. hese racks and
railcar positions enable Seeler to offer transloading services
to its customers. To optimize its transloading options, Seeler
installed a series of sliding vane pumps, which were chosen
for this application because their stainless-steel construction
makes them compatible with the chemicals, solvents, caustics,
sulfates and acids that the terminal handles on a regular basis.
To increase its transloading options, Seeler also had a
sliding vane pump mounted on a portable cart that is moved
wherever it is needed in the facility.
Conclusion
While transloading in some form has been around since the
age of steam engines and horse-drawn tank wagons, it has seen
a marked resurgence during the past decade.
According to some estimates, the volume of transloaded
cargo has grown by 50 percent since 2000. his increase in
transloading coincides with the realization by many ship-
pers that the cost and efficiency benefits of this multimodal
approach to moving products in bulk can have an extremely
positive effect on their bottom lines.
P&S
Ted Ratcliff is the senior product specialist in Transport for
Grand Rapids, Mich., based Blackmer, an operating company
within Dover Corporation’s Pump Solutions Group (PSG™).
He can be reached at 817-460-1369 or ratcliff@blackmer.
com. Downers Grove, Ill., USA-based PSG is comprised of six
leading pump companies—Wilden®, Blackmer®, Griswold™,
Neptune™, Almatec® and Mouvex®. You can find more infor-
mation about Blackmer at www.blackmer.com and PSG at
www.pumpsg.com.

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circle 119 on card or go to psfreeinfo.com

PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 41
 From the voice of the fluid sealing industry

SEALING SENSE
If stress analysis can ensure that piping loads are within
ASME limits, why are rubber expansion joints needed?

This month’s “Sealing Sense” was prepared by FSA member Lloyd Aanonsen

T
oday’s pipe stress analysis software provides engi-
neers with a tool for designing complete piping sys-
tems and performing structural analysis in compli-
ance with ASME and other well-known piping codes. he
typical PC-based software is easy to use with spreadsheet
inputs and quick reporting. It has facilitated the design to
analyze iteration cycle and enabled the engineers to quickly
create better and more reliable piping systems.
Rubber expansion joints have long been recognized
for reducing pipe and anchor stresses. Unfortunately, for
equally as long, they have been viewed as being the weak
link in any piping system. hat an engineer would look to
eliminate any inherent reliability risk is understandable, and
with the advancements in pipe stress analysis, they have the
tools to design the system without expansion joints.
Why are rubber expansion joints needed? he answer
starts with disputing the theory that rubber expansion joints
are a piping system’s weak link. In fact, with finite element
analysis (FEA) and strong engineering principles, it can be
verified that the rubber expansion joints have an equal or
greater safety factor than the adjacent piping or equipment. Figure 1. Expansion joint FEA
he answer continues with the numerous design
advantages that can only be obtained with the use of rubber often accomplished by incorporating advanced materials
expansion joints. hese advantages can and should be quan- and technologies into what would otherwise be considered
tified and added to pipe stress analysis databases. his will a conventional product line. Advanced materials would
enhance the tools available to engineers. include premium elastomeric compounds, tire cord and
high tensile steel reinforcements. Using tire cord is a good
Performance and Reliability example of optimizing a design with advanced materials.
Improved performance and reliability are directly related Tire cord is engineered with a resorcinol-formaldehyde
to the materials of construction and engineering design. latex (RFL) coating for superior bonding to the rubber. he
Rubber is one of the most compliant and resilient materials cords themselves can be aligned on an optimal-bias, ply
available. his not only makes it an ideal material for car angle, offering tailored strength in the directions needed.
tires but for expansion joints as well. With a flexing cycle his often eliminates delamination and reduces the total
life in the tens of millions, fatigue is not a design concern. number of plies required. he result is improved perfor-
Improved performance and engineered solutions are mance in the form of increased movement capability,
decreased spring rates and improved reliability.

42 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

 Today’s rubber expansion
joints are designed by licensed
engineers using advanced
software for simulation and
FEA. Documented safety fac-
tors can equal or exceed that
of the adjacent piping and
equipment.
Critical design elements
of piping systems are support
and flexibility. An obvious
consequence of inadequate
support is catastrophic and
potentially life-threatening
system failure. Figure 2. Absorbs all directional movements and vibration
Less obvious, however, is
that inadequate flexibility can
Absorbs All Directional Movement
produce the same devastating consequence. System flexibility
Rubber expansion joints provide superior movement capabil-
is required to absorb thermal movements, ground settlement,
ity in axial compression, axial extension and lateral deflection,
misalignment, vibration and shock.
as well as in the angular and torsional directions. his per-
he features and benefits of rubber expansion joints
formance cannot be obtained with metallic joints, grooved
include absorbing these forces and displacements and replac-
couplings or large pipe loops. he low stiffness and deflection
ing them with the rubber expansion joint’s low stiffness (spring
forces can and should be incorporated into databases accessed
rate). hey absorb noise and vibration and provide easy access
by pipe stress analysis programs.
to piping and equipment.

circle 107 on card or go to psfreeinfo.com

PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 43
FSA Sealing Sense

Reduces Noise and Vibration

Rubber expansion joints dampen and insulate against
the transmission of noise and vibration generated by
mechanical equipment. his is important in HVAC
applications where the disturbing frequency of pipe
and fluid-conducting noise can resonate and amplify
throughout a building. Metallic joints and grooved cou-
plings do little to reduce noise and vibration.

High Resistance to Shock

he compliant and resilient characteristics of rubber
expansion joints make them suited for earthquake and
bomb blast isolation. hey are also effective for pressure-
surge and water hammer dampening.

Relieves Pipe and Anchor Stress

Figure 3. Large pipe misalignment
hermal movements along with other external forces and
displacements, including ground settlement, can exceed
the allowable pipe and anchor stresses. Ground settle-
ment is a good example of unanticipated system con-
ditions that, without an expansion joint, could develop
into serious problems. Rubber expansion joints absorb
these stresses and replace them with their low stiffness
(spring rate).

Compensates for Misalignment

It is common in both new construc-
tion and replacement applications to
encounter pipe misalignment. Minor
misalignment can be corrected with
standard expansion joints, and custom
units can be fabricated with large per-
manent offsets. he custom fit units are
easier to install and will have a longer,
maintenance-free life.

Provides Access to Piping and Equipment

Access to piping and equipment can be
easily achieved by treating the rubber
expansion joint as a removable spool
piece. If a self retracting design is
needed, a dismantling joint can be used.
his is another example of system dif-
ficulties that may arise without the use
of rubber expansion joints.

Conclusion
Rubber expansion joints have numer-
ous design advantages—including their
enhanced construction and expansive
application capabilities. hey should
not be viewed as the weak link in the
piping system. Instead, they are a

circle 124 on card or go to psfreeinfo.com

44 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
 “Sealing Sense” is produced by the Fluid Sealing Association as part of our commit- he following members of
ment to industry consensus technical education for pump users, contractors, distrib- the Piping Systems Non-Metallic
utors, OEMs and reps. As a source of technical information on sealing systems and Expansion Joint division sponsored
devices, and in cooperation with the European Sealing Association, the FSA also this “Sealing Sense” series:
supports the development of harmonized standards in all areas of fluid sealing tech-
nology. he education is provided in the public interest to enable a balanced assess- Bachmann Dampjoint, Inc.
ment of the most effective solutions to pump systems technology issues on rational Daikin America, Inc.
total life cycle cost (LCC) principles. Dinatecnica Ind. E Com.
he Piping Systems’ Non-Metallic Expansion Joint division of the FSA is one DuPont Performance Elastomers
of six with a specific product technology focus. As part of their mission, they develop L.L.C.
publications such as the newly revised seventh edition Technical Handbook Non- 3M Dyneon
Metallic Expansion Joints and Flexible Pipe Connectors and the Non-Metallic Piping Garlock Sealing Technologies
Expansion Joint Installation Guide. he former provides construction, installation General Rubber Corp.
and application details while the latter is a “hands-on” simplified guide for main- KE-Burgmann A/S
tenance operators and engineers. Both are primers intended to complement manu- Meccom Industrial Products Co.
facturers’ documents produced by the member companies. In addition, standards Mercer Rubber Company
have been developed in response to important user issues such as FSA-PEJ-701-06 he Metraflex Co.
Piping Systems Non-Metallic Expansion Joint Hydrotesting and Vacuum Testing, FSA- Proco Products, Inc.
PEJ-702-06 Rubber Flanged Non-Metallic Expansion Joint Installation, Maintenance, Solvay Solexis, Inc.
and Storage, and FSA-NMEJ-703-99 Specifications of Elastomers Used in Piping Systems Unaflex Incorporated
Non-Metallic Expansion Joints.

functional component that have little

or no alternative replacements.
In addition, expansion joints
can adapt to misalignment that is
often found in modular construction.
Ultimately, the use of rubber expan-
sion joints is imperative for a success-
ful operation on all functional levels.
Although stress analyses can ensure
proper pipe design codes, expansion
joints safely accommodate variables and
contingencies and enhance the system’s
overall reliability and performance.
Quantifying and incorporating
these design advantages into useful
databases will ultimately enhance the
pipe stress analysis program and its
applications.

Next Month: How do I choose a gasket

for an FDA application?

We invite your questions on sealing issues

and will provide best effort answers based
on FSA publications. Please direct your
questions to:
sealingsensequestions@fluidsealing.com.
P&S
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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 45
 PUMPFAQs ®

Q. What are the parameters for pump baseplate design, and
why must baseplates be grouted in place?
A. A baseplate is the structure to which the pump, motor,
gearbox and all auxiliary equipment are mounted. he purpose
of a baseplate is to provide a foundation under a pump and its
driver that maintains shaft alignment between the two pieces of
equipment. his baseplate must:
• Survive handling during transportation to the installation
site
• Be capable of being installed properly with minimum
difficulty
• Allow for the initial mounting and alignment of the
equipment
• Allow for the final alignment of the mounted equipment
• Control spillage
• Allow for the removal and reinstallation of equipment
the grout to be poured underneath the base. he grout placed
inside the base contributes to the baseplate’s installed rigidity
and damping. See Figure 1.3.8.2.1a.
he cross members used on the baseplate in Figure
1.3.8.2.1a are normally designed to lock into the grout and
further resist any deflection or vibration of the baseplate.
Typically, the cross member geometry chosen to achieve this is
an L-section (shown), a T-section or an I-section.
If the baseplate is a closed design (i.e., the grout cannot be
poured inside the baseplate perimeter due to the presence of
a drain pan or deck plate), then grout and vent holes must be
provided to allow the grout to be placed inside the base.
he grout used may be either cementitious or epoxy-based.
he surface preparation required for a baseplate to successfully
bond to the grout is different depending on which grout will be
used. It is, therefore, important that the vendor and customer
agree in advance which type of grout will be used.
he baseplate described and shown in Figure 1.3.8.2.1a
is typical of a fabricated baseplate. Cast-iron baseplates are
another type of grouted baseplate. he ability to integrally cast
in features such as bracing, grout holes and sloping surfaces
provides a highly functional and economical solution for many
applications.
For additional details on baseplates, see ANSI/HI 1.3
Rotodynamic (Centrifugal) Pumps for Design and Application.

