2 2020 PDF

F E B R UA R Y 2 0 2 0
SYSTEMS
PUMPSANDSYSTEMS.COM
The Leading Resource for Pump Users Worldwide
SELECTING
THE RIGHT
PUM P
THE POWER
OF PARALLEL
PUMPING
DANGERS OF
LOW CAPACITY
PUMPING
❱❱ P&S 101
1-Day Seminar
See page 2 for details
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Check 104 on index.
FROM THE EDITOR
Our readers desire more articles EDITORIAL
PUMPS &
about basics, and this is the
EDITOR-IN-CHIEF: Alecia Archibald
second straight February issue
101
aarchibald@cahabamedia.com • 205-278-2843
where the cover series has been
SYSTEMS
EDITOR: Jennifer King
on selecting the right pump. jdking@cahabamedia.com • 205-278-2826
This year, we wanted to PRODUCTION MANAGER: Amy Cash
make sure we hit the major acash@cahabamedia.com • 205-314-8274
industries. Starting on page MANAGING EDITOR: Drew Champlin
REGISTER AT PUMPSANDSYSTEMS.COM/EVENT dchamplin@cahabamedia.com • 205-314-8264
28, you can read articles on
chicago
CONTRIBUTING EDITORS: Lev Nelik,
selecting the right pump in EARLY BIRD Ray Hardee, Jim Elsey, William Livoti
wastewater, chemical, oil RATE $899 CREATIVE SERVICES
april 23
and gas, power generation,
AFTER MARCH 1 $999 DIGITAL PROJECT MANAGER &
construction dewatering, and SENIOR ART DIRECTOR: Greg Ragsdale
CHICAGO
food and beverage processing. MARRIOTT OÕHARE ART DIRECTOR: Elizabeth Chick
To top it off, our talented WEB DEVELOPER: Greg Caudle
graphic artist Melanie Magee
MANAGER OF EMAIL OPERATIONS:
created illustrations of pumps used for the applications. You can find them next to the Brent Godwin
headline in the articles and, of course, on the front cover. We hope this series will be a
CIRCULATION
benefit to readers who need to make that important choice.
AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
This is going to be a big year for the Pumps & Systems team. Along with putting together lmasaoay@cahabamedia.com • 205-278-2840
a magazine, hosting webinars, producing podcasts and three newsletters, and more, we’re
ADVERTISING
also planning to host a training event this spring. It is basic in nature, but designed for end
NATIONAL SALES MANAGER:
users with all experience levels.
Derrell Moody
Pumps & Systems 101 will be held in Chicago April 23. Our lineup of presenters is dmoody@pump-zone.com • 205-345-0784
a strong one, headlined by columnist Jim Elsey and Hydro’s Dr. Gary Dyson. Elsey has SENIOR ACCOUNT EXECUTIVES:
been a mainstay and favorite in our magazine for the last five years, and Dyson has also
Mark Goins
contributed many articles and columns, including one this month on the dangers of mgoins@pump-zone.com • 205-345-6414
operating pumps at low capacity (page 20). Gannon Greene
Fly or drive in on the 22nd for a welcome reception and networking, attend the training ggreene@pump-zone.com • 205-278-2876
seminars on the 23rd, and stay through April 24 for a wastewater plant tour. For more Garrick Stone
information, check out the full page ad on the inside back cover. gstone@pump-zone.com • 205-212-9406
Please let us know what you enjoy reading, and what you want to read more about. CLIENT SERVICES COORDINATOR:
Send us those ideas plus press releases on new hires and new products to pumpeditors@ Carra Barnes
cahabamedia.com. cbarnes@pump-zone.com • 205-561-2600
As always, thanks for reading.
PUBLISHER: Walter B. Evans Jr.

VP OF SALES: Greg Meineke
Managing Editor, Drew Champlin CREATIVE DIRECTOR: Terri Jackson
CONTROLLER: Brandon Whittemore
dchamplin@cahabamedia.com
P.O. Box 530067

Birmingham, AL 35253
EDITORIAL & PRODUCTION
Pumps & Systems 1900 28th Avenue South, Suite 200
is a member of the following organizations: Birmingham, AL 35209
205-212-9402
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue S., Suite 200, Birmingham, AL 35209.
Periodicals postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. ADVERTISING SALES
Publisher reserves the right to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air
mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call 205-278-2840 inside or outside the U.S. POSTMASTER: 1806 6th Street, Suite 200
Send changes of address and form 3579 to Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253. ©2020 Cahaba Media Group, Inc. No part of Tuscaloosa, AL 35401
this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication,
the factual accuracy of any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions 205-345-0784
offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent
the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the
advice or any advertisements contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by
the editors, by sending us your submission, you grant Cahaba Media Group, Inc., permission by an irrevocable license (with the right to license to
third parties) to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free to publish your
submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 28, Issue 2.
2 PUMPS & SYSTEMS FEBRUARY 2020

HANDLING REAL WORLD
PROBLEMS
The INNOMAG TB-MAG sets a new benchmark
for magnetic drive pump value and performance.
This versatile pump is engineered to provide low total

cost of ownership and exceptional leakage protection
in extremely corrosive and environmentally critical
applications.
While the TB-MAG boasts many innovative design

elements, the key to its proven performance is its
revolutionary dynamic thrust balancing system.
This cleverly engineered system eliminates the need

for thrust bearings and results in highly efficient
operation with outstanding reliability, even
in applications containing solids.
Experience In Motion Check 103 on index. flowserve.com

IN THIS ISSUE
FEBRUARY 2020
COVER SERIES: PLUS DEPARTMENTS
▲
PUMP SELECTION
28 Selecting the Right 22 Packaged Pump Systems 44 FLOW METERS
Wastewater Pump for Your Running in Parallel With Ultrasonic Flow Meters
Lift Station Modular Construction Improve Reliability &
By Mitch Strand By Reece Robinson, GRUNDFOS Efficiency in Hydronic
CRANE ENGINEERING HVAC Applications
25 The Power of Parallel Pumping By Rob Fehl, BADGER METER
30 Selecting the Right Pump for By Alan Jones, XYLEM INC.
Chemical Applications 46 SEALING SENSE
By Pete Scantlebury Current Standards for Fire
FINISH THOMPSON COLUMNS Testing of Flange Gaskets &
Stem Packing
32 Selecting the Right Pump for By Matthew Wasielewski
Oil & Gas Applications 10 PUMP SYSTEM IMPROVEMENT YARMOUTH RESEARCH AND
By Heinz P. Bloch Don’t ‘Over-FEED’ Your Pumps TECHNOLOGY, LLC
PROCESS MACHINERY CONSULTING By Ray Hardee
49 HI PUMP FAQS
36 Selecting the Right Pump 14 COMMON PUMPING MISTAKES Variable Speed Pumping in
for Power Generation Navigating Pump Curves: A HVAC Systems
Applications Roadmap to Reliability, Part 2
By Mike Radio By Jim Elsey
FLOWSERVE CORPORATION
18 PUMP SYSTEM STANDARDS EVERY ISSUE
40 Selecting the Right Root Cause Failure Analysis
Submersible Pump for Case Study 2 FROM THE EDITOR
Construction Dewatering By William Livoti
By Anik Patel, TSURUMI AMERICA 6 NEWS
20 GUEST COLUMN 51 PRODUCTS
The Dangers of Operating Pumps
at Low Capacity 53 ADVERTISERS INDEX
By Gary Dyson, Ph.D
54 PUMP USERS
HYDRO INC.
MARKETPLACE
56 PUMP MARKET ANALYSIS
EDITORIAL ADVISORY BOARD

THOMAS L. ANGLE, P.E., MSC, JIM DRAGO, Principal Applications WILLIAM LIVOTI, Senior Pump MICHELE SHAUGHNESSY,
Geschaeftsleiter (CEO), Swiss Flow Engineer, Garlock Sealing System Engineer Vice President Marketing & Sales,
Solutions GmbH Technologies PSG Dover
TODD LOUDIN, President/CEO
AXEL BOKIBA, Vice President of WALT ERNDT, Vice President of North American Operations, SCOTT SORENSEN, Oil & Gas
Project Management, Pulsafeeder Business Development, Pump and Flowrox Inc. Automation Consultant & Market
Process Equipment, Inc. Developer, Siemens Industry Sector
R. THOMAS BROWN III, President, JOHN MALINOWSKI, Industrial
Advanced Sealing International (ASI) JOE EVANS, Ph.D., Customer & Motor Consultant ADAM STOLBERG, Executive Director,
Employee Education, PumpTech, Inc. Submersible Wastewater Pump
KEVIN CLARK, VP, Fluke Accelix MICHAEL MICHAUD, Executive Association (SWPA)
GEORGE HARRIS, President & CEO, Director, Hydraulic Institute
JACK CREAMER, Market Segment Hydro JERRY TURNER, Founder/Senior
Manager – Pumping Equipment, LEV NELIK, Ph.D., P.E., APICS, Advisor, Pioneer Pump
Square D by Schneider Electric ROB LAIRD, Engineering Manager, International Center for Pumps
Sulzer Research and Development, Israel DOUG VOLDEN, Global Engineering
BOB DOMKOWSKI, Business Director, John Crane
Development Manager – Transport LARRY LEWIS, President, Vanton HENRY PECK, CEO, Geiger
Pumping and Amusement Markets/ Pump and Equipment Corp. Pump & Equipment Company CHRIS WILDER, CEO, SEPCO
Engineering Consultant, Xylem, Inc.,
Water Solutions USA – Flygt

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Check 102 on index.
NEWS
NEW HIRES, PROMOTIONS & RECOGNITIONS
STEVEN WESTFALL, Throughout her 25-year career, Miller Boise MARKUS

TUTHILL CORPORATION has held various executive leadership roles, BRANDSTETTER,
BURR RIDGE, Ill. – Tuthill including general counsel, head of global GRUNDFOS
Corporation announced Steven mergers and acquisitions and corporate BJERRINGBRO, Denmark –
Westfall as chief executive secretary at Avintiv. Grundfos has named Markus
officer and president. Over the past several eaton.com Brandstetter as its new chief technology
months, he transitioned from the role of officer (CTO).
president, Tuthill Fort Wayne, to the Burr SCOTT WALKER, LEC Brandstetter comes to Grundfos from
Ridge Corporate office. JACKSON, Miss. – LEC Bosch Buildings and Energy business
Westfall has more than 20 years of announced that Scott Walker sector, heading the operational strategy
senior leadership experience working in the will serve as the company’s development with focus on IoT and service-
manufacturing, mechanical and industrial new director of sales. oriented business strategy.
engineering industries. He began his Walker brings 20-plus years of sales, grundfos.com
career with Tuthill in 2013 as president of marketing and business development
Tuthill Springfield. Before joining Tuthill, experience to LEC where he will be CHRISTOPHER KUEHN,
Westfall held CEO roles with EaglePicher responsible for managing day-to-day sales INGERSOLL-RAND
Technologies, Detroit Tool Metal Products endeavors and ensuring success with LEC’s SWORDS, Ireland – Ingersoll-Rand plc
and was president of CST Industries. channel partner network. announced that Susan K. Carter, senior
He holds an MBA, finance and business lecinc.com vice president and CFO of Ingersoll-Rand,
management degrees from Pittsburg State will retire in 2020. Christopher J. Kuehn
University. tuthill.com PETE MORGAN, BENSHAW will succeed Carter as senior vice president
PITTSBURGH, Pa. – Benshaw Inc. has and CFO of the pure-play climate company,
CHRIS PACER, finalized an agreement to acquire Aucom effective on the close of the transaction
MOTION INDUSTRIES Electronics LTD, a New Zealand-based expected in early 2020. He will report
BIRMINGHAM, Ala. – Motion manufacturer of soft starters. Pete Morgan, directly to Chairman and CEO Michael W.
Industries has named Chris the former general manager of Aucom Lamach. Since joining Ingersoll-Rand in
Pacer as vice president of the North America, has been appointed as 2015, Kuehn has served as vice president
company’s Central Group. president of Benshaw Inc. The combined and chief accounting officer, and as an
He has spent the last 22 years with organization is held in Pittsburgh. elected officer of the company.
Motion Industries, dedicated to various Prior to his employment with Aucom, ingersollrand.com
key roles throughout the organization. Morgan served as general manager of
He will now lead the company’s newly Benshaw’s OEM division. His career includes NICK ADCOCK, TRILLIUM FLOW
formed Central Group. Pacer joined Motion experience in engineering, operations, HOUSTON, Texas – Nick Adcock joined
Industries as a certified fluid power sales and business management in the soft Trillium Flow Technologies as managing
specialist in 1997, working his way starter and industrial controls industries. director of the Trillium Valves Division. In
up to branch manager throughout the benshaw.com this role, Adcock will be responsible for
various markets within Northern Ohio. Trillium Valves worldwide. Adcock has held
motion-ind.com WOLFGANG EHRK, PFEIFFER VACUUM several senior leadership roles in the oil and
ABLAR, Germany – Pfeiffer Vacuum gas and energy markets and joins Trillium
APRIL MILLER BOISE, named Wolfgang Ehrk a member of from IMI where he was president of IMI CCI
EATON the management board and new chief & IMI Bopp & Reuther.
UBLIN, Ireland – Eaton operations officer (COO) of Pfeiffer Vacuum trilliumflow.com
announced that April Miller Technology AG. Ehrk took control of his
Boise has been appointed position on Jan. 1. KALLE SIPILA, METSO
executive vice president and general Most recently, Ehrk worked as COO HELSINKI, Finland – Metso announced
counsel. She will serve as counsel to for CHIRON Group, an international changes to its executive team in early
Eaton’s executive management team manufacturer of CNC-controlled vertical 2020. Kalle Sipilä has been appointed
and its board of directors and will lead processing and turning centers. president, pumps business area and
the company’s global legal organization, Until 2016, EHRK enjoyed a 26-year a member of Metso’s executive team.
including the corporate governance and career with Leybold GmbH, a vacuum Previously, he has been operationally
compliance functions. technology manufacturer, in multiple in charge of the pumps business area in
Miller Boise was most recently senior management and leadership positions, addition to his role as head of finance and
vice president, chief legal officer and including eight years as COO. business control of the minerals services
corporate secretary for Meritor, Inc. pfeiffer-vacuum.com business area.

Giuseppe Campanelli has been
appointed president, minerals services
business area and a member of Metso’s
executive team. Previously, he has
been a member of the minerals services
business area management team heading
professional services.
Mikko Keto, president of Metso’s
minerals services and pumps business
areas and a member of the Metso
executive team, terminated his
employment with Metso on Jan. 1.
metso.com
Upcoming Events
AHR EXPO
Feb. 3-5
Orange County Convention Center
Orlando, Florida
ahrexpo.com
CON EXPO
March 10-14
Las Vegas Convention Center
Las Vegas, Nevada
conexpoconagg.com
WQA CONVENTION &

EXPOSITION
April 1-3
Orange County Convention Center
Orlando, Florida
wqa.org/convention
Eliminate Disruptive Downtime With
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April 6-9
Pioneer Pump¨ Vortex Seriesª
Kuala Lumpur Convention Centre Using a recessed impeller with fewer
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technology passes through punishing
OTC solids to diminish clogs and lower
May 4-7 the cost of ownership compared to
NRG Park chopper and macerating systems. That
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Check 108 on index.
EASA See Us At CONEXPO Booth C32929

June 14-16
Gaylord Opryland Resort &
Convention Center
Nashville, Tennessee pioneerpump.com
easa.com/convention
PUMPSANDSYSTEMS.COM 7
NEWS
AROUND THE INDUSTRY
EPA Funding Bill Includes “The legislation passed today provides recommendations, maintenance
Key Provisions for Public Clean new funding for key clean water priorities strategies, fatigue life and wear
Water Sector while also underscoring the importance resistance of the bearing in relation to the
WASHINGTON, D.C. – On Dec. 17, the of allowing communities the freedom application. emersonbearing.com
Senate passed the 2020 Interior- to better sequence and prioritize their
Environment and Related Agencies obligations and investments under the Voith Group Plans Takeover of
Appropriations Act. The National Clean Water Act’s Integrated Planning ELIN Motoren GmbH
Association of Clean Water Agencies provision,” said Adam Krantz, the CEO of YORK, Pa. – Voith plans to acquire 70
(NACWA) applauds Congress for its NACWA.” nacwa.org percent of the shares in the Austrian
decision to provide funding for a variety electric motor manufacturer ELIN
of initiatives critical to the continued Emerson Bearing Announces Motoren GmbH. ELIN Motoren GmbH
success of the public clean water sector. Pump Division is a global high-tech company in the
The final language includes an additional BOSTON, Mass. – Emerson Bearing area of electric motors and generators
$200 million in EPA funding, for a total of Boston, a bearing company serving and provides customized solutions for
$9.06 billion. to OEM and maintenance, repair and industrial applications. The closing of the
Of this total funding, $1.6 billion is operations (MRO) markets around the transaction is anticipated to occur at the
for the Clean Water State Revolving world, has established a pump industry beginning of the second quarter of 2020
Fund (CWSRF); $28 million for Sewer division dedicated to a fast-growing and is subject to regulatory approvals and
Overflow and Stormwater Control Grants; customer base, particularly in the oil and meeting other usual closing conditions.
$1 million for the Water Workforce and gas market. Emerson Bearing marketing Both parties agreed not to disclose the
Infrastructure and Utility Development specialist Richard Furtado oversees purchase price. ELIN Motoren GmbH
Grants; as well as language to ensure the division. Furtado assists clients in focuses on electric machinery, low- and
timely implementation of the Integrated determining which bearing technologies medium-voltage motors and generators
Planning Clean Water Act Amendment would be most suitable by taking for wind energy and decentralized energy
that passed in January. into consideration the specifications, generation. voith.com
TRADE SHOW PREVIEW Recognized as the largest trade be held concurrently with the show. The
show of its kind, the 72nd International AHR Expo features exhibitors and attendees
Air-Conditioning, Heating, Refrigerating from around the world and every segment
Exposition (AHR Expo) will be hosted at of the HVACR industry, including more
AHR EXPO the Orange County Convention Center in
Orlando, Florida.
than 1,800 exhibiting companies from 35
countries representing every facet of the
Feb. 3-5, This year marks 90 years since the show
hosted its first gathering in 1930, bringing
industry, more than 500,000 net square feet
of exhibits and attendance representation
2020 together HVACR professionals from all

sectors of the industry. Serving commercial,
from more than 160 countries. For more
information, visit ahrexpo.com.
Orange County industrial, residential, institutional and
▲
technology markets, the show is the Mergers

Convention Center industry’s cumulative gathering of all & Acquisitions
markets under one roof.
Orlando, FL Each year, manufacturers from around Warburg Pincus Acquires Sundyne
the world exhibit their systems, equipment Jan. 7, 2020
and components with air-conditioning,
Exhibition Hours heating, plumbing, ventilation and Hyperion Acquires AFC Hartmetall
Monday, Feb. 3 refrigeration applications. Thousands of Jan. 2, 2020
10 a.m. – 6 p.m. contractors, engineers, OEMs, distributors
SPX Acquires Patterson-Kelley
and other industry professionals attend the Dec. 23, 2019
Tuesday, Feb. 4 exposition in search of new and innovative
10 a.m. – 6 p.m. products and services that enhance the way Eaton Acquires Souriau-Sunbank
they do business. Dec. 23, 2019
Wednesday, Feb. 5
The American Society of Heating,
10 a.m. – 4 p.m. Benshaw Acquires Aucom Electronics
Refrigerating and Air-Conditioning
Dec. 17, 2019
Engineers (ASHRAE) Winter Conference will

—
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The ABB Ability™ Digital Powertrain connects drives, motors, pumps and bearings,
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even better decisions to ensure safe, reliable and efficient operations.
Safety. Reliability. Efficiency.
new.abb.com/drives/digital-powertrain-monitoring
Check 101 on index.

