Pumps & Systems Nov2017

N OV E M B E R 2 0 17
PUMPSANDSYSTEMS.COM
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FLOODING SIPHONING 101 HARMONICS
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4
This issue NOVEMBER Volume 25 Number 11
COVER COLUMNS
SERIES CHEMICAL PUMPS N OV E M B E R 2 0 17
PUMPSANDSYSTEMS.COM
SYSTEMS
PUMP SYSTEM IMPROVEMENT
39 HANDLE ABRASIVE 14 By Ray Hardee
CHEMICALS WITH THE RIGHT Engineered Software Inc.
PUMP DIAPHRAGM
Streamlining Nuclear Reactor
By Michael Brooks,
System Balancing
Garlock Sealing Technologies
Depending on the type of material COMMON PUMPING MISTAKES
being handled, especially the
CHEMICAL amount of abrasives and solids,

ePTFE could be the best
diaphragm material.
18 By Jim Elsey
Summit Pump Inc.
PUMPS
What a Drag: Effects of Fluid Viscosity on
Centrifugal Pumps
43 NEW DESIGNS ENHANCE
& Advanced Designs METERING PUMP HIRING
EFFICIENCIES
By Axel Bokiba, 24 By Pumps & Systems Editors
Pulsafeeder Shannon Baity, PMQ Engineer
PTFE diaphragms can serve in
even more applications now.
SIPHONING 101
2
FLOODING HARMONICS
FROM THE EDITOR
46 CHEMICAL MANUFACTURER SAVES $70,000 PER YEAR WITH
SUBMERSIBLE SHREDDER PUMPS
By Ben Stolt, Tencarva Machinery & Steve Mosley, BJM Pumps 8 NEWS
How one company fixed constant pump failures
12 TRADE SHOW PREVIEW
49 IIOT IN CHEMICAL PUMPING 90 PRODUCTS
By Todd Loudin, Flowrox
Digital twin technology and packaged pump systems can be smart solutions. 92 ADVERTISERS INDEX
52 CHEMICAL PUMPING WITH ELECTRIC DIAPHRAGM PUMPS 92 PUMP USERS MARKETPLACE
By Jeff Shaffer, Graco
This equipment is another tool in a pump users toolbox. 96 PUMP MARKET ANALYSIS
SPECIAL
63 DEWATERING PRESENTS
CHALLENGES IN CONSTRUCTION
63
REPORT By Joe Cherlucks,
Mersino Dewatering Inc.
PUMPS IN HARSH Companies sould gather data and
CONDITIONS implement systems to keep job sites
dry so contractors can complete their
work on time and within budget.
57 PROTECTING PUMPS & SYSTEMS
IN OIL & GAS OPERATIONS
By Kevin Bates, 67 CONSIDERATIONS IN FLOW
JWC Environmental METER SELECTION
By Brian Kettner,
Grinder manufacturers adapt for a BADGER METER
new kind of environment.
Last of Two Parts
November 2 0 1 7 | Pum p s & S y st e m s

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6
This issue NOVEMBER
GROUNDWATER
& STORMWATER
SPECIAL
SECTION
26 VALVES CAN STOP SURGES & 36 EMERGENCY AVERTED AT

PREVENT PIPE BURSTS POWER PLANT HOLDING POND
By Mark Strijack, Singer Valve By Tripp Brown, United Rentals &
David Haas, Cornell Pump Company
These valves can alleviate a variety of
pump system issues. Rental pump provides a temporary fix
to avoid spill.
34 FLOOD EVENT PROMPTS
PORTABLE BACKUP SOLUTION
FOR POTABLE WATER NETWORK
N OV E M B E R 2 0 17
PUMPSANDSYSTEMS.COM
SYSTEMS
ON THE COVER
By Chris Bauman, Xylem & Cover photo
Jason Fox, Central Service courtesy KSB
and Supply CHEMICAL
Trailer mounted equipment with diesel PUMPS
& Advanced Designs
engines and advanced controllers give
34
SIRWA an advantage.
FLOODING SIPHONING 101 HARMONICS
DEPARTMENTS 79 GUEST COLUMN 85 HI PUMP FAQS

Siphons and the Siphon Effect: Throttling Valves & Pump
That Sucking Sound Corrosion Issues
70 MAINTENANCE MINDERS By Joe Evans, Ph.D. By Hydraulic Institute
Rotor Rubbing in a Pump
By Amin Almasi, 79 MOTORS & DRIVES
5 Ways to Reduce Harmonics 87 FLOW METER
Rotating Machinery Consultant
Infographic How to Make the Most of Smart
Flow Meters
By EATON SOLUTIONS
73 EFFICIENCY MATTERS By Larry Bachus, PumpGuy &
Pump Rebuild Boosts Efficiency Jerry Spindler, Endress+Hauser
& Max Flow 82 SEALING SENSE
By Loren Nauss, Henkel Controlling the Seal Chamber
Environment
By Mark Savage,
FSA Member, John Crane
EDITORIAL ADVISORY BOARD

THOMAS L. ANGLE, P.E., MSC, Vice BOB DOMKOWSKI, Business TODD LOUDIN, President/CEO North SCOTT SORENSEN, Oil & Gas
President Engineering, Hidrostal AG Development Manager Transport American Operations, Flowrox Inc. Automation Consultant & Market
BRYAN S. BARRINGTON, Machinery Pumping and Amusement Markets/ MICHAEL MICHAUD, Executive Developer, Siemens Industry Sector
Engineer, Lyondell Chemical Co. Engineering Consultant, Xylem, Inc., Director, Hydraulic Institute ADAM STOLBERG, Executive Director,
Water Solutions USA Flygt Submersible Wastewater Pump
RUSSELL SMITH, Business Dev. JOHN MALINOWSKI, Senior Manager
Manager - Wastewater, Grundfos WALT ERNDT, VP/GM, CRANE Pumps of Industry Affairs, Baldor Electric Association (SWPA)
Americas Corporation & Systems Company JERRY TURNER, Founder/Senior
R. THOMAS BROWN III, President, JOE EVANS, Ph.D., Customer & WILLIAM E. NEIS, P.E., President, Advisor, Pioneer Pump
Advanced Sealing International Employee Education, PumpTech, Inc. Northeast Industrial Sales DOUG VOLDEN, Global Engineering
(ASI) LARRY LEWIS, President, Vanton LEV NELIK, Ph.D., P.E., APICS, Director, John Crane
CHRIS CALDWELL, Director of Pump and Equipment Corp. President, PumpingMachinery, LLC KIRK WILSON, President, Services &
Advanced Collection Technology, WILLIAM LIVOTI, Business HENRY PECK, President, Geiger Pump Solutions, Flowserve Corporation
Business Area Wastewater Solutions, Development Manager/Energy & Equipment Company JAMES WONG, Associate Product
Sulzer Pumps, ABS USA Efficiency Specialist, WEG Electric Manager Bearing Isolator, Garlock
Corporation MARIANNE SZCZECH, Director,
JACK CREAMER, Market Segment Global Marketing and Product Sealing Technologies
Manager Pumping Equipment, Management, Pump Solutions Group
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8 NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
BRAD STEVENS, QUANTUMFLO Eckert has more than two decades of financial experience. Before
DEBARY, Fla. Brad Stevens brings more than joining CHC Group LLC, he served as chief financial officer of the U.S.
10 years of commercial plumbing, HVAC and division of National Grid Plc. In addition, he served in various executive
energy efficiency experience to QuantumFlo. His capacities at MeadWestvaco Corporation, including vice president of
background consists of successful solutions-based, operations and healthcare, and chief financial officer of the Packaging
consultative and energy performance contracting Resource Group. He also served in senior finance roles at Electronic Data
(EPC) outside sales in both the commercial Systems (EDS) and General Electric (GE). flowserve.com
and municipal sectors. As a new regional sales Brad
manager for QuantumFlo, Stevens will be focused Stevens PAULO RUIZ STERNADT, SIEMENS
on growing the companys customer-base in the expansive mountain HOUSTON Paulo Ruiz Sternadt has been appointed
and western markets by implementing a proven track record of strong CEO of the Dresser-Rand business, part of Siemens
relationship-building skills, responsiveness and a dedication to both Power and Gas Division. He succeeds Judith Marks,
professional business development and account management. He who leaves the company at her own request.
received his educational and professional management certification in Ruiz Sternadt brings to this position extensive
business administration and human resources from California Lutheran leadership experience including more than 16
University in Thousand Oaks and was a facilities manager there for more years with Siemens in multiple global roles in the Paulo Ruiz
than eight years during his early career. quantumflo.com U.S., Germany, Mexico and Brazil. He most recently Sternadt
was executive vice president of Global Solutions for the Dresser-Rand
ALAN SHULTICE, VENTURE PLASTICS business and a member of its executive staff. In this role, he was
ORLANDO, Fla. Venture Plastics Inc., a full-service, responsible for creating new business opportunities and delivering
certified custom thermoplastics injection molder solutions to customers for the Dresser-Rand business, which will serve
with processing facilities in Newton Falls, Ohio, and the business well in the future.
El Paso, Texas, has promoted Alan Schultice to the Before joining Dresser-Rand, Ruiz Sternadt held a number of senior
position of director of commercial sales. global business leadership roles at Siemens Energy Management
Prior to his promotion, Schultice held the position Division in markets around the world. This experience provides valuable
of sales account manager of Venture Plastics for Alan perspective to the Dresser-Rand business as energy markets continue to
10 years. Prior to joining Venture, Schultice had 20 Shultice integrate along the value chain. dresser-rand.com
years of experience in the plastics industry as a general manager and
production supervisor for several plastic molding and tooling operations COLIN SABOL & MATTHEW LATINO, XYLEM
in Ohio and Florida. RYE BROOK, N.Y. Xylem Inc. announced that Colin
Alan Schultice has positively contributed to our growth for the past Sabol has been named Xylem senior vice president
10 years as a sales account manager. We are really looking forward to and president of Sensus & Analytics. Sabol succeeds
his continued success as director of commercial sales, Venture Plastics Randy Bays, who will move into an advisory role with
president Steve Trapp said. This role will be critical for our organization, a focus on Xylems global manufacturing operations.
especially as we expand in the next couple of years to meet the growing Xylem combined its Sensus and Analytics
demand from new and current customers. ventureplastics.com businesses effective second quarter 2017, and now Colin
reports the financial and operational results from Sabol
LEE ECKERT, FLOWSERVE these businesses as one segment.
DALLAS Flowserve Corporation announced that Lee Eckert will join This change brought together Xylems broad portfolio of advanced
Flowserve as senior vice president and chief financial officer. Eckert joins sensing technologies and solutions sold under brands such as Sensus,
Flowserve from CHC Group LLC., a global commercial helicopter service YSI, WTW, Tideland and Visenti. This portfolio of solutions addresses a
provider to the offshore oil and gas industry, where he served as senior wide range of monitoring and analytics needs across the water cycle
vice president and CFO since 2015. and in electric and gas utilities.
I am pleased to welcome Lee to the Flowserve executive leadership Xylem Inc. also announced that Matthew Latino has been named
team, said Scott Rowe, Flowserve president and chief executive officer. director, Investor Relations. In this role, he will be responsible for leading
Lee has a strong foundation in operational and manufacturing finance the companys investor relations program, providing the investment
and accounting, which will lend itself well to a smooth transition into community with an accurate presentation of Xylems strategy, business
our global manufacturing environment. performance and growth plans. Latino most recently served as manager
This experience will allow him to have an immediate impact on of investor relations for the company. He will continue to report to Xylem
improving and driving consistent and sustainable financial results for senior vice president and CFO Mark Rajkowski, and be based in Rye
Flowserve and our shareholders. Brook, New York. xylem.com
Nov ember 2 0 1 7 | Pum p s & S y st e m s

9
EVENTS
ADIPEC
November 1316
Abu Dhabi
adipec.com
NGWA Groundwater Summit

December 57
Music City Center
Nashville, Tennessee
groundwatersummit.com
Power-Gen
December 57
Las Vegas Convention Center
Las Vegas, Nevada
power-gen.com
Rescheduled
46th Turbomachinery & 33rd
International Pump Users
Symposia (TPS 2017) THE SOLUTION FOR
December 1214
George R. Brown Convention Center
ALL YOUR PUMP
Houston, Texas AND COMPRESSOR
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January 30February 1
Georgia World Congress Center
Atlanta, Georgia
ippexpo.com
WQA Aquatech
March 26-29
Colorado Convention Center
Denver, Colorado For more information on our product
630-505-0160
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p u m p s a n d s y s te ms . co m | Nov ember 2017

10 NEWS
AROUND THE INDUSTRY

HI Launches its First Flow requirements are often overstated Members of the TRA CReWSers are:
Personnel Certification when specified and components can be David Brown, Dale Burrow, Raudel Juarez,
Program for Pump Systems oversized to ensure requirements are Quintin Winters, and Jake Burwell (coach).
met. These inefficiencies add up to a lot Members of Aqua Techs are: Edward
Assessment Professionals
of potential waste in a system and create Burrell (coach), Kevin Willey (captain),
PARSIPPANY, N.J. Pumping systems
opportunities not only to improve the Ryan Brunette, Christian Mendez, and
account for more than 40 percent of
overall system performance but lower Ernesto Romero.
industrial energy usage, revealing a vast
maintenance costs and increase uptime One of the most anticipated events
industry need for more reliable and more
and overall system reliability, he said. during WEFTEC, Operations Challenge is a
energy efficient systems. In response, the
By pursuing the PSAP, individuals unique and fast-paced test of the essential
Hydraulic Institute (HI) developed the PSAP
can advance their career and become a skills needed to operate and maintain
certification program to provide pump
stronger asset to their organization. For wastewater treatment facilities, their
end-users and other stakeholders with a
certified individuals, the PSAP program: collection systems, and laboratoriesall
means to assess complicated systems with
assures organization and/or clients vital to the protection of public health and
highly qualified, certified pump system
that the certified individual has the environment. This years competition
assessors. The certification program sets
the required knowledge and skills included 44 teams from the U.S., Canada,
the standard for the knowledge, skills and
to perform a comprehensive pump and Argentina and Denmark.
abilities necessary for performing pump
system assessment Over the past 30 years, Operations
system assessments and utilizing pump
validates field expertise and Challenge has grown from the original
system optimization techniques.
aligns knowledge with industry 22-team event to this years 44-team,
The PSAP program addresses a
best practices two-division format. Teams are judged on
key market need in the industrial and
enhances career opportunities and a the best combination of precision, speed
commercial marketplace, said Michael
commitment to continuous learning and safety. The winners are determined
Michaud, executive director of Hydraulic
Institute. Energy and maintenance costs by a weighted point system for five events
Applicants must have a minimum of including collection systems, laboratory,
combine to represent some 65 percent of
three years of pump/pumping system maintenance, safety and process control.
the total cost of ownership of a medium-
experience and possess an undergraduate This years process control event was
size industrial pumping system. A thorough
degree from an accredited university revised to include the installation of an
system assessment often identifies energy
or college in a technical/business field. Insetra Tee compression fitting, provided
efficient upgrade opportunities that
Applicants may also possess five or more by Advanced Drainage Systems.
usually pay for themselves in less than a
years of direct industrial or commercial Winners in both divisions include:
year, lowering overall energy costs while
fluid transfer/pumping systems experience
increasing reliability, reducing downtime
having completed a minimum of seven Division 1
and maintenance costs. The key to
pump system assessments. After an First Place: TRA CReWSers
unlocking the savings starts with a holistic
application is accepted by HI, candidates Water Environment Association
assessment from a professional who can
sit for a 3.5 hour proctored exam. of Texas
assess and optimize the overall system.
HI is currently accepting applications. Trinity River Authority, Dallas, Texas
Corporations gain a competitive edge
To learn more about the PSAP Second Place: L.A. Wrecking Crew
by employing PSAPs and performing
certification program or to apply, visit California Water Environment
more pump system assessments. For
pumps.org/psap pumps.org Association
corporations, the PSAP program:
increases the value of corporate Sanitation Districts of Los Angeles
capabilities TRA CReWSers, Aqua County, Whittier, Calif.
validates employee knowledge and Techs Win 2017 WEFTEC Third Place: OCWA Jets
experience by the pump industry Operations Challenge Water Environment Association
authority CHICAGO Two teams from Texas clinched of Ontario
ensures the highest level of system first place in their respective divisions Ontario Clean Water Agency,
assessments are being performed during the 30th annual Operations Stratford, Ontario
Challenge competition. TRA CReWSers
According to Edgar Suarez, technical won Division 1, and Aqua Techs took Division 2
program manager of Hydraulic Institute, home the top prize in Division 2. Both First Place: Aqua Techs
PSAPs are professionals who distinguish teams represent the Water Environment Water Environment Association of
themselves as true experts in assessing all Association of Texas. The fun-filled, Texas
types of pumping systems, adding that, high-energy event took place at WEFTEC Dallas Water Utilities, Dallas, Texas
examining system interactions means 2017the Water Environment Federations Second Place: Jamaica Sludge Hustlers
looking beyond the individual components 90th annual technical exhibition and New York Water Environment
to identify inefficiencies. conferencein Chicago. Association
To have a news item considered, please send the information to Georgia Duke, gduke@cahabamedia.com.

12 NEWS
AROUND THE INDUSTRY Preview:

New York Department of Environmental Protection,
Brooklyn, N.Y.
Third Place: Controlled Chaos
Chem Show
Water Environment Association of South Carolina October 31-November 2
Mount Pleasant Waterworks, Mount Pleasant, S.C.
wef.org
Javits Center
New York City
WEF Announces 2017-2018 Board of Trustees
ALEXANDRIA, Va. The Water Environment Federation (WEF)
T
announced its 2017-2018 Board of Trustees as confirmed by WEFs
House of Delegates during WEFTEC 2017 in Chicago and led by
he Chem Show is where Exhibition Hours
2017-2018 President Jenny Hartfelder. engineers, plant manag-
Tuesday, Oct. 31
At a ceremony on October 3, the WEF gavel of leadership was ers and other CPI personnel
10 a.m. 5 p.m.
passed from President Rick Warner (Reno, Nevada) to incoming come together to see the latest
President Jenny Hartfelder, who is currently a vice president with equipment and technology,
MWH, now a part of Stantec, and serves as a national campaign Wednesday, Nov. 1
meet product experts, and
manager out of Denver, Colorado, where she provides strategic 10 a.m. 5 p.m.
planning and leadership for the business development activities for discover new ways to optimize
the water sector across the United States. their plant operations. Bring-
Thursday, Nov. 2
During her year as WEF president, Hartfelder will continue to help ing together more than 5,000
fulfill the federations strategic direction and critical objectives 10 a.m. 3 p.m.
industry professionals and 300
to connect water professionals, enrich the expertise of water
exhibiting companies, the show
professionals, increase the awareness of the impact and value of
water, and provide a platform for water sector innovation. is the largest North American event exclusively focused on
This past year, we have made great progress on WEFs the processing of fluids, powders and gases. Held every odd
objectives, Hartfelder said during her acceptance speech. In this year since 1915, the Chem Show has a proven track record of
next year, I want to focus our efforts on increasing the awareness helping the CPI meet the ongoing demand for faster, smarter,
of the value of water, and I am very excited to have this opportunity
cleaner, and more efficient processing facilities. For more
to continue to work with all of you to make a positive impact on the
water industry. information or to register, visit chemshow.com.
In addition to Hartfelder and Warner, the complete 2017-2018
Board of Trustees includes: President-Elect Tom Kunetz (Chicago,
Illinois), Vice President Jackie Jarrell (Charlotte, North Carolina),
Treasurer Jamie Eichenberger (Denver, Colorado), and Secretary Preview:
Groundwater Week
and WEF Executive Director Eileen ONeill (Alexandria, Virginia).
Trustees are Lynn Broaddus (Wauwatosa, Wisconsin), Joan Hawley
(Muskego, Wisconsin), Claus Homann (Aarhus, Denmark), Mark
Poling (Hillsboro, Oregon), Peter Vanrolleghem (Quebec City, December 5-7, 2017
Canada) and Ifetayo Venner (Tampa, Florida). wef.org
Music City Center
Hydro Announces New Texas Facility Nashville, Tennessee
HydroTex, a subsidiary of Hydro Inc. announced the move of its
Deer Park operation to a new 33,000 square foot building in La
T
Porte, Texas. The new service center will offer expanded capacity
for analysis, engineering, rebuilding and repair services for pump he National Ground Water Exhibition Hours
systems and rotating equipment as well as climate controlled Associations (NGWA)
Wednesday, Dec. 6
storage of pumps and parts. Located near the busy Houston Groundwater Week 2017
Ship Channel, the new facility is situated to serve the needs of 11 a.m. 5 p.m.
will take place in Nashville
surrounding industries using pumping equipment of any capacity. December 5-7. The groundwa-
Hydro Inc. provides pump engineering and repair technology Thursday, Dec. 7
with service centers throughout the world. The company has 48 ter industrys annual event
11 a.m. 5 p.m.
years of experience servicing industries including oil and gas, showcases cutting-edge tech-
nuclear and combined cycle. hydroinc.com nology while offering educa-
tional sessions presented by industry experts. In addition to
MERGERS & ACQUISITIONS exhibits, there is also a hands-on activity area, 50 hours of
educational opportunities and networking events.
This years NGWAs technical conference, the Groundwater
SUEZ acquires GE Water Process Technologies October 2, 2017
Summit, is taking place alongside Groundwater Week.
Gulf Electroquip aliate acquires Hyundai Ideal Electric Company Attendees of the Groundwater Summit can also attend,
September 13, 2017 at no extra cost, Groundwater Week activities. For more
information or to register, visit groundwaterweek.com.