Figure 1.3.8.2.1a. Grouted baseplate, fabricated steel
To meet these requirements, an absolutely rigid baseplate
is not necessary. At the same time, the baseplate must not be
permanently deformed after the equipment is mounted at the
manufacturing facility. Compliance with these design criteria,
Q. What are mixed flow impellers, and when are they used?
A. he impellers described below are used in a wide variety of
services. For any given service, one type may be preferred. In
most cases, however, the users’ and manufacturers’ experience is
the best guide for making a selection.
Impeller shrouds

in conjunction with proper installation procedure, will contrib- Impeller shrouds

Impeller shrouds
Impeller shrouds
ute significantly to meeting the functional requirements.
Impeller hub
Any baseplate must be designed to satisfy numerous func- Hub Hub Hub Hub
Vanes Vanes
Vanes Vanes Vanes
tional requirements. To ensure correct design of the baseplate, Radial-vane area Francis-vane area Mixed-flow area Axial-flow area
Axis of
rotation

all application parameters must be reviewed—including equip- US Units US Units

ment selection, installation and operational requirements. For

500

600

700
800
900
1000

1500

2000

3000

4000

5000

6000

7000
8000
9000
10000

15000

20000

standardized pump ranges with predefined and specific applica- Metric Metric
tions, the equipment manufacturer should have taken all these
10

20

40

60

80

100

150

200

300

400

factors into account. For customized pump applications, these Values of specific speeds

fundamentals should be reviewed at the time of the proposal.

Figure 1.3.4.1. General impeller types
he grouted baseplate shown below is designed to allow

46 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

 Rotodynamic pump designs are generally described as as mixed flow impellers. hey are used when the impeller spe-
any of three types: radial flow, mixed flow or axial flow. For cific speed is from 80 to 140 (4,000 to 7,000).
examples, see Figure 1.3.4.1. Radial flow impellers are designed For more information on impeller design, see HI Standard
so that the liquid exits purely radially or perpendicular to the ANSI/HI 1.3, Rotodynamic (Centrifugal) Pumps for Design and
shaft centerline. hey have lower specific speeds, in the range of Application.
10 to 50 (Ns 500 to 2,500), and most often are used for lower-
flow, high-head applications. P&S
As design flow increases, specific
speed increases, and the impeller will
become more axial in its configuration,
with fluid flow in line with the shaft
centerline. Fully axial impellers produce Rotary Lobe Pumps
high flow rates with little head. Macerating Technology
Between these two extremes, the
liquid exit angle transitions from radial
to axial as shown in Figure 1.3.4.1.
hese transitional designs are referred to

Pump FAQs® is produced by the

Hydraulic Institute as a service to
pump users, contractors, distributors, The Leading Manufacturer of
reps and OEMs as a means of ensur-
ing a healthy dialogue on subjects of Rotary Lobe Pumps
common technical concern. in the Wastewater Industry!
HI standards are adopted in the Rotary Lobe
Pump
public interest and are designed to help
eliminate misunderstandings between Macerating Technology
the manufacturer, the purchaser and/ Multicrusher"

or the user and to assist the purchaser

in selecting and obtaining the proper
product for a particular need.
As an ANSI approved stan- Multichopper
dards developing organization, the
Hydraulic Institute process of develop-
ing new standards or updating current Applications include:
standards requires balanced input from Unwfig1Dkquqnkfu."Itgcug."Rtkoct{"Unwfig."YCU."TCU."Fkiguvgf"
Unwfig."Vjkemgpgf"Unwfig."Hggf"qh"Vjkemgpkpi"cpf"Fgycvgtkpi"
all members of the pump community.
Fgxkegu."Nqcfkpi""Uvcvkqpu."Ugycig."Uewo."Ogodtcpg"Dkqtgcevqt"
We invite questions and will Crrnkecvkqpu."Rqn{ogt"gve0"
endeavor to provide answers based on Technical Features:
existing HI standards and technical Okpkocn"Nkhg"E{eng"Equvu."Tgxgtukdng"Qrgtcvkqp."Ugnh"Rtkokpi."
r . Ugnh"Rtkokpi."
guidelines. Please direct your inquiries Jkij"Ecrcekvkgu"wr"vq"7.222"wuiro"
r"vq"7.222"wuiro"
to: pumpquestions@pumps.org.
For more information about HI,
its publications, Pump LCC Guide,
Energy Saving Video-based educa-
tion program and standards please
visit: www.pumps.org. Also visit the Maintenance In Place
new e-learning portal with a com- Cnn" #wkf" ygvvgf" rctvu" ctg" tgrncegcdng" qpukvg" vjtqwij" vjg" htqpv"
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Pumps: Fundamentals, Design and Boerger, LLC"~":99094805965"~"yyy0dqgtigt0eqo"~"kphqBdqgtigt0eqo
Applications,” which can be found at:
www.pumplearning.org.
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Practice & Operations

Proactive Planning
Paul Boyadjis & Chris Hurrell, Mechanical Solutions, Inc.

Potential vibration problems were avoided

through design-stage finite element analysis.

T
he Lower Cape Fear Water and Sewer Authority had
begun to expand its main raw-water pump station
at Kings Bluff, near the Lower Cape Fear River in
southeastern North Carolina. he core of this municipal
project revolved around three, identical, new vertical turbine
pumps.
One of these pumps was a replacement for an exist-
ing pump, and two were part of an addition that included a
newly constructed extension of the station building. Charles
R. Underwood, Inc., the original equipment manufacturer
(OEM) of the pumps, requested that Mechanical Solutions,
Inc. (MSI) perform a detailed finite element analysis (FEA)
of the vertical turbine pumps prior to their manufacture,
installation and acceptance testing at the pump facility.
he structural natural frequencies of vibration and their
mode shapes would be predicted through the FEA, and the
proximity of these natural frequencies to the pump operating
speed range would be revealed.
With this information, the influence of the vibration
on the performance and the reliability of the pumps could
be assessed appropriately and modifications could be imple-
mented, if necessary, before the installation of the pumps.
Since modifying machinery during design is easier than
implementing modifications after installation, this proactive
approach could conserve a significant amount of the project’s
budget.
The Pumps Were Modeled With the
Finite Element Technique
Detailed technical data, including drawings of the pumps
and of the pumping facility, were provided to the company
that performed the FEA, by both Charles R. Underwood,
Inc., the pump OEM, and the Lower Cape Fear Water and
Sewer Authority.
Because this municipal water project involved the exten-
sion of the pump station’s building to contain two of the
three new raw-water pumps, the information from the latter
source proved to be especially relevant during the analysis.
Based on the extensive set of data, two detailed finite ele-
ment models that represented portions of the pump system
were created. hese models accounted for the differences
Figure 1. A solid model of one of the new vertical turbine
pumps with a portion of the new structural foundation on the
left and of the existing structural foundation on the right.
in the construction details of the foundations to which the
pumps were attached.
Each model incorporated sufficient portions of the adja-
cent building foundation structures and piping, as shown in
Figure 1. he pump system finite element models also simu-
lated both the minimum and the maximum submergence
levels of each foundation, which accounted for the added
internal and external water mass effects on the column pipes,
bowls and suction bells of the pumps.
An FEA that used each of the models was performed
to predict the structural natural frequencies of the pump
system. he main criterion of the FEA, taken from the speci-
fication for the vertical turbine pumps, was that no structural
natural frequencies should fall within 15 percent of the 9.75
Hz through 14.8 Hz running speed range of the pumps.
In parallel with this FEA, pump shaft lateral and tor-
sional analyses were performed. Both predicted that the cri-
teria for the shaft lateral and torsional natural frequencies
would be satisfied by the existing design.
FEA Uncovered Potential Resonances
Within the Running Speed Range
he pumps’ below-ground column modes and frequencies
of vibration that were predicted by the FEA were similar.

48 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

herefore, any potential modifications to the column pipes to
shift their vibration modes would be effective for the pumps
that were located on either of the foundations.
However, depending on the foundation, the above-ground
motor and motor-stand vibration modes that the FEA pre-
dicted differed markedly. his difference was attributed to the
variation between the stiffnesses of the two foundations.
Below ground level, the second bending mode structural
natural frequencies of the column pipe, which were parallel to
the discharge nozzles, had separation margins that were at least
18 percent above the maximum running speed.
However, the results of the FEA predicted that the natural
frequency for this column pipe, in the direction perpendicular
to the pump discharge, would fall within the pump’s operating
speed range. his is illustrated in Figure 2.
Excessive vibration would occur because the natural fre-
quencies of vibration that were forecast by the FEA, 13 Hz in
Figure 2. The pump column pipe second bending mode is shown
a minimum-submergence and 11 Hz for the case of maximum
with a color contour plot of the displacement superimposed over
submergence, would be excited during the anticipated normal
the exaggerated, deformed shape of the pump assembly.
operation.
Potentially troublesome above-ground modes of vibra- of vibration would fall within 15 percent of the upper end of
tion were also predicted by the FEA. his might occur with the pump running speed range. his condition would fail to
the pumps that were located at both foundation structures. satisfy the pump specification.
he FEA of the pumps at the new section predicted that the In addition, the FEA of the existing foundation indicated
natural frequencies for the above-ground first bending modes that the natural frequency for one of the above-ground first

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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 49
 Practice & Operations

However, the FEA results for the pump that rested on

the existing foundation showed that the thickened stiffening
ribs would not be effective. his disparity was caused by the
comparatively reduced foundation stiffness, which in turn was
attributed to the access ports that were located in the floor of
the building.
To alleviate this issue, a concrete pillar was modeled in the
existing building between the piping gallery level and the upper
level, the location of the motor-stand and motor. he FEA of
this proposed modification predicted that the addition of the
concrete pillar would increase the magnitude of the above-
ground natural frequencies and create an acceptable separation
margin, as shown in Figure 4.
he FEA results of the vertical turbine pumps were reported
to the OEM, and the suggested solutions were reviewed.
Because the pumps were equipped with variable frequency
Figure 3. The above-ground, FEA-predicted, first bending mode drives (VFDs) and after considering the anticipated operating
of the new pump on the existing foundation is shown with a color environment of the pumps at the station, the OEM suggested
contour plot of the displacement superimposed over the exag- an additional solution to the pending vibration issues.
gerated deformed shape of the pump assembly. Features of the By programming lock-out ranges into the VFDs of the
pump assembly in the undeflected position have been superim- pumps after their installation, the undesirable vibration fre-
posed on the image to aid in seeing the deflected shape of the quencies that were predicted to occur within the running speed
column. range would be avoided.
bending modes would land short of the desired 15 percent
separation margin. See Figure 3. Conclusion
he three new vertical turbine pumps were installed and the
expansion of the station was completed. Figure 5 shows one
Potential Solutions Investigated With FEA
of the newly installed OEM vertical turbine pumps within the
hrough additional FEA, a practical, potential solution to the
finished pump station. As it was ramped through its operating
predicted, below-ground pump vibration problem was investi-
speed range during the initial evaluation process, an increase in
gated. A 3/4-inch thick split steel plate was modeled between
the vibration response of one of the pumps was measured at 13
the bottom flange of the pump discharge and the floor of the
Hz, where the FEA had predicted that a natural frequency of
station to constrain the motion of the column pipe during the
vibration of the column pipe would occur. his demonstrated
second bending mode.
the accuracy and the practicality of the FEA.
he results of the FEA showed that this straightforward
modification would increase the two offending natural fre-
quencies of the pumps to between 21 Hz and 22 Hz. his is
approximately 42 percent above the maximum pump operating
speed. An acceptable margin of separation from the running
speed range would be created when the split steel plates were
included in the pump installations. If the split steel plates were
implemented, the vibration frequency of the second bending
mode of the pump column that was in line with the pump dis-
charge direction would also increase. his would enhance the
already-satisfactory margin of separation that existed for this
vibration mode.
To address the potential above-ground pump vibration
problems, thicker stiffening ribs were modeled on the motor
stand, and an FEA was performed for the pumps that were
located at both foundations of the station.
At the new foundation, the modified stiffening ribs were
predicted to shift the offending natural vibration frequency Figure 4. The above-ground, first bending mode of the new ver-
higher. his would increase the margin of separation from the tical turbine pump on the existing foundation structure (which
maximum running speed to 16 percent and enable the pump was predicted by the FEA) is shown with the addition of the
specification to be met. below-ground concrete support column.