PUMP SYSTEM IMPROVEMENT
Don’t ‘Over-FEED’ Your Pumps

Ray Hardee | Engineered Software Inc.
Sometimes engineers can be both safe

and sorry.
Creating specifications for a pump
system usually takes a long time, and
pump selection has a major impact
on subsequent design calculations.
Specification development happens early
in the design process, and it requires
engineers to make many assumptions that
drive sizing calculations and pump specs.
In engineering, it is often said that good
design is based on experience, and you gain
experience by making mistakes. But no
one wants to make a mistake when sizing
a pump for a process system, so there’s IMAGE 1: Flow diagram showing the location and elevations of all the equipment along with the details needed
a tendency—“for safety’s sake”—for the for pump sizing. (Images courtesy of the author)
pump’s specs to exceed what is needed.
Oversizing pumps is insurance for early intended system design. The pump element engineering group and the design
stage design uncertainties. It is natural to is sized to pass the design flow rate through values of tank levels and pressures from
factor in life’s uncertainties; that’s why we the process and control elements to make the process group to arrive at the energy
purchase insurance. I’d never recommend the product or provide the service. at Tank 1 of 105.6 feet, and at Tank 2 of
going without insurance, but I don’t want In the example I’m about to describe, 189.6 feet. The system static head is the
to pay for more coverage than I need. So, in a manufacturing company needs to change in energy between Tank 2 and
pump selection, we must respect the need expand its plant to add a new product to Tank 1, or 84.6 feet.
for insurance but be realistic about our its line. After completing a market study, • Pipeline head loss: The pipe diameters
assumptions and document the results. it estimates that it requires a system are sized based on the firm’s piping
Another thing about engineers is that we capacity of 600 gallons per minute (gpm) specification, based on an average fluid
like to come up with acronyms to describe for the foreseeable future. Because of velocity, which is based on process
existing processes. Back in the day, the first the facility’s long life expectancy and, fluids and pipe material. The pipeline
step in any design was called preliminary seeking to leverage the expense of a new head loss is calculated using the pipe
engineering. Now it is called FEED, for front- system, the company decides to double its diameter, the estimated pipe lengths,
end engineering design. designed capacity to 1,200 gpm. It selects and valve and fitting counts.
My column this month discusses the an engineering firm for system design, • Process element heat exchanger
FEED process for pump selection, how it specifies this desired output and provides (HX): The firm’s HX specification states
can lead to oversizing pumps and how the process requirements. the maximum allowable differential
these plus-sized pumps impact system Then the FEED process begins. The pressure shall be no greater than 15
operations. In a future article, we will cover first step is estimating the locations and pounds per square inch (psid) at the
how to obtain a realistic view of pump elevations of the system equipment within design flow rate. This results in a head
requirements and suggest ways to reduce the facility. The engineering firm estimates loss of 34.6 feet.
the costs of oversized pumps. design requirements for the process and • Control element control valve (CV):
control elements based on the firm’s sizing The CV specification states all valves
The Pump FEED Process criteria. For example: should be sized with a differential
All piping systems consist of pump • Static head: The mechanical pressure of 15 psi with the valve in the
elements, process elements and control department uses the estimated 80 percent open position at the design
elements, all working together to meet the equipment elevations from the civil flow rate.

Equipment Head loss for
design operation
Static head 84.6 feet Quality Metering Pumps & Flowmeters
Pipeline head loss 56.5 feet
Process element HX 34.6 feet
Control element CV 34.6 feet
Pump total head 210.3 feet
IMAGE 2: The method of determining the

pump total head sizing requirements during the
FEED process
Image 2 summarizes the system losses

needed for calculating the pump’s total
developed head. It equals the sum of the
calculated head losses for the process and
control elements at the design flow rate.
The minimal pump head requirement of
210.4 feet of fluid is needed at the design
flow rate of 1,200 gpm.
Introducing the ‘Safety Factors’ IP66

At this point, for the sake of insurance, the NEMA 4X
WASH DOWN
firm adjusts head loss estimates upward to
account for unforeseen conditions. These
are “safety factors” that, in this example,
may reflect uncertainties associated with
Flex-Pro A3
estimated pipe length, the count of valves
and fittings, losses associated with heat ¨
exchanger fouling, control valve operation,
variations in tank levels and pressures, and
PERISTALTIC
any other concerns expressed by members METERING PUMPS
of the review team. For precise dosing
Often, Engineer A may add a safety of peracetic acid
factor to the calculated value before and other harsh
passing the spec on to the next person, chemicals.
Engineer B, who is involved in the review
NEW
process. Engineer B may add his or her
own safety factor, and so on, until the
team has reviewed and recommended
S6A
a final design. In this example, after
completing the review, the resulting pump
total head requirement of 274 feet of head
at 1,200 gpm was used. PRECISION CHEMICAL
FEED FLOWMETER
Accurately measures the
The Pump Supplier
output of your chemical
The engineering firm completes the pump
Check 109 on index.
metering/dosing pumps. IP66

specification using the design point of
NEMA 4X
1,200 gpm and 275 feet of head and sends WASH DOWN
it to the pump suppliers.

The winning supplier recommends
is
an 8 x 6-20 end suction process pump
ISO 9001:2015
operating at 1,750 rpm. The selected Certified
pump needs a 16.5-inch diameter impeller
www.blue-white.com • 714-893-8529
5300 Business Dr., Huntington Beach, CA 92649 USA • info@blue-white.com
PUMP SYSTEM IMPROVEMENT
with a pump efficiency of 70 percent,

requiring 119 horsepower (hp).
The pump’s best efficiency point (BEP)
of 73.4 percent occurs at a flow rate of
1,550 gpm. The pump is selected because
the design flow was left of the BEP, so as
the system capacity increases, the pump’s
efficiency would improve.
The person selecting the pump
increases the impeller diameter to
17 inches to take advantage of the
200-hp motor supplied with the pump.
This results in a pump head of 296 feet of
fluid at the design flow rate of 1,200 gpm,
shown on Image 3.
The selected pump is purchased, and
IMAGE 3: Pump curve for the recommended pump, along with the BEP, and the recommended range of the pump details are used in various
80 percent to 110 percent of BEP flow. stages of the engineering process. The
pump is shipped and installed.
Equipment Current operation Expected operation Design operation
400 gpm 600 gpm 1200 gpm The Pump in an
Pump element 305.6 feet 306.2 feet 296.4 feet Operating Environment
Process elements After the system is commissioned and
turned over to operations, the current
Static head 84.6 feet 84.6 feet 84.6 feet
usage only requires a capacity of 400
Pipeline head 5.9 feet 13.1 feet 51.6 feet gpm. The operations group wants to know
loss the effects of operating the system at this
Process 3.7 feet 8.3 feet 33.2 feet lower capacity.
element HX A system energy balance is developed
Control element 211.4 feet 200.2 feet 127.0 feet using the displayed pump curve and heat
exchanger operational data supplied by
IMAGE 4: The system energy balance showing how the energy is used within the system.
the manufacturers.
The pipeline head loss is based on
Equipment Current operation Expected operation Design operation the installed piping, and the static head
400 gpm 600 gpm 1,200 gpm is calculated by the energy difference
Pump element between the tanks. The control element
is determined by subtracting the energy
Percent of BEP 26% 39% 74%
flow (%) of the process elements from the pump
elements (see Image 4).
Pump 42% 53% 70%
The system energy balance shows
efficiency (%)
how the energy provided by the pump
Pump power (hp) 68 86 127 elements equals the sum of the energy
Process element consumed by the process and control
HX pressure drop 1.6 3.6 14.4 elements of the system.
(psid) Using the results of the energy
balance, the operations group compares
Pipeline fluid 2.6 3.8 7.7
velocity (ft/sec) how the system equipment is performing
to industry norms. Image 5 shows key
Control element
equipment information under the
Valve open 13% 20% 53% actual operations of 400 gpm, the
position (%) expected operations of 600 gpm, and
Differential 92 87 55 the design operations of 1,200 gpm based
pressure (psid) on future conditions. Looking at the
IMAGE 5: Comparing the operation of the system elements to industry guidelines. supplied pump curve, notice the BEP is

SCHENCK USA CORP.
80 percent at 1,550 gpm. The “Rotodynamic Pumps’ Guideline
for Operating Regions (ANSI/HI 9.6.3)” standard recommends
operating the pump at a flow rate between 80 percent to 110
percent of the BEP flow rate as shown on the pump curve.
Route-Based
The ratio of the actual pump flow to the pump’s BEP flow
results in the percentage of BEP flow. Vibration Analyzers
We can see the selected pump will not operate within the
recommended range at any time during pump’s operation. Predictive Maintenance Machine Diagnosis
This will have a major impact on the pump’s operation and the Condition Monitoring Field Balancing
system’s reliability for the foreseeable future.
The differential pressure across the heat exchanger is much
lower than the maximum value stated in the specification for
the expected operation. This lower pressure drop across the
heat exchanger reduces pumping requirements but comes at a
greater capital cost.
Fluid velocity within a pipe has a major effect on head loss.
Common industry practice recommends a pipe’s fluid velocity
between 4 to 10 feet per second. We can see the fluid velocity
for expected operations is outside this range. The lower pipeline
head loss reduces pumping requirements but, again, comes at a
greater capital cost.
In looking at the control valve, notice the valve positions
range between 13 percent to 53 percent open with a resulting
differential pressure from 92 psid to 55 psid. VIBROTEST 80 (VT-80)
The fact that the control valve position is 20 percent or less at
flow less than 600 gpm can cause major operational problems. Collect Vibration Data on a
Notice the differential pressure at the design condition is much
greater than the 15 psi differential pressure stated in the control
Predetermined Route as part of your
valve specification. The higher differential pressure does not Predictive Maintenance Program.
improve the valve operation.
Full Data Collection Package:
Conclusion Unlimited number of routes
In the process we’ve described for selecting pumps in piping (up to 5000 measurements / route)
systems, each step was based on sound engineering principles. Up to 12 measurements per point
The use of “safety factors” reflects the team members’
Up to 2 channels plus reference sensor supported
experiences when dealing with system unknowns early in the
design process. Data review at site possible
But, as we saw in this example, when the piping system was
placed in operation, both the pump and process elements were
oversized. This, in turn, resulted in a differential pressure across
the control valve that is much greater than expected. These
factors, in my judgment, increased the system’s capital costs,
operational costs and maintenance costs.
In my next Pumps & Systems column, I will explain ways
to improve the pump selection process, while still maintaining
operational flexibility to efficiently run the system through
its lifetime.
Check 122 on index.
VIBROPORT 80 (VP-80)
Ray Hardee is a principal founder of Engineered Software, creators of PIPE- 1(800) 873-2352
FLO and PUMP-FLO software. At Engineered Software, he helped develop two
training courses and teaches these courses internationally. He may be reached
sales@schenck-usa.com
at sales@eng-software.com. www.schenck-usa.com
COMMON PUMPING MISTAKES
Navigating Pump Curves:

A Roadmap to Reliability, Part 2
Jim Elsey | Summit Pump Inc.
This column is a continuation of Part 1,

which appeared in the January 2020 issue
of Pumps & Systems. The first section BEP is the point of highest efficiency.
explained that the manufacturer’s pump
curve can be a useful tool to manage It is also the point of lowest radial forces, sha
the reliability of the equipment and,
subsequently, the system. But the pump
deflection, noise and vibration.
curve can also be used in ways you may
not have thought of before. Here is a
continuation of that discussion. radial forces, shaft deflection, noise and Runout or End of the Curve
vibration. For some of us, it is also the The point of runout (RO) is also commonly
Best Efficiency Point operating point at or near shockless entry referred to as the end of the curve (EOC),
The best efficiency point (BEP) is simply for the fluid entering the impeller eye. which is all the way at the right of the
the design point for the pump. It is the curve. In our example, flows approaching
hydraulic condition point of both head and Preferred vs. Allowable 4,500 gpm would be the RO point. This is
flow rate where the pump is most efficient. The preferred operating region (POR) is the point of maximum flow for the curve
In our example, the BEP for the pump at normally defined as flow rates between 70 and also the lowest head for that impeller
maximum impeller is approximately 3,450 and 120 percent of the flow at BEP, and the diameter and speed. To attempt operating
gallons per minute (gpm) at 190 feet. wider allowable operating region (AOR) is at higher flow rates would yield severe
All commercial centrifugal pumps are usually defined by the manufacturer and cavitation in the pump regardless of the net
essentially designed for one single point will vary with pump type, casing design positive suction head (NPSH) margin. If the
(BEP); any other operating points in the and other factors including the shaft. Note pump was capable of operating at higher
operating envelope are a commercial that for pumps with high specific speed flow rates, the manufacturer would surely
compromise. BEP is the point of highest impellers that the POR is normally reduced publish that information.
efficiency. It is also the point of lowest to 80 to 110 percent of BEP. People frequently ask me about the EOC
operating region and the questions fall
into two distinct camps. The first group is
comprised of folks stating: Why not operate
here? Followed by: Why won’t the pump
operate past the EOC? The other group are
people that for various reasons know or
perceive the potential or imagined issues
at the end of the curve and will not operate
their pump anywhere near this area. In
a way it is like dealing with fire. Get too
close to the flames, and you will be burned
or damaged. But, if you understand and
carefully manage the fire as a useful tool—
and if you maintain the correct distance—
it will provide warmth and light.
If you don’t know the details of your
system curve and how it changes with time
and dynamic conditions, then you should
IMAGE 1: How curve shapes change as result of geometry and specific speed (Image courtesy of the author) not operate in this region at the EOC. In my

pump classes, I refer to this region as one
filled with dragons and wizards whose sole
purpose is to make your life miserable. A
simpler alternative explanation may be, it
is a world without bacon.
Implied or Title Block Information