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14 PUMP SYSTEM IMPROVEMENT
A better understanding of complete system operation
By Ray Hardee
Engineered Software Inc.
Streamlining Nuclear Reactor System Balancing

Figure 1. The component cooling water (CCW) system (Courtesy of the author)
I
n this months Pumps &
Systems column, we will look
at how simulating a large heat
transfer system balance found in
many industrial plants can be used
to streamline plant operations. The
system balancing ensures each heat
exchanger is receiving the proper
flow rate and pressure needed for
the system to operate properly.
Early in my career, I worked
as a startup and test engineer at
Millstone Power Station Unit 2 for
Northeast Utilities. Millstone 2
was a Combustion Engineering 870
MWe nuclear power plant, and was
much larger that the plants I had
worked on in the Navy.
One of the first preoperational
tests I was involved in was
balancing the Component Cooling
Water (CCW) system for Millstone
Unit 2. The system had a normal
operating mode in which cooling system also had to be balanced for positions. After all the balancing
water was supplied to various off-normal operation in the event valves were set to the prescribed
heat generating equipment in the of an accident. positions, plant test data was
reactor compartment and auxiliary The CCW system was large, collected for further analysis.
machinery spaces. The system had encompassing multiple pumps, The results of the nightly tests
Nuclear Regulatory Commission heat exchangers, control valves were compiled and sent to Bechtel
(NRC) licensing requirements to be and pipelines covering most of Power in Gaithersburg Maryland,
operational when the reactor was the plant. Since this was a safety- which was the A&E firm for Unit
producing power and when it was related system, the CCW balancing 2. Their engineers reviewed the
shut down. In addition, the system had to be completed prior to the results to determine the flow rates
was designed to automatically NRC issuing an operating license, through each of the CCW heat
provide cooling water to specific which would allow the loading loads. Based on the test results
equipment during an off normal of radioactive fuel. The test was they would generate a new table
(post-accident) condition. planned to take approximately 10 with the adjusted valve positions
Once all the equipment in the days, with the actual plant testing for each balancing valve to achieve
CCW system was tested, the entire to occur during the swing shift the designed flow rate.
system was placed in operation and and midnight shift. The testing The CCW system was a network
then balanced so that each heat required most of the operational of looped loads, and changing the
exchanger received the designed staff to operate the equipment, and position of any of the balancing
flow rate and pressure required a group of test engineers to set the valves affected the flow rates to all
for proper system operation. The balancing valves to their prescribed the loads. Each night, we would
November 2017 | Pumps & Systems

16 PUMP SYSTEM IMPROVEMENT
adjust the balancing The CCW system was a network I asked how well
valves in the CCW that worked. He said
system to the new of looped loads, and changing that by setting the
positions and then the position of any of the balancing valves
re-run the test, compile for each loop to the
the results and submit balancing valves affected the calculated position,
them to the engineers flow rates to all the loads. they were able to
in Bechtel. balance the entire
The above process system with just one
was continued until the change and completed the entire
Going Full Circle
system was balanced and the flow system in one day.
A few years later, I was conducting
rate through each heat exchanger
a training class on the use of
was at its designed value. This test Conclusion
our simulation software. One
took approximately eight days Most industrial processes have
of the course attendees was a
to complete with many different multiple piping systems to remove
test engineer that I worked with
iterations. Since it needed to be excess heat from operating
complete prior to the issuance of from my Millstone days. For 10
equipment, provide chilled water
the plants operating license by the years, he worked for Combustion and hydronic heating for HVAC
NRC, it received the highest level Engineering and was involved
systems or use heat tracing
of interest and scrutiny from the with balancing CCW systems for to warm fluids to operating
management team. numerous nuclear plants. He was conditions. Each of these systems
working as the lead engineer for an needs to be balanced so each load
Fast Forward operating nuclear power plant. meets its designed flow rate. If
After 10 years of starting up and During the class, one of the the system is balanced by hand,
testing power plants for EBASCO attendees asked what was the then multiple iterations must be
Services, I decided to try something maximum number of pipelines the performed to balance the system
new. I became a co-founder of software could simulate. I stated to the design values. Often, the
Engineered Software in 1982. there were no program limits and system will operate with throttling
PIPE-FLO was our first program to asked the attendees to comment valves open further than required
help simulate the operation of fluid on the largest system they had to balance the system. This reduces
piping systems. modeled. My friend from Millstone the need to balance the system,
As time went on, more features mentioned that he had created a but it requires a greater flow rate
were added to the program to allow model of their entire CCW system than needed, which increases the
for the simulation of larger fluid to help balance the system. systems energy cost and reduces
piping systems. After sharing our mutual the future capacity of the system.
During a support call, one of experience with balancing the By employing a simulation of
our customers at a nuclear plant Millstone CCW system, he the piping system, the position of
mentioned they were modeling mentioned that he used the model the systems balancing valves
their plants CCW system with to balance his current plants CCW can be calculated during the first
our piping simulation program. system. After entering data for pass, greatly streamlining the
They needed to meet the needs of the piping system model, he set balancing process.
an NRC-mandated study of the the flow rates through each heat
plants cooling water system. After exchanger using a throttling valve. Ray Hardee is a principal founder
a few months, I followed up with The simulation calculated the of Engineered Software, creators
our customer at the nuclear power differential pressure across each of PIPE-FLO and PUMP-FLO
plant and asked about their CCW throttle valve in the CCW system software. At Engineered Software,
study. They mentioned that they to achieve the designed flow rate. he helped develop two training
modeled their entire CCW system, Using the information provided courses and teaches these courses
and using the software they could by the supplier of the balancing internationally. He may be reached
effectively communicate the results valves, he calculated the valve at ray.hardee@eng-software.com.
of their system study to the NRC. position of each balancing valve.
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18 COMMON PUMPING MISTAKES
Simple solutions for end users
By Jim Elsey
Summit Pump Inc.
What a Drag: Effects of Fluid Viscosity on

Centrifugal Pumps
A
frequently stated a pumps efficiency in conjunction BEP). The down side was that
expression around the with marked reductions in head as viscosity increased the
pump industry is that and flow. The net result is an reliability diminished. This
viscosity is the Kryptonite of increase in the brake horsepower was mostly due to the effect of
centrifugal pumps. Pardon the required for the driver. the Reynolds number in the
allusion to Superman, but it is formula calculations.
a reference most of us not only Viscosity Corrections 3. Hydraulic Institute original
relate to, but also understand. All centrifugal pump performance method using viscous
Further, viscous fluids do have a curves are based on pumping correction charts to obtain
negative and weakening effect on water, unless stated otherwise. viscous correction factors (for
centrifugal pump performance. When I started in the pump head, flow and efficiency). The
Viscosity is a measure of a business, there were no computer method was an improvement
fluids resistance to flow at a given programs to cipher the necessary over previous ones because of
temperature. You can also think of viscosity corrections and the the ease, accuracy and wide
it as fluid friction. A more technical manual methods could take hours range of applicability. For
definition would explain viscosity to complete. With the advent of people who have been in the
as a force required to move a liquid computerized programs for pump business for some time, it would
plane (think plate) of some unit selection, it is now simple to be prudent to review the newer
area, over some distance above correct the pumps performance methods presented by the
another plane of equal area in a for viscosity in one keystroke, but Hydraulic Institute (Refer to
defined time period. In training we often overlook the details and ANSI/HI guideline 9.6.7-2010).
classes, I simply define viscosity effects of what viscosity changes The new method uses a formula
as a fluids resistance to pour but, do to the pump performance and called parameter B to yield
more importantly, a resistance to especially the required brake viscous correction factors. The
be pumped. horsepower. newer method also eliminates
Isaac Newton was probably Prior to computer programs, some of the confusion and
the first person we know to there were basically three methods inaccuracy in the 100 gallons
quantitatively define a coefficient to correct a centrifugal pumps per minute (gpm) range.
of viscosity. His concept and performance from water to viscous.
related work was not completed, 1. The A.J. Stepanoff model was Corrections to Pump Curves
but was later refined by Jean viable at the best efficiency In a perfect world, a centrifugal
Leonard Marie Poiseuille (see point (BEP) for head and flow pump performance curve would
Poiseuille s Law). but reliability and validity actually be a straight line, but in
diminished with increased the real world, it is curved due
Why are we concerned departure from the BEP. to losses in the pump. The major
about viscosity in regards to 2. The Paciga method was slightly factors are a combination of
centrifugal pumps? better than the Stepanoff mechanical, leakage, shock and
Mainly because viscosity has model because it could be more disc friction losses. Disk friction
such an extraordinary and often accurate across a wider range of is the major contributor and most
negative effect on centrifugal flows. Paciga had incorporated important factor when quantifying
pump performance. An increase in specific speed and a flow ratio the losses. The curves as mentioned
viscosity will dramatically reduce (actual flow as compared to are based on water performance,

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but with applications on viscous short answer is that it depends. fluids in excess of 1000 centipoise.
fluids those water curves must be A better and less fl ippant answer If your application is above 250
corrected for the viscosity to be is to consider the reduction in centipoise, I recommend you work
accurate. The head, flow, efficiency pump efficiency (also head and with your pump manufacturer/
and brake horsepower (BHP) flow) and calculate the maximum vendor to arrive at the answer. The
curves will all require modification required and corrected horsepower two important points to take into
(viscous corrections). (hp) for the viscous fluid. Several consideration are these:
references limit centrifugal pumps 1. There is a torque and hp limit
At what minimum value of to a maximum of 3,000 centistokes. for the pump shaft that will
viscosity to start corrections? (Note that this limit is also be negatively impacted with
The pump manufacturer is the published as 3,300 centistokes.) an increase in viscosity. Make
best source for this value, as it There is an older technical sure to check this viscosity
will depend on the application, paper on the subject by C.E. correction factor to ensure
fluid personality and the pump Petersen (delivered at the Pacific a satisfactory and reliable
geometry. Note that at 100 Energy Association conference in installation.
centipoise, the viscous effects will September 1982). Mr. Petersen 2. You may still be able to pump
be significant. I will state that at presents an argument that the highly viscous fluid with
30 to 40 centipoise or greater, you the maximum viscosity can be the centrifugal pump, but there
should use the corrections or risk calculated by the size of the pump will be a point of diminishing
adverse effects. I also recommend discharge nozzle. returns due to reduced
that somewhere in the area of 5 to Mr. Petersen postulated a efficiency. Perhaps you are using
10 centipoise, you must at least be formula as follows: 25 hp to pump the viscous fluid
aware and conscious of the effects I would only use this formula as a with a centrifugal pump that
however minor. would only require 5 hp with a
Since checking the correction positive displacement pump.
Vmax = 300 (D-1)
curves is so easy these days it would
be unwise not to check. Equation 1 Horsepower/Torque
All pump shafts have a speed,
Impeller Shape & Size Effects Where: horsepower and torque limit. In
The lower the specific speed (Ns) Vmax = the maximum the case of single stage pumps
of an impeller, the higher the disc kinematic viscosity in SSU many manufacturers will express
friction will be. This is simply due (Saybolt Second Universal) this as a hp per 100 revolutions
to the geometry of the impeller allowed for that pump per minute (rpm) limit. Note that
and the 90 degree flow angle that D = the diameter of the torque is inversely proportional
the fluid enters and then exits the discharge nozzle in inches. to horsepower, so the lower the
impeller. As an impellers specific speed the more torque is applied to
speed increases, the entrance-to- the shaft.
exit angle becomes lower and the thumb rule. While most shaft limits are based
interaction with the fluid is less. To be accurate, you should have on speed, hp and continuous torque
The smaller an impeller is, the input from the pump manufacturer limits, keep in mind that if the
more likely the disc friction effects on this subject with regard to pump is driven by an engine then
will be higher simply because the shaft torque and hp limits. There the limits will be further reduced
surface area of the impeller and may also be frame limits and (internal combustion means
casings have more interaction with occasionally (rare) impeller blade intermittent in lieu of continuous
the fluid than in a larger pump. load torque limits. torque). Additionally, if the pump
Depending on the pump size and shaft is side loaded, as in the case
Maximum Viscosity for a impeller geometry, the viscosity of belt or chain drives, there will
Centrifugal Pump limits for the average centrifugal be a striking reduction on the shaft
I am frequently asked; what is pump will vary from 250 to 700 limits due to the cyclic bending
the maximum viscosity that a centipoise, and I have witnessed fatigue factor.
centrifugal pump can handle? My many pumps successfully pumping

standard, usually water. Note that Viscosity & Net Positive

since SG is a ratio there are no units. Suction Head Required/
[(Torque) X (RPM)]
HP = Specific gravity is used in the Available (NPSHR/NPSHA)
(5252) equation when we are converting Intuitively, you would think that
Equation 2 to or from dynamic and kinematic changes in viscosity will effect
viscosities. Centipoise = NPSHR (aka NPSH3), but most
Where: (Centistokes) (Specific Gravity) published empirical data disputes
HP is measured in ft.-lbs. per that line of thinking. On pump
minute Dynamic & Kinematic Viscosity suction line applications where
Torque is measured in lbs.-ft. Centipoise is a dynamic (absolute) highly viscous fluids have issues
viscosity and centistoke (also SSU) flowing in the pipe to the pump
is a kinematic viscosity. A simple suction come to mind, but these
Viscosity &
way to explain the difference is issues would normally be covered
Temperature/Pressure
that kinematic viscosities are in the friction component of the
For a given liquid, the viscosity
timed flow rates through orifices NPSHA calculation. That is, the
will decrease for an increase in
where the driving force is typically friction factor would be higher for
temperature and vice versa. Note
gravity, while dynamic viscosity is a the viscous fluid and consequently
that for gases, it is the opposite
measurement of the force required reduce the NPSHA. My advice on
relationship. For stated viscosities
to overcome fluid resistance to flow viscous fluids is to increase the
a temperature must also be
through a tube (capillary). Simply margin between available and
given, typically 40 and 100 C
put, kinematic is a measurement of required NPSH.
are standards.
time and dynamic is a measurement Several well respected (but older)
Temperature can be an issue
of force. reference books state that there is
in the field because pumps are
little to no evidence that viscosity
frequently sized and sold to pump
Viscosity & the Affinity Rules affects the NPSHR (NPSH3) value.
a viscous liquid at some stated
Always be careful with the affinity The new edition of the ANSI/
temperature, but then the pumps
rules as they do not take system Hydraulic Institute guideline 9.6.7
are actually operated at a lower
interaction into consideration. states that an analytical approach
temperature, which yields a higher
Before applying the rules, convert may be considered (refer to section
viscosity and, of course, a higher
to the corrected performance for all 9.6.7.5.3 of the guideline). The guide
required hp with less flow and head
applicable parameters. offers an equation to calculate a
than desired or promised.
corrected NPSHR (NPSH3).
Pressure effects on a liquids
Pipe Friction & System Losses To quote one paragraph from this
viscosity are typically very small
When pumping fluid, the more section: There is a dual influence
and in most cases can be ignored.
viscous the liquid the more friction of the pumped liquid viscosity on
will occur. The resistance (friction) is NPSH3. With increased viscosity
Viscosity & Specific Gravity
due to the shear stress properties of the friction goes up, which results in
Viscosity is frequently mistaken
the fluid and the wall surface of the an increase of NPSH3. At the same
for specific gravity (SG). They are
pipe/pump. Note that the smother time, higher viscosity results in a
two different things. Common
the pump and pipe surfaces/walls decrease of air and vapor particle
vernacular expressions confuse
are the less effect the viscous fluid diff usion in the liquid. This slows
us, as viscosity is more often than
friction will have. down the speed of bubble growth
not erroneously referred to as a
See Chapter 3 (Friction) in the and there is also a thermodynamic
thickness or weight. Mercury has a
Cameron Hydraulic Data Book for effect, which leads to some decrease
high SG (13), but a low viscosity and
more information on this, and the of NPSH3.
many lube oils have a low SG (lower
connection to the Darcy Weisbach
than water or less than 1.0) but have
equation and the Reynolds number. Pump Shut Off Head When
a high viscosity.
If you are calculating a system head Pumping a Viscous Fluid
SG is ratio of the density of a
resistance curve and the fluid is Does a pump on viscous fluid service
substancefluid in this case
viscous you must take that into still approach the same shutoff
to the density of a benchmark
consideration. head as when pumping water? This

23
question comes up frequently in Conclusion

my work, and I have researched It is extremely important to
extensively for an answer (but no know the actual viscosity of the Jim Elsey is a mechanical
actual testing). The answer appears pumped fluid. I frequently witness engineer who has focused on
to be that at zero flow rate the head pump issues in the field due to rotating equipment design and
developed by the pump is the same differences in perceived versus applications for the military
for water as it is for a viscous fluid actual viscosity values. and several large original
where we assume the viscosity is equipment manufacturers for
less than 600 centipoise. References 43 years in most industrial
Several of my respected mentors ANSI / HI standard 9.6.7 -2010 markets around the world. Elsey
Centrifugal and Axial Flow Pumps, A.J. is an active member of the
seem to think the same thing. Stepanoff
I am open to input if you have American Society of Mechanical
Centrifugal Pumps Design and Application,
data either way. I still would like VS Lobanoff and RR Ross Engineers, the National
to believe that a pump of mid- to The influence of viscosity on centrifugal Association of Corrosion
low-specific speed that is pumping pump performance, Ingersoll Rand Engineers and the American
technical paper issued 1957 in Society for Metals. He is the
a fluid of mid-range viscosity conjunction with Lehigh University,
(approximately 250 centipoise) will general manager for Summit
Arthur Ippen
not quite make the same head that Engineering and System Design Pump Inc. and the principal of
it would with water. But, I surmise Considerations for Pump Systems MaDDog Pump Consultants LLC.
that velocity and gravity will argue and Viscous Service, C.E. Petersen Elsey may be reached at
with me on that issue. jim@summitpump.com.
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24 RECRUITING
Hiring: an opportunity to literally know the

ins and outs of pump design. Learning
Anyone looking to get into the pump
industry should pursue a proper college
SHANNON about different facets of pump design

from understanding the behavioral
education, Baity said.
My recommendation would be to
BAITY science of fluid dynamics relative to

controlling fluids and understanding the
understand the principles of fluid
dynamics and pumps in your mechanical
PMQ Engineer parameters that impact performance engineering training, he said.
really appealed to me. Baity also said to consider taking on
A couple of months later, the 31-year- a college capstone project to further
old Baity secured a position as a PMQ understand/apply fluid dynamics
engineer at Zoeller Pump Company in pumps.
based in Louisville, Kentucky. In his I would recommend in any relative
engineering role, Baity supports the project that you encounter in academia,
qualification of new manufacturing that you really grasp projects that will
processes, educates vendors and suppliers lead you down a path to becoming a
about new components in product pump engineer, Baity said.
line, provides root cause/solutions for What Im finding from my going
resolving manufacturing challenges and on seven years of experience is that
designs new products. its really important, once you become
Just nine months into the job, Baity an engineer, you become very focused
said he does not envision pursuing on projects, and in working on those
employment in another industry. projects you become a local subject
I think my outlook is
Beyond the technical aspects and the matter specialist. So taking on projects
extremely brightbeing
growth opportunities, I understand the early on in your academic experience
professionally exposed industry is definitely in need of great really exposes you to important subject
to multiple industries, pump engineers that know the ins and matter that you can capitalize on in your
Ive personally witnessed outs of producing, he said. I think its a career as a pump engineer.
corporate patterns of growth great opportunity to grow because of the Baity is optimistic about his career in
and decline. I feel like I increasing demand we anticipate seeing the pump industry.
have some insight into over the next five or 10 years. My personal outlook, I would say
understanding the health of a Baity pointed to his college education is really good in the industry and,
company/industry. as an important part of achieving the particularly, Zoeller is an excellent
goals in his career path. company, he said.
A
He started at Embry-Riddle The fact that theyre a world class
fter graduating with a bachelors Aeronautical University in Florida organization that is thriving within
degree in mechanical engineering before transferring to the University of the industry and provide opportunities
in 2009, Shannon Baity spent Louisville in Kentucky and earning his for new engineers to advance their
several years on a career path that mechanical engineering degree. careers while at the same time allowing
involved the automotive, aerospace and Talking about my own experience professionals to really take stake in the
food service sectors before he decided to as an engineer in the industry, I would business is very important.
work in the pump industry. say having that education is valuable, He added, I think my outlook is
In my previous position, my team he said. It laid the foundation for extremely brightbeing professionally
and I were faced with challenges understanding fluid dynamics. Pumps exposed to multiple industries, Ive
regarding pump failures that no one are one of the biggest components you personally witnessed corporate patterns
internally had the technical skill set to learn about as a mechanical engineering of growth and decline. I feel like I have
provide corrective action, Baity said student along with other things like some insight into understanding the
about his experience working for a food heat exchangers That really lays the health of a company/industry. The
service company. groundwork for understanding what is in growth of the industry was another point
Having experienced this challenge this industry and it gives you a leg up for of attraction to my current career path as
drew me into specializing in a sector of what to expect as a pump engineer. a pump engineer.
engineering that would provide me with

