Pumps & Systems Sep2010
Pumps & Systems Sep2010
Pumps & Systems Sep2010
pump-zone.com
The Magazine for Pump Users Worldwide
pump-zone.com
September 2010
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2 SEPTEMBER 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 ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the right to determine qualications. Annual sub-
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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
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republish your submission. Submissions will not be returned.
is a member of the following organizations:
I
ts September, and as the mother of two
extremely active children (ages 12 and 15), I
am continually asked if Im ready for back
to school. Is it just meor am I the only mom
in America who embraces September as an
opportunity to focus on wastewater treatment?
Yes, its probably just me.
his is the time of year that we prepare for
WEFTEC, our biggest tradeshow of the year.
his generally means it is also our biggest issue.
So while I am helping my daughter with her
Civil War essay and my son is cramming all his
summer reading into about two days, Im learn-
ing about wastewater treatment. Surprisingly,
they do not teach this stu in the Alabama
public school system.
I have learned that it was not until the 19th
century that large cities began to realize the
necessity of reducing the amount of pollutants
used in the water that was discharged into the
environment. Many outbreaks of life-threat-
ening diseases were traced to bacteria found
in polluted water. Since then, many impactful
technological advancements have been made to
perfect wastewater collection and treatment.
Several million gallons of wastewater ow
through a typical wastewater treatment plant
daily. Some statistics show this can amount to
50 to 100 gallons for every person using the
system.
In this issue of Pumps & Systems, which
is All About Water, we explore technologies
that contribute to the importance of wastewa-
ter treatment, and Dr. Lev Nelik takes a look at
the future of wastewater treatment (page 24). In
this issue, we also cover everything from sealing
technologies, the importance of ow meters and
eective remote communication used in water
applications to reverse osmosis and metering
and submersible pump technologies. Even the
island of Alcatraz cannot escape from the need
for wastewater treatment (page 80).
Please visit the Pumps & Systems team at
our WEFTEC Booth (#2959 in F Hall) in
New Orleans, La., Oct. 2 6. We will also be
attending and co-sponsoring the Submersible
Wastewater Pump Associations 5th Annual
Advanced Controls Training Seminar in con-
junction with its 9th Annual Pumping Systems
Training Seminar. For more information on this
event, please contact SWPA Executive Director
Adam Stolberg at [email protected].
In the meantime, please let us know about
any advancements in wastewater treatment
technologies that you are using.
Best Regards,
Michelle Segrest
Editor
[email protected]
PUBLISHER
Walter B. Evans, Jr.
ASSOCIATE PUBLISHER
VP-SALES
George Lake
[email protected]
205-345-0477
EDITOR
VP-EDITORIAL
Michelle Segrest
[email protected]
205-314-8279
MANAGING EDITOR
Lori K. Ditoro
[email protected]
205-314-8269
MANAGING EDITOR
ELECTRONIC MEDIA
Julie Smith
[email protected]
205-314-8265
CONTRIBUTING EDITORS
Laurel Donoho
Joe Evans, PhD
Dr. Lev Nelik, PE, APICS
SENIOR ART DIRECTOR
Greg Ragsdale
PRODUCTION MANAGER
Lisa Freeman
[email protected]
205-212-9402
CIRCULATION
Tom Cory
[email protected]
630-482-3050
ACCOUNT EXECUTIVES
Charli K. Matthews
[email protected]
205-345-2992
Derrell Moody
[email protected]
205-345-0784
Mary-Kathryn Baker
[email protected]
205-345-6036
Mark Goins
[email protected]
205-345-6414
ADMINISTRATIVE ASSISTANT
Ashley Morris
[email protected]
205-561-2600
A Publication of
P.O. Box 530067
Birmingham, AL 35253
Editorial & Production
1900 28th Avenue South, Suite 110
Birmingham, AL 35209
Phone: 205-212-9402
Advertising Sales
2126 McFarland Blvd. East,. Suite A
Tuscaloosa, AL 35404
Phone: 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)
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
Focus on what you
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4 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
ALL ABOUT WATER
p
Predictable Pump Motor Maintenance at
a Cranberry Bog
Chris Rayburn, Fluke Corporation
Due to the delicate nature of the cranberry, pump failure is not an option.
p
Cellular Communications for SCADA Applications
Ira Sharp, Phoenix Contact
Effective and secure cellular communications for remote data acquisition.
p
Technology Saves Valuable Equipment
Brad Clarke & Kari Oksanen, Singer Valve
Airdrie, Canada, prevents cavitation damage by using an anti-cavitation trim.
p
Considerations for Choosing a Flow Meter
Marcus P. Davis, McCrometer
Find the right ow meter for your process and plant.
p
Clean Water for Florida Community
Henia Yacubowicz, Koch Membrane Systems
An RO system solved the problem of purifying brackish water.
p
The Balancing Act of DP Flow Meter Selection
Kitty Elshot & Emily Vinella, Emerson Rosemount Measurement
Choosing the right differential pressure ow meter for an application can be
challenging. This article outlines the considerations and trade-offs in selecting
the optimal technology.
p
WEFTEC Preview
Learn what to expect at North Americas largest water quality event.
SEALING TECHNOLOGIES
p
Reliable Flange Sealing
Pamela Dauphinais, A.W. Chesterton Company
Improve sealing reliability in bolted ange connections.
p
Unique Sealing Solution Solves Sulfur Leakage
Problem
Alton R. Smith, EagleBurgmann
Sulfur leakage, causing housekeeping and environmental issues in a renery,
was stopped with an innovative seal conguration.
METERING & SUBMERSIBLE PUMPS
SPECIAL SECTION
p
Non-Metallic Mag Drive PumpsGreat
Equipment for Abrasive Fluids
Travis Lee, Pulsafeeder, Inc.
Non-metallic magnetic driven gear pump technology improves equipment life
and maintenance costs for metering and transfer applications.
p
Peristaltic Pump Facts
Todd Loudin, Larox Flowsys
The peristaltic pump explainedfrom advancements to maintenance.
p
Escape to Alcatraz
Bill Nestor
A low-pressure wastewater disposal alternative offers a cost-saving
installation solution for wastewater and raw sewage disposal.
Table of Contents
29
32
38
40
46
50
58
60
66
70
78
82
PRACTICE & OPERATIONS
p
Reclaiming the Gold
Mike Dwyer, Quadna
Investment in mine expands production capabilities.
p
When Maintenance Becomes Emergency
Donald Spencer, P.E., HydroAire, Inc.
In this case study, routine maintenance of a condensate pump at a nuclear
power plant becomes an emergency situation.
DEPARTMENTS
Readers Respond. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Joe Evans, Ph.D.
AC Power (Part Four): Transformers
Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 24
Dr. Lev Nelik, P.E., APICS, President, Pumping Machinery, LLC
Chris Staud, Engineering, Wastewater Group, Atlanta, Ga.
Wastewater Treatment Industry: Present Challenges and
Future Horizons
Business of the Business . . . . . . . . . . . . . . . . . . . . . 26
Jen Yao, Frost & Sullivan
Electric Motors: Driving to Higher Efciency
Maintenance Minders. . . . . . . . . . . . . . . . . . . . . . . . . 86
Preston Walker, Jr., Caliber Pump Repair
Understanding the Basics of Pump Repair
Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Greg Kriebel
Primer on Polymer Handling
HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Centrifugal pumps: how do they handle slurries, and what is
their maximum allowable working pressure?
FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 96
What is the Sealing System Energy Footprint for Controlling
Process or Barrier Fluid Temperature?
Product Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . 107
P&S Stats and Interesting Facts. . . . . . . . . . . . . . . .112
September 2010
Volume 18 Number 9
The Magazine for Pump Users Worldwide September 2010
pump-zone.com
The Magazine for Pump Users Worldwide
pump-zone.com
September 2010
100
102
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MICRO-TEC
II ISO-GARD
GUARDIAN
tot
P
1
= Power input
= Density of the medium
g = Gravitational acceleration
tot
= Total e ciency of the unit
Formula 2. Power requirement of a centrifugal pump
Also, in Formula 5, if p is used without a g, the result-
ing units would be weight per unit volume for friction loss, and
you wondered if g were a missing factor in the numerator of
Formula 5. he friction loss here is given as pressure p. Anyway,
even here a mistake came in. Below, you will nd the correct
formula, where I have added the metric units in brackets (see
Formula 5 below).
You are absolutely right regarding Formula 6. he correct
formula is of course:
H
tot
=
p
a
- p
e
g
+ (z
a
- z
e
) + H
v
(Q) +
v
a
2
- v
e
2
2g
p
a
- p
e
= Pressure dierence between suction and discharge tank
z
a
- z
e
= H
geo
= geodetic height
H
v
(Q) = Pressure loss in dependancy of ow rate
v
a
, v
e
= Pipe length
Formula 6. Head of the plant
I am somewhat surprised that so many mistakes came into
our article. It says to me that we have to improve our quality
management for such documents throughout the whole pro-
cess. Finally, I want to apologize for any trouble that may have
been caused by this incorrectness.
Once again, thank you for your feedback.
p
v
[
Pa =
N
m
2
=
kg m
s
2
m
2
=
kg
s
2
m
]
=
U [m] L [m]
4A [m
2
]
[
kg
m
3 ]
= v
2
[
(
m
s
)
2
=
m
2
s
2 ]
2
[]
p
v
= Friction loss
A = Passed cross section area
U = Circumference related to A
L = Pipe length
= Density of uid
v = Average ow velocity
= Friction factor
Formula 5. Friction loss in straight pipes
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8 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Readers Respond
Suction-Side System Design, March 2010
he Relative Resistance of Materials to Cavitation
Damage chart shows two aluminum alloys. Can these be
dened?
Excellent magazine.
Alexander Kargilis, PE
ALKAR Engineering Company
Terry Henshaw responds:
Stepano (Note 1 from the article) places aluminum
between bronze and steel. Yedidiah (Note 5) places aluminum
and certain alloys below plastics. I dont know which is correct
or why the apparent discrepancy. I would put more faith in the
Stepano report.
Vertical Turbine Pump
Reliability, March 2010
I read your interesting VT Pump
Reliability article in the March P&S.
I am curious if Item 13 in Figure 2
could possibly be a lan-
tern ring. If so, maybe
there was a ush con-
nection at the box that
wasnt being used.
Lee Ruiz
Oceanside, CA
Lev Nelik resonds:
Very observant and true. he ush
indeed was disconnected. Otherwise,
it would (at least) provide an expan-
sion outlet for the vapors being formed
(water boiling) to expand and not create
a pressure cooker eect.
Responding to other
readers, April 2010
My eye was caught by the graphic
accompanying Jim Elseys letter in the
Readers Respond section, April 2010.
His point was in reference to the posi-
tioning of an eccentric reducer at the
suction inlet of a pump. His conten-
tion is that the at side of the eccentric
Lee Ruiz
714-893-8529
www.bluwhite.com
[email protected]
fax: 714.894.9492
5300 Business Drive
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PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 9
reducer should be on top only if the suction source is below the
pump and that the at side should be on the bottom if the suc-
tion source is above the pump.
Mr. Elsey is absolutely correct if the pump in question is a
horizontal, end suction design, and if we ignore the fact that the
elbow should be 5 to 10 diameters away from the pump suction
in any well-designed piping system.
However, when you relate his state-
ment to the diagram accompanying the
letter and the fact that it identies a
double suction pump, the positioning of
the eccentric reducer has very little eect
on the ow pattern to the impeller eye
in the pump. he ow patterns within
the casing design in such a pump can
accommodate any disruption that may
be caused by either arrangement.
A more frequent and expen-
sive problem of pump suction piping
arrangements with a double suction
design occurs when the elbow approach-
ing the pump suction is on a parallel
plane with the pump shaft. When the
pump is horizontal and the suction
piping leading to the pump is also in
a horizontal plane and turns through a
horizontal elbow into the pump suction,
then the trouble starts. Under such con-
ditions, seal or bearing failure will occur
with alarming regularity owing to the
hydraulic imbalance created within the pump.
Ross Mackay
Consultant in Pump Reliability
Author of he Practical Pumping
Handbook
Creator of he Mackay Pump School
P&S
Ross Mackay
Dont Forget
to Enter Your
Product
Deadline for Submissions
October 1
www.pump-zone.com
Answers.
3126
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800-323-4340 ColeParmer.com/8036
Think Cole-Parmer
Unique products combined with
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10 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
P&S News
PEOPLE
CRANE PUMPS & SYSTEMS (PIQUA,
OHIO) adds key sales personnel to support
growth in the plumbing, pressure sewer,
HVAC and municipal markets. Graham
Hackett is the new regional sales manager
for the Western Region, Plumbing. He
will develope and manage wholesale repre-
sentatives and distribution channels in the
plumbing market. Nathan Kimball is the
new regional sales manager for the West-
ern Region, HVAC and Industrial. Nathan
will be growing Crane Pumps & Systems
presence in the region. John Lazinski is the
new regional sales manager for the South-
east Region, Municipal and Pressure Sewer.
He will be growing municipal sales and
supporting pressure sewer projects in the
region.
Crane Pumps & Systems is a manu-
facturer of pumps, accessories and services,
providing solutions for pressure sewer,
municipal, plumbing, HVAC, industrial,
military and dewatering markets.
www.cranepumps.com
ITT WATER & WASTEWATER U.S.A.
(CHARLOTTE, N.C.) announces that Chris
Ambrose has joined the company as the new
director of marketing and business develop-
ment. Ambrose was most recently the vice
president of sales and marketing for John
Zinc Company managing the sales and mar-
keting of engineered combustion products
throughout the Americas. Ambrose received his Bachelor of
Science Chemistry degree from Florida Atlantic University.
ITT is an engineering and manufacturing company in
water and uids management, global defenses, and motion
and ow control. www.itt.com
HINES INDUSTRIES (ANN ARBOR, MICH.)
names Matthew Pohl as general manager of
sales and marketing. Pohl will be respon-
sible for all sales and marketing initiatives,
expanding the industrial, high-perfor-
mance, and aftermarket business units in
North America and abroad.
Hines Industries provides balancing
solutions to pump manufacturers, pump rebuilders and rotat-
ing equipment professionals through a wide variety of standard
machines and custom equipment. www.hinesindustries.com
COLFAX CORPORATION (RICHMOND, VA.) announces
that William E. Roller has been promoted to executive vice
president of Colfax Americas. He was most recently senior
vice president and general manager of
Colfax Americas. In his expanded role, he
is responsible for the companys operations
in the Americas, as well as its global oil &
gas and Colfax Defense Solutions organi-
zations. His duties also include expanding
the two-screw pump business and driving
global sourcing.