Information that is inferred, unless
otherwise stated/published, is that the
curve is based on hydraulic performance
while pumping water at 60 F or 68 F. If the
curve is based on a fluid different from
water, and therefore a potentially different
viscosity, the manufacturer must make
that statement.
Viscosity-corrected curves will normally
state that they are corrected. Additionally,
the standard curve is based on a liquid with
a specific gravity (SG) of 1.0. SGs other than
1.0 will result in different brake horsepower
(BHP) requirements.
Note: There is potential for confusion on Same Look. Same Installation.
New Technology.
exactly which temperature is the standard
water temperature and SG that pump
manufacturers should use for the basis
of published curves. This article will not It’s all about efficiency. The MagForce™
expound further except to state that users High Efficiency Motor System offers a
should check with the manufacturer of the 90% motor efficiency rating, which
pump and/or see Chapter 4 of the “Cameron
is up to 12% higher than traditional
Hydraulic Data” book, 19th edition.
What may not be patently obvious is submersible motor designs. With
that the information required to permanent magnet technology,
calculate several additional parameters is you can now offer an investment
also present, such as BHP specific speed
payback of less than 2 years
(NS), suction specific speed (NSS) and
suction energy (SE). in most long- or continuous-
run applications*. They get a
Brake Horsepower trusted product, you become
Most published curves will offer the BHP
their solution provider.
information and my recommendation is to
do the actual calculation anyway before *Results based on field trial data.
anything is purchased to be safe. Again,
note the BHP published on the curve will be
based on water at 68 F unless noted.
See Us At CONEXPO
Knowing the efficiency and, Booth C32929
subsequently, the BHP, you can calculate
your operating expenses and total cost
Check 110 on index.
of ownership. From that cost data you

can determine if you need to operate
differently, change the system design,
or even perhaps replace the pump with franklinengineered.com
another model or convert to variable speed.
You can also use the BHP formula to solve
for other parameters.
COMMON PUMPING MISTAKES
▲
Mathematically, you can easily solve
the equation for any one unknown. In Normally: BHP = [(head) (flow
Equation 1, I already know the BHP, but rate) (specific gravity)] ÷ [(3,960)
In addition ... not the flow rate, so I set up the equation (efficiency)]
to solve for flow (where percent efficiency
If you laboratory test 25 different impellers
is expressed as a decimal). Alternately solved: flow rate =
of the same design in 25 different casings
Following this logic, you could also [(BHP) (3,960) (efficiency)] ÷
where all impellers and casings are from
use this equation to solve for SG, head [(head) (SG)]
the same respective patterns, you will get
25 different curves that are all close, but or efficiency.
they will be different. Also, if you test a Equation 1
given sample impeller pattern today, the Understanding Specific Speed &
results will be different than they were a Suction Specific Speed flow at BEP (and also the pump speed),
year ago (earlier in the pattern life), and The manufacturer may or may not offer then you can calculate the NS. Further, if
they will be different next year (later in the this information somewhere in the title you know the NS and the NPSH required
pattern life). Note that using investment block, but to the experienced pump (NPSHr), you can calculate the NSS. For
castings will reduce this variance person the slope, size and shape of the dual suction impellers (two eyes), use half
substantially, but not all sizes and models curve will lend clues as to the NS range. of the flow at BEP.
lend themselves economically to the Please see Image 1 for a simple Why is any of this information
process. For this reason and other nuances, drawing on how curve shapes change as important to you?
manufacturers publish their hydraulic a result of their geometry and NS. Well, depending on your system curve
performance with stated tolerances and I will leave the details for a future and where it intersects, the pump curve
restrictions for specific pump applications. article, but suffice to say that the number can make a big difference in the proper
Please refer to ANSI/Hydraulic Institute and shape/geometry of the impeller pump selection. You would not want to
specification 14.6 – 2011 for details.
vanes will paint an illustrated story as to use a pump with a drooping curve if it
the NS. If you know the pump’s head and was going to operate at lower flows, but if
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Check 118 on index.

it was markedly higher in efficiency at high The pump curve is a statistical measure the pump performance then you
flows you would. If you had a system that representation (albeit a conservative one) can’t manage it. Left unmanaged, the
used variable speed pumps, would you want of empirical data collected and composed pump will prematurely fail, and prior to
a flat curve or a steep curve? For a boiler from the manufacturer’s test facility. that day it will needlessly cost you time
feed system in a base-loaded power plant, The curve is a published proof of the and money.
what curve shape would you want? manufacturer’s ability and it holds them
accountable to the pump purchaser and Reference
Pump Curve from the end user. 1. Pumps & Systems February 2017 article
Manufacturer’s Perspective Since most industrial pumps are by Jim Swetye: “Reading a Centrifugal
constructed from castings, there are Pump Curve”
As I mentioned earlier, the published pump
2. Pumps & Systems July 2017 article by Peter
curve is a promise, a sort of manufacturer variables; and because no two castings
Gaydon: “The Basics of NPSH & Preferred
guarantee that the pump will operate on are exactly alike when a curve is Operating Region”
that curve as indicated. published, there are stated and acceptable
It does not mean the pump will operate industry tolerances.
where you wish and hope it to run, unless
that point is exactly where the system curve Conclusion
intersects the pump curve (see my August I strongly recommend that you know where
Jim Elsey is a mechanical engineer with more
2019 article for more details). your pump is operating on its curve. If
than 48 years of design and operating experience,
For emphasis, I again point out that you don’t know where it is operating, then primarily focused on rotating equipment reliability
if the fluid has different properties not please try your best to find out. in most all industrial applications and markets
around the world. Elsey is an active member of the
accounted for, or the system has issues with If you have any management by American Society of Mechanical Engineers, the
NPSH available (NPSHa), air entrainment, a objectives (MBO), quality assurance/ American Society of Metals, the National Association
miscalculated system curve or if the pump quality control (QA/QC), Kaizen or Six of Corrosion Engineers and the Naval Submarine
League. Elsey is the principal of MaDDog Pump
clearances are not set properly, the pump Sigma training, you already know (and I Consultants LLC and may be reached at
will operate somewhere else off the curve. am paraphrasing here) that if you don’t jim.elsey@spiohio.com.
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Check 115 on index.
PUMP SYSTEM STANDARDS
Root Cause Failure Analysis Case Study

William Livoti | Senior Engineer
I found this quote while reading a news

publication: “Sometimes the easiest way to
solve a problem is to stop being part of the
problem.” That’s because many of the most
common problems in pumping systems
are of our own making—specifically failure
to develop a general scope document
(GSD). I will reference the GSD many times
throughout this series of articles on root
cause failure analysis (RCFA). Why? Becaus
I firmly believe (from firsthand experience)
the root cause of most pumping system
component failures is due to lack of clarity
during the development of the project.
Failure Analysis vs. RCFA

Yes, there is a difference. Failure analysis IMAGE 1: Total number of failures from 2000 to 2004 (Image courtesy of the author)
(FA) is replacing the failed component. This
is nothing more than parts replacement Equipment: 700 horsepower (hp) vertical, Experience level dropped over the years,
because the failure mode was never 1,750 revolutions per minute (rpm) and the site had difficulty retaining
identified. It has been my experience that condensate pumps/motors, two 60 percent experienced mechanics.
failure analysis is the typical course of pumps with one 60 percent installed spare
action taken by most facilities. Operations: Same scenario as mechanics,
RCFA, though, involves a comprehensive Situation: The plant began experiencing additionally the plant deviated from its
analysis identifying all of the root causes a number of condensate pump failures operating procedure.
(physical, human and latent). on one unit (2B). The site experienced
To make my point and to set the tone nine failures in the four years, resulting Maintenance/operating cost over 30 years:
for this series of articles, the following in lost production/downtime. When the Upon review of maintenance records, we
RCFA from 2004 is a classic case for plant experienced an equivalent forced were able to develop an idea of the life
differentiating FA from RCFA, as well as outage rate (EFOR) event during peak cycle cost (LCC) of the unit 2B condensate
the cost associated with the common load, corporate took control and brought pump.
strategy of getting the equipment back in a third-party consultant to resolve the Note: This is valuable information when
in service ASAP. This RCFA case study has situation. The data below was compiled justifying your solution. obtain this data
been condensed from its original 30-page by the balance of the plant engineering when evaluating an application.
version. Key points and findings have been team in conjunction with the third-party
used to make a solid business case for consultant. The maintenance staff became Rebuild pump: According to plant
identifying the root cause of a failure as quite proficient in replacing the wet end of personnel, until four years ago the pumps
opposed to component failure/replacement. the subject pump, performing change out would last about four and a half years—
in approximately 12 hours upon failure. therefore, the pump required rebuild seven
Combined-Cycle Power Plant and a half times over a 30-year period. In
Condensate Pump History: Over the years, the plan the last four years, the pump required an
Plant Configuration: 400-megawatt (MW) has experienced a high turnover in additional eight rebuilds.
combined-cycle power plant, oil/gas fired, maintenance personnel. The plant would Note: Customer expectations/mean
commissioned in 1972, two 200-MW units, swap pump wet ends and motors from time between repair (MTBR) is four years
load swings daily one unit to another without documenting. (industry standard is 10 to 15 years)

Soleplate out of level:
▲
Cause & of check valve
• pipe stress • incorrect startup
Effect • misalignment procedure
• seal failure
Pipe stress: Pump failures:
Cost to rebuild pump: $60,000 x 7.5 + • seal failure Coupling out of • combination of above
$60,000 x 8 = $930,000 • motor failure tolerance: findings as well as
Labor to remove and install pump: • vibration • vibration incorrect operation
$5,760 x 15.5 = $89,280 • misalignment of pumps; two pumps
Motor repair: 25,000 x 7.5 + $25,000 x 5 = Misalignment: in parallel when only
$312,500 • motor failure Water hammer: one unit is required
Coupling: $3,000 x 5 = $15,000 • vibration • incorrect placement
Mechanical seal: $5,000 x 7.5 + $5,000 x 9
= $82,500 Findings The operators failed to vent the pump prior
Total = $1.5 million (approximate) Due to loss of expertise, the pump was to startup. In addition, they would start two
not installed or aligned correctly, the pumps when only one was needed.
Lost MW: Best guess based on fleet records motor was not set level, the coupling had Surprised by the total cost? I call this the
is 60 days = 200 MW x 24hrs = 4,800 MW x a significant run-out and the pump was cost of doing nothing because the plant
60 days = 288,000 MW x $40 (average per installed with 0.6-inch pipe stress. The only replaced failed components. I have
MW over 30 years) = $11.5M subbase was degraded and crumbling. As found this course of action to be the norm.
Valve damage: No record of repair, however, a result, the sole plate was out of level 0.2 For the next 12 months, I will outline a
valve failure did result in EFOR inches. The motor had a run-out of 0.1-inch process for performing a structured RCFA to
Main condensate recirculation regulator: shaft to motor face. The coupling was not avoid the cost incurred by this case study.
Again, no record of repair, failure of main manufactured correctly with a 0.005-inch
condensate recirculation regulator will run-out on concentricity and, due to the William Livoti is retired after more than 40 years
in the industry. Livoti is a member of the Pumps &
result in EFOR run-out at the motor shaft to face, the Systems Editorial Advisory Board. He may be reached
Total cost: $13 million (approximate) coupling face was out more than 0.2 inches. at wlivoti@outlook.com.
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Check 111 on index.
GUEST COLUMN
The Dangers of Operating Pumps

at Low Capacity
Gary Dyson, Ph.D | Hydro Inc.
CASING
CUTWATER IMPELLER
Operating at low flow places the machine over both surfaces of the vane that also
MECHANICAL HYDRAULIC
under a great amount of duress. It is fluctuates with its position relative to CENTER CENTER
always wise to have a mental picture of the diffuser.
what is happening within the passages of This difference spreads into the
the machine to understand why this is diffuser and anything connected to it will
the case. experience a fluctuating pressure field once
per impeller blade pitch.
Vibration 1x At partial capacity, this flow picture
The days have long passed where pump greatly deteriorates. Each passage is
vibrations were viewed as a matter of filled with slow moving fluid. Operated
mechanical balance. Now, we recognize that in this condition, it is easy to see how IMAGE 1: Hydraulic cam causing high 1x vibration
even if the pump had perfect mechanical vibration and heat can become a problem (Images courtesy of Hydro Inc.)
balance, it would still exhibit vibrations. for pump reliability.
The intensity of this remnant vibration
turns out to be flow related with its Vibration Caused by Inlet
minimum level being at or around best Backflow Recirculation
efficiency point (BEP). The phenomenon is always present within a
Vibration at “one times” shaft rotational pump operating at low capacity and always
frequency is often ascribed to mechanical contributes to the vibration level.
balance. However, this can also be High-energy liquid is expelled from
caused by the impeller if it is machined the impeller eye. Each impeller blade
eccentrically to its hydraulic center. The generates an individual stream, and
impeller behaves like a hydraulic cam while these velocity streams, impacting on
in the pump, even though it may be in features in the suction nozzles and suction
near-perfect mechanical balance in air. pipework, contribute to the vane pass
No amount of mechanical balance frequency vibration.
can reduce this cam effect as each blade From these images, it is easy to IMAGE 2: Velocity experienced by diffuser
passage is a different length and holds a understand why the disturbed flow
different weight of liquid. Performing a regimen within a pump can cause so many
mechanical balance in air cannot solve reliability issues. In all of these situations,
this issue. the flow is violently disturbed when it
should be smooth and follow the passage
Hydraulically Generated shape. Living with a machine at partial
Vibration—Vane Pass capacity means an inevitable adverse effect
From a hydraulic design standpoint, on pump reliability.
vibrations at vane pass frequency are
always present due to the way impellers
generate head. This vibration is inevitable, Gary Dyson, Ph.D., is managing director with Hydro
and the only pump that does not have vane Global Engineering Services, an aftermarket service
provider specializing in improving reliability and
pass vibration is one that is not running. operating performance. Dyson has a doctorate from
Each vane had a pressure differential Cranfield University and 30 years of experience.
between the pressure (top) and suction His expertise includes pump hydraulic performance,
design and reliability improvement. For more
side (under) of the vane. This pressure information, contact Dyson at engineering-support@
differential results in a velocity difference hydroinc.com and visit hydronic.com. IMAGE 3: Spiraling inlet backflow in suction piping

HVAC/BUILDING SERVICES
Packaged Pump Systems Running in

Parallel With Modular Construction
The labor shortage could cause these to run together in newer buildings.
REECE ROBINSON | Grundfos
Currently, the United States economy is

strong and experiencing historically low
unemployment rates; therefore, one could
assume construction projects are running
smoothly and on time. But even with
the decline in unemployment rates, the
amount of skilled labor is declining relative
to the construction demand—there are
simply not enough skilled workers to build
all the needed projects in the same manner
as in the past.
The U.S. construction industry was
developed under the assumption that the
work would occur on the final building
IMAGE 1: Timeline showing site-built construction vs. modular construction (Image courtesy of Grundfos)
site. This work also includes design,
procurement, contracts, logistics, financing,
insurance, building codes, materials when put together on-site, reflect the efficient construction process that is poised
handling, labor laws and safety. This identical design intent and specifications to help the construction industry grow.
assumption is no longer valid; many, of the most sophisticated site-built facility,
possibly all areas of the construction without compromise. Benefits to Modular Construction
process, must be revisited. In the past five There are two types of modular Factory-controlled environment
years, there has been a growing trend that construction: permanent modular Probably the No. 1 benefit is that the
is addressing the decline of available skilled construction (PMC) and relocatable process is factory controlled, allowing
labor: modular construction. building (RB). Many opinions of modular for tighter construction, fewer site
The modular construction market is construction is what is seen on one of those disturbances and less waste. Speaking of
projected to grow at a compounded annual “wide-load” marked flatbed, semitrailers less waste, modular construction is a
growth rate (CAGR) of 6.9 percent from rolling down the highway. These fall into green approach.
$112.4 billion today to $157 billion by the RB category as they are designed to be When building in a factory environment,
2023. Plus, buildings constructed through reused or repurposed multiple times and waste is eliminated through the recycling
off-site, prefabricated modular units are can be moved from one location to another. process. Factory environments also allow
stacking increasingly taller.1 RBs are commonly seen at schools, medical for controlling inventory as well as the
clinics and construction sites. protection of building materials.
What Is Modular Construction? The growing trend lies within the scope Another green aspect is that modular
According to the Modular Construction of PMC, which involves modules, sometimes buildings can be disassembled and
Institute: Modular construction is a process referred to as pods. These modules can relocated or refurbished for new use. This
in which a building is constructed off-site, come in the form of wall panels, complete reduces the demand for raw materials and
under controlled plant conditions, using the bathrooms or even complete hotel rooms. substantially reduces the amount of
same materials and designing to the same These modules are delivered to the job site energy expended to create a building for
codes and standards as conventionally and pieced together like building blocks. the new need.
built facilities, but in about half the time. Recently, research has come out Factory-controlled environments
Buildings are produced in “modules” that supporting modular construction as an also have improved air quality because

The biggest hurdle for both packaged Always-On Monitoring.
pump systems and modular
construction is cultural.
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construction inside allows for use of dry materials, so the
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Speed
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With the construction of modular buildings occurring
simultaneously with the site foundation work, projects can be
completed 30 to 50 percent sooner than traditional construction.
Since 60 to 90 percent of the construction is completed inside
a factory, weather becomes a nonfactor to the construction
timeline. Buildings can be occupied sooner, creating a faster The world’s most cost-effective
return on investment. An example of such a timeline is shown
in Image 1.2
Industrial IoT solutions.
Built to code & safe
Modular buildings are built to meet or exceed the same
standards and building codes as structures built on-site.
PRE-ORDER NOW
The same materials, as specified by the architects, used in Machine Health Monitoring
conventionally constructed buildings are used in modular
construction projects—wood, concrete and steel. Modular units Batteryless sensors continuously
can be designed to fit in with external aesthetics of any existing
building, and modular units, once assembled, are virtually
collect & wirelessly transmit data.
indistinguishable from their site-built counterparts.
 Overall vibration level
Connection to Pump Systems  Triaxial acceleration
Since the building moves in a modular construction methodology,  6 Hz – 3.2 KHz frequency range
the components going into that building also take the same
approach, leading to pumps. The traditional way of building a
 Magnetic field frequencies
pump system, sourcing it component by component, can be at  Ambient & skin temperature
odds with this new methodology. Think about the traditional  Relative humidity
way of installing pumps in a building: pouring foundation,
housekeeping pads, mounting the pumps, motors and controls,  Runtime
and all the ancillary components (e.g., isolation valves, check  1,000-ft. wireless range
valves, gauges and sensors).
With the skilled labor shortage and the need for speed when
building these modular buildings, there will be an increased
demand for pumps and pumping systems to follow suit. Users
can look to packaged pump systems to follow the methodology of
Check 114 on index.
modular construction.
Benefits of Packaged Pump Systems

Factory-controlled environment www.everactive.com
Many of the site-built activities can occur in a factory-controlled
environment. The pumps, motors and drives can be installed on sales@everactive.com
a base frame along with all of the isolation valves, check valves,
gauges and sensors. The drives and controls codes as pump systems built on-site. Tasks professionals, contractors and owners do
can also be mounted on the base frame, such as welding, pipefitting and wiring not understand it or they see it as a luxury
prewired with controls preprogrammed up electrical equipment may be safer in a and feel that doing the work on-site will
to job site requirements from the factory. controlled environment. cost less.
This can save hours of job site labor, both In the case of meeting water quality Those who have taken the modular or
mechanically and electrically, and the standards, this can also speed up the packaged system approach were able to
high quality of work can be repeatable in inspection process as a complete pump see the value in terms of the quality of the
the controlled environment. Just as with system can carry the required approval product, the ease of installation and the
modular construction, factory-built pump (NSF 61, for example), which includes shorter timeline for project completion.
systems also eliminate waste. all ancillary components, whereas
the inspection agency would have to Reference
Speed verify compliance on job site installed 1. Slowey, Cowin and Beeton (2019, January
Production of the packaged pump system components separately. 7). 7 trends that will shape commercial
can occur at the same time as the site With new Department of Energy (DOE) construction in 2019, retrieved from
constructiondive.com.
foundation/mechanical room. Pumps, efficiency requirements for individual
2. What is Modular Construction, retrieved from
motors, drives, controls and all of the pumps becoming effective last month, modular.org.
ancillary items arrive as one module. packaged systems with multiple pumps
Modular construction of complete pump allow for greater system-wide efficiency
systems in their own building is also done levels on top of what the DOE requires. Reece Robinson is Grundfos’ building services
today, especially in the municipal market. technical content manager. He has been with
Grundfos since 1997 and has held positions in
Changing the Culture product engineering, product management and
Built to code & safe The biggest hurdle for both packaged technical training. Robinson received a bachelor’s
degree in mechanical engineering from California
Packaged pump systems are built to meet pump systems and modular construction State University, Fresno. For more information, visit
or exceed the same standards and building is cultural. Even today, many design grundfos.com.
Check 119 on index.