26 SPECIAL SECTION GROUNDWATER & STORMWATER
Diaphragm Operated Control

Valves Can Stop Surges &
Prevent Pipe Bursts
These valves can alleviate a variety of pump system issues.
BY MARK STRIJACK
SINGER VALVE
P
ipe bursts due to transients and surges are common. valve is normally mounted off a tee on the header or mainline
Not only are the maintenance costs of these repairs and opens under high pressure to discharge the relief flow to
high, but when adding possible litigation for third atmosphere or other suitable low-pressure zone.
party damages combined with the potential cost of It is important to consider the discharge that is released
water loss, another pipe burst can have big consequences. from the relief valves when they react to the overpressure.
Surges, or transients, are the result of a rapid change in The discharge can often be chlorinated, which poses a threat
liquid mass velocity within a pipeline. This kinetic energy, for fish-bearing streams, landscaping, etc. A well-considered
released as pressure, acts to expand the pipe diameter and approach to the proper management of the discharged relief
can destroy fittings, pipes, valves, instrumentation and water is always required.
pumps. Pressure waves travel the length of the pipeline of the A good initial guideline for sizing a relief valve is to base the
offending device, then reverse direction. The waves move at flow rate capacity of the valve at 25 percent of the maximum
a constant speed until they meet a barrier. The reflected and flow in the main pipeline. It is important that the relief valve
incident waves may superimpose each other to produce a more be sized so as not to be too small or too large. An undersized
compounded wave pattern that includes double peaks and relief valve will not have enough capacity to relieve the
double troughs. The consequence of improper protection from overpressure while an oversized valve will result in excessive
surges or transients could be a pipe burst or equipment failure flow and possibly a non-recoverable pressure loss.
and result in damage, water loss or litigation. Pressure relief valves are typically used where there is a risk
Transients, surges and the resulting pipe bursts can to the system of higher pressure occurring, and frequently
be caused by numerous events: loss of power at a pump used in systems that have pumps. Their selection and sizing
station, pump station programmable logic controller (PLC) is determined on whether a simple over pressure protection is
malfunction, single-speed pump motors without adequate required, or if there is risk of transients, in which case a surge
pump control valves or the rapid closure of isolation valves. anticipating relief valve may be selected.
The selection and sizing of pressure relief valves is very
important to protect pipelines, piping equipment and pumps. Pressure Relief Valves
The application and selection of relief valves may require a A diaphragm actuated, hydraulic pilot operated pressure
detailed analysis by a transient specialist who looks at all relief valve responds to opening only when a system is
factors before making an informed choice. Pressure relief over pressured, typically 10 to 15 percent over the normal
valves do not have to be limited to pump stations and can be operating pressure. If an overpressure or surge pressure
strategically located anywhere in the distribution system to occurs, the relief valve opens quickly to dissipate the surge by
deal with overpressures and transients. The pressure relief discharging water to atmosphere. When the system pressure

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has stabilized, recovering below the surge pressure, the in additional and repeated surge waves created within the
pressure relief valve closes at a controlled rate and normal system. The time, frequency and severity of these waves may
operation of the system resumes. Rapid or uncontrolled become catastrophic and end in a pipe burst or other system
closure of a relief valve may result in secondary surges in the failure, even in system where a relief valve was installed and
satisfactorily sized. Having the ability to anticipate
Image 1. Pressure relief valves, installation schematic and application (Images and
a surge event would allow the valve to respond and
graphics courtesy of Singer Valve)
open more quickly and effectively to a surge event.
A dual pilot relief valve, with the addition of a low
surge pilot, anticipates the impending high return
surge by opening the relief valve upon sensing
a low pressure surge. This low surge pilot allows
the valve to open and relieve a greater capacity to
minimize the surges below a critical level and of
shorter duration. The high surge pilot will function
normally to allow the relief valve to open fully
on high surge pressure, but operating from an
system. Closure rate should not be too fast to create closing already partially open relief valve. Surge anticipating relief
surges and not too slow to result in excessive relief water loss. valves need significant static pressure to operate properly. A
minimum of 43 pounds per square inch (psi) is typical.
Surge Anticipating Relief Valves The low surge pilot is typically set at approximately 60
Standard or single pilot relief valves only open when percent of the static system pressure, sufficiently below the
the system pressure exceeds the relief pilot setting. In a system operating pressure. The setting of this pilot is critical,
pumping system, where an unexpected pump shutdown as is the capacity and sizing of the valve. It is imperative that
occurs, the mass velocity of the water moving away from upon operation of this surge-anticipating relief valve that
the pump will initially create an excessively low pressure system pressure can recover above this low surge pilot set
within the pumping system. This low pressure surge wave point so that the valve may close and allow normal operation
will occur prior to an eventual returning high pressure of the system to resume. If this low surge pilot is set too low
surge wave. The time to open and the capacity of the relief or the valve is sized too large, excessive relief flow volume will
valve opening under this resultant high surge may not be prevent the system pressure from recovering, since the low
sufficient to adequately dissipate the system surge, resulting surge pilot will not close and so the relief valve will not close,
resulting in a complete loss of system pressure and excessive
Figure 1. Depicting effectiveness of surge anticipating relief valves water loss.
Since many relief valves, including surge anticipating relief
valves, are often oversized, valves are frequently specified
with valve devices designed to limit or restrict the lift or
opening under low surge pilot operation. Limiting the valve
travel under low surge pilot relief acts to promote the system
pressure to recover above the low surge pilot and allow the
valve to more reliably close when the surge waves have been
dissipated through the open relief valve. These devices are
referred to as hydraulic flow limiters (HFL). These provide
a compromise to allow the surge anticipating relief valve to
be oversized for high pressure relief capacity, yet allow for
reliable valve closure under low pressure relief.
Bigger is not necessarily better when it comes to surge
anticipating relief valves. It is also very important that the
sensing line is connected directly from the header and not
from the valve body port, to ensure accurate header pressure
sensing. Surge anticipating relief valves act as an insurance
policy by allowing the valve to start opening before a peak
on the transient returns. Surge anticipating relief valves are
often a good selection when design criteria calls for valves

29
Image 2. Surge anticipating relief valve and

installation schematic
AGGRESSIVE CUTTER
PUMP FOR RAGGING
six inches or larger. Surge anticipating

relief valves can be easily tested, and their
operation can be replicated in a static
condition in the field.
Electrically Timed Closure

After Power Failure
This valve is similar to the surge
anticipating relief valve, with the
exception that the low pressure pilot is
replaced with a solenoid valve. All other
sizing protocol and design criteria remain
the same. No static pressure is required
as the valve closes on a timer. The valve
opens because of either power loss or by
way of the high pressure pilot. If power
loss is the major concern, then this style of
valve can be an excellent selection. Timing
for the solenoid to close is normally
coordinated with the critical periodthe
time it takes for the surge return. Always
consult with a transient specialist for
sizing and selection concerns.
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Image 3. Electrically timed surge anticipating valve
percent of the mainline flow rate. The rate of rise

relief valve starts opening immediately when
pressure begins to rapidly rise. It uses a nitrogen
bladder accumulator for very accurate sensing of
pressure rise.
The source of surging is most commonly initiated
by the routine starting and stopping of pumps
within a pump system. Minimizing the system
surges on pump start and stop cycles can vastly
improve the health of a pump system by using
Rate of Rise Relief Valve inline or bypass pump control valves, which slowly open and
Surge anticipating valves based on the detection of a system close to gradually increase or decrease flow into the mainline.
pressure abnormality leads to another surge anticipating
valve model, the rate of rise relief valve. Valve opening Booster Pump (Inline) Control
pressure relief on a rapid pressure rise system, even before Booster pump control (BPC) valves are located in line,
a high pressure relief setting is reached, anticipates a surge downstream of the pump. When started, the pumps start
event to allow the valve to respond and open more quickly and against a closed valve. The solenoid is then energized,
efficiently to a surge event. opening the BPC. At pump shutdown, the solenoid valve
Rate of rise relief valves add another safety feature to is de-energized by the system control to put the valve into
standard relief valves. The valves open when they detect a closing mode.
sudden change in pressure. There is an electronic limit switch on the stem of the BPC,
On power failure, and after the low pressure interval, the so when the valve is almost fully closed, a signal goes back to
returning wave starts building pressure. The rate of rise the pump control panel to shut the pump down. The opening
pilot senses this rapid increase and immediately opens. This and closing speeds are adjustable. This is a very efficient way
rate of rise surge pilot allows the valve to open, even if only to manage pump control and does not require any
Image 4. Rate of rise relief valve and installation schematic static pressure in the piping system downstream.
When sizing BPC valves, consultants often prefer
to oversize the valves to minimize pressure loss
through the valves.
The dilemma is that when selecting pumps,
efficiency is always a concern. When a BPC valve
is used, if sized too small, pressure loss or lack of
efficiency may be affected.
Deep Well (Bypass) Pump Control

If site conditions permit, deep well (DW) pump
partially, to relieve a greater capacity of the returning surge control valve solutions can be a very economical and practical
to minimize the surge below a critical level and of shorter solution to pump control. This type of valve requires some
duration. Also equipped with a high surge relief pilot, this static pressure downstream to work effectively. Elevations
pilot will also open fully to ensure the relief valve opens are the best method to ensure the static condition, which
fully, on high surge pressure, but operating from an already
partially open relief valve. Image 5. Booster pump inline control valves, installation schematic
This valve model is very attractive, as equipped with a
pre-charged accumulator, the valve has positive pressure to
force the pilot to open and close. It removes the risk of failure
to close, should the pressure not recover. Downstream static
pressure is not required for this valve to operate effectively, so
downstream elevation is not required.
Another major advantage of the rate of rise relief valve
is that sizing is not critical. If the valve is oversized, it will
recover and close on conclusion of the transient. It is still
recommended that the valve be sized based on roughly 25

Flood Event Prompts

Portable Backup Solution
for Potable Water Network
Trailer mounted equipment with diesel engines and advanced controllers
give SIRWA an advantage.
BY CHRIS BAUMAN, XYLEM &

JASON FOX, CENTRAL SERVICE AND SUPPLY
T
he Southern Iowa Rural Water Association (SIRWA)
provides quality drinking water to the residents of
southwest Iowa. Included in its 4,000 miles of pipeline
is a 16-mile, 12-inch line that runs from the cities
of Creston to Corning. A pump station maintains pressure Image 1. One of the two final customized trailers and pump sets
in that line. A second pump station is used to pump water delivered to SIRWA (Images courtesy of Xylem)
through a 16-inch line to counties south of Creston.
Flooding was an ongoing issue at the second pump station, back-up systems to any station within the network any time.
but when a severe storm shut down both pump stations, local The solution also needed to facilitate a flow rate of 900
authorities scrambled to move water to customers in Creston gallons per minute (gpm) with 240 feet of total dynamic head
and Corning, bringing the issue to a head. (TDH). The portable pumps would need to be equipped to run
Following this event, SIRWA began exploring options to dry and include a self-contained power source.
minimize the impact of another flooding event and ensure It was also important that the pumps had the ability to
it was better prepared for emergencies into the future. integrate with the SIRWA supervisory control and data
Implementing permanent and redundant backup pump acquisition (SCADA) network. The solution needed to meet
systems at each of their 40-plus stations would prove too National Safety Foundation (NSF)-61 requirements.
costly for SIRWA to install and maintain. Instead, a more
economical, yet robust and reliable solution was required. Delivering a Customized Portable Solution
To address this issue, SIRWA engaged a pump distributor SIRWA teamed with a longtime pump and industrial
to develop a reliable and cost-effective solution that would equipment partner. The distributor designed a customized
support the entire water network in the event of flooding. engineered-to-order solution for SIRWA. The manufacturer
supplied two diesel-driven pumps equipped with liquid bath
Identifying the Right Backup Pumping Solution mechanical seals to address dry-running requirements.
SIRWA began by identifying the specific pumping The pumps offer flow rates up to 1,320 gpmmore than
requirements necessary to support all the pumping stations enough to meet the 900 gpm flow capacity needed to support
across their network in instances of severe flooding. The the pumping stations within the SIRWA coverage area.
pumps needed to be portable, allowing SIRWA to deploy the The pumps were also equipped with 375 gallon fuel tanks,

35
gooseneck hitch to accommodate easy powered by the pump battery that would
connections with the trucks that would allow the pump to tie into SIRWAs
be called on to tow the pumps within SCADA system. The controller enabled
SIRWAs coverage area. SIRWA to monitor and control pump
The distributor and manufacturer activity remotely, and could plug into
team recommended that the trailer the SCADA system at any pump station
also carry a state-of-the-art controller, across the SIRWA network.
Mission is Simply More Intelligent

Advanced Monitoring Low Cost Managed SCADA
Image 2. The controller was customized

for each pump, allowing SIRWA to monitor
and control the pump activity remotely Proactive Secure Data Hardware Support Managed by
Notifications Access Mission
Alarms dispatched Defense-in-depth Purpose-built U.S. based technical Everything needed is
more than twice the size of a standard to all your devices security policies economical to buy, support 24-7-365 includedno hidden
phone, email, text, install, operate fees
tank, allowing the pumps to run and more Securely access your Live weekly webi-
data in the office or Advanced remote nars, newsletters, No software or
approximately 70 to 80 hours at full load Alarm notification field control business logic instructional videos cellular carrier
on one tank of diesel should there be a rules are as simple
or sophisticated Reportsruntime- New MyDro RTU Audit trail for
relationships to
maintain
variance, station smart and expanded accountability
long-term power outage. as you want
summary, flow, many I/O, LCD screen, Continual system
enhanced electronics No additional
The solution was customized to meet Convenient alerts more
charge
enhancements
MyDr
NSF-61 certification requirements. New state-of-the-art
web portal, multiple
A number of pump components were windows, live data
treated with a certified NSF-61 coating

and the pumps were connected to the
SIRWA network with 6-inch food-grade
hoses approved by the NSF. Additional
safety customization included work
lights and roadside hazard lights to
support night and emergency work.
To ensure portability, the pumps were
each installed on customized trailers
and accessories, including a toolbox,
spare tire, night work lights and an 8
kilowatt (kW) generator. Each pump
trailer was outfitted with a hose rack
and 100 feet of the NSF-approved 6-inch
hose. The trailers were equipped with a
Chris Bauman is a controls design

engineer at Xylem and holds a chemical
engineering degree from Rowan
University.
Jason Fox is an outside sales specialist

at Central Service and Supply. He holds
(877) 993-1911 | www.123mc.com | sales@123mc.com
degrees from Minnesota State and
Indiana universities.

Emergency Averted at
Power Plant Holding Pond
Rental pump provides a temporary x to avoid spill.
BY TRIPP BROWN, UNITED RENTALS &

DAVID HAAS, CORNELL PUMP COMPANY
A
n Alabama power plant employs turbine pumps The pump was packaged with an electronically controlled
to move spent fuel pumpage into several holding engine, enabling the use of a pressure transducer to maintain
ponds for particulate settling and clarifying. The a steady flow of water without approaching the maximum psi
pump on the last pond began to fail because of age specified by the power plant.
and fine particle caking of the pump. At the time of year, The panel on the pump was set to maintain at 115 psi,
frequent rainstorms swell the pond by several feet, and ensuring that the pump would not approach the 125 psi
the freeboard available before a spill would occur was at a threshold. The system was designed so that in the event of
premium. Compounding the issue of moving a new pump an unexpected pressure spike in the discharge line, the pump
temporarily was the need to protect the pond liner from tears. would idle down and shut off to prevent damage to the power
The particulates could not leak into the surrounding area, as it plants permanent piping system.
was an environmentally sensitive location. There was limited The pumps design was seen as forgiving in the various
space to place a temporary pump on the levee wall. run conditions that the pump could experience, with a broad
The discharge run was just over two miles, made of 8-inch working range and high efficiency. The pumps reliability was
fiber line with a 150 coefficient. The age of the line prevented also a strong consideration in selecting it for the critical job.
it being pressurized above 125 pounds per square inch (psi). The pump was in place for five months and worked without
To tackle the freeboard with limited space to place a pump issues. No damage to the liner occurred, the pond did not
coupled with the environmentally sensitive area and tear overtop, the pump worked well and was easily accessible in
susceptible pond liner, the power company turned to a rental the confined levee space, and the time allowed the permanent
solutions provider with a national presence. Guidelines for pump to be rehabilitated and brought back online. The pump
the rental original equipment manufacturer (OEM) include package has been repurposed by the OEM for use in the
achieving maximum flow while limiting pressure in the applications such water transfer in the oil and gas industry.
fiberglass line to lower the pond quickly in case rain caused
an overspill. The rental OEM looked at the head, flow and Tripp Brown is regional product development manager at
psi constraints and determined that a single frame mounted United Rentals Pump Solutions, a full-service rental OEM
centrifugal pump with a two-port 17.5-inch enclosed impeller, providing rental equipment for construction, municipal,
6-inch suction and an 8-inch discharge was the best option. industrial and mining sites across North America. He has
The rental OEM completed the setup using dual 8-inch more than 17 years of experience in pump application design
suction lines that were manually installed to ensure the and management. Visit unitedrentals.com.
integrity of the pond liner. On the discharge side of the pump,
200 feet of 8-inch crimped tank truck hose was connected David Haas is rental market manager for Cornell Pump
to the fiberglass line. Initial suction lift was approximately Company. Haas has been a pump professional for more than
17 feet on a 3-to-1 slope. However, the pond water level was 30 years, with experience in municipal, construction, general
subject to change with any additional rainfall near the plant. dewatering and rental applications. Visit cornellpump.com.

37
TROUBLESHOOTING A RENTAL PUMP
This installation went off without a hitch, but from time to time there can be issues with rental pumps in the field.
These troubleshooting tips can help with rental pump operations. There are three main problems with a portable
priming pump:
1. Pump will not prime, or takes an excessively long time to prime

Here are some common issues and possible fixes.
Part to Inspect/Examine Possible Fix

Air compressor hose Check for damage, nicks or leaks that will prevent priming. Replace if necessary.
Check valve Examine to make sure it is free of debris/obstructions.
Discharge Make sure discharge is clean, and also check that priming valve is working properly.
Drain valves Ensure drain valves are closed. Open valves will affect priming.
Float adjustment Inspect for proper tightness, and determine that rubber components seat properly.
Also check that float is intact (not filled with fluid) and that linkages and pins are
properly connected.
Hoses Inspect suction hose for leaks or improper connection.
Pop off valve If heard releasing air, priming system could be leaking air. Ensure proper fit.
Priming system Refer if vacuum assist dry prime or venturi and follow manufacturer maintenance and
cleaning standards.
Vacuum shutoff valves Make sure it is open. Inspect hose for kinks, discoloration or blockage.
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2. Unit will not pump

Field experience shows that close to 90 percent of problems when a unit will not pump are suction-side related. Most of the other
problems are on the discharge side, with very few mechanical seal problems. Start with the most probable and easiest to remedy
issues on the suction side. This chart offers some ideas of what to check:
Suction Lines A. Inspect that they remain leak and damage free. Replace if necessary.
B. Check position and readjust. Avoid vortexing. Ensure hose is not on bottom of fluid source, where it
is likely to clog.
Discharge A. Check for airlock. Symptoms include very low vacuum pressure on suction, with high pressure or
low flow on discharge.
B. Check for vapor lock (stem may be present).
C. Determine valves are open and line is not blocked/obstructed.
Seal A. Check that seal is not damaged or contaminated.
3. Pump exhibits high vacuum with little or no flow

High vacuum with low or no flow conditions generally indicate a suction side restriction.
Suction strainer Check for clogs and that it is not buried in the mud.
Suction hose Check for kinks, leaks, inner liner collapse and improper fitting.
Suction lift If NPSHR is too high, lower the pump towards the water source.
Discharge piping valve Determine that it is open and operating properly.
Pump speed Verify that pump is operating at expected speed for sized conditions.
Discharge head Analyze conditions and see if improper NPSHA could contribute.
Impeller Check for blocks and restrictions.
Whatever You Rebuild, Repair and Protect.