Colfax Corporation produces uid-handling products
and technologies. hrough its subsidiaries, Colfax manufac-
tures positive displacement industrial pumps and valves used
in oil & gas, power generation, commercial marine, defense
and general industrial markets. www.colfaxcorp.com
DANFOSS (NORDBORG, DENMARK) announces that its
VLT division has appointed Frank Taaning-
Grundholm as Global Pump OEM business
manager.
In this position, Taaning-Grundholm
will be responsible for sales to all interna-
tional and major regional pump original
equipment manufacturers (OEMs), includ-
ing business development, marketing, prod-
uct portfolio and application support.
Danfoss is a manufacturer of electronic and mechani-
cal components and controls for air-conditioning, heating,
refrigeration and motion systems. www.danfoss.us
AROUND THE INDUSTRY
KSB GROUP (FRANKENTHAL, GERMANY) acquired Stan-
dard Alloys Inc., based in Port Arthur, Texas, on July 29,
2010. Standard Alloys Inc. specializes in spare parts man-
agement for pumps and compressors. Standard Alloys brings
experience in Rapid Cast Technology (RCT) and engineer-
ing expertise in pump hydraulics to KSB Group. KSB will
use this experience and applied technology to bring a greater
level of service and satisfaction to its customers.
Standard
Alloys has two
locations with
a total employ-
ment of 90
people. he
main facility
located in Port
Arthur, Texas,
houses engineering, administration and foundry activities.
Component machining, pump repair, and assembly take
place in the Vidor, Texas, location.
KSB is a manufacturer of pumps, valves and related
systems for industrial applications and building services, for
water and wastewater management and for the energy and
mining sectors. www.ksb.com
Graham Hackett
William E. Roller
Frank Taaning-
Grundholm
Chris Ambrose
Matthew Pohl
John Lazinski
Nathan Kimball
THE ORIGINAL
BEARING ISOLATOR
STRONGER THAN EVER
www.inpro-seal.com
As part of Waukesha Bearings and Dover Corporation, Inpro/Seal is
stronger than everwith the horsepower to deliver our high-performing solutions
and superior customer service around the globe. Industry-leading bearing protection,
unmatched experience and same-day shipments only with Inpro/Seal.
So dont lay awake at nighttrust Inpro/Seal to design and deliver your custom-engineered
bearing isolator, right when you need it; our installed base of over 4,000,000 speaks for itself.
Trust Inpro/Seal, the clear leader in bearing isolators.
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12 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
P&S News
PUMPTECH, INC., (BELLEVUE, WASH.) has been appointed
the Grundfos Master Distributor for its Grundfos/Aldos line
of chemical dosing pumps in the Pacic Northwest. he prod-
uct line includes the DDI and DME digital dosing pumps as
well as the DM and DMH series of diaphragm dosing pumps.
PumpTech has invested $100,000 in inventory to service the
states of Washington and Oregon.
PumpTech is a distributor and manufacturer of packaged
pumping systems for the municipal and industrial sectors.
www.pumptechnw.com
TENCARVA MACHINERY COMPANY (GREENSBORO, N.C.)
announces the acquisition of the assets and operations of
Greensboro-based Electric Service and Sales Company Inc.
(ESSCO), a division of Enerphase Industrial Solutions Inc., as
of May 28, 2010.
ESSCO is a distributor for Toshiba motors and drives,
Marathon motors, and ABB drives and controls. he assets of
ESSCO were acquired from Enerphase Industrial Solutions,
Inc., of which ESSCO was a division.
Tencarva Machinery Company is a distributor specializ-
ing in liquid process, compressed air, vacuum equipment and
custom-designed systems for the industrial and municipal mar-
ketplace. www.tencarva.com.
GRAPHITE METALLIZING CORP. (YONKERS, N.Y.) announced
that NSF Internationalan independent, not-for-prot/non-
governmental organization that provides mate-
rials evaluation, standards testing and product
certication services involving public health and
safety issueshas just certied two grades of
GRAPHALLOY material for use in municipal
well pumps and water treatment plant applica-
tions. he two newly certied GRAPHALLOY
Grades are certied to NSF/ANSI Standard
6Drinking Water System Components
Health Eects and approved in the category
for Multiple Water Contact Materials (MLTPL)
up to 180 deg F. hese newly certied grades are
used in the manufacture of pump bushings and
bearings for both vertical and horizontal pumps.
Graphite Metallizing Corporation produces
GRAPHALLOY, a graphite/metal alloy bearing
material used in the manufacture of self-lubricat-
ing bearings and components for pumps, machin-
ery and process systems. www.graphalloy.com
VARNA PRODUCTS (CAMERON PARK, CALIF.) announced
the release of Calculating the Value of Prelube spreadsheet &
ANDROID phone application. his application can be used to
Your process needs.
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Bigger doesnt necessarily mean better. You may think were small, but EagleBurgmann
has been producing products of uncompromising quality, durability and reliability for more than
120 years. Weve got the engineering expertise and the know-how to meet your toughest sealing
challenge, no matter what the size. Our 5,200 employees worldwide remain strong in their
customer commitment to ensure you can always rely on EagleBurgmann for your seal and service
needs. To nd out more, visit www.EagleBurgmannSeals.com or 1-800-303-7735.
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14 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
P&S News
calculate the savings and value of prelube for your industrial/
marine application.
VARNA produces solutions for prelube, soakback, transfer
and many other applications in industrial/marine oil & fuel
pumps & turnkey control.
VARNA Products is the production arm of Transportation
Research Corporation specializing in custom uid control solu-
tions for diesel engine systems. www.varnaproducts.com
EAGLEBURGMANN (HOUSTON, TEXAS) has become one of
four Fraunhofer institutes and seven other partners to receive
the Stifterverband Award. he award, one of German industrys
joint initiatives for supporting research and higher education,
was presented to EagleBurgmann as one of the partners in the
alliance that developed DiaCer, a new diamond-ceramic com-
posite material for applications under extreme conditions in
industrial environments.
EagleBurgmann manufactures mechanical seals, systems,
packing and expansion joints. www.eagleburgmann.com
JWC ENVIRONMENTAL (COSTA MESA, CALIF.) announced
that Big Fish Environmental is using its products in a unique
and e cient septage receiving and treatment plant design. he
products being used are the Honey Monster septage receiving
system, the Mu n Monster grinder and the Auger Monster
screen. Part of Big Fishs development process is achieving EPA
Environmental Technology Verication (ETV) which is now
in the nal approval stages. Biosolids produced at some plants
are approved by the State of Michigan as EQ Class A reusable
biosolids and are being distributed over agricultural elds.
JWC Environmental produces a family of wastewater,
stormwater and sewage treatment products. JWC Environmental
distributes its products through a global network of indepen-
dent representatives and distributors. www.jwce.com
IDEX CORPORATION (NORTHBROOK, ILL.) announced
the acquisition of OBL, S.r.l. A provider of mechanical and
hydraulic diaphragm pumps, OBL provides polymer blending
systems and related accessories for a diverse range of industries,
including water, wastewater, oil and gas, petrochemical and
power generation markets. Headquartered in Milan, Italy, with
annual revenues of approximately 8.5 million, OBL will oper-
ate within IDEXs Fluid and Metering Technologies segment as
part of the water and waste water group of companies.
IDEX Corporation is an applied solutions company spe-
cializing in uid and metering technologies; health and science
technologies; dispensing equipment; and re, safety and other
diversied products built to its customers specications.
www.idexcorp.com.
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16 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
P&S News
UPCOMING EVENTS
PUMPTEC
September 20 21
Holiday Inn Select / Norcross, Ga.
Presented by Pumping Machinery, LLC
770-310-0866 /
www.pumpingmachinery.com
SPE ANNUAL TECH CONFERENCE
September 20 22
Fortezza da Basso / Florence, Italy
Presented by Society of Petroleum Engineers
+39-055-33611 / www.spe.org/atce/2010
CADWORX UNIVERSITY
September 27 29
Woodlands Waterway Marriott Hotel /
Houston, Texas
Presented by COADE
www.cadworxuniversity.com
WEFTEC
October 2 6
Ernest N. Morial Convention Center /
New Orleans, La.
Presented by the Water Environment
Federation
877-933-4734 / www.weftec.org
TURBOMACHINERY SYMPOSIUM
October 5 7
George R. Brown Convention Center /
Houston, Texas
Presented by the Texas A&M
Turbomachinery Lab
979-845-7417 / turbolab.tamu.edu
SMRP CONFERENCE
October 18 21
Midwest Airlines Center / Milwaukee, Wisc.
Presented by the Society for Maintenance
and Reliability Professionals
703-245-8011 / www.smrp.org
FSA FALL MEETING
October 19 21
Austin, Texas
Presented by the Fluid Sealing Association
610-971-4850 / www.uidsealing.com
CERTIFIED OPC PROFESSIONAL
TRAINING
Level 1: OPC & DCOM Diagnostics
October 19 20
Level 2: OPC Security October 21 22
Level 3: OPC Unied Architecture
October 25 26
Level 4: OPC Integration Projects
October 27 28
ExecuTrain Houston / Houston, Texas
780-784-4444 / www.opcti.com
PACK EXPO
October 31 November 3
McCormick Place / Chicago, Ill.
Presented by the Packaging Manufacturers
Machinery Institute
703-243-8555 / www.packexpo.com
INFRAMATION
November 8 12
Ballys Hotel / Las Vegas, Nev.
Presented by FLIR Systems, Inc.
866-872-4647 / www.inframation.org
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18 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Pump Ed 101
L
ast month, we studied the properties and eects of
resistive, inductive and capacitive loads in an AC cir-
cuit. his month, we will take self induction a step
further and apply it to that simple machine that is at the
heart of AC powerthe transformer.
As I mentioned in Part One, (Pumps & Systems, June
2010) a unique quality of AC power is that its voltage can
be changed easily and in either directionup or down.
his allows us to generate power at some voltage and step
it up to a higher voltage for long distance transmission. his
decreases losses due to heat and signicantly reduces the wire
size. Once it reaches its point of use, voltage can be reduced
to a useable intensity. he key element in this process is the
transformer, and the key to its operation is a phenomenon
known as mutual induction.
Mutual Induction
If two coils of wire are placed near each other (see Figure 1),
an alternating current owing in one will create a magnetic
eld that induces a voltage and current in the one nearby,
even though they are not in direct contact. his occurs
because the lines of ux associated with the magnetic eld
extend well beyond the coil that created them. his property
is called mutual inductance or mutual induction, and it is the
basis of the transformer. he transformer gets its name from
the process of transforming electrical energy into magnetic
energy and then back to electrical energy. he coil that pro-
duces the magnetic eld is called the primary (input) and the
coil that intercepts that eld is called the secondary (output).
Although some transformers consist of coils separated by
an air gap, most use insulated wire wound about a laminated
iron core (see Figure 2). he iron core increases transformer
e ciency by directing nearly all the ux produced by the
primary through the secondary coil. he laminations reduce
eddy current losses that would be much higher in a solid
core design. Depending on the design and capacity, trans-
former e ciency can range from 20 to 99 percent. Larger
onesfor example those designed for power distribution
Joe Evans, Ph.D.
AC Power (Part Four):
Transformers
Figure 2 Figure 3
Figure 1
Last of four parts
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 19
applicationsoperate at 98 percent or better. Another impor-
tant property of the transformer is electrical isolation. Since
the primary and secondary coils are not in contact, the power
source is isolated from the point of use.
Voltage, Current and the Turns Ratio
According to Faradays law, voltage produced in the secondary
of a transformer depends on the voltage
in the primary and the number of turns
(loops) in the primary and secondary
coils. his may sound a little compli-
cated, but this relationship can be simply
stated with something called the turns
to voltage ratio. he equation below
where V is voltage, N is the number of
turns, p is the primary and s is the sec-
ondaryexplains this relationship:
Vs = (Ns / Np) x Vp
Secondary voltage is directly pro-
portional to the product of the turns
ratio and primary voltage. If Ns is greater
than Np, then the voltage in the second-
ary coil is greater than that of the pri-
mary coil, and the transformer is called
a step-up transformer. If the opposite is
true, we have a step-down transformer.
For example, suppose a transformer has
a primary with 1,000 turns and a sec-
ondary with 100 turns. Based on the
equation above, the turns ratio is 1/10
or 0.1. If the voltage feeding the primary
is 1,200 V then the secondary voltage
will be 120 V.
However, what about current? How
do we calculate its change? he trans-
former is an intelligent machine because
it automatically adjusts the current to
keep power (in watts) constant. A slight
modication of the original equation
explains this relationship:
Is = (Np / Ns) x Ip
In the equation above, current (I)
replaces voltage and the turns ratio is
reversed. When fewer turns are in the
secondary, a transformer steps down
voltage, but it increases current and,
therefore, keeps power constant. In
the case of our step-down transformer
example above, if the primary is fed
by 1,200 V at 1 A, then the secondary
would provide 120 V at 10 A. Both volt/amp combinations
provide 1,200 W of power.
Winding Congurations
Transformers allow an extremely exible secondary output and
are not limited to a single secondary winding. Figure 3 shows
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20 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
an example of a typical power supply transformer. he primary is fed
by 110 V and induces three individual secondary coils providing 5 V,
6.3 V and 700 V. he 700-V coil shows another feature of the trans-
former. A tap placed at the center of the coil provides two 350-V
outputs in addition to its full voltage output. Multiple taps may also
be placed within a single coil.
Three Phase Transformers
Transformers used in three-phase appli-
cations can consist of three, single-phase
transformers or a single transformer
wound in a manner that accommo-
dates all three phases. he primary and
secondary windings of the three-phase
transformer are congured in two basic
patternsDelta and Wye. he primary
and secondary can be any combination
of the two (such as Wye/Delta, Delta/
Wye, Delta/Delta and Wye/Wye).
his article will examine the Delta and
Wye secondary characteristics only.
Additional resources are provided at the
end of the article if you are interested in
pursuing the eect of a particular pri-
mary on a secondary.
Figure 4 is the schematic of a Delta
secondary that produces three individ-
ual-phase voltages of 120 V. he Delta
gets its name from the Greek letter that
has a similar appearance. You might
think that such a conguration would
short circuit since they are connected in
series. However, note the angle associ-
ated with each phase starting at the top
and proceeding counter clockwise. If you
refer to the three-phase power curve in
Figure 3 of Part Two (Pumps & Systems,
July 2010), you will see that the volt-
ages cancel one another and no current
ows through the circuit. If, however, a
load is connected across any two of the
three lines, a current will ow and the
line-to-line voltage will be the sum of the
phase voltages, which equals 240 V.