50 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS


Figure 5. The above-ground portion of one of the new
vertical turbine pumps
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PUMPS & SYSTEMS
Once the installation of the pumps was completed and the on-site per-
formance of the pumps was verified, the pump OEM programmed lock-out
speed ranges into the VFDs, which prevented the operation of the pumps at
the speeds during which undesirable vibration had been predicted.
By performing the FEA prior to the installation of the vertical turbine
pumps, several natural frequencies of vibration were identified. his vibra-
tion could have adversely affected the long-term reliability of the pumps.
his process was far more efficient than a trial-and-error, on-site implemen-
tation of experimental solutions.
If the pumps had not been equipped with VFDs, the structural modifi-
cations that were suggested through the FEA would have been implemented
to ensure that the unwanted vibration would not occur.
P&S
Paul Boyadjis, manager of turbomachinery analysis for
MSI, has 25 years of diverse experience in the analysis and
design of rotating equipment. He can be reached at 973-
326-9920, ext.115, or pab@mechsol.com.
Christopher Hurrell, manager of test facilities at MSI, has
extensive rotating machinery troubleshooting experience at
MSI, including the testing of large turbomachinery both
domestically and at locations as distant as Southeast Asia.
He can be reached at 973-326-9920, ext.113, or cch@
mechsol.com.
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www.pump-zone.com DECEMBER 2010 51
Practice & Operations
Pump System Energy
Assessment
Greg Case, PD3
Improved reliability, performance and energy efficiency
can result from pump system assessment.
Second of Two Parts
I
n Part One of this series (Pumps & Systems, November
2010), a method was developed to determine which
pump systems in a facility offer the best opportunity for
significant cost reduction through energy conservation and
reliability improvement.
After selecting a candidate system, data must be taken
to determine its actual operating range. For a system with
a small operating range, only a simple, one-point test may
be needed. Systems with a larger range may require a per-
formance test at each of several operating conditions. More
complex systems or systems of which little is known about
the operating range may need continuous monitoring over
a period of time.
Data Needed to Assess a Pump System
A pump assessment is a mini performance test of the pump
within the system in which it normally functions. he assess-
ment generally requires measuring the pump’s flow rate, head
and power input to determine its actual operating point
within its system. Specifically, collected data should include:
1. Pressures
a. Suction
b. Discharge
2. Flow rate
3. Pump input power
4. Shaft speed
5. Fluid properties at the operating condition(s)
6. Pump performance curve (from the manufacturer)
7. Motor performance—Possibly the VFD performance
also (from the manufacturer)
Warning—Before any data collection is begun, all data
must be collected by trained and qualified personnel. Data
collectors will be connecting test equipment to live electri-
cal wires and to rotating equipment. All company, local,
state and federal safety protocols must be followed includ-
ing, but not limited to, NFPA 70E and OSHA 29CFR
1910.335. If any reservations in the collectors’ ability to
52 DECEMBER 2010 www.pump-zone.com
gather these measurements safely arise, consult a professional
for assistance.
Pressure Gauges
Pressure gauges are often permanently installed on pumps,
but these may not be the gauges that should be used during
an assessment. Because of pressure spikes, water hammer,
fouling, etc., these gauges are often inaccurate. If safety per-
mits, mount accurate pressure gauges onto the system. he
gauges should be of good quality and accurate enough to read
pump suction and discharge pressures within +/- 3 percent.
Be aware that the suction pressure may be below atmo-
spheric, requiring a compound gauge (able to read both posi-
tive and vacuum pressures). he gauges should be mounted
as close to the pump as possible to eliminate potential errors
caused by losses in pipe fittings.
he head level in and out of the pump must be deter-
mined. he difference between the inlet head (input energy)
and the discharge head (exiting energy) is the amount
of energy added to the flow measured in foot-pounds per
pound. If only the inlet or outlet head or pressure is known,
determining the amount of energy transferred to the fluid is
impossible. he formula to convert pressure to head is (see
nomenclature for definition of terms):
P x 2.31
hg =
SG
If a suction gauge is not available, as on a vertical immer-
sion sump pump, use the level of the fluid above the inlet to
the impeller to determine the suction head level. he equa-
tion to determine suction head from a fluid level measure-
ment is:
GP x 2.31
Hs = + hvs ± Zs - hfs
SG
Flow Rate
he next required measurement is the flow rate through
the pump system. his can be determined by an inline flow
PUMPS & SYSTEMS
 Nomenclature Another type, common in some industries, is a pitot tube
H = Total head (feet) that measures velocity by determining the difference between
P = Pressure (psi) the total and static pressures in a flow. here are several other
SG = Speciic gravity (no unit) insertion type meters, including paddlewheel and turbine-type
hg = Head (from gauge pressure) (feet) meters. All these meters require that the internal diameter of
hvs = Velocity head (suction side of pump) (feet) the pipe be known so that the velocity and the pipe’s internal
hfs = Friction head loss (suction side of pump) (feet) cross-sectional area can be used to find the volumetric flow rate.
Zs = Elevation head (level of liquid above pump impel-
ler inlet) (feet) Flow rate = velocity × cross sectional area
Hs = Total head (suction side of the pump) (feet) π x D2
GP = Gas pressure (applied to liquid surface, zero if Cross-sectional area = (for round pipe)
4
open tank) (psig)
D = Internal diameter of the pipe (feet) Shaft Speed
Shaft speed has changed from a guessed number to a param-
meter that is permanently installed in the system or by one eter that must be measured. Efficiencies of electric motors have
installed temporarily for the test. Whichever method is used, been increased with a complimentary reduction in slip. his
the flow meter needs to be installed correctly with the proper means that motor speeds have increased, moving closer to their
amount of straight pipe before and after the meter. synchronous speeds.
Temporary flow meters must not change the system loss When taking performance measurements, this may lead
characteristics during the measurement. A popular type of tem- to significant changes in the pump’s performance in both head
porary flow meter is an ultrasonic flow meter. It uses changes in and power consumption. his measurement does not need to
a sound signal passed through the pipe and the flow to deter- be extremely accurate. Knowing the shaft speed within ±5 rpm
mine the velocity of the flow in the pipe. his is non-invasive is acceptable in most cases.
and does not require the pipe to be penetrated. However, they Sometimes, this can be done using an inexpensive contact-
can be temperamental and error-prone when misapplied. type tachometer. Generally, these use a rubber-tipped shaft that

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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 53
 Practice & Operations

is pressed against the pump or motor shaft, directly measuring

the shaft’s rpm. his works well if there is a location available to
make contact with the spinning shaft.
Non-contact tachometers are an alternative. On the lower
end of the expense scale are optical tachometers that use a light
source bounced off a piece of reflective tape attached to the
shaft. hese work well but require that the pump be stopped
to attach the tape. Some non-contact tachometers, such as key-
phasers or optical strobes, can be used without stopping the
equipment.

Input Power
Determining the input power for a pump can be as simple as
taking the voltage and amperage data on the output side of the
motor starter. hese measurements combined with the power
factor and efficiency data from the motor manufacturer will
provide a fair estimate of the motor output power, which is usu-
ally the pump input power. his method works well on fixed-
speed pumps.

Due to the potential safety hazards, it is advised that

all electrical meters be attached to the pump’s electri-
Figure 1. PSAT input area
cal system when the power to the pump motor control
center is off. his reduces the risk of electrical shock and
arc flash.

If the motor is driven by a variable frequency drive (VFD),

things get more complicated. he drive output to the motor
is not running on a true sine wave, and the frequency of the
output may also be outside the range of the meters being used
for the measurements. hese two factors along with change in
the power factor modified by the drive complicate measure-
ments at this location. Many drive manufacturers suggest mea-
surements be taken with the power meter at the input side of
the drive where the power is coming in at line frequency and
voltage. his requires that the efficiency of the drive at various
power and frequency outputs be known. he readout on the
drive’s display can be used, but it is rarely calibrated and may
be prone to errors. Figure 2. Head calculation tool for suction and discharge pressures
Pump power input =
Drive input power × (Drive efficiency) × (Motor efficiency) shows approximately how much money could be saved yearly if
the optimal pump were installed.
Analyze the Data To run PSAT, the user enters information about the pump
Data analysis can be done by hand. An example document can and the motor driving it in the PSAT input area (Figure 1). he
be downloaded at www.pdcubed.net showing a complete hand box at the bottom of the column is where the flow head and
calculation with the accompanying equations. hese formulas input power data is entered. he user can calculate the total
can be used to develop a custom spreadsheet. head of the pump by hand, or it can be calculated by the PSAT
Also, a free tool from the U.S. Department of Energy by clicking the blue “Head tool” button next to the input box.
can help analyze the data. he program is called Pump System his brings up a calculator where the system and measured data
Assessment Tool (PSAT). It can be downloaded at www1.eere. is entered. he tool will calculate the total head (Figure 2). If
energy.gov/industry/bestpractices/software_psat.html. you have a system without a suction pressure gauge, the tool
Input for this tool is the raw measurement data. Output is can also calculate the total head by selecting “suction tank ele-
the pump’s performance, yearly energy usage and cost to oper- vation, gas space pressure and discharge line pressure.”
ate. he tool also compares the current pump against a theoreti-
cal, optimum pump based on the achievable efficiency estimate Use of the Information
generated from the Hydraulic Institute Standard. his contrast Now that the pump’s performance is known, the actual per-
54 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
 It gives a fairly accurate simple system curve for each operating
condition. his curve generator uses the measured condition
point and the zero flow static head to create a system curve
showing the actual losses within the system. his curve can be
output to a spreadsheet.
With straightforward testing and the analysis tools shown,
pump system assessment can be conducted, and the pump
and system’s reliability and energy efficiency can be improved
having major positive impact on the bottom-line of operations,
and helping a company meet its energy reduction goals.
Additional Resources
A new ASME standard for conducting pump system energy assessments
Figure 3. Free PSIM system analysis tool is available at the website: estore.pumps.org/ASME-EA-2---2009-Energy-
formance can be plotted on the manufacturer’s performance Assessment-for-Pumping-Systems-Secure-PDF-P129C27.aspx
curve. his determines if the pump is operating near its best effi- Additionally, there is a free awareness seminar to help users understand the
content of the standard. Webinar dates and times are available at:
ciency point (BEP). If the goal is to improve the reliability of the www.pumpsystemsmatter.org/content_detail.aspx?id=5685
pump, and the pump is operating far away from the BEP, this P&S
may indicate that the hydraulic loads within the pump are caus- Greg Case is president of Pump Design, Development &
ing shaft deflection, seal or bearing problems, internal rubs, etc. Diagnostics, LLC (PD3). He consults on pump design and
If reliability problems exist and the pump is operating near troubleshooting issues. Case is a qualified instructor for both
its BEP, this may point to mechanical problems—such as poor the U.S. Department of Energy’s Pump System Assessment
alignment, weak base plates, improper assembly techniques, etc. course and the Hydraulic Institute’s Pump Systems Matter,
If efficiency improvement was the main goal, this infor- Pumping System Optimization course. Contact him at
mation can determine if the pump is the best fit for the gregcase@pdcubed.net.
application. A pump running far away from its BEP will be
less efficient than one running close
to its BEP. he pump, control system
or operating practices may need to be
modified to improve the pump system’s
performance. Unfortunately, no single
approach will improve the efficiency of
every system.
Many factors need to be consid-
ered to optimize system efficiency. In
some systems, the optimization may
require nothing more than turning off
the pump when there is no demand. In
other systems, trimming the impeller to
the proper size so it can meet flow and
head demand will suffice. In more com-
plex systems, the use of motor control,
parallel pump systems and state-of-the-
art PLC control may be required.
If complex system changes are
required, analyzing the effects of vari-
ous operating conditions on a simula-
tion tool is suggested before physical
changes to the system are made. A free
analysis tool (PSIM) is available on
the Hydraulic Institute/Pump Systems
Matter website at: www.pumpsystems-
matter.org/content_detail.aspx?id=110
(Figure 3).
Another powerful tool, found
within PSAT, is the system curve tool.
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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 55
ANNUAL PRODUCT SHOWCASE SPECIAL ADVERTISING SECTION
Alignment & Monitoring Alignment & Monitoring Alignment & Monitoring

