PumpsAndSystems April

A P R I L 2 0 16
PUMPSANDSYSTEMS.COM
SYSTEMS
The Leading Magazine for Pump Users Worldwide
REFINING
THE PROCESS
Strategies for advancing todays
oil & gas facilities
4 WAYS TO PREVENT
Seal Failure
TAKE THE Valve
Maintenance Test
ON PAGE 70
TRADE SHOW PREVIEW:
Houstons OTC 2016
Circle 100 on card or visit psfreeinfo.com.
FROM THE EDITOR
ust a couple of weeks ago, oil

prices were continuing to make
headlinesin a good way. As this April
issue of Pumps & Systems went to the
printer, the price of U.S. crude was right
around $38 a barrel. A few days earlier
it had reached its highest price of
$38.51 a barrel since Dec. 9, 2015. Brent
crude futures were around $40 a barrel
after reaching a high of $41.48 over the
same time.
Oil prices are still a far cry from the
Pumps & Systems Managing Editor Martin Reed,
$70-a-barrel range a year ago, making
Senior Editor Alecia Archibald, Managing Editor
the need to increase efficiencies and
Amelia Messamore and Vice President of Sales Greg
Meineke attend the Hydraulic Institutes annual
save money as important as ever in the
conference in Tucson, Arizona, in February.
oil and gas industry. The cover series in
this issue of Pumps & Systems focuses
on operational advancements in refineries.
The series begins with an article on page 46 about how a preventive maintenance
program can reduce costs and increase reliability at refineries, while the benefits of
monitoring technology at these facilities are explained starting on page 54. An article on
page 50 showcases an example of a Texas refinery improving its water management with
reverse osmosis units and by reusing 100 percent of its water on-site.
An article about the benefits encountered at a Midwest refinery from using graphitemetal alloy bearings begins on page 52, and the series concludes with an article on page
58 about a Southwest pipeline station and tank farm addressing vibration-related issues.
This issues special section dives into the topic of sealing challenges with four
educational articles. Check out the benefits of using dry gas seals to pump liquids on
page 32, followed by four ways to prevent seal failure starting on page 36. An article
on page 40 looks at how the right bearings and seals help in harsh conditions, while
advancements in seal ring and face materials are discussed starting on page 42.
In addition, anyone who has questioned the right time for performing maintenance
on control valves must check out the article by Singer Valve on page 68. The article
concludes with a matrix and scorecard that can help keep your equipment operating at
optimal performance.
At Pumps & Systems, we strive to be your primary go-to source for information
pertinent to individuals working in numerous facets of the industries we cover. With
every issue, we are committed to delivering informative articles that can help end users
with their jobs on a daily basis.
We have an open-door policy for suggestions, ideas and comments, so please email me
at mreed@cahabamedia.com.
Sincerely,
Managing Editor Martin J. Reed
mreed@cahabamedia.com
EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
aarchibald@cahabamedia.com 205-278-2843
SENIOR TECHNICAL EDITOR: Mike Pemberton
mpemberton@cahabamedia.com
205-314-8279
MANAGING EDITOR: Amelia Messamore
amessamore@cahabamedia.com
205-314-8264
MANAGING EDITOR: Martin Reed
mreed@cahabamedia.com 205-278-2826
MANAGING EDITOR: Savanna Gray
sgray@cahabamedia.com 205-278-2839
CONTRIBUTING EDITORS: Lev Nelik,
Ray Hardee, Jim Elsey
CREATIVE SERVICES
DIGITAL PROJECT MANAGER: Greg Ragsdale
ART DIRECTORS: Melanie Magee, Elizabeth Chick
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ACCOUNT EXECUTIVES:
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Birmingham, AL 35253
EDITORIAL & PRODUCTION
Pumps & Systems

is a member of the following organizations:
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the
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A pr i l 2 0 1 6 | Pum ps & S y st e m s
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This issue
COVER
SERIES
APRIL
Volume 24 Number 4
COLUMNS
OIL & GAS REFINERIES
PUMPING PRESCRIPTIONS
16 By Lev Nelik, Ph.D., P.E.
Pumping Machinery LLC
Letter from a Reader:

Vibration Spectrum Analysis
PUMP SYSTEM IMPROVEMENT

20 By Ray Hardee
Engineered Software Inc.

Examine Pump, Process & Control
Elements to Solve Fluid Piping
System Problems
COMMON PUMPING MISTAKES
46
24 By Jim Elsey
Summit Pump Inc.
Guidelines for Submergence &

Air Entrainment
46 IMPROVE ASSET PERFORMANCE WITH INNOVATIVE SERVICES

By Harald Gromann, Sulzer
Preventive maintenance programs at refineries can result in reduced costs

and better reliability.
INDUSTRY INSIGHTS
30 By Mike Pemberton
Pumps & Systems
50 TEXAS REFINERY REVAMPS WATER TREATMENT SYSTEM
The Future of Predictive

Maintenance
By Mike Jenkins, Progressive Water Treatment
The custom solution reduces supply and maintenance costs and provides a
consistent feedwater supply.
52 FACILITY CHOOSES GRAPHITE-METAL ALLOY BEARINGS

By Eric Ford, Graphite Metallizing Corp.
The materials are able to withstand dry-run conditions.
54 SOPHISTICATED MONITORING SAVES LABOR HOURS

& DOWNTIME IN REFINERIES
By Brian Phillippi, National Instruments
2
8
88
92
92
96
FROM THE EDITOR

NEWS
PRODUCTS
ADVERTISER INDEX
PUMP USERS MARKETPLACE
PUMP MARKET ANALYSIS
An industry with aging infrastructure and increasing demands needs better

monitoring technology.
58 SOUTHWEST PIPELINE STATION EMPLOYS MODERN TOOLS TO

IMPROVE PUMPING SYSTEM
By Jay Marchi, ProPump Services
Various analyses can identify problems and predict future system

vibratory responses.
ON THE COVER
Petro Stars North Pole Refinery
processes petroleum from the Trans
Alaska Pipeline and distributes diesel
products across the state. (Photo Judy
Patrick, courtesy of Petro Star)
58
This issue
SPECIAL
SECTION
APRIL
DEPARTMENTS
SEALING CHALLENGES
62 EFFICIENCY MATTERS
Compressors Assist in Propane

Transfer Transition
By Bill Holmes
Blackmer
32 USING DRY GAS SEALS TO PUMP LIQUIDS
This unconventional solution features bonding consisting of a micro-crystalline layer

that has attributes of natural diamond.
68 MAINTENANCE MINDERS
By Emery Johnson, EagleBurgmann
How Reliable Is Your Control

Valve Maintenance Program?
By Mark Gimson
Singer Valve
36 4 WAYS TO PREVENT SEAL FAILURE
Take these precautions to maximize your investment.