Figure 5 is the schematic of a WYE
secondary that also produces three indi-
vidual-phase voltages of 120 V. It gets its
name from its resemblance to the letter
Y and is sometimes called a star. At the
junction of the three phases, a separate
connection, known as a neutral is usu-
ally supplied. A load connected between
the neutral and any of the three lines
Pump Ed 101
Figure 4
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22 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Pump Ed 101
will see a voltage of 120 V. When a load is connected across any two
of the three lines, the voltage will not be the sum of the two phases.
Instead, it will be approximately 208 V. he reason this occurs is due to
the phase angle and the way the coils are connected. Although we will
not show one here, a phasor diagram would illustrate that the voltage
vector created by any two WYE phases produces a voltage that is only
1.732 of the phase voltage. If you are interested in viewing WYE and
Delta phasors, check out he Changing
Voltage Puzzler on my website.
Based on the line-to-line voltage, it
would appear that the WYE transformer
is less e cient than the Delta. However,
an interesting event occurs within the
Delta conguration. A phasor diagram
would show that the line-to-line cur-
rent is only 1.732 of the phase current.
herefore, the relationship below will
hold true for any circuit regardless of
whether it is Delta and WYE connected:
Power (watts) =
volts x amps x 1.732 x power factor
I hope that this brief introduction
to AC power has been useful. A lot more
is involved, so below are several websites
that you can visit for more information.
In the future, I plan to write a similar
series on AC motors.
P&S
Resources
All About Circuits: www.allaboutcircuits.com/
vol_2/index.html
Integrated Publishing EE Training Series:
www.tpub.com/content/neets/
Electronics Tutorials:
www.electronics-tutorials.ws/index.html
Siemens:
www3.sea.siemens.com/step/templates/lesson.
mason?bep:2:1:1
Electricians Toolbox: www.elec-toolbox.com
RLC Circuits Java Applet:
www.walter-fendt.de/ph14e/accircuit.htm
Joe Evans is responsible for cus-
tomer and employee education
at PumpTech, Inc., a pumps and
packaged systems manufacturer and
distributor with branches through-
out the Pacic 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.
Figure 5
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All About Water
SPECIAL SECTION CONTENTS
Predictable Pump Motor Maintenance at a Cranberry Bog . . . . . . 29
Cellular Communications for SCADA Applications. . . . . . . . . . . . . 32
Technology Saves Valuable Equipment. . . . . . . . . . . . . . . . . . . . . . 38
Considerations for Choosing a Flow Meter . . . . . . . . . . . . . . . . . . 40
Clean Water for Florida Community . . . . . . . . . . . . . . . . . . . . . . . . 46
The Balancing Act of DP Flow Meter Selection . . . . . . . . . . . . . . . 50
WEFTEC Preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 29
W
hen a pump or motor fails at Sea Wind Cranberry
Farm in Langlois, Ore., farm manager Knute
Anderssons business is at stake. An equipment
malfunction could allow the farms cranberry elds to cool just
a couple degrees, and on a cold night, that can mean losing part
of the crop. For modern cranberry farmers, properly function-
ing pumps, motors and sprinklers help ensure that their berry
yield will be high. Without them, the berries are at the mercy
of hostile climates that can cause crop-killing frost or destruc-
tive heat.
Because of the fragile nature of the cranberry crop,
Andersson needs an on-call electrician who can provide emer-
gency repair service eectively and e ciently enough to save
the berries, sometimes in the middle of the night. Even more
important, Andersson needs an electrician who can ensure
through eective predictive maintenance that many of these
emergencies do not happen at all. Anderssons electrician is
Joe Buchanan, project lead man and safety chairman at Kyle
Electric, North Bend, Ore. Buchanan has been in the electric
business 33 years; since I was a pup, he says. hroughout that
career, he has made safety and customer satisfaction his per-
sonal mantra.
Buchanan helps keep his customers happy by maintain-
ing and repairing their equipment before it fails. Buchanan has
worked with Andersson on the maintenance of the cranberry
farms pump system for about six years.
Berry Particular
Andersson has 11 pump houses, each with between two and ve
pumps and just as many motors for those pumps. he motors
range from 10 to 100 hp. All the elds have temperature sen-
sors that relay back to the pump houses. If the temperature goes
up or down too far, the pumps come on to start the sprinklers,
which then use water to adjust the air temperature in the bogs.
he equipment maintains the proper temperature of the
elds 24 hours a day, 10 months each year. he cranberry vines
must stay within two or three deg of their ideal temperature,
otherwise the crop is damaged and the yield is reduced.
If they get frosted, they freeze. hats a throw away,
Andersson says. If it gets too hot, it will cook them, and they
will rot on the vine. Yield is all about temperature control.
While high temperatures are less common in temperate,
coastal Oregon, often the air and water on early spring nights
can dip dangerously low. If a motor fails then, when the ambi-
ent temperature is too high or low, Andersson could lose part or
all of an entire eld before the pump is up and working again.
Since he started managing the farm in 1991, Andersson
Predictable Pump
Motor Maintenance at a
Cranberry Bog
Chris Rayburn, Fluke Corporation
Due to the delicate nature of the cranberry, pump failure is not an option.
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PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 31
has worked on his pump and motor system to maintain the nec-
essary temperature for the berries in his elds. Buchanan began
helping him six years ago when he installed the farms most
recent pump house and its four 100-hp motors and pumps at
a price of more than $100,000. Each pump can move as much
as 1,500 gal of water per min to provide frost protection, irriga-
tion, weed control and ooding of the bogs at harvest time or
when otherwise necessary.
Water, Water, Everywhere
Mother Nature not only provides haz-
ards for the berries, it can also cause
abuse to the equipment. Buchanan must
be mindful of those hazards during
maintenance of the farms 27 motors.
he salt air eats through insulation,
and the constant presence of water
slowly corrodes the motors and relays.
Windings fail faster. here is corro-
sion and insulation degradation ahead
of schedule, Buchanan says. However,
equipment failure is not an option.
Buchanan has worked to eliminate
failure by implementing a predictive
maintenance plan. Each winter, he visits
the farm for an annual inspection of
motors, controls and pumps and checks
for loosened terminals and connections
and any damage from moisture or age.
On each predictive call, Buchanan
looks for changes in readings, and he
checks the insulation and lining around
each motor. We want to prevent criti-
cal shut down, he says. To do this, he
compares all his readings against those
he measured at the same time the pre-
vious year. He also tests for any power
dips, looks for any damage to the insu-
lation or the lining of the motor, and
ensures that no feedback or deteriora-
tion is present.
Weve gone through it all, and
it is now pretty much trouble free,
Andersson says. If a problem occurs
in any of his pump houses, most com-
monly, starters burn up or a relay fails.
The Bottom Line
Safety is Buchanans top priority, and he
says that the right tools can make a dif-
ference. Use quality tools and be a good
craftsman. hese tips not only ensure
safety but keep customers coming back,
Buchanan says.
P&S
Marketing Manager for clamp meter, earth ground, and
insulation test products, Chris Rayburn has an extensive
background in aerospace with a masters of science in aero-
nautics and astronautics from the University of Washington
and an MBA from the same school. Prior to Fluke, Chris
worked for Aerojet, Accenture and GE. You can contact
him at [email protected].
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32 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
All About Water
M
anagers of water/wastewater
facilities need to collect accurate
information from remote assets
such as pumps, tanks and booster stations.
Traditionally, this information is collected
manually by collecting the chart record-
ings. his might be done monthly, weekly
or daily, depending on available sta ng.
While manual collection of this data
is the norm, plants want to move to an
automated process using a central station
for all monitoring and control, which can
reduce or eliminate the need for manual
data collection. his type of system is
called a SCADA (Supervisory Control and
Data Acquisition) system. hese advanced
networking SCADA systems can provide
all the information from remote assets at
a single location, improving the accuracy
and timeliness of the operation.
A SCADA system requires a network
with a secure communication path. Many dierent technolo-
giesincluding dial-up, DSL, leased line and private radio
can provide this communications link. In water applications,
networks must often reach areas where phone lines or tradi-
tional wiring does not exist. Conduits can be trenched and
wire can be laid, but this is often cost-prohibitive. Radio can
provide access to these remote locations without the need for
wires. When it comes to radio, there are a variety of options
available. his article examines the use of cellular technology in
SCADA applications, how it can be implemented, the dierent
networking options available and security.
Cellular Network Options
In the world of cellular communications, two network options,
voice and data, are available. Each has dierent capabilities
for SCADA applications. In this article, we will focus on the
Global System for Mobile Communication (GSM) network
for voice communications and General Packet Radio Service/
Enhanced Data Rates for GSM Evolution (GPRS/EDGE) for
data communications, but the same principles exist for other
cellular technology segments.
he general dierence between these types of networks is
that the GSM network addresses all devices on the network by
a phone number. On the GPRS/EDGE network, all devices
are addressable via an IP address, making data communications
easy.
Simple Control with the GSM Network for
SCADA applications
he GSM network connects with the Public Standard
Telephone Network (PSTN), allowing communications from
cellular devices to land-based modems using a phone number.
his is used for voice communication and Short Message
Service (SMS), also known as text messaging.
Cellular Communications
for SCADA Applications
Ira Sharp, Phoenix Contact
Effective and secure cellular communications for remote data acquisition.
Cellular modem-to-modem text message communications can be used for autonomous
tank-level control
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 33
However, in the U.S., dial-up networking, where one
modem calls another using the PSTN, is not permitted over the
cellular infrastructure. his limits the use of the GSM network
for SCADA applications in the U.S. to SMS-only. Despite this
limitation, the GSM network can be useful for simple control
applications in a SCADA system.
For these simple control applications, modems can use a
text message to take an eventsuch as
a door alarm, high- or low-level tank
alarm, or change in pump statusand
report it to a control room or another
modem for autonomous system opera-
tion. In modem-to-modem commu-
nications, when the second modem
receives a command, it provides some
action or status update. he modems
create an autonomous system that can
control some part of an event-based
process.
For example, Modem A receives a
low-level alarm message from the tank.
his modem then sends a text mes-
sage to Modem B, which turns on the
pump and lls the tank. Once the water
reaches an adequate level, Modem A
sends another message to Modem B,
requesting that the pump be turned o.
While this process occurs, the modems
also send the text message to a second
number for the control room. his pro-
vides real-time updates to the control
room SCADA system about the actions
occurring on site.
If an autonomous system is not nec-
essary, the facility can still use text mes-
saging. he modem can send informa-
tion about the processes to the control
room SCADA master, which will pro-
vide the needed logic for control. It can
also send a text message directly to the
technicians who are responsible for the
system. he technicians can then make
the necessary changes to the system.
Text messaging can be an eective way
to monitor and control simple processes.
Advanced Networking
with GPRS/EDGE for
SCADA Applications
For applications that demand more than
simple, event-based monitoring and
control, the GPRS and EDGE networks
oer additional capabilities. he GPRS
and EDGE networks can connect to a
private network or to the Internet using standard networking
protocols. Since this allows for more information exchange
from the remote assets, greater exibility is available for moni-
toring, controlling, or even programming over the cellular
infrastructure than the GSM network allows. When using the
GPRS or EDGE network for data communications, you must
decide if you will leverage a private network or use the standard
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34 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
public network.
Private networks oer a great deal of exibility. Just about
any network architecture can be realized, including host-ini-
tiated communication, and all communications do not need
to ow over the Internet. However, to create a private cellu-
lar network, you must work with a carriersuch as AT&T,
T-Mobile, Verizon, etc.to dene how your network should
be constructed. hese private networks typically charge a one-
time setup fee to create the network. his fee can range from
hundreds to more than $2,500, depending on the type of net-
work being constructed.
With this type network, you will also need to do some
network management to ensure proper network use. Private
networking can be ideal for larger cellular networks, but smaller
systems usually nd the public network
more suitable.
he public network does not require
any special congurations. Service plans
are easily accessible, and generally, no
setup fees are required. However, all
data communications will ow over the
Internet, which heightens the chance of
network security threats.
In addition, typical poll-response
networks used in SCADA systems will
not work over the public network with-
out proper preparation. he public net-
work is designed for mobile-originated
communications. In other words, the
remote device talks, and the host receives
the information. In most SCADA sys-
tems, however, the host initiates the
communication to the remote device. A
VPN (virtual private network) can over-
come both the security concerns and
the remotely initiated communication
issues.
Security with VPN
Tunneling
A VPN tunnel is one simple way to
ensure the security of the Ethernet traf-
c over the Internet. To use a VPN
tunnel, the modem must support VPN
networks. A router that supports VPN
networking must also be at the control
room.
Leveraging the VPN tunnel to
secure the communicated information
also solves other cellular issues. As men-
tioned earlier, cellular networks typically
require that the remote modem initiate
all data communications. Many indus-
trial protocols, such as MODBUS and
EtherNet/IP, however, are designed for
poll response. he SCADA master at the
control room must initiate the commu-
nications, not the remote modem.
By creating a VPN tunnel between
the remote modem and the SCADA
system, the modem will be available on
demand. his allows the SCADA master
All About Water
The MPT
family of self-
priming solids-
handling pumps
Family
Matters
Worthington
Durco
t
IDP
Industries 1957
Boerger, LLC 3243
Cole-Parmer 1644
Crane Pumps & Systems 3417
Danfoss Drives 2017
Environment One Corporation 3017
Fairbanks Morse 1035
Fluke Corporation 810
Fuji Electric 3629
Global Pump 6647
Griffco Valve, Inc. 7605
Hyundai Heavy Industries Co. Ltd. 6113
ITT Corporation 5025
Iwaki America 6657
KSB, Inc. 2351
Larox Flowsys, Inc. 7857
LobePro Rotary Lobe Pumps 5757
Lutz-JESCO America 5414
Meltric Corporation 1843
Mercoid Division, Dwyer Instruments Inc. 6531
Moyno, Inc. 5739
MTH Pumps 4750
Company Name Booth Number
Myers 1035
National Pump Company 2951
Neptune PSG 2538
Orival, Inc. 7017
PeriFlo, Inc. 6555
Proco Products 5939
ProMinent Fluid Controls 5531
Racine Federated Inc. 1634
Revere Control Systems 2401
Rockwell Automation 2409
Salem Republic Rubber Company 7227
seepex 3043
Shanley Pump 2963
ShinMaywa
1245
SJE Rhombus 5119
Swaby Manufacturing Co. 5421
SWPA 5353
TECO-Westinghouse 2571
Valve & Filter Corp 1654
Vaughan Company, Inc. 2613
Verder GPM 5428
VibrAlign, Inc. 2582
WAGO 1638
Weir SP 4828
WILO USA LLC 1015
Yaskawa America, Inc. 7125
Zoeller Company 2041
Perferred Booths
60 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Sealing Technologies
T
ypical operating environments create unique chal-
lenges for plant maintenance personnel when
meeting their goals of reliably sealing bolted ange
connections.