We have the Solution
LOCTITE Protective Coatings and Compounds restore worn surfaces and
extend the life of new and existing equipment.
Increase efficiency
Save costs by avoiding part replacement and reducing spare-part inventories
Protect parts against abrasion, erosion, chemical attack and corrosion
Restore and Improve the Performance of:

Pumps Exhausters
Chutes Conveyors/Augers
Cyclones Centrifuges
Fans Dust Collectors
To locate a Henkel Certified Applicator visit:

www.na.henkel-adhesives.com/protectivecoatings
or call 1-800-LOCTITE (562.8483)
All marks used are trademarks and/or registered trademarks of Henkel and its affiliates in the U.S. and elsewhere.
= registered in the U.S. Patent and Trademark Office. 2017 Henkel Corporation. All rights reserved. 800886 (8/17)

39
CHEMICAL PUMPS
Handle Abrasive
Chemicals with the Right
Pump Diaphragm
Depending on the type of material being handled, especially
the amount of abrasives and solids, ePTFE could be the best
diaphragm material.
BY MICHAEL BROOKS
GARLOCK SEALING TECHNOLOGIES
A
ir operated diaphragm pumps are used in PTFE diaphragms can provide superior chemical
many applications requiring abrasive and resistance, but less abrasion resistance and flexibility
chemical resistance. When both are needed, than elastomer diaphragms. Several factors influence the
an elastomer with some chemical resistance, abrasion resistance and flexibility of PTFE.
or a polytetrafluoroethylene (PTFE) diaphragm with an Most diaphragm manufacturers use a skived PTFE
elastomer backing, is typically used. made from a conventional or modified material, both
The problem with most elastomer diaphragms in abrasive of which offer strong chemical resistance. Conventional
chemical applications is they eventually weaken from PTFE is highly crystalline and has less flexibility than
chemical attack and erosion from abrasives. This results modified PTFE. Modified PTFE tends to have less
in loss of tensile strength and durometer, making them abrasion resistance because of its amorphous structure.
vulnerable to rupture and disintegration into the media.
Image 4. The ePTFE

composite diaphragm after
372 continuous hours of
Image 1. Abrasives in the test testing (2,400,000 cycles and
Image 2. The ePTFE composite Image 3. The ePTFE/fabric/rubber
slurry, which consisted of one 53,000; gallons pumped).
diaphragm after 24 continuous diaphragm after 194 continuous
part abrasives and 70 parts water. The ePTFE began to tear, but
hours of testing (155,000 cycles hours of testing (1,250,000 cycles
(Images courtesy of Garlock did not break apart from the
and 3,456 gallons pumped) and 27,000 gallons pumped)
Sealing Technologies) diaphragm.

40 COVER SERIES CHEMICAL PUMPS
Expanded and tensilized PTFE, Test Results

or ePTFE, is manufactured by a Internal testing was conducted to
proprietary process. ePTFE provides compare the performance of ePTFE
toughness and abrasion resistance, composite diaphragms with two-piece,
while a rubber backing lends flexibility. rubber-backed PTFE diaphragms (see
Image 5. Conventional skived PTFE overlays
after 24 continuous hours of testing (155,000
cycles and 3,456 gallons pumped)
Images 1-5). It involved two identical

1.5-inch inlet/outlet air operated
double diaphragm (AODD) pumps
at the same elevation and air inlet,
media inlet and outlet pressures. One
was fitted with an ePTFE composite
diaphragm, and the other with a two-
piece diaphragm with PTFE facing the
media and a thermoplastic elastomer
facing the air side.
The media was a slurry of one part
abrasives and 70 parts water. The
abrasive media consisted of 41 to 53
percent silicon dioxide, 7 to 31 percent
iron oxide, 17 to 25 percent aluminum
oxide and 3 to 15 percent calcium
oxide with trace amounts of various
inorganic materials.
Many users of air operated
diaphragm pumps encounter problems
with abrasives and chemicals in
the media. These problems result
in expensive downtime, equipment
damage, maintenance and repair costs,
and lost production.
An applications engineer or pump
manufacturer should be contacted
when selecting a diaphragm. One-
piece ePTFE composite diaphragms
resist chemical attack and physical
disintegration from abrasives to deliver
long service life, improved productivity
and greater safety. Four examples show
companies resolving problems by using
ePTFE composite diaphragms.
1 Chemical Cleaning Company

Delta Tech Service Inc. in
Benicia, California, specializes
in decontaminating oil refinery
equipment. The company designs and
fabricates skids that utilize two 3-inch

41
phosphoric acid (D2EHPA), kerosene, Abrasives in the media drastically

metal powder and metal fl akes. AODD reduced the diaphragm life. Initially,
pumps were used because of their the company used two-piece PTFE
ability to handle solids and move to diaphragms with rubber backings,
different areas of the process. which developed concentrated areas of
Image 6. The two-piece PTFE and thermoplastic
elastomer diaphragm is shown. The conventional
PTFE separated from the assembly, and pieces of
the diaphragm entered the media after abrasives
and flexural stresses tore it apart.
AODD pumps joined at the manifolds,

allowing users to simultaneously
operate one or both pumps.
One of the challenges in the field was
the short life of the fluoroelastomer
diaphragms that came with the pumps.
Ethylene propylene diene monomer
(EPDM) and conventional skived
PTFE diaphragms with thermoplastic
elastomer backings were used, but
none lasted longer than a 30-day rental
period (see Images 6-7).
Delta Tech then tried an initial
set of ePTFE composite diaphragms
that lasted for more than 90 days
more than four times the life of the
EPDM and two-piece PTFE/elastomer
diaphragms. Most of Delta Techs
pump applications involved coke dust,
condensate and various chemical
cleaning agents, which can soften
the thermoplastic elastomer and tear
through the PTFE.
By converting to the one-piece
ePTFE composite diaphragms, the
company realized significant savings
in maintenance costs and system
downtime.
2 Zinc Refining Company

Extracting metals from a refining
process requires pumps that can move
various chemicals, metal fragments
and dust particles. A U.S.-based
company that specializes in the
extraction of zinc uses 10 AODD
pumps to move slurries of sulfuric
acid (up to 90 percent concentration),
hydrochloric acid (up to 36 percent
concentration), Di-(2-ethylhexyl)

wear that cracked and fl aked off into reduce concentrated flex points and its pumps with ePTFE composite
the process media and pump motors. compare its performance to the diaphragms. Now on a routine
The PTFE was forced into the air side diaphragms they had been using. maintenance schedule where the
of the pumps, which damaged their After five weeks of operation, the diaphragms are replaced every six
air distribution sections and cost the two types of diaphragms were removed months, the company is experiencing
company more than $5,000 per pump from the pumps and examined (see greater efficiency resulting from
in downtime, repairs and other costs. Images 8-9). decreased wear on their pumps and
The companys maintenance, repair The ePTFE composite diaphragm systems, less downtime and reduced
and operations (MRO) distributor showed no crease marks or signs of maintenance. Employees are also less
suggested using an ePTFE composite significant wear or chemical attack. likely to be exposed to highly corrosive
diaphragm with molded-in ribs to The two-piece diaphragm was torn acids while repairing the pumps.
apart by the metal fl akes, and the
elastomer backing had indications of
wear and chemical attack, eventually
leading to rupture and pieces of the
4 Automobile Manufacturer
A major U.S. car manufacturer was
using primarily AODD pumps to move
diaphragm mixing with the media. phosphoric, sulfuric and hydrochloric
Because the composite diaphragm is acids and an abrasive slurry of dirt and
bonded together, the ePTFE does not metal fl akes. The temperature of the
disintegrate easily and enter the media. media ranged from 100 to 120 F.
The ePTFE composite diaphragms The company was using AODD
lasted more than seven months, while pumps ranging from one-half to 3
Image 7. The fluoroelastomer diaphragm was the original two-piece conventional inches with varied diaphragm life. They
softened by the temperature and exposure to PTFE and elastomeric diaphragms were using two-piece conventional
a cleaning solution. Various abrasives in the lasted an average of five weeks. skived PTFE and elastomer diaphragms
media caused it to rupture.
with an average life of three months.
3 Mining Company
A precious metals mining company
wanted to get better life out of the
Eventually, however, the company
selected ePTFE composite diaphragms
as a more durable alternative.
diaphragms in its vertical AOD pumps. Testing began and the difference was
These pumps operated outdoors at noticed within months. The PTFE was
temperatures ranging from 15 to no longer fragmenting and breaking off
100 F and inlet pressure of 40 pounds into the media; wear from the metal
per square inch (psi) for more than fl akes was greatly reduced; and the
20 hours a week. The media typically rubber was not being attacked by the
consisted of 70 percent hydrofluoric phosphoric acid. Based on these test
Image 8. The original conventional PTFE acid concentration. results, the company began changing
diaphragm after five weeks of pumping The company used chlorosulfonated out the failed diaphragms for ePTFE
hydrochloric and sulfuric acids, metal
shavings and particulates
polyethylene synthetic rubber composite diaphragms, extending
until it was discontinued by the diaphragm life from three months
primary manufacturer before trying to 18 to 24 months and reducing
fluoroelastomer and EPDM as downtime by more than 80 percent.
replacements. These diaphragms had
to be replaced every four weeks. Each
replacement required two employees
working an average of seven hours. Michael Brooks is the applications
This added up to 22.75 work days engineer for pump diaphragms
annually per pump. and valves for Garlock Sealing
The companys head of maintenance Technologies. He may be reached
selected an ePTFE composite at michael.brooks@garlock.com or
Image 9. The ePTFE composite diaphragm diaphragm. It was tested for six 1-800-448-6688
after five weeks of operation months and the company retrofitted

CHEMICAL PUMPS COVER SERIES 43
New Designs Enhance

Metering Pump Eciencies
PTFE diaphragms can serve in even more applications.
BY AXEL BOKIBA,
PULSAFEEDER
S
ize matters when it comes to pumping
infrastructure. Larger pumps are more powerful
than smaller pumps, but theyre also more expensive.
A pumps footprint brings added costs to the shop
floor or to the offshore platform.
Whether its a refinery, a chemical plant or a power
plant, the footprint and ergonomic design of pumping
infrastructure plays a key role in the efficiency of the plant.
When it comes to metering pumps, the quest to make smaller
and lighter pumps that do not compromise performance has
previously been constrained by the size of the diaphragm, Figure 1. Metering pump (Graphics courtesy of Pulsafeeder)
which dictates the size of the liquid end and the stainless
steel surrounding the pumps head. additional costs to eliminate those chemicals further along in
Today, new enhancements with polytetrafluoroethylene the process.
(PTFE) diaphragm designs are producing smaller, lighter and
less expensive metering pumps that offer greater efficiency How Metering Pumps Work
without compromising performance. Chemicals enter a pumps wetted chamber when the motor
drives a piston to create a vacuum that sucks chemicals into
The Role of the Metering Pump the liquid end from external tanks. Alternating piston strokes
Metering pumps are positive displacement chemical dosing create pressure that closes the inlet valve, opens the outlet
devices that deliver measured volumes of chemicals. In valve and forces the liquids out to the process. Within the
chemical or petrochemical plants, metering pumps are liquid end is a diaphragm, which acts as a barrier between the
used to dose specific volumes of chemicals (under certain piston and the process fluid (see Figure 1).
temperatures and at specific pressures) to make products. The pistons pumping motion is applied to hydraulic fluid,
In offshore environments, metering pumps deliver flow which causes the diaphragm to flex back and forth as the
assurance chemicals that prevent hydrates from forming and piston reciprocates. The movement of the piston, which is
ensure the smooth flow of oil through long subsea tiebacks. called deflection, flexes the diaphragm between concave and
In midstream applications, metering pumps dose chemicals convex positions. The periphery of the diaphragm is clamped
that dehydrate gas or treat heavy crude to make it easier and does not move during the deflection. The greater the
to move through pipelines. In power plants or refineries, deflection of the diaphragm, the higher the flow rate.
metering pumps inject corrosion inhibitors and anti-scaling For processes that require high flow rates, pump
chemicals to protect pumping and piping infrastructure. manufacturers have always had to build large diaphragms,
For each of these applications, the accuracy of the with large liquid ends and large housing areas, to deliver
metering pump is paramount, because over-injecting the volume and pressure required. As expected, this results
treatment chemicals in one part of the process can result in in large and heavy pumps. Metering pumps must be able
pumpsandsystems.com | November 2017

to deliver a wide range of harsh and corrosive chemicals

at different concentrations and temperature levels. To
accommodate this diversity, all the wetted parts of the pumps
liquid ends should feature materials that are compatible with
those chemicals
The pump should be equipped with a diaphragmeither
metallic or plasticwhose material plays a key role in the
equipment cost and weight.
PTFE vs. Metallic Diaphragms

Flow: PTFE allows for a smaller diaphragm diameter
thanks to a higher deflection.
Chemical compatibility: PTFE has a larger chemical
compatibility than most metals due to its naturally high
resistance to chemical corrosion.
Pressure: Without the slippery properties of the PTFE
material, metallic diaphragms can easily be clamped to
withstand piston pressures up to 20,000 pounds per square
inch (psi) and above, whereas reaching high pressure levels
with PTFE diaphragms is said to be the biggest technical
challenge for metering pump manufacturers.
Temperature: Metallic diaphragms can withstand
higher temperatures than PTFE without compromising
accuracy. Temperatures in excess of 150 C negatively
impact PTFE/plastic. On some occasions, the diaphragm
could soften, impacting the degree of deflection and the
resulting accuracy. API675 requirements stipulate that
metering pumps must be able to inject chemicals with +/- 1
percent accuracy. So to be considered a viable alternative
for offshore applications, pumps with PTFE diaphragms
needed to overcome this limitation.
PTFE diaphragms have existed for a long time. The challenge

has been the use of this flexible material at high pressures.
Because of the slippery nature of PTFE, it has always been
difficult to clamp the diaphragm tight enough to withstand the
high piston thrust required for high pressure injection, but not
too tight, to prevent densification, buckling and even rupture.
As opposed to PTFE, metallic diaphragms can crack in the
peripheral clamping area when significantly deflected. To

fulfi ll the pumps high flow requirements and conciliate it with
a small metallic diaphragm deflection, the only solution is to
increase the diameter of the diaphragm. This results in a much
larger diameter liquid end when using a metallic diaphragm
versus a PTFE diaphragm. Additional trade-offs associated
with metallic designs include the size and the weight of the
diaphragm, the liquid end and the stainless steel surrounding
the pumps head. These materials are expensive, which
increases the cost of each pump and brings ripple effects to the
overall costs on the shop floor or on the offshore platform.

Chemical Manufacturer
Saves $70,000 Per Year with
Submersible Shredder Pumps
How one company xed constant pump failures.
BY BEN STOLT, TENCARVA MACHINERY &

STEVE MOSLEY, BJM PUMPS
A
large chemical company in Tennessee had
experienced frequent pump failures due to
solids and pH issues in a waste pit application.
Mechanical seal failure due to solids
contamination was suspected to be the main culprit.
The manufacturing facility had a sump that relied on
two effluent pumps to transport wastewater out of the
plant. While one pump had initially been intended to
operate as a backup, both pumps had been operating
continuously to accommodate the high flow rate into the
wastewater sump.
Image 1. Wastewater fluid entered the motor, causing pump failure
Solid materials, such as zip ties, plastic tags and
(Images courtesy of BJM)
bags that entered the wastewater stream from drains
throughout the production facility would enter the pumps failed at the same time. At that point, the rental
wastewater sump and damage the effluent pumps. equipment company provided them with a submersible
When the first pump failed, it was sent to a repair shredding pump to use as an emergency spare.
facility in Virginia. The repair technicians found that the
plastic debris had become trapped on the backside of the A Temporary Solution Provides Lasting Value
pump impeller, causing the mechanical seal to fail. The The rental equipment company worked with an inside
mechanical seal failure allowed wastewater fluid to enter applications engineer at the pump manufacturer to
the motor, resulting in failure of the effluent pump. select an explosion-proof, submersible, corrosion-
The first effluent pump was repaired and reinstalled, resistant shredder pump for the chemical manufacturers
but only lasted a month in the manufacturers wastewater wastewater sump. It was a priority for the chemical
sump. According to a company who provides rental manufacturer to keep workers safe and with the potential
equipment, the chemical company had an emergency for an explosive atmosphere, the plant required pumps
spare, but it failed after a few weeks. They learned with explosion-proof motors. The submersible shredder
that the manufacturers in-house maintenance team pump was chosen for its FM-approved explosion-proof
had set up a backup diesel pump in case both effluent motor (for use in Class I, Division 1, Groups C & D
N o v e m b e r 2 0 1 7 | Pu m p s & S y s t e m s
47
hazardous locations) as well as its effluent pumps failed a dozen times,

ability to effectively shred and pass using valuable maintenance dollars.
large solids. For the cost of two pump rebuilds,
Theres a constant flow into this the chemical manufacturer could
wastewater sump, and even though have purchased one new submersible
its 30 feet deep, its critical that the shredder pump. But the chemical
sump doesnt overflow. The pump manufacturer had to see the pump
manufacturer was confident that the in action before realizing theyd save
submersible shredder pump was going money switching to a different type
to pump reliably in that sump because of pump.
its made of 316 stainless steel, has After dealing with excessive pump
a cutting impeller with a tungsten failures, the chemical manufacturer
carbide tip to shred solids and an decided they could achieve
epoxy-coated motor housing, which more reliable pumping and save
was needed because of the high pH of maintenance dollars by switching
the pumped fluid. from the effluent pumps to the
While the pump was initially submersible shredder pumps. They
meant to be a temporary solution, it decided to do a complete change out,
continued to operate reliably in the replacing the effluent pumps with the
sump, even as the original effluent submersible shredder, which was rated
pumps continued to fail. Over the for 550 gallons per minute (gpm) at 80 Image 2. A submersible shredder pump shreds
course of a year, the more expensive feet of head. discarded material
p u m p s a n d s y s t e m s . c o m | Nov em ber 20 17
After nine months of uninterrupted service, two additional Doing that math clearly demonstrates the importance of
explosion-proof submersible shredder pumps were installed selecting the right pump for your specific application.
in April 2017 into the manufacturers wastewater sump. A
custom adaptor plate was designed and manufactured to
install the new pumps onto the existing guide rail system. Ben Stolt is Western regional sales manager with Tencarva
Two of the pumps operate continuously to keep up with the Machinery, which has been providing pumps and associated
24/7 inflow, and operation rotates among all three pumps to equipment to industrial and municipal customers since 1978.
further extend pump life. Offering premier pump equipment products and professional
With a six-inch pump connection reduced to a three-inch application experience, Tencarva has grown into the leading
flanged slide rail connection, the pumps are now sending liquid handling equipment supplier in the Southeast U.S.
all the shredded material through the discharge pipe. Some Learn more about this employee-owned company at
of the particulate is collected in a strainer and sent out for tencarva.com.
proper disposal.
The manufacturer spent about $180,000 purchasing Steve Mosley is the Atlantic regional sales manager for BJM
the effluent pumps and approximately $100,000 in a year Pumps, headquartered in Old Saybrook, Connecticut, which
repairing pumps that were just not right for their specific has been providing fluid handling solutions for industrial
application. By switching to explosion-proof submersible and municipal services since 1983. Over its thirty
shredder pumps, the manufacturer saved money through year history, BJM Pumps has grown quickly by
reliable operation and reduced maintenance. supplying world class pumps and accessories,
The chemical companys maintenance manager says, Even priced competitively, through its global
if we just get one year out of these pumps and throw them network of stocking distributors. Learn
away, we are winning. The pump had a two month payback. more at bjmpumps.com.

issue is typically detected far in advance and allows integrated with digital twin technologies. All documents
the owner to replace the failing bearing before there is pertaining to a given asset can be instantly accessible
housing damage. Therefore, an issue can be resolved with to plant personnel on their smart devices that have an
a few hundred dollars rather than expensive repairs or internet connection. Spare parts can also be visible from
replacement of the pump housing. In many cases, the the enterprise resource planning (ERP) system so that
maintenance team will not believe there is an issue. But plant personnel know part availability without having to
this is their chance to salvage an asset for little cost and reach out to ERP operators.
very little or no process downtime. Companies employing digital twin technology in
Some companies offer their smart solutions for other their processes can achieve some remarkable savings.
manufacturers pumps or equipment, customers with For instance, process downtime can be reduced to a
problems of hard to maintain assets, remote assets that point where the process owner could achieve a full
are hard to access and even for total plant intelligence. month of additional production. Maintenance, repair
This is called digital twin technology. Some companies and operations (MRO) costs can decrease by as much
are using digital twin technology for optimizing asset as 10 percent, profits can increase 5 to 10 percent and
performance before the asset is physically manufactured. fuel and energy savings may be reduced by as much as 2
Others are using digital twin technology to create to 3 percent. Pumps are vital elements for maintaining
the asset in the digital world and then tie in real time process stability. Digital twin technology is valuable
monitoring of a valuable asset. Access to the asset can be for monitoring high value assets and environments or
24/7 for anyone. All that is required is a connection to the equipment where safety is at a very high level of concern.
internet from any smartphone, tablet or computer, and Another trend is the use of complete pumping
the owner can have unlimited access from any location. systems supplied by pump manufacturers rather than
Also, intelligent document management systems can be individual pumps delivered to the site and then installed
STRENGTH
IN NUMBERS
BADGER ALLOYS has worked closely with us to
OPTIMIZE PRODUCT DESIGN and manufacturing
processes, enabling us to REMAIN COMPETITIVE
in the global marketplace.
- Director of Engineering, Global Water Technology Company
Learn more about how you can benefit from Badger Alloys strength in numbers: badgeralloys.com/strength