By Andrew Kalinen, Flex-A-Seal Inc.
72 MOTORS & DRIVES
40 ADVANCED BEARINGS & SEALS
How Power Factor & Induction

Motors Can Impact the
Bottom Line
By William Livoti
WEG Electric Corporation
OFFSET HARSH CONDITIONS
A large petrochemical plant increased

the service life of its equipment from six
months to three years.
By Tom McDermott, SKF USA Inc.
74 SEALING SENSE
42 SOLVING SEALING PROBLEMS BY
Manage Rubber Expansion

Joints in Piping Systems
to Maximize Reliability &
Efficiency
By Lloyd B. Aanonsen, P.E.,
& Joshua Cocciardi
FSA Members
KEEPING FACES CLOSE & PARALLEL
Advances in seal ring and face materials

can improve basic design issues
associated with mechanical seals.
32
By Mark P. Slivinski,
Carbide Derivative Technologies Inc.
78 HI PUMP FAQS
PRACTICE & OPERATIONS

81 SOLID FOUNDATIONS INCREASE
ROTATING EQUIPMENT RELIABILITY
Air Pockets in a Piping System,

Sealing Device Basics & Rotary
Pumping System Leakage
By Hydraulic Institute
By Scott Sapita, BaseTek LLC

& Thomas Hines, Chemtrade Logistics Inc.
84 A NEW APPROACH TO
84
PRODUCT DEVELOPMENT
By Bill Blankemeier & Bill Taylor
PeopleFlo Manufacturing
EDITORIAL ADVISORY BOARD

THOMAS L. ANGLE, P.E., MSC, Vice
President Engineering, Hidrostal AG
BRYAN S. BARRINGTON, Machinery
Engineer, Lyondell Chemical Co.
KERRY BASKINS, VP/GM, Milton Roy
Americas
R. THOMAS BROWN III, President,
Advanced Sealing International
(ASI)
CHRIS CALDWELL, Director of
Advanced Collection Technology,
Business Area Wastewater Solutions,
Sulzer Pumps, ABS USA
JACK CREAMER, Market Segment
Manager Pumping Equipment,
Square D by Schneider Electric
BOB DOMKOWSKI, Business

Development Manager Transport
Pumping and Amusement Markets/
Engineering Consultant, Xylem, Inc.,
Water Solutions USA Flygt
WALT ERNDT, VP/GM, CRANE Pumps
& Systems
JOE EVANS, Ph.D., Customer &
Employee Education, PumpTech, Inc.
LARRY LEWIS, President, Vanton
Pump and Equipment Corp.
WILLIAM LIVOTI, Business
Development Manager/Energy
Efficiency Specialist, WEG Electric
Corporation
TODD LOUDIN, President/CEO North

American Operations, Flowrox Inc.
MICHAEL MICHAUD, Executive
Director, Hydraulic Institute
JOHN MALINOWSKI, Sr. Product
Manager, AC Motors, Baldor Electric
Company, A Member of the
ABB Group
SCOTT SORENSEN, Oil & Gas

Automation Consultant & Market
Developer, Siemens Industry Sector
ADAM STOLBERG, Executive Director,
Submersible Wastewater Pump
Association (SWPA)
JERRY TURNER, Founder/Senior
Advisor, Pioneer Pump
WILLIAM E. NEIS, P.E., President,

Northeast Industrial Sales
DOUG VOLDEN, Global Engineering

Director, John Crane
LEV NELIK, Ph.D., P.E., APICS,

President, PumpingMachinery, LLC
KIRK WILSON, President, Services &

Solutions, Flowserve Corporation
HENRY PECK, President, Geiger Pump

& Equipment Company
JAMES WONG, Associate Product

Manager Bearing Isolator, Garlock
Sealing Technologies
MARIANNE SZCZECH, Director,

Global Marketing and Product
Management, Pump Solutions Group
Motors and drives, the key components of

facility, can be prone to a number of unse
problems causing costly downtime.
Download Flukes most popular applicatio
note that discusses:
Common causes of motor failure
What to look for
What the impact is
What tools to use
How critical the issues are
Download 13 common causes of motor failure at
fluke.com/13CommonCauses
Fluke.Keeping your world

up and running.
2015 Fluke Corporation. 6006434a-en
NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
BRYCE W. DAVIS
& JEFF KOEHLER
WATER PLANET
LOS ANGELES (Feb. 29, 2016)

Water Planet announced
that Bryce W. Davis, Ph.D.,
and Jeff Koehler, Ph.D.,
Bryce Davis Jeff Koehler
joined its growing team.
Davis, who possesses a
doctorate in analytical chemistry, joined Water Planet as a
research and development (R&D) scientist. Previously, he was a
principal engineer at Polymer Group Incorporated, an application
engineer for Fiberweb plc. and a materials scientist with FibeRio
Technology Corporation. Koehler is product development specialist
technical liaison for commercialization of Water Planets PolyCera
membranes. Previously, Koehler was principal scientist and
director of process development at NanoH2O Inc./LG NanoH2O, and
principal scientist at Nanostream Inc. waterplanet.com
JOE ACCETTA, KALENBORN ABRESIST
URBANA, Ind. (Feb. 26, 2016) Joe Accetta,

president of Kalenborn Abresist Corporation,
has announced that he will be retiring in May
2016. Accetta, a 1973 graduate of Northwestern
University, was originally employed as vice
president of sales in 1983 and was named
president in 1990. He has served in that
Joe Accetta
capacity for 26 years. For 10 years prior to
1983, Accetta was involved in the sales and
Abresist product management for M.H. Detrick, an early joint
venture partner in Kalenborn Abresist Corporation. abresist.com
CHRISTOPHER BRIDGEWATER
CORNELL PUMP
CLACKAMAS, Ore. (Feb. 25, 2016) Cornell

Pump has announced that Christopher
Bridgewater has joined its team as Southwest
agricultural regional manager, with
responsibilities for irrigation, farm dewatering
and manure in California, the desert Southwest
Christopher
and the Mountain West. He has more than 20
Bridgewater
years of experience in the industries, working
in the supply chain process from manufacturing to installation.
He has spent the last nine years as a territory manager, increasing
sales in his area by more than 600 percent. cornellpump.com
JOHN TOMLJENOVIC, MIKE MURRAY & KEVIN MOLONEY

SUMMIT PUMP INC.
GREEN BAY, Wis. (March 1, 2016) John Tomljenovic is Summit

Pump Inc.s newest addition as Western regional sales manager.
Tomljenovic is responsible for the Western region of the U.S.,
Western Canada and all of Mexico. He has more than 25 years

of experience in direct sales and sales management in the
mechanical seal business. Mike Murray has transitioned from
direct sales to Midwest regional manager. He has more than 30
years of direct professional experience in pump sales, applications
and troubleshooting. Kevin Moloney is the Eastern regional sales
manager and has responsibility for the Eastern U.S., Canada and
portions of the Caribbean. He has more than 30 years of pump and
mechanical seal experience. The regional sales managers report to
Jim Elsey, general manager for Summit Pump.
summitpump.com
NATHAN OLDS, GRUNDFOS
DOWNERS GROVE, Ill. (Feb. 11, 2016) Grundfos

Pumps Corporation has appointed Nathan Olds
as the vice president of Domestic Building
Services (DBS) Trade for the U.S. In this role,
Olds will manage wholesale distribution for the
companys heating and plumbing products. He
will report to the DBS executive vice president,
Terry Teach. us.grundfos.com
Nathan Olds
STEVE BASCLAIN, PSG EBSRAY
OAKBROOK TERRACE, Ill. (Feb. 10, 2016) PSG

has appointed Steve Basclain to business
development manager for PSG Ebsray. In this
role, Basclain will help drive new business
opportunities for the Ebsray brand and support
the PSG sales teams globally while directing the
functional areas of applications engineering,
Steve Basclain
customer care, contracts, product management
and aftermarket. He will report directly to John Cosgrove, general
manager for PSG Ebsray. psgdover.com/en/ebsray
ANTHONY MISIAK
& JEFF DAVIS
TSURUMI PUMP
GLENDALE HEIGHTS, Ill. (Feb.