The Power of Parallel Pumping

Reach peak efficiency with technologically advanced controllers and variable speed drives.
ALAN JONES | Xylem Inc.
Parallel pumping has emerged as one

method of improving efficiency in pumping
systems with higher control heads. With
the advent of sensorless pump control
technology, hydronic systems can be
optimized for maximum system efficiency.
In a parallel pumping system, the
controller makes decisions dynamically
based on what the current flow and head
requirements show.
While variable speed control in a parallel
pumping system can increase efficiency
and reduce costs, adding sensorless
IMAGE 1: Table of part loads considering 100 percent flow at 1 percent; 75 percent flow at 42 percent; 50
control technology to the pump percent flow at 45 percent; and 25 percent flow at 12 percent, considering no staging and optimal staging
staging process creates a solution (Images courtesy of Bell & Gossett)
that combines high efficiency, backup
capacity and potential savings on space performance is not as simple as optimizing must be considered. In a parallel pumping
and initial investment. pump performance at a single duty environment, this makes selection and
In an environment where partial point. The entire profile of the pump’s staging strategies even more complex.
loading is the norm, optimizing system efficiency at varying flows and speeds Technology helps reach these solutions
Science Museum of Minnesota Achieves

▲
Unparalleled Energy Efficiency

Sustainability is a challenging pursuit Following an energy analysis in 2018, frequency drive and a parallel pump
for museums, which possess distinct the museum undertook several building system controller.
building characteristics and other upgrades to reduce energy costs and Embedded building management
unique challenges like climate- boost efficiency. Those improvements system (BMS) communication enabled
controlled storage and gallery space included serving as a pilot test site for a the parallel pump system to seamlessly
to preserve irreplaceable exhibits. With new parallel pump system. integrate with the museum’s existing
the help of a parallel pump system, Sensorless pump controllers included BMS. A touch screen displays real-time
the Science Museum of Minnesota—a in the parallel pump system have the feedback and enables energy modeling so
major destination for 700,000 visitors ability to manage output from multiple the museum’s facility team can optimize
per year—is lowering energy costs and pumps without a wired differential hydraulic performance.
reducing its carbon footprint. pressure transducer. Eliminating the To accommodate fluctuating visitor
Located in downtown St. Paul, the need for an external sensor reduces both traffic, the parallel pump system stages
Science Museum of Minnesota has installation and maintenance costs. and destages pumps incrementally
370,000 square feet of space, including Two end suction pumps were depending on varying demand. Since
a 10,000-square-foot temporary exhibit installed to boost the flow rate of the upgrading, the Science Museum has
gallery, five permanent galleries and an museum’s existing hydronic system. The realized higher energy efficiencies and
IMAX Convertible Dome Omnitheater. pumps were then paired with a variable lower operating costs.
It should also be understood that in a

diverse system, there is a control area
rather than a simple control curve.
IMAGE 2: 10 x12 x15.5 double suction pump with 100-hp 6-pole motor
more easily, and parallel pump controllers with the best

efficiency staging capability pay dividends.
Selecting a pump for parallel operation using the same
methods as choosing a single pump involves cutting the flow in
half or a third and picking the most efficient option. When flow
gets past 120 percent of best efficiency point (BEP), it is time to
stage the next pump. However, that process does not leverage
technology, and while the system will provide required head and
flow, it likely will not be at optimal efficiency.
How can pump staging be truly optimized for efficiency?
When examining different staging scenarios and comparing and
contrasting the weighted part load efficiency values (PLEV), the
challenges and solutions of designing parallel pumping systems
IMAGE 3: Two parallel 8 x10 x13.5 end suction pumps with 50-hp 6-pole motor
become clear.
In the first scenario, the full load requirement is 4,000
gallons per minute (gpm) at 65 feet of head with a control head
requirement of 19.5 feet. These design parameters should be
carefully considered, as they dictate the system curve driving
the selection decisions.
With such a large pump, the selection would likely be a
double suction pump. In Image 2, the curve depicts an efficient
solution, especially at full load. There is some tapering at 50
percent and 25 percent of load, yielding a weighted PLEV of 81.6
percent. This is a 10 x 12 x 15.5 pump with a 100-horsepower
(hp), 6-pole motor—a large investment and footprint, but one
that provides zero backup capacity.
The next option provides backup capacity and even greater
IMAGE 4: Single 8 x10 x13.5 end suction pump variable speed curve running as one
PLEV. Image 3 shows two end suction pumps in parallel—8 x
of two pumps and solo at 100 percent, 75 percent, 50 percent and 25 percent of load
10 x 13.5-inch pumps with 50-hp motors. This constant speed
graph demonstrates efficiencies over 86 percent for portions of
this curve, meaning there will only be improvements over the
curves when variable speed is introduced into the equation. In
general, the system curve crosses all of the test speed curves
and demonstrates acceptable efficiencies.
Image 4 reflects individual pump efficiency improvements
created by variable speed. Dividing the flow between both
pumps at full load, efficiency is 86.3 percent—even higher than
the double suction pump in Image 2. If both pumps continue to
run at partial loads, the weighted efficiency is 77 percent, below
the double suction performance.
As demand decreases, the second pump must be destaged.
IMAGE 5: 6 x 8 x 9.5 end suction pump variable speed curve running in parallel As system requirements drop below 2,400 gpm, the two-pump
as one of three pumps, one of two pumps, and solo at 100 percent, 75 percent, efficiency is dropping below 80 percent, while the single-pump
50 percent and 25 percent of load efficiency climbs to 88 percent as demand drops to 1,400 gpm.

Based on the system curve for this pump, it appears the best
staging/destaging occurs around 10 percent past BEP. With two
parallel pumps, one pump can drop off and the system will still
operate at 75 percent capacity.
WE CAN
HELP
Image 5 demonstrates coverage up to 50 percent of load with
one pump—if system losses have not been underestimated.
With two pumps, nearly 90 percent of load is covered. In fact, if
the requirement was to meet full duty with two pumps, motors
and drives could be upsized to 40 hp and the pumps oversped to
almost the same efficiency as the pumps in Image 5, just short
of 60 feet at 2,000 gpm per pump.
Based on this pump’s efficiency profile, optimal system
efficiency will be achieved by running two pumps from 3,600 Our high performance solutions
gpm all the way down to just over 100 gpm or the 25 percent
partial load point.
make us your source for everything
The initial investment savings on three 30-hp, 4-pole sealing, including mechanical seals,
motors versus a 100-hp, 6-pole motor is 40 percent. The initial
investment savings on three 6-inch pumps versus the single 10-
pump and valve packing, air seals
inch pump is roughly 25 percent. and bearing isolators.
Image 1 (page 25) shows efficiency benefits that can be
achieved by determining the optimal staging point for each
parallel pumping solution. It is important to evaluate the
system curve and pump efficiency curves to optimize staging.
In these scenarios, optimal staging in a parallel pumping
solution can save 3 percent on energy costs versus the
double suction solution while increasing backup capacity
and potentially eliminating system downtime required for
maintenance. But if pumps are not staged properly, the
system could operate 3 percent less efficiently than the single-
pump solution, resulting in more than $1,000 in increased
energy costs per year, depending on operating conditions and
utility rates.
The staging points are based on system design and
anticipated system losses. In these examples, the system is
modeled using a system curve.
In actual application, this will need to be reviewed following
commission. It should also be understood that in a diverse
system, there is a control area rather than a simple control
curve. The more diversity in the system, the larger this area
and the greater the benefit from dynamic, real-time staging
performed by a capable pump controller versus a fixed-staging
strategy based on predetermined staging points. GFO is a registered trademark of WL Gore and Assoc.
Conclusion
Staging solutions for best efficiency can be complex, but with
the aid of a parallel pump controller equipped with built-in best
efficiency staging, calculations happen dynamically, ensuring
Check 116 on index.
the system can actually deliver these theoretical efficiencies.
Alan Jones is the global product manager for Bell & Gossett centrifugal
pumps. He holds a Bachelor of Science in systems engineering from the
United States Military Academy at West Point, and an MBA from Syracuse
University. For more information, visit bellgossett.com. 800-633-4770 www.sepco.com
COVER SERIES: Pump Selection
Selecting the Right Wastewater

Pump for Your Lift Station
Impeller choices are equally as important as selecting the right pump.
MITCH STRAND | Crane Engineering
Wastewater pumps perform a behind the

scenes, yet critical, job that most people
do not think about. They are found in lift
stations and wastewater treatment plants
doing their job day in and day out. Yet,
if a user comes across an experienced
wastewater operator and asks what they
like or dislike about the pumps, the
operator will have a must-have list of
features that keep the station running.
Sizing a wastewater pump is like sizing
a pump for a clean water application:
Users need to know the application IMAGE 1: Submersible pump installation (Image courtesy of Crane Engineering)
information such as flow and head, fluid
type, and installation orientation or space alarm relay. An alarm sounds when it possibility of flooding. Water in the dry-pit
constraints. With wastewater applications, detects water in the oil chamber. This would destroy standard pump motors.
however, there are a few other factors to sensor protects against moisture entering If the dry-pit is susceptible to flooding,
consider—the biggest being solids. Fibrous the motor and causing issues by alerting a dry-pit submersible pump might be an
materials such as flushable wipes and rags the operator to the seal failure. option. These are similar, if not identical,
lead to ragging issues in lift stations and Since submersible pumps are installed to the submersible pumps discussed
wastewater plants. Wastewater and sewage- in wastewater wet wells, access to the before. Traditional submersible pumps use
type impellers are specifically designed to pumps is limited. Operators must remove wastewater to cool the motor. In a dry-pit
deal with this issue. the pump via the guide rail system to application, there is no surrounding fluid
This article explains the types of solids- inspect or service the equipment. to use for cooling. Therefore, submersible
handling pumps and impeller types that dry-pit pumps have oil-filled submersible
will help users make a smart choice when Dry-pit pumps motors and/or cooling jackets to provide
selecting a pump for a wastewater lift Dry-pit pumps are installed next to a wet adequate cooling and insurance against
station application. well or sump. This allows for the use of inadvertent dry-pit flooding.
a nonclog centrifugal pump and motor.
Types of Pumps Solids-handling impellers will pass many Self-priming pumps
Submersible pumps types of solids. They can be mounted Self-priming pumps are an aboveground
Submersible pumps are designed to operate vertically or horizontally, allowing flexibility alternative to submersible or dry-
in wastewater. A close-coupled sealed for space constraints within the dry-pit pit pumps. Designed for suction lift
motor allows for complete submergence, vault. Dry-pit pumps keep the pump out of applications (like lift stations), self-priming
eliminating the need for a separate dry- the wastewater, allowing for personnel to pumps prime by extracting air from the
well, which can decrease installation costs. easily diagnose a pump during operation. suction side and discharging it back into
Submersible pumps typically feature Working on a pump that is not covered in the wet well. Once primed, this pump
dual oil-lubricated mechanical seals with sewage minimizes safety risks. operates the same as standard solids-
moisture sensing probes and an associated A downside of the dry-pit pump is the handling centrifugal pumps.

Self-priming, solids-handling pumps are allow for higher efficiency when compared Enclosed channel impeller
designed to pass solids. Like dry-pit pumps, to vortex impellers, but less than enclosed This impeller design contains a front and
they usually have a longer anticipated life channel impellers. This impeller type is back shroud, creating enclosed channels
than submersible pumps due to the clean standard in submersible, dry-pit and self- for wastewater and solids to pass through.
atmosphere above the wet well and access priming pumps. Due to the enclosed channels and tight
for preventative maintenance. clearances between impeller and wear
Vortex impeller rings, this impeller is known to be efficient.
Types of Impellers Vortex impellers are for applications with Issues with this impeller arise with stringy
The aforementioned wastewater pumps extreme ragging issues and are found fibrous materials like rags.
are often fitted with one of the following in submersible and dry-pit applications.
impeller types. Each is designed specifically These impellers are installed in the top of Conclusion
for a combination of solids-handling and the volute and out of the flow path. Vortex When selecting a wastewater pump,
efficiency, and there is always a trade-off impellers create a whirlpool effect in the consider the application constraints and
between the two. volute, carrying water and solids through features needed in a pump system. If easy
the pump and out the discharge without maintenance is of the essence, choose a
Semi-open impeller direct contact. self-priming or dry-pit installation. If cost
Semi-open, nonclog impellers feature a This reduces the risk of pump clogging is an obstacle, submersible pumps will
back shroud with a limited number of vanes and impeller wear. Pumps with vortex allow for a more compact installation. In
(one-vane or two-vane are typical) and can impellers have reduced efficiency due to either case, weigh efficiency versus solids-
usually pass a 3-inch spherical solid with the vortex and lack of tight clearances. handling capability for long-term operation
a 3- or 4-inch submersible sewage pump. A decrease in efficiency of about 30 and reliability of the lift station.
The small number of vanes provides large percent is possible from a semi-open
impeller openings for the solids to pass impeller. Reduced maintenance costs may
Mitch Strand is an application engineer at Crane
through. Set clearances between the wear outweigh the loss in efficiency for some Engineering. He may be reached at 920-733-4425.
plate and the leading edge of the impeller high ragging applications. For more information, visit craneengineering.net.
No Part Number? No Problem.

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

EXPERT BEARING KNOWLEDGE
Call us : 800-523-3382
visit us on the web at
www.bartlettbearing.com
Check 123 on index.
Selecting the Right Pump for

Chemical Applications
Review pump types and pick proper construction materials.
PETE SCANTLEBURY | Finish Thompson
▲
There are many considerations when application, reduces NPSHa and reduces
selecting the right pump for chemical cooling by an electric motors fan.
applications. When working with materials
such as corrosive or flammable chemicals, Pump Selection Review Possible Pump Types
extra care should be taken to ensure that Here are some of the most common pump
the product selected is suitable. There are many variables to the types for transferring chemicals.
selection of the best pump type with Drum/barrel pumps: Ideal for transferring
Define the Fluid Characteristics the correct materials of construction. a wide variety of chemicals from pails,
The safety data sheet (SDS) and chemical • Gather information on the fluid to drums, totes [(such as intermediate bulk
be pumped.
manufacturer or chemical distributor can containers (IBCs)] and other containers used
• Gather information on the
provide required information such as fluid by chemical manufacturers to transport
hydraulic and application
name, concentration, fluid temperature, products to the user. These can be powered
requirements.
specific gravity and viscosity at pumping • Consult the experts. Consult by electric, lithium ion battery or air motors.
temperature. If solids are present, with the chemical manufacturer, Centrifugal pumps: Provide smooth
determine at what concentration, particle chemical distributor, pump flow and have a wide range of flows
size and hardness, and if the material is manufacturers, local pump and head capabilities. These pumps are
corrosive, flammable or combustible. distributors, and even industrial available in a wide range of materials and
supply catalogs that are either mechanically sealed or sealless
Describe the Application experienced in the selection of magnetically coupled. They are typically
The more detailed the description, the chemical pumps. operated with electric motors.
better. Make sure to verify: Air-operated double diaphragm pumps:
• What type of container is the chemical head made available to the pump and Versatile, simple to operate, and can pump
stored in? Is it a drum or tote, bulk provided by the piping system. To avoid solids and viscous fluids. They typically
storage tank, rail car or tanker truck? cavitation (causes erosion damage to operate with compressed air.
• Where will the fluid be moved? From a pump components) the NPSHa must Positive displacement pumps: Includes
drum to a bucket, from a rail car to bulk exceed the NPSH required (NPSHr). gear, rotary vane or piston pumps. These
storage, or simply recirculating in the • How long will the pump be operating pumps are good with high viscosity fluids
same container, for example. per day or week? This is important in and can generate high pressures.
• Is the liquid below the pump? In this evaluating energy costs. For example, if
case, a pump that is either self-priming a pump is going to be operating many Selecting Proper Materials
or one that can be submerged in the hours per day, a pump driven with an of Construction
liquid is needed. electric motor could have considerably The proper materials of construction are
• What is the flow rate required? Flow rate lower operating costs compared to an critical to safely transfer chemicals and
is required to calculate friction loss in air-driven pump. provide a long life. Here are some common
the piping system. • Is it indoors or outdoors? What are examples of materials used for chemicals.
• What is the total head or pressure the maximum and minimum ambient Metals
required? Total head is based on the temperatures? This is important for the • Stainless steel: 304 and 316 are used;
piping system and is used (along with correct selection of the construction 316 has increased corrosion resistance.
flow rate) to help choose a pump. materials for the pump and motor. • Hastelloy C/Inconel/Alloy 625:
• What is the net positive suction head • What is the altitude? Higher altitudes This contains high nickel and
available (NPSHa)? It is the suction reduce available lift if it is a self-priming chromium levels and up to 13 percent