51
by contractors or plant personnel. These systems place situation where the all three parties (pump manufacturer,
the pump on a pre-manufactured structure with all electrical contractor and mechanical contractor) point
auxiliaries, piping and electrical assembled as a complete fingers at each other as the cause of issues. With a
unit. These packaged pumping systems offer some packaged pumping system, users have one person to call
valuable features. First, the system is assembled so the and hold accountable to make the system correct.
pump systems are plug-and-play. Drop the packaged It is estimated that the digital world will continue to
pump system in the proper space and connect the piping grow at staggering levels. Well-packaged systems are
and electrical and the system is ready to go. A factory proving to have significantly greater reliability and lower
assembly test (FAT) is typically performed before the cost. In the Internet of Things, there will be as many as
system is shipped. All auxiliaries, safety devices and 100 billion devices connected by 2025. In 1995, there
recommended procedures are adhered to on the system were fewer than one million. The question becomes how
to help provide the pump the best environment for the quickly it can be deployed by multiple sectors of industry.
pump to be successful. It is an ideal time to research suppliers employing these
These packaged pump systems help to minimize the technologies and begin to deploy technology into those
outside influence of improper installations and improve high-valued critical assets.
pump performance. The manufacturer of the pump
systems lays out the pump and auxiliary configuration to
maximize asset performance. An advantage of a complete Todd Loudin is president of Flowrox Inc.,
system manufactured by one company is that there is in Linthicum, Maryland. Loudin may be
only one company to call in the event of a problem or reached at todd.loudin@flowrox.com. For
issue. If pumps are purchased and installed by both more information, visit flowrox.us.
mechanical and electrical contractors, users may be in a

Chemical Pumping
with Electric
Diaphragm Pumps
This equipment is another tool in a pump user s toolbox.
BY JEFF SHAFFER Figure 1. Electric double diaphragn pump advantages (Images and graphics courtesy of Graco)
GRACO
I
n todays industrial world,
selecting a chemical pump from
the various pump technologies
and brand names can seem
like an endless array of choices.
With so many different benefits,
sizes, materials and other features
available, choosing the best pump can
be overwhelming. Deciding between
electrically driven pumps, such as
centrifugal or peristaltic, versus
pneumatically driven pumps, such as
air driven double diaphragm pumps,
can be a difficult choice for chemical
pumping and transfer applications
throughout a plant.
A technology that has recently
been introduced provides a new tool
to a users toolbox when trying to
select the right pump technology for
chemical pumping applications. The
electric double diaphragm pump has
combined the well-known diaphragm
pump technology with the control
and energy-saving benefits of electric
drives. This new technology also
offers some unique advantages.
Worker & Plant Safety

or pump failures, which could risk human contact with
One of the most important considerations when weighing
harmful chemicals. Many typical electric rotary pumps
options for different pumps is making sure the plant
employ a shaft seal that will wear over time and can allow
environment is safe for all workers by preventing leaks
corrosive and dangerous chemicals to leak onto the floor

53
and expose workers to the dangers of The particulates will damage seals, it is imperative to ensure that the
contact with the chemical or inhalation impellers and bearings, forcing pump pump materials of construction are
risks due to fumes. repairs or replacements frequently. compatible with the chemical that they
This can be especially true if the Apart from the cleanliness of are trying to pump. These days, most
chemical being pumped contains any the chemical, as most users know, pump styles offer different options
particulates that could expedite seal
wear within the pump.
The Calming Effect of Griffco

If users are not using an electric
rotary pump for transfer, it is possible
that an air driven pump is being
used for transfer of the aggressive
chemicals. In general, air driven double Pulsation Dampeners
diaphragm pumps offer the benefit
of a sealless style pump design for
the fluid section, which will prevent
seal leaks. However, the diaphragms
in the fluid section for pumping will
wear over time. In a pneumatically
driven pump, if there is a rupture
of the fluid diaphragm the chemical
being transferred will inevitably leak
into the air section of the pump. This
will not only have problematic results
for the pump, but it could also allow
hazardous chemicals to be pumped
F
through the air section and exhausted
out of the pumps muffler. This would
introduce dangerous chemical fumes
into the air in the plant environment or 25 years you have relied on
and potentially expose or harm Griffco back pressure and pressure
workers in the area. relief valves. Now you can rest
same
assured that you will enjoy the sam
quality and reliability with Griffco pulsation
Material & Chemical dampeners on the job.
Considerations
Another important consideration From the tank to the process, Griffco offers
a full line of chemical feed accessories that
for users is what type of chemical or
will give you confidence in the safety and
media they are looking to transfer in performance of your system. Ask about our
their process. If it is a clean chemical calibration columns, gauge guards, injection
without any particulates, then quills, corp-stops, y-strainers, and more.
standard centrifugal style pumps are Visit our website to:
a great solution at a reasonable price Download free datasheets and 3D CAD drdrawings
g
point, depending on the materials Find your nearest distributor
of construction. Request detailed info or a quote
If the chemical contains any
particulates, is a chemical slurry
Use our Pulsation Dampener Sizing Calculator
Griffco Valve, Inc.

25
or is potentially a waste chemical YEARS OF
1-800-GRIFFCO
with unknown matter in the fluid,
centrifugal pumps may struggle and sales@griffcovalve.com
SERVICE
have frequent breakdowns because www.GriffcoValve.com
they cannot handle the solids in the
fluid very well. ISO CERTIFIED MADE IN USA

items are compatible, but ancillary components within

the pump may not be the right match for the chemical.
Process Operation
Verifying that the pump and chemical will work well
together is usually step one in the pump selection process.
Step two is verifying that the pump fits well into a
process. Many items need to be considered for this part of
the selection to make sure the right pump is installed.
The first considerations at this stage are generally flow
rate and pressure required. For high flow applications,
centrifugal pumps are hard to beat. They can also be
staged to achieve higher head pressure where required.
For lower flow rate applications or higher pressure
Image 1. Electric air charged double diaphragm pump. applications, users will probably enter the realm of
positive displacement pumps: rotary lobe, gear, peristaltic
to accommodate different chemicals, but it is always and progressive cavity, for example. Although the positive
important to check to ensure no issues will arise. Aside displacement style pumps generally do not provide as
from the main components, it is important to check high of flow rate as their centrifugal counterparts, they
rotary pumps for bearings, seals or other components offer the ability to accurately measure flow (meter) since
within the pump for compatibility with the chemical. they are positive displacement. If this is important to an
Often times main housings, impellers, rotors or other application, it can be a deciding factor.

The pump is completely sealed for fluid and will not

allow chemical leakage in case a diaphragm fails.
The electric double diaphragm pump also provides
the ability to properly handle particulates in the
chemical or a chemical slurry without damage to the
pump. They have replaced several centrifugal pumps in
pickling and plating applications for this reason. The
centrifugal pumps do not hold up to the particulates
in the plating chemicals, while the double diaphragm
pumps handle them without issue.
The electric diaphragm pumps also offer a wide
range of fluid contact materials and can be configured
to be compatible with just about any chemical a user
requires handling.
Electric drive double diaphragm pumps can
also exhibit some of the great benefits of their air
driven counterparts without the large compressed
air requirement. They allow for self-priming where
required in the process and can also protect against
clogs or pressure spikes with stalling under pressure
technology in the pump. Because the double diaphragm
pump is not powered by an electric motor, it can also
more accurately measure flow.
Finally, one of the most obvious changes is being
able to operate the diaphragm style technology when
air is not available or, as in the case of most users
these days, to be able to operate in replacement of an
air pump to save up to 80 percent of the operational
energy costs.
Another Tool in the Toolbox

All pumping technology has its place within the
process, and for good reason. There are specific things
that each pump technology does very well that others
dont do very well. What is important is for users to
walk through their process and chemical handling
needs and be able to select the pump that best fits what
they are trying to do.
The electric diaphragm pump is now an additional
tool in the toolbox that can be used where other

technologies may have fallen short before.
Jeff Shaffer is product marketing manager at

Gracos Process Division. He is responsible for
developing products for the fluid handling
applications targeted toward electric drive
technologies, general process applications, and
food and beverage applications. He may be reached
at jshaffer@graco.com or 612-269-5204. For more
information, visit graco.com/process.

57
SPECIAL REPORT
PUMPS IN HARSH CONDITIONS
Protecting Pumps &

Systems in Oil & Gas
Operations
Grinder manufacturers adapt for a new environment.
BY KEVIN BATES
JWC ENVIRONMENTAL
O
il and gas drilling and processing operations
are arguably one of the harshest industrial
environments into which any equipment can
be deployed. These can be high risk and high
reward operations with success and profitability closely
linked to maximizing equipment uptime to maintain a
consistent throughput of production. This performance
is imperative within the oil and gas industry, which relies
heavily on the movement of fluids in closed systems and
can be slowed or brought to a standstill due to a clogged
pump or valve.
Crude oil refineries and drilling sites are especially at
risk because of the high solids content of slurries moving
through these operations, particularly relating to storage
tank bottom cleaning at refineries and the reclamation
of drilling fluids at the drill sites. Pumps, centrifuges and Image 1. Crude oil drilling sites are at risk due to high solids
liquid-solid separators, critical to keeping production content of slurries. (Images courtesy of JWC Environmental)
moving in these operations, are subjected to extremely
demanding industrial conditions under a constant down rocks, wood debris and paraffin sludge to ensure
onslaught of hydrocarbons like paraffins and asphaltenes pumps do not clog and that liquid-solid separators and
and inorganic solids like rock, sand, rust and heavy centrifuges receive properly-sized content for separation.
metal oxides. Consequently, this equipment experiences This enables them to operate at optimum throughout
a high incidence of interruption and repair, impacting without interruption.
production throughout as well as operational costs.
Increasingly, drill sites and refineries are now relying Crude Oil Tank-Bottom Sludge Removal
on powerful in-line, two-shafted grinders to protect their One of the most challenging issues for refineries is
pumping systems as well as costly downstream processing the development of methods to minimize the cost of
equipment. These grinders are powerful enough to grind removing and disposing of crude oil sludge in storage

Image 2. Crude oil sludge from storage tanks
tank bottoms. Crude oil sludge from storage tanks an already lengthy method. Because it is a process open
is a multiphase water/oil/solid composite, composed to the environment, sludge spills do occur, and volatile
primarily of heavy hydrocarbon deposits, paraffins and hydrocarbons are able to evaporate. This raises issues
asphaltenes and possessing a semisolid physical state. with plant emissions, which in some states has caused the
It is produced under normal storage conditions by the process to be restricted.
gradual sedimentation of heavy oil components, varying In response to these concerns, the petroleum industry
in consistency, density, thickness and composition has developed better, safer, faster and less expensive
across the whole tank bottom. Inorganic solids in the methods for tank cleaning, allowing tank bottom
crude oil, such as clay, silica, calcite and corrosion- hydrocarbons to be recovered and recycled back into
produced residues contribute to this process, bringing the refining process. These systems are overwhelmingly
more hardness and higher density to the deposit. The closed-loop processes where, once removed, the
accumulating sediment compacts, resulting in a thick hydrocarbons are recovered via enclosed external
layer of sludge, which is difficult to remove. The sludge can systems, such as centrifuges and liquid-solid separators.
accumulate many feet in depth and up to 100,000 barrels Many of these closed-loop systems are designed to
in volume, which causes a gradual reduction in the tanks improve throughput efficiency by reducing the size of
storage capacity, and uncertainty of available volume. solids in the slurry-sludge solution to protect downstream
Refineries have inspection policies to verify the pumps, valves, centrifuges and liquid/solids separators.
integrity of tank seals, flooring and roofs. To perform In a closed-loop system for cleaning crude oil tanks,
these periodic maintenance and inspection programs, the everything in that tank exits through a pump, before
sludge must be removed. Tank cleaning, in the traditional going to a centrifuge or liquid/solids separator, and
sense, has involved opening or cutting a hole in the tank then gets pumped back again into the tank under high
to remove the sludge, which is then openly transported pressure, said Charlie Gioielli, industrial markets
to shaker screens, fed through a liquid/solids separator manager with Hahn Equipment in Houston.
or centrifuge to reduce the volume of sludge waste, and Crude oil sludge is hard, it crumbles, it settles fast, and
subsequently transported to an off-site location. it is abrasive. The pumps are producing in the vicinity of
This process, however, has come under scrutiny. 1,500 pounds per square inch (psi), a lot of pressure that
Frequent throughput interruptions, in part caused by is being pushed through a relatively small passageway.
malfunctions with shaker screening systems, add time to Anything of size that gets in that passageway can block it

59
Reclaiming Drilling Mud are a mixture of various chemicals in

from Drill Cuttings a water-based, oil-based or synthetic-
Drilling fluids (drilling mud) are based solution. Drill cuttings are
integral to the drilling process, serving broken bits of solid material that
to lubricate and cool the drill bit, as are produced as the drill bit breaks
well as convey the drilled cuttings the rock. Drill cuttings vary in size,
away from the bore hole. These fluids ranging from fine silt to gravel.
and cause the pump to fail. That stops

the throughput dead, right there, until
it gets declogged, or if necessary, the
pump repaired or replaced.
The solution to prevent the
pump from clogging is to install an
in-line grinder before the pump.
We recommend dual-shafted, slow-
speed, high-torque grinders that
can handle up to 6,860 gallons per
minute (gpm) and easily shred the
toughest hydrocarbons, rust, rocks and
whatever debris might come through
from the tank.
The grinders serve a dual purpose.
Not only do they protect the pumps
from clogging and damage, but they
provide a consistent particle size for
optimum centrifuge performance.
Randomly too big and too small
particles inhibit their performance.
Centrifuges are used frequently in
these closed-loop systems, Gioielli
said. The more consistent the particle
size, the faster they can be fed the
sludge for separation, which reduces
the overall time required for tank
cleaning and hydrocarbon recovery.

60 SPECIAL REPORT PUMPS IN HARSH CONDITIONS
For both environmental reasons

and to reduce the cost of drilling
operations, drilling fluid losses are
minimized by stripping them away
from the drill cuttings before the
cuttings are disposed of. The drilling
fluid is often reused.
On drill sites, the systems used to
reclaim mud are considered critically
important to the process throughput
and efficiency of the operation.
Mud reclamation is primarily
accomplished using shale shakers
with vibrating screens to separate the
mud from the shale, with subsequent
processing of larger drill cuttings
with centrifuges.
The mud passes through the
screens and is collected into mud
tanks. The drill cuttings remain on
top of the shale shaker screens.
The vibratory action of the shakers
moves the cuttings down the screen
Image 3. Drilling fluid losses are minimized by stripping them away from drill cuttings.
and off, where they can be collected
at ion
Flo
w s
Solid Under
Pressure
ov
nn
ereI
Wh
New Almatec AHD & AHS Series AODD pumps are designed for safe
operation in high-pressure applications such as filter press feeding.
AHD with internal pressure booster provides 2:1 ratio with max drive pressure of PSG Euro-Center
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almatec.de

62 SPECIAL REPORT PUMPS IN HARSH CONDITIONS
pumps in petroleum-related applications, the suppliers of extremely fast and can easily destroy all the metal on the
grinders have been adapting. impeller passing too large of a solid.
One of the common needs in the industry is the easy So, in many applications we specify high-torque
relocation of the grinders from site to site as drilling or grinders, preferably dual-shaft, to grind up sludge or
tank cleanout operations move. debris that could harm the pump.
To fulfi ll this requirement grinders are now being One of our customers had a large settling pond that
built into plug-and-play skid packages that can be moved was laced with petroleum, and needed to use polymers to
by standard job site equipment like forklifts or cranes bind with the petroleum for extraction.
wherever they are needed. The polymer coagulated the petroleum, and those
These skids have pre-wired programmable logic big solids could not be run through their pump without
controller (PLC) control packages that only need power to clogging it.
run autonomously. So, we supplied a portable high-torque, dual-shafted
Additionally, most oil and gas operations are working grinder which protected his pump from potential damage.
within hazardous areas with the possibility of explosive A simple solution that may have saved them thousands of
gasses. The grinders are outfitted with controls and dollars in pump damage.
motors certified for use in hazardous locations.
Kevin Bates is the director of global marketing &
Proven Solution for Pumps
product management for JWC Environmental based in
Pumps are designed for different applications, so you are
Santa Ana, California. Bates has more than 20 years of
going to be more efficient at pumping clean water than
experience working with global industrial leaders to solve
you will be at pumping a slurry, said Daniel Namie, who
challenging technical problems spanning a wide range of
works with Superior Pumps in Sycamore, Illinois.
markets including wastewater, construction and mining.
When a pump impeller is cruising along at 3,600
He can be reached at kevinb@jwce.com.
rotations per minute (rpm) the velocities at the tip are
FOR PROCESS
CONTROL CONVEYING CAPACITY
PRECISION PUMPS 0.016264 USGPH
PRESSURE
Experience the precision of SEEPEXs BENEFITS UP TO 350 PSI

progressive cavity metering pumps. These Minimal pulsation with no dampeners
pumps require no valves and have steady, Reduced chemical consumption
unvarying flow. They handle abrasive /
Will not vapor lock
harsh chemicals or viscous materials with
Reduced energy consumption
low shear gentle handling. Low internal SEEPEX Inc.
velocities and a continuous cavity mean Lower NPSHa sales.us@seepex.com
minimal pulsation and greater material T +1 937 864-7150
flow accuracy. www.seepex.com

BUILDING SERVICES SPECIAL REPORT 63
Dewatering Presents Unique

Challenges in Construction
Companies should gather data and implement systems to
keep job sites dry so contractors can complete their work
on time and within budget.
BY JOE CHERLUCK
MERSINO DEWATERING INC.
Figure 1. DNR storm sewer line (Images and graphics courtesy of Mersino Dewatering)
I
nfrastructure projects often
involve excavation work to
subgrade depths that require
aggressive groundwater control
to make construction feasible and
safe. Construction dewatering
can be achieved by designing and
installing a subgrade pumping
system that operates continuously
to draw down the water table
sufficiently to allow work.
Dewatering presents unique
challenges because the variables
relevant to completing a project
are not easily identifiable and can
often require services beyond what
was originally expected.
Interstate Improvements
The total infrastructure
improvement efforts around I-29
in Council Bluffs, Iowa, required For this project, open cut excavations were required for
the work of many companies, including one that partnered installation of the 48-inch storm sewer at depths as much
with the general contractors to provide dewatering services. as 13 feet below grade. Geotechnical information indicated
Beginning in mid-2014, one of those companies installed that site conditions consisted of clay soil with interconnected
a dewatering system for the installation of a 48-inch storm sand seams extending from the ground surface to depths as
sewer for the Department of Natural Resources (DNR), which much as 30 feet below ground surface, with fine to coarse
now conveys flows from Mosquito Creek to Lake Manawa. sand underlying the less permeable soils. Groundwater was
This new storm sewer was a portion of the larger project to encountered as much as four to six feet below grade, and the
demolish and rebuild the I-29 and US-275 intersection. geotechnical information demonstrated an upward gradient

64 SPECIAL REPORT BUILDING SERVICES
for WATER
AND WASTEWATER
APPLICATIONS
within the natural aquifer, suggesting that hydrostatic pressure

would be encountered and would need to be relieved for work to
be successfully completed.
To efficiently dewater the site, the company proposed a deep
well dewatering system adjacent to the pipe alignment. After
developing the well, the company installed each additional well
in sequential order, approximately 15 feet from centerline of
the proposed utility.
These deep wells were eventually fitted with 10-horsepower
submersible pumps and plumbed into a common header system.
Collective discharge waters were conveyed approximately 1,000
linear feet from the system to Mosquito Creek and away from
the site.
Based on the relatively low permeability of the soils near the
The Most Complete Line of invert elevation of the proposed utility, the company advised
that an extended, continuous pumping duration would be
Swing Check, Ball Check, required to achieve sufficient drawdown.
and Plug Valves. To better affect the dewatering effort, the company targeted
the coarser zone of soil underlying the less permeable soils with
the screened portion of the deep wells.
By pumping the aquifer from the coarse stratum well
below invertgiven the interconnectedness of the less
permeable soils above with those coarser soils below
over time, the drawdown curve from each individual well
TOLL FREE 1-800-833-2040 FAX (518) 761-9798 progressively lowered.
www.omatic.com E-mail: omatic@omatic.com This caused an overlap of the conic effect on the water table
drawdown from well to well sufficiently below invert, allowing
MADE IN GLENS FALLS NEW YORK a dewatered excavation to take place. The pumping effort on