4, 2016) Tsurumi Pump
has announced that it has
added two new regional sales
managers to its staff. Joining
Anthony
Jeff
the management team are
Misiak
Davis
Anthony Tony Misiak and
Jeff Davis. Misiak joined Tsurumi as a regional sales manager in
December 2015. Misiak will be based in Byron Center, Michigan,
and he will be responsible for the Midwest region. Also joining
Tsurumi as a regional sales manager is Davis, who started
his employment in January of this year. He will oversee
Tsurumis Western region and will be based in Lake Sherwood,
Missouri. tsurumipump.com
AROUND
THE INDUSTRY
Hydraulic Institute Recognizes
Four Industry Leaders
PARSIPPANY, N.J. (Feb. 24, 2016)
The Hydraulic Institute (HI) announced
the recipients of several awards
and honors during its 2016 Annual
Conference in Tucson, Arizona. Jack
Claxton, vice president of engineering,
Patterson Pump Company, received HI's
Lifetime Achievement Award; Patrick
Hogg, product manager, Nidec Motor
Corporation, was HI's Young Engineer
of the Year award recipient; William C.
Livoti, business development manager,
WEG Electric Corporation, received the
organization's first PSM Leadership
Award; and Paul Ruzicka, global COE
residential, commercial wastewater and
chief engineer at Xylem Inc.- Applied
Water Systems, received the 2015
Member of the Year award. Claxton
has more than 40 years of service in
the pump industry and has been an
instrumental HI member for more
than 30 years. Hogg has been involved
with HI since 2013, is a member of
10 committees, serves as a webinar
instructor, and holds leadership positions
on three committees. Livoti has more
than 40 years in the pump industry,
designing, field testing, repairing and
troubleshooting mechanical seals,
compressors, motors and pumping
systems. The HI Board of Directors
selected Ruzicka for his commitment to
HI in leading and actively participating
in numerous HI committees in the
advancement of the institute's technical
work and guiding young engineers
within the institute's extensive technical
organization. pumps.org
US Poll Finds 60 Percent of

Participants Would Pay More
for Secure Water Service
ALEXANDRIA, Va. (Feb. 24, 2016) - The
Value of Water Coalition has released the
results of a new national poll on public
attitudes about water, which found that
Americans are deeply concerned with
the state of water infrastructure and are
willing to support efforts to invest and
modernize these systems to ensure and
maintain reliable water and wastewater
services. Of the participants, 9 5 percent
support investment in water systems,
and 60 percent said they would pay more
for secure water. theva/ueofwater.org
Flex-ProPeristaltic
Metering Pumps
provide smooth,
quiet pumping action and deliver accurate amounts of chemical
to your system. Three Flex-Pro models are offered, featuring a broad range of
output rates, electronics options and features .
Exclusive- Built-in, patented Tube Failure
Advanced Electronics- with
easy access to controls.
Detection.
Multiple Signal Input and
Innovative, Heavy Duty Rotor: Single piece plastic
rotor means no flexing and increased accuracy
Output (4-20mA, etc.).
One Button Prime Mode.
with no metal springs or hinges to corrode.
Flex-A-Prene
Heavy-Duty Peristaltic Pump Tubing
Flex-A-Preneis a multichannel pump

tube assembly designed by Blue-White
exclusively for Proseries-M 8 and Flex-Pro
Peristaltic Metering Pumps. Flex-A-Prene
is engineered for optimum performance,
including up to four times longer
service life than other pump
tube assemblies.
pumpsandsystems.com
I April
2016
10
NEWS
AROUND THE INDUSTRY

Pentair Named Water
Innovator of the Year
ENSCHEDE, The Netherlands (Feb.

23, 2016) Pentair was named Water
Innovator of the Year during the Water
Vision Congress, Feb. 18, 2016, in
Rotterdam, the Netherlands. Pentairs
new X-Flow Helix technology was
recognized for its ability to prevent
membrane fouling and reduce energy
use in the treatment of industrial
wastewater. Pentairs Helix technology
design features a helical shape on
the inside of a tubular membrane,
creating continuous turbulence to
prevent rapid fouling. By introducing
turbulence right at the membrane
wall, the Helix technology provides
continuous mixing and efficient
removal of the cake layer that would
otherwise reduce the membranes
hydraulic permeability.
pentair.com
Flowserve Facility Certified

through HIs Pump Test Lab
Approval Program
PARSIPPANY, N.J. (Feb. 23, 2016) The

Hydraulic Institute (HI) introduced
member company, Flowserve
Corporation, as the latest company
to have their pump test laboratory
approved through the HI Pump Test
Lab Approval Program. The HI program
helps pump original equipment
manufacturers (OEMs) and other pump
test laboratories improve their current
laboratory procedures and policies by
working with an experienced thirdparty auditor to develop and maintain
accurate, uniform and repeatable
pump testing protocols. pumps.org
flowserve.com
EPA Releases Online Mapping

Tool to Help Protect Drinking
Water Sources
WASHINGTON (Feb. 19, 2016) The

U.S. Environmental Protection Agency
has released DWMAPS the Drinking
Water Mapping Application to Protect
Source Waters. This online mapping
tool provides the public, water system
operators, state programs and federal
agencies with critical information to
help them safeguard the sources of
Americas drinking water.
DWMAPS allows users to learn about

their watershed and understand
more about their water supplier.
DWMAPS also lets users see if sources
of their drinking water are polluted
and if there are possible sources
of pollution that could affect their
communities water supply. It allows
them to identify potential sources
of contamination in their locations,
find data to support source water
assessments and plans to manage
potential sources of contamination,
and evaluate accidental spills and
releases. epa.gov
Global Water PPP Market

to Triple by 2020
BOSTON (Feb. 18, 2016) Many

countries are facing a perfect storm
of financing constraints and water
infrastructure shortfalls. Declines in
oil and commodity prices, low water
tariffs, groundwater overdrafts and
untreated wastewater discharges are
prompting governments to tap the
private sector through public-private
partnership (PPP) schemes. According
to a report from Bluefield Research,
the market for water PPP projects
is set to nearly triple between 2016
and 2020, adding an average of 16
million cubic meters per day (m3/
day) of treatment capacity annually
versus approximately 6 million m3/
day between 2010 and 2015. Total
investment is expected to surpass $58
billion, of which 80 percent will target
new seawater desalination and
wastewater treatment plants.
bluefieldresearch.com
Siemens Announces New