Many factors can prove detrimental to the performance
of a gasket used to seal angesincluding ange alignment
and ange imperfections, vibration, pressure and tempera-
ture surges, chemical attack, gasket creep, changes in clamp-
ing force and improper gasket loading. An understanding
of bolted ange connections is critical to ensure optimum
gasket performance and improve ange sealing reliability.
Bolted Flange Connections
A ange is a method of connecting pipes, valves, pumps and
other equipment to form a system. A bolted anged con-
nection versus a welded connection provides easy access for
cleaning, inspection and modication of a piping system.
Flange joints are made by bolting two anges together with a
gasket between them to form a seal.
Many types of bolted ange connections have been
designed for dierent equipmentincluding ANSI/DIN
pipe anges, valve bonnets, site gages, manways, handholes
and heat exchangers. An ideal anged joint would consist of
two, mirror-nish, perfectly at and parallel surfaces bolted
directly together to create a leak-free seal. However, manu-
facturing processes do not allow for perfect sealing surfaces.
Most ange faces have surface irregularities that cannot be
sealed without the use of some type of compressible, resil-
ient material or a combination of materials between them
to seal the uid being transferred. herefore, a gasket is
used between these surfaces to compensate for real world
conditions.
he ange faces are the eective sealing areas of the
ange. A gasket is placed between the ange faces, and they
are mated together when the ange is bolted and the gasket
is compressed between them.
Bolted ange joint leaks have been a cause for concern
across all industriesincluding chemical, hydrocarbon pro-
cessing, power and pulp and paper. While advancements
have been madesuch as gasket design, materials and bolt-
ingthe high-temperature, high-pressure applications con-
tinue to create a sealing challenge.
Flange leakage can be gradual, sudden or drastic. Visible
ange leakage is recognizable and leads to costs associated
with loss of uid. In addition, uid leakage can result in
environmental and safety concerns. Even though individual
ange leaks may not be considered to have large leakages, so
many anges are used throughout a plant that they do con-
tribute to overall leakage. An average plant may have from
3,000 to 30,000 anged components to be monitored, and
large facilities may have more than 100,000 components,
with dierent standards applied for monitoring and compli-
ance with environmental regulations.
In some industries, non-visible leakage can also be a
concern such as fugitive emissions from Volatile Organic
Compounds (VOCs) and Volatile Hazardous Air Pollutants
(VHAPS). Leak Detection and Repair (LDAR) is a program
implemented to comply with environmental regulations for
reducing the leakage of targeted uids into the environment.
Process components subject to LDAR are often monitored
to detect VOC and VHAP leaks, which are required to
be repaired within a predened time period. Enforcement
Consent Decrees and LDAR monitoring programs can result
in signicant nes for non-compliance.
Proper Selection and Techniques
Some important items to consider in ange sealing are
selecting the right gasket and applying the correct load.
Selecting the Proper Gasket
To ensure that an application is sealed properly, the rst step
is to choose the right gasket.
When selecting a gasket there are many factors to con-
sider including:
Chemical compatibility
Temperature resistance
Pressure capability
Compressibility
Recovery
Reliable Flange Sealing
Pamela Dauphinais, A.W. Chesterton Company
Improve sealing reliability in bolted ange connections.
hickness
Temperature cycling
Flange condition
Flange vibration
Larox Flowsys has been providing
innovative ow solutions to the process
industry for the past 30+ years.
High Performance PVE valves are constructed in
a manner to create the longest sleeve lifetime in a
slurry valve. The valve closing mechanisms close the valve from two sides squeez-
ing the sleeve closed on the valve centerline.
The ow through the valve is directed to center causing the least amount of wear
in the valve and pipeline
very low stress is placed on the sleeve during closing creating a rubber sleeve
that can be open and closed millions of cycles without damaging the rubber sleeve
ual closure allows for shorter face-to-face for lined slurry valves
No Jauuing or Clogging, 100% full port and no pockets of cavities for uaterial
accumulation
Larox PVEG offer Larox quality durability and abrasion resistance for an extremely
affordable price.
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offer the most radical cost savings
coupared to other types of peristaltic,
progressive cavity and centrifugal
pumps. The LPP peristaltic pump is a perfect solution for pumping
slurries, viscous, or aggressive uedia.
The LFF puup incorporates a unique rolling design which eliuinates
friction, uiniuites hose wear, and lowers energy consuuption
Single, bearing-uounted roller presses against the hose only once per
30 degree operating cycle and produces unprecedented hose life
Fuup hose is the only part in contact with the uediuu.
The LFF fauily of puups can run continuously at high speeds without
heating or causing damage to the pump hose or bearings
The annual operating cost savings frou using the Larox LFF coupared to
other peristaltic or progressive cavity pumps is often enough to recoup the
cost of the pump investment in the first year of operation.
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0 - 33 0Fh flow capability with nuuerous flow capabilities
has LE display and touchpad for local operation
Larox Flowsys heavy duty slurry knife gates are the uost abrasion resistant and
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and bottou ash. 1"-0" with all actuator types.
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62 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Sealing Technologies
hese factors are all related. Many times, a change in one
parameter can aect, another so all need to be considered to
determine the best gasket for the application.
Proper Bolting Techniques
Proper bolting practices ensure that the gasket gets the proper
sealing stress. he primary factors aecting gasket loading from
bolting are:
hread Frictionlubrication of bolts is necessary to reduce
excess thread friction and maintain a consistent coe cient of
friction during assembly. Proper lubrication of all thread con-
tact areas, nut faces and washers with an anti-seize lubricant will
help ensure that the torque applied to the ange bolts yields as
accurate and consistent a gasket stress as possible.
Bolting Sequenceproper bolting
sequences must be followed to ensure
even loading of the gasket.
Tightening Methodthe installation
and torquing procedures are important
to the reliability and operational safety
of anges. Assuring that a correct seal-
ing force is applied and maintained will
help avoid problems with anges. Use of
a torque wrench, hydraulic tensioning
equipment or stretch control to apply
the recommended sealing force is critical
to establish bolt loads and gasket seating
stress above the minimum required to
maintain a seal.
Often selecting the right gasket and
using proper bolting techniques will
be enough to ensure ange reliability.
However, some anges such as criti-
cal and problematic anges can benet
from an engineering analysis.
Engineered Flange Sealing
System
Optimizing Gasket Sealing Stress
Improving ange reliability requires an
understanding of why the bolted con-
nection failed. Critical and di cult
ange applications at a plant often need
a more detailed understanding and anal-
ysis of the anged joint. Heat exchang-
ers are often critical problematic appli-
cations due to thermal variations and
hydrostatic pressures. See Figure 1. An
engineered ange sealing system takes
into consideration proper gasket sealing
stress and optimized bolt loading.
Improper gasket load is a leading
reason for gasket failures in plants. he
ASME Boiler & Pressure Vessel Code
establishes code for ange design and
discusses m & y factors. he gasket must
conform to the ange surface and must
be compressed enough to seal any voids
and prevent leaks. his stress referred
to as the minimum gasket seating stress
(psi, MPa) is the Yield y value. he m
maintenance value is used to determine
Before
After
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PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 63
the compressive load on the gasket to maintain a seal when the
vessel is pressurized. However, these m and y values have limi-
tations and can not be used solely to ensure a leak-free anged
joint. A complete analysis of the entire assembly needs to be
completed to ensure anged joint reliability.
Too little applied stress results in excessive leakage; too
much applied stress can result in gasket creep and irrevers-
ible damage to the gasket and excessive
ange and/or bolting deformation. See
Figure 2.
Optimized Bolt Loading
Gaskets perform the sealing in anges,
but the ange bolts provide the gasket
stress necessary to achieve an eective
seal. A bolt is an elastic element. When
it is tightened, it will stretch. When the
bolt is stretched in its elastic region it will retain its memory.
As a result, when the bolt is stretched it will exert a force on
the ange and the gasket as it tries to get back to its original
length. he more you stretch it in its elastic region, the higher
the bolt force transferred to the ange. he stretch of the bolt is
limited by the yield strength. It is important that the bolt stress
is within its elastic limits. If the bolt is stressed beyond its yield
Figure 1.
Typical heat
exchanger
Figure 2. Flange
rotation as a result
of overloading.
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64 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Sealing Technologies
point, it will no longer provide the required elasticity for the
anged joint to seal reliably. See Figure 3.
A correct and constant bolt load is essential to reach and
maintain the proper compression of a gasket throughout its
service life.
he seal is aected by the action of force on the gasket
surface. Su cient stress/load must remain on the gasket surface
to prevent leakage. Hydrostatic end thrust works to open the
ange joint and reduces gasket seating stress. See Figure 4. he
bolt load force must be greater than the force created by system
pressure to maintain the seating stress on the gasket above the
minimum required to maintain a seal.
Many problem anges are subject to thermal expansion
and contraction, pressure surges and vibration. hese factors
can either decrease or increase the bolt load and gasket stress
from the initial installed values, which can lead to prema-
ture leakage and failure of bolted assemblies. Flanges can be a
dynamic component and often require a dynamic sealing solu-
tion to be properly sealed.
Maintaining Gasket Sealing Stress
An engineered ange sealing system provides a complete engi-
neered solution focused on uid compatibility, pressure and
temperature and maintaining the proper seating stress of bolted
joints through temperature cycling and mechanical distortion
due to vibration. All these dynamics are considered to recom-
mend the best ange sealing solution, and where applicable will
incorporate ange live loading engineered specically for the
ange. Upon engineering analysis Flange Live Loading often
provides the necessary increased margin of safety and reliability
for these applications when used in conjunction with the opti-
mal gasket and bolt loading.
Flange live loading uses specially designed ange discs to
Figure 3. Typical Elastic Curve for a Bolt.
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PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 65
replace washers under the bolt nuts and increases the original
bolt stretch. he typical engineered live loading system will pro-
vide approximately six to eight times the stored energy through
the use of ange discs to maintain a load on the sealing system
when compared to standard bolting. he live loading system
allows stored energy to automatically adjust to system uctua-
tions and maintain enhanced pressure on the gasket.
he use of ange live loading can help maintain proper
gasket stress through thermal cycling by storing elastic energy.
Stored elastic energy minimizes the loss of bolt stress resulting
in a longer life.
For di cult ange sealing applications, an engineered
ange sealing system will:
Maintain a uniform clamping force, improving bolted joint
sealing reliability
Compensate for thermal expansion and contraction
Absorb vibration shock
Dampen the eects of pressure surges, preventing gasket
blowouts
Provide a cost eective solution for expensive leakage and
maintenance on critical equipment
Plant personnel working together with a supplier who has
the engineering expertise, tools and resources to evaluate ange
sealing needs can properly implement an engineered ange
sealing reliability program designed to improve MTBR, lower
leakage and reduce total maintenance and operating costs.
P&S
Pamela Dauphinais is the marketing analyst, Mechanical
Packing and Gaskets, for A.W. Chesterton Company, 860
Salem Road, Groveland, MA 01834, 978-469-6448 Fax:
781-481-7030, www.chesterton.com.
Figure 4. Hydrostatic End Thrust.
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Sealing Technologies
N
o other industry has come under such intense scru-
tiny as the oil rening industry. Still, no one can deny
that processing crude oil into useful petroleum prod-
ucts such as gasoline, diesel fuel and heating oil is an impor-
tant part of the global economy. he oil rening industry has
strived to become more environmentally friendly both in its
product line and process facilities.
Liquid molten sulfur is a by-product of clean fuel produc-
tion. As environmental legislation mandates stricter controls
on rened products, oil reneries must remove more sulfur
from rened products, such as diesel fuel. he recovered sulfur
is sold to other industrial companies for use in other prod-
uctssuch as fungicides, black gunpowder, detergents and
phosphate fertilizersand for rubber vulcanization.
Leaking Liquid Sulfur
For one major U.S. renery, the sulfur recovery process created
problems in its process line. Sulfur has a high melting tempera-
ture of 250 deg F and must be constantly heated at or above
this temperature to maintain a liquid state for pipeline trans-
portation. However, molten sulfur also has an upper tempera-
ture limit of 300 deg F, at which point the viscosity increases,
and it begins to re-solidify. Trying to control this narrow tem-
perature range and maintain the molten liquid state can be
di cult. As a result, the renery experienced reliability issues
with its pumps and mechanical seals.
Immediately after installation and start-up, the pumps
mechanical seal would begin to leak. Within weeks, a large
pile of hardened sulfur formed around the pump base causing
huge housekeeping issues along with environmental disposal
problems. he plant would operate the pump for an extended
period of time, while the hardened sulfur formed around the
pump. When an opportunity arose, they would replace the seal
and clean up the sulfur. his bad-actor pump and seal congu-
ration was a never-ending problem for the renery. Not only
did the plant have to contend with continually cleaning up
the leaking sulfur, it also had to make sure that the sulfur was
disposed of in an environmentally safe manner.
In searching for a solution to its problem, the renery
tried several dierent sealing congurations, but the leaking
still occurred. Since the standard seal designs were not provid-
ing a solution, the renery looked for customized help from
a mechanical seal manufacturer. After assessing the situation,
the manufacturers team realized that the typical seal congu-
ration would not work for this application and a new approach
was needed.
The Sealing Situation
he engineers at the renery gave all the details of the applica-
tion and process conditions to the seal company. he existing
seal was a typical rotating bellows design with a carbon bush-
ing outboard of the seal faces and a steam jacket around the
bushing. However, no steam quench was being used between
the bushing and seal faces. Although a traditional steam 5-psig
quench had been employed in the past to prevent the sulfur
from accumulating and solidifying around the seal faces, the
quench line would become plugged with sulfur and tended
to accelerate the formation of solid sulfur around the pump.
Unique Sealing Solution
Solves Sulfur Leakage
Problem
Alton R. Smith, EagleBurgmann
Sulfur leakage, causing housekeeping and environmental issues
in a renery, was stopped with an innovative seal conguration.