65
umps
Seal-less P
A Pump Like No Other
Image 1. Bypass pumps prevented catastrophic sewer interruptions
the coarser aquifer allowed the less permeable soils to be

drained over time.
Related Project
The interchange work on I-29 near the intersection of US-275
included relocation of a 48-inch combined sewer interceptor
line. This sewer, one of the main interceptor lines leading to
the Council Bluffs Wastewater Treatment Plant south of the
city, is vital to providing sewer service to tens of thousands of No leaks or VOC emissions
residents. An interruption would be catastrophic for the city. No dynamic seals, packing or cups to leak, wear or
For this portion of the project, a temporary bypass system replace. No leak path so there is full containment of
capable of diverting flows up to 20,000 gallons per minute liquids, vapors, and gases.
(gpm) was proposed. This system flows a distance of 1,400 feet
around the work area and back into the sewer downstream No pulsations
of the active construction. The system includes three 18-inch Hydraulically-balanced, multiple diaphragms provide
pumps, each configured for flow capabilities of 7,000 gpm for a virtually pulse-free flow and accurate metering. No need
combined capacity of 21,000 gpm. to buy expensive pulsation dampeners.
A fourth pump serves as a backup. In emergency conditions,

this pump will automatically turn on through the use of float
switches. Each primary pump pulls suction from nine feet below No problem
grade through an 18-inch high-density polyethylene (HDPE) Runs dry without damage to the pump. Minimal mainte-
suction pipe installed into an existing upstream manhole. The nance avoids costly downtime common to other types
system discharges through a manifold into a single 36-inch of pumps.
HDPE pipe to the downstream manhole about 1,400 feet away. Need to know more? Visit our new website.
Dewatering Solutions
Any job that involves excavation, particularly in the loose
unconsolidated soils common throughout the Midwestern
612-332-5681 www.Hydra-Cell.com

FLOW CONTROL IN IRRIGATION SPECIAL REPORT 67
Considerations in Flow
Meter Selection
Last of Two Parts
BY BRIAN KETTNER
BADGER METER
COMMON FLOW APPLICATIONS
F
low measurement is a critical aspect in a wide range
of plant operations. Users choosing equipment to HVAC and energy Diesel and fuel oils
meter the flow of liquid or gas processes must consider Utilities monitoring Sludge and slurries
various factors to arrive at an optimal solution. Water/glycol solutions Ultra-clean monitoring
Experience has shown there are significant differences
Pump monitoring Food products
between meter technologies, with each type of device having
its own advantages and disadvantages for industrial facilities. Balanced system flows Pulp stock
The previous article in this series (Pumps & Systems, Water treatment Chemicals
October 2017) described common flow applications and Sewage Effluents
types of flow technology. This article will look at important
Fuels and lubricants Irrigation and water use
selection criteria.
In a typical industrial facility, fluid characteristics Deionized water Open channels
(single or double phase, viscosity, turbidity), flow profi le
(laminar, transitional, turbulent), flow range and accuracy
requirements are all important considerations in determining Volumetric flow rate is the volume of fluid passing through a
the right flow meter for a particular measurement task. given volume per unit time. Mass flow rate is the movement
Additional considerations such as mechanical restrictions of mass per time. It can be calculated from the density of the
and output-connectivity options impact the users choice. liquid (or gas), its velocity and the cross-sectional area of flow.
Volumetric measuring devices, like variable area meters or
Some of the key criteria in flow meter selection include: turbine flow meters, are unable to distinguish temperature
1 Process media. Different flow meters are designed

to operate best in different fluids and under different
operating conditions. Thats why it is important to
or pressure changes. Mass flow measurement would require
additional sensors for these parameters and a flow computer
to compensate for variations in these process conditions.
understand the limitations inherent to each style of Thermal mass flow meters are virtually insensitive to
instrument. Fluids are conventionally classified as either variations in temperature or pressure.
liquids or gases. The most important difference between
these two types of fluid lies in their relative compressibility
(i.e., gases can be compressed much more easily than liquids).
3 Flow rate information. A crucial aspect of flow
meter selection is determining whether flow rate
data should be continuous or totalized. A flow rate has to
Any change that involves significant pressure variations do with the quantity of a gas or liquid moving through a
is generally accompanied by much larger changes in mass pipe or channel within a given or standard period of time.
density in the case of a gas than in the case of a liquid. A typical continuous flow measurement system consists of a
2 Type of measurement. Industrial flow measurements

fall under one of two categories: volumetric or mass.
primary flow device, flow sensor, transmitter, flow recorder
and totalizer.

68 SPECIAL REPORT FLOW CONTROL IN IRRIGATION
4 Desired accuracy. Accurate flow measurement can

be the difference between on-spec quality and wasted
product. Flow meter accuracy is specified in percentage
barriers to eliminate a potential spark. Another option
is to employ fiber optics. Turbine flow meters offer an
advantage in environments where a power source is not
of actual reading (AR), percentage of calibrated span available. They do not require external power to provide
(CS) or percentage of full-scale (FS) units. It is normally a local rate/total indicator display for a field application,
stated at minimum, normal and instead rely on a
and maximum flow rates. A battery-powered indicator.
clear understanding of these Solar-powered systems can
requirements is needed for also be used in remote areas
a meters performance to be A crucial aspect of flow meter without power.
acceptable over its full range.
5 Application
environment. Flow
selection is determining
whether flow rate data should be
9 Necessary approvals.
Approvals for the
use of flow measurement
meters can be employed
continuous or totalized. equipment in hazardous
under a host of varying plant locations include FM
conditions in an industrial Class 1 Division 1, Groups
plant. For example, users A, B, C and D; and FM Class
must decide whether the low 1, Zone 1 AEx d (ia) ia/IIC/
or high flow range is most important for their metering T3-T6. Standards such as the Measuring Instruments
application. This information will help in sizing the Directive (MID) in the European Union (EU) apply to
correct instrument for the job. Pressure and temperature fiscal and custody transfer metering for liquids and gases.
conditions are equally important process parameters. In terms of environmental emissions, industrial flow
Users should also consider pressure drop (the decrease meters must meet the Electromagnetic Compatibility
in pressure from one point in a pipe to another point (EMC) Standards EN55011:1992 and EN61326-1:1997.
downstream) in flow measurement devices, especially
with high-viscosity fluids. In addition, viscosity and
density may fluctuate due to a physical or temperature
1O Output/indication. Flow meter users
must decide whether measurement data is
needed locally or remotely. For remote indication, the
change in the process fluid. transmission can be analog, digital or shared. The choice
6 Fluid characteristics. Users should make certain

that the selected flow meter is compatible with the
fluid and conditions they are working with. Many plant
of a digital communications protocol such as HART,
FOUNDATION Fieldbus or Modbus also figures into
this decision. In a large industrial facility, flow readings
operations involve abrasive or corrosive fluids, which are typically supplied to an industrial automation and
move under aerated, pulsating, swirling or reverse-flow control system (IACS) for use in process control and
conditions. Thick and coarse materials can clog or damage optimization strategies.
internal meter componentshindering accuracy and
resulting in frequent downtime and repair. Summary
7 Installation requirements. Planning a flow meter

installation starts with knowing line size, pipe
direction, material of construction and fl ange-pressure
Choosing the right flow measurement solution can
have a major impact on operational and business
performance. For this reason, companies anticipating a
rating. Complications due to equipment accessibility, flow meter purchase should consult with a knowledgeable
valves, regulators and available straight-pipe run lengths instrumentation supplier in the early stages of a project.
should also be identified. Nearly all flow meters must The effort spent learning about basic flow measurement
be installed with a run of straight pipe before and after techniques, and available meter options, will ensure a
their mounting location. Where this is not possible, a flow successful application once the equipment is installed.
conditioner can be used to isolate liquid flow disturbances
from the flow meter while minimizing the pressure drop
across the conditioner.
8 Power availability. Pneumatic instrumentation

was once used in most hazardous area applications,
since there was no power source to cause an explosion.
Brian Kettner is a product manager at Badger
Meter. He may be reached at 414-371-5989 or
Todays installations normally call for intrinsically bkettner@badgermeter.com. For more information,
safe instruments, which are current limited by safety visit badgermeter.com.

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70 MAINTENANCE MINDERS
Rotor Rubbing in Pumps

Learn the risk factors and how to mitigate damage.
By Amin Almasi
Rotating Machinery Consultant
T
he rotor-to-stator rub has been an design and operation parameters of malfunction could be an unbalance,
important malfunction in many a pump. Sometimes, modifications of misalignment, fluid-induced excitations
pumps. The rotor rub could result the shape and wideness of rotor orbits and self-excited vibrations, which all
in serious damages such a shaft failure. (and consequent changes in the rotor result in high vibration amplitudes
The bending movements associated centerline position inside the bearings (or changes in the shaft centerline
with the shaft bow caused by rubs could and seals) can allow the available radial position within available clearances)
result in very high stresses on a pump clearance to become sufficient to and eventually result in the rubbing.
shaft. Proper vibration-based condition avoid rubs. When rotor-to-stator rubs The unbalance and misalignment are
monitoring systems can be employed occur during a transient situation relatively easy to model. Other effects
to identify the rub severity and rub such as a start-up or a shutdown, the are relatively difficult to analytically
location. The rub phenomena and related shaft bow evolution can become more model. The common rub models reflect
vibration signature are discussed. complex, particularly considering some an intermittent action of the rub. The
high-speed pumps passing through shaft simplified mathematical formulations
Introduction flexural critical speeds in the start-up become piece-wise continuous with
The study of rotor-to-stator rub and shutdown. variable stiff ness. The modal stiff ness is
phenomenon is one of the necessary split into several sections. For simplified
items for proper operation, reliability and Rotor Rubbing models, usually three sections are used.
monitoring of a pump. It is important Advanced vibrational condition The friction is commonly approximated
because of relatively small clearances monitoring methods have been used by using the Coulomb model. The friction
present between the rotor assembly for effective operation of pumps. force is oriented in the tangential
and various static parts. Many types of Understanding basic factors of the pump direction opposite to the direction of
malfunctions or degradations such as a vibrational behavior goes beyond pump rotation. The effect of short-lasting,
high value of unbalance, a misalignment, dynamic modeling. It should involve deep impact-related rotor/stator contact could
high shaft vibrations or some induced understanding of the pumps dynamic be considered (estimated) in terms of
dynamic instabilities can cause rotor-to- behavior during its operation and any rotor free-vibration response, following
stator rubs in a pump. malfunction situation. A pump vibration each impact.
Rubs can cause impacts, chaotic monitoring requires appropriately The rubbing usually presents fractional
motions, sub-synchronous vibrations selected and strategically located sub-synchronous vibrations, often
and super-synchronous vibrations. On vibrational sensors for capturing the with backward directions (resulting
the other hand, light partial arc rubs pump vibration. in external loops on the rotor orbits).
and full annular rubs often cause major The rubbing between the rotor In other words, because of particular
progressive changes in synchronous assembly and stationary part of a pump is system nonlinearity, the unbalance force
vibrations. Sometimes, depending on the a serious malfunction that could lead to a excites fractional frequency responses.
mechanical and thermal characteristics catastrophic failure. The rubbing involves The rubbing could cause self-excited
of a pump and the shaft rotating speed, several physical phenomena, such as vibrations (known as dry whip or
stable or unstable synchronous spiral the friction, stiffening effects, coupling full annular rub, occurring mainly in
vibrations could occur. effects and impacting. The rubbing could seals) independently from the excited
Often, the rub phenomena that occur affect the fluid and thermal balance vibrations. Pump seals could offer the
in operating conditions can be prevented inside a pump. The rubbing usually minimum clearance in a pump rotor
by properly modifying some suitable occurs as a secondary effect. The primary assembly. The seals are usually the

71
first places to rub. In a typical high-speed pump rotor rubbing

incidence, a rotor is lightly rubbed on a surface of a seal.
Fractional sub-synchronous vibrations (particularly 1/2, 1/3,
1/4) and the synchronous vibration (1) are observed in such
cases. At a high-speed pump, a full annular rub could occur. In
relatively low-speed pumps, a rotor could bounce inside a seal,
producing multiple higher harmonics (2, 3) in addition of the
synchronous vibration (1).
High radial (normal) and corresponding friction (tangential)
forces at the contacting surfaces could lead to extremely severe
damages of the seal and rotor surfaces in a very short time.
In addition, because of the backward mode of vibrations in
a rubbing case, the rotor operates under severe alternating
stresses with relatively high frequencies. The rub-related failures
of pumps occur quite often.
Any dynamic response of a pump rotor rubbing usually
contains a spectrum of higher harmonics (besides the
fundamental component). The impact, as a nonlinear mechanism
involved in the rubbing, can increase the strength of higher
harmonics spectrum even more. The rotor-to-stationary element
rubbing is actually a very harmonic rich phenomenon resulting
in rapidly changing system parameters with a tendency to
chaotic motions. The diagnosis of rotor rubbing using vibrational
data is mainly based on:
appearances of sub-synchronous fractional components
(particularly 1/2 sub-synchronous vibration)
brief appearances of components with natural frequencies
(because of the transient character of the rubbing)
appearances of high harmonics of the fundamental speed
component (1, 2 and 3)
changes in shaft centerline positions. Partial or fully
backward orbiting of the rotor is one of the important
characteristics of rubs, distinguishing this malfunction
from others.
The vibration amplitudes could become limited at the

rubbing location, and the dynamic amplitudes may increase in
other shaft sections. The thermal effect of rubbing can cause
ever-changing vibrations of the shaft. These mechanical and
thermal effects may lead to vibration amplitude fluctuations

and continuous phase-lagging as a function of time resulting in
spiral characteristics.
The friction forces generated during heavy contacts or rubs
could produce a considerable amount of heat. Sometimes,
depending on characteristics of the rub phenomena, this heat
is transmitted to the rotor through a small portion of the
circumferential surface; of course, the effect of pumped liquid
should always be considered. This local heating (locally high flux
of heat) could cause a shaft thermal bow and sudden changes in
synchronous vibrations.

72 MAINTENANCE MINDERS
Special Considerations for Rubbing

The rubs can significantly affect the vibrations of a
pump. These dynamic effects could be particularly
pronounced on a pump shaft portion near the rub
location. The heat introduced into the rotor assembly by
friction forces and impact effects could induce time-
varying excitations to a pumps shaft.
This can generate time-varying (transient) vibrations.
The time-varying characters should be considered in
analytical models and condition monitoring exercises.
The rate of magnitude increase of the time-dependent
bending moments induced by rubs can give very helpful
information in the monitoring exercises on a pump
rotor system.
An accurate nonlinear method that combines thermal
equations and motion equations of a pump system
should be employed for an accurate modeling of the rub.
The nonlinear modeling is absolutely necessary to obtain
satisfactory results. The sub-synchronous vibrations
(1/2, 1/3, 1/4) and super-synchronous vibrations (2,
3, 4) show clearly the importance of nonlinear effects
in a rubbing incident. The evaluations of the rate of
changes in vibration amplitudes, shaft bow and bending
moments (and stresses in a shaft) are important in a rub
incident modeling.
The heaviest rubs usually occur on limited portions of
a pump rotor where some small clearances are located.
The shaft can be affected by one (or more) local bow(s),
the amplitude of which is time-dependent.
A higher vibration is expected at the rotor side near
the rub location.
The rub location could be identified by comparing the
vibrations of two sides of the rotor (where vibration
sensors are usually installed).
To read more Maintenance Minders articles, visit

pumpsandsystems.com/tags/maintenance-
minders
Amin Almasi is a senior rotating machinery consultant

in Sydney, Australia. He holds a bachelors degree
and masters degree in mechanical engineering. He
specializes in rotating machinery including pumps,
compressors, gas turbines, steam turbines, engines,
condition monitoring and reliability. Almasi is an active
member of Engineers Australia, IMechE, ASME and SPE.
He has authored more than 150 papers and articles
dealing with pumps, rotating equipment, condition
monitoring and reliability.

EFFICIENCY MATTERS 73
Pump Rebuild Boosts Efficiency & Max Flow

How one company accomplished a complete overhaul of four pumps at water treatment facility.
By Loren Nauss
Henkel
N
early every business,
industry, municipality,
school and home has
and uses pumps. They pump
everything from drinking water
and wastewater in cities and towns
to heavy aggregate solutions in
mines, quarries, power plants,
and in oil and gas fields. As
common as pumps are, when
normally functioning they are
often overlooked until they need
attention. This usually shows itself
in a few ways:
increasing bearing noise
sudden increase in vibration
pumping output dropping 25 to
50 percent, which shows up as
an increase on the electric bill
Image 1. Failure to repair a pump can lead to more expensive
For discussion here, a problems. (Images courtesy of Henkel)
homeowner takes a walk outside
early one Saturday morning and Now, lets scale this up to happen in the industrial workplace
hears his 17-year-old pool pump industrial application proportion all the time requiring analysis of
screaming for attention. Then, and to situations many of the situation, investment in repairs
after a quick analysis and $150, the engineers, managers and or new equipment and potential
the homeowner picks up the maintenance professionals either for very high downtime costs. The
new motor, swaps it out and the have run into or likely will in untimely failure of a single piece of
summer fun continues. the future. Situations like this equipment like a pump can lead to
astronomical costs, and they can
add up in a hurry.
There are many types of pumps
in an array of industries that, at
As common as pumps are, when normally some point or another, require
service and maintenance to
functioning, they are often overlooked until they optimize their functionality. At
need attention. one point in time, the only cost
that seemed important was the
purchase and installation price
of the pump. Today folks realize

74 EFFICIENCY MATTERS
that purchase price is often only Waterbury, Connecticut, reached

a small part of the overall cost the point where major mid-life
of a pump, and other factors like service was required on all four of
warranty, installation/rigging, their Allis Chalmers Model NSYV
operating parameters, plant/ 250 Influent pumps. The pumps
facility alteration requirements, had been in service for 19 years
pump service and repair, and and were showing signs that major
pump efficiency all factor into service would be required in the
the total cost of ownership. In near future.
the pool pump, the decision was The City of Waterbury employed
pretty simple with a low-cost the professional engineering
motor replacement solution. services of Tighe and Bond to
In an industrial application, develop proposals and assist in
a pump issue decision is more managing the project for the
complicated, and the associated sequential overhaul of the pumps,
costs can run into tens of motors, drive shafts and
thousands of dollars and more. discharge check valves over a
12-month span.
Examining Cost to Repair The technical and price
Pumps vs. Cost to Replace evaluation resulted in the project
Image 2. Purchase price is only a small component of Recently, the regional Water award to New England Pump and
maintaining the life of a pump. Pollution Control Authority in Valve Company (NEPV).
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Contact the Hydraulic Institute at psap@pumps.org or 862.217.2441


75
Many factors are taken into consideration

when it comes to performing a job of this type
and there are typically two perspectives that
weigh heaviest. The pump owner is usually
looking at the following factors in a service
provider:
knowledge and experience
the providers resources (technical,
financial, and workforce) to complete the
work as proposed
the relationships within complementary
industries required in order to complete
the work
their professional reputation
Technically the pump owner is weighing the

costs to repair versus to replace. Some of these
considerations include: new versus overhaul
costs, new pump system modification costs,
parts obsolescence and original equipment
Image 3. Studies of large pump efficiency have
manufacturer (OEM) support, and energy become popular due to the potential for significant
efficiency gains. cost savings.
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In an industrial
application, a pump
issue decision is more
complicated, and
the associated costs
can run into tens of
thousands of dollars
or more.
Sometimes, a pump housing or casing

may be so unique that refurbishment and
repair is the only way to go.
Even though the technology
exists today, years after the original
installation a different type of pump
Circle 149 on card or visit psfreeinfo.com. might perform the same function in
a much simpler way. Lastly, often the
equipment required to rebuild some
IXON PUMPS
larger pumps is not found in todays
standard machine shops.
Studies of large pump efficiency have
become popular due to the potential for
significant cost savings.
The City of Waterbury recognized the
potential to reduce total ownership costs
while completing this major overhaul
project and partnered with the local
electrical provider Eversource Energy to
reduce energy consumption.
The project is comprehensive and
rigorous in approach to ensure
the customer achieved all of their
objectives including the following major
project components.
Performance testing (pre- and
post-overhaul) that included pump
and motor energy consumption
and efficiency
Vibration testing (pre- and
post-overhaul) that is critical to
optimizing pump and motor function
and life. This also validated the
dynamic balancing of the pump,
motor and driveshaft

balanced with the impeller. All

tolerances were restored to factory
specifications and the exterior surfaces
coated with a two-part epoxy.
Conclusion
So what did the test results show in
this rebuild? An average efficiency
improvement of 6 percent, and significant
improvements in both pump head/flow
and maximum flow rates. The targeted
2 percent energy reduction for this 250
horsepower (hp) motor-driven pump was
exceeded, and these results are in line
with prior studies by federal, state/local
and industry groups. This is expected
to expand as the work on the three
remaining pumps is completed.
The key to the success of this project
and the efficiencies gained in the
equipment performance are tied to the
expertise of the service provider and
Circle 153 on card or visit psfreeinfo.com. their ability to properly select, prep and
apply the correct ceramic coatings to meet
the need.
Mobile Flood Rigorous oversight and documentation
of the project by the design team ensured
Control Pumps that the project goals were measured
3 - 30 inch pumpsets and achieved.
400 - 40.000 GPM So when faced with what may appear at
100 - 10.000 m3/h first to be a negative situation, seek out
the right solution coupled with the correct
solution providers and it is likely the
outcome will be a positive one.
Loren Nauss is a business development

manager of maintenance chemicals at
Henkel Corporation focusing on protective
coatings. He has a bachelors degree in
business from Eastern Connecticut State
University and 25 years of experience
supporting, rebuilding, repairing and
fabricating industrial equipment.
Nausss industry experience includes
products, projects and applications in
Contact us now for more details!

info@bbapumps.com mines, quarries, pulp and paper, power
www.bbapumps.com generation, and oil and gas.