Channel Partner Process
Technology Inc.
HOUSTON (Feb. 18, 2016) Siemens

Analytical Products and Solutions
has announced a partnership
with new channel partner Process
Technology Inc. (PTI). The new
partnership will focus on the Rocky
Mountain region, as PTI is based
out of Salt Lake City, Utah. PTI is a
process analyzer, instrumentation
and automation control company
operating since 1986. siemens.com
processtechnology.com
Study Finds 34 Percent

of Manufacturers Do Not
Track Asset Data
CENTER HARBOR, N.H. (Feb. 9,

2016) Smartware Group Inc. and
Technology Evaluation Centers
Inc. (TEC) has released the results
of a comprehensive survey of U.S.
manufacturers and their usage of
computerized maintenance and
management system (CMMS) and
enterprise asset management (EAM)
software. According to the survey, 34
percent of respondents stated they
arent capturing operational asset data
at all. Of the 60 percent that said they
are capturing this data, two-thirds
said they do so manually. The findings
show a significant gap between
common maintenance practices in the
field and existing technological tools.
bigfootcmms.com
Chesteron Announces Opening

Date for its New Groveland
Facility Expansion
GROVELAND, Mass. (Feb. 9, 2016)
The A.W. Chesterton Company has
announced that its new, extensive
expansion project at its North
American headquarters in the
Groveland, Massachusetts, facility will
officially open its doors May 5, 2016.
Breaking ground on April 22, 2015,
Chesterton incorporated new
corporate offices as well as a customer
and employee training facility and
large service center covering the
New England area. This new facility
represents the first time in more than
115 years the firms Massachusetts
employees will all be under the same
roof. chesterton.com
DC Water & WEF Launch

Development of a National
Green Infrastructure
Certification Program
WASHINGTON, D.C. (Feb. 8, 2016)

DC Water and the Water Environment
Federation (WEF) have signed an
agreement to develop a National
Green Infrastructure Certification
Program aimed at promoting skilled
individuals who will install, inspect
and maintain green infrastructure
(GI) systems. In addition, the program
11
Private Water Players Reshape

Global Desalination, Poseidon
Enters Top 25
BOSTON (Feb. 3, 2016) The top 25

desalination system owners, including
both public and private companies,
added a quarter (approximately 25
percent) of total capacity additions
in 2015, representing an estimated
524,000 cubic meters per day, according
to a study. Private water players took
an active role in the desalination
market in 2015, representing nine of
the top 10 biggest movers by capacity
additions, according to rankings
released by Bluefield Research. With
the commissioning of its Carlsbad,
California, desalination plant, Poseidon
Resources became the first U.S.
company to rank among the top 25
private water owners globally,
according to Bluefield Research.
bluefieldresearch.com
ISA Announces the

Continuation of Beamex
as its Premier Strategic
Partner for Calibration
RESEARCH TRIANGLE PARK, N.C. (Feb.

3, 2016) The International Society
of Automation (ISA) announced that
Beamex, a calibration company with
products, services and support in 80
countries, will continue to serve as
its strategic partner for calibration.
Over the past several years, through
the partnership, Beamex and ISA
have collaborated to provide ISA
members and customers with access to
Beamexs diverse calibration resources,
including publications, case studies,
webinars, expert advice and more. This
announcement signifies that Beamex
will continue to work with ISA to codevelop informational and educational
resources. isa.org
Little thermal
relief valve.
Big water
conservation
savings.
The EcoFlow Seal Flush thermal relief valve automatically and

reliably controls seal water flow and temperature from your double
mechanical seals for a drastic reduction in water consumption
and significant cost savings. A simple installation reduces water
usage and waste water treatment while boosting cost savings:
Immediate, significant reduction in seal water consumption
with no outside power required
No more monitoring and manually adjusting flow
Avoids dry runs and protects seal life
Allows users to leave the water supply on and ensures
water flows only when needed
Reduces pump downtime
Find out how this little valve creates such BIG savings,
visit ThermOmegaTech.com/EcoFlow today.
(877) 379-8258
THE WORLD LEADER IN SELF-ACTUATED TEMPERATURE CONTROL SOLUTIONS
p u m p s a n d s y s te ms . c om | A pr il 2016
will help support community-based

job creation in U.S. cities and establish
national standards for professionals
seeking to work on GI projects. This
joint effort will support DC Waters
recently announced legal agreement to
construct large-scale GI to help control
combined sewer overflows in the District
of Columbia, according to the groups.
wef.org
12
NEWS
Recommended Practice for

Motor Repair Re-Approved as
ANSI Standard
Process Pumps & Steam Turbines
Generating Power for Human Life, SNM

TOTAL SOLUTIONS APPROACH
SNM is the only manufacturer in the world that produces
API610 process pumps and API611/612 steam turbines in

the same factory. This total solutions approach uniquely
addresses the needs of the oil and gas industry.
ENERGY-SAVING SOLUTIONS
ST. LOUIS (Feb. 1, 2016) An updated

edition of the only American National
Standard for repair of motors and
generatorsANSI/EASA AR100-2015:
Recommended Practice for the Repair
of Rotating Electrical Apparatuswas
recently published for use by the repair
industry and its customers. The standard
describes industry best practices for
the repair, rewinding and testing of
electrical apparatus in order to maintain
or enhance the energy efficiency and
reliability of both alternating and direct
current motors and generators. ANSI
requires that standards be re-approved
at least every five years, prompting
the review and approval of the AR1002015 edition. The revision introduced
new requirements, added or tightened
performance tolerances in several critical
areas and expanded testing procedures.
The standard now includes requirements
relating to the machining of commutators
and slip rings, and it establishes
temperature limits for the process of
removing motor windings. Additional
performance tolerances were added
for balancing motors rated above 2,500
rpm. Finally, testing procedures were
established or clarified relating to bearing
insulation, winding surge comparison
and resistance, no-load performance and
vibration. ansi.org
To have a news item considered, please
send the information to Amelia Messamore,
amessamore@cahabamedia.com.
Mounting data confirms that
energy savings are realized when

old pumps in aging plants are
replaced with high efficiency,
MERGERS &
ACQUISITIONS
latest model pumps. At SNM our

pump products and solutions
address energy-savings concerns

facing clients across the globe.
Hydro International has entered into

conditional agreements to acquire
Hydro-Logic Limited.
Feb. 29, 2016
CLARCOR Industrial Air has acquired
U.S.-based TDC Filter from MRFI.
Feb. 9, 2016
www.snm.co.jp
Xylem Inc. has acquired Tideland Corporation.