Easy-Laser® E710 Real-Time Measurement of Machine

he new Easy-Laser® E710 is the irst system to Positional Change
ofer next-generation features like wireless Blue- ROTALIGN ULTRA Live Trend monitors
tooth™ operation, color graphics and ininite bat- machine movement during run-up or coast-down Pump Laser Alignment
tery life—all at an industry-best price. Combined to determine the positional change over time. It SHAFTALIGN is the irst low-cost, color display
with the industry’s longest warranty (two years), utilizes a ive-axis sensor to monitor continuously, shat alignment. Avoid costly downtime. Align
ergonomic design, free electronic documentation in real-time and simultaneously both the vertical your pumps with SHAFTALIGN in three easy
and unmatched durability, the E710 is clearly the and horizontal parallel and angular displacement steps: enter the dimensions, measure, view the
most value-added ofering in laser shat alignment of rotating machinery, from cold to hot conditions results—with 3D graphics and centerlines to scale.
systems. We make it easy! or vice versa. Upgradable, keeps up with your needs!
Alignment Supplies, Inc. LUDECA, Inc. LUDECA, Inc.
1681 Lance Pointe Road, Suite 2 1425 NW 88th Avenue 1425 NW 88th Avenue
Maumee, OH 43537 Doral, FL 33172 Doral, FL 33172
Phone: 419.887.5890 Phone: 305-591-8935 Phone: 305-591-8935
Fax: 419-887-5893 Fax: 305-591-1537 Fax: 305-591-1537
Website: www.alignmentsupplies.com Website: www.ludeca.com Website: www.ludeca.com
Email: info@alignmentsupplies.com Email: info@ludeca.com Email: info@ludeca.com

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Alignment & Monitoring Alignment & Monitoring Alignment & Monitoring

GO Pro
New to VibrAlign, Inc., is the Fixturlaser GO Pro. UPAD XA
GO Basic his laser is the irst in the GO series to have a he UPAD XA has the functionality of the larger,
he Fixturlaser GO Basic delivers live values color screen and wireless measurement units. he hand-held XA display unit with a smaller, 3.5-inch
and icon-based guidance to its users. GO Basic, biggest advance in the Fixturlaser GO Pro tool is screen. he screen is backlit and trans-relective to
VibrAlign’s entry product, comes with high-tech its unique, adaptive user interface. Depending on provide good visibility in poor lighting conditions
hardware and sotware and many functions to what the measurement results show, the tool will and strong sunlight. he UPAD XA touch-screen
increase its user friendliness. GO Basic features an guide the user throughout the alignment process. uses animated, on-screen graphics to guide the user
intuitive user interface that is based on icons and hanks to the “Compound Moves” function, no through the alignment process. Its display unit is
symbols that will guide the user throughout the remeasurements are required. equipped with a Velcro® strap that keeps it in place
measurement and adjustment process. on the user’s arm.
VibrAlign, Inc. VibrAlign, Inc. VibrAlign, Inc.
530-G Southlake Blvd. 530-G Southlake Blvd. 530-G Southlake Blvd.
Richmond, VA 23236 Richmond, VA 23236 Richmond, VA 23236
Phone: 804-379-2250 Phone: 804-379-2250 Phone: 804-379-2250
Fax: 804-379-0189 Fax: 804-379-0189 Fax: 804-379-0189
Website: www.vibralign.com Website: www.vibralign.com Website: www.vibralign.com
Email: info@vibralign.com Email: info@vibralign.com Email: info@vibralign.com

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56 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
SPECIAL ADVERTISING SECTION
Alignment & Monitoring
XA Pro
he sotware package contains all you need
for performing the shat alignment of rotating
machinery—horizontal and vertical shat align-
ment, alignment of machine trains, hot check, and
sotfoot. A time-saving function in the XA Pro is
“Machine Deined Data,” which allows the user
to save machine conigurations as templates. All
machine data for each machine, including machine
dimensions, measurement distances, tolerances,
and target values, are available in the Fixturlaser
XA Pro alignment tool. he hardware package
now includes thin magnetic brackets and an exten-
sion ixture.
VibrAlign, Inc.
530-G Southlake Blvd.
Richmond, VA 23236
Phone: 804-379-2250
Fax: 804-379-0189
Website: www.vibralign.com
Email: info@vibralign.com
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Couplings
Lubrication-Free Disc Couplings
What’s involved in lubricating a coupling on a
pump? Qualiied maintenance personnel to lock
out and tag the electric motor. Followed by, lock-
ing out the intake and outlet valves, draining the
pump case and removing a guard. his could all be
eliminated by using a Lovejoy disc coupling which
is maintenance free—replacing gear and grid
coupling designs.
Lovejoy, Inc.
2655 Wisconsin Avenue
Downers Grove, IL 60515
Phone: 630-852-0500
Fax: 630-852-2120
Website: www.lovejoy-inc.ocm
Email: info@lovejoy-inc.com
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PUMPS & SYSTEMS
Alignment & Monitoring
XA Ultimate
Fixturlaser XA Ultimate is a measurement tool
with an expanded sotware package that includes
shat alignment and geometric measurements,
such as latness and straightness. Properly aligning
a machine starts at its installation. he machine’s
foundation should be checked to determine if it’s
skewed or warped, which would inluence the
machine’s capability to work under optimal condi-
tions. he Fixturlaser XA Ultimate tool gives the
user access to all the sotware and hardware that is
required for a successful machine installation.
VibrAlign, Inc.
530-G Southlake Blvd.
Richmond, VA 23236
Phone: 804-379-2250
Fax: 804-379-0189
Website: www.vibralign.com
Email: info@vibralign.com
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Couplings
Vibration Damping,
Torque Limiting Couplings
Manufacturing couplings for pumping applications
from 0.1 to 160,000 Nm, R+W Coupling Tech-
nology has the solutions for vibration damping,
easy mounting, torque limitation and lexibility
for almost every application. Whether you require
ATEX certiication, custom interface or special
materials, our experienced coupling engineers have
the knowledge and dedication to keep you running
with the ULTIMATE COUPLING—WORLD-
WIDE.
R+W Coupling Technology
1120 Tower Lane
Bensenville, IL 60106
Phone: 630-521-9911
Fax: 630-521-0366
Website: www.rw-america.com
Email: info@rw-america.com
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www.pump-zone.com
ANNUAL PRODUCT SHOWCASE
Condition Monitoring
Non-Metallic Polymer Concrete
Baseplates
BaseTek ofers a complete line of solid, corrosion-
resistant non-metallic Polymer Composite Base-
plates. Designed to accommodate most ANSI/
ASME pump products, the PoxyBase® product line
is ofered in ZANITE®, a superior epoxy-based
system, providing the lattest, strongest (80 percent
greater than common vinyl ester resin types) and
most attractive design on the market today—all
at very competitive prices. Custom conigurations
also available.
BaseTek, LLC
14646 Ravenna Road
Newbury State: OH Zip: 44065
Phone: 877-712-2273
Fax: 216-274-9296
Website: www.basetek.com
Email: info@basetek.com
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Couplings
Self-Aligning Pipe Couplings
he Tuf-Lok ring grip pipe couplings are low-cost,
heavy-duty, self-aligning couplings for either high
pressure, to 150 psig, or full vacuum-rated applica-
tions. hese couplings install quickly and easily,
reducing installation costs. hey are available in
1-inch (25-millimeter) through 10-inch (250-mil-
limeter) pipe sizes and are made for use on plain
end pipe, regardless of pipe wall.
TUF-LOK International
Madison, WI
Phone: 608-270-9478
Fax: 608-270-2080
Website: www.tuflok.com
Email: info@tuflok.com
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DECEMBER 2010 57
ANNUAL PRODUCT SHOWCASE SPECIAL ADVERTISING SECTION
Engines Filtration Flow Meters
Two Filters
in One
Hurricane ilters
provide unsurpassed
performance because
they separate dense
solids prior to
cartridge iltration
for extended ilter
life, increased dirt
Fairbanks Morse Engines holding capacity and
For decades, Fairbanks Morse has been manu- reduced maintenance
facturing medium-speed engines for rigorous costs. In many respects, Harmsco Hurricane ilters
military, government and nuclear applications. are two ilters in one! Components include outer Non-Contacting Portable Flow Meter
his expertise has resulted in the Colt-Pielstick chamber for particle separation, inner chamber for he new PDFM 5.0 Portable Doppler Flow Meter
PA6B engine—a rugged and technologically- cartridge iltration and built-in drain for purge, if is designed for wastewater, sludge and slurries.
advanced product for emergency pumping stations required. Deep angled pleats are directed toward Mount the ultrasonic sensor on the outside of
in catastrophic environments. A fully-skidded, rotational low for increased dirt holding capacity. metal or plastic pipes, ½-inch diameter or larger.
custom-engineered system, the PA6B comes in 12 Unlike conventional designs, Hurricane patented Use it for pump tests and troubleshooting. his
to 20 cylinder conigurations delivering 350 bkW cartridges are made with deep, angled pleats to battery-powered low meter includes a backlit
per cylinder at 900 rpm. direct the low into the pleated area for increased display, 4-20mA output, data-logger with USB
Fairbanks Morse solids removal. output and sotware.
701 White Avenue Harmsco Filtration Products Greyline Instruments Inc.
Beloit, WI 53511 P.O. Box 14066 105 Water Street
Phone: 800-356-6955 North Palm Beach, FL 33408 Massena, NY 13662
Fax: 608-364-8411 Phone: 800-327-3248 Phone: 888-473-9546
Website: www.fairbanksmorse.com Fax: 561-485-2474 Fax: 315-764-0419
Email: Website: www.harmsco.com Website: www.greyline.com
Kevin.lidbury@fairbanksmorse.com Email: gwillis@harmsco.com Email: info@greyline.com
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Flow Meters Instrumentation & Controls Instrumentation & Controls

