Pumps & Systems

The Magazine for Pump Users Worldwide December 2010

pump-zone.com

The Magazine for Pump Users Worldwide

pump-zone.com

December 2010

Hydro, Inc. l Chicago, IL

Headquarters

800.223.7867

www.hydroinc.com

HydroAire, Inc. Chicago, IL

Madison Street Facility

40th Street Facility

312.738.3000

Hydro South, Inc.

Atlanta, GA

770.475.3393

HydroTex Dynamics, Inc.

Houston, TX

713.937.9001

HydroTex Golden

Triangle, Inc.

Beaumont, TX

409.842.3619

HydroTex Deer Park, Inc.

Deer Park, TX

713.937.9141

U.S. Service Centers

In our continuing commitment to the pump industry, Hydro has designed

and built a new state of the art Test Lab dedicated to the needs and

requirements of the pump aftermarket.

Key features include:

• Designed in compliance with Hydraulic Institute Standards and API 610

• Capable of testing horizontal, vertical and submersible pumps

• Maximum of 5000 HP

• Variable Frequency Drive; 2300 - 4160 volts

• Flows of up to 21,000 GPM on the horizontal loop and 42,000 GPM on the vertical loop

• State of the art data collection system

Critical TestingOptimum Performance

Evans Hydro, Inc.

Los Angeles, CA

310.608.5801

Hydro East, Inc.

Philadelphia, PA

610.497.7867

Because we are independent, we offer unbiased recommendations in

every test situation. We are committed to our customer – not our brand.

This new capability enables Hydro to work with our customers to develop

and implement engineering modifications for improving the performance

of your critical pumps and then to verify that performance in the lab. And

because the test lab is dedicated to the aftermarket we have the flexibility

to schedule tests to meet your needs.

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

strategically located to service pump users throughout North America.

For additional information contact Jeff Johnson at

[email protected] or call 281.475.9680.

CW Hydro, Inc.

Incheon Metropolitan, Korea

82.32.561.0971

Hydro Australia, Inc.

Morwell, Australia

61.3.5165.0390

Hydro Scotford, Inc.

Edmonton, AB Canada

780.992.0100

Safe-T Hydro, Inc.

Port Coquitlam, BC Canada

604.941.1116

Hydro Middle East, Inc.

Dubai, United Arab Emirates

971.50.5547129

International Service Centers

Being Independent Makes All the Difference

Companies

circle 100 on card or go to psfreeinfo.com

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

Letter from the Editor

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

is a member of the following organizations:

One of the best parts of my job is the opportunity to learn about the newest tech-

nologies in the industry. To help us stay aware of some of the industry’s latest developments, the Pumps & Systems team attends tradeshows and visits our advertisers’ manufacturing and testing facilities.

When we implemented our fi rst awards program two years ago, we were thrilled with the response. As Pumps & Systems continues to be the expert source for pump users worldwide, we collaborate with our Editorial Advisory Board to fi nd the latest and greatest pump inno-vations.

h is month, we are pleased to announce the winners of our 2nd annual Product Innovation of the Year award. First place is awarded to Warren Rupp’s AirVantage® Energy Saving Technology. It manages the amount of air volume required for AODD pumps to run at desired fl ow rates, and produces its own elec-tricity to save energy and reduces air usage by up to 50 percent.

Other fi nalists are Active Water Sciences’ portable water treatment system, SDT Ultrasound’s ultrasonic detector, LUDECA’s high-resolution processor, Mouvex’s sealless positive displacement pumps and Wanner Engineering’s sealless, triplex diaphragm pump. Products from A.W. Chesterton, Baldor Electric Company, GF Piping Solutions and seepex

were worthy of honorable mention.Please see page 18 for full Product

Innovation of the Year coverage, and visit our Awards page on www.pump-zone.com for information and criteria

about our 2011 awards.Meanwhile, we wrap up another busy year

of tradeshows when our team attends POWER-GEN International in Orlando (Booth #2683). We continue to maintain a presence at more tradeshows than any other industry publica-tion, attending 23 shows in 2010 (distribut-ing more than 6,900 additional copies of P&S and our new publication, Upstream Pumping Solutions). We will continue to stay at the fore-front of industry trends, news and the latest technologies in 2011.

We will also explore new pumping mar-kets. In January, we will publish a supplement, HVAC Pumping Solutions, which explores motors, drives and packaged pumping systems in HVAC applications.

Please send us your ideas and feedback for 2011 coverage.

Best Regards,

Michelle [email protected]

PUBLISHER

Walter B. Evans, Jr.

ASSOCIATE PUBLISHER

VP-SALES

George [email protected]

205-345-0477

EDITOR

VP-EDITORIAL

Michelle [email protected]

205-314-8279

MANAGING EDITOR

Lori K. [email protected]

205-314-8269

ASSOCIATE EDITOR—

WEB EDITOR

Julie [email protected]

205-314-8265

CONTRIBUTING EDITORS

Laurel DonohoJoe Evans, Ph.D.

Dr. Lev Nelik, PE, APICS

SENIOR ART DIRECTOR

Greg Ragsdale

PRODUCTION MANAGER

Lisa [email protected]

205-212-9402

CIRCULATION

Tom [email protected]

630-482-3050

ACCOUNT EXECUTIVES

Charli K. [email protected]

205-345-2992

Derrell [email protected]

205-345-0784

Mary-Kathryn [email protected]

205-345-6036

Mark [email protected]

205-345-6414

ADMINISTRATIVE ASSISTANT

Ashley [email protected]

205-561-2600

A Publication of

P.O. Box 530067Birmingham, AL 35253

Editorial & Production1900 28th Avenue South, Suite 110

Birmingham, AL 35209Phone: 205-212-9402

Advertising Sales2126 McFarland Blvd. East,. Suite A

Tuscaloosa, AL 35404Phone: 205-345-0477 or 205-561-2600

Editorial Advisory Board

William V. Adams, Director, New Business Development/Corp. Mktg., Flowserve Corporation

Thomas L. Angle, PE, Vice President, Product Engineering, Weir Specialty Pumps

Robert K. Asdal, Executive Director, Hydraulic Institute

Bryan S. Barrington, Machinery Engineer, Lyondell Chemical Co.

Kerry Baskins, Vice President, Grundfos Pumps Corporation

R. Thomas Brown III, President, Advanced Sealing International (ASI)

Chris Caldwell, Director of Advanced Collection Technology, ABS, & President, SWPA

John Carter, President, Warren Rupp, Inc.

David A. Doty, North American Sales Manager, Moyno Industrial Pumps

Ralph P. Gabriel, Director of Product Development,

John Crane

William E. Neis, PE, President, NorthEast Industrial Sales

Dr. Lev Nelik, PE, Apics, President, Pumping Machinery, LLC

Henry Peck, President, Geiger Pumps & Equipment/Smith-Koch, Inc.

Mike Pemberton, Manager, ITT Performance Services

Earl Rogalski, Sr. Product Manager, KLOZURE®, Garlock Sealing Technologies

2009 R&D 100 Award Winner Synchrony Fusion

®

Magnetic Bearing



PRODUCT INNOVATION OF THE

YEAR AWARD

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

SPECIAL SECTION: PUMPS IN POWER GENERATION

p New Solutions for Solving Coal Handling Pumping Problems

Matt Vetter, Chicago Industrial Pump CompanyPositive displacement technology helps solve maintenance headaches at a power plant.

p Pumps in the Global Power Generation IndustryRebecca Tucker and Laurel Donoho, Frost & Sullivan

Business of the Business

p Power-Gen Preview

PRACTICE & OPERATIONS

p Proactive PlanningPaul Boyadjis & Chris Hurrell, Mechanical Solutions, Inc.

Potential vibration problems were avoided through design-stage fi nite element analysis.

p Pump System Energy AssessmentGreg Case, PD3

Improved reliability, performance and energy effi ciency can result from pump system assessment.

ANNUAL PRODUCT SHOWCASE

p Innovative products, technologies and solutions from selected suppliers.

Table of Contents

25

30

33

48

52

56

18

DEPARTMENTS

P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Joe Evans, Ph.D.The Benefi ts of Pump Restoration and Coating

Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 16Dr. Lev Nelik, P.E., P&S Editorial Advisory Board, & Jerry Skelton, Pumping Machinery, LLCImproper Grease Lubrication Could Be Troublesome

Maintenance Minders. . . . . . . . . . . . . . . . . . . . . . . . . 34Jerry Rigsby, Georgia Power Company, Plant Scherer & Will Gates, Morrow Repair Services11-Year-Old Source of Forced Outages Found

Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Ted RatcliffThe Importance of Transloading Effi ciency

FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 42If stress analysis can ensure that piping loads are within ASME limits, why are rubber expansion joints needed?

HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 What are the parameters for pump baseplate design, and why must baseplates be grouted in place? What are mixed fl ow impellers, and when are they used?

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

Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . 69

P&S Stats and Interesting Facts . . . . . . . . . . . . . . . . 72

December 2010

Volume 18 • Number 12 Phot

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The Magazine for Pump Users Worldwide December 2010

pump-zone.com

The Magazine for Pump Users Worldwide

pump-zone.com

December 2010

48

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FW Murphy was our first choice when we decided to upgrade – we didn’t need to

look anywhere else. We were happy with our existing Murphy controller for pump

automation, but we wanted to expand our capabilities to include remote monitoring.

By upgrading to the EMS controller, our customers can reduce fuel and water usage,

cut emissions, and in turn save money.

Working with Murphy made the transition easy. We were able to write our own

specifications, and Murphy provided the firmware developed specifically to meet

our application needs.

We received personal attention that most companies don’t provide. With direct access

to engineers, sales people, and technical support – their customer service cannot be

matched. That’s why we stick with Murphy for our electronic monitoring needs.

Kevin ConnollyOwner, KC Irrigation Automationwww.irrigationautomation.com

“

“

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

flexible, all-in-one industrial pump controller. Its customization and

easy interface make it the perfect fit for engine-driven equipment.

FW Murphy

P.O. Box 470248 Tulsa, Oklahoma 74147 • Phone: 1.918.317.2610 • www.fwmurphy.com/EMSPRO-PAS

1010642-EMSPRO-PAS



P&S News

PEOPLE

GODWIN PUMPS (BRIDGEPORT, N.J.) announced the loss of Joseph L. Abbott, Jr., the company’s national sales manager. Abbott joined the Godwin Pumps team in 1989 and brought sales and manufactur-ing expertise to the company from the sewer rehabilitation industry. In addition, he helped build Godwin’s distribution network throughout the U.S. and Canada, managed product pricing and oversaw bids. Abbott is sur-vived by his wife and their three children.

Godwin Pumps is a direct, wholly-owned subsidiary of ITT Corporation and the manufacturer and supplier of the Dri-Prime automatic self-priming pump. www.godwinpumps.com

FREEWAVE TECHNOLOGIES (BOULDER,

COLO.) added Blair Harness to its engi-neering department. Harness, who has worked as an engineering contractor for FreeWave since 1999 will continue to act as the engineer responsible for wireless radio products and technical development of the FreeWave product line.

FreeWave also added Ralph Oriscello, a seasoned sales professional with more than 25 years of sales management experi-ence, to its business development team. He will deliver wireless radio data solutions to global OEM accounts.

FreeWave Technologies manufactures spread spectrum and licensed radios for mission-critical data transmission. www.freewave.com.

KOCH MEMBRANE SYSTEMS (WILM-

INGTON, MASS.) promoted Dr. Hamid R. Rabie to the newly created role of chief operating offi cer responsible for all aspects of KMS’s technology, product develop-ment, manufacturing, process engineering, supply chain and purchasing. He joined KMS in early 2010 as senior vice president of technology.

Koch Membrane Systems, Inc., off ers membrane fi ltra-tion technology and engineering support. www.kochmembrane.com

JDA GLOBAL (REDLANDS, CALIF.) announced the addition of two key pump veterans to its team. Tom Brown, whose most recent position was director of Global Sourcing for the Dover Corporation, has more than 25 years experience in the pump industry. He will serve as president and partner of JDA

Global, LLC. He will oversee the Redlands, Calif., facility as well as the Chinese and Indian base of operations.

Sam Featherston will serve as acting managing director of JDA Global’s Wholly-Owned Foreign Enterprise (WOFE) in Shanghai, China. Featherston will assume full managing director status once legal proceedings are concluded and the Chinese business entity is offi cial. His most recent position as director of procurement for the Pump Solutions Group provided Featherston with an extensive skill set in castings and injection molding.

JDA Global, LLC, is a pump holding company that creates start-up pump companies and/or acquires small to mid-size pump manufacturers that serve fl uid transfer needs. www.jdaglobal.com

EAGLEBURGMANN (HOUSTON, TEXAS) announced that Rick Page, managing director of EagleBurgmann Canada, Inc., has been recognized with an Award of Merit from the Fluid Sealing Association (FSA). Page was recognized for his distinguished and exceptional contribution and leadership to the FSA Mechanical Seal Division and the association, as well as his service as a mem-ber of the board of directors since 2007.

EagleBurgmann manu-factures mechanical seals, systems, packing and expan-sion joints. www.eagleburgmann.com

AROUND THE INDUSTRY

HYDROAIRE (CHICAGO, ILL.), on September 29 and 30, unveiled its new service center and test lab at an open house attended by hundreds of customers, dignitaries, neighbors and friends. h is new facility has 46,000 square feet dedi-cated to pump aftermarket services. In addition to new machining equipment and 82 tons of crane capacity, the new facility also has a unique test lab.

HydroAire is a subsidiary of Hydro Inc., a Chicago-based organization formed in 1969, and is an independent pump rebuilder. www.hydroinc.com

NATIONAL PUMP COMPANY (GLENDALE, ARIZ.) announced that it has been acquired by the Gorman-Rupp Company. Gorman-Rupp, headquartered in Mansfi eld, Ohio, has been manufacturing and designing centrifugal pumps and pumping systems for more than 77 years.

National Pump Company manufactures pumps and pump systems for irrigation, municipal, power, industrial, mining and oil and gas applications. www.nationalpumpcompany.com

Joseph L.

Abbott, Jr.

Dr. Hamid R.

Rabie

Blair Harness

Ralph Oriscello

Rick Page and FSA President

Ed Marchese



P&S News

BEST PUMPWORKS (HOUSTON, TEXAS) acquired Centrifugal Technologies (CTI), a manufacturer of horizontal multistage pumps (API confi guration BB3, Model HSM) and service pro-vider to the oil and gas market, based in Shreveport, La. CTI’s operation and products will be aligned and marketed with Best PumpWorks OEM pump brand PumpWorks 610.

Best PumpWorks is a pump manufacturer, remanufacturer,

distributor and service provider. www.pumpworks610.com

NATIONAL HIRE GROUP, LTD., (LANDSDALE, WA, AUSTRA-

LIA) will acquire Sykes Group, an Australian pump company. h e completion of the acquisition will take place in the near future.

National Hire Group, Ltd.’s indus-tries include many equipment busi-nesses. www.nationalhire.com.au

MEGGITT (GERMANTOWN, M.D.) Meggitt added a new partner—Trans-ducers, Measurements & Instruments, Inc., (TMI). TMI focuses on transduc-ers and data acquisition systems and test instrumentation.

Meggitt has also added a Spanish-language page to the www.wilcoxon.com website, which focuses on vibration sensors for industrial machinery health monitoring.

Meggitt PLC is an international group operating in North America, Europe and Asia and off ers aerospace equipment, sensing systems, defense training and combat support products and systems. www.meggitt.com

PUMP-FLO™ SOLUTIONS (LACEY,

WASH.) announced that Met-Pro Global Pump Solutions, part of the Met-Pro Corporation, has awarded PUMP-FLO Solutions a contract for its ePUMP-FLO™ web-based selection software for its Sethco® product line. h e Sethco Division will license the full-fea-tured ePUMP-FLO software including a hosted online pump selection solution and lead generation and management tools.

PUMP-FLO Solutions is an engi-neered software business. www.pump-fl o.com

ABB (ZURICH, SWITZERLAND) experi-enced accelerated order growth and rev-enues rose in the third quarter. Orders rose 18 percent and revenues 2 percent in local currencies, including an 11-per-cent increase in service revenues.

ABB off ers power and automation technologies. www.abb.com

Do you have flows up to1,400 US GPM (320 m3/hr),heads up to 3,400 feet (1,000 m), pressures up to1,500 psig (100 bar),temperatures from 20˚F to 300˚F (-30˚C to 149˚C), and speeds up to 3,500 RPM? Then you need Carver Pump RS Series muscle!

Designed for moderate to high pressure pumping applications, the RS is

available in five basic sizes with overall performance to 1,000HP. As a

standard, with a product lubricated radial sleeve bearing and two matched

angular contact ball bearings for thrust, it only takes a mechanical seal on

the low pressure, suction side to seal the pump. Optional features include

ball bearings on both ends with an outboard mechanical seal, various seal

flushing arrangements and bearing frame cooling. These features make

the RS ideally suited for Industrial and Process applications including

Pressure Boost Systems, Boiler Feed, Reverse Osmosis, Desalination

and Mine Dewatering. Whatever your application,

let us build the muscle you need!

1967 Nova Pro Street

RS Series

Creating Value.Carver Pump Company2415 Park AvenueMuscatine, IA 52761563.263.3410Fax: 563.262.0510www.carverpump.com


Phoenix Contact ofers industrial

modem and router solutions for

machine-to-machine communications

and remote equipment access.

For more information, call

1-800-322-3225 or visit

© 2010 PHOENIX CONTACTcircle 106 on card or go to psfreeinfo.com


P&S News

RUHRPUMPEN (TULSA, OKLA.) opened a new manufacturing facility in Orland, Calif. h is new Ruhrpumpen facility adds another full manufacturing location to the already existing ones in Witten, Germany; Tulsa, Okla.; Monterrey, Mexico; Cairo, Egypt and Buenos Aires, Argentina.

Ruhrpumpen is a centrifugal pump technology company and off ers a range of pumps to support petrochemical, power,

mining, and water industries and heavy industry applications. www.ruhrpumpen.com

GE (ATLANTA, GA.) announced that it has signed a contract to acquire Dresser, Inc., a global energy infrastructure technology and service provider. h e $3 billion deal is the latest in a series of acquisitions over the last 10 years. Headquartered in Addi-

son, Texas, Dresser operates in more than 100 countries, delivering compres-sion, fl ow technology, measurement and distribution infrastructure and services.

GE is an infrastructure, fi nance and media company and operates in more than 100 countries. www.ge.com.

GRUNDFOS PUMPS CORP. (OLATHE,

KAN.) announced the launch of its cor-porate Facebook fan page to promote its products, programs, services and events.

Grundfos manufactures pumps, motors and pumping systems for HVAC, liquid transfer, boiler feeding, water and wastewater treatment, groundwater and digital dosing applications. www.grundfos.com

Stay Connected With

on

@PumpsSystemsMag

and at

www.pump-zone.com

All around the world, KSB gate, globe, and check valves ensure that fluids stay where they have to, or go where they should. Whether it’s a SICCA gate, globe or check valve for power stations or industrial processes, KSB customers know they can rely on one partner for their valve and pump applications, particularly on large-scale projects.

KSB, Inc. · 4415 Sarellen Road · Henrico, Virginia 23231

Tel./Fax: (804) 565-8330 · E-mail: [email protected] · www.ksbusa.com

One partner for valves and pumps.

Globe

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

WÄRTSILÄ (HELSINKI, FINLAND) signed three operations and maintenance (O&M) contracts for power plants with Bor-borema Energética S.A. in Paraiba, Brazil; Maracanaú Gera-dora de Energia in Ceará, Brazil; and Linhares Geração S.A. in Linhares, Espirito Santo, Southwest of Brazil. With these con-tracts, Wärtsilä now operates and maintains 15 power plants in the country.