Feb. 4, 2016
SALES OFFICES
TOKYO, JAPAN
+81-3-6737-2631
HOUSTON, TEXAS
+1-281-990-8594
GLENDALE, CALIFORNIA
+1-818-500-8165
FACTORY
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+66-2-262-0740
HIROSHIMA, JAPAN
+81-823-71-1111
Danfoss has acquired Vacon.

Feb. 3, 2016
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14
NEWS
Offshore Technology
Conference
Exhibition Hours
Preview
Monday, May 2
May 2-5, 2016
NRG Park
Houston, Texas
he Offshore Technology
Conference (OTC) 2016,
the offshore energy industrys
premier annual event, will
take place May 2-5 at NRG
Park, formerly Reliant Park,
in Houston, Texas. This years
theme is Endless Innovation.
Sponsored by 13 nonprofit
technical societies involved
in the energy business, OTC
2016 is an opportunity to gain
technical knowledge, learn
more about best practices and
see new products and services.
More than 90,000
professionalsincluding
industry leaders, investors and
entrepreneursfrom more
than 130 countries are
expected to attend. This years
event is expected to include
more than 2,100 exhibitors
from 45 countries and 18
international pavilions.
OTC offers learning
opportunities that include a
technical program featuring
global experts and topics
spanning risk management,
new and emerging markets, and
the operation of aging fields
and hardware.
9 a.m. to 5:30 p.m.

Tuesday, May 3
9 a.m. to 5:30 p.m.
Wednesday, May 4
9 a.m. to 5:30 p.m.
Thursday, May 5
9 a.m. to 2 p.m.
The event will offer training
courses on deepwater riser
engineering, marine broadband
technologies and petroleum
geology for engineers. Courses
will be held at the George R.
Brown Convention Center on
the days before and the day
after the conference.
Other events and activities
at OTC 2016 include the
Distinguished Achievement
Awards Luncheon at the NRG
Center on May 3.
The second d5 conference
an OTC event designed to spark
creativity and innovation in
the industrywill be at Rice
University on May 6. Speakers
will include Helen Greine,
co-founder of iRobot and CEO
of CyPhyWorks; Ram Shenoy,
former chief technology officer
at ConocoPhillips; and Gindi
Vincent, an author, speaker and
counsel at ExxonMobil.
For registration or more
information about OTC 2016,
call 972-952-9494 or visit
otcnet.org.
EVENTS
Reliable Plant 2016
April 5 7, 2016
Kentucky International
Convention Center
Louisville, Kentucky
800-597-5460 / conference.reliableplant.com
PumpTec 2016
(Advanced Training)
April 6 7, 2016
Atlanta, Georgia
770-310-0866 / pumpingmachinery.com/pump_
school/pump_school.htm
Offshore Technology Conference
May 2 5, 2016
NRG Park
Houston, Texas
972-952-9494 / 2016.otcnet.org
2016 EASA Convention
June 12 14, 2016
Metro Toronto Convention Centre
Toronto, Ontario
314-993-2220 / easa.com/convention
National Fire Protection Association
Conference & Expo
June 13 16, 2016
Mandalay Bay Convention Center
Las Vegas, Nevada
800-344-3555
nfpa.org/training/conferences/conference
American Water Works Association
Annual Conference & Exhibition
June 19 22, 2016
McCormick Place
Chicago, Illinois
800-926-7337 / awwa.org
World Nuclear Exhibition
June 28 30, 2016
Paris Expo - Le Bourget, Hall 2B
Paris, France
33 147 56 65 37 / world-nuclear-exhibition.com
INDOWATER 2016
July 20 22, 2016
Grand City Convex
Surabaya (East Java), Indonesia
+49-40-3999905-0 / indowater.com
(Image Courtesy of Corporate Event Images)
16
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.

Pumping Machinery, LLC, P&S Editorial Advisory Board
Letter from a Reader:

Vibration Spectrum Analysis
egarding the vibration

spectrum on page 12 of
the February 2016 issue
of Pumps & Systems (Using Pump
Efficiency Monitoring to Make
Faster Decisions, Figure 1), your
question of what the spectrum is
showing needs more information
to enable an accurate answer:
Where is the sensor located?
What kind of pump?
What is the orientation of the
sensor? X, Y or Z axis?
Is the data averaged, peak hold
or instantaneous?
Is the pump speed constant
or changing?
Is the flow steady or changing?
How many vanes are on
the impeller?
Are the units root mean square,
peak or other?
What is the power required by
the pump?
Is this a Category I or II pump
per International Standards
Organization (ISO) 10816-7?
Making some assumptions

about the data, an unbalance
problem appears to be present. It
is not misalignment or cavitation.
However, if you look at the
spectrum, there is a slight peak
just above one time per revolution
at maybe 70 hertz (Hz). This could
be resonance. If so, the running
speed is less than 20 percent away
from this natural frequency, and
the response could be amplified by
this resonance. While unbalance
is indicated, it may be a resonance
problem, and balancing is not, in
my opinion, a permanent fi x.
Assuming this is a small pump,
judging by the operating speed, the
amplitude is probably acceptable
per ISO 10816-7. The overall level
of vibration is probably less than
0.098 in/s-RMS, which is the Zone
A/B boundary for new machines.
But if the small peak at 70 Hz is a
resonance, then all bets are off. If
I were the end user, I would not be
happy with a resonance less than
20 percent above running speed. As
the machine wears, the resonance
will drop in frequency, potentially

to the point where the running
speed will sit right on the natural
frequency. With the low amount of
damping present in the spectrum,
this would create amplitudes well
in excess of the ISO 10816-7 limit.
Reader from California
Neliks Response
Let me start with your ending
notes first: very observant! The
small peak just past the 1X is a
potential problem. With wear and
lowered stiff ness of the system over
time, the 70 Hz peak may creep
right onto the 60 Hz resonance.
Frequent or even continual
monitoring would be important.
The values are still small, and the
unit is small, judging from data
shown on the performance curve
above the spectral plot. Unbalance
(1X) is small, but the proximity to
the possible critical frequency may
lead to issuesthough it is hard to
predict how soon. While immediate
pump pull and fi x is not necessary,
monitoring is.
Making some assumptions about the data, an unbalance

problem appears to be present. It is not misalignment or cavitation.
However, if you look at the spectrum, there is a slight peak just
above one time per revolution at maybe 70 hertz (Hz). This could be
resonance. ... While unbalance is indicated, it may be a resonance
problem, and balancing is not, in my opinion, a permanent fix.
Choose the
Right Pump for
the Application
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Sponsored by
Regarding your other points, the

location of the sensor is relevant, but
they are most often on bearing housings.
The type of pump would not make much
difference, although if it is vertical, then

any unbalance would be a serious issue.
Impeller wear way below the soleplate
is not often detectable by the analyzers
IBEPCO"
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at the top of the structure (motor area),