Ultrasonic Flow Meter Technology
he advanced TFX Ultra by Dynasonics® is an
ultrasonic low meter that clamps on the outside of
existing pipes without contacting liquids. here is
no need to shut down the process for installation
or maintenance. herefore, the TFX Ultra can be
installed and fully operational in minutes, ofering
repeatable and reliable low measurement.
Racine Flow Meter Group
8635 Washington Avenue
Racine, WI 53406
Phone: 262-639-6770
Fax: 262-639-2267
Website: racinefed.com/flow
Email: blakeegan@racinefed.com
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58 DECEMBER 2010
Series EDA Electronic Pressure
Controller
Mercoid, Division of Dwyer Instruments, Series
EDA Electronic Pressure Controller can replace
a separate gauge, two switches and a transmitter
in a system. he front face has LED indicators
with switch status and a large backlight, two-line
display showing process value and indication
units. Weatherproof housing—panel mount, lush
mount, or pipe mount ability.
Dwyer Instruments Inc.
P.O. Box 373
Michigan City, IN 46361
Phone : 1-800-872-9141
Website: www.dwyer-inst.com
Email: lit@dwyer-inst.com
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www.pump-zone.com
EMS PRO Controller
he EMS PRO controller is a lexible, all-in-one,
customizable unit that meets the needs of engine-
driven pumping equipment applications. he EMS
PRO is a dedicated microprocessor-based, single
engine controller. It ofers ield-adjustable operat-
ing parameters that can be changed without the
need for a computer. It is also able to support both
mechanical and J1939 electronic engines.
FW Murphy
P.O. Box 472248
Tulsa, OK 74147
Phone: 918-317-4200
Fax: 918-317-4266
Website: www.fwmurphy.com
Email: jkopp@fwmurphy.com
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PUMPS & SYSTEMS
SPECIAL ADVERTISING SECTION ANNUAL PRODUCT SHOWCASE
Instrumentation & Controls Instrumentation & Controls Instrumentation & Controls

Pump Motor Ground Monitor

Monitor and protect your pump motor:
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and automatic alarming applications. equipped with state-of-the-art controls and VFD
TZTUFNT
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 Phoenix Contact technology. UL/cUL Listed. Patent Pending.
MSE of Canada Ltd. P.O. Box 4100 SJE-Rhombus®
261 Millway Avenue Harrisburg, PA 17111 22650 County Highway 6, P.O. Box 1708
Concord, ON L4K 4K9 Canada Phone: 717-944-1300 Detroit Lakes, MN 56502
Phone: 905-738-3744 Fax: 717-944-1625 Phone: 218-847-1317
Fax: 905-738-5732 Website: www.phoenixcontact.com/ Fax: 218-847-4617
Website: www.msegroup.net industrialmodems Website: www.sjerhombus.com
Email: jkhan@msegroup.net Email: info@phoenixcon.com E-mail: sje@sjerhombus.com
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Instrumentation & Controls Maintenance Products Maintenance Products

VARNA Products
Turnkey Pump
Control Solutions
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leak-sealing capacity signiicantly higher than with
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ing for pumps and valves. Other products include
2,000 psi (138 bar) assuming a 5:1 safety margin.
QSFMVCF packing tools, gasket sheets, joint sealant, lip seals,
Stop It HP™ is compliant with U.S. DOT 49CR
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InduMar Systems, LP, division of
VARNA Products InduMar Products, Inc. Palmetto Inc.
4305 Business Drive 3355 W. Alabama, Ste. 110 25 Engerman Avenue
Cameron Park, CA 95682 Houston, TX 77098 Denton, MD 21629
Phone: 888-676-7770 (U.S. & Canada) Phone: 800-523-7867 Phone: 410-479-2244
530-676-7770 (International) Fax: 713-977-4164 Fax: 410-479-0836
Website: www.varnaproducts.com Website: www.indumar.com Webstie: www.palmettopackings.com
Email: tmcachran@varnaproducts.com Email: sales@indumar.com Email: info@palmettopackings.com

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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 59
ANNUAL PRODUCT SHOWCASE SPECIAL ADVERTISING SECTION
Metal ID Tags Mixers Motors & Drives
Disc Mixer
he Discmixer is
based on
DISCFLO’s inno-
vative disc technol-
ogy. It is superior
when mixing shear
sensitive luids,
abrasive slurries and Aurora Vertical Hollow Shaft Motors
luids with high Aurora Motors is a leading global supplier of
Durable Identification solid content. premium vertical hollowshat motors for OEMs,
of Pumps & Valves r
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electic motor distributors, well drillers and mu-
Durable identiication tags for pumps, valves, of delicate solids nicipalities. We are currently manufacturing and
motors, instruments, small piping, cables and other r
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stocking the following vertical turbine motors to
maintenance equipment are made to withstand and stringy meet your application needs:
chemical cleanings, high temperatures, and solids without r

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of weathering and chemicals. With a credo “We r
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InfoSight DISCFLO CORPORTAION Aurora Motors
20700 U.S. Highway 23 10850 Hartley Road 2031 American Avenue
Chillicothe, OH 45601 Santee State: CA Zip: 92071 Hayward, CA 94545
Phone: 740-642-3600 Phone: 619-596-3181 Phone: 510-264-1318
Fax: 740-642-5001 Fax: 619-449-1990 Fax: 510-264-1317
Website: www.infosight.com Website: www.discflo.com Website: www.aamotor.com
Email: sales@infosight.com Email: lthompson@discflo.com Email: tony@aarotating.com
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Motors & Drives Motors & Drives Motors & Drives

®
U.S. Motors
Vertical
HOLLOSHAFT®
Motor
he U.S. Motors®
brand vertical HOL-
LOSHAFT® motor
has been a standard in
the pumping industry
since 1922. his mo-
Quickly Connect and tor is recognized for
MAX-VH™ Vertical Motors
its longevity, reliabil-
Disconnect Motors & AC Drives
ity and ease of use. In
UL switch-rated plugs and receptacles allow TECO-Westinghouse MAX-VH™ vertical hollow
addition to the HOL-
technicians to quickly connect/disconnect power shat, high thrust motors are stocked from 7.5
LOSHAFT®, we ofer
to pump motors. he device operates as a “line of horsepower to 400 horsepower at 1,800 rpm.
a broad selection of
sight” disconnect switch up to 60 horsepower, 200 Motors have high eiciencies that meet/exceed
U.S. Motors® brand pump motors for virtually any
amps. Safety features protect from live parts and EPAct levels and have an industry leading warranty
centrifugal pump application in every major stage
arc lash injury. NEC/NFPA 70E code compliance of 36 months from date of manufacture. Pair your
of water treatment and processing.
is simpliied. A safety shutter on the receptacle MAX-VH™ motors with the MA7200 Plus pump
ensures an NFPA 70E deined hazard risk category Nidec Motor Corporation (FKA Emerson AC drive or the EQ5 multi-purpose AC drive for a
= 0. Motor Company, a division of Emerson custom pump driving solution.
Meltric Corporation Electric Co.) TECO-Westinghouse Motor Co.
4640 Ironwood Drive 8050 W. Florissant Avenue 5100 North IH-35
Franklin, WI 53132 St. Louis. MO 63136 Round Rock, TX 78681
Phone: 800-433-7642 Phone: 314-595-8486 Phone: 800-451-8798
Fax: 414-817-6161 Fax: 314-595-8315 Fax: 512-244-5502
Website: www.meltric.com Website: www.nidec-motor.com Website: www.tecowestinghouse.com
Email: mail@meltric.com Email: paul.deal@nidec-motor.com Email: sales@tecowestinghouse.com
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60 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
SPECIAL ADVERTISING SECTION ANNUAL PRODUCT SHOWCASE
Motors & Drives Pump Services Pumps: Centrifugal
iQpump
Intelligent
Pump Controller

he iQpump® control-
ler was designed
with pump service
operators and pump
system owners in
mind. he integrated
pump sotware allows
the operator to setup Reserve Your FREE 2011/12 Quality Ductile, Gray and
speciic control values Cole-Parmer® General Catalog Alloy Iron Castings
for a wide range of Select the latest luid handling, laboratory Decatur Foundry means quality castings in less
applications. he research, industrial process and electrochemistry than four weeks, guaranteed. Located in Central
iQpump® controller will automatically adjust products to help you get your job done! More Illinois, DFI provides ductile, gray and alloy iron
pump operating conditions as the process variables than 2,600 pages feature brand names such as castings from 200 to15,000 pounds for water,
change while still maintaining optimum pump Masterlex®, Oakton®, Polystat®, StableTemp®, and oil and gas pumps, compressor, motor and the
performance and protection. more. Also includes information about technical mining industry. DFI is an air set foundry making
assistance, database tools and calibration services. short-run, low-volume, highly cored castings for
Reserve your copy! Call 800-323-4340, or visit fast turnaround.
Yaskawa America, Inc. ColeParmer.com/8168. Ductile and Gray Iron Foundry
2121 Norman Drive South Cole-Parmer 1745 North Illinois Street
Waukegan, IL 60085 625 East Bunker Court Decatur, IL 62526
Phone: 800-927-5292 Vernon Hills, IL 60061-1844 Phone: 217-429-5261
Fax: 847-887-7310 Phone: 800-323-4340 Fax: 217-426-2834
Website: www.yaskawa.com Website: www.coleparmer.com Website: www.decaturfoundry.com
Email: marcom@yaskawa.com Email: info@coleparmer.com Email: terryyoung@decaturfoundry.com
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Pumps: Centrifugal Pumps: Centrifugal Pumps: Centrifugal

Centrifugal Pumps for

FM Series 5300 Chopper Pumps
Designed for excellent solids conditioning, the
Fairbanks Morse Series 5300 Chopper pump uses
an enclosed impeller with a rugged cutting proile
and delivers pump eiciencies 20 to 30 percent
beyond the current chopper pump designs.
Fairbanks Morse Pump
3601 Fairbanks Avenue
Kansas City, KS 66106
Phone: 913-371-5000
Fax: 913-748-4025
Website: www.fmpump.com
Email: fairbanks_info@pentairwater.com
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PUMPS & SYSTEMS
Industrial Applications
Haight Pump is excited to be ofering centrifugal
Ruhrpumpen, Heavy Duty Process
pumps. Constructed of 316L stainless steel, nickel Pump—SCE
aluminum bronze or Duplex 2205—these pumps he SCE is a heavy-duty, single-stage, centrifugal
are designed to be used in various industrial ap- process pump that meets API 610 standards. With
plications including power plants and chemical improvements to the casing, shat and bearing
processing. Contact Haight today to conigure a bracket, the improved SCE is ideally suited for
pump that is right for your centrifugal application. reineries and petrochemical plants, oil ields and
With over 75 years experience manufacturing pipelines, as well as ofshore, marine, and dock
pumps, we can ind the one for you! services.
Haight Pump Ruhrpumpen, Inc.
133 Enterprise Street 4501 S. 86th E Avenue
Evansville, WI 53536 Tulsa, OK 74145
Phone: 800-871-9250 Phone: 918-627-8400
Fax: 608-882-3777 Fax: 918-624-2471
Website: www.haightpump.com Website: www.ruhrpumpen.com
Email: marketing@baker-mfg.com Email: info@ruhrpumpen.com
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www.pump-zone.com DECEMBER 2010 61
ANNUAL PRODUCT SHOWCASE SPECIAL ADVERTISING SECTION
Pumps: Centrifugal Pumps: Centrifugal Pumps: Diaphragm
Graco Husky
Double
Diaphragm
Pumps