PRACTICE & OPERATIONS 79
Siphons & the Siphon Effect 101:

That Sucking Sound
By Joe Evans, Ph.D.
Figure 1. The layout of a simple siphon.
(Figures courtesy of The Central Arizona
Editors Note: This article originally appeared in the November 2007 issue of Pumps & Systems. Irrigation Project)
T
L
his past summer I received a the liquid in the longer (or down) leg
suggestion from a Pumps & Systems causes continuous downward flow. One
reader to discuss siphons and their of the key phrases in this definition is
effect on pump head and pipeline flow. continuous flow this separates a true
If you are like me, your first experience siphon from the siphon effect that may 2
with one of these devices probably led to occur in a piping system.

your first and hopefully last taste of Although the siphon appears quite
gasoline. The siphon is an example of a simple, there is still some debate as
natural and extremely simple machine to how it actually operates. Gravity
that we take advantage of daily. obviously causes a liquid to flow through must also be completely full and free
Their earliest known use dates back the down leg, but what causes it to of air and liquid vapor. If any of these
to the Egyptians around 1500 BC, but navigate the up leg? conditions are violated, the siphon will
the siphon principle was not described If you submerge the end of a long tube cease to operate. Under ideal conditions
until about 240 BC. The man credited was in a container of water, the water within and an atmospheric pressure of 34 feet
the Greek mathematician and inventor the tube will rise to a level equal to its (ft) at sea level, the maximum height of
Tesibius of Alexandria. He was known for surface level in the container. If you were the upper leg is limited to about 33 ft.
three major inventions: the piston pump, to evacuate all of the air in the tube, the So, if you had to guess, what is one
the water clock, and the hydraulis, which level inside would rise to a level equal to of the most common uses of a siphon
was the ancestor of the pipe organ. All of the atmospheric pressure pressing down that we see every single day? It is The
his written works have been lost, but his on the surface of the container. Silent Valveless Water Waste Preventer,
successors refer to him in their writings The traditional explanation of a siphon patented in England in 1819 and better
as the father of pneumatics. states that the flow in the down leg, due known today as the flush toilet.
to gravity, creates a partial vacuum in If you look at the side of many modern
True Siphons the upper most portion of the conduit. toilets, you can actually see the outline
There are several definitions of a siphon. That partial vacuum allows atmospheric of the siphon conduit. The height of the
The Pump Handbook provides a couple: pressure to initiate flow through the upper leg dictates the static water level in
one explains it as a pipe or other closed upper leg. This sounds reasonable, but the bowl. When the flush valve is opened,
conduit that rises and falls, while a more there is quite a bit of debate as to the water flows from the tank into the bowl,
specific definition refers to a jet pump effect the cohesive forces of the liquid the water level rises and water begins to
that utilizes a condensable vapor as a molecules have on maintaining flow. I flow into the down leg. Once the down leg
motive fluid. Both can be examples of think it is reasonable to expect that both is completely full, the system becomes a
the siphon effect, but neither describes cohesion and a partial vacuum play a role. true siphon and ends with that sucking
exactly how I was able to transfer Here we see water flowing from sound when the tank and bowl are empty.
gasoline from my dads car to our lawn an upper reservoir and discharging The J trap beneath your bathroom
mower (and my mouth). into a lower one. For a siphon to flow lavatory is often referred to as an
I define a true siphon as a tube continuously, the height of the upper inverted siphon, but it is not a siphon at
or pipe through which a liquid can be leg (h) must be less than atmospheric all. It relies on the weight of the water in
moved from a higher to a lower level by pressure and the outlet of the down leg the longer down leg to force water though
atmospheric pressure forcing it up the (L2 ) must be below the surface of the the shorter up leg. Once the lavatory has
shorter (or up) leg while the weight of upper reservoir (L1 ). The siphon conduit completely drained, some water remains
p u m p s a n d s y s te ms . co m | Nov ember 2017

MOTORS & DRIVES 81
5 Ways to Reduce Harmonics

Several kinds of equipment can help, depending on the system.
By EATON SOLUTIONS
Consider
Add a line- using active
side matrix- front-
type passive end VFD
reactor for packages for
mid-to-large applications
(20 hp to 200 where power
hp) loads. regeneration
is beneficial.
18-pulse VFD Use active

packages use harmonic
Use VFDs phase-shifting filters to
with built-in transformers address
AC reactors and additional harmonics
or DC chokes rectifier issues at the
for low hp bridges to point of
(<20 hp) achieve THDi common
loads. around 3%, coupling, ideal
ideal for for existing
>200 hp loads. installations.
Take a look back at previous Motors & Drives columns

for technical information from our experts to help you
handle some of the toughest problems in the industry.
Visit pumpsandsystems.com/motors.
82 SEALING SENSE
Controlling the Seal Chamber Environment

Lowering temperature can create a more stable fluid film.
By Mark Savage Figure 1. Typical mechanical seal with integrated pumping ring and throat bushing (Courtesy
FSA Member, John Crane of FSA)
R
educing the temperature in
the seal chamber offers many
benefits to the performance and
reliability of a mechanical seal operating
in hot service. This is one of the most
effective ways to increase the vapor
pressure margin and prevent the pumped
fluid from flashing in the seal chamber or
at the interface of the mechanical seals
faces. Additionally, lowering the seal
chamber temperature also increases the
fluids viscosity, providing a more stable
fluid fi lm at the interface of the seal faces.
One method of achieving a reduction
in temperature is to circulate fluid
from the seal chamber through a heat selection and installation of the flow Plate-style heat exchangers, although
exchanger and return the cooled fluid circuit is optimized to provide the least compact and with large heat transfer
back into the seal chamber. The heat resistance to flow, thereby maximizing rates, should be avoided as their
exchanger is often referred to as a seal the circulation rate and the ability of heat resistance to flow is high. Air-cooled
cooler since it is not part of the process, energy to be transferred from the seal heat exchangers can be used in water
but just an auxiliary system component. chamber to the heat exchanger. constrained installations. However
This piping arrangement is known as an careful design and selection is required
API Plan 23. When installed, operated Optimizing the Flow Circuit to meet the cooling capacity needed while
and maintained correctly, a Plan 23 is one There are three main elements to the flow not being excessively large.
of the most effective methods of lowering circuit that can be optimized: The preferred method to connect the
the seal chamber temperature. 1. The heat exchanger heat exchanger to the seal chamber is
2. The interconnecting tubing between using drawn tubing (where codes and
Creating Flow the heat exchanger and seal chamber standards allow). The diameter should
Fluid is circulated through the 3. The entry and exit ports in the match that of the heat exchanger coil.
heat exchanger by a pumping ring seal chamber (or mechanical seal) If in doubt, a larger size should be
incorporated into the mechanical seals and their position relative to the selected. Note that excessively large
design. The pumping ring, typically a pumping ring sizes will not yield positive results and
slotted wheel or helical scroll, is spinning may be detrimental to lowering the flow
with the pump shaft and functions as a The heat exchanger needs to be of a resistance of the circuit. To minimize the
miniature pump within the seal chamber. suitable size to dissipate the heat load resistance to flow in the tubing, valves
In comparison to the main impeller on placed on it while offering minimal should be avoided. If they are required,
the pump shaft, the pumping ring only resistance to flow. Water-cooled shell they should be full-ported gate type or
generates an extremely small fraction and tube heat exchangers meet these locking -turn ball valves. The number
of pressure head and flow. Thus, it is requirements and are often the first of bends in the tubing should also be
of critical importance that the design, choice for a heat exchanger design. minimized, only using long radius bends

84 SEALING SENSE
Figure 2. Typical API Plan 23 arrangement
Waxy fluids or fluids that solidify

at ambient or cooling water
temperatures can solidify in the heat
exchanger while the pump is idle.
Fluids with high viscosities may not
be able to be pumped through the
Plan 23 circuit at a sufficient flow
rate to transfer the heat load placed
on the system.
For these situations, alternative

cooling methods such as API Plan 21
or Plan 32 should be considered. The
need for seal chamber cooling can
also be eliminated by the use of a dual
pressurized seal.
Conclusion
API Plan 23 provides an effective
slope upwards towards a high point vent interconnecting tubing. Process side method of controlling the seal chamber
at a minimum slope of 0.5 inches per venting often requires special sizing temperature around the mechanical
foot (40 millimeters per meter). As the and routing considerations depending seal. This reduction in seal chamber
interconnecting tubing will be hot during on fluid properties, system pressure, temperature can suppress vaporization
operation, the potential for contact burn temperature and hazards. The design and improve the properties of the fluid at
injuries to maintenance and operation must ensure effective venting capability the interface of the mechanical seal faces
personnel is present. Expanded mesh while maintaining safe operation. resulting in improved seal reliability.
heat guards are the preferred method of
mitigating burn hazards since they allow Maintenance Next Month: What cautions are
natural heat convection to occur from the Cleaning the heat exchanger should necessary when using a gasket
exposed tubing. For installations where be performed when loss of efficiency is manufacturers torque charts?
space is tight, mechanical insulation can apparent. Normally, this results from
be used to mitigate the hazards. fouling of the cooling water side of the We invite your
The orientation of the heat exchanger heat exchanger. The rate at which fouling suggestions for article
topics as well as questions
should be selected so that any air trapped occurs depends on the quality of the on sealing issues so we
in the cooling coils can naturally flow to cooling water and the heat load placed can better respond to the
a high point and be vented. The location on the heat exchanger. Areas with hard needs of the industry. Please direct suggestions and
and height of the heat exchanger should water will require frequent cleaning of questions to sealingsensequestions@fluidsealing.com.
be selected so that it facilitates access the heat exchanger to remove mineral
for servicing the heat exchanger while scale. The heat exchanger should be Mark Savage is a product group man-
minimizing the impact of access to cleaned at every seal change. ager at John Crane, responsible for the
the pump for maintenance. The heat design, development and application
exchanger should never be mounted Additional Considerations of metal bellows seals for compressors,
directly over the pump or motor. There are some applications where this pumps and rotating machinery. He
Prior to starting the pump, the process solution may not be the ideal choice: has worked in the sealing industry for
and water side of the heat exchanger Dirty fluids can result in accumulation 23 years and has been involved with
need to be vented of any trapped air of solids in the seal chamber that developing best practices for
or vapor. High point vents fitted to interfere with operation. shaft seals and their support
both the cooling water and process Fluids with gaseous constituents can systems. Mr. Savage holds a
piping facilitate the venting. Venting Bachelor of Engineering from
cause the Plan 23 circuit to vapor
of the process side also vents the heat the University of
lock and prevent flow through the
exchanger, the seal chamber and the Sydney, Australia.
heat exchanger.

HI PUMP FAQS 85
Throttling Valves & Pump Corrosion Issues

By Hydraulic Institute
Figure 4.11. Control of pump flow by changing the system resistance using a throttle valve
(Graphics courtesy of Hydraulic Institute)
What are throttling valves

and how are they used to
control flow rates?
Throttling valves are a type of

valve that can be used to start, stop
and regulate the flow of fluid through
a rotodynamic pump. When the flow
of a pump is regulated using a
throttling valve, the system curve is
changed. The operating point moves to
the left on the pump curve when the
flow is decreased.
Throttling valves are one way of
controlling flow rates, by throttling Radial flow (centrifugal pumps) have We have experienced
flow directly or in a bypass line. a reduction in pump power as flow corrosion issues with our
Variable speed operation is an rate is decreased, however the flow pumps. Are there different
alternative method of controlling the multiplied by the head drop across types of corrosion I should
flow of a system. the valve is wasted energy that could evaluate, and how does the
With the throttling valve control be recovered if speed control was corrosive nature of a process
method, the pump runs continuously, used as an alternative. On the other fluid impact pump selection?
and a valve in the pump discharge line hand, using throttling control with
is opened or closed to adjust the flow mixed or axial flow pumps, where Corrosion is the destructive
to the required value. To understand the pump power curve is normally attack of a material by chemical
how the throttling controls flow rate, increasing with deceased flow, could or electrochemical reaction with
see Figure 4.11. With the valve fully lead to unacceptable increases in its environment. Chemical and
open, the pump operates at Flow 2. power consumption, which results in electrochemical corrosion can be
When the valve is in the partially open overloading the driver in addition to further divided into several subtypes
position, it introduces an additional wasted energy. of corrosion, which all pump users
friction loss in the system, resulting When evaluating the life cycle should be aware of in order to select
in a new system curve that intersects cost, in addition to energy costs, proper construction materials
the pump curve at Flow 1, which is the maintenance cost of control valves and ensure the longevity of pump
new operating point. need to be considered, particularly in components. The following list
The head difference between the oversized situations where excessive provides general information about
two curves operating points shown throttling is ongoing and results in the different types of corrosion.
is the head (pressure) drop across the cavitation across the valve. The result Uniform corrosion, also known
throttling valve. is that the life cycle costs of this as general attack corrosion.
It is usual practice with throttling widely used control method can be Uniform corrosion is the overall
control to have the valve partially shut surprisingly high. attack of a metal by a corroding
even at maximum system design flow For more information on controlling liquid that results in a relatively
to achieve controllability. Therefore, the flow rate in pumps, refer to uniform metal loss over the
energy is wasted overcoming the the Hydraulic Institutes Application exposed surface. It is the most
resistance through the valve at all Guideline for Variable Speed Pumping common type of corrosion, and it
flow conditions. at pumps.org. can be minimized with the proper

86 HI PUMP FAQS
Figure 6.8. Section of a severely corroded impeller
selection of corrosion- liquid become trapped and

resistant material. This a difference in potential
kind of corrosion is is established due to the
typical of pumps handling oxygen concentration
chemicals. difference in these cells.
Galvanic corrosion, Stress corrosion is a
also called dissimilar corrosion process that
metal corrosion. Galvanic results from a combination
corrosion occurs when of chemical, temperature
two dissimilar metals and stress-related
are located together in conditions.
electrical contact in an Erosion corrosion, or
electrolyte. One of the two flow-associated corrosion,
metals becomes the anode results when the protective
and the other the cathode. layer of fi lm on a metal
Circle 158 on card or visit psfreeinfo.com. The anode is the sacrificial surface is destroyed by
metal and corrodes faster high-velocity fluids. This
than it would alone, while kind of corrosion can be
Statement of Ownership, Management and Circulation
the cathode deteriorates especially harmful to pump
Publication Title: Pumps & Systems Magazine Full Names and Complete Mailing Address of
Publication Number: 1065-108X Publishers, Editor and Managing Editor more slowly than it would components, as seen in
Filing Date: 9/28/2017 Publisher: Walter B. Evans, Jr.
Frequency: Monthly 1900 28th Avenue South Ste 200 otherwise. Figure 6.8.
Number of Issues Published Annually: 12 Birmingham, Alabama 35209
Annual Subscription Rate: $48.00
Editor: Alecia Archibald Intergranular
1900 28th Avenue South Ste 200
Complete Mailing Address of Known Office
of Publication
Birmingham, Alabama 35209 corrosion is a chemical For more information on
Managing Editor: Georgia Duke
1900 28th Avenue South Ste 200
Birmingham, Alabama 35209
1900 28th Avenue South Ste 200 or electrochemical attack how corrosion affects pumping
Birmingham, Alabama 35209
Complete Mailing Address of Headquarters or Owner: Cahaba Media Group on the grain boundaries systems, refer to Reliability of
General Business Office of Publisher P.O. Box 530067 Birmingham, AL 35253
1900 28th Avenue South Ste 200 Walter B. Evans Jr of a metal. It is often due Pumping Equipment: Guidelines
Birmingham, Alabama 35209 P.O. Box 530067 Birmingham, AL 35253
to impurities in the metal, for Maximizing Uptime,
Known Bondholders, Mortgagees & Other Security Holders Owning or Holding 1% or More
of Total Amount of Bonds, Mortgages, or Other Securities. ......................................................... None which tend to be present in Availability, and Reliability. To
Tax Status: Has Not Changed During Preceding 12 Months
higher concentrations near see corrosion allowances for
Average No. of No. Copies of
Copies Each Issue Single Issue grain boundaries. different pump components,
Issue Date of Circulation Below: September 2017 During Proceeding Published Nearest
12 Months to the filing date. Pitting corrosion is a refer to ANSI/HI 1.3
Total Number of Copies (Net Press Run)......................................................................................... 41,707 43,049
Paid/Requested Outside County Mail Subscriptions Stated on form localized type of attack. It Rotodynamic Centrifugal Pumps
3541 (Include advertisers proof and exchange copies) .............................................................. 26,131 26,650
Sales Through Dealers and Carriers, Street Vendors, Counter is caused by a breakdown for Design and Application.
Sales, and Other Paid or Requested Distribution Outside USPS ....................................................4 7
Total Paid and/or Requested Circulation ........................................................................................ 26,135 26,657 of the protective fi lm
Non-Requested Distribution Outside County as stated on 3541 ............................................ 13,881 13,737
Non-Requested Copies Distributed Outside the Mail ........................................................................672 1,685 and results in rapid pit
Total Non-Requested Distribution..................................................................................................... 14,553 15,422
Total Distribution ................................................................................................................................... 40,688 42,079 formation at random
Copies not Distributed............................................................................................................................ 1,019 970
Total:.......................................................................................................................................................... 41,707 43,049 locations on the surface. HI Pump FAQs is produced
Percentage Paid and/or Requested Circulation...........................................................................64.23% 63.35%
Crevice corrosion is by the Hydraulic Institute as a
Electronic Copy Circulation service to pump users, contractors,
Requested and Paid Electronic Copies .............................................................................................9,412 9,132 similar to pitting. This
Total Requested and Paid Print Copies (Line 15c) + distributors, reps and OEMs. For
Requested/Paid Electronic Copies (Line 16a) ...............................................................................35,547 35,789 type of corrosion is often more information, visit pumps.org.
Total Requested Copy Distribution (Line 15f) + Requested/Paid
Electronic copies (Line 16a) .............................................................................................................. 50,099 51,211 associated with a stagnant
Percent Paid and/or Requested Circulation (Both Print & Electronic
Copies) (16b divided by 16c 100) ................................................................................................ 70.95% 69.89% microenvironment, such
I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading
information on the form or who omits material or information requested on the form may be subject to criminal sanctions (including
as under gaskets or clamed
fines and imprisonment) and/or civil sanctions (including civic penalties) Walter B. Evans, Jr. Publisher 9/28/2017
surfaces. Portions of the

FLOW METERS 87
How to Make the Most of Smart Flow Meters

Knowing more about how to solve pump problems can help engineers and technicians save
their companies money.
By Larry Bachus, PumpGuy &

Jerry Spindler, Endress+Hauser
M
aintenance personnel
in industrial plants and
facilities know a great
deal about pumps. They can replace
seals and bearings in a jiff y, remove
and install pumps and generally
fi x anything that goes wrong
mechanically. They know how, because
many of them do it a loton the same
pumps, month after month.
Plant engineers know how to read a
data sheet and (often with the help of
a pump manufacturer) can spec pumps
to meet flow, pressure and service
requirements. Pumps can be properly
sized initially for ideal conditions Image 1. An electronic differential pressure (EdP) transmitter is well suited for monitoring
when a system is designed. The only the performance of a pump. An EdP transmitter can monitor the suction and discharge
problem is those conditions in the pressure of a pump and its temperature. (Courtesy of Endress+Hauser)
process are dynamic and rarely stay
seal pot leaks of toxic, hazardous to pumps, and train maintenance
the same over the life of the pump, so
or corrosive fluids personnel and engineers on how to
it may not be the ideal pump size for
excessive pump case pressure or diagnose pump problems using data
the conditions five years from now.
pressure spikes that can damage from the instruments.
But it can be difficult for these
pump seals
maintenance technicians and plant
excessive temperature within a Adding Instrumentation
engineers to tell when a pump is
motor that can cause damage Most pumps already have (or should
having problems, performing badly or
have) a flow meter to monitor pump
is about to fail. So many pumps run
Without flow, pressure or discharge flow rates. Pumps also need
to failure. A big part of the problem is
temperature sensorsand the a differential pressure (DP) instrument
the lack of sensors on many pumps,
knowledge of what to do with the data and a temperature instrument. A DP
resulting in insufficient data to detect
provided by these sensorsmany instrument can monitor the suction
common problems, such as:
pumps fail unexpectedly and upset and discharge pressurei.e., the
vibration that can damage pumps,
processes, use too much energy or differential pressureof a pump. Too
pipes and foundations
require excessive maintenance. high or too low suction and discharge
cavitation that can destroy
And when a pump fails, it can pressures can cause or indicate various
impellers and volutes
shut down a process or an entire pump issues such as cavitation, loss
dead head operation (zero flow)
plant, cause spills, fires or explosions of flow, mechanical failure, vibration
that can overheat the liquid, maybe
and harm personnel. The solution issues, excessive noise, or bearing
causing the liquid to fl ash to vapor
is twofold: add instrumentation and sealing wear. And some newer