and vertical turbine vibrations are
not easily detectable by the vibration
instruments at the top.
Your point on sensor location has
another important aspect. If the signal
comes from the axial direction, then
the angular misalignment may be an
issue, which is often shown not as a
2X but a lX component. In such cases,
having another sensor direction is
important. If it is at the offset direction
(parallel of vertical, for example) and
shows 2X (twice running speed), then
misalignment is likely (presence of lX
and 2X).
The pump speed is constant in this
case, but the cloud of higher head data is
an indication of the second pump joining
in at some time, with two of them now
generating higher head, but at a flow
only slightly higher-a typical situation
with two pumps running in parallel.
Vibration data are at RMS, as shown
at the vertical axis. The pump is small,
and vibrations are well within the
limits, as you noted. Interestingly, the
resonance concern was expressed in this
particular case, which is why continual
monitoring is planned.
Thank you for your insightful
comments and observations. If you
want to be involved in our committee
work, let me know, and we will get you
involved. For more information, visit
pumpingmachinery.com.
Dr. Nelik (aka "Dr. Pump") is president

of Pumping Machinery, LLC, an
Atlanta-based firm specializing in
pump consulting, training, equipment
troubleshooting and pump repairs. Dr.
Nelik has 30 years of experience in
pumps and pumping equipment. He
may be reached at pump-magazine.
com. For more information, visit
pumpingmachinery.com/pump_school/
pump_school.htm.
April 2016
I Pumps
& Systems
20

A better understanding of complete system operation
By Ray Hardee
Engineered Software, Inc.
Examine Pump, Process & Control Elements to

Solve Fluid Piping System Problems
y past Pumps & Systems

columns have dealt with
using basic engineering
principles to better understand the
interaction of pump, process and
control elements in fluid piping
systems. The articles demonstrate
how to hone your troubleshooting
skills while improving the
operations of piping systems.
This month, we will start
demonstrating how to use this
knowledge to work through
problems on real-life systems.
I am not calling them case
studies because case studies
provide a system description,
as well as information on the
company, the plant facility, the
problems encountered and maybe
even the people involved. This
degree of detail requires multiple
levels of permissioneven before
the lawyers take a look at it.
Instead, I will use the line
from the movies: Based on an
actual event. In this column, all
the names and places have been
omitted, but the other pertinent
facts are presented. These columns
are based on actual system
problems I have encountered in
my 45-year career in operating,
designing, testing and supporting
fluid piping systems. Many of the
examples come from technical
support questions from our
software users and feedback from
our piping system training classes.
Increasing System Flow Rate

In the late 90s, I was working
with an electrical utility in British
Figure 1. Flow diagram showing the mine water piping system with calculated results
(Graphics courtesy of the author)
Figure 2. Pump curve for one of four identical 10-stage vertical turbines
for the river water system
Columbia that had a program to

help its large utility customers
reduce their plants energy
consumption. The utility would
evaluate a customers pump
systems to see what could be done
to reduce energy consumption.
I got a call from the consultant
performing the analysis on a water
makeup system in a nickel mine,

where water was pumped from
a river to the mill through a
5-mile pipeline.
Over the years, the plants river
water requirements increased.
The sales engineer for the vertical
turbine pump manufacturer was
called in each time. The increased
21
The Total System
ELIMINATE YOUR SHAFT SEALING PROBLEMS

CASE STUDY
Drastically Increase MTBF

A PackRyt System, one of SealRyts patented bearing sealing
methods, was installed on 4 hard coated shaft tank agitator
units and they have been running trouble free for 2 years.
The utilitys consultant modeled

the river water system using a
commercially available piping
APPLICATION: 4 Tank Agitators
system simulation program. The
Previously these units had shaft
MTBF
BEFORE: 12 months
river water level was 100 feet above
change outs every year at a very high
MTBF AFTER: 24 months+
sea level, and the elevation of the
SILVER = C0.M0.Y0.K30
Letterhead, Bills, envelopes... Simple and on
cost of parts, labor
down-time.
For use inand
layouts
where the logo will be
DARK
BLUE = C90.M50.Y5.K40
white
background
- darker blue with
PMS 877
PRODUCT:
PackRyt BLR
mine
reservoir
liquid
level was 435
placed on a dark color field such as technical
for contrast on white
LIGHT BLUE = PMS285 or C91.M53.Y0.K0
services gray.
High
Solids
Process
Industry,
S. Carolina
feet. The supply header was 12-inch
SAVINGS:
Estimated $80,000
SILVER = C0.M0.Y0.K30
Orange
= C0.M56.Y92.K0
Replacement cost/year
LIGHT BLUE = PMS285 or C91.M53.Y0.K0
steel schedule 40 pipe with a length
of 21,000 feet from the river to the
mill. The consultant built the system
BLUE = C90.M50.Y5.K40
PMS2955?
or
model
and asked
me orifPMS7693
I would
look
647 or 7462
ROTATING SHAFT SEALING EXPERTS
= PMS877 or C47.M38.Y38.K2
at SILVER
his results
(see Figure 1).
TESTIMONIALS
The first thing I asked was if he
BLACK
- FAX, ETC. pump curve for the
hadONLY
anLOGO
accurate
SealRyt had a solution when no one else did.
installed vertical turbine pumps. He
did and provided me with a copy (see
Mill Supervisor, Oklahoma
PATENTED TECHNOLOGY
Figure 2).
I then asked how the models
GRAYSCALE LOGO
Your product has performed
calculated results matched the
physical system. He said the only
as advertised and the service by your
system instrumentation was
team has exceeded what was expected.
PATENTED TECHNOLOGY
a pressure gauge on the pump
PREMIUM MECHANIC AL
PACKING job by everyone at SealRyt.
Great
discharge header reading 430
Steve C., Maintenance/Shutdown Planner, Pulp and Paper Industry
pounds per square inch (psi), which
closely matched the simulations
64 Servistar Industrial Way | Westfield, MA 01085 | Phone: 413-564-5202 | Fax: 413-564-5203
calculated
results.
TECHNICAL SERVICES
GRAY He also
64 Servistar Industrial Way | Westfield, MA 01085 | Phone: 413-564-5202 | Fax: 413-564-5203
C78.M64.Y50.K39
mentioned
that he double-checked
the river and tank elevations, pipe 64 Servistar Industrial Way | Westfield, MA 01085 | Phone: 413-564-5202 | Fax: 413-564-5203
lengths and pipe diameters based on
PACKING AND PACKRYT BLUE
existing design documents, and they
C90.M50.Y5.K40
were correct.
ROTATING SHAFT SEALING EXPERTS
The fact that he had a
manufacturers
supplied
pump
curve
FUTURE BLUE
Call us to find out why reliability and maintenance managers are flocking to our patented solutions!
C91.M53.Y0.K0
and that
the actual pump discharge
pressure closely correlated with the
white url
MADE IN THE U.S.A.
Designed and
calculated pump pressure indicated
64 Servistar Industrial Way
Phone: 413-564-5202
Manufactured
FUTURE
GRAY closely resembled
that the
model
Westfield, MA 01085
Fax: 413-564-5203
in Westfield, MA
C60.M46.Y41.K10
system capacity was accomplished by