Graco Husky™
air-operated double
diaphragm pumps
feature ¼-, 3/8-, ½-,
¾-, 1-, 1½-, 2-, and
APV W+ Series Centrifugal Pumps
3-inch sizes with
SPX is a leading innovator of solutions with
SIMSITE® Structural Composite low rates from 5
decades of experience in centrifugal pump design,
to 275 gallons per
Pumps covering premium brands such as APV. From the
minute for transfer-
SIMSITE® Structural Composite Pumps are supply of engineered components to complete
ring paint, chemicals, ink, cleaners, adhesives, seal-
simply “the best,” because they are “unsurpassed” process engineering and design, we specialize
ants and lubricants. hese pumps feature extremely
in their design, performance, eiciency, & life in helping our customers improve their plant’s
reliable, externally serviceable air valves—making
cycle. SIMSITE® Pumps are superior to metallic performance and proitablility. Years of product
our Husky pumps one of the best in the industry.
pumps because of their outstanding corrosion and development has enabled SPX to ofer a complete
A variety of construction materials are available to
erosion resistance. hey will not corrode in salt range of hygienic pumps in the brewery, dairy,
meet numerous luid transfer requirements.
water or wastewater and have excellent resistance food, beverage, chemical, healthcare and pharma-
to chemicals. ceutical industries.
SIMS PUMP VALVE CO. INC. SPX Flow Technology Graco Inc.
1314 Park Avenue 611 Sugar Creek Road P.O. Box 1441
Hoboken, NJ 07030 Milwaukee, WI 53115 Minneapolis, MN 55440
Phone: 201-792-0600 Phone: 262-728-1900 Phone: 877-844-7226
Fax: 201-792-4803 Fax: 262-728-4904 Fax: 877-340-6427
Website: www.simsite.com Website: www.spxft.com Website: www.graco.com/process
Email: simspump@aol.com Email: answers.us@spx.com Email: info@graco.com

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Pumps: Diaphragm Pumps: Diaphragm Pumps: High Pressure

Advanced™ For Xtremely
Series Demainding
Air-Operated Process
Double- Applications
Diaphragm
Pumps he Yamada® Xtreme
Duty Pro™ XDP
he Advanced™ Series is designed for use
metal and plastic in process type
air-operated double- applications—includ-
diaphragm (AODD) ing ilter press, high Versatile High Pressure Pump
pumps from Wilden pressure, extended General Pump (GP Companies, Inc.) introduces
Pump & Engineering deadheading, long it’s new 100-horsepower MW series pumps. hese
feature its Pro-Flo X™ runs of discharge pipe pumps ofer multiple luid end options and allow
air distribution system to provide true cost savings and where air con- for moving a variety of luids—including high-
when compared to other AODD pumping tech- sumption is critical. temperature glycol, recycled water, deionized water
nology. Advanced™ Series metal pumps are ofered Available in 1½-inch, and produced well water or seawater. he MW
in a variety of materials including construction 2-inch and 3-inch port sizes, these pumps are built series drive features external gear reduction, SAE
and elastomer options that enable them to meet on the liquid platform of a standard Yamada NDP “C” hydraulic mount and optional PTO accessory
abrasion, temperature and chemical-compatibility series pump but with a mechanically-actuated air shat. Flows up to 105 gallons per minute and
concerns. motor. pressures up to 4,350 psi with available lushing
option.
Wilden Pump & Engineering, LLC. Yamada America, Inc. General Pump
22069 Van Buren Street 955 East Algonquin Road 1174 Northland Drive
Grand Terrace, CA 92313 Arlington Heights, IL 60005 Mendota Heights, MN 55123
Phone: 909-422-1730 Phone: 800-990-7867 Phone: 651-686-2120
Fax: 909-783-3440 Fax: 847-631-9274 Fax: 651-454-8015
Website: www.wildenpump.com Website: www.yamadapump.com Website: www.generalpump.com
Email: rob.guertin@wildenpump.com Email: sales@yamadapump.com Email: info@gpcompanies.com
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62 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
SPECIAL ADVERTISING SECTION ANNUAL PRODUCT SHOWCASE
Pumps: Magnetic Drive Pumps: Magnetic Drive Pumps: Magnetic Drive

High Alloy Mag Drive Pumps

Advanced Magnetic Drives
Dickow Pump has manufactured centrifugal
pumps for 100 years, always emphasizing preci-
sion hydraulic eiciency and longevity in service.
Today, we ofer the most complete and technologi-
cally advanced range of magnetic drive pumps
available. his includes the PRM, manufactured
in accordance with API 685. Dickow’s PRM was
speciically designed to meet rigorous API 685
requirements for sealless pump applications in the
petroleum, heavy duty chemical and gas service
industries.
Dickow Pump Company
1738 Sands Place, #200
Marietta, GA 30067
Phone: 770-952-7903
Fax: 770-933-8846
Website: www.dickow.com
Email: sales@dickow.com
Non-Metallic, Close-Coupled,
Sealless Pumps
Fybroc® 2530 Series is the irst completely non-
metallic, iberglass-reinforced-plastic (FRP),
magnetic-drive pump. he pump’s FRP (continu-
ous strand) thermoset construction features a
one-piece, reinforced casing with NO SEPARATE
LINERS. he Series 2530 provides excellent cor-
rosion resistance against acids, bleaches, caustics,
solvents, seawater, brine and other diicult ser-
vices. Ten sizes with capacities to 1,500 gallons per
minute and heads to 400 feet are available.
Met-Pro Global Pump Solutions-Fybroc
700 Emlen Way
Telford, PA 18969
Phone: 215-723-8155
Fax: 215-723-2197
Website: www.mp-gps.com
Email: info@mp-gps.com
Chemsteel Mag-Drive close coupled pumps are it-
ted for applications that require a pump for highly
corrosive chemicals. Nominal low rates from ½
gallons per minute to 30 gallons per minute are
available in either an upper- or lower-drive conigu-
ration. Helical gears ofer noise reduction of up to
10db. Chemsteel is also available as a convention-
ally sealed pump with mechanical, lip or packing.
Oberdorfer Pumps
5900 Firestone Drive
Syracuse, NY 13206
Phone: 800-448-1668
Fax: 315-463-9561
Website: www.oberdorferpumps.com
E-mail:
oberdorfermail@gardnerdenver.com

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Pumps: Metering Pumps: Metering Pumps: Mud

Procam
Metering
Pumps
Bran+Luebbe
has been a
worldwide
leader in meter-
ing, analyzing
and processing
liquids for more
than 75 years.
he Procam Hydrocyclone Charge Pumps—
series is made Produced Water & Sand
IX Precise Control Chemical
up of modular, he world’s best kept secret. DISCFLO is becom-
single and
Dosing Pump
A new generation of advanced metering pump ing the pump of choice in the oil industry on and
multi-stream ofshore for produced water, tank bottoms, subsea
technology! Iwaki’s IX Seris is digitally controlled,
pumps with operations and reineries. Our unique design
direct-drive diaphragm pumps. Years of experience
conigurations features a pulsation-free, laminar low, no close
in high-end motor technology result in extremely
to match the process requirement. he ProCam tolerances, non-emulsifying and non-impingement
accurate and energy-eicient metering pumps
Smart is a high-quality, economic pump for cus- pumping, with little to no wear and low mainte-
with high resolution. he IX Series meets today’s
tomers with less demanding applications. nance.
demand for automated chemical delivery.
SPX Flow Technology Walchem, an Iwaki American Company DISCFLO CORPORTAION
611 Sugar Creek Road 5 Boynton Road 10850 Hartley Road
Milwaukee, WI 53115 Holliston, MA 01746 Santee, CA 92071
Phone: 262-728-1900 Phone: 508-429-1110 Phone: 619-596-3181
Fax: 262-728-4904 Fax: 508-429-7433 Fax: 619-449-1990
Website: www.spxft.com Website: www.walchem.com Website: www.discflo.com
Email: answers.us@spx.com Email: info@walchem.com Email: lthompson@discflo.com

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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 63
ANNUAL PRODUCT SHOWCASE SPECIAL ADVERTISING SECTION
Pumps: Oil Pumps: Oil Pumps: Packaged Pumping Systems

VARNA Products Model CF-15 VARNA Products

Oil/Fuel Pump up to 15 GPM Model EP-4 Oil/Fuel Pump to 4 GPM
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VARNA Products VARNA Products PumpingSol
4305 Business Drive 4305 Business Drive 2230 Justin Trail
Cameron Park, CA 95682 Cameron Park, CA 95682 Alpharetta, GA 30004
Phone: 888-676-7770 (US & Canada) Phone: 888-676-7770 (US & Canada) Phone: 770-740-8866
530-676-7770 (International) 530-676-7770 (International) Fax: 770-740-8812
Website: www.VARNAProducts.com Website: www.VARNAProducts.com Website: www.pumpingsol.com
Email: tmcachran@varnaproducts.com Email: tmcachran@varnaproducts.com Email: sales@pumpingsol.com
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Pumps: Packaged Pumping Systems Pumps: Packaged Pumping Systems Pumps: Peristaltic

Wet Well Mounted Pump Stations

Smith & Loveless Wet Well Mounted Pump
Stations revolutionize wastewater pumping. By New M Series Pump
mounting a complete wastewater lit station—in- Bran+Luebbe Systems he ProSeries® Flex-Flo® M3 and M4 peristaltic
cluding S&L pumps, piping, valve—outside and metering pumps feature 10,000:1 turndown ratio,
Bran+Luebbe has been a worldwide leader in me-
above the wet well, pumping becomes simpler, ive year warranty, NSF Standard 61, patented tube
tering, analyzing and processing liquids for more
safer and more economical. No CONFINED failure detection (TFD) system and brushless DC
than 75 years. Our packaged pump systems used
SPACE entry. Pumps sewage, process wastewater motor. M3 and M4 Series pumps have output rates
for chemical injection and autoblend applications
& stormwater...Capacities to 20,000 gallons per up to 158.5 gallons per hour / 600 liters per hour,
dramatically improve productivity, product quality
minute and 500 feet TDH (pumps up to 12 pressure rating up to 125 psi / 8.6 bar and specially
and help reduce running costs.
inches). engineered tubing for long service life.
Smith & Loveless Inc. SPX Flow Technology Blue-White Industries
14040 Santa Fe Trail Dr. 611 Sugar Creek Road 5300 Business Drive
Lenexa, KS 66215 Milwaukee, WI 53115 Huntington Beach, CA 92649
Phone: 800-898-9122 Phone: 262-728-1900 Phone: 714-893-8529
Fax: 913-894-0488 Fax: 262-728-4904 Fax: 714-894-9492
Website: www.smithandloveless.com Website: www.spxft.com Website: www.bluwhite.com
Email: answers@smithandloveless.com Email: answers.us@spx.com Email: sales@blue-white.com
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64 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
SPECIAL ADVERTISING SECTION ANNUAL PRODUCT SHOWCASE
Pumps: Peristaltic Pumps: Peristaltic Pumps: Piston Plunger
Graco Fast-Flo Piston
Transfer Pumps
Graco’s Fast-Flo® piston transfer pumps
are ideal for low- to medium-viscosity
luids and shear sensitive materials. hese
Single Roller Peristaltic Pumps pumps ofer superior reliability at an
Lower Operational Costs afordable price!