molybdenum. It has better corrosion chemical resistance. It is used in piping, the elastomeric form of PTFE that are
resistance than stainless steel but is fittings, pumps and instrumentation. fully fluorinated providing a high level
more expensive. • ETFE: Ethylene tetrafluoroethylene of corrosion resistance.
• Titanium: This works best in oxidizing (ETFE) is a fluoropolymer with better Other materials
media such as hot nitric acid and chemical resistance and a wider • Ceramic: Alumina ceramic (aluminum
sodium hypochlorite and is expensive. temperature range than PVDF. It is used oxide) is commonly used in mechanical
Plastics to line pipe, valves and pump housings seals and as thrust rings, shafts and
• CPVC: Chlorinated polyvinyl chloride and can be injection molded into a bushings. Higher purity (99.5 percent)
(CPVC) is a thermoplastic that can be variety of products including pumps. alumina demonstrates enhanced wear
processed using injection molding Elastomers and corrosion resistance.
technology. It has reasonable corrosion • Nitrile (Buna N): A general-purpose • Alpha sintered silicon carbide: Alpha
resistance and is used in piping, valves, oil- and water-resistant rubber with a sintered silicon carbide (SiC) offers
filters and pumps. moderate working temperature range, superior hardness, high strength, high
• Polyethylene: Versions of cross- nitrile is not compatible with many abrasion/wear resistance and excellent
linked polyethylene (XLPE) are used corrosive materials. corrosion resistance.
for chemical storage tanks, chemical • FKM: FKM is a fluorocarbon elastomer • Carbon graphite: Carbon graphite offers
transfer hoses and can be found in low- with extensive chemical compatibility good chemical resistance, even to many
cost, hand-operated drum pumps. that spans considerable concentration that are extremely corrosive. Used in
• Polypropylene: Polypropylene is and temperature ranges, making it good mechanical seals and as a bushing
resistant to many corrosive materials. for many applications. material in other pump types.
It is used for piping, fittings and pumps • EPDM: Ethylene propylene diene
used in the transfer of corrosive fluids. methylene (EPDM) rubber is compatible
• PVDF: Polyvinylidene fluoride with most caustics and has a good Pete Scantlebury is the vice president of
development at Finish Thompson. He has worked
(PVDF) is a strong, abrasion-resistant temperature range. there for more than 40 years. For more information,
fluoropolymer with outstanding • FFKM: Perfluoroelastomers (FFKM) are visit finishthompson.com.
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Check 121 on index.

Oil & Gas Applications
Buyers should look at failure risk and examine system drawings.
HEINZ P. BLOCH | Process Machinery Consulting
Process and pipeline pumps in modern suction, centerline (self-

industry are usually designed and built venting) discharge, back
in accordance with one of the three most pull-out and frame mounting.
prevalent industry standards for pumps. However, either standard
In the United States, a combined American can be useful in applications
National Standards Institute/American involving other frequencies—
Society of Mechanical Engineers (ANSI/ variable frequency drives
ASME) document is widely used for pumps (VFDs) in all types and sizes of
in water and aqueous (nonhydrocarbon) process pumps.
services. The primary aim of the standard Broadly speaking, the IMAGE 1: A centerline-mounted, back pull-out, single-stage process
is to allow the kind of dimensional same thought processes pump (Image courtesy of Hydro Inc.)
interchangeability that permits insertion govern the dimensional

of a pump from Vendor A in the space interchangeability limited to pumps made
originally occupied by products from in compliance with ASME and pumps made
Vendor B. in accordance with ISO standards. In either
case, principal dimensions include, but are
ASME B73.1 & ISO 5199 not limited to, the distance from base-
The widely referenced centrifugal pump mounting surfaces to the shaft centerline,
standard known as ASME B73.1 can trace and the elevations and distances from
its origins to 1974 when, after combining pump suction to discharge nozzles.
and consolidating the ASME standard with
a similar Hydraulic Institute (HI) standard, ANSI & ISO vs. API Pumps
the two became ANSI B73.1. This new ANSI/ASME and ISO-compliant pumps
standard has been periodically updated and usually have their mounting pads (feet)
the current version is called “Specification incorporated in the casing’s base. The
for Horizontal End Suction Centrifugal thermal rise of the shaft centerline of ANSI/
Pumps for Chemical Processes.” ASME and ISO-compliant pumps can be as
In the International Organization for much as three times greater than that of
Standardization (ISO) community where centerline-mounted American Petroleum
IMAGE 2: Custom-built vertical pipeline pump
50-hertz (Hz) power systems are the norm, Institute (API) pumps. For many decades, with drive motor removed (Image courtesy of
ISO 5199:2002 represents a “Technical the API has issued pump standard API Alfred Conhagen Inc.)
Specification for Centrifugal Pumps—Class 610 for products considered flammable,
II.” ASME B73.1 or ISO 5199 are not fully toxic or prone to explode under reasonably facilitate back pull-out of hydraulic
interchangeable; separation is based on possible circumstances. assemblies in need of exchange or repair.
the regionally prevailing electric power The emphasis of the API 610 pump
frequency, B73.1 for 60 Hz and ISO 5199 standard is on strength, quality and Deciding Between Available Pumps
for 50 Hz. Both standards are widely reliability. API pumps are centerline- Experience-based selection strategies often
referenced worldwide for centrifugal pump mounted (Image 1) and the stipulated follow the practices of Monsanto Chemical’s
projects, even outside of chemical process distance between driver and driven shaft Texas City plant in the 1970s.1 Among
applications. The core coverage of these ends is 7 inches. Spacer couplings keep these was the recommendation to use in-
standards encompasses single-stage end misalignment angles low and greatly between-bearing whenever the product of

power input and rotational speed [kilowatts for such an exception, the pumped Because competent bidders employ
(kW) x revolutions per minute (rpm)] fluid should be nonflammable, nontoxic a satisfied workforce of experienced
exceeded 675,000. and nonexplosive. specialists, conduct effective training and
Others adopted Monsanto’s practices.1 In general, exceptions would be granted mentoring, and provide quality control and
It was also recommended that API if the vendor demonstrated years of inspection departments, their products
610-compliant pumps be given strong successful operation for the proposed pump should command reasonable pricing.
consideration when one or more of these six in a comparable or perhaps even more Reasonable pricing should not be confused
conditions are reached or exceeded: critical service. with lowest pricing, although reasonable
• head exceeds 350 feet pricing may indeed be lowest in terms of
• temperature exceeds 300 F on pipe up to Best-in-Class Experience life cycle cost projections.
and including 6-inch nominal diameter; Best-in-class (BiC) pump users are ones Vertical pumps are available in many
alternatively, if the temperature exceeds that obtain long failure-free runs from their hundreds of styles and configurations, and
350 F on pipe starting with 8-inch pumps. BiCs have on their bidders’ lists only Image 2 shows a two-stage pump custom
nominal diameter vendors (or custom builders) with proven built for pipeline service. On this pump, the
• pumps with drivers rated in excess of experience records. Such pump vendors and entire pumping element can be removed
100 horsepower (hp), starting at 75 kW manufacturers would be well established as one piece for maintenance. The motor
and higher and would have recorded sound quality and mount (with the motor attached) would be
• suction pressures over 75 pounds per on-time deliveries. removed first, 24 screws are removed next,
square inch gauge (psig) Exceptions taken by a bidder to the and the whole pump is then lifted out.
• flow in excess of the best efficiency BiC owner-operator’s specification should It is an example of a design that is
point (BEP) for the pump at issue be carefully examined for their potential user-oriented in terms of maintenance and
• speeds in excess of 3,600 rpm reliability impact. This examination probable overall reliability.2
process serves as a check on the pump Both API and non-API standards are
Exceptions to the six conditions can manufacturers’ understanding of the used in custom-built pumps, depending
be made judiciously. However, to qualify buyer’s long-term reliability expectations. on user preference, type of service and
PRIMEROYAL® H METERING PUMP

COMPACT. ACCURATE.
CONFIGURABLE.
Milton Roy PRIMEROYAL® H Metering pump
provides accurate dosing of a broad spectrum of
fluids used in many industrial processes.
Its modular design offers several types of liquid
ends, capacity control, and other configuration
options to meet the specific requirements of your
process application.
To learn more about the multiplexing options, safety
features and robust capabilities for model H, contact
your local representative or visit our website.
www.miltonroy.com
Check 112 on index.
The mechanical seal in Image 3 is at (a) an excessive speed, with (b) worn
typical of six or more add-ons that preferred tires, on (c) a wet road, and (d) followed the
vendor-manufacturers should be willing to leading car too closely, a rear-end collision
provide in support of their desire to provide resulted. Had there just been any three
high-reliability products. They should have of the four violations, the event might be
no reluctance to provide a listing of proven recalled as a near-miss incident. Had there
user experience. been any two of the four, it would serve no
purpose to tell the story in the first place.
IMAGE 3: Cartridge-style dual mechanical seal Better Pumps Too much cost-cutting by pump
suitable for many pumps and services in the oil and
gas industries (Image courtesy of AESSEAL) Anybody can buy a cheap pump. The term manufacturers and purchasers will
“better pumps” describes fluid movers that negatively affect the drive-ends of pumps.
prevailing experience. Competent designs are designed beyond hydraulic efficiency Flawed drive-end components are therefore
are available not only from OEMs, but also and modern metallurgy. Better pumps are among the main contributors to repeat
from certain key custom design innovators ones that avoid risk areas in the mechanical failures that often plague process pumps.
and manufacturing specialists. portion commonly called the drive-end. Drive-end flaws should be addressed with
In all instances, the pump owner- That part of process pumps that has been urgency, and this article is intended as an
operator would compile a specification neglected most often and is where cost- overview of what guides BiC oil and gas
document. The pump owner-operator or cutting should cause the greatest concern. companies in selecting better pumps.
its designated project team would mail Deviations from best available
the document to at least two, but probably technology increase the failure risk. As Why Insist on Better Pumps?
three or four, of these bidders or providers. three or four or more deviations combine, a Well-informed reliability professionals
Their replies or cost quotes would be failure is likely to occur. An analogy could will be reluctant to accept pumps that
carefully reviewed. Whenever possible, be drawn from an incident involving two incorporate risky drive-ends. The short
these replies would describe the vendor’s automobiles, with one driving behind the overview of reasons is that reliability-
offer pictorially. other. When the trailing vehicle traveled focused professionals take seriously
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their obligation to consider the actual, that includes a close examination and provide the least expensive constant
lifetime-related and not short-term cost of comparison of pump cross-sectional level lubricator configuration.
ownership. They have learned that price is drawings and bills of materials. • Each issue merits further explanation
what one pays and value is what one gets. Among the important vulnerabilities, and additional ones exist.
As we make it our standard procedure deviations from best available technology
to review pump drawings, we will quickly or just plain risk areas, subject matter References
realize that not all pump manufacturers experts have found: 1. Ingram, J.H., “Pump Reliability—Where do
are on top of user experience. While at first • Oil rings (intended to lift oil from the you Start,” presented at ASME Petroleum
Mechanical Engineering Workshop and
glance the reviewer might see nothing sump into the bearings) are incorrectly
Conference, Dallas, Texas, Sept. 13-15, 1981.
wrong, we must remember that, in any designed and/or manufactured. 2. Alfred Conhagen Inc., La Marque/Houston,
given time period, approximately 7 percent • Back-to-back oriented thrust bearings Texas
of the pump population in U.S. oil refineries are not located in a cartridge. Therefore, 3. Bloch, Heinz P., “Pump Wisdom: Problem
fails three to four times as often as that retrofitting flinger discs to take the Solving for Operators and Specialists,”
refinery’s average pump. place of deficient oil rings will not (2011), John Wiley & Sons, Hoboken, New
Jersey, ISBN 978-1-118-04123-9
Whenever reliability professionals make be possible.
4. Bloch/Ehlert/Geitner; “Optimized Equipment
it their practice to review pump drawings, • Bearing housing protector seals are
Lubrication, Oil Mist Technology and Storage
they will uncover details as to why 7 inferior to the ones representing best Preservation,” (2020) Reliabilityweb,
percent of the total pump population fails available technology. Bearing housings Ft. Myers, Florida
relatively frequently and sometimes lack oil drain holes from locations where
quite randomly. Drawings often show areas trapped oil will overheat and deprive Heinz P. Bloch has authored or co-written over
750 publications, among them 22 books on
of risk and vulnerability that have been bearings of proper lubrication.4 machinery management, failure analysis/avoidance,
found and eliminated by BiCs. Their • There is uncertainty as to the type compressors, steam turbines, pumps and lubrication.
subject matter experts have been or style of constant-level lubricator Bloch holds a Bachelor of Science and a Master
of Science in mechanical engineering from New
instrumental in eliminating flaws in that will be supplied. Unless specified, Jersey Institute of Technology. He may be reached at
a specification and review process process pump manufacturers will often heinzpbloch@gmail.com.
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Check 120 on index.

Power Generation Applications
Understand critical pump services in combined-cycle power plants.
MIKE RADIO | Flowserve Corporation
Combined-cycle gas turbine (CCGT) high-pressure (HP) sections of the heat

power plants present difficult challenges recovery steam generator (HRSG).
for pumps and associated equipment, Multistage, inline diffuser, ring-
such as valves and seals. section pumps are most typically
High operating temperatures and specified for this service in combined-
pressures are characteristic of many cycle plants. Occasionally, customers
applications operating within CCGT will specify a double-case design for
plants. CCGT plants are also expected these applications.
to handle rapid load variations and are Boiler feedwater is chemically treated
required to start and stop frequently. As to a high purity level, making it more IMAGE 1: Diffuser ring-section pump (Images courtesy
a result, the pumps must be designed corrosive than untreated water. As a of Flowserve)
and selected to handle severe transient result, the fluid-handling components
operating conditions. (e.g., stage casings, diffusers and
A typical combined-cycle plant may impellers) that see high fluid velocities
have between 50 to 100 pumps. These must be provided in 12 percent
pump types typically include: chrome (CA6NMN) to avoid erosion-
• multistage, between bearings, ring- corrosion damage. On higher-pressure
section pumps (BB4) applications, the suction and discharge
• vertical, wet-pit, single-stage heads are also recommended to be in
pumps (VS1) 12 percent chrome. Laser hardening or
• vertical, canned, multistage direct laser deposition (DLD) at running
pumps (VS6) fits can be offered to make the pump
IMAGE 2: Double-case barrel pump
• horizontal, single-stage, axially split resilient to damage that may be caused
pumps (BB1, BB2) by transient operation, including loss of
• general service end-suction suction pressure. The laser-hardening
pumps (OH1) treatment only hardens the outer
• high-pressure and temperature end- surface of the part; the base material
suction pumps (OH2) remains unchanged.
• sump pumps (VS4, VS5) The result is a reliable, ductile part,
• liquid ring vacuum pumps with maximized surface hardness, which
is the ideal blend of part characteristics.
This article focuses on several critical DLD is a welding process that
services in combined-cycle plants: main metallurgically bonds a metal powder
feedwater, condensate extraction and to the base material. Due to a controlled
condenser cooling. and localized heat input, this process
can be applied to various base metals
Main Feedwater Pumps without distortion or the need for post-
The purpose of a main feed pump is to weld heat treatment.
Suction performance, while important IMAGE 3 (left): Condensate pump with a single-suction,
deliver feedwater from the low-pressure
first-stage impeller.
(LP) drum to the economizer inlets of for all pumps, is a concern for high- IMAGE 4 (right): Double-suction, first-stage
the intermediate-pressure (IP) and energy pumps in boiler feed service. condensate pump

RunfiDryfianfi
KfifipfionfiRunnfing
The net positive suction head available
(NPSHa) is limited by the physical height
of the suction vessel, but certain NPSHa
and NPSH required (NPSHr) margin ratios
must be maintained to achieve optimum
performance and long life. The first-stage
impeller is selected with particular care and
often features a larger suction eye or, in some
cases, a double-suction design.
The pumps offer an intermediate
takeoff connection to provide flow to the IP
section of the HRSG. Boiler feed pumps are Pumpsfifififififififififififi
subject to sudden load swings and operation
GRAPHALLOY® fifiarfi
parfisfisurvfivfifiupsfifis.
at numerous operating conditions. As a
result, the typical bearing arrangement is
sleeve radial bearings and tilting pad-type • Self-lubricating
thrust bearings on applications exceeding • Non-galling
4,000 horsepower (hp). • Won’t swell
With this type of arrangement, a forced • Corrosion resistant
• Dimensionally stable
feed lubrication system is used. On lower hp
• Improved efficiencies GRAPHITE METALLIZING
applications, other bearing arrangements • -400˚F to 1000˚F (-240˚C to 535˚C) CORPORATION
may be considered. Yonkers,, NY USA
Feed pumps may be direct drive or
+1.914.968.8400 • www.GRAPHALLOY.com
variable speed drive with the use of fluid
couplings or variable frequency drives (VFDs). Check 124 on index.
The most common configuration is 2 x 100
percent per HRSG.
Condensate Extraction Pumps