Wärtsilä off ers lifecycle power solu-tions for the marine and energy markets. www.wartsila.com

CONTROL MICROSYSTEMS (OTTAWA, ONTARIO), announced the manufactur-ing expansion of its Accutech wireless instrumentation product off ering.

Control Microsystems, a Schneider Electric company, is a supplier of auto-mation products for SCADA systems. www.controlmicrosystems.com

IMI SENSORS (DEPEW, N.Y.), a division of PCB Piezotronics, Inc., announced ATEX approval of the company’s Series 686B USB Programmable Smart Vibra-tion Switch, designed for 24/7, continu-ous protection of cooling towers, fi n fans, pumps, HVAC systems and other critical machinery operated in hazardous areas.

IMI Sensors off ers vibration sensing products for condition monitoring, pre-dictive maintenance and process control requirements. www.imi-sensors.com.

ULTRA-CHEM, INC., (NEW CASTLE, DEL.) updated its online synthetic lubri-cant resource guide to include new infor-mation on food grade, high pressure and gas compression lubricants. A synthetic lubricants cross-reference allows profes-sionals to select the proper oil for a par-ticular application.

Ultra-Chem, Inc., manufactures products designed to meet the cleaning and maintenance needs of today’s busi-ness. www.ultracheminc.com

COLFAX CORPORATION (RICHMOND, VA.) has added a 17,000-square-foot expansion to its factory in Monroe, N.C. h e $3 million space opened in October 2010 and includes a 6,000-square-foot laboratory for high-tech pump testing.

Colfax will design and manufacture a variety of fl uid-handling systems at the expansion.

Colfax Corporation manufactures fl uid-handling products and technologies. www.colfaxcorp.com

P&S

Answers.

3202

Call, click, or chat live!

800-323-4340 ColeParmer.com/8167

Think Cole-Parmer Unique products combined with

exceptional service and tech support.



P&S News

UPCOMING EVENTS

CENTRIFUGAL COMPRESSORS: OPERATIONS FOR THE 21ST CENTURY USER SHORT COURSEDecember 7 – 10South Shore Harbor Resort & Conference Center / League City, Texas979-845-8943 / engrevent.tamu.edu

POWER-GENDecember 14 – 16 Orange County Convention Center Orlando, Fla.918-831-9160 / www.power-gen.com

EVERYTHINGABOUTWATER INTERNATIONAL EXHIBITIONJanuary 6 – 8, 2011Bombay Exhibition Centre / Mumbai, India+91-11-430 0519 / www.eawater.com/expo

INTERNATIONAL POULTRY EXPOJanuary 26 – 28 Georgia World Congress CenterAtlanta, Ga.770-493-9401www.internationalpoultryexposition.com

AHR EXPOJanuary 31 – February 2Las Vegas Convention CenterLas Vegas, Nev.203-221-9232 / www.ahrexpo.com

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

WQA AQUATECH USAMarch 8 – 11Henry B. Gonzalez Convention CenterSan Antonio, Texas210-201-8500 / www.wqa.org

INTERPHEXMarch 29 – 31Jacob K. Javits Center / New York, N.Y.203-840-5324 / www.interphex.com

TEXAS WATER 2011April 5 – 8 Ft. Worth, Texas512-251-8101 / www.texas-water.com

OFFSHORE TECHNOLOGY CONFERENCE (OTC)May 2 – 5 Reliant Park / Houston, Texas972-952-9494 / www.otcnet.org

WINDPOWER CONFERENCE & EXHIBITIONMay 22 – 25Anaheim Convention CenterAnaheim, Calif.202-383-2500 / www.windpowerexpo.org

SOCIETY OF MANUFACTURING ENGINEERS ANNUAL CONFERENCEJune 5 – 7Hyatt Regency Bellevue / Bellevue, Wash.1-800-733-4763 / www.sme.org/conference

To have an event considered for Upcoming Events, please send information to Lori Ditoro at Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253, 205-314-8269, [email protected].

P&S

A “DESIGNATED DRIVER” FOR YOUR ROTATING EQUIPMENT

Skinner Power Systems, LLC8214 Edinboro RoadErie, Pennsylvania 16509 U.S.A.

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Choose a Skinner steam turbine to do your driving. You can always count on it to get where you want to go.


Visit us at Booth #337 at Power Gen International


Pump Ed 101

The Restoration Process—

Before and After

In the November 2010 issue of Pumps & Systems, this column began a two-part series to analyze a study conducted on the Monroe County Water Authority

(MCWA) in Rochester, N.Y., pump restoration project. As discussed in Part One, the restoration consisted of the mechanical refurbishment (replacement of wear rings, bear-ings and shaft sleeves), sandblasting, application of a metal fi ller (if required) and two coats of epoxy coating.

Several types of coatings were considered for the project, but brushable, ceramic-fi lled epoxy coatings were the fi nal choice for several reasons. h e MCWA wanted coatings that could be applied in-house without sophisticated tools. h ey also wanted coatings with good adhesion and abrasion char-acteristics. Finally, the coatings had to be NSF-61 approved and available at a reasonable cost. h e coatings selected for the study were Henkel / Loctite Brushable Ceramic Grey, Belzona 1341 Supermetalglide and Enecon Chemclad XC.

Figure 1 shows a typical pump’s internal condition prior to sandblasting. h is particular pump is a 600 horsepower model that was installed in the mid 1980’s. As shown, the interior exhibits both surface corrosion and tuberculation. In certain areas of the casing and cover, tubers were larger than one-half inch.

Figure 2 shows the interior of the pump following sandblasting. After sandblasting, the surface was evaluated to determine if application of the metal fi ller was required prior to coating. h is particular pump exhibited a signifi cant amount of surface pitting, and those pits were fi lled prior to the coating process. Figure 3 shows the same pump after application of the metal fi ller and two coats of ceramic-fi lled, epoxy coating.

Brush-On Coating DurabilityAs the project progressed, one of the most frequently asked questions was “how long will the coating last?” h at ques-tion may not be fully answered for many years, but a greater understanding is achieved as time goes on.

MCWA tests all the pumps every six months to look for performance changes that could indicate premature coating failure. h ey also remove the upper casings annu-ally and inspect the coating’s integrity. h is detailed

monitoring continues to provide the information necessary to fully answer that question.

Figure 4 is an example of information gained by peri-odic visual inspection. It shows the interior of a pump cover after four years of operation. At fi rst glance, it appeared that the coating was beginning to fail. However, upon closer examination, the discoloration was due to “rust staining.” h e staining was caused by the rusting of a small part of uncoated machined surface between the upper and lower

Joe Evans, Ph.D.

The Benei ts of Pump Restoration and CoatingSecond of Two Parts

Figure 1. The pump’s internal condition before sandblasting

Figure 2. The pump casing after sandblasting

Figure 3. The interior after pit fi lling and two applications of

epoxy coating


casing of the pump. h e coating remained smooth to the touch and did not

fl ake off at its edges. After cleaning with a steel wool pad (Figure 5), the coating returned to its original, post-coating appearance.

Cost vs. PaybackTable 1 summarizes the restoration costs, energy savings and payback periods for all the pumps in the study. It assumes that the pumps operated nearly continuously prior to restoration. h e energy savings are based on a demand charge of $10 per kilowatt and an energy charge of $0.085 per kilowatt hour.

As shown, the estimated total post restoration annual energy savings for all 16 pumps is $122,190 versus a total resto-ration cost of $101,461. h e payback period ranges from 0.47 to 2.84 years, while the average for all pumps is 0.83 years. h e total power reduction exceeded 1.3 million kilowatt hours.

Relationship of Specifi c Speed

and Effi ciency IncreaseA European study published in 2001 suggested that lower specifi c speed (Ns) pumps would show a greater increase in

effi ciency after coating than higher Ns pumps. MCWA’s results showed a similar pattern. Pumps with an Ns between 1,000 and 1,200 saw an increase of about 12 percent while those between 2,000 and 2,500 increased by about 8 percent.

As the Ns approached 2,800, the increase dropped to about 5 percent, and at 3,900, the effi ciency increase reached a low point of 2 percent. h ese results may be somewhat skewed since some of the pumps did not exhibit the same degree of roughness prior to restoration, and a roughness variable was not developed for the effi ciency comparisons.

Project Conclusions

and Recommendationsh e MCWA’s goal was to prevent or signifi cantly delay the inevitable decline of pump performance due to internal cor-rosion. MCWA believes that it achieved its goal, and the con-clusion is that restoration and coating off ers multiple benefi ts including increased effi ciency, head and fl ow. h e study showed that sandblasting and coating resulted in higher initial and long-term effi ciencies than sandblasting alone, and to date, the coatings have shown no signs of failure. MCWA recommends that new pumps be coated by the manufacturer or a coating vendor selected by the manufacturer prior to pump delivery. Internal coating is now part of its specifi cations for new and replacement pumps.

h is study involves much more than space allows. If you have questions or would like a copy of the complete WEFTEC presentation, please contact Paul Maier by email.

P&S

Joe Evans is responsible for customer and employee educa-tion at PumpTech, Inc., a pumps and packaged systems manufacturer and distributor with branches throughout the Pacifi c Northwest. He can be reached via his website, www.PumpEd101.com. If there are topics that you would like to see discussed in future columns, drop him an email.

WEFTEC presentation authors:

Paul Maier (can be reached at [email protected]); Randy White; Steve Connell; Chris King, PE and Richard Metzger, PE Monroe County Water Authority, Rochester, N.Y.

Figure 4. Rust staining initially thought the result of

coating failure

Figure 5. Coating after four years of operation and rust stain

removal

Table 1.

Restoration cost, energy savings and payback period


Jerry, my repair shop manager, called me for advice on a recent problem he had with an end-suction, vertically-mounted, raw sewage intake pump. He was troubleshoot-

ing the problem at the lift station of a major municipal water treatment plant.

The Problem

“Lev, the bearings are running hot, and the plant maintenance guys are concerned,” Jerry tells me. “h ey say they follow the IOM proce-dures by the book, but the temperature is going above 200 degrees F, and the pump shuts down at these temperatures. h ey wonder if my guys should pull the pump and inspect it at our shop, but I would fi rst like to do some checking in the fi eld to see if we can fi nd something obvious.”

“Can you send me some photos of the installation and a sectional drawing?” I ask. “Also, tell me more about this problem. Is the pump running continuously or with leads/lags?”

I asked this question because infl uent lift station pumps typically run in sequence. h e fi rst pump may run for 20 to 30 minutes drawing down the wet well and then shuts off , and the station idles until the well builds up. h en the second pump takes the lead, runs and shuts off , and then the third, and so on. In this mode, a pump would hardly get its bearings higher than 130 to 150 degrees F for the short time it operates.

“No problem. I’ll email the photos to you right away,” Jerry says. “But call me back as soon as possible. I am run-ning out of ideas, and the grease plugs at this housing do not look right.”

Jerry was timing the pumps between runs and measuring the tem-perature climb. h e 200 degrees F, after 20 minutes of run time, did not sound right to him, nor to me. Something was wrong.

After examining the images (Figures 1 & 2) that he emailed me, I called him back. “h e lower hous-ing seems to have a double-row, radial load bearing. h e upper housing has two bearings: a tandem arrangement,

40-degree angular contact to take the main thrust, and a bumper single row bearing to take a start-up, transient up-thrust. I am confused about the greasing arrangement. h e lower housing has a grease fi tting [Figure 2 (B)] on the top, and a pop-up relief plug at the bottom. h e top housing has two grease injection fi ttings (one at the top chamber and another between the bearings) and a pop-up relief plug at the bottom. Is that right?”

“h at’s right,” Jerry says. “h at is what’s bothering me. How do they make sure the bearings are not over-greased? h e relief plugs are supposed to pop open and relieve the pressure if the chambers are full of grease. However, as soon

as the pressure relieves, the pop-up relief closes, and the chambers remain mostly fi lled. h is would make the bearings run hot. I also see clear signs of that because the whole housing is a mess—mostly at the top, but it’s OK at the bottom.”

“h ey say the IOM procedure manual tells them to pump two strokes of the grease gun,” Jerry continues. “h ey showed me where they inject the grease: into A at the top housing and B

Dr. Lev Nelik, P.E., P&S Editorial Advisory Board, & Jerry Skelton, Pumping Machinery, LLC

Improper Grease Lubrication Could Be Troublesome

Pumping Prescriptions

Figure 1 (above). End-

suction, vertically-mounted,

raw sewage intake pump

Figure 2 (left). Drawing of

the pump

Figure 3. Excess grease on the housing


at the bottom. h ey do this monthly per work order request. h ey have been doing it for about seven months, since the pump was installed.”

Two strokes are barely a fraction of an ounce. h rough seven months, the number of strokes would be 14, which would perhaps be an ounce or two, not enough to even be close to over-greasing. h is assumes that they did what they said and did not add a few more strokes just to be safe.

“What else do you see?” I ask. “Is the pump pumping OK? Is it vibrating?”

“It pumps fi ne. h e operators are happy, and vibrations are low. I just took measurements myself. h e issue is that the housing defi nitely looks over-greased but only at the top side of the housing.”

Jerry pauses thinking, “It would make sense according to the fi ttings. Grease cannot be injected into the bottom portion of the upper or lower housings, other than relying on the dripping of grease through the entire row of bearings.”

“You’ve said enough,” I say, now worried too. “Pull the pump, and get it to the shop. I will see you there when the pump is opened.”

The Answer

Grease arrangements are many.1 Sealed-for-life, open, shield-on-one-side, dead-headed arrangement, thru-fl ow arrange-ment and cross-lubrication are some of the numerous tech-niques used. Improper lubrication—too much, or not enough, grease—could mean trouble.2

In practice, perfection is almost impossible.3 Bearings are initially greased at the OEM manufacturer or after repairs. h e amount of grease is usually 50 percent (half the space within the bearing is fi lled), plus some grease is added within the cham-ber itself. h at is all that the bearings actually need, and they will run cool, about 100 to 130 degrees F, or 10 to 20 degrees F higher for a roller bearings case. Going over 150 degrees F, approaching 180 degrees F and certainly going beyond 200 degrees F is a sign of too much grease or other bearing-related issues.

h e real challenge is not when the bearings are greased at the shop but when they are re-greased in the fi eld. Not know-ing what is inside, how much grease should a mechanic add? Manuals vary on recommendations, but the simplest, and per-haps most reliable, is to inject new grease until the old grease is purged and is followed by the new fresh grease coming from the relief port (which must be open completely).

h e pump may or may not have pop-up plugs. If it does

have them, they should serve as a precautionary measure, and the relief plugs should also be present. Sometimes if relief plugs are not pres-ent, the pop-ups should be entirely removed during re-greasing, and the pump allowed to run for 15 to 30 minutes, while watching the fresh grease leak out, being pumped out by the bearings.

After that time, the plugs would be put back in to keep the remaining grease inside. h is procedure would result with roughly 50 to 70 percent of the grease left inside the housings, without the bearings being over-packed with grease and, therefore, running cool.

Jerry’s next action was to modify the housings to make sure each chamber had its own way in (grease fi tting) and its own way out (pop-up

plugs). h e pop-up, plugs would need to be removed at each re-greasing and replaced after 15 to 30 minutes of the pump running.

In Figure 4, Ctop, Cmid and Cbot are cavities on top of the top bearing at the upper bearing housing. Gt, Gm and Gb are injection ports (grease fi ttings), and Pt, Pm and Pb are pop-up relief plugs (also served as relief plugs to be opened during relube). Similar designations are shown for the lower housing (G = grease in and P = pop-ups).

h e logic made too much sense, and the plant mainte-nance did not completely buy it. Why waste so much grease every month? “Is there a simple method?” they had asked Jerry. h ere is indeed—perhaps not perfect but a compromise.

h at is how the fi nal procedure was modifi ed. Can you guess how? h e person with the winning answer gets a free ticket to our Pump School session: www.pumpingmachinery.com/pump_school/pump_school.htm. Email me, and let me know what you think. h e solution will be included in the January 2011 issue of Pumps & Systems.

P&S

References

1. Nelik, L., “To Grease or Not to Grease,” Pumps & Systems, August 2005.

2. SCOPETM Reliability Program, www.pumpingmachinery.com/pump_

magazine/pump_articles/articles_summary.htm (Article #33).

3. Nelik, L., “Reliability of Grease Lubrication Methods,” www.pumpingma-

chinery.com/pump_magazine/pump_articles/article_07/article_07.htm.

Figure 4. The pump

with injection ports

labeled

Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machinery, LLC, an Atlanta-based fi rm specializing in pump consulting, training, equipment troubleshooting and pump repairs. Dr. Nelik has 30 years of experience in pumps and pumping equipment. He can be contacted at www.PumpingMachinery.com.


Product Innovation of the Year Award

In Pumps & Systems’ second annual Product Innovation

of the Year Award, 14 entries from 12 manufacturers contended for top honors. h e contest examined prod-

ucts that entered the market between September 1, 2009 and August 31, 2010. h e winners, fi nalists and honorable men-tions were chosen by the magazine’s editorial advisory board and editors. h e editors extend a special thank you to the board members for their much-valued help in making this decision.

h e winner of this year’s award is Warren Rupp’s AirVantage Energy Saving Technology, which is used on air-operated double diaphragm (AODD) pumps. h e AirVantage technology continuously manages the amount of air volume required to operate the pump at desired fl ow rates and pro-duces its own electricity, ultimately saving energy and cutting air usage by up to 50 percent.

h e second place fi nisher is Active Water Sciences (AWS), a newcomer to the pump industry. AWS’s Water Phoenix is a portable water treatment system that can provide clean water within 24 hours of setup. It is currently in use by the U.S. military in Afghanistan.

SDT Ultrasound’s SDT270 Ultrasonic Detector receives third-place honors. h e SDT270 provides early indication of bearing re-lubrication requirements, bearing failure and pump cavitation.

Fourth place goes to LUDECA’s VIBXPERT II, which has the best resolution on the market at 102,400 lines of resolution FFT and a new, fast processor that provides rapid operation and high-speed data collection.

In a two-way tie for fi fth place are Mouvex’s SLP pump range and Wanner Engineering’s T8030 Pump. h e SLP pump range is the fi rst positive displacement pump that is sealless without using a magnetic drive system. h e T8030 Pump has a patented valve system that maintains the correct volume of hydraulic fl uid in the pumping chamber behind the diaphragm.

AW Chesterton, Baldor Electric, GF Piping Solutions and seepex receive honorable mentions.

Congratulations to our winner, fi nalists and honorable mentions! We appreciate your participation in the contest this year. For information about next year’s competition, please go to the Awards section of www.pump-zone.com.

Lori K. Ditoro

Product Innovation oftheYear

2010 WINNER2010 WINNER

Warren RuppAirVantage Energy Saving Technology

Innovation

Coming to market in August 2010, AirVantage® Energy Saving Technology is used on air-operated double diaphragm pumps (AODD), which are industrial pumps that employ the use of a twin diaphragm system for positive displacement to move liquids. Important specifi cations for diaphragm pumps include maximum discharge fl ow, maximum pressure discharge, inlet size, discharge size and media temperature. Power sources are primarily pneumatic or hydraulic and incorporate the use of compressed air or natural gas.

AODD pumps with AirVantage Energy Saving Technology are equipped with a microprocessor that is adaptive and contin-uously manages the amount of air volume required to operate the pump at the desired fl ow rates. h is technology determines the optimal diaphragm rod velocity and relays the informa-tion to an air distribution valve at the pump’s air inlet location.

h e valve acts as a gated air management system, allowing only enough air to enter each inner pump chamber. Diaphragms perform at their optimal operating point with less air consump-tion. As the pump experiences air inlet fl uctuations or other changes that aff ect air fl ow, the system adapts to optimize the pump’s performance.


AirVantage uses existing air fl ow to provide its own elec-tricity and power to the device. h is eliminates the need for batteries or hard wiring. No training or special setup is required to operate the energy saving technology, which installs in the same way as traditional AODD pumps.