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 67
herefore, it was eliminated. Because of the barrier uid sulfur
contamination, a double seal was not a viable option.
he sulfur temperature in the pump was at 280 deg F,
and the pump speed was 3,600 rpm. he renery engineers
and incumbent seal manufacturer theorized that the heat gen-
eration in the seal gap was signicant enough that the sulfur
migrating across the seal faces was reaching its upper solidi-
cation temperature (300 deg F). A
steam quench on the atmospheric side
of the seal faces was keeping the sulfur
at this upper temperature. Without the
quench, the solidication still occurred
but at a much lower rate.
In either case, the result was a
domino eect, said Je Batinick, a rep-
resentative of the seal company. Sulfur
leaking past the faces was accumulating
and solidifying around the atmospheric
side of the faces, causing them to hang
up, and ultimately leading to additional
and accelerated sulfur leakage.
A Non-Traditional
Approach
After examining the situation at the
renery, the seal company engineering
department was asked to nd the best
solution. he engineers recommended
a pusher seal instead of a metal bel-
lows seal to eliminate the sulfur build-
up. We looked at the application
and, although a bellows seal is the tra-
ditional approach, we knew that what
was required here was out-of-the-box
thinking, Batinick said.
his non-traditional approach
looked beyond standard product oer-
ings. Ocassionally, in mature indus-
tries such as rening, the industry
gets hooked into canned solutions to
problems, commented Batinick. We
looked at it dierently.
he pusher seal is a slurry seal
design. It features a sti, single-coil,
stationary spring that loads up the faces
to resist hang-up. It also has a dynamic
O-ring on the OD of the spring-loaded,
stationary face with the spring on the
atmospheric side, and it uses faces with
large clearances between their ID and
the sleeve OD to resist hang-up if sulfur
begins to accumulate on the atmo-
spheric side. he other unique feature is
a segmented carbon (Espey-type) bushing on the atmospheric
side of the faces that can be used for a high-pressure (30- to
40-psig) steam quench.
Steam at 35 psig has a saturation temperature of 260 deg
F, which is near the lower solidication temperature for sulfur.
herefore, introducing a steam quench between the faces and
the segmented carbon bushing at this pressure and temperature
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68 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Sealing Technologies
and controlling it with a needle valve on the ange drain line
would:
Equalize the temperature around the faces to create a better
environment for the sulfur in the seal gap, resulting in a
more even transfer of the seal-generated heat away from the
faces to keep the temperature in the gap below the upper
solidication temperature
Improve the heat transfer capability of the seal, since steam
conducts heat better than air, which is an insulator
Prevent the sulfur from reaching the lower solidication
temperature as it leaks across the faces
Move the sulfur leakage away from the ID of the faces to
prevent it from accumulating, solidifying and hanging up
the faces
Sealing the Deal
To install this solution, the renery had to make a few design
modications to its process line. Engineers from the renery
and the seal company teamed up to minimize equipment
modications. he seal companys engineers made recommen-
dations both for the equipment design and for implementing
environmental controls.
Teamwork made this a successful outcome, said Batinick.
We were present for the seal installation and start-up, and we
provided training and support. here should be no issues with
the seal based on operators following the revised recommen-
dations and procedures from plant engineering and the seal
manufacturer.
Within two weeks after the pump start-upthe time
when sulfur would have started to accumulate around the
pumpno sulfur leakage was detected. Housekeeping is now
a non-issue for the renery and although it has had other pump
issues, none were related to the seal. he renery is pleased
with this solution and is currently in the process of modifying
a second pump to accommodate the pusher seal and is consid-
ering retrotting several other pumps within the facility.
P&S
Alton R. Smith is the senior regional sales manager for
EagleBurgmann. He can be reached at
[email protected].
Rotary Lobe Pumps
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70 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Metering & Submersible Pumps Special Section
F
inding an e cient and economically feasible way to
transfer and meter aggressive chemicals is a constant
challenge in many industries ranging from chemical pro-
cessing to food and beverage production to municipal water
treatment. Limited maintenance resources and critical service
demands put a premium on equipment uptime and extending
MTBF (mean time between failures).
In metering applications, choices have traditionally
included: controlled volume reciprocating diaphragm metering
pumps; peristaltic hose pumps; and, for certain applications,
even progressive cavity-type pumps. Critical factors for deter-
mining which technology to use for a given application include:
Material selection/chemical compatibility
Accuracy and repeatability requirements
Total cost of ownership (TCO)
Mean time between failures (MTBF)
Ease of maintenance
Initial capital cost
Installation considerations (footprint, compatibility with
existing control schemes, etc.)
With the continued focus on lean operating principles
in many industries, the importance of MTBF, ease of main-
tenance, and TCO continue to play a greater role in the deci-
sion of which process technology to use for a given application.
A relatively new entrant into the eld provides a solution for
many applications and meets the expectations of users regard-
ing these key categories. Non-metallic magnetically driven gear
pumps are becoming a frequent choice due to their simple
operation and maintenance, long-term reliability and ability to
meet performance requirements.
Non-Metallic Magnetically Driven
Gear Pumps
While positive displacement rotary gear pumps have been
around for years, the designs featured metallic construc-
tions, which required the use of high-grade alloys (Alloy 20,
Hastelloy C, etc.) for aggressive chemical applications. hese
material requirements required larger capital investments than
other technologies chosen for these applications. his has lim-
ited the application of rotary gear pumps in chemical metering
and transfer applications. However, a completely non-metallic
magnetically driven (mag drive) gear pump has been developed
that solves many of the critical issues faced in chemical transfer
and metering.
Non-metallic mag drive pumps include all wetted parts
in non-metallic construction including ETFE housings, PTFE
Non-Metallic
Mag Drive Pumps
Great Equipment for
Abrasive Fluids
Travis Lee, Pulsafeeder, Inc.
Non-metallic magnetic driven gear pump technology improves equipment
life and maintenance costs for metering and transfer applications.
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72 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Metering & Submersible Pumps Special Section
gears, and alumina ceramic shafts. he non-metallic construc-
tion extends to the containment can portion of the mag drive.
his is critical not only for chemical resistance in harsh environ-
ments, but also to eliminate energy loss and heat increase that
can be caused by eddy current losses in metallic gear pumps.
Bearings are also oered in both carbon graphite and silicon car-
bide constructions. hese material oerings allow the pumps to
accommodate almost all the hazardous and classied chemical
applications that a plant operator or engineer would encounter.
hey are also cost eective. A non-metallic mag drive pump can
cost up to 30 percent less than a comparable alloy pump and 60
percent less than Hastelloy C.
In addition to material compatibility, the pumps oer
sealless mag drive technology. his eliminates the need for a
mechanical seal, the potential for leaks
and the need for frequent maintenance.
his also ensures that no emission issues
arise when regulated chemicals are
involved.
A Good Choice for Many
Applications
Reducing the TCO for process equip-
ment is a priority for most users, and
several features of the non-metallic mag
drive gear pump assist with this goal.
One of the most important consider-
ations for equipment users is MTBF.
he overall cost of equipment failures
in chemical applications goes far beyond
the expense to repair the equipment. It
also includes the downtime costs; labor
hours required for the repairs; and the
potential product loss and safety consid-
erations, especially in aggressive chemi-
cal applications. he non-metallic mag
drive gear pump allows for extended
MTBF in chemical metering applica-
tions when compared to other choices.
Peristaltic technology relies upon
unpredictable hose/tube life, which
may result in frequent replacement.
he potential risk of product loss due to
catastrophic failure of a hose/tube is
also eliminated with non-metallic gear
pumps. In addition, the sealless mag
drive technology eliminates the need
for seal maintenance when compared to
non-mag drive gear pumps. hese sav-
ings manifest themselves throughout the
life of the equipment.
Another consideration when
attempting to reduce TCO is the ease
and cost of maintenance. While reduc-
ing MTBF is important, so is repair cost
reduction when repairs are necessary.
In this regard, the non-metallic gear
pump provides a unique solution. hese
pumps contain only 16 wetted compo-
nents (comparable metallic gear pumps
contain 46 components), allowing for
quick repair and servicing. All wetted
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74 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Metering & Submersible Pumps Special Section
components are easily accessible from the front-pullout design
(see Figure 1). his allows the pump to be repaired without
disconnecting process piping or removing the pump from its
installation location. his saves time and expense.
he simplicity and intuitiveness also allows for quicker
training of operations and maintenance personnel. he com-
bination of extended MTBF, low-cost maintenance and simple
operation ensures a low resource requirement piece of equip-
ment for maintenance and operations departments that are
continually asked to operate with fewer resources.
Many users operate multiple chemical dosing and transfer
applications on-site and may have to maintain a wide range
of spare parts to t dierent technologies and varying chemi-
cal compatibility requirements. With the non-metallic mag
drive gear pump, the basic conguration
handles the majority of chemical feed
applications. his allows the end user to
maintain a minimum inventory of spare
parts to service chemical feed systems.
Perhaps even more important than
the economic factors are the application
benets. hese pumps can handle a wide
range of process conditions including:
Dierential pressures to 150 deg F
psig
Working pressures to 200 deg F psig
Temperature range to 200 deg F
(with de-rated pressures; 150 deg F at
full pressure)
Flow ranges from 0.1 gpm to 33 gpm
Viscosities to 10,000 cps
In addition to standard chemical
applications, these pumps are an ideal
t for high viscosity applications, such
as polymer blending, as the gear pump
e ciency improves with higher viscosity
uids.
Metering Applications
he non-metallic mag drive gear pump
can be an excellent t for metering appli-
cations. hese pumps provide a pulse-
less ow which eliminates the need for
pulsation dampeners in the system. A
metering application with a vector type
variable frequency drive for the pump, a
ow meter for ow measurement and a
PID controller provides a high level of
accuracy (less than one percent variation
for properly sized ow meter and drive)
and performance in metering applica-
tions. his type of system also allows for
ow verication due to the ow meter,
which is not typically available in most
other metering applications in which
reciprocating or pulsating ows are used.
his provides a high level of accuracy
and a high level of turndown capacity
with ow rate proportional to the rpm
of the motor.
his compact metering pump
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76 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Metering & Submersible Pumps Special Section
system contains all the functionality required for
most systems.
Transfer Applications
With ow rates available up to 33 gpm, this tech-
nology can be a good t for small to mid-sized
transfer applications as well as metering applica-
tions. Te pulse-free ow and ability to handle a
wide range of chemical applications with a single
conguration makes this type of technology an
excellent t for chemical transfer applications.
Te pulse-free ow eliminates the need for com-
plicated piping congurations, such as pulsation
dampeners, while the transfer application may not
require the ow meter and verication required in
metering pump systems, which results in a simple
and eective transfer system with a low TCO due
to MTBF, ease and reduced maintenance costs.
Recommended Applications:
Sodium hypochlorite
Hydrouorosilicic acid (uoride)
Polymers
Ferric chloride
Ammonia
P&S
Travis Lee is the western regional sales manager
for Pulsafeeder, Inc., Rochester, N.Y. Pulsafeeder is
a manufacturer of chemical metering pumps and
electronic control systems for a variety of chemical
dispensing and control applications. He may be
reached at 800-292-8000 or at [email protected].
Pulsafeeder is an IDEX water and wastewater company.
The Pumps & Systems
News You Can Use
e-Newsletter
Everything you need to know,
when you need to know it.
Go to
www.pump-zone.com
to sign up.
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www.vibralign.com
800-379-2250
Innovations like over-sized digital detectors, line lasers, and
True Position Sensing (TPS). TPS allows the GO to compensate
for both intended AND unintended movements of the moveable
machine made during the alignment process. The result?
Alignments usually can be completed in just one set of horizontal and
vertical moves without re-measurement in between. Now thats fast.
2010 Vibralign, Inc.
Figure 1. Front pullout design of the non-metallic mag
drive gear pump.
WILO USA LLC
Toll-Free: 866-945-6872
Web: www.wilo-usa.com
Email: [email protected]
Your Pump
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Metering & Submersible Pumps Special Section
T
he earliest peristaltic pumps have
been in existence since the 1930s.
hrough the years, the designs have
been continuously rened for improved
performance and enhanced lifetime.
During the early developmental years, the
greatest peristaltic pump improvements
have been advancements in rubber tech-
nology. he average consumer of automo-
biles has also experienced this improved
rubber technology with automobile tires,
wiper blades, hoses, and tubes. In earlier
years, these automobile components were
not durable and often required repairs.
As rubber technology advanced, the
need for replacements became seldom.
Peristaltic pump technology has advanced
similarly, but the quality and prevalence
of rubber gets overlooked. If average con-
sumers take the time to consider the reli-
able performance of their automobile tires, they may realize
that rubber is a durable material that is used globally in millions
of products that we rely on daily to make our lives easier and
more e cient.
To further establish the signicance of superior rubber
technology in pumping systems, we must examine progressive
cavity, centrifugal and diaphragm pumping technologies and
also larger diameter peristaltic pumps. hese all rely on rubber
as one of the most important wear components of their pumps.
he rubber hose is the main wear element and, in most per-
istaltic pump designs, is the only repair part that is replaced
periodically.
Sliding Shoe vs. Roller Designs
Early designs and even some current designs of peristaltic
pumps have high friction from xed shoes that slide against
the hose and limits a pumps capabilities. he sliding shoes
generate friction and heat, and enormous amounts of glycerin
are required to transfer the heat to the casing to help dissipate
the heat generated. Many sliding shoe peristaltic pump users
understand that the large quantity of glycerin used is a costly
nuisance when the pump needs to be repaired. One gallon of
peristaltic pump glycerin costs approximately $85 per gal. A
typical 3in. sliding shoe peristaltic pump uses about 10 gal
of glycerin. herefore, every hose failure is a loss of $850 in
glycerin, not including the 10 gal of contaminated glycerin that
must be disposed.
Sliding shoe design peristaltic pumps also cannot be con-
tinuously run at a high rpm. For instance, a 3in. shoe design
peristaltic pump may have a limit of 40 rpm to maintain con-
tinuous service. For a larger shoe design pump to be run at
higher rpms, it must be run for two hours and then turned o
and allowed to cool for one hour. Obviously, this downtime is
not possible or ideal with many processes. Some require two
pumps for continuous process running.
Newer and more advanced peristaltic designs use either
single or double rollers, which can eliminate 80 percent of the
friction caused by sliding shoe peristaltic pump designs, allow-
ing peristaltic pumps to run at higher rpms. Roller designs
require only a fraction of the glycerin used in shoe designs
and have hose lives that are signicantly longer. In the larger
diameter peristaltic pumps, the motor size required is smaller in
roller designs than in sliding shoe designs. A 3-in. roller design
Peristaltic Pump Facts
Todd Loudin, Larox Flowsys
The peristaltic pump explainedfrom advancements to maintenance.