Condensate extraction pumps are used
to pump condensate from the hot well
of the condenser to the inlet of the LP
economizer of the HRSG. The most common
configurations are 2 x 100 percent or 3 x 50
percent capacity pumps per condenser
(not per HRSG).
The first-stage impeller design is critical,
as condensate pumps are required to operate
with low NPSHa. The condenser operates
at a vacuum of approximately 0.65 pounds
per square inch absolute (psia) bar (0.045
bar absolute). The condensate is near its
vaporization point with a typical temperature
of 35 C to 40 C (95 F to 105 F). This means the
NPSHa at the liquid level in the condenser
hot well is zero. As a result, a canned vertical
multistage pump is typically selected for
this application.
The setting or length of the pump must
provide sufficient NPSH to the first-stage
impeller. Smaller CCGT plants use a vertical,
multistage canned pump, with a single-
suction, first-stage impeller. On larger plants,
a double-suction, first-stage impeller can
Check 125 on index.
The setting or length of

the pump must provide
sufficient NPSH to the
first-stage impeller.
IMAGE 5-7: Condenser cooling water (CCW) pump types
reduce the pump length and should be Condenser Cooling Environmental requirements in
considered on applications exceeding 4,000 Water (CCW) Pumps many regions no longer allow once-
gallons per minute (gpm) per pump. All thermal power plants eject large through cooling from rivers or lakes. Even
For reliable operation, the design for the amounts of heat to the environment, and conventional wet-cooled cooling towers
first-stage impeller should include: a CCGT plant is no exception. A typical can be an issue, as water withdrawals are
• suction-specific speed (NSS) lower than combined-cycle plant with a 57 percent still required to make up for blowdown
12,000 to ensure flow stability over a thermal efficiency will eject 43 percent of as well as evaporation and drift from the
wide range of operation the heat input by the fuel. About 9 percent tower. As a result, air-cooled condensers
• an impeller inlet peripheral velocity will go out the HRSG stack. The rest is are becoming more common. Their initial
(inlet tip speed) that is below 70 feet per removed by the cooling water pumped capital cost is much higher and plant
second (ft/s) through the condenser. thermal efficiency may be reduced by as
• cavitation-resistant material, such as Condensers have traditionally been much as 3 or 4 percent in high ambient
12 percent chrome cooled by water using either once-through temperature locations.
or closed (cooling tower) systems. The The most frequent choice for this
Due to the high pressure on this critical cooling water requirement of a typical application is a vertical, single-stage
application, a cartridge-style mechanical CCGT plant using a cooling tower can be pump with a semi-open impeller.
seal is recommended to seal the fluid estimated at about 250 gpm per megawatt However, depending on end user specific
pumps. The associated pump-sealing (MW). As a result, a 750 MW combined-cycle preference, single-stage, double-suction
systems must stop air from entering the plant will require a cooling water flow of horizontally split, or concrete volute pumps
pump when on standby under a vacuum. about 187,500 gpm, which would normally may be used.
API Plans 13 and 32 accomplish this. be shared between two pumps.
CCW Pump Types
Regardless of the construction type, these
critical items must be reviewed to ensure
optimum and reliable performance under
all operational modes:
• Ensure there is ample submergence from
the low-water level to suppress vortexing
and provide sufficient NPSHa to prevent
cavitation at the maximum flow or
runout condition.
• Evaluate material options for all
critical components, particularly when
handling either brackish or seawater.
Material options range from coated
carbon steel to super duplex. When
handling seawater or other high-chloride
solutions, a stainless-steel alloy with a
IMAGE 8: Actual model intake test showing a floor vortex (Image courtesy of Clemson Engineering pitting resistance equivalent number
Hydraulics, Inc.)

SEE IT. SHOW IT.
FIX IT.
(PREN) greater than 40 should be
considered. (The PREN is a measure of
the relative pitting corrosion resistance
of stainless steel in a chloride-containing
environment.) The elements that have
a significant impact are chromium (Cr),
molybdenum (Mo) and nitrogen (N). The
PREN formula, which quantifies their
respective contribution, is shown in
Equation 1:
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PREN = 1 × %Cr + 3.3 × %Mo + way to monitor and detect machine, structure, and
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• Non-contact measurements
• Simple communication through video
• Higher PREN values indicate greater
• Enables root cause problem solving
corrosion resistance.
• When evaluating materials, the first cost,
while important, should not be the only TM www.rditechnologies.com
factor. The total life cycle cost of the
equipment should be considered. Check 128 on index.
• The performance and reliability of these
high-flow CCW pumps are greatly affected
by the design of the intake structures in
which they are installed. Stable pump
conditions require a uniform distribution
of the flow approaching the pump suction
inlet. Hydraulic Institute Standard ANSI/
HI 9.8-2019 “Rotodynamic Pumps for
Pump Intake Design” provides guidelines
RELIABLE POWER
for pump intake designs. One of the most
proven methods to predict performance
of an installation is to duplicate it with a When your engine package powers your business, you
physical scale model test. need a reliable source of power that you can depend on
under the harshest of conditions. At engines, inc., we
Conclusion engineer solutions for pump packagers for a large variety
This article has focused on CCGT power of industries, including: water/wastewater; chemical;
oil/gas; and mining. We offer a large variety of engine
plants that use high-temperature exhaust
options, from leading engine manufacturers, and we
from the gas turbine as the source of heat stand behind our packages with the most reliable support
for steam generation. Any power plant structure in the business. Our skilled staff is always
using a Rankine cycle with steam as the available to you on our 24-Hour Service Line to give you
working fluid—whether the source of the the support you need, when you need it, wherever you
heat is coal, biomass, oil, trash or the sun— are. We are your power source.
includes the same pump services, and
the issues discussed herein should be
properly evaluated.
24-HOUR SERVICE LINE
Mike Radio has worked on power generation
870-268-3799
applications at Flowserve Corporation for more than
40 years. For more information, visit flowserve.com. Jonesboro, AR | 800-562-8049 | www.enginespower.com
Check 127 on index.
Selecting
the Right
Submersible
Pump for
Construction
Dewatering
Whether the pump is using a motor or engine is just one
important consideration.
ANIK PATEL | Tsurumi America
Many construction sites require the materials, such as high-chrome cast iron, parameters with a friction loss calculator.
excavation of materials, such as soil, rock, to resist abrasion. In general, a longer pipe, smaller diameter
sand and clay. These sites can be in the Many pumps are designed with an and higher flow rate leads to higher friction
form of trenches, pits, caissons, cofferdams agitator attached to the impeller to stir up loss. The total elevation change, from the
and more. For all of these forms, one the solids, preventing solids from settling water level and the pipe discharge height
important environmental factor to consider near the suction. It is important to know (static head), plus the total friction loss
when managing a job site is water. what the water contains, as pumps not head, will give the total dynamic head
Water will naturally flow to the lowest meant for solids can clog or suffer damage. (TDH). The proposed pump will need to
point in an area, and the excavated If the site contains acidic water or other achieve this TDH and flow rate, or target
region will collect water from rain or a pollutants, the parts within the pump must duty point.
high water table. Excess water can make be compatible to handle such damaging Pump horsepower or discharge size
the surrounding material and working conditions. Those applications may require is not indicative of performance, as a
environment unstable. For proper operation materials such as stainless steel housings manufacturer can have dozens of models
of machinery and worker safety, a dry or fluoropolymer elastomers for chemical for each size. The performance curves
work site is necessary. Engineers often resistance. Pumps encountering seawater should be looked at instead. The chosen
employ wellpoints, eductor wells, sumps or brackish water may require sacrificial pump should have a curve closest to the
and deep wells to access this water, making anodes to prevent galvanic corrosion. target duty point, while also being as close
dewatering pumps necessary. Choosing as possible to its best efficiency point
the right pump can make the difference Meeting the Required Duty Point (BEP)—ideally within 30 percent. A pump
between a safe or unsafe working area. The next step is to choose the pump with will rarely achieve the exact target duty
the right performance for the target duty point, so the engineer will make a judgment
Choosing the Right Pump Type point. The dewatering plan should include call to balance the operating duty point
When choosing a pump, it is important to a proposed piping system plan that details with the proximity to the BEP.
consider the properties of the water at the the required flow rate and geometry of Running too far left of the BEP can
particular job site. These characteristics will the system. This will include pipe length, cause an imbalance of forces on the
determine the type of pump and materials diameter and elevation change. The plan pump shaft, leading to mechanical seal
of construction needed. should also account for any settling of and bearing failures. The water will also
For example, clean water has minimal solids in piping. A minimum velocity is recirculate inside the pump casing, wearing
contaminants and sediment, making needed depending on the type of solids and it down in the presence of abrasives. On
typical cast iron pumps a viable option. On that velocity is dependent on the pipe size the other hand, running too far right of the
the other hand, water with a high amount and flow rate. BEP can also lead to imbalanced forces on
of solids, such as sand or mud, requires The pressure loss, or head loss, can be the shaft as well as cavitation, which will
slurry or trash pumps with harder impeller determined due to friction by using these damage the impeller.

IMAGE 1: Submersible pump for dewatering
at a construction site (Image courtesy of
Tsurumi America)
should be lowered with a rope or chain, not

the power cable. This is crucial to ensuring
no damage occurs to the cable, which could
lead to motor failure.
For three-phase power, test the startup
reaction of the submersible pump to ensure
proper rotation. The pump should turn in
the opposite direction of proper impeller
rotation. The pump should not operate
below its given continuous running water
level and should be monitored either
manually or with an on/off float system.
For larger sites with long-term
dewatering, proper engineering is
imperative to account for power draw and
piping installations.
Selecting the Right Power Source Installation & Operation Anik Patel has been an engineer at Tsurumi
America, a division of Tsurumi Manufacturing, for
There are two options for a power source: Precautions must be taken to prevent any more than five years. For more information, visit
engine- or electric-powered pumps. damage. If the pump has to be lowered, it tsurumiamerica.com
Engine-powered pumps require fuel
to operate, while submersible pumps
are typically powered by generators or
line power. The pumps should be sized
according to the startup amp draw and type
of power connection needed. For example,
if a generator is providing power, make sure
the pumps have the right plugs.
The pumps may also need longer than
standard cables to cover long distances
between the pumps and the power source.
With longer cables, there may be a voltage
drop outside of the allowable range for the
pump, so a larger gauge may be needed.
Choosing the Right Controls

For larger sites with more sophisticated
pumping systems, water level sensing
devices may be needed to maintain a
certain water level. These devices,
such as floats or water level transducers,
can be integral to the pump or connected
to a central controller. Typically, there
is an “on” float to turn the pump on at
high water levels and an “off” float to
turn it off at a set low water level. The
“off” float should be placed above a
submersible pump’s continuous running
water level to prevent it from running dry or
experiencing cavitation.
Check 126 on index.
Selecting the Right Food

& Beverage Pump
These four characteristics should guide a user’s decision.
JEFF SHAFFER | Graco
Proper ingredient transfer equipment is

crucial in maintaining optimal efficiency
and high product quality while balancing
operating costs. Food and beverage
processors have a difficult task making
purchasing decisions when installing
new equipment or upgrading outdated
equipment. A four-ingredient recipe exists
to select the right pump technology for
food and beverage applications.
Food and beverage processing has no
shortage of options for material pumping.
The options can seem overwhelming for
users, from the industry’s new twin screw IMAGE 1: Large particle AODD pump
(Images courtesy of Graco)
pumps, the reliable rotary lobe pumps,
the adaptable electric and air-operated
diaphragm pumps, the powerful piston
pumps, and so on. There is a configuration for the application will run too hard or to upwards of 25 percent performance
available in the market to meet a user’s too hot, which may cause pump failure. reduction. Typically, centrifugal pumps are
needs. The following considerations will A pump that is too large will incur larger used for lower viscosity fluids and pumps
steer users in the right direction. purchase and operating costs. As a general such as piston, lobe, diaphragm and others
1
rule, pumps should operate at 30 percent are used for higher viscosity liquids.
Flow Rate to 60 percent of maximum capacity. This Material viscosity will affect how well
The volume flow rate is determined by reduces unnecessary wear due to high the pump can load material into the inlet of
multiplying material velocity and tubing speeds and allows for future expansion or the pump as well as output. Lobe pumps do
size to determine gallons/liters per minute. process capabilities if needed. This holds not create significant inlet suction and have
Determining flow rate is critical in selecting true for rotary lobe, diaphragm, twin screw, a difficult time priming higher viscosity
the perfect pump. A pump that is too small sine pumps, and just about any other pump liquids. Electric or pneumatic diaphragm
that may be installed in an application. pumps and peristaltic pumps are able
2
to load high viscosity materials into the
Product Characteristics pump with the suction they produce. If the
Viscosity material’s viscosity exceeds 100,000 cP, a
Fluid viscosity is the most concerning ram unit will be required to apply downward
characteristic to pump operators. The above pressure to material into the pump when
flow rate performance rating for pumps unloading from containers.
will decrease with material viscosity. Most
pumps are rated for maximum flow rate Abrasion
with water at 1 centipoise (cP). Most food Material abrasiveness can wear out pump
ingredients are thicker than water, reducing components easily, especially when using
IMAGE 2: An EODD pump in an installation maximum output anywhere from 5 percent centrifugal-style pumps, which causes

higher repair costs. Material with high sugar Many faults occur when a pump elastomer meets all FDA standards and complies
content will quickly wear out components or seal is compatible with the food with FDA Code of Federal Regulations (CFR)
compared to other materials. Lobe pumps ingredient but cannot handle the caustics Title 21. Many other approvals may drive
will sometimes use specialty materials and used to clean the equipment. specific pump selections. When processing
coatings to properly handle this increased Pump clean-ability and plant cleaning solvents proof or atmosphere explosible
abrasion but can still struggle with leaking procedures must be considered to select (ATEX) approval is required. European
rotary seals and rotor wear over time. the right pump. Does the facility require manufacturers may require equipment
Diaphragm pumps, which do not employ a a pump that is capable of being cleaned meeting European Framework Regulations
rotary seal or rotating components, handle in place and not removed? This may (EC) 1935 approvals, and many personal
abrasive materials much easier than the direct users toward rotary lobe or other care and pharmaceutical facilities require
tight tolerances required in lobe pumps. rotary pumps designed for CIP capability. U.S. Pharmacopeia (USP) Class VI approved
Diaphragm pumps can be cleaned in place components. The approvals are driven by
Material shear but are material dependent. Many plants the material being produced and how the
In applications like tomatoes, pie fillings, are now using steam-in-place cleaning— customer will ingest or use the product.
ricotta cheese, meat and poultry, users meaning all pump components must There are many factors driving
should be aware of material shear. withstand the extreme steam temperatures equipment selection for food and beverage
Diaphragm, peristaltic and sine pumps are run through the pumps. applications. It is important that material
4
gentle on materials and will not shear the fluid handling requirements are understood
material being pumped like a centrifugal, Approval Requirements completely before selecting a pump.
lobe, twin screw or other rotary-style pump. Are there are any equipment approvals
This is important for users whose products required for the process? United States Food Jeff Shaffer is worldwide sanitary (hygienic)
are affected by shear and heat where it can and Drug Administration (FDA) approval and equipment product manager and North American
design is the most widely used standard sanitary (hygienic) equipment sales manager for
alter the final product produced by
Graco. He may be reached at jshaffer@graco.com.
the equipment. in the food industry. Ensure equipment For more information, visit graco.com/sanitary.
Particle size
Users should be aware of any solids
or particles within the material being
transferred. Food ingredients such as salsa,
fruit fillings and others have large-sized
Sprague Intensifier
pieces of food within the liquid. Diaphragm
pumps with flapper checks and peristaltic
pumps are designed to handle solids
Pumps and Boosters
upward of 4-plus inches in diameter. Rotary
pumps can handle some solids, but not
of any significant size and often damage
Trusted, Reliable
particles and degrade the material due to
the pump style and operating speed.
Pressure Since 1947
• Sprague pumps and boosters now
3 Construction Materials
Ensuring the pump materials are
compatible with the ingredient being
manufactured and supported by
High Pressure Equipment
transferred will keep the pumps operating • Made with pride in the USA
for a long time. Most sanitary pumps
are built with stainless steel, but all use • Pressures to 36,500 psi
some sort of elastomer seals that are • Complete range of pumps, boosters
more susceptible to compatibility issues.
In the meat and poultry business, many and skids for liquid and gas
elastomers do not hold up well to animal
fats and oils in the material.
Pump construction and elastomers also
need to be compatible with the facility
cleaning solutions and clean-in-place (CIP)/
clean-out-of-place (COP) requirements. www.HighPressure.com • 800-289-7447
Check 129 on index.
FLOW METERS
Ultrasonic Flow Meters requirements, installation environment,

output requirements, interconnectivity
needs, maintenance and serviceability
Improve Reliability & requirements and budget limitations.
Ultrasonic transit time flow meters
Efficiency in Hydronic have become a popular choice for HVAC-
related applications. With this technology,
HVAC Applications ultrasonic waves transmit upstream and