Statistical Datah is product was tested at 20 manufacturing facilities during an 18-month period. During these tests, Warren Rupp vali-dated that AirVantage saves up to 50 percent air consumption over competitive pumps when applied to heavy fl ow applica-tions. h is information was validated by standard cubic feet per minute (SCFM) meters and recorded on data-loggers within these facilities.

Warren Rupp has published comparison charts show-ing greater than 50 percent energy consumption versus major pump brands on a 3-inch pump comparison point, 150 gal-lons per minute and 40-psi head. h is information is based on published performance curves. At 150 gallons per minute/40-psi head, Versa-Matic AirVantage air consumption is 67 stan-dard cubic feet per minute (SCFM), where other manufactur-ers’ AODD pumps measured 155 SCFM, 150 SCFM and 117 SCFM (manufacturers’ names were removed by Pumps & Systems’ editors for the purposes of this article). h ese compari-sons are indisputable when comparing published data sheets.

AirVantage has also qualifi ed under the Iowa Custom Energy Rebate Program as an energy saving technology where

the utility (MidAmerican Energy) has committed project fund-ing to install the equipment.

End-User TestimonyRick Klok, plant manager, Grains and Powders manufactur-ing facility, Saint Gobain, Niagara Falls, N.Y.h e Saint-Gobain Grains and Powders manufacturing facility took on a 30-day energy savings challenge. h e facility reduced its energy costs by 23 percent at its fl uid separation points, the most process-critical applications within the facility, according to Rick Klok. h ey perform several functions and run 24 hours per day, seven days per week.

“Over this period of time, AirVantage reduced our air con-sumption by 23 percent while maintaining our desired fl ow rates,” Klok says. “It was simple. All we did was install the trial AirVantage pump, and it did the rest, optimizing our energy consumption without special handling or monitoring.

At the end of the product trial, the test results showed the amount of compressed air that the pump consumed with AirVantage versus data points collected before the product trial began.

“We were surprised to learn that we can save as much as $1,200 in energy costs and increase our air compressor capacity by 2.5 horsepower per pump,” Klok says. “We were very satis-fi ed with the performance of the new system, and we plan to use AirVantage on all [our] AODD pumps in the future.”

2nd Place2nd Place

Advanced Water Sciences

The Water Phoenix

InnovationIntroduced in September 2009, the Water Phoenix from Advanced Water Sciences (AWS) was recently recognized by the Wall Street Journal in its 2010 Technology Innovation Awards. It is a patented wastewater treatment system that can be used in any situation in which clean water is a priority—including disaster relief, nation building, agricultural applications and industrial and municipal wastewater cleanup eff orts

Based on a continuous fl ow technology, the Water Phoenix uses special bacteria to convert wastewater into EPA standard water, producing little to no sludge. Portable and scalable, it can be fully functional within a matter of hours, can provide clean water within 24 hours after set up, can operate virtually autonomously and can be monitored remotely.

h e Water Phoenix provides an energy-effi cient, cost-eff ec-tive and ecologically proven wastewater cleanup solution across

a broad range of applications in diverse locations throughout the world. h e Water Phoenix’s ability to clean water is indi-cated below:



End-User TestimonySix Water Phoenix systems are in use by the U.S. Army in Afghanistan. Sonny H. K. Van-Skyhawk, environmental con-sultant for the U.S. Army, was doubtful at fi rst but has since become impressed with the Water Phoenix.

“When I fi rst heard about this and was asked by our… project manager to evaluate this system fi rsthand, I was skep-tical,” Van-Skyhawk says. “I have heard of these ‘new and

improved’ technologies for all of my 35 plus years in the busi-ness and have rarely, if ever, been impressed. Typically, I would have and did consider this just another pipe dream being mar-keted by another ‘snake oil’ sales person. I was wrong.

“I believe this technology will change our industry. [It] will simplify operation/maintenance and reduce overall cost for an ongoing necessity (wastewater treatment) for many years to come. I see this technology growing exponentially. I am excited that our industry is really taking a leap forward with this tech-nological development in helping manage our environmental resources as good stewards of our planet. I have been around for quite awhile, and believe it or not, I had actually envisioned our industry getting to this point. I just honestly did not believe it would happen during my watch. It has.”

Parameter (avg. value)

Infl uent (mg/L)

Effl uent (mg/L)

Reduction (percent)

BOD 272 15 95 percent

TSS 166 13 92 percent

3rd Place3rd Place

SDT Ultrasound

SDT270 Ultrasonic Detector

InnovationReleased in January 2010, the SDT270 Ultrasonic Detector, in conjunction with its powerful database software, gives the earliest indication of bearing re-lubrication requirements, bear-ing failure and pump cavitation. In addition, it is useful as a total product data management tool for fi nding compressed air leaks, vacuum leaks, checking steam trap conditions, fi nding leaks in condensers, inspecting electrical systems for possible arc fl ash and inspecting non-rotating and rotating equipment for fault. It is useful on slow speed bearing monitoring where other technologies such as vibration analysis can struggle.

h e SDT270 is the fi rst ultrasound instrument to incorporate: • An onboard SQL database for PC/instrument

synchronization• True amplitude for collecting accurate and comparable

wave fi les• A USB or Ethernet IP addressable connection for remote

support/training• Two channel inputs• Multi-functional data collection including (dBμV, rpm,

degrees C/F, SCFM, dBA, and acceleration) • Onboard messaging• Independent amplifi cation and headphone volume

adjustment• Sensor recognition in survey mode to prevent data collec-

tion with the wrong sensor• Powerful database software that is both simple and

sophisticated

• Building blocks platform that allows the user to defi ne the instrument with only the needed features, but the user has the fl exibility to unlock other features in the future if the facility’s needs change

End-User Testimony Mike Chesson, reliability engineer, General Mills, Inc.Mike Chesson felt that using the SDT270 hardware and soft-ware to standardize the ultrasonic monitoring program at General Mills, Inc., in Murfreesboro, Tenn., was an easy deci-sion. “We are going to begin approaching reliability engineers in our other facilities to inform them of our decision and recommend that they contact SDT for further information,” Chesson says.


4th Place4th Place

LUDECA

VIBXPERT II

InnovationIntroduced in June 2010, the VIBXPERT II (VXP II) has many diff erent uses and func-tions. Its primary use is to extend the lifespan of equipment within a plant or facility using vibration signatures. One of its many appli-cations is detecting bearing faults, either early or pre-existing within the machinery. It can also detect cavitation within pumps.

h e VXP II was designed with the end user in mind—faster, tougher and sleeker and intuitive to operate. It is a true, two-channel data collector and signal analyzer. It off ers 102,400 lines of res-olution FFT. A new fast processor provides rapid operation and high-speed data collection. h e screen is a full VGA (480 x 640 pixels), 18-bit, TFT LCD non-refl ective color display.

h e greatest improvement is at lower lines of resolution, where the VXP II is almost 20 percent faster than the VXP I. h is means that data can be collected quicker than ever before. h e VXP II uses between 9 and 13 percent of its battery life per hour. h e variation depends on the data acquisition method being used. h is allows the VXP II to provide eight hours of continuous use.

End-User TestimonyRay Wonderly, Advanced Maintenance Technologies, Germantown, OhioAfter using an evaluation unit of the VXP II, Ray Wonderly was anxious for his own model. “I recently had the chance to borrow and use an evaluation unit which proved to be faster than my current VIBXPERT,” Wonderly says. “Speed is important when working with big routes since it cuts down in data collection time. I was also impressed by its crisp and bright color display and record-

ing functionality.”Besides the acquisition of accurate and consistent vibration

measurements, other features stood out to Wonderly, including:• h e unit’s light weight • Long battery life • Route storage capacity • h e ability to download past measurements and history

trends into data collector.• h e ease to edit or customize instrument setup in the fi eld

when needed

InnovationIntroduced in April 2010, the SLP25i is a positive displace-ment vane pump that can be used on a variety of industrial and chemical fl uids. h is pump is sealless, which means that packing or a mechanical seal is not used. It features an all 316L stainless steel construction with PTFE encapsulated FKM O-rings. It provides a maximum fl ow rate of 110 gallons per minute, can stand a maximum 174-psi diff erential pressure and can handle viscosities up to 278000 SSU.

h is pump is the fi rst rotary, positive displacement pump that is sealless without using a magnetic drive system. Shaft

sealing is provided by a double, stainless bellows that houses an eccentric shaft. By rotating, the shaft drives the bellows end in a rotating movement. h is rotation is transmitted to the pump rotor shaft by a crank system. Sealless drive system cooling is provided by the whole fl ow rate crossing the bellows

5th Place5th Place

Mouvex

SLP Pump Range



5th Place5th Place

Wanner EngineeringT8030 Pump

InnovationIntroduced in August 2010, the Hydra-Cell T8030 is a sealless, triplex diaphragm pump that reduces maintenance and down-time by eliminating packing, has zero leakage of production fl uid, has the ability to pump abrasives and can run dry without damage. h e T8030 high-pressure pump employs asynchro-nous, hydraulically-balanced diaphragms with a patented valv-ing system. h is asynchronous design allows the diaphragms to be hydraulically coupled to the displacing plungers with no mechanical coupling required. It is capable of fl ow rates to 926 barrels per day (27 gallons per minute) and pressures to 4,500 psi.

h e heart of the Hydra-Cell T8030 is a patented valve system that maintains the correct volume of hydraulic fl uid in the pumping chamber behind the diaphragm. h is valve system uses a spool valve combined with one-way hydraulic check valves to maintain the proper diaphragm position. h is breakthrough in diaphragm pump design enables diaphragm pumps to have much higher fl ow rates and pressures than

previous diaphragm pumps. h e improvement over current technology comes through

the elimination of plunger pump packing, and the diaphragm in the T8030 does not wear.

End-User TestimonyMatt James, J & J Technical Services, Shreveport, La.J & J Technical Services (JJ Tech) is convinced that the Hydra-Cell T8030 is the pump of choice for its oil and gas applica-tions. JJ Tech manufactures artifi cial lift jet pump systems that increase the fl ow of liquids such as crude oil or water from a

chamber and then driven to the pumping chamber by the side tube. Cooling does not require the diversion of part of the fl ow, which would reduce pump effi ciency, or a separate cooling system, which would make the pump more complex to operate and maintain.

When comparing the SLP25i to mechanical seals, it pro-vides the following advantages:• Suppresses leakages• Reduces or even suppresses maintenance• Suppresses fl ushing system, which is often necessary with

mechanical seals• Accepts pump dry running up to 10 minutes

Compared to a pump with a magnetic drive, it provides these advantages:• Reduces power consumption up to 40 percent• Increases pump global effi ciency up to 20 percent• Simplifi es maintenance• Suppresses all side precautions due to magnetic fi eld• Needs much less monitoring when used in potentially

explosive atmosphere• Accepts pump dry running up to 10 minutes without

damages

In addition, the SLP25i is self priming. h e wear parts (vanes) can be replaced while the pump is online and without total dismantling. h e bearing lubrication is made by synthetic oil needing replacement only every 12,000 to 17,000 hours, and pump dismantling and reassembly is simple and requires neither specifi c tooling nor accurate clearance settings.

End-User TestimonyA methyl di-p isocyanates plant in Hungary has been using an SLP25i for the past four months. h e pump is used at its maxi-mum speed, 24 hours per day. According to the plant main-tenance manager (name not provided), the pump has allowed signifi cant process improvement:• Pump monitoring was reduced. h e previous installation

of magnetic driven pumps required constant monitoring of fl ow, power and temperature (ATEX Zone 1). h e Mouvex SLP pump only requires temperature monitoring to comply with ATEX.

• h e crystallization that was occurring inside the magnets cooling channels was suppressed.

• h is pump was more accepting of accidental dry running without damage and keeping inside ATEX certifi cation fi eld.

• It is a “start and forget” pump.


production well. For decades, oil wells throughout the world have been produced by beam pumps (also referred to as pump jacks or sucker rod pumps). With numerous downhole moving parts, beam pumps have regular costly maintenance. JJ Tech’s jet pump system has zero moving parts downhole thereby reducing maintenance and avoiding costly shutdowns.

Jet pump systems needed a positive displacement surface pump to power the jet pump downhole. To avoid the regu-lar maintenance of the packed plunger pump family, JJ Tech has been testing the Hydra-Cell T8030 for their high pressure well applications since February and is convinced of the pump’s superior performance over the competition.

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

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

Introduced in May 2010, the type 514 High Flow Diaphragm Valve is suitable for extremely contaminated media, media con-taining solids and high purity liquids for a variety of applications such as the chemical process industry to microelectronics, water treatment, cooling and control. h e valve’s innovative fl ow geometry and bolt-less design are the two signifi cant features that make it a true break-through.

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

P&S

Honorable MentionHonorable Mention


A.W. Chesterton170 Slurry Seal

Baldor ElectricSuper E Motor with

AEGIS Shaft Grounding Ring



GF Piping SolutionsType 514 High Flow

Diaphragm Valve Series

seepexSmart Conveying Technology


Pumps in Power Generation

PUMPS IN POWER GENERATION

A Special Section of

December 2010

A Special Section of

December 2010

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Top: Freighter Unloading to Coal Pile

Bottom: Transfer Belt Area Sump

Top: Freighter Unloading to Coal Pile

Bottom: Transfer Belt Area Sump


Alarge amount of fuel is needed to generate 2,100 megawatts of power. A boiler’s appetite for coal

is as relentless as a customer’s demand for power. In the case of the power plant discussed in this article (corporate policy prevents name disclosure), the generating station provides enough electricity to serve 1.3 million people.

h ose familiar coal piles (black mini-mountains) are the result of a constant, supply-and-consume process that requires substantial conveyor belt systems includ-ing dumping stations, transfer points, sloped belts and outside bulldozers.

Millions of tons of coal arrive each year at the Midwestern plant, either by rail car or freighter, and must be unloaded. Rail cars are dumped, and the dumper infrastructure and belt systems are located about 80 feet below ground. h is coal is conveyed over and up onto the coal piles via underground and sloped belts. Eventually, it is fed to the boilers again through a conveyor belt system. Coal from freighters is offl oaded to the coal pile and fed to the plants using the same conveyor systems.

Coal Handling Pump ProblemsTwo key factors cause problems when handling coal. First, coal sinks in water. Second, water collects in low spots. Combine this with a conveyor system, which operates below ground and has dust, fi ne particles and chunks falling from the belt. With nowhere to drain, water collects, and whatever is with it must

be pumped up and out together. h e conditions cause diffi cult pumping situations.

However, coal handling applications have ever-changing variables. Under upset conditions, solids can be dumped so quickly that they literally bury the pumps. Water fl ow is gen-erally low and intermittent with variable sources such as rain, snow melt, groundwater seepage, automatic fl ush and dust sup-pression systems. In addition, operators manually wash down these areas to control dust and build-up. h e sumps are often small and sized for lower fl ows. h is dirty, dusty environment is, in most cases, rated as Class II, requiring explosion-proof motors and controls.

h e net result is a variable, medium-to-low fl ow slurry

New Solutions for Solving Coal Handling Pumping ProblemsMatt Vetter, Chicago Industrial Pump Company

Positive displacement technology helps solve

maintenance headaches at a power plant.

Coal Pile Unloading



application that is critical to plant operation. Flooding the con-veyor equipment and stopping the fl ow of fuel are not options.

Typical Solutions and Limitationsh e common approach is to use vertical and submersible slurry pumps, but this is often a poor matchup for the fl ow rates, solids concentrations and solids sizes involved in this type application.

One example is a 30-inch square sump with fi nes draining in at a normal rate of 10 gallons per minute. h is is followed by 2-inch chunks pushed in with a pile of solids as an operator washes the area down with a 70-gallons-per-minute hose. h e 10-gallons-per-minute infl ow, which carries the quick-settling fi nes, can easily silt-in a typical centrifugal pump as it waits for a sump high-level indicator to activate it.

In addition, the 3-inch solids capac-ity (needed to pass the chunks) requires a much larger pump and higher fl ows to function properly. h e small sump is drained in seconds, bumping the pump on and off too quickly, assuming that it was not silted-in during the low-fl ow conditions.

h e fi nal problem can come from the slug of solids pushed in all at once during the wash-down process, creating slurry too thick to be pumped.

All these factors can create excess maintenance, pump failure and expense. h e fi nancial costs involve:• h e labor to pull the pumps, clear

the area and unplug the piping• h e erosive damage from abrasive

solids • Motor and seal failures from running

dry

Coal Sump Issues

Addressed At the power plant, the maintenance supervisor for fuel handling is responsi-ble for keeping the coal handling equip-ment up and running to feed the plant. Downtime is critical, and eliminating problems, as well as the maintenance that accompanies them, is essential to keeping the plant running at capacity.

h e coal handling sumps at this plant were a continuous source of prob-lems and expense for the supervisor’s maintenance team.

Submersible and vertical centrifugal slurry pumps with grinders were used to handle the coal slurries. h e average time between rebuilds and/or replacements was about six months. In addition, downtime due to plugging, silt-in issues, unintentional debris and fl oat controls hanging up was substantial, requiring considerable labor.

“It was nothing to spend a whole shift just to get a pump to work,” the supervisor noted.

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A New Solution Using Different

Technology Tired of fi ghting the same problems with the same technology, about four years ago, the supervisor looked for new solutions.

A local area pump and sealing specialist, Todd Sherwood of Dubric Packing and Seals, was aware of the supervisor’s maintenance issues and suggested going in a new direction. He proposed using a diff erent type of pump to address these maintenance issues. h e supervisor took the risk of trying a new approach and selected a 3-inch sub-mersible pump for one of the problem sumps. h is test sump handled primar-ily coal fi nes, grit and ground run-off as is called the de-ionized (DI) water treat-ment equipment area pit.

h is positive displacement (PD), air-operated pump used two check valves as the only wetted, moving parts. It is similar conceptually to a diaphragm or piston pump but without the dia-phragm, piston or any sort of mem-brane. h e design employed full pipe diameter passages and check valve ports to route fl uid into and out of the pump-ing chamber.

Compressed air was used to directly push the surface of the fl uid, eliminating the need for dynamic seals while allow-ing for a large stroke-to-volume ratio. h is design kept cycles to a minimum for a given fl ow rate and the internal velocities low, reducing wear in abrasive slurries and diffi cult fl uids.

When used in an application such as a coal handling sump, this PD pump is fi lled by vacuum. h is allows the pump to operate in just a few inches of liquid, minimizing both the volume and the amount of time that solids have to settle out because the sump does not have to reach a high level for this pump to function.

Probably the most important dif-ference under these conditions is that the PD pumping technology does not require the relationship of solids diam-eter to fl ow capacity and discharge head that centrifugal pumps need. h is allows large diameter solids to pass through the pump at both low- and high-fl ow rates.

At this plant, the 2-inch chunks would be able to pass through the pump under the 10-gallons-per-minute, low-fl ow condition. Consistent with other

air-operated pumps such as single and double diaphragm pumps, this PD pump had an extensive tolerance to solids con-centrations. It also had the option of increasing discharge pres-sure to handle diff erent slurry densities and discharge heads.

The Results h e results have been successful. “h e original pump is still in

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service in the DI area sump and has been untouched these last four years,” says the supervisor.

Given the prior six-month replacement/rebuild intervals the return on investment has been dramatic on the purchase costs alone. h e eight-fold (and still growing) service life also reduces the overhead of spare parts inventory, purchasing and the substantial labor to switch out pumps.

Most benefi cial for this supervisor has been the savings in manpower, allowing him to apply his personnel to other pressing problems.

h ree years ago, after the initial success, he installed a second 3-inch PD pump in his transfer conveyor sump. h is sump is next to the belt and receives solids, chunks and fi nes along with welding rods DI Area Test Sump



and other materials that fi nd their way into the sump during wash-downs.

h e transfer conveyor sump is considered a diffi cult appli-cation at the plant and required high maintenance. A long, convoluted discharge run further complicated problems and plugging. Again, the PD pumping technology was able to greatly reduce maintenance with the original pump still in place without rebuilding.