88 FLOW METERS
Image 2: One type of Coriolis flowmeter not only measures flow, it detects problems. Image 3. An instrumented pump training unit demonstrates
principles taught in the classroom.
electronic DP devices have built-in the software compare the pumps actual Pump training is available from
temperature measurement capabilities performance to what it should be. instrument vendors, the DOE, pump
(see Image 1, page 87). Temperature Pump software is also available from specialists and educational institutions.
instruments can measure pump, fluid the Department of Energy (DOE). The For example, the DOE offers a free
and motor temperatures. Pumping System Assessment Tool (PSAT) qualification program in the use of
To avoid cavitation, the net positive is a free online software tool to help PSAT software. Those who successfully
suction head (NPSH) available must industrial users assess the efficiency complete the PSAT qualification
be greater than or equal to the NPSH of pumping system operations. PSAT workshop and exam receive recognition
required with a safety margin. uses achievable pump performance data from DOE as Qualified Pump System
Monitoring the suction head identifies from Hydraulic Institute standards Specialists. For more information,
conditions that can damage the pump. and motor performance data from the go to energy.gov/eere/amo/articles/
Several factors can change the NPSH MotorMaster+ database to calculate training-pumping-systems.
required, including increases in flow potential energy and associated Many companies also offer pump
rate and changes to the pressure or cost savings. It can be downloaded training courses and process training
liquid level in a supply tank in front at energy.gov/eere/amo/articles/ units (Image 3).
of the pump. Smart flow meters are pumping-system-assessment-tool. One subject covered in many courses is
available that can diagnose problems The savings from reduced maintenance, how to analyze pump and system curves
such as entrained air, vibration (which longer pump life, fewer process upsets (Figure 1). While this was covered in the
could be caused by pump cavitation), and improved efficiency far outweigh August issue of Pumps & Systems, training
coating, corrosion and inhomogeneous or any modest investment in pump courses can go into more detail. For
unsuitable media (see Image 2). instrumentation. example, engineers and technicians who
Data from a Coriolis flow meter can attend the one training seminar complete
detect an empty pipe, density shift, Training the Pump Experts an evaluation at the end of the training.
temperature shift and other conditions. Even if pumps are instrumented properly Many participants comment they learned
Data from flow, temperature and DP and the data from these instruments their process pumps are constantly
instruments is sent to the control system is analyzed with a pump monitoring dragged all over the performance curve.
and routed to pump analysis software. system, the engineers and maintenance Most come into the class believing the
This softwarewhich is available in personnel may not know what to do pump operates at a particular set of head
many asset management, condition with the data without proper training. and flow coordinates.
monitoring or maintenance platforms In some cases, the instruments indicate They believe this because most pump
typically incorporates pump curves from a problem, but expertise is needed to engineers show a static system curve.
all pumps being monitored. This lets determine the best fi x. Some pump engineers eliminate the

89
system curve and draw a simple

Figure 1. Typical pump curve. Training helps engineers and maintenance people understand it.
triangle on the pump curve
indicating the primary head and
flow coordinates, as though the
pump has only one duty.
It is true that some pumps
perform one primary duty like
recirculating water in a cooling
tower reservoir or moving a liquid
(orange juice or laundry soap)
from a holding tank to a bottling
carousel. Some pipe systems are
simple and static.
However, refinery and chemical
process systems are dynamic.
Levels constantly rise and drop in
tanks. Pressures and temperatures
constantly vary in reactors, boilers
and pressure vessels. Valves
open and shut all day. Filters and
strainer baskets are clean in the
morning and clogged with debris
at midday.
Then, new equipment (check
valve, heat exchanger, in-line
Pumps are vital, expensive components august-2017-pump-monitoring-electronic-
mixer, flow meter) is installed into differential-pressure-transmitters
consuming a great deal of energy, and
an existing pipe system, altering the 2. Pump sensors can improve system operation
they are expensive to rebuild or replace. and detect dangerous faults, Pumps & Systems,
resistance and the pumps performance.
Adding a few instruments to a system June 2015. http://www.pumpsandsystems.com/
A process system curve is more like the
and learning how to interpret the data instrumentationcontrols/june-2015-protect-
wagging tail of a happy puppy, and the
from these instrumentscan help pumps-one-essential-tool?page=2
pump does what the system makes it do. 3. How Smart Instruments Enable Improved
pumps run more efficiently and identify
A pump seminar shows engineers Pumping, automation.com. https://www.
problems before they cause incidents. automation.com/portals/process-automation/
how to design a pump into a truly
fluid-power-valves-pumps/how-smart-
dynamic system. Operators learn to References
instruments-enable-improved-pumping
coax a misbehaving pump away from 1. Monitoring Pumps with Pressure Transmitters,
vibrations, cavitation and premature Pumps & Systems, August 2017 https://
www.pumpsandsystems.com/pumps/
failure. The seminar shows engineers and
technicians alike how to contribute to
Larry Bachus is a mostly retired pump consultant and inventor based in
pump reliability.
Nashville, Tenn. Bachus is known around the globe as the Pump Guy. His
book, Everything You Need to Know About Pumps, is a go-to resource on
Summary
industrial pumps.
A modest investment in instruments,
software and training can improve the
Jerry Spindler has worked for Endress+Hauser Inc. since 1996. He has
reliability and performance of expensive
served as training manager, Customer and Field Service Training since 2012.
pumps and pumping systems.
Previous positions held at Endress+Hauser were in product marketing
Spending a few thousand dollars in
and business development. He spent 11 years as a product marketing
these areas can protect a $50,000
manager for another instrument manufacturer, and five years as a
pump from serious damage, prevent
process engineer with two manufacturing companies. Spindler has an
process upsets, help protect personnel
MBA in product management & advertising and a BS in electronics &
from injuries and stop spillage of
mechanical technology.
dangerous materials.

90 PRODUCTS
New & Notable Technology 3
Products selected by the Pumps & Systems editors
2
1 IMPELLERS
BADGER ALLOYS 50+ years of experience
manufacturing impellers and other pump parts
has allowed them to specialize in the art of making 4
these critical parts. Impellers up to 4000 pounds
can be poured on site in more than 200 different
alloys. Performance is maximized by the smooth
passage finish, and keyways can be machined up to
4.5 inches wide/40 inches long.
2 TEMPORARY RUBBER
ASSEMBLY LUBRICANTS
INTERNATIONAL PRODUCTS CORPORATIONS
P-80 Temporary Rubber Assembly Lubricants
enable rubber parts to slide easily into place with
minimal force. Since P-80 does not contain silicon
or any other persistent ingredients, once it dries it
stops lubricating and the slipping action goes away.
P-80 Emulsion IFC and P-80 THIX IFC meet FDA
regulation 21 CFR 178.3570 and are NSF-Registered 5
as H1 lubricants. Both are biodegradable and
non-toxic, ideal for use in incidental food contact
applications when a thin film of lubricant is desired.
3 PRESSURE DATA LOGGERS

MONARCH INSTRUMENTS Track-it Pressure Data
Loggers can be directly wired or have battery power
for remote monitoring and record up to 130,000
samples on a single device. They can also set
in cyclical recording mode. They are extremely
accurate (0.25 percent of full scale) and come with
or without a digital display. Display versions show 6
min, max and live values, and offer an optional
transmitter output. Factory NIST Certificate is
available on all models. Pressure ranges from -760
vacuum to 14,500 PSI with an overpressure rating of
1.5 times max. 5 DIAPHRAGM PUMP
Circle 203 on card or visit psfreeinfo.com. ALL-FLO PUMP CO. introduced a new and 6 VARIABLE FREQUENCY DRIVE
improved version of its 2 inch air diaphragm FRANKLIN CONTROL SYSTEMS announced
pump. The new model offers improved suction the release of the Q-link variable frequency
4 AC DRIVE lift and is capable of self-priming up to 17 drive that provides intuitive smartphone
The Emotron FDU AC Drive from EMOTRONDIRECT ft-H20. Additionally, the A200 consumes 30 operation. The drive was designed for HVAC
offers performance and control for variable percent less air than previous iterations of applications and users in that industry, with
torque applications. A wide array of features such All-Flos 2 inch plastic pump. The A200 streamlined start-up, reporting and support.
as patented Load Curve Monitoring and multi- employs All-Flos proven simple air valve The Q-link provides an array of inputs and
pump control are standard. Additional features technology. During operation, only three outputs including damper control. The Q-link
include availability in both NEMA 1 and NEMA parts of the air mechanism move. The pump uses R3 filtering a sophisticated filtering
12 configurations, copy function via detachable is manufactured from a variety of plastic algorithm to reduce harmonic distortion and
keypad, sleep functionality and automatic pump materials and thus is suitable for a wide range provide equivalent performance to an AC line
rinsing. Models available from 0.5 200 HP. of chemical transfer applications. reactor without the added cost.
Circle 204 on card or visit psfreeinfo.com. Circle 205 on card or visit psfreeinfo.com. Circle 206 on card or visit psfreeinfo.com.
To have a product considered for this section, please send the information to Savanna Gray, sgray@cahabamedia.com.

92 PUMP USERS MARKETPLACE
Adverti se rs
Advertiser Name RS# Page Advertiser Name RS# Page Advertiser Name RS# Page
Advanced Industrial Devices . . . . . 118 9 Hydraulic Institute . . . . . . . . . . . . . . 131 74 SEEPEX . . . . . . . . . . . . . . . . . . . . . . . . . 141 62

AE Pumps . . . . . . . . . . . . . . . . . . . . . . 159 95 Hyundai Heavy Industries . . . . . . . 107 13 SEPCO . . . . . . . . . . . . . . . . . . . . . . . . . 142 45
AIGI Environmental Inc . . . . . . . . . . 121 48 International Products
Sero PumpSystems, Inc . . . . . . . . . . . 174 94
All-Flo Pump Co . . . . . . . . . . . . . . . . . 101 1 Corporation . . . . . . . . . . . . . . . . . . 132 51
Smith & Loveless, Inc . . . . . . . . . . . . 111 3
Almatec . . . . . . . . . . . . . . . . . . . . . . . . 122 60 JDA Global LLC . . . . . . . . . . . . . . . . . 133 40
Apex Engineering Products JDA Global LLC . . . . . . . . . . . . . . . . . 134 41 Summit Pump, Inc . . . . . . . . . . . . . . . 153 78
Corporation . . . . . . . . . . . . . . . . . . 160 93 Jordan, Knauff & Company . . . . . . 156 83 Summit Pump, Inc . . . . . . . . . . . . . . . 154 80
Automationdirect .com . . . . . . . . . . . 102 IFC Load Controls, Inc . . . . . . . . . . . . . . . 135 61 Teledyne Isco, Inc . . . . . . . . . . . . . . . . 158 86
Badger Alloys . . . . . . . . . . . . . . . . . . . 123 50 Load Controls, Inc . . . . . . . . . . . . . . . 164 93 ThermOmegaTech . . . . . . . . . . . . . . . 143 44
Baldor . . . . . . . . . . . . . . . . . . . . . . . . . . 103 17 Lobe Pro, Inc . . . . . . . . . . . . . . . . . . . . 165 93
Titan Manufacturing, Inc . . . . . . . . . 175 95
BaseTek LLC . . . . . . . . . . . . . . . . . . . . 161 93 Magnatex Pumps . . . . . . . . . . . . . . . . 166 94
Tuf-Lok International . . . . . . . . . . . . 176 92
BASF The Chemical Company . . . . . 104 11 MasterBond Inc . . . . . . . . . . . . . . . . . . 167 94
BBA Pumps Inc . . . . . . . . . . . . . . . . . . 148 78 Mesco Pump Parts . . . . . . . . . . . . . . . 168 93 Vanton Pump & Equipment Corp . 112 27
BJM Pumps LLC . . . . . . . . . . . . . . . . 149 76 Milton Roy . . . . . . . . . . . . . . . . . . . . . . 136 66 Vaughan Company . . . . . . . . . . . . . . 113 BC
Blue-White Industries Ltd . . . . . . . . 119 33 Mission Communications . . . . . . . . 137 35 Vertiflo . . . . . . . . . . . . . . . . . . . . . . . . . 177 95
Boerger . . . . . . . . . . . . . . . . . . . . . . . . . 124 71 Motion Industries (P&S) . . . . . . . . . 108 5
Vesco Plastics Sales . . . . . . . . . . . . . . 178 95
Carver Pump Company . . . . . . . . . . 105 15 Motor Diagnostic Systems . . . . . . . 157 83
Wanner Engineering . . . . . . . . . . . . . 144 65
Cornell Pump Company . . . . . . . . . . 120 29 Nidec Motor Corporation . . . . . . . . 138 47
Crane Pumps & Systems . . . . . . . . . 125 56 Watson Marlow Pumps . . . . . . . . . . 145 23
NOV . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 IBC
Dan Bolen & Associates . . . . . . . . . . 162 93 Peak Mechanical & Components, Inc ./ Weil Pump Co . . . . . . . . . . . . . . . . . . . 117 30
Dickow Pump Company . . . . . . . . . . 126 59 APEX Heavy Duty . . . . . . . . . . . . . 139 72 Wilden Pump & Engineering . . . . . 146 75
Dixon Pumps . . . . . . . . . . . . . . . . . . . 150 76 Pinnacle-Flo, Inc . . . . . . . . . . . . . . . . . 169 95 WILO USA LLC . . . . . . . . . . . . . . . . . . 114 31
Equipump, Inc . . . . . . . . . . . . . . . . . . . 163 92 Proco Products, Inc . . . . . . . . . . . . . . 140 37
WorldWide Electric Corp . . . . . . . . . 115 21
Flomatic . . . . . . . . . . . . . . . . . . . . . . . 147 64 Pruftechnik, Inc . . . . . . . . . . . . . . . . . 171 94
Yaskawa America Inc . . . . . . . . . . . . 116 19
FLSmidth Inc . . . . . . . . . . . . . . . . . . . . 151 77 Pulsafeeder, Inc . . . . . . . . . . . . . . . . . . 152 77
Franklin Electric . . . . . . . . . . . . . . . . 127 55 PumpWorks Industrial . . . . . . . . . . . 109 7 YellowTail Pump Corp . . . . . . . . . . . . 180 94
Griffco Valve, Inc . . . . . . . . . . . . . . . . 128 53 R-K Electronics, Inc . . . . . . . . . . . . . . 172 94

HCP Pumps America Inc . . . . . . . . . . 129 54 Rotech Pumps & Systems, Inc . . . . . 173 95 The Index of Advertisers is furnished as a courtesy, and
Henkel Corporation/Loctite . . . . . . 130 38 Ruthman Companies . . . . . . . . . . . . 110 25 no responsibility is assumed for incorrect information.
Self-aligning & self

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


94 PUMP USERS MARKETPLACE
Sub ANSI magnetic drive pumps Limited NPSH!! Volatile process fluid. Low flow
and high pressure. Entrained gas! Tough conditions,
IN STOCK, READY TO QUICK SHIP. but not for SERO! With a MAWP of 1450 psig,
the Model SHP pump offers numerous API 610
features and is designed to handle challenging
service requirements. Eliminate pulsation problems
and concerns with high speed pumps. Find a True
Solution with SERO side channel pump technology.
For details, please contact: sales@seropumps.com
ABRASION RESISTANT
Silicon Carbide Filled Epoxy
Adhesive Supreme 45HTQ-4
Phone: 713.972.8666 | Toll Free: 866.624.7867 Robust chemical resistance
FAX: 713.972.8665
3575 West 12th Street, Houston, TX 77008 Serviceable from -100F +450F
-100F to +450F
www.magnatexpumps.com Very high compressive strength
Exceptionally long pot life QUALITY MEANS TO US:
BRINGING
PRECISION AND
CONNECTIVITY
MPLE
TOGETHER.
SA
CU RED Presenting ROTALIGN touch, the only

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96 PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

By Jordan, Knauff & Company Figure 1. Stock Indices from October 1, 2016 to September 30, 2017
T he Jordan, Knauff &

Company (JKC) Valve Stock
Index was up 6.6 percent over
the last twelve months, while the
broader S&P 500 Index was up 16.5
57 percent over the
first half of 2016 and
distillate exports grew
14 percent reaching
a record high of 1.3
percent. The JKC Pump Stock Index million barrels per day.
increased 10.1 percent for the same Despite strong domestic
time period.1 demand, U.S. exports of
The Institute for Supply motor gasoline averaged
Managements Purchasing a record high of 756,000 Local currency converted to USD using historical spot rates. The JKC Pump and Valve
Managers Index (PMI) increased barrels per day in the Stock Indices include a select list of publicly traded companies involved in the pump and
valve industries weighted by market capitalization. Source: Capital IQ and JKC research.
2.0 percent to 60.8 percent in first half of 2017, a
September. The production index 3 percent gain from the first half of world energy consumption through
recorded its fourth consecutive 2016. Exports to Central and South 2040. Natural gas is expected to be
month of above-60 readings, America increased 24 percent over the fastest growing fossil fuel with Reference
increasing 1.2 percent to 62.2 this time period. global natural gas consumption 1. The S&P Return
percent. The new orders index Total propane exports reached increasing by 1.4 percent per figures are provided
improved 4.3 percent to 64.6 a record high of 913,000 barrels year due to abundant natural gas by Capital IQ.
percent and suggests strength per day in the first half of the year, resources and rising production.
in manufacturing will continue with most of the increase going to On Wall Street the Dow Jones
for the next couple of months. Asian markets. Since 2014, total Jordan, Knauff
Industrial Average rose 2.1 percent, & Company is an
The prices paid index jumped 9.5 U.S. propane exports have grown the S&P 500 Index increased investment bank
percent to 71.5 percent with survey with the expansion of export 1.9 percent and the NASDAQ based in Chicago that
respondents citing higher input infrastructure. Lower tanker rates Composite grew 1.0 percent for provides merger and
costs due to recent hurricanes. and additional locks in the Panama the month of September. For the acquisition advisory
services to the
The U.S. unemployment rate fell Canal have lowered export costs. third quarter, the Dow, the S&P pump, valve and
to 4.2 percent in September, the Driven by strong economic 500 and the NASDAQ gained filtration industries.
lowest level since December 2000. growth in Asia (especially China 4.9 percent, 3.9 percent and 5.8 Please visit
Major hurricanes Harvey and Irma and India), the U.S. Energy percent, respectively. The markets jordanknauff.com for
halted hiring during the month and Information Administration further information.
were boosted by the Federal Jordan, Knauff &
temporarily prevented as many as projects that world energy Reserve Banks announcement of Company is a member
1.5 million people from getting to consumption will grow by 28 the unwinding of its $4.5 trillion of FINRA.
their jobs. The economy lost 33,000 percent between 2015 and balance sheet and the indication
jobs in September, the first decline 2040. Although nonfossil fuels that an interest rate increase
since 2010, with the restaurant (renewables and nuclear) are was likely in December. The
industry losing 105,000 jobs. expected to grow faster than fossil administration also unveiled tax
These materials were
prepared for informational
In the first half of the year, fuels, fossil fuels will still account policy reforms intended to decrease purposes from sources that
are believed to be reliable
U.S. crude oil exports increased for more than three-quarters of corporate and individual taxes. but which could change
without notice. Jordan,
Figure 2. U.S. energy consumption and rig counts Figure 3. U.S. PMI and manufacturing shipments Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or com-
pleteness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
any investment offering or
deployment of capital.
Source: U.S. Energy Information Administration and Baker Hughes Inc. Source: Institute for Supply Management Manufacturing
Report on Business and U.S. Census Bureau
The only process that
matters is yours.
From petrochem to paint and

chemicals to refining, were ready
to support your process.
We have decades of application experience, equipment and solutions
to serve a wide variety of process industries. However, we understand
that your specific needs are the only ones that matter. Thats why we
work with you to understand your unique challenges and provide
Moyno pumps, screens and grinders, Chemineer agitators, and
Kenics static mixers and heat exchangers to help you improve
productivity, efficiency, quality and performance. Whether you need a
specific piece of process equipment, or an integrated solution, were
here for you.
Learn more about Process and Flow Technologies at nov.com/pft/cpi.
2017 National Oilwell Varco | All rights reserved

OUR HYDRAULIC MIXING
CAUSES QUITE A STIR
With over 2,000 systems operating worldwide, Vaughans Rotamix System sets the standard for hydraulic
mixing. Combining lower operating costs with a more efficient breakdown of organic solids, all backed by
Vaughans UNMATCHED RELIABILITY, makes it the perfect solution for mixing digesters, sludge storage
tanks, equalization basins, or any other process where you need reliable, effective mixing.
Guaranteed 90% Active Mixing

Even Distribution of Solids and Temperature
10-Year NON PRORATED Nozzle Warranty
No Internal Moving Parts
Various Materials of Construction Available
Available with Vaughan Chopper or Triton Screw Centrifugal Pumps
Design Flexibility to Meet Process Mixing Needs
See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP

ChopperPumps.com | 360.249.4042 | info@chopperpumps.com

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N OV E M B E R 2 0 17

PORTABLE PUMPS FOR 5 WAYS TO REDUCE

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From selecting the optimal construction materials, to