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 79
peristaltic pump only requires 2.2 gal of glycerin, instead of
10 gal for a sliding shoe design. At $85 per gallon, the savings
on each hose change for the rolling design pump is $663 in
glycerin alone.
Roller design pumps can run at higher rpms and still pro-
duce a longer hose lifetime than shoe design peristaltic pumps.
In many cases the work or ow rate that a 3-in. shoe design
pump produces can be accomplished by
a 2.5-in. roller design peristaltic pump.
In peristaltic pumps the number
one determining factor of pump hose life
is the number of times the hose is com-
pressed. he medium being pumped
can have an impact, but the number of
hose compressions is the most impor-
tant factor. Sliding shoe designs generate
signicant heat which also factors into
how quickly the hose breaks down. A
majority of peristaltic pumps compress
the hose two times per revolution. So
in almost all cases, the hose lifetime of
a single roller design pump is two times
longer than a shoe design or multiple-
roller peristaltic pump.
For example, the costs of running a
peristaltic pump on abrasive slurry for a
one-year timeframe are more economi-
cal than other pumping technology. For
instance, if a 3-in. progressive cavity
pump was used in the above application,
the cost of rotor and stator replacement
during that same year may be as much
as $50,000. Regardless of the peristal-
tic pump type chosen, it may produce
signicant cost savings versus other
pumps. Also, peristaltic pumps can run
dry, which is often the cause of rotor
and stator failure in progressive cavity
pumps.
Peristaltic Pump Maintenance
Maintenance of all peristaltic pumps is relatively simple. It con-
sists of removing a broken or damaged hose, cleaning the inte-
rior casing of the pump of contaminants and then installing a
new hose with the manufacturer-required amount of glycerin.
In some designs, this can be accomplished by one man in 15 to
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Metering & Submersible Pumps Special Section
20 minutes. In other designs, the maintenance may require two
or three people, but it is still a fairly easy and uncomplicated
procedure.
Also with peristaltic pumps, you do not need to remove
the pump from the pipeline or take it to a repair shop. he
repair work can be done at the pump installation location.
With centrifugal or progressive cavity pump re-builds, the
pump is almost always removed from its mounting and piping
and taken to a repair shop. In general, the rebuild time with
other pumps is an eight-hour shift if all the parts are in stock.
With peristaltic pumps, the only required parts are a new hose
and the necessary glycerin.
Peristaltic pumps do produce pulsations. Many applica-
tions require a high-quality pulsation dampener. Since peristal-
tic pumps are positive displacement devices, it is recommended
to install a programmable pressure transmitter on the pump
outlet that can shut the pump down if the pressure increases to
higher-than-desired levels. Another option is to have a rupture
disc installed downstream of the pump to prevent any undesir-
able pressure escalations if the pipeline becomes blocked.
The Varied Uses of Peristaltic Pumps
Peristaltic pumps are used in many applicationssuch as print-
ing inks and colorings, mining slurries, wastewater slurries,
bleach, food, beverages, titanium dioxide, sodium bromide and
lime slurry pumping to name a few. Peristaltic pumps are also
excellent for abrasive slurries and suction lift applications.
As with all technologies, peristaltic pumps have evolved
and improved. he early designs of peristaltic pumps were
limited by the shoe design or the inferior rubber technology.
Today, peristaltic pumps have come a long way and provide
signicant reliability.
P&S
Todd Loudin is the president of Larox Flowsys Inc. in
Linthicum, M.D. Larox Flowsys is headquartered in
Lappeenranta Finland and also manufactures in Linthicum.
On pump-zone.com . . .
Read about other peristaltic pump
applications.
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86 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Maintenance Minders
T
echnical manuals with speciications such as
tolerance and pressures are important tools
for troubleshooting hard-to-ix problems.
General shop tools and a range of wrenches, sockets
and screwdrivers are also helpful. Packing pullers,
grease guns and the proper lubricants save time and
money.
In addition to these physical tools, most pumps
require that the user have a certain depth of knowl-
edge when inspecting or servicing. Problems with
pumps normally have an underlying cause of failure,
which oten extends beyond the failed item. he
maintenance methods described below form some of
the basic knowledge needed for servicing.
Packing
When checking the packing gland, look for exces-
sive leakage and repack if needed. When leakage is
excessive, the maintenance operator should tighten
the packing gland. Keep in mind the leakage should
not be completely stopped because water serves as the
coolant for the packing in the stui ng box.
Packing around the shat should be tightened just enough
to allow about 20 drops per minute. If the follower cannot be
properly adjusted anymore, the pump needs to be repacked
with the proper packing.
When selecting packing, keep in mind the pumps pres-
sure and shat speed.
Repacking a Pump
When repacking a pump, ensure that the driver and pump have
been safely isolated and that all safety precautions are followed.
New packing should never be added on top of old pack-
ing. Start by removing all existing packing and the lantern ring.
Once you have removed the old packing, clean out the stui ng
box and inspect the shat sleeve for unusual wear. Proper tools
should be usednever use a screwdriver. Using the wrong
tools may damage the stui ng box or shat sleeve.
New packing should it around the shat with no gaps at
the joints. Place the joint of the second piece of packing 90
deg away from the joint of the irst piece of packing. Stagger
each joint 90 deg from the last one, and ensure that the lantern
ring aligns with the coolant port attachment. his method of
staggering the joints prevents water from escaping through the
joints. Follow this process until the stui ng box is full.
he packing gland should be placed on top of the packing.
Tighten down the followers. Adjust the followers one lat or
of a turn every 30 minutes or until the leakage is controlled.
Feel the packing gland (be careful of the rotating shat) to see
if the packing gland is too hot or uneven, which will result in
damage to the pump shat.
Bearings
Overheated bearings are caused by friction, which can result
from a lack of lubrication. When inspecting a bearing, all it-
tings and grease cups should be cleaned before greasing to
remove any dirt. Dirt particles can cause bearing contamina-
tion and premature bearing failure.
Lubrication of a bearing should follow the manufacturers
Understanding the
Basics of Pump Repair
Preston Walker, Jr., Caliber Pump Repair
General troubleshooting tips can simplify preventive maintenance.
Improperly adjusted packing gland with no leak off.
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 87
recommendations. Additional grease above the recommended amount may cause the
bearings to overheat.
When you start greasing a bearing, remove all relief plugs. Removing the plugs
allows the old grease to pump out as the new grease is pumped into the housing.
Conduct an inspection of the old grease and look for metal particles or metal shaving.
Any particles found in the old grease indicate wear, which needs to be addressed.
Couplings
Like bearings, couplings require lubrication. When performing maintenance on cou-
plings, ensure that safety procedures are followed.
When preventive maintenance is performed, remove the coupling guard to
expose the lexible grid. Remove the grid, and inspect it for wear. Whenever metal
particles are found, check for misalignment. Immediately inspect the grease for any
metal particles.
Once it is determined that the coupling can be reused or if a new one is needed,
clean all parts to ensure that no dirt or grit is on the grid or coupling halves. To reas-
semble, the grid goes on the drive end of the motor and the driven end of the pump.
Put the couplings bolt in place and remove the relief plug. New grease should be
pumped into the grease itting until it is expelled from the relief port. Take care not to
over-grease the coupling since it will damage the rubber seal on the coupling halves.
Inspection
Inspections play a vital role in a preventive maintenance program. Inspections are con-
ducted to determine the operation condition of pumps and associated equipment and
to help predict what corrective or preventive maintenance will be needed to avoid seri-
ous problems.
Inspections, cannot be overlooked or falsiied. hey should be routinedaily or
even weekly.
During a visual inspection, the operator should look for clogged drain lines,
excessive leaking from packing glands, overheated bearings or bearings operating at
higher than normal temperatures.
Listen for any unusual noise or vibration or anything uncommon when con-
ducting a visual inspection. Vibration is associated with pump operation and must be
addressed immediately before serious problems occur and the pump ultimately fails.
Noisy bearings can be caused by vibration from loose bearings on the shat or a failed
shat coupling.
Excessive leaking at packing gland.
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88 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Maintenance Minders
An inspection checklist is a great way to ensure that
nothing is overlooked. I highly recommend that main-
tenance operators carry a copy of past inspection data to
compare with new indings. his will allow them to detect
any new problems and identify trends among the normal
operations.
Operation conditions may not be ideal to start and
stop equipment. However, an inspection must be con-
ducted before the next inspection cycle.
Ater inspections, maintenance operators must sit
down with supervisors to discuss any problems that were
found. Supervisors must be able to prioritize concerns and
schedule preventive and corrective maintenance.
Although problems vary, corrective maintenance can
be minimized with proper operation and preventive main-
tenance procedures.
Basics Checklist
1. Packing glands must not be allowed to leak excessively
and should be corrected.
2. Bearings must have the proper amount of grease and
it clean to prevent premature failure.
3. Vibration must be addressed, or serious pump failure
will result.
4. Maintenance operators must document all inds and express
their concerns so the proper corrective or preventive mainte-
nance action occurs.
P&S
Preston Walker, Jr., is a plant maintenance senior and pump
repairer. He can be reached at 678-698-5366.
Improperly adjusted packing gland with no leak off.
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Tel: 404 816 4760 Fax: 404 816 4759
Web: www.eccentricpumps.com
Email: [email protected]
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Atlanta, GA 31119
MiniPump
Maxi results.
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UDelivers 1 to 120 gal/hr small footprint
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UOne squeeze per 360 = longest hose life
UUsed for sampling, dosing, abrasive,
corrosive and shear sensitive fluids
Figure 12.17
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 95
based on existing designs and experience.
Allowance for casing wall corrosion and manufacturing
thickness is also added to the desired wall thickness. In this
regard, manufacturers often provide minimum casing wall
thickness for use in monitoring the service life of a pump
casing.
Pressure ratings for standard design anges used to connect
pumps to the system are a major consideration, and many
pump MAWP ratings are equal to the ange ratings. he
minimum casing wall thickness is then calculated to match
the ange rating.
Mechanical seal housing design and seal selection must also
be capable of withstanding the MAWP.
On pump-zone.com . . .
Explore the HI PumpFAQs archive.
Also, purchase pump standards and other
pump related material at PumpBooks.com.
Pump FAQs is produced by the Hydraulic Institute as
a service to pump users, contractors, distributors, reps and
OEMs as a means of ensuring 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 standards developing organiza-
tion, the Hydraulic Institute process of developing new stan-
dards 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 education program
and standards, please visit: www.pumps.org. Also visit the new
e-learning portal with a comprehensive course on Centrifugal
Pumps: Fundamentals, Design and Applications, which can
be found at: www.pumplearning.org.
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RUN DRY, AND
KEEP ON RUNNING.
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Yonkers, NY 10703 U.S.A.
ISO 9001:2008
Pumps fitted with GRAPHALLOY
bushings
and case rings:
Run hot, cold, wet or dry
Reduce maintenance
New pumps or retrofits
Non-galling
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Corrosion resistant
96 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
T
his is the second of a four-part Sealing Sense series
that provides guidance on best practices to mini-
mize the size of the sealing system energy footprint.
he rst article discussed energy losses from the interaction
between the seal faces of a mechanical seal. his article will
discuss the thermal energy needed to maintain a suitable
temperature for the interfacial lubricating uid in high-tem-
perature processes.
Process Fluid Flush
he reliability and emission performance of any mechanical
seal depends on the ability to maintain a stable uid lm
between the faces. he three types of mating face lubrication
regimes were discussed in the August 2010 Sealing Sense.
For most applications, it su ces to provide a small amount
of process uid ow as ush to remove the seal-face-gener-
ated heat and lubricate the faces. he minimum ush ow
rate is based on a 10 deg C (18 deg F) maximum allowable
process uid temperature rise.
his ush-ow rate represents a small energy loss because
the process uid used for the ush needs to be re-pumped
from suction back to discharge. hese systems do not rely
on the cooling of the uid, so they consume an insignicant
amount of energy compared with the total energy footprint
of the pumping system. API Piping Plans 1,11,12,13, 14
and 31 are examples of sealing systems that use process uid
without cooling as ush. hey are applicable to single seals
and the process side seal of a dual, unpressurized seal.
he maximum recommended operating temperature of
these piping plans will depend on the process uids lubri-
cating qualities at operating conditions such as seal chamber
pressure and pump speed. Other considerations include the
temperature limits of the secondary seals and the potential
consequences of normal and transient leakage rates, or a
major leak (seal failure) to the surrounding environment and
the safety of personnel.
External cooling
he small energy footprint for operating seals at high tem-
perature has been recognized, but in some cases, cooling of
the process uid is needed to achieve acceptable reliability,
emission and safety targets. Historical data of seal OEMs
show that an annual energy savings of approximately 2.3
What is the Sealing System Energy Footprint for
Controlling Process or Barrier Fluid Temperature?
Second of four parts
This months Sealing Sense was prepared by FSA member Eric Vanhie
Figure 1. API Piping Plans 21 and 23.
From the voice of the uid sealing industry
SEALING SENSE
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 97
kW per 25 mm (1 in.) of shaft size can be realized for every 38
deg C (100 deg F) of cooling requirements that can be removed
from the seal cavity. Many high-temperature applications are
found in reneries, power plants and some chemical processes.
he most common sealing systems to incorporate cooling of
the process uid are API Piping Plans 21 and 23.
API Piping Plans 21 and 23
In these plans, an external heat exchanger reduces the process
uid temperature considerably and provides a cool ush over
the seal faces. his may be needed to protect against vapor for-
mation, meet temperature limits of secondary sealing elements,
reduce coking or polymerizing of the leakage or improve the
lubricating qualities of a process uid such as hot water.
he primary benet of Plan 21 is a su cient pressure dif-
ferential to achieve the high ow rates needed to cool the seal.
he drawback is that the cooler duty is high and the ush ow
needs to be re-pumped to discharge, which may result in a sig-
nicant energy foot print.
Plan 23 is the default for many hot water and hydrocarbon
services in power plants and reneries. he cooler duty is much
lower than that for Plan 21 because it only removes the seal
face generated heat and a small amount of heat soak from the
process. he seal incorporates a pumping device that circulates
the process uid to the cooler and back to the seal chamber. he
process uid in the seal chamber is isolated from the hot process
uid with a throat bushing in the impeller area to minimize the
heat soak loss.