In the meantime, the crews have learned to take advan-tage of the new ability to handle solids and now stir the sump bottom after wash-downs to eliminate solids build up.

“Downtime was the issue,” says the supervisor, “and that has been greatly reduced.”

Based on the successes and savings in both manpower and repairs, this PD pumping technology was specifi ed for an upgrade project on the plant’s longest underground conveyors. h e project included new dust suppression and wash-down systems resulting in higher fl ow requirements, and this time, larger 6-inch inlet by 4-inch discharge pumps were selected. h ese have been installed during 2010 and are performing up to expectations.

h e supervisor stated that based on the fi eld experiences at his plant, he would consider this pump technology fi rst as the way to solve future diffi cult sump applications.

P&S

Matt Vetter is currently the president of Chicago Industrial Pump Company and was the inventor/designer of the CIPC (Pitbull®) pump line. He can be reached at [email protected] or 847-214-8988. For more information about Chicago Industrial Pump Company, go to www.pitbullpumps.com.

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Pumps in Power Generation: Business of the Business

The global, growing demand for power has softened the impact of the recent recession on the power generation sector. Going forward, this growth is expected to reach

signifi cant proportions, as evidenced by some key projected metrics and trends, including:• A 60-percent increase in global demand for electricity by

2030, led by growth in India and China• h e literally trillions of dollars expected in infrastructure

investment in the industry to 2030• Projected growth in nuclear power, with China, Russia,

India and the rest of Asia leading the way in future planned or proposed plants

h ese trends promise notable revenue opportunities for pumps suppliers in both new plants and existing plant upgrades and refurbishments.

Global Pump Forecasth e world’s positive displacement (PD) and centrifugal pumps markets witnessed fl at to negative growth in 2009, as end-user segments across the board experienced the impact of global recession. h e expected strength of pump revenue growth within the power generation industry depends on regional trends.

Emerging economies, such as the BRIC (Brazil, Russia, India and China) nations, are expected to witness considerable growth over the short term of the forecast period, mainly due to infrastructure developments in these countries. Population growth, urbanization and the resulting increase in power demand will help fuel growth in the Asia Pacifi c.

Pump demand is also expected to increase within the power generation sector in northern Africa and the Middle East, although recovery in southern Africa is expected to be slower.

Mature economies, on the other hand, are

dealing with the crippling aftereff ects of the worldwide reces-sion. Investments in plant infrastructure and retrofi t needs were put on hold for the duration of the downturn. As the gen-eral economic environment improves in North America and Europe, pump revenues in this industry are expected to gradu-ally return to moderate growth rates.

In 2009, the power generation segment accounted for about 6.7 percent of the total revenues in the PD pumps market. In the same year, as shown in Figure 1, revenues for PD pumps within this industry totaled $484.7 million, with a steady growth rate expected to occur over the next few years. By 2013, the revenue growth rate for PD pumps within the power generation sector is forecast to meet or exceed pre-recession rates, at about a 6 percent revenue growth rate by 2016.

h e power generation segment, in 2009, accounted for about 9.9 percent of revenues in the centrifugal pumps market. Figure 2 shows a forecast for this industry. In the same year, revenue for centrifugal pumps within the power generation market totaled $1.72 billion.

Revenue growth for this product type within the power

Pumps in the Global Power Generation IndustryRebecca Tucker and Laurel Donoho, Frost & Sullivan

Figure 1. PD pumps revenue forecasts


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

Key Trends and Issues A number of top-level trends are expected to aff ect pump demand in this industry through-out the forecast period, including the following positive trends:• End-user need for environmental compli-

ance with increasingly stringent regulations has signifi cant impact on the market. h is will continue to be a strong market driver for pumps used within the power genera-tion industry, as well as in other industries. In addition, growing interest in alternative energy sources to counter greenhouse gas (GHG) emissions is likely to contribute to the growth.

• h e focus on energy effi ciency off ers a considerable poten-tial for growth, mainly due to rising energy costs and the intense focus on driving costs out of process/production. End users are increasingly seeking the optimization of their processes to reduce energy consumption. As PD pumps are

suited for applications emphasizing more effi ciency, this is expected to off er a great potential for suppliers of these pumps.

• Replacement/retrofi t demand will increase. Increasing investments in the water and power generation sectors over the next decade, coupled with the rising trend of PD pumps replacing centrifugal pumps in applications focused on energy effi ciency, are expected to fuel the growth of the PD

Figure 2. Centrifugal pumps revenue forecast

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pumps market • Rising demand from the utility sector will continue to fuel

the growth for centrifugal pumps.

Of course, challenges also exist in the industry that can impede growth, such as:• Price pressure from low-cost participants has intensifi ed the

competition, which can push suppliers to off er higher qual-ity, more reliable and advanced technology at competitive prices. However, the price pressure is a restraining factor on the overall revenue growth potential of the pumps market.

• Although the impact of the global recession has been some-what mitigated for the power generation sector as a result of the rising global need for power, a short-term impact from

the economic slowdown will occur as production slowly ramps up, capital expenditure resumes and excess pump inventory is sold.• Maturity of the market: both PD

pumps and centrifugal pumps are commonly used pieces of equipment for power generation, as well as many other industrial process/production areas. In mature markets, demand for such products typically fl attens out over a period of time owing to consistent supply, few technologi-cal innovations and the presence of supply-side competition.

h e power generation sector is a critical industry that cannot aff ord downtime. As such, the industry pro-vides a consistent, if not stellar, rate of growth for the pumps industry.

In addition, the aftermarket busi-ness for pumps within the power gen-eration sector will continue to generate growth as plants undergo retrofi ts and upgrades. h e opportunities for growth exist. h e challenge will be identifying the fastest growing regions for the power generation sector, such as in the BRIC countries, while also taking advantage of the aftermarket opportunities in mature economies.

P&S

Rebecca Tucker is a research analyst for Frost & Sullivan. She has over a decade of marketing research and communications expertise, which includes marketing communications, industrial research reports and techni-cal writing.

Laurel Donoho is the global program manager, Industrial Automation & Process Control, for Frost & Sullivan. She has 19 years of strategy, analysis and consulting expertice in the indus-trial space. She can be reached at [email protected].



Along with more than 1,200 exhibitors and 18,000 attend-ees, Pumps & Systems will attend this year’s Power-Gen International at the Orange County Convention Center in

Orlando, Fla. h is year, attendees can participate in 12 conference tracks, mega sessions, and networking breakfasts. Preconference activities, beginning Sunday, December 12, include technical tours and Competitive Power College (CPC) workshops.

While at the show, stop by and visit us at Booth 2683. For more information about Power-Gen International visit www.power-gen.com.

P&S

PREVIEW

Exhibit Hall Hours

Tuesday, December 14: 11:30 a.m. – 6 p.m.

Wednesday, December 15: 9 a.m. – 5 p.m.

Thursday, December 16: 9 a.m. – 2 p.m.

Photo Credit Barchfeld Photography


Maintenance Minders

Troubleshooting rotating equipment failures and improving reliability is a process of elimination. h e process of elimination should strip away the layers

of possible contributors until the true root cause can be identifi ed and corrected. Rarely does an opportunity arise that allows for taking incremental steps to solve a problem.

In the case study below, the symptom was addressed, and the solution provided manageable results, which meant that forced plant outages were stopped. However, it still required a plant shutdown every 12 to 18 months to replace the unreliable but improved component.

h is was a manageable process until fi ve years later, when forced outages began to recur. h is recurrence required a re-examination of the failures and, ultimately, led to fi nd-ing the root cause of the problem.

The Initial SolutionA Southern Company plant has four 818-megawatt electri-cal plants with identical General Electric (GE) turbine gen-erator units. In November 1990, Unit 1 had a forced outage due to a false trip of the overspeed governor during normal operation. h e same failure and forced outage occurred on Unit 4 in August 1993 and again on Unit 1 in November 1993. In October 1993 and April 1994, the overspeed trip mechanisms were inspected on Unit 2 and 3 respectively. In each case, severe wear was detected in the bushing and spin-dle areas, and the overspeed trip mechanisms were replaced.

h e original failures seemed to be related to excessive overspeed guide bushing wear. It was thought that either the overspeed guide bushings wore and placed undue stresses on the spindle threads causing them to fail, or the trip ring

became unsupported and allowed contact with the mechan-ical trip linkage.

While the source, or root cause, for the wear was not identifi ed, GE addressed the excessive bushing wear by upgrading the material to a more durable “Chemloy,” a Tefl on-based material with 5 percent Mo52 and 15 percent glass fi ber. h e material upgrade was made on all four units in 1994 and provided some improved life of the overspeed trip device, but signifi cant bushing wear still occurred. h e overspeed trip devices were placed on a schedule to be inspected/replaced every 12 to 18 months, and the forced outages were eliminated until January 1997.

Recurrence of the ProblemIn January 1997, Unit 4 had a forced outage due to a false overspeed trip. h is occurred three months after a scheduled maintenance outage in which the turbine overspeed trip device had been replaced. h e failed overspeed device had been rebuilt by a company other than GE, and the quality of that rebuild was brought into question.

A new overspeed trip device rebuilt by GE was installed and carefully inspected for quality. h en 13 months later, another false overspeed trip occurred on Unit 4. After this failure, the decision was made to measure Unit 4’s and Unit 1’s control rotor vibration and compare the results. h e vibration data revealed 10 times greater vibration ampli-tudes at six times the running speed on Unit 4’s control rotor than on Unit 1’s.

The Investigationh e overspeed trip device was located on the end of the

11-Year-Old Source of Forced Outages Found

Jerry Rigsby, Georgia Power Company, Plant Scherer & Will Gates, Morrow Repair Services

Main oil pump hydraulic geometry was the root cause

of numerous false turbine/generator overspeed trips.


control rotor stub shaft. h e supporting sleeve was screwed on the end of the con-trol rotor stub shaft and was encircled by the ring assembly. h e ring ran concentric with the shaft but was dynamically unbalanced, and the weight of the moving parts was distributed so that their center of gravity lay about 0.220 inches from the center of rotation in the tripping direction of the ring.

h e centrifugal force of the ring assembly, due to this unbalance, was counter-acted by the force of a compressed helical spring. When the speed increased, this centrifugal force overcame the spring’s force. h e ring moved out and struck the trip fi nger of the mechanical trip linkage.

Attached to the front of the overspeed trip device was the spur gear, which served three functions:• A coupling for the quill shaft to the permanent magnet generator (PMG) • A balance point for the control rotor • An oil channel for the oil trip test feature

In an eff ort to determine the cause of the vibration, a detailed review of the Unit 4 1996 outage report was performed. h e review revealed that the steady bearing and overspeed governor had been replaced without the necessary testing to determine if the components were assembled within specifi cations.

As a result of the 1998 failure, a detailed analysis of the Unit 4 front standard was performed during the subsequent outage to determine the cause of the high vibration. h e outage investigation resulted in the following fi ndings, modifi ca-tions and corrective actions:• h e spur gear was bent and prevented centering on the overspeed trip device.• h e insulated spacer between the overspeed and spur gear was 0.008 thicker on

one side than the other and caused the spur gear to be cocked on the overspeed trip device.

• h e spur gear’s soft-fi t design allowed movement, which changed the balance point of the control rotor and caused vibration.

• h e overspeed governor was not tight enough on the control rotor and was

Figure 1. New design after Unit 4’s detailed analysis

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Maintenance Minders

seated against the uneven surface of the locking ring, causing it to be cocked on the control rotor.

• h e steady bearing had sealant on the face preventing slip.

• h e steady bearing force movement check was not completed, and no policy was in place to require that one be performed.

• Runout checks were not completed, and no policy was in place to require that one be performed.

• Policies and procedures were put in place requiring that a steady bearing force move-ment check, runout checks and alignment should be performed after all front standard work is completed.

• h e PMG, quill shaft and spur gear were removed. h e spur gear was replaced by an oil collector with a rabbet to prevent movement.

• h e control rotor was balanced with the gov-ernor assembly attached.

• Final runout checks were completed, and personnel verifi ed that all the checks were within specifi cations.

• A force movement check was completed, and personnel verifi ed that both were within specifi cations.

• Proximity probes were installed on the control rotors and a monthly vibration monitoring program for the front standard control shaft was established.

• h e overspeed trip point was reduced from 113 percent of rated speed to 110 percent.

After the outage, vibration readings were taken on the control rotor to verify that the revisions made solved the six-times vibration problem. However, the vibration readings showed it was four times greater than before the outage work was performed. A reasonable conclusion was that the vibra-tion change was in response to a natural frequency. h en the search began to fi nd a structural, natural frequency. However, after extensive tests, a structural natural frequency could not be found.

h e control rotor in question was the turbine/generator oil pump shaft being driven on the end of the turbine/gen-erator shaft. h e oil pump impeller had six vanes, and it was discovered that the pump casing had been welded and repaired during the outage due to erosion damage on the visible side of the volute tongue.

A primary source for high vane pass vibration in a pump would be a tight or insuffi cient Gap B. Gap B refers to the distance between the impeller vane exit and the diff user/volute vane inlet and is normally expressed as the percent of the impel-ler’s diameter. A tight Gap B results in shock waves or pressure pulses that are generated each time an impeller vane passes the volute tongue. h ese shock waves can cause cavitation/erosion

damage typical of the ones weld-repaired during the outage. h e shock waves and pressure pulsations can be so great

that the volute tongue and/or shafts can fail in fatigue, the impeller-side plates can break, or the pump fl ow control sys-tems may become unstable. A typical Gap B ranges from 6 to 8 percent in volute-style pumps, and many installations require 12 to 15 percent to reduce the vane pass vibration amplitudes to acceptable levels.

h e case and impeller were measured, and the measure-ments revealed that the Unit 4 oil pump Gap B was only 3.5 percent. Unit 4’s Gap B was opened to 8.5 percent, and the vibration dropped from 1.6 inches per second to 0.43 inches per second.

After fi nal opening, Unit 4’s Gap B was 12 percent with resultant vibration amplitudes of less than 0.14 inches per second. All the oil pumps on the four units were modi-fi ed by the end of 2001. Since that date, no forced outages have occurred due to a false overspeed governor trip during normal operation, and none of the overspeed trip devices have required replacement.

As the pump cases on each unit were examined and modi-fi ed, it was apparent that the equipment manufacturer for the pump case placed no control on the fi nal confi guration of the volute vane. h e confi gurations were not the same in any of the pump cases. Several of the cases had the volute vanes cut to a diameter but not fi nished to provide a proper and consistent profi le.

Conclusion

h e initial focus on the overspeed trip device, installation procedures and practices resulted in a robust unit. However, increasing Gap B to 12 percent minimized the vibration amplitudes that were having the most signifi cant eff ect on the

Figure 2. Clearance for the impeller was improved by removing additional metal.


reliability of the overspeed trip device. Millions have been saved as a result of this solution,

including:• An average cost of $15,000 per trip device• $50,000 labor per replacement• No lost electrical generation

h e solution may have taken 11 years to accomplish, but today, only a few remember the weekends and nights required to get a unit back online following a false trip of the overspeed governor.

P&S

Jerry Rigsby is the startup manager for the Southern Company Plant Scherer environmental projects to add bag houses, SCR’s and scrubbers on all four units. Rigsby was supervisor of the reliability and root cause analysis group during the investigation of the false generator overspeed trips.

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

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Transloading is the practice of transferring products between modes of transport, whether from refi nery to terminal, terminal to supplier, supplier to storage

facility or supplier to end user. h e products that are typi-cally transloaded can run the gamut from liquid chemicals and petroleum products, to animal fats and vegetable oils, to raw and semi-fi nished commodities such as grains and dairy products.

h e modes of transport include marine, pipeline, rail, air and truck. Goods, whether raw or fi nished, rarely travel directly from their source to the end user.

h e focus of this article will be the transloading of products or raw materials from railcar to truck. Transloading allows shippers and their customers to enjoy many of the cost benefi ts of rail transportation without having a rail siding at their door, which can be an expensive proposition, and for many companies, a physical impossibility.

In most instances, a transload facility operator, third-party logistics company or transportation broker facilitates the transloading for both the shipper and the consignee. h ese companies coordinate truck and rail connections and frequently off er inventory management and facilitate stor-age and delivery.

h e main objective of transloading is to place the goods as close as economically possible to the point of fi nal pro-cessing, packaging and consumption. h erefore, transload-ing can occur at any location at which a truck can pull up to another truck or a train.

In a typical transaction, a bulk shipment moves by rail to a transload facility where it is offl oaded with specialized pumping equipment that has the necessary operational char-acteristics to handle the specifi c product or material. h e bulk product can then be scheduled for delivery in smaller

quantities to the consignee for further processing or delivery directly to an end-user.

Some advantages of transloading are: • Quick response to replenish inventories• Transportation costs kept to a minimum• Accelerated turnover and reduced inventory costs

Since transloading requires the handling of the goods at diff erent points in the supply chain, there is an inherent risk of damage or the loss of expensive materials that could potentially harm the environment or personnel. Shipping vessels must also be completely cleared of product during the transloading process.

With all these factors considered, it is imperative that the proper equipment be used during the transloading pro-cess. Proper pumps and compressors are needed, especially for the transfer of chemicals, petroleum products, animal fats, vegetable oils and other liquid commodities.

The ChallengeTransloading has grown rapidly in recent years, so much so that it now has its own trade association. h e Transloading Distribution Association—TDA (www.transload.org)—West Linn, Ore., represents the interests of the transloading industry as it relates to business and political leaders, while positioning transloading as the preferred method for effi -cient distribution of product in the 21st century. Currently, the TDA has more than 200 members throughout the U.S., Canada and Mexico.

As mentioned, the main challenge for shippers is moving their products in the safest manner while also mini-mizing the risk of costly and environmentally damaging product spills. Recently, however, economics have played an

The Importance of Transloading Effi ciencyTed Ratcliff

As the popularity of transloading continues to grow, operators may

consider sliding vane pump and gas compressor technology

for low maintenance costs and high energy effi ciency.

Effi ciency Matters


increasingly important role in a shipper’s decision to move product via a transload-ing operation. h ese economic pressures have come to bear in the form of driver and equipment shortages, record high fuel costs found in long haul trucking and increased demand for shipping capacity.

A producer relying on long-distance trucking to service a set of customers faces many diffi culties. h e most signifi cant is the likelihood of empty cargo holds on return trips, in addition to the need for a large fl eet of trucks to ensure service frequency.

Adopting a transloading operation can allow these shippers to rely on a smaller fl eet of trucks that travel shorter distances, which may also allow them to make several deliveries per day. A transloading facility can also off er a large number of value-added incentives for the shipper, including storage, blending, packaging, consolidated invoicing, combined product shipments, bar-coding and labeling.

For shippers who are considering a switch from a single transportation mode to transloading, some useful benchmarks can help guide the decision. A main con-sideration is whether the product’s travel distance is great enough to make the cost of transloading worthwhile.

As a transloading general rule, 300 miles is the diff erentiation breakpoint for transloading. h is is about the distance that a long-haul trucker can safely and effi ciently travel in one day. Another thing that should be taken into consideration is the transportation and handling costs associated with trucking and transloading.

In a true bulk-transport transloading operation, a shipper can often ship four truckloads of product on a railcar while paying about the equivalent of only two-and-a-half truckloads.

Currently, according to the TDA, approximately 650 transloading terminals are in the U.S., with more planned for the future. h e TDA forecasts double-digit growth in throughput by its members through 2015. h e average number of avail-able railcar positions per transloading facility is 50.

If these estimates are correct, then more than 32,000 tank cars can be unloaded at any one time. Granted, that full capacity will probably never happen, but these numbers do off er an idea of the potential size of the market.

Operators at this chemical distribution/storage terminal facility transload hydrogen per-

oxide from a railcar to a transport via a sliding vane pump.