adding stages to the existing vertical
turbine pumps, as well as adding
new pumps. When I was called, four
10-stage vertical turbine pumps
were providing approximately 4,100
gallons per minute (gpm) of river
water to the mine with a fifth pump
on standby.
We solve sealing
problems others cant.
22
the physical system. With an accurate system model,

proposed system changes could be evaluated.
Each of the four pumps were supplying 1,043 gpm,
which is within the manufacturers allowable operating
range. But with the pumps best efficiency point (BEP)
flow of 2,600 gpm, this represents only 40 percent
of the pumps BEP flowwell outside the preferred
operating range recommended in the American
National Standards Institute/Hydraulic Institute
(ANSI/HI) 9.6.3-2012 Rotodynamic (Centrifugal and
Vertical) Pumps Guideline for Allowable Operating Region
standard. Running a pump this far from its BEP can
cause premature bearing and seal failure.
Next, I looked at the flow rate through the supply
header. With 4,200 gpm through the 12-inch diameter
pipeline corresponding to a fluid velocity of 12 feet per
second, the result was a dynamic head loss of 660 feet
in the pipeline. This head loss added to the 335 feet of
system static head results in a required pump head of
1,000 feet.
Considering the Options

The flow rate in the river water system needed to be
increased to 4,500 gpm. As previously stated, a fluid
piping system is made of the pump, process and control
elements. Increasing the flow rate to 4,500 gpm in the
existing system resulted in a head loss in the supply
header of 767 feet, or a total pump head of 1,102 feet.
Each element affects the total system operation, and
when users need to increase the system flow, their first
thought is to call the pump manufacturer.
Pump Option
When the pump manufacturer was called, he stated that

the existing pumps could not meet the head required for
the new flow rate because the installed vertical turbine
pumps were not designed for more than 10 stages.
Additional pumps were not an option because there
was no space in the pump house for the added pumps.
As a result, the pump sales representative suggested
replacing the existing pumps with higher-capacity
pumps. The plants utility manager was concerned the
larger pumps would increase the sites electrical utility
demand charges.
Process Option
In this system, the process elements consist of the river,
mine reservoir and the interconnecting piping complete
with valves and fittings. Because the fluid velocity in
the 12-inch supply header was so great, installing a new
23
System Evaluation
The cost to operate the existing system with four pumps
running 8,000 hours per year with a power cost of $0.03
a kilowatt/hour was approximately $358,000 per year.
Installing a 20-inch pipeline in parallel to the existing
supply header resulted in a head loss in the supply
header of only 51 feet. As a result, the new pump head
requirement was only 406 feet.
Discussions with the pump supplier determined that
two of the existing pumps with only five stages per
pump could deliver 2,350 gpm with 390 feet of head,
resulting in a total system flow rate of 4,700 gpm. The
existing pumps have an efficiency of 83 percent at
this flow rate, resulting in an annual operating cost
of $106,000. This created an annual energy savings of
more than $250,000 across the existing system.
The cost to replace the five existing pumps with new,
larger pumps to meet the increased system flow rate
and head was in the same price range as adding the
20-inch pipeline. Because the addition of the pumps
would do nothing to reduce the energy consumption
of the existing system, the client decided to install the
pipeline instead of considering pump replacements.
After the client had installed the pipeline in parallel,
I called to see how the system changes had turned
out. He sent me an as-built model of the system, and
I noticed that the last 3,000 feet of the new pipeline
was 24 inches in diameter. I asked if there was a reason
for the larger pipe diameter in the new pipeline. He
responded that they had purchased all the 20-inch pipe
in Western Canada and wanted to get the improvement
made as quickly as possible, so they purchased 24-inch
diameter pipe for the remainder. In addition, the utility
documented the $250,000 savings in energy cost.
As you can see, there are three elements in a fluid
piping system. As they all work together, they have an
effect on how the system operates. It is best to consider
all options when looking at any piping system.
SETTING A NEW STANDARD IN

RECIPROCATING PLUNGER
PUMPS
High quality
Exceptional reliability
Low leakage
Reduced running noise
pipeline parallel to the existing pipe was considered.

This would allow for a greater flow rate and minimize
the head loss in the supply header.
Ray Hardee is a principal founder of Engineered

Software, creators of PIPE-FLO and PUMP-FLO software.
At Engineered Software, he helped develop two training
courses and teaches these courses internationally. He may
be reached at ray.hardee@eng-software.com.
24

Simple solutions for end users
By Jim Elsey
Summit Pump Inc.
Guidelines for Submergence & Air Entrainment
ubmergence is a
commonly overlooked
pump suction side issue
that can create mechanical and
hydraulic performance problems.
Insufficient submergence can lead
to increased vibration, a broken
shaft, shortened mechanical seal
life, premature bearing failure,
lower flow rates and diminished
discharge heads (pressure) for the
pump. In the worst cases, these
issues will cause surging and will
actually stall (air block) the pump.
Submergence (simple
submergence) is defined as the
distance (D) measured vertically
from the surface of the liquid to the
centerline of the inlet suction pipe.
A more important term is required
submergence, also known as
minimum or critical submergence
(SC). Required submergence is
the vertical distancefrom the
fluid surface to the pump inlet
required to prevent fluid vortexing
and fluid rotation (swirling and
or pre-swirl). Vortexing will
introduce unwanted air and noncondensable gases, which can cause
pump damage and reduce pump
performance. A centrifugal pump is
not a compressor, and performance
is greatly affected when pumping
dual and/or multi-phase fluids (gas
and air entrainment in the fluid).
A common misconception is that
inadequate submergence issues are
found only on vertical and/or very
large pumps. This issue, however,
can and will occur on small and/or
horizontal pumps.
Figure 1. General guide for minimum submergence based on fluid velocity

(Courtesy of the author using data from Hydraulic Institute)
When a centrifugal pump

operates at a given flow rate (Q),
there is a corresponding fluid
velocity in the suction line (V). You
can calculate this velocity easily
by using Equation 1 or by simply
looking it up in references such as
Cameron Hydraulic Data (Chapter 3)
or Crane Technical Paper No. 410,
Flow of Fluids.
The velocity of the fluid is an
important value to know because
it will determine the correct
submergence required to prevent
the formation of vortices.
Figure 1 shows two separate
cases; both are for a flow rate of
300 gallons per minute (gpm),
but the suction pipe diameter is
4 inches in one case and 6 inches
in the other.
Using Equation 1 and Figure 1,

we can see that the 4-inch pipe
yields a velocity of 7.7 ft/s, and
V = (GPM) X (0.4085) (D) 2