Heat soak
Heat soak is a source of heat ow into or out of the uid that
lubricates the seal faces. It is the result of the temperature dier-
ence between the seal chamber and the environment surround-
ing the seal chamber. Calculating the heat soak loss is a complex
matter because of the many variables involved. Mechanical seal
standard API 682 provides a simplied method for estimating
this heat loss. he cooling capacities of the heat exchangers
that are used in Plan 23 are 6 and 36 kW, which cover the
majority of all high-temperature applications. From an energy
standpoint, Plan 23 has a smaller footprint than Plan 21, but
the process uid cannot contain many solids or be too viscous,
sticky or have polymerizing tendencies.
Dual seals
Sealing systems for dual seals require an external cooler to con-
trol the barrier uid temperature within a specied range, with
the maximum at 80 deg C (176 deg F) for many barrier uids.
he thermal loss due to heat soak may become signicant for
process temperatures above 150 deg C (302 deg F). he sources
of energy consumption in these auxiliary systems include the
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98 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
FSA Sealing Sense
pumps and motors to create
the ow and pressure in the sealing system, the heat removed
by cooling water through heat exchangers and additional
system heat removed above and beyond the seal chamber heat
load because of system design.
Each service is somewhat dierent and can best be esti-
mated by your local seal manufacturer. he maximum cooling
capacity of systems for dual seals is 8 kW for Plans 52 and
53A and up to 36 kW for Plans 54 and 53B. Systems for gas-
lubricated seals consume an insignicant amount of energy as
described in the August Sealing Sense.
Air cooling
his is an eective method for reducing the energy footprint
of sealing systems in general. he elimination of cooling water
reduces the cost to operate the seal and pump. he drawbacks
of air cooling include its limited capacity and typical restriction
to outdoor installations. Another method for eliminating the
cooling water is to use product cooling. In this case, the process
uid is circulated through a coil in the barrier uid reservoir or
heat exchanger to remove the heat from the seal. his method
is limited to process temperatures up to 50 deg C (122 deg F),
and the uid must be free of solids. he energy required to re-
pump the process uid back to discharge must be considered as
the ow rates may be fairly high in this scenario.
Conclusions
1. he energy footprint for controlling process or barrier
uid temperature can be estimated for any ush plan
application. Meaningful comparisons can be made to
determine the most energy-e cient system.
2. Reliability, emissions and safety aspects of the seal must be
considered during the evaluation and selection process.
3. For the majority of seal applications, the energy footprint
for controlling process or barrier uid temperature is
small compared with the overall footprint of the pump.
Exceptions apply in services involving high temperatures
and/or dirty uids.
4. For single seal and dual unpressurized seals in a high-
temperature environment, the footprint for API Plan 23 is
smaller than that for Plan 21. Plan 21 should be used only
when Plan 23, for some reason, cannot be applied.
5. Heat soak losses can be reduced signicantly by having a
close clearance bushing at the bottom of the seal chamber.
6. For dual seals in a high-temperature environment, API
Plans 52 and 53 consume less energy than Plan 54.
7. Air cooling and product cooling may be eective methods
for reducing the energy foot print in specic applications.
In next months article we will focus on the energy required
to remove external uids or diluents from a process stream.
Next Month: What is the Sealing System Energy Footprint for
removing diluents from the process stream?
We invite your questions on sealing issues and will provide best
eort answers based on FSA publications. Please direct your ques-
tions to: [email protected].
P&S
Figure 2. API plans 52, 53A and 54.
Sealing Sense is produced by the Fluid Sealing
Association as part of our commitment to industry con-
sensus technical education for pump users, contractors,
distributors, OEMs and reps.
In the September 8, 2008 issue
of the Wall Street Journal, an
article appeared, headlined
New Nukes. Reporter Rebecca
Smith led the piece with the
statement:
If there ever were a time that
seemed ripe for nuclear energy,
it's now. For the first time in
decades, popular opinion is on
the industry's side. A majority
of Americans thinks nuclear
power, which emits virtually no
carbon dioxide, is a safe and
effective way to battle climate
change, according to recent
polls. At the same time, legisla-
tors are showing renewed
interest in nuclear as they hunt
for ways to slash greenhouse-
gas emissions.
CLYDEUNION Pumps could not agree more with these
sentiments about the nuclear industry. In July of this
year, CLYDEUNION Pumps formed the Nuclear Services
Group and appointed Timothy B. Frisbie, Sales Director,
to develop this important and ever-growing business in
the Americas.
It was also in 2008, that Clyde Pumps (formerly Weir
PumpsGlasgow) and Union Pump merged to form
CLYDEUNION Pumps. This new company brought about
the best of two worldsit retained almost 300 years of
combined proven experience and generated a youthful
vitality to meet the challenges of todays fast pace and
ever-increasing demands.
Tim Frisbie embodies CLYDEUNION Pumps persona of
vitality and experience. He brings nearly thirty years of
experience in the fluid-handling industry from oil
refineries to desalination plants. Yet, one would never
guess his age when you first meet him.
CLYDEUNION Pumps is well positioned to serve the nuclear
industry with new and rebuilt OEM quality pumps and
24/7 on-site service. The company is a world leader in the
design and manufacture of pumping plant for the power
generation industry and has been authorized since 1977
by the American Society of Mechanical Engineers to mark
its products manufactured to ASMESec III Classes 2 and
3 with the N and NPT stamps. We are currently seek-
ing U.S. and Canadian accreditations for our BattleCreek
Michigan and Burlington, (Toronto) Ontario facilities to
support dedicated nuclear repairs and component supply.
Frisbie says, I am excited to be part of our companys
nuclear aftermarket services group. It has been my vision
for a long time to be a leader in the Nuclear industry for
the supply of new pumping equipment, repairs of all
manufacturers and to be the go to company for field
service. We never ran away from the nuclear market, but
never really did support it like it deserved. Now, with the
merger of our two companies, it is finally coming to
fruition. My years of working with engineers, machinists
and customers in the field taught me the importance of
making sure I stand behind everything I promise and
deliver on those commitments without question and on
schedule. This has become one of CLYDEUNION Pumps
real competitive advantages.
Tom Tesoriero, a former U.S. Navy nuclear professional
with more than 25 years of commercial nuclear machinery
experience, leads the groups marketing efforts. Tesoriero
says, These are exciting times at CLYDEUNION Pumps as
we bring together expertise from both the European and
United States nuclear pump machinery industries. This
enables us to provide the best global solutions for the
resurgence of the U.S. commercial nuclear power fleet.
To find out what CLYDEUNION Pumps can do for you, talk
to a CLYDEUNION Pumps representative today. Whether
its a new or rebuilt system or on-site service on existing
equipment, you can count on CLYDEUNION Pumps.
Please visit our web site www.clydeunion.comor call Tim
Frisbie directly at (269) 317-2892 for sales or service with
24/7 on-site service support.
Tim Frisbie
www.clydeunion.com
circle 104 on card or go to psfreeinfo.com
100 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Practice & Operations
D
uring the third quarter of 2009, a
new grass roots gold mine opened
in the state of Zacatacas, Mexico.
GoldCorps Minera Peasquito mining proj-
ect soon became the largest open pit mine in
Mexico and a signicant contributor to its
annual production and prots. he huge proj-
ect encompasses traditional mining, crushing,
grinding and otation circuits of sulphide
ores. Signicant by-products of silver, zinc,
and lead add considerably to the viability and
protability of this state-of-the-art mineral
processing facility.
A need for multiple pumps
he facility needed products and services for
several of the process pump applications found
in this massive mining endeavor. he largest
single order was for the reclaim water pumping
system, which returns water from the tailings
pond to the plant for use in multiple processes.
he system consisted of eight barge-
mounted vertical turbine pumps equipped
with 900 hp motors. he pumps and motors,
located in the tailings pond and gravity fed
to the processing plant, deliver 10,000 gal of
water per min each, or a maximum of 80,000
gpm, to a secondary booster pump station that
houses eight additional 1,000-hp, can-type
vertical turbine pumps. In the mineral process-
ing circuit of this plant, after the metals have
been extracted from the ore, the waste material
is sent by gravity ow to the tailings pond. he
excess water in the tailings is reclaimed and
pumped back up to the processing circuit via
this barge mounted pump station and a secondary booster
station for reuse. he systems 100-plus million gal per day
of total ow are reused continuously. Additional make-up
water is added to the system, as needed, for use in the mineral
process facility.
he process required pumps that could not only handle
the abrasive nature of the dirty mine water, but pumps that
are also adaptable to the varying conditions expected over
the 22-year estimated life of the mine. Multi-stage turbine
pumps that could be de-staged at future intervals as the tail-
ings pond levels rise and the pump system head requirements
Reclaiming the Gold
Mike Dwyer, Quadna
Investment in mine expands production capabilities.
The 900 hp vertical turbine pumps are situated on the Minera Penasquito mines
barge.
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 101
decrease over the life of the mine were chosen. In
addition, special chrome oxide bearing and shaft
surfaces that will greatly extend the wear life of the
pump components were supplied for the project.
A Boost to Mexicos Gold
Production
he more than $2-billion-USD investment made
by GoldCorp in the Peasquito mine has been
important to the domestic mining sector in Mexico
and will position Mexico as one of the ve largest
gold producers in the world. It will generate 2,500
direct jobs and 12,500 indirect jobs. On March 23,
2010, Goldcorp celebrated the mine with a visit
from Felipe Caldern, the president of Mexico.
In the second quarter of 2010, a second sul-
phide line, which further expanded production
capabilities, was completed. he annual production
life of the mine will ramp up to approximately 500,000 ounces
of gold, 30 million ounces of silver and more than 400 million
pounds of zinc.
With gold and other commodity prices continuously on
the rise, the possible protability of this mine is impressive.
P&S
Mike Dwyer, project manager for Mining Accounts, has
23 years experience with Quadna and 31 years total in
the pumping industry. He can be contacted at 2803 E.
Chambers Street, Phoenix, AZ 85040, 602-323-2370.
Quadna, a DXP Company, engineers, fabricates and ser-
vices mechanical systems that move uids and gases for
industrial applications.
All pump systems are installed and the barge readied for operations in the mines
pond.
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1. Water Sampling & Chemical Injection
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3. Seal Flushing
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5. Portable Washdown
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Arlington Heights, Illinois 60005
Phone: 847-439-9200 Fax: 847-439-9388
Visit our Website at www.shanleypump.com
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102 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Practice & Operations
W
hen a nuclear power plant pulled
its vertical IR32 APKDnine-stage
condensate pump for routine
maintenance, an emergency situation was
not expected. he plant pulled the pump and
installed a replacement from storage, but it
failed catastrophically after only two days in
service.
Requiring a solution for the emergency
need, the plant accepted a workscope from
a service center that promised a refurbished
pump within nine days. he plant shipped
both pumps to the service center and sent
a condensate system engineer to oversee the work and
maintain an open line of communication between the
organizations.
his case study highlights the root cause of pump fail-
ure for a nuclear power plant and the emergency response
required to repair the pump. One key factor to handling
this emergency pump failure was the teamwork between
the plants management, an onsite plant engineer located at
the repair facility and the personnel at the repair facility. A
lesson learned for pump users in emergency situations is that
close teamwork and having a customer engineer onsite is
critical to facilitating a rapid response.
Root Cause of Failure
he pump failed as a result of having been previously incor-
rectly repaired, coupled with contributing installation issues,
ultimately causing the upper shaft to break. his root cause
became apparent during the disassembly process. hese
photos illustrate what the pump service center found.
Best practice is to maintain stringent alignment and
concentricity between interfacing parts. his ensures cor-
rect concentricity and perpendicularity between shaft and
bearings and rotor to casing. he service center discovered
that the top bowl male t had been previously repaired by
pad welding (see Figure 1), which is an improper practice
due to the presence of a sealing O-ring. When a pad weld is
performed on a pump that uses the O-ring design, ts and
tolerances no longer meet acceptance criteria. It appeared
that the previous repair provider coated the faces with sil-
icone or another sealant in an attempt to re-establish the
proper ts or control leakage (see Figure 2).
he top of the discharge bowl did not t properly in
the bottom of the discharge head (see Figure 3). Excessive
force used to make these components t bent the shaft and
created a condition ripe for fatigue failure. he forced bend-
ing of the shaft caused the impeller ring to contact the case
(bowl) ring during operation (see Figures 5 and 6). he
motor had to produce more torque to drive the assembly
due to frictional resistance from the heavy rub (see Figure
7). Furthermore, the suction bell was not properly seated in
the alignment ring (see Figure 8).
he misalignment and excessive bending load on the
entire rotating element assembly caused the shaft to break at
the snap ring groove, which resulted in catastrophic pump
failure.
When Maintenance
Becomes Emergency
Donald Spencer, P.E., HydroAire, Inc.
In this case study, routine maintenance of a condensate pump
at a nuclear power plant becomes an emergency situation.
Figure 1. Pad welded male t for the top bowl.
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 103
Figure 8. he alignment ring at the bottom has a damaged edge, which
is evidence that the suction bell was not properly seated in the alignment
ring.
Emergency Response Required to Repair
the Condensate Pump
he agreed plan to repair the pump was to use in-spec parts from the rst
pump and reusable parts from the failed pump to deliver one working
pump. he plants ability to supply condensate pump parts from its inven-
tory helped decrease the turnaround time because fewer parts needed to
be manufactured.
Bowls and Bearings
Bowls from the rst pump were used because the impeller case wear ring
running clearances were acceptable; however, the shaft graphalloy bearing
Figure 2. Silicone coating appears to have been used in a previous repair after the
male ts were pad welded in an attempt to seal the proper t between the top
bowl and the discharge head.
Figure 4. The bolts between the can ange and the discharge head appear to have
been tightened with additional force as one section of the ange rose up about
in. on one side after the discharge ange was unbolted from the base-plate.
Figure 5. Damaged case ring as a result of galling
contact.
Figure 6. Heavy grooving from running stage impeller
eye ring.
Figure 3. The male t of the top discharge bowl was
over size at 18.754 in. and the female t of the dis-
charge head was 18.7445 in., causing an interference
t (Exaggerated diagram, not to scale).
104 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Practice & Operations
running clearances were not. Fortunately, the plant had
new bowl/shaft bearings in their inventory and pro-
vided them for use. After installing the bearings, bowl
TIRs (wear ring and bearing bores) were checked. In
the lower ve bowls, the wear rings had excessive run-
out. he plant had ve bowl wear rings in stock that
could be used with the impellers and bowls.
Shaft
he upper shaft from the original pump and the lower
shaft from the failed pump were used because both had
acceptable TIR readings of less than 0.003 in.