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Effi ciency Matters

Using these estimates and assuming only a 60 percent use factor, each facil-ity would require three to fi ve pieces of off -loading equipment to keep up with demand. At the lowest level, that would be almost 2,000 units on the ground.

While transloading may make sense for a shipper, both economically and logistically, the world’s most effi cient transloading operation will not function successfully if the pumping and compres-sor equipment for the transloading process does not work eff ectively.

The Solution

Fortunately for shippers who are imple-menting transloading operations, an easy solution is available for their product-transfer needs—sliding vane pumps and reciprocating-gas compressors. Sliding vane pumps and compressors used in trans-loading operations must be highly energy effi cient and eliminate many of the maintenance concerns that are inherent in these pumps and compressors.

h e sliding vane technology makes these pumps ideal for transloading applications. h ese pumps are self-priming, designed to run dry for short periods and their high suction makes them ideal for line-stripping. h ey are available in cast iron, ductile iron and stainless steel models with special elasto-mers that make them compatible with the handling of many products.

For self-loading trucks, the pumps come with port sizes to 4 inches and have maximum working pressures up to 175 psi (12.1 bar). h ey can reach speeds of 1,200 rpm with both PTO and hydraulic drive capabilities.

For transloading applications that involve stationary and portable onsite pumps, by manifolding the railcars, the fl ow rates are limited to the receiving capacity of the system. Some sliding vane pumps are also available in sealless designs for applications that require zero shaft leakage.

h e vanes in a sliding vane pump move freely into or out of slots in the pump rotor. When the pump driver turns the rotor, centrifugal force, rods and/or pressurized fl uid causes the vanes to move outward in their slots and bear against the inner bore of the pump casing, forming pumping chambers.

As the rotor revolves, fl uid fl ows into the area between the vanes when they pass the suction port. h is fl uid is transported around the pump casing until the discharge port is reached. At this point, the fl uid is squeezed out into the discharge piping.

h is simple pumping principle, which has been an indus-try standard for more than a century, allows sliding vane pumps to handle numerous products safely and effi ciently. Among these are:

• Clean, non-corrosive industrial liquids and petroleum products

• Liquids ranging in viscosity from thin solvents to heavy oils• Hazardous fl uids• Biofuels• Non-lubricating solvents to highly viscous liquids or abra-

sive slurries• Corrosive or caustic fl uids• Inks, paints and adhesives

Like the sliding vane pump, some reciprocating-gas com-pressors have been designed with liquefi ed gas transloading operations in mind. A compressor draws vapor from the stor-age vessel and boosts the pressure into the top of the railcar. h e increased pressure in the railcar and slightly decreased pressure in the storage vessel results in a pressure diff erential between the two tanks that will easily push the liquid from the railcar to storage.

h e result is fast and quiet liquid transfer with no NPSH or cavitation problems. h ese compressors are equipped with high effi ciency valves, ductile-iron cylinders, self-adjusting piston rod seals and other robust features.

Some specialty compressors not only evacuate a railcar or truck tank, but they can also recover vapors, which is similar to adding 3 percent capacity to every load. h ey are designed to handle transfer and recovery of propane, butane, liquefi ed petroleum gas (LPG) and anhydrous ammonia. Compressors can handle the transfer and recovery of carbon dioxide, refrig-erants, sulfur dioxide, chlorine, vinyl chlorine, natural gas, nitrogen and other gases.

If the sliding vane pumps and compressors are portable, the option may be available for shippers and operators of

This transloading application features compressors transferring LPG from railcars to

transports.


storage facilities to create moveable skids that allow the pumps and compressors to be moved around a facility to perform transloading operations.

h ese transloaders can be placed between two railcars on a siding if product needs to be pumped out of one and into another or positioned between a truck and railcar to facilitate the transloading process.

For an example of how eff ective a transloading operation can be, consider the case of Seeler Industries. Seeler operates the 3 Rivers Terminal in Joliet, Ill. h is 100-acre facility fea-tures 17 storage tanks and 15 blend tanks. It has become one of the Midwest’s leading storage facilities, handlers and pack-agers of hydrogen peroxide, along with other industrial liquids such as caustics, amines, glycerin propylene, glycol and chemi-cal de-icers.

h e 3 Rivers Terminal is served by seven truck-loading racks and 42 railcar-unloading positions. h ese racks and railcar positions enable Seeler to off er transloading services to its customers. To optimize its transloading options, Seeler installed a series of sliding vane pumps, which were chosen for this application because their stainless-steel construction makes them compatible with the chemicals, solvents, caustics, sulfates and acids that the terminal handles on a regular basis.

To increase its transloading options, Seeler also had a

sliding vane pump mounted on a portable cart that is moved wherever it is needed in the facility.

Conclusion

While transloading in some form has been around since the age of steam engines and horse-drawn tank wagons, it has seen a marked resurgence during the past decade.

According to some estimates, the volume of transloaded cargo has grown by 50 percent since 2000. h is increase in transloading coincides with the realization by many ship-pers that the cost and effi ciency benefi ts of this multimodal approach to moving products in bulk can have an extremely positive eff ect on their bottom lines.

P&S

Ted Ratcliff is the senior product specialist in Transport for Grand Rapids, Mich., based Blackmer, an operating company within Dover Corporation’s Pump Solutions Group (PSG™). He can be reached at 817-460-1369 or ratcliff @blackmer.com. Downers Grove, Ill., USA-based PSG is comprised of six leading pump companies—Wilden®, Blackmer®, Griswold™, Neptune™, Almatec® and Mouvex®. You can fi nd more infor-mation about Blackmer at www.blackmer.com and PSG at www.pumpsg.com.

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Today’s pipe stress analysis software provides engi-neers with a tool for designing complete piping sys-tems and performing structural analysis in compli-

ance with ASME and other well-known piping codes. h e typical PC-based software is easy to use with spreadsheet inputs and quick reporting. It has facilitated the design to analyze iteration cycle and enabled the engineers to quickly create better and more reliable piping systems.

Rubber expansion joints have long been recognized for reducing pipe and anchor stresses. Unfortunately, for equally as long, they have been viewed as being the weak link in any piping system. h at an engineer would look to eliminate any inherent reliability risk is understandable, and with the advancements in pipe stress analysis, they have the tools to design the system without expansion joints.

Why are rubber expansion joints needed? h e answer starts with disputing the theory that rubber expansion joints are a piping system’s weak link. In fact, with fi nite element analysis (FEA) and strong engineering principles, it can be verifi ed that the rubber expansion joints have an equal or greater safety factor than the adjacent piping or equipment.

h e answer continues with the numerous design advantages that can only be obtained with the use of rubber expansion joints. h ese advantages can and should be quan-tifi ed and added to pipe stress analysis databases. h is will enhance the tools available to engineers.

Performance and ReliabilityImproved performance and reliability are directly related to the materials of construction and engineering design. Rubber is one of the most compliant and resilient materials available. h is not only makes it an ideal material for car tires but for expansion joints as well. With a fl exing cycle life in the tens of millions, fatigue is not a design concern.

Improved performance and engineered solutions are

often accomplished by incorporating advanced materials and technologies into what would otherwise be considered a conventional product line. Advanced materials would include premium elastomeric compounds, tire cord and high tensile steel reinforcements. Using tire cord is a good example of optimizing a design with advanced materials.

Tire cord is engineered with a resorcinol-formaldehyde latex (RFL) coating for superior bonding to the rubber. h e cords themselves can be aligned on an optimal-bias, ply angle, off ering tailored strength in the directions needed. h is often eliminates delamination and reduces the total number of plies required. h e result is improved perfor-mance in the form of increased movement capability, decreased spring rates and improved reliability.

If stress analysis can ensure that piping loads are within

ASME limits, why are rubber expansion joints needed?

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

From the voice of the fl uid sealing industry

SEALING SENSE

Figure 1. Expansion joint FEA


Today’s rubber expansion joints are designed by licensed engineers using advanced software for simulation and FEA. Documented safety fac-tors can equal or exceed that of the adjacent piping and equipment.

Critical design elements of piping systems are support and fl exibility. An obvious consequence of inadequate support is catastrophic and potentially life-threatening system failure.

Less obvious, however, is that inadequate fl exibility can produce the same devastating consequence. System fl exibility is required to absorb thermal movements, ground settlement, misalignment, vibration and shock.

h e features and benefi ts of rubber expansion joints include absorbing these forces and displacements and replac-ing them with the rubber expansion joint’s low stiff ness (spring rate). h ey absorb noise and vibration and provide easy access to piping and equipment.

Absorbs All Directional Movement

Rubber expansion joints provide superior movement capabil-ity in axial compression, axial extension and lateral defl ection, as well as in the angular and torsional directions. h is per-formance cannot be obtained with metallic joints, grooved couplings or large pipe loops. h e low stiff ness and defl ection forces can and should be incorporated into databases accessed by pipe stress analysis programs.

Figure 2. Absorbs all directional movements and vibration



FSA Sealing Sense

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

High Resistance to Shockh e compliant and resilient characteristics of rubber expansion joints make them suited for earthquake and bomb blast isolation. h ey are also eff ective for pressure-surge and water hammer dampening.

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

Compensates for MisalignmentIt is common in both new construc-tion and replacement applications to encounter pipe misalignment. Minor misalignment can be corrected with standard expansion joints, and custom units can be fabricated with large per-manent off sets. h e custom fi t units are easier to install and will have a longer, maintenance-free life.

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

Conclusion

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

Figure 3. Large pipe misalignment



functional component that have little or no alternative replacements.

In addition, expansion joints can adapt to misalignment that is often found in modular construction. Ultimately, the use of rubber expan-sion joints is imperative for a success-ful operation on all functional levels. Although stress analyses can ensure proper pipe design codes, expansion joints safely accommodate variables and contingencies and enhance the system’s overall reliability and performance.

Quantifying and incorporating these design advantages into useful databases will ultimately enhance the pipe stress analysis program and its applications.

Next Month: How do I choose a gasket for an FDA application?

We invite your questions on sealing issues and will provide best eff ort answers based on FSA publications. Please direct your questions to: sealingsensequestions@fl uidsealing.com.

P&S

“Sealing Sense” is produced by the Fluid Sealing Association as part of our commit-ment to industry consensus technical education for pump users, contractors, distrib-utors, OEMs and reps. As a source of technical information on sealing systems and devices, and in cooperation with the European Sealing Association, the FSA also supports the development of harmonized standards in all areas of fl uid sealing tech-nology. h e education is provided in the public interest to enable a balanced assess-ment of the most eff ective solutions to pump systems technology issues on rational total life cycle cost (LCC) principles.

h e Piping Systems’ Non-Metallic Expansion Joint division of the FSA is one of six with a specifi c product technology focus. As part of their mission, they develop publications such as the newly revised seventh edition Technical Handbook Non-Metallic Expansion Joints and Flexible Pipe Connectors and the Non-Metallic Piping Expansion Joint Installation Guide. h e former provides construction, installation and application details while the latter is a “hands-on” simplifi ed guide for main-tenance operators and engineers. Both are primers intended to complement manu-facturers’ documents produced by the member companies. In addition, standards have been developed in response to important user issues such as FSA-PEJ-701-06 Piping Systems Non-Metallic Expansion Joint Hydrotesting and Vacuum Testing, FSA-PEJ-702-06 Rubber Flanged Non-Metallic Expansion Joint Installation, Maintenance, and Storage, and FSA-NMEJ-703-99 Specifi cations of Elastomers Used in Piping Systems Non-Metallic Expansion Joints.

h e following members of the Piping Systems Non-Metallic Expansion Joint division sponsored this “Sealing Sense” series:

Bachmann Dampjoint, Inc.Daikin America, Inc.Dinatecnica Ind. E Com.DuPont Performance Elastomers

L.L.C.3M DyneonGarlock Sealing TechnologiesGeneral Rubber Corp.KE-Burgmann A/SMeccom Industrial Products Co.Mercer Rubber Companyh e Metrafl ex Co.Proco Products, Inc.Solvay Solexis, Inc.Unafl ex Incorporated



Q. What are the parameters for pump baseplate design, and why must baseplates be grouted in place?

A. A baseplate is the structure to which the pump, motor, gearbox and all auxiliary equipment are mounted. h e purpose of a baseplate is to provide a foundation under a pump and its driver that maintains shaft alignment between the two pieces of equipment. h is baseplate must:• Survive handling during transportation to the installation

site• Be capable of being installed properly with minimum

diffi culty• Allow for the initial mounting and alignment of the

equipment• Allow for the fi nal alignment of the mounted equipment• Control spillage• Allow for the removal and reinstallation of equipment

To meet these requirements, an absolutely rigid baseplate is not necessary. At the same time, the baseplate must not be permanently deformed after the equipment is mounted at the manufacturing facility. Compliance with these design criteria, in conjunction with proper installation procedure, will contrib-ute signifi cantly to meeting the functional requirements.

Any baseplate must be designed to satisfy numerous func-tional requirements. To ensure correct design of the baseplate, all application parameters must be reviewed—including equip-ment selection, installation and operational requirements. For standardized pump ranges with predefi ned and specifi c applica-tions, the equipment manufacturer should have taken all these factors into account. For customized pump applications, these fundamentals should be reviewed at the time of the proposal.

h e grouted baseplate shown below is designed to allow

the grout to be poured underneath the base. h e grout placed inside the base contributes to the baseplate’s installed rigidity and damping. See Figure 1.3.8.2.1a.

h e cross members used on the baseplate in Figure 1.3.8.2.1a are normally designed to lock into the grout and further resist any defl ection or vibration of the baseplate. Typically, the cross member geometry chosen to achieve this is an L-section (shown), a T-section or an I-section.

If the baseplate is a closed design (i.e., the grout cannot be poured inside the baseplate perimeter due to the presence of a drain pan or deck plate), then grout and vent holes must be provided to allow the grout to be placed inside the base.

h e grout used may be either cementitious or epoxy-based. h e surface preparation required for a baseplate to successfully bond to the grout is diff erent depending on which grout will be used. It is, therefore, important that the vendor and customer agree in advance which type of grout will be used.

h e baseplate described and shown in Figure 1.3.8.2.1a is typical of a fabricated baseplate. Cast-iron baseplates are another type of grouted baseplate. h e ability to integrally cast in features such as bracing, grout holes and sloping surfaces provides a highly functional and economical solution for many applications.

For additional details on baseplates, see ANSI/HI 1.3 Rotodynamic (Centrifugal) Pumps for Design and Application.

Q. What are mixed fl ow impellers, and when are they used?

A. h e impellers described below are used in a wide variety of services. For any given service, one type may be preferred. In most cases, however, the users’ and manufacturers’ experience is the best guide for making a selection.

PUMPFAQs®

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Hub Vanes Hub Vanes

Impeller shrouds

Impeller shrouds

Radial-vane area

Impeller shroudsImpeller shrouds

HubVanes

HubVanes Vanes

Francis-vane area Mixed-flow area Axial-flow area

Impeller hub

Axis ofrotation

US Units

Metric Metric

US Units

Figure 1.3.4.1. General impeller types

Figure 1.3.8.2.1a. Grouted baseplate, fabricated steel


Rotodynamic pump designs are generally described as any of three types: radial fl ow, mixed fl ow or axial fl ow. For examples, see Figure 1.3.4.1. Radial fl ow impellers are designed so that the liquid exits purely radially or perpendicular to the shaft centerline. h ey have lower specifi c speeds, in the range of 10 to 50 (Ns 500 to 2,500), and most often are used for lower-fl ow, high-head applications.

As design fl ow increases, specifi c speed increases, and the impeller will become more axial in its confi guration, with fl uid fl ow in line with the shaft centerline. Fully axial impellers produce high fl ow rates with little head.

Between these two extremes, the liquid exit angle transitions from radial to axial as shown in Figure 1.3.4.1. h ese transitional designs are referred to

as mixed fl ow impellers. h ey are used when the impeller spe-cifi c speed is from 80 to 140 (4,000 to 7,000).

For more information on impeller design, see HI Standard ANSI/HI 1.3, Rotodynamic (Centrifugal) Pumps for Design and Application.

P&S

Pump FAQs® is produced by the

Hydraulic Institute as a service to

pump users, contractors, distributors,

reps and OEMs as a means of ensur-

ing a healthy dialogue on subjects of

common technical concern.

HI standards are adopted in the

public interest and are designed to help

eliminate misunderstandings between

the manufacturer, the purchaser and/

or the user and to assist the purchaser

in selecting and obtaining the proper

product for a particular need.

As an ANSI approved stan-

dards developing organization, the

Hydraulic Institute process of develop-

ing new standards or updating current

standards requires balanced input from

all members of the pump community.

We invite questions and will

endeavor to provide answers based on

existing HI standards and technical

guidelines. Please direct your inquiries

to: [email protected].

For more information about HI,

its publications, Pump LCC Guide,

Energy Saving Video-based educa-

tion program and standards please

visit: www.pumps.org. Also visit the

new e-learning portal with a com-

prehensive course on “Centrifugal

Pumps: Fundamentals, Design and

Applications,” which can be found at:

www.pumplearning.org.

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Practice & Operations

The Lower Cape Fear Water and Sewer Authority had begun to expand its main raw-water pump station at Kings Bluff , near the Lower Cape Fear River in

southeastern North Carolina. h e core of this municipal project revolved around three, identical, new vertical turbine pumps.

One of these pumps was a replacement for an exist-ing pump, and two were part of an addition that included a newly constructed extension of the station building. Charles R. Underwood, Inc., the original equipment manufacturer (OEM) of the pumps, requested that Mechanical Solutions, Inc. (MSI) perform a detailed fi nite element analysis (FEA) of the vertical turbine pumps prior to their manufacture, installation and acceptance testing at the pump facility.

h e structural natural frequencies of vibration and their mode shapes would be predicted through the FEA, and the proximity of these natural frequencies to the pump operating speed range would be revealed.

With this information, the infl uence of the vibration on the performance and the reliability of the pumps could be assessed appropriately and modifi cations could be imple-mented, if necessary, before the installation of the pumps.

Since modifying machinery during design is easier than implementing modifi cations after installation, this proactive approach could conserve a signifi cant amount of the project’s budget.

The Pumps Were Modeled With the

Finite Element Technique Detailed technical data, including drawings of the pumps and of the pumping facility, were provided to the company that performed the FEA, by both Charles R. Underwood, Inc., the pump OEM, and the Lower Cape Fear Water and Sewer Authority.

Because this municipal water project involved the exten-sion of the pump station’s building to contain two of the three new raw-water pumps, the information from the latter source proved to be especially relevant during the analysis.

Based on the extensive set of data, two detailed fi nite ele-ment models that represented portions of the pump system were created. h ese models accounted for the diff erences

in the construction details of the foundations to which the pumps were attached.

Each model incorporated suffi cient portions of the adja-cent building foundation structures and piping, as shown in Figure 1. h e pump system fi nite element models also simu-lated both the minimum and the maximum submergence levels of each foundation, which accounted for the added internal and external water mass eff ects on the column pipes, bowls and suction bells of the pumps.

An FEA that used each of the models was performed to predict the structural natural frequencies of the pump system. h e main criterion of the FEA, taken from the speci-fi cation for the vertical turbine pumps, was that no structural natural frequencies should fall within 15 percent of the 9.75 Hz through 14.8 Hz running speed range of the pumps.

In parallel with this FEA, pump shaft lateral and tor-sional analyses were performed. Both predicted that the cri-teria for the shaft lateral and torsional natural frequencies would be satisfi ed by the existing design.

FEA Uncovered Potential Resonances

Within the Running Speed Range h e pumps’ below-ground column modes and frequencies of vibration that were predicted by the FEA were similar.

Proactive PlanningPaul Boyadjis & Chris Hurrell, Mechanical Solutions, Inc.

Potential vibration problems were avoided

through design-stage fi nite element analysis.