MORE EFFECTIVE & COST EFFICIENT:

Larox Flowsys peristaltic pumps utilize a single
roller design that will signiicantly lower opera-
tional costs. It compresses the rubber hose only
once every 360-degree revolution, so 80 percent of
the heat and friction caused by sliding shoe designs
that wear down the hose are eliminated, ensuring
longer hose life. Single roller designs require less
than a quarter of the glycerin and can run continu-
ously at much higher rpms than double roller and
sliding shoe designs!
Verderflex Peristaltic Pumps r
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A single source pumping solutions provider, our
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reliable and eicient hose pump available—and
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the Verderlex® 125, the largest hose pump in the
world.

Verderflex Graco Inc.

Larox Flowsys Inc. 110 Gateway Drive P.O. Box 1441
808 Barkwood Court, Suite N Macon, GA 31210 Minneapolis, MN 55440
Linthicum, MD 21090 Phone: 877-476-3569 Phone: 877-844-7226
Phone: 410-636-2250 Fax: 478-476-9867 Fax: 877-340-6427
Fax: 410-636-9026 Website: Website:
Website: www.larox.us www.vergergpm.com/peristaltics www.graco.com/process
Email: jane.gaughan@larox.us Email: info@verder.com Email: info@graco.com

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Pumps: Positive Displacement/Centrifugal Pumps: Progressive Cavity Pumps: Rotary

Bronze Close Coupled,

Colfax Fluid-Handling Solutions
Colfax strong legacy brands allow us to serve
customers like you with an unmatched portfolio
of luid-handling products, technologies and
application expertise: Allweiler, Baric, Fairmount
Automation, Houttuin, Imo AB, Imo Pump,
Lubrication Systems Company, Portland Valve,
Tushaco, Warren Pumps, Zenith Pumps.
Colfax Corporation
1710 Airport Road
Monroe, NC 28110
Phone: 877-853-7868
Website: www.colfaxcorp.com
Email: cc@colfaxcorp.com
Smart Conveying Technology Pedestal Pumps
Have you heard the news? “Smart Conveying
Oberdorfer has been manufacturing Bronze close
Technology (SCT)” is now available from seepex
coupled and pedestal gear pumps since 1890. Flow
for existing seepex pumps and other progressive
rates from ½ GPM to 175 GPM are available with
capacity pumps. SCT was developed for quick
a wide selection of seal choices available. Helical
and easy removal of the stator and rotor without
gears ofer noise reduction of up to 10db. We
removing the discharge pipes. Pumps no longer
specialize in “custom” products for most OEM
have to be removed for maintenance. he laborious
application.
and time-consuming work of dismantling pipe
work and the removal of associated equipment
are eliminated. SCT components are lighter and
easier for maintenance personnel, which facilitates
compliance with health and safety policies. Oberdorfer Pumps
seepex Inc. 5900 Firestone Drive
511 Speedway Drive Syracuse, NY 13206
Enon, OH 45323 Phone: 800-448-1668
Phone: 937-864-7150 Fax: 315-463-9561
Fax: 937-864-7157 Website: www.oberdorfer-pumps.com
Website: www.seepex.com Email:
Email: dlakovic@seepex.net oberdorfermail@gardnerdenver.com

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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 65
ANNUAL PRODUCT SHOWCASE SPECIAL ADVERTISING SECTION
Pumps: Rotary Pumps: Rotary Pumps: Rotary Lobe

Rotary Lobe Pumps

Plenty Mirrlees Pumps
With decades of experience in the design and
manufacture of rotary positive displacement
pumps, Plenty Mirrlees Pumps has built an
excellent reputation supplying reliable pumping
equipment to the oil processing, petrochemical
processing, power generation, marine, defense,
sugar and general industries.
SPX Flow Technology
611 Sugar Creek Road
Milwaukee, WI 53115
Phone: 262-728-1900
Fax: 262-728-4904
Website: www.spxft.com
Email: answers.us@spx.com
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Waukesha Universal Series BOERGER is the leading manufacturer of Rotary
PD Pumps Lobe Pumps equipped with elastomer coated
rotor designs. Boerger pump units are ideally
Waukesha brand pumps have long been known
suited for various municipal and industrial pump
as the “pump of choice” for many processors.
applications with lows between 1- to 5,000-gpm
Versatile in application, its reliability has made it
and pressures up to 200-psi. All wetted parts are
the industry standard worldwide for more than 50
exchangeable through the front cover (MIP =
years. With pressures up to 500 psi, the pumps can
Maintenance In Place). Axial and radial casing
be ofered in several conigurations and are used in
liners eliminate the expense of replacing pump
both sanitary and industrial applications.
casings. BOERGER Screw Rotor Technology
SPX Flow Technology provides Pulsation Free Operation.
611 Sugar Creek Road BOERGER, LLC
Milwaukee, WI 53115 740 NE Harding Street
Phone: 262-728-1900 Minneapolis, MN 55413
Fax: 262-728-4904 Phone: 877-726-3743
Website: www.spxft.com Fax: 612-331-8769
Email: answers.us@spx.com Website: www.boerger.com
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Pumps: Rotary Lobe Pumps: Sludge/Slurry Pumps: Submersible

MUNIFLO Infinity Submersible Pumps

he New Design of the MUNIFLO Rotary Lobe
Pump incorporates: he new Gorman-Rupp line of Ininity™ submers-
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PQUJPOT GIW is a leading manufacturer of high-perfor- industry-leading, self-priming pumps. he Inin-
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GIW serves industries such as mining and mineral up to 3,100 gallons per minute and heads to 190
the rotor case beneiciation, industrial process, dredge, aggregate feet.
MUNIFLO PUMP and coal preparation.
Division of Equipompe Inc. GIW Industries, Inc. Gorman-Rupp Company
16681 Hymus Blvd. 5000 Wrightsboro Road 600 S. Airport Road
Kirkland, QC Canada H9H 4R9 Grovetown, GA 30813 Mansfiled, OH 44903
Phone: 800-783-5623 Phone: 706-863-1011 Phone: 419-755-1011
Fax: 800-693-5623 Fax: 706-863-5637 Fax: 419-755-1251
Website: www.muniflo.com Website: www.giwindustries.com Website: grpumps.com
Email: info@muniflo.com Email: marketing@giwindustries.com Email: grsales@gormanrupp.com
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66 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
SPECIAL ADVERTISING SECTION ANNUAL PRODUCT SHOWCASE
Pumps: Submersible Slurry Pumps: Sump Pumps: Vertical
Heavy Duty Vertical Air-
Industrial Cooled Inline
Sump Pumps Pumps
Dean Pump®
Sethco® UD Series
RAV (hot oil)
Pumps are ideally
and RWAV (hot
suited, structurally
water/glycols)
and hydraulically,
product lines
for heavy-duty
represent the
Non-Impeller Submersible service. UD pumps
highest quality,
are constructed of
Slurry Pumps most efective,
rigid CPVC and
he Pitbull® pump design eliminates seals, impel- high-temperature, air-cooled vertical inline pump-
PVC materials to
lers, diaphragms and internal components to ing equipment available. Features include vertical
provide outstand-
reduce pump maintenance. Two check valves route inline coniguration, reduced pump footprint,
ing mechanical
large solids/liquids through full pipe-diameter pas- diminished pump alignment requirements,
strength at elevated temperatures and excellent
sages at low velocities. CIPC manufactures a full air-cooled design and no external water cooling re-
chemical resistance to concentrated acids and
line of these unique, air-operated pumps in lows quired. hree sizes of each model are available with
alkalies. he pumps resist wear, withstand impact
from 5 to 1,500 gallons per minute. Submersible, pumping temperatures to 650 degrees F (RAV)
and maintain dimensional stability through long-
transfer, self-priming and ilterpress feed conigura- and 400 degrees F (RAV).
life service.
tions/models are available in stainless, steel and
FRP construction. Met-Pro Global Pump Solutions-
Chicago Industrial Pump Company Met-Pro Global Pump Solutions-Sethco Dean Pump
822 Schneider Drive 700 Emlen Way 6040 Guion Road
South Elgin, IL 60177 Telford, PA 18969 Indianapolis, IN 46254
Phone: 847-214-8988 Phone: 215-799-2577 Phone: 317-293-2930
Fax: 847-214-8998 Fax: 215-799-0920 Fax: 317-297-7028
Website: www.pitbullpumps.com Website: www.mp-gps.com Website: www.mp-gps.com
Email: sales@pitbullpumps.com Email: info@mp-gps.com Email: info@mp-gps.com
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Seals Seals Seals: Mechanical/Support Systems

Bearing
Isolators
Garlock…the
next generation
in bearing isola-
tor technology.
Since 1887, Gar-
lock has been the
leader for all your
sealing needs.
Garlock ofers the Complete Bearing Protection
most expansive As the inventor of the original bearing isolator,
product range, Non-Metallic Mechanical Seal
Inpro/Seal® leads the industry in permanent
a robust global With the ASI Model 724, Advanced Sealing
bearing protection for rotating equipment. Inpro/
infrastructure, a International has redeined the non-metallic seal.
Seal’s Motor Grounding Seal™ (MGS®) combines
world class and Made of high-performance composite material,
the patented VBXX® Bearing Isolator with proven
stable supply its wetted components provide superior chemi-
shat grounding technology to deliver complete
chain and ofers the industry’s most efective cal resistance in a wide range of applications. It
bearing protection in severe-duty applications.
sealing technology. Give us a call today! Watch features monolithic seal faces, a metallic frame
Proprietary conductive ilaments safely divert stray
for news about some exciting and revolutionary and seal components speciically designed for
shat currents—protecting your bearings, your
technologies launching soon! maximum repairability, while allowing material
coupled equipment and your bottom line.
upgrades when necessary. Its stationary design
Garlock Sealing Technologies Inpro/Seal and self-adjusting cushioned rotary face guarantee
1666 Division Street 4221-81st Avenue West perfectly aligned seal faces.
Palmyra, NY 14522 Rock Island, IL 61201 Advanced Sealing International (ASI)
Phone: 877-GARLOCK Phone: 309-787-4971 Baton Rouge, LA
Fax: 800-543-0598 Fax: 309-787-6114 Phone: 225-272-2155
Website: www.klozure.com Website: www.inpro-seal.com Website: www.advancedsealing.com
Email: earl.rogalski@garlock.com Email: info@inpro-seal.com Email: info@advancedsealing.com
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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 67
ANNUAL PRODUCT SHOWCASE SPECIAL ADVERTISING SECTION
Seals: Mechanical/Support Systems Seals: Mechanical/Support Systems Seals: Support Systems

Carbon Vanes

Helwig Carbon Products, Inc., has been manu-

facturing high-quality, long-running carbon and Wear Resistant Parts
HN 8-WD Plug with Sealing Formring
graphite bearings, bushings, seals, and vanes for r
*40

$FSUJđFE Our HN 8-WD screw plug with the integrated
over 40 years. We are ISO certiied, provide quick r
4FBM
SJOHT
QVNQ
CVTIJOHCFBSJOHT sealing ring stays tight all the time. Our customers
service and are American made. Our materials are r
.FDIBOJDBM
TFBMT in the automotive, drive technology, hydraulics
self lubricating; dry running; chemical, corrosion r
4JMJDPO
DBSCJEF
3#
4J$
BOE
44J$
and pneumatics industries know they can rely on
and oxidation resistant; have low wear rates and r
5VOHTUFO
DBSCJEF it. Pressure-resistant and easy to use. Heinrichs is
have a low coeicient of friction for maximum r
$BSCPO
HSBQIJUF ISO/TS 16949:2002-certiied and the preferred
performance. r
"MVNJOVN
PYJEF
"M0

supplier for many well-known companies all over
r
;JSDPOJVN
EJPYJEF
;JSDPOJB
the world.
Helwig Carbon Products, Inc. Junty Industries, Ltd. Heinrichs USA LLC
8900 West Tower Avenue No. 7 Bei Tu Cheng Xi Lu 1020 Arbor Tech Drive, Ste. J
Milwaukee, WI 53224-2849 Post Code 100029, Beijing, China Hebron, KY 41048
Phone: 414-354-2411 Tel: +86-10-8227 5326 Phone: 859-371-4999
Fax: 800-365-3113 U.S. Fax & Voicemail: +1-815-642-4953 Fax: 859-371-4899
Website: www.helwigcarbon.com Website: www.SealChina.com Website: www.heinrichs-usa.com
Email: info@helwigcarbon.com Email: info@sealchina.com Email: mail@heinrichs-usa.com