Impellers
he impellers from the original pump had to be used
because the bowls were taken from that pump and the
impeller wear ring diameters were sized to those bowl
rings. Each impeller was balanced individually to 1
W/N, and then each rotor was balanced (upper with
ve impellers and lower with four impellers).
Discharge Head
Plants often use a common discharge head in a given conden-
sate pump position. Spare heads are not usually kept. Using
the same discharge head with dierent bowl assemblies can
aect the geometric centerline between the rotor and the
casing as well as the head-to-bowl assembly. After inspection,
the discharge head was welded and machined at critical t
locations to re-establish proper concentricity. he completed
pump was shipped back to the plant within the agreed nine-
day turnaround time.
Lessons Learned
here is no doubt that the disassembly, inspection, analysis and
complete repair would have required much more time in a typ-
ical pump repair shop. he service center, which was dedicated
to nuclear pump aftermarket services, was able to determine
the root cause of failure and provide a rebuilt pump within
nine days because they had an in-house engineering team and
customer partnership during the repair process. Working with
a pump service facility that combines experienced individuals
using proper repair and rebuilding practices for vertical pumps
is important. Vertical pumps require precision manufactur-
ing and attention to detail during the rebuild and installation
process because of their multiple components, which when
assembled, result in a tolerance stack-up that must be concen-
tric within fairly narrow limits from top to bottom.
P&S
Donald Spencer, who has over 30 years experience in
the nuclear pump industry, recently became HydroAires
Manager of Nuclear Services. With a Bachelors of Science
in Nuclear Engineering, Dons career spans major OEMs,
including Bingham-Willamette, Johnston Pump Co., and
Sulzer. For details on this article or HydroAires Nuclear
Services, contact Donald Spencer at dspencer@hydro-aire.
com or by calling 312-738-3000.
Figure 7. The high amps reading at pump failure show motor torque.
Figure 8. The alignment ring at the bottom has a damaged edge,
which is evidence that the suction bell was not properly seated in
the alignment ring.
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 105
ReliaSource
6x6T
he ReliaSource 6x6T above-
ground lift station is the newest
addition to the Gorman-Rupp
line of fully-customizable, com-
pact and pre-engineered pack-
aged stations. his unit comes
standard with all the existing
features of the 6x6, with an additional 3 ft of height. he
added space allows for easier access to routine maintenance
items, such as check valves, plug valves, gauges and air
release valves.
Circle 202 or go to psfreeinfo.com
Self-Leveling Mounting Chock
he RotaChock, an
innovative and proven
product, will save
time in the eld and
minimize the down-
time of equipment.
he RotaChock is a self-leveling, adjustable and reusable
machinery mounting chock and is available in carbon steel,
stainless steel 316L and other materials. Used under the
driver, driven machines or equipment that requires coplanar
mounting surface, it eliminates soft foot for equipment
in production lines and for the life cycle.
Circle 203 or go to psfreeinfo.com
Self-Priming Chopper Pumps
Vaughan Company intro-
duces its line of self-priming
chopper pumps, which are
designed for lift stations,
scum wells, portable cleanout
or any retrots of clogging
pumps. Vaughan Company
Inc. is the only manufacturer
of a self-priming chopper
pump. he new, high-e ciency chopper impeller design
allows priming up to 24 ft. hese pumps cover a wide
range of applications with ows up to 6,000 gpm.
Circle 204 or go to psfreeinfo.com
Self-Aligning Pipe Couplings
Tuf-Lok pipe cou-
plings, with a built-in,
self-aligning feature,
are rated for both
high-pressure and full-
vacuum conditions.
hey are available in
1-in. (25-mm) through
10-in. (250-mm) pipe sizes, and are ideal for pneumatic
conveying systems as well as gas and liquid applications.
Tuf-Lok pipe couplings can be used on mild steel, stainless
steel, aluminum and most other thick or thin wall pipe.
Numerous gasket materials are available for diverse design
conditions.
Circle 218 or go to psfreeinfo.com
MAGDOS LB from Lutz-Jescothe
new dosing pump with great savings
potential
he MAGDOS LB is available in
several sizes with a dosing capacity
of up to 15 l/h or up to 16 bar. he
MAGDOS LB can be used in almost
all process applications. he compact,
space saving design and footprint of
the pump is suitable for integration
into almost every metering system.
Moreover, the pump can be installed
in diverse positions. As part of the new Plug&Play con-
cept, dosing pump congurations with a range of 110 to
240 VAC are available worldwide for immediate use.
Circle 215 or go to psfreeinfo.com
Product Pipeline
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- Smooth Precision Ground Cover
- Mul-ply High Tensile Cord Reinforcement
- Tube Compounds: Natural Rubber, EPDM, Nitrile (Buna-N), and
FDA Safe White & Tan Materials
- For Watson-Marlow, Blackmer, Verder, Ponndorf, Perio,
and Other Posive Displacement Pump Manufacturers
Peristaltic Pump Hose
Call us for a quote or visit our website for addional informaon.
ID
(mm)
OD
(mm)
Length
(mm)
ID
(in)
OD
(in)
Length
(in)
10 31.0 508.0 0.39 1.22 20.0
15 36.0 762.0 0.59 1.41 30.0
25 53.2 1006.4 0.98 2.09 39.6
32 61.0 1250.9 1.25 2.40 49.2
40 66.4 1489.0 1.57 2.61 58.6
50 80.0 1820.8 1.96 3.14 71.6
65 99.2 2336.8 2.55 3.90 92.0
80 122.0 2781.3 3.14 4.80 109.5
100 144.0 3276.6 3.93 5.66 129.0
Non-standard or custom built peristalc hoses are also available.
TOLL FREE: 1-800-686-4199
www.salem-republic.com
106 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
Product Pipeline
ASI Model 550 Seal
he ASI Model 550 is suited
for slurry applications, particu-
larly those with harsh operat-
ing parameters and diering
product consistencies and
those of a corrosive nature.
It also seals many bleaching
materials, including multiple
forms of HTH paste, as well as
higher concentration caustic products. In addition, the 550
(equipped with its pumper option) lends itself to hazardous
waste applications, overcoming the large abrasives, varying
chemicals and occasional dry-run scenarios typical to the
service.
Circle 222 or go to psfreeinfo.com
Vortex Pumps
Zoeller Engineered Products introduces their
broad selection of 1 to 15 hp submersible,
solids-handling pumps with vortex impellers.
Vortex pumps, recognized for their superior
solids handling capabilities, are being applied in
challenging wastewater pumping applications.
Zoeller oers these pumps in either 2.5 in. or 3 in. solids han-
dling capacity. Discharge sizes are 3 in., 4 in. and 6 in. with
standard or explosion proof motors.
Circle 224 or go to psfreeinfo.com
KSB Dry-Pit Submersible
KSB announces
a new, dry-pit
submersible series
with NEMA
MG1 premium
e ciency motors.
his versatile
pump can be
mounted in a ver-
tical or horizontal
position in areas
that are prone to ooding. Modular construction incorporates
motors up to 10 hp, using three dierent impeller types and
sixteen dierent hydraulics, covering a wide range of ows and
heads.
Circle 223 or go to psfreeinfo.com
P&S
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INDEX OF ADVERTISERS
ABB Discrete Automation & Control 129 31
ABS USA 102 71
ABZ, Inc. 188 108
AE Pumps, Inc. 194 109
All Prime Pumps 195 110
ATC Diversiied Electronics 130 14
Baldor Electric Company 103 35
BaseTek, LLC 159 84
Benshaw 133 33
BLACOH Fluid Control, Inc. 134 20
Blue-White
Industries 135 8
Boerger, LLC 136 68
Boerger, LLC 196 111
Caliber Pumps 197 110
Chemicals Direct 198 109
CLYDEUNION Pumps 104 99
CLYDEUNION Pumps 199 109
Cole-Parmer 137 9
Coupling Corporation of America 171 107
Crane Pumps & Systems 138 19
Dan Bolen & Associates 300 109
Danfoss Drives 160 52
Dwyer Instruments, Inc. 105 17
Environment One Corporation 108 69
EagleBurgmann 106 13
Eccentric Pump 172 88
Electro Static Technology 139 25
Equipump 189 108
Fairbanks Morse 161 51
Flowserve 140 34
Fluke Corporation 110 45
Frost & Sullivan 173 93
Fuji Electric Corporation of America 111 49
Garlock Sealing Technologies
112 5
Global Pump 117 73
Graphite Metallizing Corporation 174 95
Griffco Valve, Inc. 141 16
Heinrichs 175 64
Holland LobePro 142 67
Hydra Service, Inc. 107 75
Hydraulic Institute 176 93
Hydromatic
131 62
Hyundai Heavy Industries Co. Ltd. 113 30
Inpro/Seal 114 11
International Products Corporation 163 84
ITT Goulds 162 87
ITT Water & Wastewater M & C 109 3
Junty Industries, Ltd. 301 110
KSB, Inc. 143 41
Larox Flowsys, Inc. 115 61
LEWA Inc. 144 27
Load Controls, Inc. 145 65
Load Controls, Inc. 190 108
Lutz-JESCO America Corp. 116 BC
MSE of Canda Ltd. 302 111
Macromatic Industial Controls 177 97
Megator 178 106
Meltric Coporation 179 97
Mid-West Instruments 180 106
Moyno, Inc. 118 21
MTH Pumps 181 101
Myers 132 79
National Pump Company 146 47
Neptune PSG 147 80
NOC 191 108
Orival, Inc. 164 53
PeriFlo, Inc. 148 72
Proco Products 165 92
ProMinent Fluid Controls 119 81
Pump Pros 166 54
Pump Solutions Group 167 91
Pumping Machinery 192 108
R + W America L.P. 149 63
Racine Federated Inc. 150 42
Rain for Rent 303 111
Revere Control Systems 182 95
Rockwell Automation 101 IFC
Ruhrpumpen 120 15
Salem Republic Rubber Co. 183 105
seepex 151 36
SEPCO 152 22
SEPCO 304 110
Shanley Pump 184 101
ShinMaywa
185 88
Sims Pump 100 56-57
Sims Pump 100 110
SJE Rhombus 168 53
St. Marys Carbon Company 186 107
Summit Pump, Inc. 306 111
Swaby Manufacturing Co. 153 74
SWPA 154 93
Synchrony, Inc. 121 IBC
Tamer Industries 307 111
Tarby,
Inc. 169 51
TECO-Westinghouse 122 37
Trachte, USA 308 111
Trask Decrow Machinery 309 110
Tuf-Lok 310 111
Turbomachinery Symposium 128 89
Unitronics, Inc. 193 108
Valve & Filter Corp. 155 43
Vaughan Company, Inc. 123 23
Verder GPM 156 12
Vertilo Pump Co. 187 64
VescoPlastics Sales 311 109
VibrAlign, Inc. 170 76
WAGO 157 48
WEFTEC 124 55
Weir SP 158 44
WILO USA LLC 125 77
Yaskawa America, Inc. 126 7
Zoeller Company 127 85
Zoeller Company 312 109
* Ad index is furnished as a courtesy and no
responsibility is assumed for incorrect information.
Advertiser Name R.S. # Page Advertiser Name R.S. # Page Advertiser Name R.S. # Page
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BULLETIN BOARD
Pump Tec 2010
EVERYTHING YOU EVER WANTED TO KNOW ABOUT PUMPS!
7th Pump Tec
Pumps Hands-On Maintenance
and Reliability Conference
Atlanta, GA USA
September 20-21, 2010
For more information go to
www.pumpconference.com
770-310-0866
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PLC+HMI
Unitronics, Inc. Toll free: 866-666-6033, [email protected], www.unitronics.com
Starting at $489
Save Ti me and Money wi t h Uni t roni cs i nt egrat ed PLC + HMI
ONE PLC+HMI in ONE unit
Unitronics - Your Advantage!
Integrated PLC & HMI
Great communication options
Datalogging and recipes
FREE Remote access
FREE programming software
Vision350
TM
PLC+HMI
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MONITOR PUMP PERFORMANCE
UNIVERSAL
POWER CELL
One Size AdjusLs for
All MoLors, lron Snall
up Lo 150HP
Works on variable lrequency
Drives, 3 Phase, DC and
Single Phase
10 Lines nore sensiLive
Lhan jusL sensing anps
4-20 Millianp, 0-10 volL
FLOW RAT
PUMP CONDITION
DRY RUNNINC
CAVITATION
BARINC FAILUR
CALL NOW FOR YOUR
FR 30-DAY TRIAL
888-600-3247
WWW.LOADCON1kOLS.COM
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PUMP USE RS MARKETPL ACE
PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 109
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''.
'
, ,' , '. ' |' |. '
.,'
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. '', '.
,, .: , .''.
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'
3649 Cane Pun Pd. - Loulsvllle, K 402ll - www.zoeller.com - 502-778-273l - PAX 502-774-3624
.,, ' '.|'
Easy to Install...
Zoeller Lnglneered Products' Progresslng Cavlty Grlnder Petrot readlly
adapts to exlstlng pump systems.
Our nned class 30 cast lron constructlon reduces heat--an arch enemy
to any electrlc motor.
For more information on the Progressing Cavity Grinder Retroit,
please visit www.zoeller.com
Model 6932
ANNIVERSARY
SINCE 1939
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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 90
th
Place, Suite 200
Scottsdale, Arizona 85258-5065
(480) 767-9000 Fax (480) 767-0100
Email: [email protected]
www.danbolenassoc.com
EXECUTIVE SEARCH/RECRUITING
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Employment
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The Source for
Pump Expertise
The Pumps & Systems
editors have carefully
selected an exclusive
collection of textbooks,
guidelines, manuals,
standards and technical
materials related to
the pump and rotating
equipment industry in our
online bookstore,
www.PumpBooks.com.
The Source for Pump Expertise
The Source for Pump Expertise
PUMP USE RS MARKETPL ACE
110 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS
For informaon:
(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-Rupps T SERIES & U SERIES,
these pumps are available as bare pumps, parts, base
mounted and assembled berglass lift station units.
Materials of construction available include Cast-Iron, CD4MCu,
316-SS, 304-SS, ADI, Hastelloy & High-Chrome.
T SERIES & U SERIES are trademarks and registered trademarks of The Gorman-Rupp Co. in the
US & other countries. All Prime is not sponsored by nor afliated with The Gorman-Rupp Company.
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C
A
N
M
A
K
E
O
B
S
O
L
E
T
E
P
A
R
T
S
F
O
R
A
N
Y
P
U
M
P
Use the Best!
Sims
Magnetic Bearing
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