Figure 1. A solid model of one of the new vertical turbine

pumps with a portion of the new structural foundation on the

left and of the existing structural foundation on the right.


h erefore, any potential modifi cations to the column pipes to shift their vibration modes would be eff ective for the pumps that were located on either of the foundations.

However, depending on the foundation, the above-ground motor and motor-stand vibration modes that the FEA pre-dicted diff ered markedly. h is diff erence was attributed to the variation between the stiff nesses of the two foundations.

Below ground level, the second bending mode structural natural frequencies of the column pipe, which were parallel to the discharge nozzles, had separation margins that were at least 18 percent above the maximum running speed.

However, the results of the FEA predicted that the natural frequency for this column pipe, in the direction perpendicular to the pump discharge, would fall within the pump’s operating speed range. h is is illustrated in Figure 2.

Excessive vibration would occur because the natural fre-quencies of vibration that were forecast by the FEA, 13 Hz in a minimum-submergence and 11 Hz for the case of maximum submergence, would be excited during the anticipated normal operation.

Potentially troublesome above-ground modes of vibra-tion were also predicted by the FEA. h is might occur with the pumps that were located at both foundation structures. h e FEA of the pumps at the new section predicted that the natural frequencies for the above-ground fi rst bending modes

of vibration would fall within 15 percent of the upper end of the pump running speed range. h is condition would fail to satisfy the pump specifi cation.

In addition, the FEA of the existing foundation indicated that the natural frequency for one of the above-ground fi rst

Figure 2. The pump column pipe second bending mode is shown

with a color contour plot of the displacement superimposed over

the exaggerated, deformed shape of the pump assembly.

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bending modes would land short of the desired 15 percent separation margin. See Figure 3.

Potential Solutions Investigated With FEA h rough additional FEA, a practical, potential solution to the predicted, below-ground pump vibration problem was investi-gated. A 3/4-inch thick split steel plate was modeled between the bottom fl ange of the pump discharge and the fl oor of the station to constrain the motion of the column pipe during the second bending mode.

h e results of the FEA showed that this straightforward modifi cation would increase the two off ending natural fre-quencies of the pumps to between 21 Hz and 22 Hz. h is is approximately 42 percent above the maximum pump operating speed. An acceptable margin of separation from the running speed range would be created when the split steel plates were included in the pump installations. If the split steel plates were implemented, the vibration frequency of the second bending mode of the pump column that was in line with the pump dis-charge direction would also increase. h is would enhance the already-satisfactory margin of separation that existed for this vibration mode.

To address the potential above-ground pump vibration problems, thicker stiff ening ribs were modeled on the motor stand, and an FEA was performed for the pumps that were located at both foundations of the station.

At the new foundation, the modifi ed stiff ening ribs were predicted to shift the off ending natural vibration frequency higher. h is would increase the margin of separation from the maximum running speed to 16 percent and enable the pump specifi cation to be met.

However, the FEA results for the pump that rested on the existing foundation showed that the thickened stiff ening ribs would not be eff ective. h is disparity was caused by the comparatively reduced foundation stiff ness, which in turn was attributed to the access ports that were located in the fl oor of the building.

To alleviate this issue, a concrete pillar was modeled in the existing building between the piping gallery level and the upper level, the location of the motor-stand and motor. h e FEA of this proposed modifi cation predicted that the addition of the concrete pillar would increase the magnitude of the above-ground natural frequencies and create an acceptable separation margin, as shown in Figure 4.

h e FEA results of the vertical turbine pumps were reported to the OEM, and the suggested solutions were reviewed. Because the pumps were equipped with variable frequency drives (VFDs) and after considering the anticipated operating environment of the pumps at the station, the OEM suggested an additional solution to the pending vibration issues.

By programming lock-out ranges into the VFDs of the pumps after their installation, the undesirable vibration fre-quencies that were predicted to occur within the running speed range would be avoided.

Conclusion h e three new vertical turbine pumps were installed and the expansion of the station was completed. Figure 5 shows one of the newly installed OEM vertical turbine pumps within the fi nished pump station. As it was ramped through its operating speed range during the initial evaluation process, an increase in the vibration response of one of the pumps was measured at 13 Hz, where the FEA had predicted that a natural frequency of vibration of the column pipe would occur. h is demonstrated the accuracy and the practicality of the FEA.

Figure 3. The above-ground, FEA-predicted, fi rst bending mode

of the new pump on the existing foundation is shown with a color

contour plot of the displacement superimposed over the exag-

gerated deformed shape of the pump assembly. Features of the

pump assembly in the undefl ected position have been superim-

posed on the image to aid in seeing the defl ected shape of the

column.

Figure 4. The above-ground, fi rst bending mode of the new ver-

tical turbine pump on the existing foundation structure (which

was predicted by the FEA) is shown with the addition of the

below-ground concrete support column.


Once the installation of the pumps was completed and the on-site per-formance of the pumps was verifi ed, the pump OEM programmed lock-out speed ranges into the VFDs, which prevented the operation of the pumps at the speeds during which undesirable vibration had been predicted.

By performing the FEA prior to the installation of the vertical turbine pumps, several natural frequencies of vibration were identifi ed. h is vibra-tion could have adversely aff ected the long-term reliability of the pumps. h is process was far more effi cient than a trial-and-error, on-site implemen-tation of experimental solutions.

If the pumps had not been equipped with VFDs, the structural modifi -cations that were suggested through the FEA would have been implemented to ensure that the unwanted vibration would not occur.

P&S

Paul Boyadjis, manager of turbomachinery analysis for MSI, has 25 years of diverse experience in the analysis and design of rotating equipment. He can be reached at 973-326-9920, ext.115, or [email protected].

Christopher Hurrell, manager of test facilities at MSI, has extensive rotating machinery troubleshooting experience at MSI, including the testing of large turbomachinery both domestically and at locations as distant as Southeast Asia. He can be reached at 973-326-9920, ext.113, or [email protected].

Figure 5. The above-ground portion of one of the new

vertical turbine pumps


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In Part One of this series (Pumps & Systems, November 2010), a method was developed to determine which pump systems in a facility off er the best opportunity for

signifi cant cost reduction through energy conservation and reliability improvement.

After selecting a candidate system, data must be taken to determine its actual operating range. For a system with a small operating range, only a simple, one-point test may be needed. Systems with a larger range may require a per-formance test at each of several operating conditions. More complex systems or systems of which little is known about the operating range may need continuous monitoring over a period of time.

Data Needed to Assess a Pump SystemA pump assessment is a mini performance test of the pump within the system in which it normally functions. h e assess-ment generally requires measuring the pump’s fl ow rate, head and power input to determine its actual operating point within its system. Specifi cally, collected data should include:1. Pressures

a. Suctionb. Discharge

2. Flow rate3. Pump input power4. Shaft speed5. Fluid properties at the operating condition(s)6. Pump performance curve (from the manufacturer)7. Motor performance—Possibly the VFD performance

also (from the manufacturer)

Warning—Before any data collection is begun, all data must be collected by trained and qualifi ed personnel. Data collectors will be connecting test equipment to live electri-cal wires and to rotating equipment. All company, local, state and federal safety protocols must be followed includ-ing, but not limited to, NFPA 70E and OSHA 29CFR 1910.335. If any reservations in the collectors’ ability to

gather these measurements safely arise, consult a professional for assistance.

Pressure GaugesPressure gauges are often permanently installed on pumps, but these may not be the gauges that should be used during an assessment. Because of pressure spikes, water hammer, fouling, etc., these gauges are often inaccurate. If safety per-mits, mount accurate pressure gauges onto the system. h e gauges should be of good quality and accurate enough to read pump suction and discharge pressures within +/- 3 percent.

Be aware that the suction pressure may be below atmo-spheric, requiring a compound gauge (able to read both posi-tive and vacuum pressures). h e gauges should be mounted as close to the pump as possible to eliminate potential errors caused by losses in pipe fi ttings.

h e head level in and out of the pump must be deter-mined. h e diff erence between the inlet head (input energy) and the discharge head (exiting energy) is the amount of energy added to the fl ow measured in foot-pounds per pound. If only the inlet or outlet head or pressure is known, determining the amount of energy transferred to the fl uid is impossible. h e formula to convert pressure to head is (see nomenclature for defi nition of terms):

hg = P x 2.31

SG

If a suction gauge is not available, as on a vertical immer-sion sump pump, use the level of the fl uid above the inlet to the impeller to determine the suction head level. h e equa-tion to determine suction head from a fl uid level measure-ment is:

Hs = GP x 2.31

SG + hvs ± Zs - hfs

Flow Rateh e next required measurement is the fl ow rate through the pump system. h is can be determined by an inline fl ow

Pump System Energy AssessmentGreg Case, PD3

Improved reliability, performance and energy effi ciency

can result from pump system assessment.

Second of Two Parts


meter that is permanently installed in the system or by one installed temporarily for the test. Whichever method is used, the fl ow meter needs to be installed correctly with the proper amount of straight pipe before and after the meter.

Temporary fl ow meters must not change the system loss characteristics during the measurement. A popular type of tem-porary fl ow meter is an ultrasonic fl ow meter. It uses changes in a sound signal passed through the pipe and the fl ow to deter-mine the velocity of the fl ow in the pipe. h is is non-invasive and does not require the pipe to be penetrated. However, they can be temperamental and error-prone when misapplied.

Another type, common in some industries, is a pitot tube that measures velocity by determining the diff erence between the total and static pressures in a fl ow. h ere are several other insertion type meters, including paddlewheel and turbine-type meters. All these meters require that the internal diameter of the pipe be known so that the velocity and the pipe’s internal cross-sectional area can be used to fi nd the volumetric fl ow rate.

Flow rate = velocity × cross sectional area

Cross-sectional area = π x D2

4 (for round pipe)

Shaft SpeedShaft speed has changed from a guessed number to a param-eter that must be measured. Effi ciencies of electric motors have been increased with a complimentary reduction in slip. h is means that motor speeds have increased, moving closer to their synchronous speeds.

When taking performance measurements, this may lead to signifi cant changes in the pump’s performance in both head and power consumption. h is measurement does not need to be extremely accurate. Knowing the shaft speed within ±5 rpm is acceptable in most cases.

Sometimes, this can be done using an inexpensive contact-type tachometer. Generally, these use a rubber-tipped shaft that

Nomenclature

H = Total head (feet)P = Pressure (psi)SG = Specii c gravity (no unit)hg = Head (from gauge pressure) (feet)hvs = Velocity head (suction side of pump) (feet)hfs = Friction head loss (suction side of pump) (feet)Zs = Elevation head (level of liquid above pump impel-

ler inlet) (feet)Hs = Total head (suction side of the pump) (feet)GP = Gas pressure (applied to liquid surface, zero if

open tank) (psig)D = Internal diameter of the pipe (feet)


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is pressed against the pump or motor shaft, directly measuring the shaft’s rpm. h is works well if there is a location available to make contact with the spinning shaft.

Non-contact tachometers are an alternative. On the lower end of the expense scale are optical tachometers that use a light source bounced off a piece of refl ective tape attached to the shaft. h ese work well but require that the pump be stopped to attach the tape. Some non-contact tachometers, such as key-phasers or optical strobes, can be used without stopping the equipment.

Input PowerDetermining the input power for a pump can be as simple as taking the voltage and amperage data on the output side of the motor starter. h ese measurements combined with the power factor and effi ciency data from the motor manufacturer will provide a fair estimate of the motor output power, which is usu-ally the pump input power. h is method works well on fi xed-speed pumps.

Due to the potential safety hazards, it is advised that all electrical meters be attached to the pump’s electri-cal system when the power to the pump motor control center is off . h is reduces the risk of electrical shock and arc fl ash.

If the motor is driven by a variable frequency drive (VFD), things get more complicated. h e drive output to the motor is not running on a true sine wave, and the frequency of the output may also be outside the range of the meters being used for the measurements. h ese two factors along with change in the power factor modifi ed by the drive complicate measure-ments at this location. Many drive manufacturers suggest mea-surements be taken with the power meter at the input side of the drive where the power is coming in at line frequency and voltage. h is requires that the effi ciency of the drive at various power and frequency outputs be known. h e readout on the drive’s display can be used, but it is rarely calibrated and may be prone to errors.

Pump power input =

Drive input power × (Drive efficiency) × (Motor efficiency)

Analyze the DataData analysis can be done by hand. An example document can be downloaded at www.pdcubed.net showing a complete hand calculation with the accompanying equations. h ese formulas can be used to develop a custom spreadsheet.

Also, a free tool from the U.S. Department of Energy can help analyze the data. h e program is called Pump System Assessment Tool (PSAT). It can be downloaded at www1.eere.energy.gov/industry/bestpractices/software_psat.html.

Input for this tool is the raw measurement data. Output is the pump’s performance, yearly energy usage and cost to oper-ate. h e tool also compares the current pump against a theoreti-cal, optimum pump based on the achievable effi ciency estimate generated from the Hydraulic Institute Standard. h is contrast

shows approximately how much money could be saved yearly if the optimal pump were installed.

To run PSAT, the user enters information about the pump and the motor driving it in the PSAT input area (Figure 1). h e box at the bottom of the column is where the fl ow head and input power data is entered. h e user can calculate the total head of the pump by hand, or it can be calculated by the PSAT by clicking the blue “Head tool” button next to the input box. h is brings up a calculator where the system and measured data is entered. h e tool will calculate the total head (Figure 2). If you have a system without a suction pressure gauge, the tool can also calculate the total head by selecting “suction tank ele-vation, gas space pressure and discharge line pressure.”

Use of the InformationNow that the pump’s performance is known, the actual per-

Figure 1. PSAT input area

Figure 2. Head calculation tool for suction and discharge pressures


formance can be plotted on the manufacturer’s performance curve. h is determines if the pump is operating near its best effi -ciency point (BEP). If the goal is to improve the reliability of the pump, and the pump is operating far away from the BEP, this may indicate that the hydraulic loads within the pump are caus-ing shaft defl ection, seal or bearing problems, internal rubs, etc.

If reliability problems exist and the pump is operating near its BEP, this may point to mechanical problems—such as poor alignment, weak base plates, improper assembly techniques, etc.

If effi ciency improvement was the main goal, this infor-mation can determine if the pump is the best fi t for the application. A pump running far away from its BEP will be less effi cient than one running close to its BEP. h e pump, control system or operating practices may need to be modifi ed to improve the pump system’s performance. Unfortunately, no single approach will improve the effi ciency of every system.

Many factors need to be consid-ered to optimize system effi ciency. In some systems, the optimization may require nothing more than turning off the pump when there is no demand. In other systems, trimming the impeller to the proper size so it can meet fl ow and head demand will suffi ce. In more com-plex systems, the use of motor control, parallel pump systems and state-of-the-art PLC control may be required.

If complex system changes are required, analyzing the eff ects of vari-ous operating conditions on a simula-tion tool is suggested before physical changes to the system are made. A free analysis tool (PSIM) is available on the Hydraulic Institute/Pump Systems Matter website at: www.pumpsystems-matter.org/content_detail.aspx?id=110 (Figure 3).

Another powerful tool, found within PSAT, is the system curve tool.

It gives a fairly accurate simple system curve for each operating condition. h is curve generator uses the measured condition point and the zero fl ow static head to create a system curve showing the actual losses within the system. h is curve can be output to a spreadsheet.

With straightforward testing and the analysis tools shown, pump system assessment can be conducted, and the pump and system’s reliability and energy effi ciency can be improved having major positive impact on the bottom-line of operations, and helping a company meet its energy reduction goals.

Additional Resources

A new ASME standard for conducting pump system energy assessments is available at the website: estore.pumps.org/ASME-EA-2---2009-Energy-Assessment-for-Pumping-Systems-Secure-PDF-P129C27.aspx

Additionally, there is a free awareness seminar to help users understand the content of the standard. Webinar dates and times are available at:www.pumpsystemsmatter.org/content_detail.aspx?id=5685

P&S

Greg Case is president of Pump Design, Development & Diagnostics, LLC (PD3). He consults on pump design and troubleshooting issues. Case is a qualifi ed instructor for both the U.S. Department of Energy’s Pump System Assessment course and the Hydraulic Institute’s Pump Systems Matter, Pumping System Optimization course. Contact him at [email protected].

Figure 3. Free PSIM system analysis tool



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XA Prohe sotware package contains all you need for performing the shat alignment of rotating machinery—horizontal and vertical shat align-ment, alignment of machine trains, hot check, and sotfoot. A time-saving function in the XA Pro is “Machine Deined Data,” which allows the user to save machine conigurations as templates. All machine data for each machine, including machine dimensions, measurement distances, tolerances, and target values, are available in the Fixturlaser XA Pro alignment tool. he hardware package now includes thin magnetic brackets and an exten-sion ixture.

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he Tuf-Lok ring grip pipe couplings are low-cost, heavy-duty, self-aligning couplings for either high pressure, to 150 psig, or full vacuum-rated applica-tions. hese couplings install quickly and easily, reducing installation costs. hey are available in 1-inch (25-millimeter) through 10-inch (250-mil-limeter) pipe sizes and are made for use on plain end pipe, regardless of pipe wall.

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XA UltimateFixturlaser XA Ultimate is a measurement tool with an expanded sotware package that includes shat alignment and geometric measurements, such as latness and straightness. Properly aligning a machine starts at its installation. he machine’s foundation should be checked to determine if it’s skewed or warped, which would inluence the machine’s capability to work under optimal condi-tions. he Fixturlaser XA Ultimate tool gives the user access to all the sotware and hardware that is required for a successful machine installation.

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holding capacity and

reduced maintenance

costs. In many respects, Harmsco Hurricane ilters

are two ilters in one! Components include outer

chamber for particle separation, inner chamber for

cartridge iltration and built-in drain for purge, if

required. Deep angled pleats are directed toward

rotational low for increased dirt holding capacity.

Unlike conventional designs, Hurricane patented

cartridges are made with deep, angled pleats to

direct the low into the pleated area for increased

solids removal.

Harmsco Filtration Products

P.O. Box 14066

North Palm Beach, FL 33408

Phone: 800-327-3248

Fax: 561-485-2474

Website: www.harmsco.com


Ultrasonic Flow Meter Technology

he advanced TFX Ultra by Dynasonics® is an

ultrasonic low meter that clamps on the outside of

existing pipes without contacting liquids. here is

no need to shut down the process for installation

or maintenance. herefore, the TFX Ultra can be

installed and fully operational in minutes, ofering

repeatable and reliable low measurement.

Racine Flow Meter Group

8635 Washington Avenue

Racine, WI 53406

Phone: 262-639-6770

Fax: 262-639-2267

Website: racinefed.com/flow


Non-Contacting Portable Flow Meterhe new PDFM 5.0 Portable Doppler Flow Meter

is designed for wastewater, sludge and slurries.

Mount the ultrasonic sensor on the outside of

metal or plastic pipes, ½-inch diameter or larger.

Use it for pump tests and troubleshooting. his

battery-powered low meter includes a backlit

display, 4-20mA output, data-logger with USB

output and sotware.

Greyline Instruments Inc.

105 Water Street

Massena, NY 13662

Phone: 888-473-9546

Fax: 315-764-0419

Website: www.greyline.com


Engines

Fairbanks Morse EnginesFor decades, Fairbanks Morse has been manu-

facturing medium-speed engines for rigorous

military, government and nuclear applications.

his expertise has resulted in the Colt-Pielstick

PA6B engine—a rugged and technologically-

advanced product for emergency pumping stations

in catastrophic environments. A fully-skidded,

custom-engineered system, the PA6B comes in 12

to 20 cylinder conigurations delivering 350 bkW

per cylinder at 900 rpm.

Fairbanks Morse

701 White Avenue

Beloit, WI 53511

Phone: 800-356-6955

Fax: 608-364-8411

Website: www.fairbanksmorse.com

Email:

[email protected]



Instrumentation & Controls

Pump Motor Ground MonitorMonitor and protect your pump motor:

motors

-

MSE of Canada Ltd.