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Software Valves Valves

Flanged One-Piece PTFE Gate, Globe, Check Valves

CAE Simulation Tool
Magsot Corporation markets leading CAE simu-
lation tools for computing physical phenomena.
hese tools are used by manufacturers to accelerate
and manage precise design solutions for motors
and generators. Our Flux product is an FEM
sotware. It provides transient electromagnetic,
and electromechanical analysis for efective virtual
prototyping. Magsot Corporation builds relation-
ships with quality products, technical support,
training and consulting.
Magsoft Corporation
1 Fairchild Square
Clifton Park, NY 12065
Phone : 518-884-0505
Fax: 518-884-8688
Web: www.magsoft-flux.com
Email: fluxinfo@magsoft-flux.com
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68 DECEMBER 2010
Construction
Innovative, one-piece PTFE uniied body/lange
construction insures leak-free performance on
critical acid installations. Available for backpres- High pressure gate, globe and check valves are in
sure and pressure relief service in a complement of cast or forged steel to ASME B16.34 or API with
sizes for 10 to 250 psi pressure adjustment range. wear and corrosion resistant seats that are used
Grifco manufactures valve equipment, calibra- in power stations, general industry and process
tion columns and related accessories under ISO engineering.
9001:2008 registered quality standards to deliver
complete satisfaction with its “Made in USA”
products.
Griffco Valve Inc. KSB, Inc.
6010 N. Bailey Avenue, 1B 4415 Sarellen Road
Amherst, N.Y. 14226 Henrico, VA 23231
Phone: 716-835-0891 Phone: 804-222-1818
Fax: 716-835-0893 Fax: 804-226-6961
Website: www.griffcovalve.com Website: www.ksbusa.com
Email: sales@griffcovalve.com Email: sales@ksbusa.com
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www.pump-zone.com PUMPS & SYSTEMS
PUMP USERS MARKETPLACE
INDEX OF ADVERTISERS
Comprehensive Industry Coverage:
Advertiser Name R.S. # Page Advertiser Name R.S. # Page
Positive Displacement Pumps
Advanced Diamond Technologies 126 51 Junty Industries, Ltd. 234 68
Advanced Sealing International 107 43 KSB 253 68 Centrifugal Pumps
AE Pumps 133 69 Larox Flowsys Inc. 219 65 Specialty & Other Pumps
All Prime Pumps 134 70 Lovejoy 224 57
Industrial Valves
Blue-White Industries 108 26 LUDECA 225 56
Boerger, LLC 120 47 LUDECA 217 56 Pneumatic & Hydraulic Valves
Carver Pump Co. 109 8 Magsoft Corp. 232 68 Custom Research
Cole-Parmer 110 11 Meltric Corp. 202 60
Dan Bolen & Associates 135 71 MetPro Global Pump Solutions- White Papers
Frost & Sullivan 132 69 Dean Pump 209 67
FW Murphy 101 5 MetPro Global Pump Solutions-
General Pump 121 45 Fybroc 240 63
Hydraulic Institute 131 53 MetPro Global Pump Solutions-
Sethco 205 67
Hydro Inc. 100 IFC
MSE of Canada, Ltd. 256 59
InduMar 128 49
InfoSight 125 55 Muniflo 272 66
Inpro/Seal 102 BC Nidec Motor Corporation 215 60
ITT Goulds Pumps 122 35 Oberdorfer Pumps, Inc. 210 63
KSB 111 10 Oberdorfer Pumps, Inc. 241 65
LEWA Pumps & Systems 112 27 Palmetto Inc. 248 59
Load Controls, Inc. 113 29 Phoenix Contact 229 59
Meltric Corporation 136 69 PumpingSol 274 64
Phoenix Contact, Inc. USA 106 9 R+W Coupling Technology 227 57
Polaris Pumps 114 32 Racine Federated, Inc. 216 58
Pump Solutions Group 123 39 Ruhrpumpen 242 61
Pumping Machinery 148 71 seepex Inc. 273 65
Racine Federated, Inc. 116 28 Sims Pump Co. 276 62
Ruhrpumpen 103 7 SJE-Rhombus 213 59
Sandpiper 115 31 Smith & Loveless 237 64 Frost & Sullivan, the Growth Consulting Company, partners with clients to accelerate their growth. The company's

Scenic Precise Element, Inc. 137 70 SPX Flow Technology 264 62 Growth Partnership Services, Growth Consulting and Career Best Practices empower clients to create a growth

SEPCO 117 37 SPX Flow Technology 281 63 focused culture that generates, evaluates and implements effective growth strategies. Frost & Sullivan employs over 45

SEPCO 138 70 SPX Flow Technology 262 64 years of experience in partnering with Global 1000 companies, emerging businesses and the investment community

SERO Pump Systems 139 70 SPX Flow Technology 277 66 from more than 30 offices on six continents. For more information about Frost & Sullivan’s Growth Partnerships, visit

Shanley Pump & Equipment Inc. 129 49 SPX Flow Technology 278 66 http://www.frost.com.

SJE-Rhombus 124 44 TECO-Westinghouse 269 60

Skinner Power Systems, LLC 118 12 Tuf-Lok International 275 57
St Mary’s Foundry 119 41 VARNA Products 252 59
visit us on the web at www.frost.com
Summit Pump, Inc. 140 71 VARNA Products 261 64
Tel: 877.GoFrost (877.463.7678)
SuperBolt 127 51 VARNA Products 221 64 Email: david.escalante@frost.com
Synchrony, Inc. 104 3 Verder Ltd. 251 65
VibrAlign 258 56
T.A.W., Inc. 141 71
VibrAlign 257 56
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Tamer Industries 142 70
Trachte, USA 143 71 VibrAlign 259 56
Trask-Decrow 144 70 VibrAlign 266 57
Tuf-Lok International, Inc. 145 71 VibrAlign 267 57
Vaughan 105 IBC Walchem, Iwaki America Co. 282 63
Vertiflo 146 71 Wilden Pump & Engineering 201 62
Vesco 147 71 Yamada America 204 62
Water Quality Association 130 53 Yaskawa America, Inc. 223 61
* Ad index is furnished as a courtesy and
Product Showcase no responsibility is assumed for incorrect
Advanced Sealing International 271 67 information.
Alignment Supplies Inc. 235 56
Aurora Motors 260 60
Baker /Haight Pump 220 61
BaseTek 211 57
Blue-White Industries 222 64
Boerger, LLC 243 66
Chicago Industrial Pump Co. 233 67
Cole-Parmer 212 61
Colfax Corp. 279 65
Decatur Foundry 249 61
Dickow Pump Co. 239 63
DISCFLO 245 60
DISCFLO 283 63
Dwyer Instruments Inc. 206 58
Fairbanks Morse Engines 238 58
Faribanks Morse Pump 268 61
FW Murphy 218 58
Garlock Sealing Technologies 207 67
General Pump 208 62
GIW Industries 270 66
Gorman-Rupp Co. 284 66
Graco, Inc. 214 62
Graco, Inc. 246 65
Greyline Instruments Inc. 231 58
Griffco Valve Inc. 236 68
Harmsco Filtration Products 203 58
Heinrichs USA LLC 228 68
Helwig Carbon Products 247 68
InduMar 226 59
InfoSight 250 60
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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 69

PUMP USERS MARKETPLACE
For informa on:
(800) 803-0353
www.allprimepumps.com
All Prime self-priming centrifugal pumps are marketed in the
United States, Canada & Mexico exclusively by the All Prime
Division of Power & Pumps Inc., Jacksonville Florida. Based
on the design of Gorman-Rupp’s T SERIES® & U SERIES®,
these pumps are available as bare pumps, parts, base
mounted and assembled fiberglass lift station units.
Materials of construction available include Cast-Iron, CD4MCu,
316-SS, 304-SS, ADI, Hastelloy & High-Chrome.
T SERIES® & U SERIES® are trademarks and registered trademarks of The Gorman-Rupp Co. in the
US & other countries. All Prime is not sponsored by nor affiliated with The Gorman-Rupp Company.

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The Best of
Both Worlds
Gorman-Rupp Quality with
Trask-Decrow Support!

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1-800-287-1538
1 800 287 1538
www.trask-decrow.com
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70 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

PUMP USERS MARKETPLACE

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Vesconite Hilube
Pump Bearings
G Can run dry
G Increase MTBR Theory Hands-On Live Performance Testing
G Avoid shaft Next Pump School Session
seizures December 16-17, 2010
EVERYTHING YOU EVER WANTED TO KNOW ABOUT PUMPS
Tollfree 1 866 635 7596 For more information go to
vesconite@vesconite.com
www.vesconite.com www.PumpingMachinery.com
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Employment

EXECUTIVE SEARCH/RECRUITING

“Serving the Pump & Rotating

Equipment, Valve, and Industrial
Equipment Industry since 1969”
Domestic & International

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Specializing in placing:
• General Management
• Engineering
• Sales & Marketing
• Manufacturing
DAN BOLEN • JASON SWANSON
CHRIS OSBORN • DAN MARSHALL
9741 North 90th Place, Suite 200
Scottsdale, Arizona 85258-5065
(480) 767-9000 • Fax (480) 767-0100
Email: danbolen@mindspring.com
www.danbolenassoc.com
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PUMPS & SYSTEMS www.pump-zone.com DECEMBER 2010 71

 P&S Stats and Interesting Facts
Plant Capacity Utilization by Industry
90.00%

85.00%

80.00%

75.00%

Chemical

70.00% Mining
Paper
Food, Beverage and Tobacco

Petroleum and Coal Products

65.00%
Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10
Source: Federal Reserve Statistical Release

Month-to-Month Percentage Price Change

in Pumps and Compressors
0.80%

Pump and Pumping Equipment Manufacturing

Air and Gas Compresor Manufacturing

0.60% Pump and Compressor Manufacturing

0.40%
Photo Courtesy of Chicago Industrial Pump Company

0.20%

0.00%

-0.20%

-0.40%
Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10

he Producer Price Index program of the U.S. Department of Labor measures the average change
over time in the selling prices received by domestic producers for their output. hese charts detail
the month-to-month percentage change in selling prices. Source: U.S. Department of Labor

Rig Count (U.S.): Jan. 7 – Nov. 16, 2010 Average Fuel Prices (U.S.)
1800 $3.20

1700 $3.10

$3.00
Number of Rigs Running

1600

$2.90
1500

$2.80
1400

$2.70

1300

$2.60

1200
$2.50

1100 Average Price of Gasoline

$2.40
Average Price of Diesel Fuel

1000 $2.30
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10

Source: Baker-Hughes Inc.

Week Source: Energy Information Administration

72 DECEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

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 SAME-
SHIPP
ING
DAY
AVAIL
AB LE

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