downstream through the pipe wall and the
liquid flowing in the pipe. By measuring the
These use two transducers, which function as both ultrasonic difference in the travel time and knowing
the pipe size, the meter determines the
transmitters and receivers.
velocity and flow rate.
Transit time ultrasonic flow meters use
ROB FEHL | Badger Meter two transducers, which function as both
ultrasonic transmitters and receivers. They
operate by alternately transmitting and
receiving a frequency-modulated burst of
sound energy between the two transducers.
Building owners are seeking to deploy consumption, energy expenses and repairs Since ultrasound energy in a moving liquid
advanced flow and energy measurement to pumps and other equipment. is carried faster when it travels in the
solutions to obtain high performance. The For facility owners/operators, the direction of fluid flow (downstream) than
reliability and efficiency of pumps and effective use of flow measurement can it does when it travels against fluid flow
other components of hydronic heating, assist with system capacity analysis, (upstream), a differential in the times of
ventilation and air conditioning (HVAC) individual building cost allocation, flight will occur. The ultrasound’s time of
systems can impact the bottom line. energy efficiency initiatives, hydronic flight is measured in both directions, and
system optimization and equipment the difference in time of flight is used to
Challenges for Facility Operators troubleshooting. Typical flow applications determine the velocity of the fluid.
Commercial and industrial businesses in building design, construction and When an existing in-line or insertion
spend much of their building costs operation include glycol and hot/chilled flow meter fails and is difficult to replace,
on processing hot and cold water and water, domestic water/domestic hot water, or additional metering is needed, the best
distributing it around their facility. There makeup water/blow down, steam/steam choice can be a noninvasive solution like an
is an increased focus on determining the condensate, boiler feed water, cooling ultrasonic clamp-on flow meter. Designed
correct amount of this resource required. towers, chiller systems, energy audits and to attach to the outside of pipes, this type
Hydronic balancing is the process of cost allocation. of meter does not contact the internal
optimizing the distribution of water in In some cases, building operators find it liquid, allowing for installation without
a building’s heating or cooling system necessary to install flow meters upstream shutting down the operation. Hot tap, in-
by equalizing the system pressure, so from pumps to provide flow data alerting field drilling and welding are not required
it provides the intended indoor climate. them to situations leading to potential when installing the device.
Recently, building hydronic systems have problems caused by low-flow conditions. Ultrasonic clamp-on flow meters provide
employed variable speed equipment and Otherwise, the result can be expensive reduced installation costs, flexibility across
pumps to vary the system’s flow. This pump repairs or even system shutdowns. pipe sizes, elimination of pressure head
technique matches the water flow (gallons loss and no moving parts to maintain.
per minute) to the demands of the building Choice of Metering Solutions This meter design allows for routine
without wasting energy and reducing the End users involved with commercial maintenance activities without having to
wear on equipment. and industrial buildings can choose cut into piping.
from a broad range of flow and energy
Need for Flow Measurement measurement products for their facility’s Recent Technology Innovations
Flow metering, in particular, is key to the hydronic HVAC systems. Common Ultrasonic transit time flow meters have
reliable operation of HVAC systems that choices range from electromagnetic flow gained wider industry acceptance for
provide climate control in large complexes. meters to vortex, differential pressure, measuring volumetric flow rates in clean
Installing this technology at multiple positive displacement, turbine, disc liquids as well as liquids with small
points in cooling tower and HVAC systems is and ultrasonic meters. The typical flow amounts of suspended solids or aeration.
a best industry practice to minimize water meter selection criteria include accuracy Also, the availability of these devices

has increased. The current generation cables. With built-in data logging and or replaced when system requirements
of ultrasonic flow meters is offered with a real-time clock, the most advanced change. The meters can be installed
configurations and features to meet ultrasonic flow meters record flow rate, total outdoors within a cooling tower system
particular application requirements. and diagnostic information with a time/ so that the owner receives precise
They include diagnostics that take the date stamp—providing the baseline and measurements for sequence and cycle
guesswork out of isolating process or load profile information needed to optimize control while using the flow data to help
application problems. Users are alerted to pump efficiency. Meters designed to use identify limits of operation.
out-of-specification flow conditions and a micro-SD card can store a large volume In addition, the latest ultrasonic transit
can access a history with the most recent of backup data for troubleshooting or time flow meters can integrate metering
alarm, error and event codes. reporting purposes. components with flow and temperature
Using an ultrasonic transit time flow sensors to measure energy costs in diverse
meter, building operators can measure Typical Industry Applications heating and/or cooling applications.
energy costs for both hydronic chilled and Building operators are faced with mapping Users can pair the meters with cloud-
hot water applications. Where dedicated all the submetering points for energy or based advanced metering analytics
thermal measurement is required, as in water usage, as well as measuring flow at (AMA) software to provide flow data for
the case of a distributed chilled water both the design rate and minimum rate consumption analysis, leak detection
system, the devices can be used with dual required for seasonal operation. This can and other purposes. These devices were
clamp-on resistance temperature detectors be accomplished by using noninvasive developed for data-centric operations to
(RTDs) for British thermal unit (Btu) energy ultrasonic flow technologies without interface with building automation systems
measurement. disruption to the hydronic system. for real-time flow balancing using Modbus
A key feature of energy monitoring is Ultrasonic clamp-on flow meters RTU, BACnet MS/TP and BACnet/IP.
the data logger. A second requirement is can control the pumped condenser
data retrieval. A number of the new meters water, condenser water blowdown
Rob Fehl is product manager for Badger Meter.
offer secure digital (SD) card data storage and evaporation. Their power and Contact Fehl at rfehl@badgermeter.com. For more
and do not require software or download communications features can be added information, visit badgermeter.com.
Keep Your
Operations Flowing
NEW Dynasonics® TFX-5000 Clamp-On Ultrasonic Flow Meter

At Badger Meter, we know that operational downtime can cost you time and money. The NEW Dynasonics® TFX-5000 clamp-on
flow meter allows you to install the meter while your system continues to operate—reducing downtime and increasing efficiency.
As a precision transit time ultrasonic device, the TFX-5000 meter is the right choice for measuring the volumetric flow of
liquids in chilled water and glycol/hot water, cooling tower blowdown, and Btu/energy metering.
Visit us at booth #6553 during the AHR Expo.

www.badgermeter.com/PS-TFX5000
Check 113 on index.
SEALING SENSE
Current Standards for Fire Testing of

Flange Gaskets & Stem Packing
Learn why updates are needed for API test standard 607 and stay tuned for more.
MATTHEW WASIELEWSKI | Yarmouth Research and Technology, LLC
Fire test standards for valves date back

API 589 – 2nd Edition API 607 – 7th Edition *
to the 1960s, with specific tests for stem
packing and gaskets not occurring until Valve / Fixture Type 6, 8, 10 or 12 inch Class Quarter-turn valves and other
the 1990s.
300 API 600 gate valve valves with non-metallic seats
In the early 1990s, Exxon was an Fire Test Duration 30 minutes 30 minutes
industry leader in developing and requiring Test Pressure 540 psig 75% of CWP
fire testing, possibly because of increased (540 psig for Class 300 CS)
concern after a large fire in 1994. Fueled Cool-Down Time 10 minutes 10 minutes
(no pun intended) by safety and insurance
requirements, fire-tested valve designs Post-Burn Low 50 psig 30 psig – through leakage only
became mandatory. Pressure Test
Post-Burn Operational 540 psig 75% of CWP
Stem Packing Fire Test Test Pressure (540 psig for Class 300 CS)
The first standard written specifically to Allowable Leakage 10 ml/min per NPS 100 ml/min per NPS
test valve stem packing was American During Burn/Cool-Down
Petroleum Institute (API) 598, released in Allowable Leakage for 0.5 ml/min per NPS Through leakage only
January 1993. The test was revised to the Low Pressure Test –
2nd Edition in 1998, and then inactivated Post Cool-Down
several years ago (though it is still available Allowable Leakage for 10 ml/min per NPS 25 ml/min per NPS
for sale on the API website). The 589 High Pressure Test –
standard was written with clear parameters, Post Operation
but the API Committee on Refinery
IMAGE 1: A comparison on API 607 and 589 (Images courtesy of Yarmouth Research and Technology)
Equipment (CRE) felt it unnecessary *Parameters for metal-seated valves
to maintain the standard due to the
prominence of the valve test standard API
607. API 607 has been adapted for use for On-Shore Off-Shore
many products outside of its scope due
Number of Burners Multiple or widespread 1
to necessity. Gasket tests will be reviewed
later in this article. Flame Temperature (F) 1400-1800 2000-2500
Calorimeter Block 1200 1800
API 607 vs. 589 Temperature (F)
The interesting point about using API 607 IMAGE 2: Temperature differences
as a packing test standard is that the valve
typically used for the test is a metal-seated typical for the API 589 test, since it is not For the API 589 test, the temperature of
gate valve, which is outside the scope defined, a 4-inch Class 300 gate valve is the bonnet must reach 1,200 F within 15
of API 607. Using an API 600 gate valve often used for an API 607 test. This makes minutes from the start of the test. Since
provides standardized dimensions for a the packing size the same as what is used temperature probes are inserted directly
5-ring packing chamber. A quarter-turn for the fugitive emission test of API 622. into the bonnet, the packing chamber for
product would not do so, since the packing In general, the test parameters of time an API 589 test may get hotter by 100 to
chamber is not defined in the applicable and temperature are similar between all 200 F. For the API 607 test, a calorimeter
design standard. While a 6-inch valve was API fire test standards. cube placed below the packing chamber

BBA Pumps products are targeted at the wellpointing,
construction and rental market. Our main focus is on
portable pumping equipment.
Visit us at Conexpo booth #F3568
IMAGE 3: API 589 fire test
must also reach 1,200 F

within 15 minutes from
the start of the test, but
since the calorimeter
cubes are only 1 1/2- Contact us now for more details!
inch cubes of steel, info@bbapumpsusa.com • www.bbapumpsusa.com
they can get hotter
quicker than the bonnet Check 131 on index.
of a large gate valve.
Besides the lower
temperature, why else
may a packing supplier SHREDDING
THE COMPETITION
IMAGE 4: Exxon-modified API 607 gasket
prefer to do the API 607 fire test
test? Image 1 shows
that the allowable leakage of API 607 is greater—as much as 10
times greater for the allowable during the burn and cool-down
period. Keep in mind that the API 607 test is a valve test standard,
so the external allowable leakage is not only for the stem packing
but also for the bonnet gasket and any body gaskets. So, for a
stem packing only test, this can be quite an advantage.
Flange Gasket Tests

There are two standards used for fire testing gaskets in the United
States: API 607 and API 6FB.
API 6FB is the dominant test standard for testing flange
gaskets used in upstream, midstream and downstream oil and gas
applications. Prior to this, the Exxon-modified API 607 4th edition
test was the leading standard for testing flange gaskets. What
started as an internal test for Exxon in 1995 to evaluate supplier’s AGPR AGP300/500/750 AGP-HC200
Single Seal Grinder Dual Seal Grinder Dual Seal Grinder
gaskets turned into an industry standard that is still used in some
cases. That standard used a pair of gaskets separated by a spool Your solution for: • Wipes • Swiffer Pads • Hygiene
Products • Dental Floss • Rags
piece with thermocouples inserted into the flange material and
required 1,200 F temperatures to be reached within 15 minutes
of the start of the burn. The test setup required millions of British
thermal units (BTUs)/hour to achieve those temperatures. P U M P
API 6FB title states that it is the test standard for end Honest, Professional, Dependable
connections, so a variety of products can be tested to this 1899 Cottage St. n Ashland, OH 44805 n 855 281-6830 n ashlandpump.com
Check 133 on index.
SEALING SENSE
Innovative Pass-Through
Technology
ShinMaywa (America), Ltd. offers the

CNWX Series of heavy-duty,
non-clog submersible pumps for the municipal
wastewater market. CNWX pumps with the SCROLL
impeller have already eliminated clogging problems IMAGE 5: On-Shore IMAGE 6: Off-Shore
in many municipal installations. Explosion Proof (FM
Approved) motors are standard. standard. The standard has the option for onshore and offshore
tests both with a bending moment applied or not. The bending
Non‑Clog Scroll Submersible Pump moment option is not a common request. The temperature
differences of each option are shown in Image 2.
API 6FB was updated recently to the 4th edition in May 2019.
While changes were made to address other components that
use this standard, some details specific to gasket testing were
Highly
Effective not addressed. Part of the reason behind the inaction is that the
Passing Upstream API committee is responsible for API 6FB, yet the flange
ShinMaywa(America), Ltd. gaskets are mostly considered a downstream product. One of the
6135 Park South Drive Charlotte, NC 28210 ■ Phone: 704‑945‑7112 biggest changes needed is to determine how qualifications are
■ Fax: 704‑945‑7101 ■ E‑mail:pump@shinmaywaamerica.com
www.shinmaywa.co.jp/america/ extended to nontested gaskets (i.e., scaling).
The standard currently says that if two sizes are tested, then
Check 134 on index.
all sizes between them are qualified and all pressure ratings lower
than the tested one’s rating are qualified. That may be fine for
some components, but does not hold muster for flange gaskets
that could have a size range from a 1/2 inch to 60 inches or more
and Class 150 to 4,500. Ninety-five percent of the tests that are
performed are done with 6-inch ANSI Class 300 gaskets and that
is all. There are only one to two manufacturers that have tested
UNMATCHABLE EXPERIENCE IN larger and smaller gaskets to try to fulfill the requirement of API
FLOW CONTROL TRANSACTIONS 6FB. In those cases, 2-inch and 24-inch gaskets were tested.
The Future
Jordan Knauff & Company is a knowledgeable and While testing can currently be performed for both packing and
experienced provider of a comprehensive line of gaskets using the available standards and modifications to them,
investment banking services to the pump, valve and there is a need to make changes to the existing ones or create
filtration industries (“Flow Control”).
something new. As of this writing, API 607 is under review. The
Our lines of business include: selling companies, committee will address making addendums for packing and/or
raising debt and equity capital, and assistance gasket tests as part of 607. If not, API 589 may be reactivated.
on acquisitions. Stay tuned.
To learn more about Jordan Knauff & Com-
pany, contact any member of our Flow We invite your suggestions for article topics as well as questions on
Control team. Access our Flow Control research sealing issues so we can better respond
at www.jordanknauff.com/research-library. to the needs of the industry. Please
direct your suggestions and questions to
sealingsensequestions@fluidsealing.com.
G. Cook Jordan, Jr. David A. Kakareka
Managing Principal Vice President
cj@jordanknauff.com dkakareka@jordanknauff.com
312.254.5901 312.254.5907
Matt Wasielewski, PE is the owner of Yarmouth Research and Technology, LLC

MEMBER FINRA, SIPC and has performed fire and fugitive emission testing since 1992. Wasielewski
is a member of API standards committees and has presented papers about fire
and fugitive emission testing in the U.S., Europe and Asia.
Check 130 on index.

HI PUMP FAQS
Variable Speed Pumping in HVAC Systems

HYDRAULIC INSTITUTE
IMAGE 1 (right): Variable speed control in

How is variable speed pumping
▲
friction dominated system (Images courtesy

used in HVAC? of Hydraulic Institute)
The energy conservation standard for Image 1 demonstrates the wasted

pumps (10 CFR 431 Subpart Y), published in energy that can be saved when the
January 2016, recognizes that pumps and speed is reduced to a lower flow and
motors equipped with variable speed drives head in a friction head dominated
(VSDs) can save significant energy and the system.
metrics in the regulation measure this. VSDs allow the pump speed to be
In heating, ventilating and air lowered or increased, depending on the
conditioning (HVAC) applications of needs of the system.
pump systems, the American Society of Reducing the speed of the pump
Heating, Refrigerating and Air-Conditioning reduces both the pump’s pressure
Engineers (ASHRAE) 90.1 standard requires and flow, which reduces power
water-cooled unitary systems that are consumption.
greater than 5 horsepower (hp) to have a While variable speed control can
VSD installed on the pump motor. provide the most efficient, reliable and
When properly applied, VSDs play a precise control to meet the system
major role in energy conservation. demand, it requires higher investment
The energy savings in variable flow cost, is less suitable for high static
pumping systems are maximized in or flat system curves, and requires
systems that are friction dominated, such consideration of mechanical design
as water circulating systems for heating issues related to resonance, minimum
its use and ensure a reliable installation,
and cooling. speed and/or over speed. To justify
it is important to analyze the system’s
suitability for the speed range and the
benefits of controlling the speed.
Vibration Vibration
When using variable speed

▲
Imbalance pumping in an HVAC system,

at 1 x RPM
should extra precautions be
taken to limit the chance of vibration?
One Revolution
0 1x 2x 3x Freq.
(Multiple of
In any system that uses a variable speed
Running Speed) drive, the chance of amplified forced
vibration due to interaction with natural
Vibration Vibration
frequencies increases. Forced vibration
is due to a mechanical or hydraulic
Vane Pass
component of the pump. Image 2 shows
at N x RPM
(N=Number imbalance and vane pass forces that lead to
of Impeller vibration in the pumping equipment. Note
Vanes) that these forces will always be present and
One Revolution
0 1x 2x 3x Freq. are normal, and also note that these forces
(Multiple of
Running Speed) occur at different frequencies. Image 3
IMAGE 2: Forced vibration at 1 times operating speed due to imbalance, and 3 times operating illustrates a Bode plot, which is a tool used
speed due to impeller vanes by analysts to evaluate if a forced vibration
HI PUMP FAQS
The Contractor’s
Choice for Enclosures
•Outstanding
protection against
water, salt,
chemicals & UV
exposure
•Meets or exceeds
industry standards
•Easy to install
•Custom colors,
cutouts, EMI/RFI
shielding and more
HMI Cover – Reduce IMAGE 3: Bode plot of forced vibration and natural frequencies versus
operating speed. Intersecting lines indicate possible resonance.
•Order online at the risk of arc flash
AlliedMoulded.com
will interact with a natural frequency. This plots both forcing

222 North Union Street frequencies and natural frequencies as a function of operating
Bryan, Ohio 43506 speed. Where the lines intersect is where resonant vibration is a
Ph: 800-722-2679 potential problem.
Fx: 800-237-7269 Upfront dynamic analysis is sometimes warranted when
using variable speed pumping to limit the risk of resonant
Check 132 on index.
vibration. Generally, HVAC pumps do not require upfront
dynamic analysis and rarely have it specified upfront. Dynamic
analysis is seldom done for HVAC pumps because:
• Most HVAC systems primarily consist of between-bearings
or overhung horizontal pumps of a well-proven design,
typically running at four-pole or slower speeds.
• Booster service typically uses vertically suspended pumps
and smaller units often run at two-pole speed. These pumps
ebook are usually catalog units of well-proven design.
• The HVAC market is generally price-sensitive and
PUMP
competitive prices typically do not bear the cost of dynamic
analysis.
SYSTEM
However, vertically suspended pumps on variable frequency
drives (VFDs) occasionally require a level 1 structural analysis
to determine the reed frequency.
EFFICIENCY
For more information about the HVAC and building
markets and variable speed pumping, refer to ANSI/HI 9.6.8
Rotodynamic Pumps Guideline for Dynamics of Pumping
Machinery and the “Pump Application Guideline for
Commercial Building Services” at pumps.org.
FREE
DOWNLOAD HI Pump FAQs® is produced by the Hydraulic Institute as a
service to pump users, contractors, distributors, reps and OEMs.
pumpsandsystems.com/efficiency For more information, visit pumps.org.