261 Millway Avenue

Concord, ON L4K 4K9 Canada

Phone: 905-738-3744

Fax: 905-738-5732

Website: www.msegroup.net







Maintenance Products Maintenance Products

Stop It HP™ – High Pressure Remidiation or Leak Repair

Stop It HP™ is a multi-component composite system for high-pressure piping repairs, providing leak-sealing capacity signiicantly higher than with the original STOP IT® formulation. It is designed for applications with working pressures up to 2,000 psi (138 bar) assuming a 5:1 safety margin. Stop It HP™ is compliant with U.S. DOT 49CR parts 182 and 195.

InduMar Systems, LP, division of

InduMar Products, Inc.

3355 W. Alabama, Ste. 110

Houston, TX 77098

Phone: 800-523-7867

Fax: 713-977-4164

Website: www.indumar.com


Palmetto Pump & Valve Packing

Palmetto is a manufacturer of high-quality braided packing. For more than 100 years, Palmetto has been providing a full line of compression seal pack-ing for pumps and valves. Other products include packing tools, gasket sheets, joint sealant, lip seals, and more. Please visit our website at www.palmet-topacking.com to learn about our new products.

Palmetto Inc.

25 Engerman Avenue

Denton, MD 21629

Phone: 410-479-2244

Fax: 410-479-0836

Webstie: www.palmettopackings.com


Industrial Modem LinePhoenix Contact’s expanded line of industrial modems now provides more options for remote communication with machines and systems. Analog, SHDSL and cellular technologis make it easier to share data in remote control, SCADA and automatic alarming applications.

Phoenix Contact

P.O. Box 4100

Harrisburg, PA 17111

Phone: 717-944-1300

Fax: 717-944-1625

Website: www.phoenixcontact.com/

industrialmodems


VARNA Products Turnkey Pump

Control Solutions

VARNA Products

4305 Business Drive

Cameron Park, CA 95682

Phone: 888-676-7770 (U.S. & Canada)

530-676-7770 (International)

Website: www.varnaproducts.com


ECO SMART STATION™ Control Panelhe ECO SMART STATION™ panel provides a safe, simple, energy-eicient solution for municipal lit station applications. he innovative, multiple-compartment design reduces the risk of injury re-sulting from arc lash. Control and power circuitry are segregated in separate enclosures, preventing unnecessary exposure to operators. he panel is equipped with state-of-the-art controls and VFD technology. UL/cUL Listed. Patent Pending.

SJE-Rhombus®

22650 County Highway 6, P.O. Box 1708

Detroit Lakes, MN 56502

Phone: 218-847-1317

Fax: 218-847-4617

Website: www.sjerhombus.com

E-mail: [email protected]





Mixers

Motors & Drives

Motors & Drives

Motors & Drives Motors & Drives

U.S. Motors® Vertical

HOLLOSHAFT® Motor

he U.S. Motors®

brand vertical HOL-

LOSHAFT® motor

has been a standard in

the pumping industry

since 1922. his mo-

tor is recognized for

its longevity, reliabil-

ity and ease of use. In

addition to the HOL-

LOSHAFT®, we ofer

a broad selection of

U.S. Motors® brand pump motors for virtually any

centrifugal pump application in every major stage

of water treatment and processing.

Nidec Motor Corporation (FKA Emerson

Motor Company, a division of Emerson

Electric Co.)

8050 W. Florissant Avenue

St. Louis. MO 63136

Phone: 314-595-8486

Fax: 314-595-8315

Website: www.nidec-motor.com


MAX-VH™ Vertical Motors & AC Drives

TECO-Westinghouse MAX-VH™ vertical hollow

shat, high thrust motors are stocked from 7.5

horsepower to 400 horsepower at 1,800 rpm.

Motors have high eiciencies that meet/exceed

EPAct levels and have an industry leading warranty

of 36 months from date of manufacture. Pair your

MAX-VH™ motors with the MA7200 Plus pump

AC drive or the EQ5 multi-purpose AC drive for a

custom pump driving solution.

TECO-Westinghouse Motor Co.

5100 North IH-35

Round Rock, TX 78681

Phone: 800-451-8798

Fax: 512-244-5502

Website: www.tecowestinghouse.com


Disc Mixer

he Discmixer is

based on

DISCFLO’s inno-

vative disc technol-

ogy. It is superior

when mixing shear

sensitive luids,

abrasive slurries and

luids with high

solid content.

of delicate solids

and stringy

solids without

clogging

DISCFLO CORPORTAION

10850 Hartley Road

Santee State: CA Zip: 92071

Phone: 619-596-3181

Fax: 619-449-1990

Website: www.discflo.com


Quickly Connect and Disconnect Motors

UL switch-rated plugs and receptacles allow

technicians to quickly connect/disconnect power

to pump motors. he device operates as a “line of

sight” disconnect switch up to 60 horsepower, 200

amps. Safety features protect from live parts and

arc lash injury. NEC/NFPA 70E code compliance

is simpliied. A safety shutter on the receptacle

ensures an NFPA 70E deined hazard risk category

= 0.

Meltric Corporation

4640 Ironwood Drive

Franklin, WI 53132

Phone: 800-433-7642

Fax: 414-817-6161

Website: www.meltric.com


Aurora Vertical Hollow Shaft MotorsAurora Motors is a leading global supplier of

premium vertical hollowshat motors for OEMs,

electic motor distributors, well drillers and mu-

nicipalities. We are currently manufacturing and

stocking the following vertical turbine motors to

meet your application needs:

-

Aurora Motors

2031 American Avenue

Hayward, CA 94545

Phone: 510-264-1318

Fax: 510-264-1317

Website: www.aamotor.com


Metal ID Tags

Durable Identification of Pumps & Valves

Durable identiication tags for pumps, valves,

motors, instruments, small piping, cables and other

maintenance equipment are made to withstand

chemical cleanings, high temperatures, and

corrosive or caustic environments. hese metal

tags provide maximum resistance to the efects

of weathering and chemicals. With a credo “We

BARCODE Diicult Stuf ™,” we will ind a solu-

tion to your identiication application.

InfoSight

20700 U.S. Highway 23

Chillicothe, OH 45601

Phone: 740-642-3600

Fax: 740-642-5001

Website: www.infosight.com




Motors & Drives

iQpump Intelligent

Pump Controller

he iQpump® control-

ler was designed

with pump service

operators and pump

system owners in

mind. he integrated

pump sotware allows

the operator to setup

speciic control values

for a wide range of

applications. he

iQpump® controller will automatically adjust

pump operating conditions as the process variables

change while still maintaining optimum pump

performance and protection.

Yaskawa America, Inc.

2121 Norman Drive South

Waukegan, IL 60085

Phone: 800-927-5292

Fax: 847-887-7310

Website: www.yaskawa.com




Pump Services

Pumps: Centrifugal

Pumps: Centrifugal

Pumps: Centrifugal Pumps: Centrifugal

Centrifugal Pumps for Industrial Applications

Haight Pump is excited to be ofering centrifugal

pumps. Constructed of 316L stainless steel, nickel

aluminum bronze or Duplex 2205—these pumps

are designed to be used in various industrial ap-

plications including power plants and chemical

processing. Contact Haight today to conigure a

pump that is right for your centrifugal application.

With over 75 years experience manufacturing

pumps, we can ind the one for you!

Haight Pump

133 Enterprise Street

Evansville, WI 53536

Phone: 800-871-9250

Fax: 608-882-3777

Website: www.haightpump.com


Ruhrpumpen, Heavy Duty Process Pump—SCE

he SCE is a heavy-duty, single-stage, centrifugal

process pump that meets API 610 standards. With

improvements to the casing, shat and bearing

bracket, the improved SCE is ideally suited for

reineries and petrochemical plants, oil ields and

pipelines, as well as ofshore, marine, and dock

services.

Ruhrpumpen, Inc.

4501 S. 86th E Avenue

Tulsa, OK 74145

Phone: 918-627-8400

Fax: 918-624-2471

Website: www.ruhrpumpen.com


Reserve Your FREE 2011/12 Cole-Parmer® General Catalog

Select the latest luid handling, laboratory

research, industrial process and electrochemistry

products to help you get your job done! More

than 2,600 pages feature brand names such as

Masterlex®, Oakton®, Polystat®, StableTemp®, and

more. Also includes information about technical

assistance, database tools and calibration services.

Reserve your copy! Call 800-323-4340, or visit

ColeParmer.com/8168.

Cole-Parmer

625 East Bunker Court

Vernon Hills, IL 60061-1844

Phone: 800-323-4340

Website: www.coleparmer.com


FM Series 5300 Chopper Pumps

Designed for excellent solids conditioning, the

Fairbanks Morse Series 5300 Chopper pump uses

an enclosed impeller with a rugged cutting proile

and delivers pump eiciencies 20 to 30 percent

beyond the current chopper pump designs.

Fairbanks Morse Pump

3601 Fairbanks Avenue

Kansas City, KS 66106

Phone: 913-371-5000

Fax: 913-748-4025

Website: www.fmpump.com


Quality Ductile, Gray and Alloy Iron Castings

Decatur Foundry means quality castings in less

than four weeks, guaranteed. Located in Central

Illinois, DFI provides ductile, gray and alloy iron

castings from 200 to15,000 pounds for water,

oil and gas pumps, compressor, motor and the

mining industry. DFI is an air set foundry making

short-run, low-volume, highly cored castings for

fast turnaround.

Ductile and Gray Iron Foundry

1745 North Illinois Street

Decatur, IL 62526

Phone: 217-429-5261

Fax: 217-426-2834

Website: www.decaturfoundry.com






Pumps: Centrifugal

Pumps: Diaphragm

Pumps: Diaphragm

Pumps: Diaphragm Pumps: High Pressure

For Xtremely Demainding

Process Applications

he Yamada® Xtreme Duty Pro™ XDP is designed for use in process type applications—includ-ing ilter press, high pressure, extended deadheading, long runs of discharge pipe and where air con-sumption is critical. Available in 1½-inch, 2-inch and 3-inch port sizes, these pumps are built on the liquid platform of a standard Yamada NDP series pump but with a mechanically-actuated air motor.

Yamada America, Inc.

955 East Algonquin Road

Arlington Heights, IL 60005

Phone: 800-990-7867

Fax: 847-631-9274

Website: www.yamadapump.com


Versatile High Pressure PumpGeneral Pump (GP Companies, Inc.) introduces it’s new 100-horsepower MW series pumps. hese pumps ofer multiple luid end options and allow for moving a variety of luids—including high-temperature glycol, recycled water, deionized water and produced well water or seawater. he MW series drive features external gear reduction, SAE “C” hydraulic mount and optional PTO accessory shat. Flows up to 105 gallons per minute and pressures up to 4,350 psi with available lushing option.

General Pump

1174 Northland Drive

Mendota Heights, MN 55123

Phone: 651-686-2120

Fax: 651-454-8015

Website: www.generalpump.com


APV W+ Series Centrifugal PumpsSPX is a leading innovator of solutions with decades of experience in centrifugal pump design, covering premium brands such as APV. From the supply of engineered components to complete process engineering and design, we specialize in helping our customers improve their plant’s performance and proitablility. Years of product development has enabled SPX to ofer a complete range of hygienic pumps in the brewery, dairy, food, beverage, chemical, healthcare and pharma-ceutical industries.

SPX Flow Technology

611 Sugar Creek Road

Milwaukee, WI 53115

Phone: 262-728-1900

Fax: 262-728-4904

Website: www.spxft.com


Advanced™ Series

Air-Operated Double-

Diaphragm Pumps

he Advanced™ Series metal and plastic air-operated double-diaphragm (AODD) pumps from Wilden Pump & Engineering feature its Pro-Flo X™ air distribution system to provide true cost savings when compared to other AODD pumping tech-nology. Advanced™ Series metal pumps are ofered in a variety of materials including construction and elastomer options that enable them to meet abrasion, temperature and chemical-compatibility concerns.

Wilden Pump & Engineering, LLC.

22069 Van Buren Street

Grand Terrace, CA 92313

Phone: 909-422-1730

Fax: 909-783-3440

Website: www.wildenpump.com


Graco Husky Double

Diaphragm Pumps

Graco Husky™ air-operated double diaphragm pumps feature ¼-, 3/8-, ½-, ¾-, 1-, 1½-, 2-, and 3-inch sizes with low rates from 5 to 275 gallons per minute for transfer-ring paint, chemicals, ink, cleaners, adhesives, seal-ants and lubricants. hese pumps feature extremely reliable, externally serviceable air valves—making our Husky pumps one of the best in the industry. A variety of construction materials are available to meet numerous luid transfer requirements.

Graco Inc.

P.O. Box 1441

Minneapolis, MN 55440

Phone: 877-844-7226

Fax: 877-340-6427

Website: www.graco.com/process


Pumps: Centrifugal

SIMSITE® Structural Composite Pumps

SIMSITE® Structural Composite Pumps are simply “the best,” because they are “unsurpassed” in their design, performance, eiciency, & life cycle. SIMSITE® Pumps are superior to metallic pumps because of their outstanding corrosion and erosion resistance. hey will not corrode in salt water or wastewater and have excellent resistance to chemicals.

SIMS PUMP VALVE CO. INC.

1314 Park Avenue

Hoboken, NJ 07030

Phone: 201-792-0600

Fax: 201-792-4803

Website: www.simsite.com




Pumps: Magnetic Drive

Advanced Magnetic DrivesDickow Pump has manufactured centrifugal pumps for 100 years, always emphasizing preci-sion hydraulic eiciency and longevity in service. Today, we ofer the most complete and technologi-cally advanced range of magnetic drive pumps available. his includes the PRM, manufactured in accordance with API 685. Dickow’s PRM was speciically designed to meet rigorous API 685 requirements for sealless pump applications in the petroleum, heavy duty chemical and gas service industries.

Dickow Pump Company

1738 Sands Place, #200

Marietta, GA 30067

Phone: 770-952-7903

Fax: 770-933-8846

Website: www.dickow.com





Pumps: Metering


Pumps: Metering Pumps: Mud

IX Precise Control Chemical Dosing Pump

A new generation of advanced metering pump technology! Iwaki’s IX Seris is digitally controlled, direct-drive diaphragm pumps. Years of experience in high-end motor technology result in extremely accurate and energy-eicient metering pumps with high resolution. he IX Series meets today’s demand for automated chemical delivery.

Walchem, an Iwaki American Company

5 Boynton Road

Holliston, MA 01746

Phone: 508-429-1110

Fax: 508-429-7433

Website: www.walchem.com


Hydrocyclone Charge Pumps—Produced Water & Sand

he world’s best kept secret. DISCFLO is becom-ing the pump of choice in the oil industry on and ofshore for produced water, tank bottoms, subsea operations and reineries. Our unique design features a pulsation-free, laminar low, no close tolerances, non-emulsifying and non-impingement pumping, with little to no wear and low mainte-nance.

DISCFLO CORPORTAION

10850 Hartley Road

Santee, CA 92071

Phone: 619-596-3181

Fax: 619-449-1990

Website: www.discflo.com


Non-Metallic, Close-Coupled, Sealless Pumps

Fybroc® 2530 Series is the irst completely non-metallic, iberglass-reinforced-plastic (FRP), magnetic-drive pump. he pump’s FRP (continu-ous strand) thermoset construction features a one-piece, reinforced casing with NO SEPARATE LINERS. he Series 2530 provides excellent cor-rosion resistance against acids, bleaches, caustics, solvents, seawater, brine and other diicult ser-vices. Ten sizes with capacities to 1,500 gallons per minute and heads to 400 feet are available.

Met-Pro Global Pump Solutions-Fybroc

700 Emlen Way

Telford, PA 18969

Phone: 215-723-8155

Fax: 215-723-2197

Website: www.mp-gps.com


Procam Metering Pumps

Bran+Luebbe has been a worldwide leader in meter-ing, analyzing and processing liquids for more than 75 years. he Procam series is made up of modular, single and multi-stream pumps with conigurations

to match the process requirement. he ProCam Smart is a high-quality, economic pump for cus-tomers with less demanding applications.

SPX Flow Technology


Milwaukee, WI 53115

Phone: 262-728-1900

Fax: 262-728-4904



High Alloy Mag Drive PumpsChemsteel Mag-Drive close coupled pumps are it-ted for applications that require a pump for highly corrosive chemicals. Nominal low rates from ½ gallons per minute to 30 gallons per minute are available in either an upper- or lower-drive conigu-ration. Helical gears ofer noise reduction of up to 10db. Chemsteel is also available as a convention-ally sealed pump with mechanical, lip or packing.

Oberdorfer Pumps

5900 Firestone Drive

Syracuse, NY 13206

Phone: 800-448-1668

Fax: 315-463-9561

Website: www.oberdorferpumps.com

E-mail:

[email protected]





Pumps: Oil

Pumps: Packaged Pumping Systems

Pumps: Packaged Pumping Systems

Pumps: Packaged Pumping Systems Pumps: Peristaltic

Bran+Luebbe Systems

Bran+Luebbe has been a worldwide leader in me-tering, analyzing and processing liquids for more than 75 years. Our packaged pump systems used for chemical injection and autoblend applications dramatically improve productivity, product quality and help reduce running costs.

SPX Flow Technology


Milwaukee, WI 53115

Phone: 262-728-1900

Fax: 262-728-4904



New M Series Pumphe ProSeries® Flex-Flo® M3 and M4 peristaltic metering pumps feature 10,000:1 turndown ratio, ive year warranty, NSF Standard 61, patented tube failure detection (TFD) system and brushless DC motor. M3 and M4 Series pumps have output rates up to 158.5 gallons per hour / 600 liters per hour, pressure rating up to 125 psi / 8.6 bar and specially engineered tubing for long service life.

Blue-White Industries

5300 Business Drive

Huntington Beach, CA 92649

Phone: 714-893-8529

Fax: 714-894-9492

Website: www.bluwhite.com


VARNA Products Model EP-4 Oil/Fuel Pump to 4 GPM

VARNA Products

4305 Business Drive


Phone: 888-676-7770 (US & Canada)


Website: www.VARNAProducts.com


Wet Well Mounted Pump StationsSmith & Loveless Wet Well Mounted Pump Stations revolutionize wastewater pumping. By mounting a complete wastewater lit station—in-cluding S&L pumps, piping, valve—outside and above the wet well, pumping becomes simpler, safer and more economical. No CONFINED SPACE entry. Pumps sewage, process wastewater & stormwater...Capacities to 20,000 gallons per minute and 500 feet TDH (pumps up to 12 inches).

Smith & Loveless Inc.

14040 Santa Fe Trail Dr.

Lenexa, KS 66215

Phone: 800-898-9122

Fax: 913-894-0488

Website: www.smithandloveless.com


Skid Mounted Pumping SystemsPumpingSol manufactures a range of customized, integrated luid transfer packages such as:

luids.

mining processes.

PumpingSol

2230 Justin Trail

Alpharetta, GA 30004

Phone: 770-740-8866

Fax: 770-740-8812

Website: www.pumpingsol.com


Pumps: Oil

VARNA Products Model CF-15 Oil/Fuel Pump up to 15 GPM

Continuous Duty

-

VARNA Products

4305 Business Drive


Phone: 888-676-7770 (US & Canada)


Website: www.VARNAProducts.com




Pumps: Peristaltic

Single Roller Peristaltic Pumps Lower Operational Costs

MORE EFFECTIVE & COST EFFICIENT: Larox Flowsys peristaltic pumps utilize a single roller design that will signiicantly lower opera-tional costs. It compresses the rubber hose only once every 360-degree revolution, so 80 percent of the heat and friction caused by sliding shoe designs that wear down the hose are eliminated, ensuring longer hose life. Single roller designs require less than a quarter of the glycerin and can run continu-ously at much higher rpms than double roller and sliding shoe designs!

Larox Flowsys Inc.

808 Barkwood Court, Suite N

Linthicum, MD 21090

Phone: 410-636-2250

Fax: 410-636-9026

Website: www.larox.us




Pumps: Peristaltic

Pumps: Positive Displacement/Centrifugal

Pumps: Piston Plunger

Pumps: Progressive Cavity Pumps: Rotary

Smart Conveying TechnologyHave you heard the news? “Smart Conveying Technology (SCT)” is now available from seepex for existing seepex pumps and other progressive capacity pumps. SCT was developed for quick and easy removal of the stator and rotor without removing the discharge pipes. Pumps no longer have to be removed for maintenance. he laborious and time-consuming work of dismantling pipe work and the removal of associated equipment are eliminated. SCT components are lighter and easier for maintenance personnel, which facilitates compliance with health and safety policies.

seepex Inc.

511 Speedway Drive

Enon, OH 45323

Phone: 937-864-7150

Fax: 937-864-7157

Website: www.seepex.com


Bronze Close Coupled, Pedestal Pumps

Oberdorfer has been manufacturing Bronze close coupled and pedestal gear pumps since 1890. Flow rates from ½ GPM to 175 GPM are available with a wide selection of seal choices available. Helical gears ofer noise reduction of up to 10db. We specialize in “custom” products for most OEM application.

Oberdorfer Pumps

5900 Firestone Drive

Syracuse, NY 13206

Phone: 800-448-1668

Fax: 315-463-9561

Website: www.oberdorfer-pumps.com

Email:

[email protected]

Verderflex Peristaltic Pumps

A single source pumping solutions provider, our extensive range of hose pumps and tube pumps are the ideal solution for liquid handling. he range includes the Verderlex® Dura—the most advanced, reliable and eicient hose pump available—and the Verderlex® 125, the largest hose pump in the world.

Verderflex

110 Gateway Drive

Macon, GA 31210

Phone: 877-476-3569

Fax: 478-476-9867

Website:

www.vergergpm.com/peristaltics


Colfax Fluid-Handling Solutions

Colfax strong legacy brands allow us to serve customers like you with an unmatched portfolio of luid-handling products, technologies and application expertise: Allweiler, Baric, Fairmount Automation, Houttuin, Imo AB, Imo Pump, Lubrication Systems Company, Portland Valve, Tushaco, Warren Pumps, Zenith Pumps.

Colfax Corporation

1710 Airport Road

Monroe, NC 28110

Phone: 877-853-7868

Website: www.colfaxcorp.com


Graco Fast-Flo Piston Transfer Pumps

Graco’s Fast-Flo® piston transfer pumps are ideal for low- to medium-viscosity luids and shear sensitive materials. hese pumps ofer superior reliability at an afordable price!

immersed in material for quicker prim-

low cost

Graco Inc.

P.O. Box 1441


Phone: 877-844-7226

Fax: 877-340-6427

Website:

www.graco.com/process






Pumps: Rotary

Pumps: Rotary Lobe

Pumps: Rotary Lobe

Pumps: Sludge/Slurry Pumps: Submersible

Slurry PumpsGIW is a leading manufacturer of high-perfor-mance, low-maintenance slurry pumps. GIW pumps have been used to pump hundreds of diferent materials—everywhere in the world. GIW serves industries such as mining and mineral beneiciation, industrial process, dredge, aggregate and coal preparation.

GIW Industries, Inc.

5000 Wrightsboro Road

Grovetown, GA 30813

Phone: 706-863-1011

Fax: 706-863-5637

Website: www.giwindustries.com


Infinity Submersible Pumps

he new Gorman-Rupp line of Ininity™ submers-ible, solids-handling pumps are built to the same exacting standards you’ve come to expect from our industry-leading, self-priming pumps. he Inin-ity line is available in 3-inch, 4-inch, and 8-inch langed discharge sizes and ranging from 2 – 75 horsepower. hese combinations will provide lows up to 3,100 gallons per minute and heads to 190 feet.

Gorman-Rupp Company

600 S. Airport Road

Mansfiled, OH 44903

Phone: 419-755-1011

Fax: 419-755-1251

Website: grpumps.com


Waukesha Universal Series PD Pumps

Waukesha brand pumps have long been known as the “pump of choice” for many processors. Versatile in application, its reliability has made it the industry standard worldwide for more than 50 years. With pressures up to 500 psi, the pumps can be ofered in several conigurations and are used in both sanitary and industrial applications.

SPX Flow Technology


Milwaukee, WI 53115

Phone: 262-728-1900

Fax: 262-728-4904



MUNIFLOhe New Design of the MUNIFLO Rotary Lobe Pump incorporates:

the rotor case

MUNIFLO PUMP

Division of Equipompe Inc.

16681 Hymus Blvd.

Kirkland, QC Canada H9H 4R9

Phone: 800-783-5623

Fax: 800-693-5623

Website: www.muniflo.com


Rotary Lobe PumpsBOERGER is the leading manufacturer of Rotary Lobe Pumps equipped with elastomer coated rotor designs. Boerger pump units are ideally suited for various municipal and industrial pump applications with lows between 1- to 5,000-gpm and pressures up to 200-psi. All wetted parts are exchangeable through the front cover (MIP = Maintenance In Place). Axial and radial casing liners eliminate the expense of replacing pump casings. BOERGER Screw Rotor Technology provides Pulsation Free Operation.

BOERGER, LLC

740 NE Harding Street


Phone: 877-726-3743

Fax: 612-331-8769

Website: www.boerger.com

Pumps: Rotary

Plenty Mirrlees PumpsWith decades of experience in the design and manufacture of rotary positive displacement pumps, Plenty Mirrlees Pumps has built an excellent reputation supplying reliable pumping equipment to the oil processing, petrochemical processing, power generation, marine, defense, sugar and general industries.

SPX Flow Technology


Milwaukee, WI 53115

Phone: 262-728-1900

Fax: 262-728-4904





Pumps: Submersible Slurry

Non-Impeller Submersible Slurry Pumps

he Pitbull® pump design eliminates seals, impel-lers, diaphragms and internal components to reduce pump maintenance. Two check valves route large solids/liquids through full pipe-diameter pas-sages at low velocities. CIPC manufactures a full line of these unique, air-operated pumps in lows from 5 to 1,500 gallons per minute. Submersible, transfer, self-priming and ilterpress feed conigura-tions/models are available in stainless, steel and FRP construction.

Chicago Industrial Pump Company

822 Schneider Drive

South Elgin, IL 60177

Phone: 847-214-8988

Fax: 847-214-8998

Website: www.pitbullpumps.com




Pumps: Sump

Seals

Pumps: Vertical

Seals Seals: Mechanical/Support Systems

Complete Bearing ProtectionAs the inventor of the original bearing isolator, Inpro/Seal® leads the industry in permanent bearing protection for rotating equipment. Inpro/Seal’s Motor Grounding Seal™ (MGS®) combines the patented VBXX® Bearing Isolator with proven shat grounding technology to deliver complete bearing protection in severe-duty applications. Proprietary conductive ilaments safely divert stray shat currents—protecting your bearings, your coupled equipment and your bottom line.

Inpro/Seal

4221-81st Avenue West

Rock Island, IL 61201

Phone: 309-787-4971

Fax: 309-787-6114

Website: www.inpro-seal.com


Non-Metallic Mechanical SealWith the ASI Model 724, Advanced Sealing International has redeined the non-metallic seal. Made of high-performance composite material, its wetted components provide superior chemi-cal resistance in a wide range of applications. It features monolithic seal faces, a metallic frame and seal components speciically designed for maximum repairability, while allowing material upgrades when necessary. Its stationary design and self-adjusting cushioned rotary face guarantee perfectly aligned seal faces.

Advanced Sealing International (ASI)

Baton Rouge, LA

Phone: 225-272-2155

Website: www.advancedsealing.com


Heavy Duty Industrial

Sump Pumps

Sethco® UD Series Pumps are ideally suited, structurally and hydraulically, for heavy-duty service. UD pumps are constructed of rigid CPVC and PVC materials to provide outstand-ing mechanical strength at elevated temperatures and excellent chemical resistance to concentrated acids and alkalies. he pumps resist wear, withstand impact and maintain dimensional stability through long-life service.

Met-Pro Global Pump Solutions-Sethco

700 Emlen Way

Telford, PA 18969

Phone: 215-799-2577

Fax: 215-799-0920



Bearing Isolators

Garlock…the next generation in bearing isola-tor technology. Since 1887, Gar-lock has been the leader for all your sealing needs. Garlock ofers the most expansive product range, a robust global infrastructure, a world class and stable supply chain and ofers the industry’s most efective sealing technology. Give us a call today! Watch for news about some exciting and revolutionary technologies launching soon!

Garlock Sealing Technologies

1666 Division Street

Palmyra, NY 14522

Phone: 877-GARLOCK

Fax: 800-543-0598

Website: www.klozure.com


Vertical Air-Cooled Inline

Pumps

Dean Pump® RAV (hot oil) and RWAV (hot water/glycols) product lines represent the highest quality, most efective, high-temperature, air-cooled vertical inline pump-ing equipment available. Features include vertical inline coniguration, reduced pump footprint, diminished pump alignment requirements, air-cooled design and no external water cooling re-quired. hree sizes of each model are available with pumping temperatures to 650 degrees F (RAV) and 400 degrees F (RAV).

Met-Pro Global Pump Solutions-

Dean Pump

6040 Guion Road

Indianapolis, IN 46254

Phone: 317-293-2930

Fax: 317-297-7028







Seals: Mechanical/Support Systems

Software

Seals: Support Systems

Valves Valves

Flanged One-Piece PTFE Construction

Innovative, one-piece PTFE uniied body/lange

construction insures leak-free performance on

critical acid installations. Available for backpres-

sure and pressure relief service in a complement of

sizes for 10 to 250 psi pressure adjustment range.

Grifco manufactures valve equipment, calibra-

tion columns and related accessories under ISO

9001:2008 registered quality standards to deliver

complete satisfaction with its “Made in USA”

products.

Griffco Valve Inc.

6010 N. Bailey Avenue, 1B

Amherst, N.Y. 14226

Phone: 716-835-0891

Fax: 716-835-0893

Website: www.griffcovalve.com


Gate, Globe, Check Valves

High pressure gate, globe and check valves are in

cast or forged steel to ASME B16.34 or API with

wear and corrosion resistant seats that are used

in power stations, general industry and process

engineering.

KSB, Inc.

4415 Sarellen Road

Henrico, VA 23231

Phone: 804-222-1818

Fax: 804-226-6961

Website: www.ksbusa.com


Wear Resistant Parts

Junty Industries, Ltd.

No. 7 Bei Tu Cheng Xi Lu

Post Code 100029, Beijing, China

Tel: +86-10-8227 5326

U.S. Fax & Voicemail: +1-815-642-4953

Website: www.SealChina.com


CAE Simulation ToolMagsot Corporation markets leading CAE simu-

lation tools for computing physical phenomena.

hese tools are used by manufacturers to accelerate

and manage precise design solutions for motors

and generators. Our Flux product is an FEM

sotware. It provides transient electromagnetic,

and electromechanical analysis for efective virtual

prototyping. Magsot Corporation builds relation-

ships with quality products, technical support,

training and consulting.

Magsoft Corporation

1 Fairchild Square

Clifton Park, NY 12065

Phone : 518-884-0505

Fax: 518-884-8688

Web: www.magsoft-flux.com


HN 8-WD Plug with Sealing FormringOur HN 8-WD screw plug with the integrated

sealing ring stays tight all the time. Our customers

in the automotive, drive technology, hydraulics

and pneumatics industries know they can rely on

it. Pressure-resistant and easy to use. Heinrichs is

ISO/TS 16949:2002-certiied and the preferred

supplier for many well-known companies all over

the world.

Heinrichs USA LLC

1020 Arbor Tech Drive, Ste. J

Hebron, KY 41048

Phone: 859-371-4999

Fax: 859-371-4899

Website: www.heinrichs-usa.com


Seals: Mechanical/Support Systems

Carbon Vanes

Helwig Carbon Products, Inc., has been manu-

facturing high-quality, long-running carbon and

graphite bearings, bushings, seals, and vanes for

over 40 years. We are ISO certiied, provide quick

service and are American made. Our materials are

self lubricating; dry running; chemical, corrosion

and oxidation resistant; have low wear rates and

have a low coeicient of friction for maximum

performance.

Helwig Carbon Products, Inc.

8900 West Tower Avenue

Milwaukee, WI 53224-2849

Phone: 414-354-2411

Fax: 800-365-3113

Website: www.helwigcarbon.com


P U M P U S E R S M A R K E T P L A C E


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INDEX OF ADVERTISERS

Advertiser Name R.S. # Page Advertiser Name R.S. # Page

Advanced Diamond Technologies 126 51

Advanced Sealing International 107 43

AE Pumps 133 69

All Prime Pumps 134 70

Blue-White Industries 108 26

Boerger, LLC 120 47

Carver Pump Co. 109 8

Cole-Parmer 110 11

Dan Bolen & Associates 135 71

Frost & Sullivan 132 69

FW Murphy 101 5

General Pump 121 45

Hydraulic Institute 131 53

Hydro Inc. 100 IFC

InduMar 128 49

InfoSight 125 55

Inpro/Seal 102 BC

ITT Goulds Pumps 122 35

KSB 111 10

LEWA Pumps & Systems 112 27

Load Controls, Inc. 113 29

Meltric Corporation 136 69

Phoenix Contact, Inc. USA 106 9

Polaris Pumps 114 32

Pump Solutions Group 123 39

Pumping Machinery 148 71

Racine Federated, Inc. 116 28

Ruhrpumpen 103 7

Sandpiper 115 31

Scenic Precise Element, Inc. 137 70

SEPCO 117 37

SEPCO 138 70

SERO Pump Systems 139 70

Shanley Pump & Equipment Inc. 129 49

SJE-Rhombus 124 44

Skinner Power Systems, LLC 118 12

St Mary’s Foundry 119 41

Summit Pump, Inc. 140 71

SuperBolt 127 51

Synchrony, Inc. 104 3

T.A.W., Inc. 141 71

Tamer Industries 142 70

Trachte, USA 143 71

Trask-Decrow 144 70

Tuf-Lok International, Inc. 145 71

Vaughan 105 IBC

Vertifl o 146 71

Vesco 147 71

Water Quality Association 130 53

Product Showcase

Advanced Sealing International 271 67

Alignment Supplies Inc. 235 56

Aurora Motors 260 60

Baker /Haight Pump 220 61

BaseTek 211 57

Blue-White Industries 222 64

Boerger, LLC 243 66

Chicago Industrial Pump Co. 233 67

Cole-Parmer 212 61

Colfax Corp. 279 65

Decatur Foundry 249 61

Dickow Pump Co. 239 63

DISCFLO 245 60

DISCFLO 283 63

Dwyer Instruments Inc. 206 58

Fairbanks Morse Engines 238 58

Faribanks Morse Pump 268 61

FW Murphy 218 58

Garlock Sealing Technologies 207 67

General Pump 208 62

GIW Industries 270 66

Gorman-Rupp Co. 284 66

Graco, Inc. 214 62

Graco, Inc. 246 65

Greyline Instruments Inc. 231 58

Griffco Valve Inc. 236 68

Harmsco Filtration Products 203 58

Heinrichs USA LLC 228 68

Helwig Carbon Products 247 68

InduMar 226 59

InfoSight 250 60

Inpro/Seal 230 67

Junty Industries, Ltd. 234 68

KSB 253 68

Larox Flowsys Inc. 219 65

Lovejoy 224 57

LUDECA 225 56

LUDECA 217 56

Magsoft Corp. 232 68

Meltric Corp. 202 60

MetPro Global Pump Solutions-Dean Pump 209 67

MetPro Global Pump Solutions-Fybroc 240 63

MetPro Global Pump Solutions-Sethco 205 67

MSE of Canada, Ltd. 256 59

Munifl o 272 66

Nidec Motor Corporation 215 60

Oberdorfer Pumps, Inc. 210 63

Oberdorfer Pumps, Inc. 241 65

Palmetto Inc. 248 59

Phoenix Contact 229 59

PumpingSol 274 64

R+W Coupling Technology 227 57

Racine Federated, Inc. 216 58

Ruhrpumpen 242 61

seepex Inc. 273 65

Sims Pump Co. 276 62

SJE-Rhombus 213 59

Smith & Loveless 237 64

SPX Flow Technology 264 62





TECO-Westinghouse 269 60

Tuf-Lok International 275 57

VARNA Products 252 59



Verder Ltd. 251 65

VibrAlign 258 56

VibrAlign 257 56

VibrAlign 259 56

VibrAlign 266 57

VibrAlign 267 57

Walchem, Iwaki America Co. 282 63

Wilden Pump & Engineering 201 62

Yamada America 204 62

Yaskawa America, Inc. 223 61

* Ad index is furnished as a courtesy and

no responsibility is assumed for incorrect

information.

Comprehensive Industry Coverage:

Positive Displacement Pumps

Centrifugal Pumps

Specialty & Other Pumps

Industrial Valves

Pneumatic & Hydraulic Valves

Custom Research

White Papers

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For informaピ on:

(800) 803-0353

www.allprimepumps.com

All Prime self-priming centrifugal pumps are marketed in the

United States, Canada & Mexico exclusively by the All Prime

Division of Power & Pumps Inc., Jacksonville Florida. Based

on the design of Gorman-Rupp’s T SERIES® & U SERIES®,

these pumps are available as bare pumps, parts, base

mounted and assembled fi berglass lift station units.

Materials of construction available include Cast-Iron, CD4MCu,

316-SS, 304-SS, ADI, Hastelloy & High-Chrome.

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US & other countries. All Prime is not sponsored by nor affi liated with The Gorman-Rupp Company.





1-800-287-1538

www.trask-decrow.com

The Best of Both Worlds

1 800 287 1538

Gorman-Rupp Quality with Trask-Decrow Support!






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Vesconite HilubePump Bearings� Can run dry

� Increase MTBR

� Avoid shaftseizures

Tollfree 1 866 635 [email protected]

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“Serving the Pump & Rotating Equipment, Valve, and Industrial Equipment Industry since 1969”

Domestic & International

Specializing in placing:

• General Management • Engineering • Sales & Marketing • Manufacturing

DAN BOLEN • JASON SWANSON

CHRIS OSBORN • DAN MARSHALL

9741 North 90th Place, Suite 200Scottsdale, Arizona 85258-5065

(480) 767-9000 • Fax (480) 767-0100Email: [email protected]

www.danbolenassoc.com

EXECUTIVE SEARCH/RECRUITING


Employment

Theory Hands-On Live Performance Testing

Next Pump School SessionDecember 16-17, 2010

EVERYTHING YOU EVER WANTED TO KNOW ABOUT PUMPS

For more information go to

www.PumpingMachinery.com770-310-0866

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P&S Stats and Interesting Facts


P&S Stats and Interesting Facts

1000

1100

1200

1300

1400

1500

1600

1700

1800

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45

-0.40%

-0.20%

0.00%

0.20%

0.40%

0.60%

0.80%

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

Pump and Pumping Equipment Manufacturing

Air and Gas Compresor Manufacturing

Pump and Compressor Manufacturing

65.00%

70.00%

75.00%

80.00%

85.00%

90.00%

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

Chemical

Food, Beverage and Tobacco

Petroleum and Coal Products

Mining

Paper

$2.30

$2.40

$2.50

$2.60

$2.70

$2.80

$2.90

$3.00

$3.10

$3.20

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

Average Price of Gasoline

Average Price of Diesel Fuel

Rig Count (U.S.): Jan. 7 – Nov. 16, 2010

Nu

mb

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Rig

s R

un

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g

Week

Month-to-Month Percentage Price Change

in Pumps and Compressors

Plant Capacity Utilization by Industry

Average Fuel Prices (U.S.)

Source: Baker-Hughes Inc.

Source: Federal Reserve Statistical Release

Source: Energy Information Administration

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


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