PRODUCTS
NEW & NOTABLE TECHNOLOGY

Selected by the
6
Pumps & Systems editors
4 ISOLATION GASKET
EVOLUTION—isolation gaskets from GARLOCK
PIPING TECHNOLOGIES (GPT)—features easier
installation, tight sealing, high-temperature
operation, no permeation, hydrotesting isolation,
fire safety and chemical resistance. Featuring a
thinner, 1/8-inch design, EVOLUTION minimizes
the difficulties often encountered when
2 attempting to install thicker isolating gaskets. The
full-coating encapsulation allows the gasket to be
hydrotested and left in the pipeline with the same
isolation properties as before it was tested.
gptindustries.com
Check 204 on index.
2 CONNECTIVITY DEVICE
The TOSIBOX Lock 500 is a high-end 5 WEAR RINGS AND CASE RINGS
connectivity device enabling customers to Pump wear rings and case rings made from
manage their operations and to build new IoT GRAPHALLOY materials can improve the
3 solutions. The Lock 500 is ideal for demanding reliability and efficiency of horizontal and
industrial environments and opens new vertical pumps. Graphalloy is self-lubricating and
opportunities in security and office networking nongalling. This means that the material is “kind”
sectors. The Lock 500 is compatible with all to the shaft and will minimize damage in the
existing TOSIBOX products. Modularity of the event of dry-run, loss of suction, and slow roll on
products enables easy and fast extension standby service. Graphalloy can be designed
of networks. to run at half of API’s recommended clearances
tosibox.com for metallic wear parts, decreasing vibration
Check 202 on index. and leakage.
graphalloy.com
1 DRAINAGE 3 PLANT CONTROL SYSTEM Check 205 on index.
PUMPS ARMSTRONG FLUID TECHNOLOGY features
CHICAGO PNEUMATIC Power Technique features the Design Envelope IPC 9521 integrated plant 6 GENERAL PURPOSE DRIVE
CPWE, a range of seven drainage pumps and control system. Featuring the new TowerMax The Optidrive E3 from INVERTEK DRIVES is
two sludge/drainage pumps. CPWE pumps are option, the IPC 9521 improves the operating compact, reliable and easy to use. An internal
ideal for construction and rental industries, efficiencies of plants using either identical or filter in every Optidrive E3 saves cost and time
where small, lightweight, portable, and easily nonidentical chillers. Designed with advanced for installation. It provides sensorless vector
maintained pumps are required to perform daily operating algorithms to reduce energy and control for all motor types and provides precise
jobs quickly. These pumps provide efficient water consumption, the TowerMax option is an and reliable control for IE2, IE3 and IE4 motors.
dewatering for a wide variety of applications. optimization feature that can help variable speed Users can switch between industrial, pump and
The design of the pump’s outer jacket for cooling chiller plants achieve up to 45 percent energy fan modes to optimize Optidrive E3 for the right
and thermo protection keeps it running safely savings. It complements both new and existing application. The drive features a 14-parameter
under a variety of conditions. These pumps can building management systems (BMS) and works basic setup. Default settings are suitable for most
handle fluid temperatures up to 95 F and have a with all brands of chillers and cooling towers to applications. Includes contactor-style connection
maximum submerged depth of 16 feet. meet the requirements of Green Mark. for simple wiring.
cp.com armstrongfluidtechnology.com invertekdrives.com
Check 201 on index. Check 203 on index. Check 206 on index.
To have a product considered for this section, please send the information to Drew Champlin, dchamplin@cahabamedia.com.
PRODUCTS
10
11
9
7 PERISTALTIC PUMP
MASTERFLEX Ismatec Reglo Digital peristaltic
pumps are ideal for the laboratory, with flow-
driven technology that supports precision
dispensing, functional versatility giving freedom in
applications, and a space-saving compact footprint
to conserve valuable benchtop space. The new
Reglo pumps have a wider overall flow range with
the option of dosing between 0.00009 and 368 mL/
min. The models include antidrip technology to
help conserve valuable samples, speed ramping to 10 FILTRATION SYSTEM
better accommodate fluids with varying viscosities, DES-CASE has released its varnish removal
and touch-screen interfacing—all while taking up system. The system reduces the rate of additive
consumption, reduces and prevents servo
little space (178 x 152 x 165; H x L x W, mm). 12
masterflex.com valve sticking, removes oxidation byproducts,
Check 207 on index. does not add water or other byproducts to the
system and operates at a wide range of oil
8 SOFT SEAT RELIEF VALVE temperatures. The system is also compatible
HIGH PRESSURE EQUIPMENT COMPANY, a with all mineral and phosphate ester fluids,
subsidiary of Graco Inc., introduces a new soft operates on fluids containing more than
seat relief valve designed to protect liquid and gas 500 ppm of water and can be configured for
tubing systems from over-pressure damage and applications with fluid volumes up to 36,000
failure. These new relief valves are available in liters (9,500 gallons). Due to its modular design,
pressure ranges from 1,500 psi through 25,000 psi users can choose from a variety of housing
for 9/16-inch O.D. tubing with adapters for other lengths or combine multiple housings for a
sizes available. Outlet connections are 1/2-inch NPT. larger system.
The soft seat valve design provides a bubble-tight descase.com
seal ideal for venting gas and can be reseated. Check 210 on index.
highpressure.com
Check 208 on index. 11 SENSORS 12 VARIABLE AREA FLOW METERS
ENDRESS+HAUSER launches Memosens ProSense FG1 Series mechanical variable
9 DIGITAL MIXING VALVE CPS47D, CPS77D and CPS97D ISFET pH sensors area flow meters from AUTOMATION DIRECT
The high-performance LEGIOMIX digital mixing for applications where glass pH sensors provide visual indication of flow rate for water
valve from CALEFFI for commercial domestic hot present risk of breakage in challenging or petroleum-based fluids. These meters
water (DHW) temperature control is now available process conditions. ISFET sensors are made provide +/- 5 percent full-scale accuracy and
with ANSI 150 flanges in sizes 2.5 inches for 17 gpm of unbreakable PEEK and are available with a repeatability of +/- 1 percent, important
to 470 gpm flow rate and 3 inches for 22 gpm to three different reference systems, providing a for cyclical applications requiring consistent
537 gpm. The valve delivers high flow in a single glass-free pH sensor to suit every requirement. readings. Two adjustable flow limit pointers are
valve compared to multiple valves in parallel. The ISFET Memosens CPS47D and CPS77D sensors available to provide preset indications of high,
3-inch flanged LEGIOMIX is a control valve that are equipped to meet the strict demands of low or normal flow rates. The flow meters are
provides a maximum flow rate over 500 gpm. The hygienic applications. Because of their new constructed of high-impact polysulfone plastic
new flanged sizes complement the existing NPT, design, with an increased chip surface, these (body, piston, cone) with brass fittings (1/2 and
press and sweat union connections. sensors are easy to clean. 3/4 NPT models).
caleffi.com endress.com automationdirect.com

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Badger Meter Inc ...................................... ❑ 113 .........45 Jordan, Knauff & Company....................❑ 130 .........48 SWPA .................................................................................34
Bartlett Bearings .....................................❑ 123 .........29 Load Controls.............................................❑ 120 .........35 Titan Flow Control, Inc. ...........................❑ 125 .........37
BBA Pumps Inc.......................................... ❑ 131 .........47 Load Controls.............................................❑ 135 .........55 Titan Manufacturing, Inc. ......................❑ 138 .........54
Blue-White Industries Ltd ......................❑ 109 .........11 Magnatex Pumps......................................❑ 136 .........54 Tuf-Lok International...............................❑ 148 .........55
C & S Associates........................................ ❑ 143 .........55 MasterBond Inc.........................................❑ 140 .........54 Vaughan Company...................................❑ 102 ...........5
Cornell Pumps ........................................... ❑ 107 ........ BC Milton Roy and Williams......................... ❑ 112 .........33 Vertiflo.........................................................❑ 137 .........54
Dan Bolen & Associates ..........................❑ 139 .........54 Moving Water Industries Vesco Plastics Sales ................................. ❑ 141 .........55
Engines, Inc ...............................................❑ 127 .........39 Corporation (MWI).................................... ❑ 145 .........55 Worldwide Electric Corp ......................... ❑ 118 .........16
Everactive ................................................... ❑ 114 .........23 NDT International, Inc.............................❑ 142 .........54 Yaskawa America Inc ..............................❑ 105 .........21
Finish Thompson ......................................❑ 126 .........41 Pfeiffer Vacuum ........................................ ❑ 111 .........19 Zoeller Pump Co. ....................................... ❑ 119 .........24
Flowserve Corporation ............................❑ 103 ...........3 Pioneer Pump ............................................❑ 108 ...........7
The Index of Advertisers is furnished as a courtesy, and
Franklin Electric ........................................ ❑ 110 .........15 RDI Technologies ......................................❑ 128 .........39 no responsibility is assumed for incorrect information.
Products
Company Name RS# Page Company Name RS# Page Company Name RS# Page
Armstrong Fluid Technology ................ ❑ 203 ...........51 Des-Case .....................................................❑ 210 .......... 52 High Pressure Equipment...................... ❑ 208 .......... 52
AutomationDirect ....................................❑ 212 .......... 52 Endress+Hauser ........................................❑ 211 .......... 52 Invertek Drives ......................................... ❑ 206 ...........51
Caleffi ......................................................... ❑ 209 .......... 52 Garlock ....................................................... ❑ 204 ...........51 MasterFlex ..................................................❑ 207 .......... 52
Chicago Pneumatic..................................❑ 201 ...........51 Graphite Metallizing ............................... ❑ 205 ...........51 TOSIBOX ..................................................... ❑ 202 ...........51
PUMP USERS MARKETPLACE
Sub ANSI magnetic drive pumps

IN STOCK, READY TO QUICK SHIP.
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NDT 715- Ultrasonic

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The NDT-715 is designed to make reliable spot check
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Phone: 713.972.8666 | Toll Free: 866.624.7867 and cast iron.
FAX: 713.972.8665
3575 West 12th Street, Houston, TX 77008 NDT INTERNATIONAL,INC.
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Check 136 on index. EASY TO USE ACCURATE LOW-COST ndtint.com

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TOUGHENED
EXECUTIVE SEARCH/RECRUITING
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(480) 767-9000
Email: jason@danbolenassoc.com +1.201.343.8983 • main@masterbond.com
www.danbolenassoc.com www.masterbond.com
54 PUMPS & SYSTEMS JANUARY 2020

ADD ELECTRIC MOTOR
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vesconite@vesconite.com
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OUR EXPERTS CAN HELP

• Licensed professional engineers on staff
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com
MONITOR PUMP PERFORMANCE
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• Flow Rate univeRsal PoweR Cell
• One Size Adjusts for
• PumP Condition All Motors, From Small
up to 150HP
• dRy Running • Works on Variable Frequency
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grounding • BeaRing FailuRe just sensing amps
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• High end pull Check 135 on index.
Tuf-Lok International
Phone: 608.270.9478 • www.tuflok.com
Check 148 on index. PUMPSANDSYSTEMS.COM 55
PUMP MARKET ANALYSIS
Wall Street Pump &

Valve Industry Watch
JORDAN, KNAUFF & COMPANY
The Jordan, Knauff & Company which comprises three-

(JKC) Valve Stock Index was up 24.8 quarters of all industrial
percent over the last 12 months, activity. This was the IMAGE 1: Stock Indices from Jan. 1, 2019 to Dec. 31, 2019. Local currency converted
to USD using historical spot rates. The JKC Pump and Valve Stock Indices include
while the broader S&P 500 Index largest monthly increase a select list of publicly traded companies involved in the pump and valve industries,
was up 28.9 percent. The JKC Pump since February 2018. weighted by market capitalization. Source: Capital IQ and JKC research.
Stock Index rose 28.8 percent for The gain comes after
the same time period.1 manufacturing was down in seven Brent crude oil prices are
Reference
The Institute for Supply of the first 10 months of the year. expected to average $61 per barrel 1. The S&P Return
Management’s Purchasing The level of factory output is down in 2020, down from an average of figures are
Managers’ Index (PMI) for December 0.7 percent from a year ago. $64 per barrel in 2019, due to rising provided by
was 47.2 percent, a decrease of The U.S. Energy Information global oil inventories, particularly in Capital IQ.
0.9 percentage points and the Administration (EIA) expects U.S. the first half of the year. West Texas
lowest reading since June 2009. crude oil production to average 13.2 Intermediate prices are forecast to Jordan, Knauff
& Company is an
Among the other indices, new million barrels per day (b/d) in 2020, average $55.50 per barrel in 2020. investment bank
orders fell 0.4 percentage points an increase of 0.9 million b/d from On Wall Street, despite a slump based in Chicago
to 46.8 percent; the production the 2019 level. The expected growth in the manufacturing sector and that provides
is slower than the 2018 growth of merger and
index reading was 43.2 percent, the lengthy trade war with China,
acquisition advisory
down 5.9 percentage points; and 1.6 million b/d and 2019 growth of the stock market soared in 2019. services to the
the employment index declined 1.5 1.3 million b/d. The slowing growth The Dow Jones Industrial Average, pump, valve
percentage points to 45.1 percent. is the result of a decline in drilling the S&P 500 Index and the NASDAQ and filtration
industries. Please
Of the 18 manufacturing industries, rigs over the past year, which is Composite rose 22.3 percent, visit jordanknauff.
only three reported growth in expected to continue into 2020. 28.9 percent and 35.2 percent, com for further
December, including miscellaneous In December, the Organization of respectively for the year. The last information. Jordan,
manufacturing. While the PMI the Petroleum Exporting Countries three months of the year saw the Knauff & Company
is a member of
demonstrated contraction for the (OPEC) and a group of other oil easing of the China trade war and FINRA.
fifth straight month, the 12-month producers announced they were strong economic data boosting
average is 51.2 percent. deepening production cuts. Amid investors’ sentiments. During the These materials were
After declines in three out of a forecast of rising oil inventories, month of December, the Dow rose prepared for informa-
tional purposes from
the four preceding months, United the EIA forecasts OPEC crude oil 1.7 percent, the S&P 500 2.9 percent sources that are be-
production will average 29.3 million lieved to be reliable but
States. industrial production rose and the NASDAQ 3.6 percent with which could change
1.1 percent in November led by b/d in 2020, down by 0.5 million b/d major indexes closing at new all- without notice. Jordan,
Knauff & Company and
the manufacturing component, from 2019. time highs. Pumps & Systems shall
not in any way be lia-
ble 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 informa-
tion 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
IMAGE 2: U.S. energy consumption and rig counts. IMAGE 3: U.S. PMI and manufacturing shipments.
investment offering or
Source: U.S. Energy Information Administration and Baker Source: Institute for Supply Management Manufacturing Report deployment of capital.
Hughes Inc. on Business and U.S. Census Bureau

PUMPS &
101
SYSTEMS a live training event
1 Day Seminar
chicago Early Bird Rate $899
april 23
After March 1 $999
JIM ELSEY
Certificate of Completion Pumps & Systems columnist
provided for each class attended. Featured Trainer
We hear it from readers and industry Classes will cover topics including: Who should attend:
experts all the time — industry • Understanding NPSH • Engineers
newcomers need basics training.
• Reading a Pump Curve • Operation & maintenance
This series of classes will offer training end-users
• Preventing Motor Failure
from some of the pump world’s best
• Distributors
instructors, as well as a chance to • Centrifugal vs. Positive
Displacement Pumps • Newcomers to the pumps
network and meet the editors.
industry
Optional plant tour: Stay overnight and visit a

Chicago Reclamation Wastewater Treatment Plant.
For all details and to register, visit

pumpsandsystems.com/event
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EW
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co-pilot.cornellpump.com Check 107 on index.
A ROBUST SOLUTION FROM THE TRUSTED NAME IN PUMPING SINCE 1946

CORNELL PUMP COMPANY · +1 503-653-0330
© CORNELL PUMP COMPANY 2020
Cornell Pump Company is an ISO 9001:2015 Registered Company

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F E B R UA R Y 2 0 2 0

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• 1/4 to 1.5 hp, 115V

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2 PUMPS & SYSTEMS FEBRUARY 2020

This versatile pump is engineered to provide low total

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4 PUMPS & SYSTEMS FEBRUARY 2020

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8 PUMPS & SYSTEMS FEBRUARY 2020

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Don’t ‘Over-FEED’ Your Pumps

Sometimes engineers can be both safe

10 PUMPS & SYSTEMS FEBRUARY 2020

IMAGE 2: The method of determining the

Image 2 summarizes the system losses

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12 PUMPS & SYSTEMS FEBRUARY 2020

Navigating Pump Curves:

This column is a continuation of Part 1,

14 PUMPS & SYSTEMS FEBRUARY 2020

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16 PUMPS & SYSTEMS FEBRUARY 2020

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Root Cause Failure Analysis Case Study

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Failure Analysis vs. RCFA

18 PUMPS & SYSTEMS FEBRUARY 2020

PUMPING STATIONS FOR INDUSTRIAL APPLICATIONS

Beneﬁts of magnetic coupling:

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The Dangers of Operating Pumps