Equation 1
Where:
V = velocity in feet per second (ft/s)
D = suction pipe diameter in inches
D = (0.0744 Q) 0.5
Equation 2
Where:
D = recommended suction inlet pipe size in
inches
Q = the flowrate in gpm
25
A common misconception is that

inadequate submergence issues
are found only on vertical and/
or very large pumps. This issue,
however, can and will occur on
small and/or horizontal pumps.
the 6-inch pipe yields a velocity of 3.4 ft/s. Note the

difference in velocity between 4- and 6-inch piping
for a flow rate of 300 gpm. Figure 1 indicates that
the required minimum submergence for the 4-inch
pipe at a velocity of 7.7 ft/sec will be about 4.5 feet.
The minimum submergence for the 6-inch pipe at a
velocity of 3.4 ft/sec will be less than 2 feet. In other
words, for a given flow rate of 300 gpm and a suction
pipe diameter of 4 inches, a minimum of 4.5 feet of
liquid above the inlet pipe will be required at all times
to prevent the risk of air entrainment due to vortex
formation. But if the suction line diameter is 6 inches,
2 feet of submergence will be required to preclude
vortex formation. That is a difference of more than
2.5 feet.
If you have the 4-inch diameter suction pipe at 300
gpm but cannot raise the suction side fluid level to
mitigate air entrainment, you can add a 6-inch suction
bell to the 4-inch pipe inlet to reduce the velocity
at the entrance and, in essence, fool the system to
prevent vortexing. Addition of the 6-inch suction bell
will reduce inlet velocity to 3.4 ft/sec and reduce the
minimum required submergence to less than 2 feet. If
a suction bell cannot be added, then a barrier (antivortex device such as floating or submerged rafts or
fi xed baffle plates) that presents a torturous path may
also be installed.
Note that, while the barrier may preclude vortices,
swirl and turbulence in the fluid stream can still
present unbalance issues with the impeller. The size
of the barrier can be calculated by knowing the added
submergence required and then sizing the barrier to
make the fluid take that same length of travel. Proper
placement and location of the barrier is important;
if you are not comfortable or experienced with this
subject, please consult someone who is. I am reminded
of an incident at a nuclear power plant 36 years ago
when I, as the factory field engineer for the pump
manufacturer, advised the user not to place a 12-foot
p u m p s a n d s y s te ms . com | A pr il 2016
12 TIPS TO REMEMBER
I-beam near the suction of the vertical pump.
The user determined that I was wrong and
sought to block any vortices while measuring
flow. He securely attached the flow meter to the
large beam and placed it near the pump suction.
Less than 3 seconds after the pump was started,
the beam became an integral part of the suction
bell and the impeller.
Besides inadequate submergence issues,
air and non-condensable gases can enter the
fluid in other ways. Liquid can fall from above
the suction tank/sump (e.g. cooling tower), or
agitation can occur in the upstream process.
Sometimes air or gases are introduced on
purpose as part of a process requirement (e.g.
pulp slurry recycling). An additional issue is
having a suction tank/sump that is not sized
properly. A properly sized tank/sump will, by
design and with respect to volume and geometry,
allow for sufficient transient time (hold time) for
the fluid to facilitate the escape of entrained air
prior to entering the pump suction.
2
3
4
5
Critical submergence (SC) must be greater than simple

submergence to prevent vortex formation, but it is still not a
guarantee of vortex preclusion.
Pumps that are larger, vertical and/or with impellers of higher
specific speeds are generally more sensitive to submergence
issues, but all centrifugal pumps are susceptible.
Opening impeller clearances by a factor of three to four times
the normal measurement can allow air and gas to pass through
the pump with fewer negative effects, but the efficiency, related
brake horsepower and cost of operation will be greatly affected.
Do not open clearances without consulting the OEM first.
There are various stages, strengths and states of vortex
generation including incipient, invisible, surface and subsurface.
Just because the vortex is not visible to the naked eye does not
mean it is not present. The vortex size is a function of the residual
angular momentum of the fluid at that point.
In respect to suction tank or sump design, if the intake pipe is
horizontal, a vertical wall (90 degrees) is better than one with a
slope (less than 90 degrees).
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27
6
7
8
When referencing charts for calculating minimum

submergence, keep in mind that the assumption is that
no obstructions or asymmetrical geometries are in the
tank/sump.
10
Do not confuse submergence with net positive suction

head available (NPSHA). I always recommend that both
values be calculated for the worse expected condition.
You can have adequate NPSHA and still not have proper
submergence and vice versa.
Critical submergence is a function of factors besides the
vertical distance and the acceleration of gravity. Other
factors are surface tension, viscosity, density and the
diameter of the suction pipe opening, especially if there
is a transition to a smaller-diameter pipe shortly after
the initial opening. Pay specific attention to the ratio of
the diameter changes. With surface tension, it is a very
small factor. In the case of viscosity, it will depend on
the Reynolds number, which is defined as the ratio of
momentum forces to viscous forces and quantifies the
relative importance of these two types of forces for given
flow conditions. Think of it as the amount of turbulence.
11
12
In some cases, you can have too much submergence

for a given system design, from the aspect of siphon
effects. This is rare.
Suction (pipe) velocities to the pump should be kept
between 5 and 8 feet per second. I recommend
not more than 6 feet per second unless there is a
requirement for suspended solids (critical carry
velocity) and other slurry rheology concerns.
The suction tank/sump should be sized and designed
so that the volume has five to eight minutes of hold
time. For example, if the pump is designed for 200
gpm then the tank should be 1,000 to 1,600 gpm in
effective volume. Proper addition of barriers, baffles
and weirs can reduce the required size.
As a general guideline only, the recommended suction
inlet pipe size (D) can be calculated using Equation 2
(see page 24). I always recommend rounding D up to
the next pipe size, not down.
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28
Dissolved air and gases will come

out of solution at the eye of the
impeller because that is typically the
lowest pressure area. The amount of
dissolved air and gases coming out of
solution will be a function of suction
pressure. The higher the pressure, the
less likely the gases will be released.
Note that many manufacturers have
successfully injected 1 percent air
into the pump suction to address
chronic cavitation problems. At air or
gas amounts higher than 1 percent,
performance issues will occur. As a
general guideline, 2 percent free air
will reduce pump flow by 10 percent,
and 4 percent air will reduce the
flow by more than 40 percent. The
degradation in pump performance
is dependent on the fluid properties,
pump design, impeller geometry and

clearances. Pump performance will
not get better with more entrained air
and gas. As a guide, most centrifugal
pumps will lose the majority of their
performance between 6 and 12
percent air entrainment. The average
pump will likely fail to operate at 14
percent air entrainment. Some pump
designs that use vortex impellers,
recessed impellers, separation
chambers or air escapes can handle air
entrainment up to 24 percent.
References
Hydraulic Institute and ANSI Specification 9.8
Hydraulic Intake Design
Ingersoll-Rand Cameron Pump Division white
paper: Pump Intake Design
The Pump Handbook, 4th edition, Paul Cooper
& Charles Heald et al.
Jim Elsey is a mechanical engineer

who has focused on rotating
equipment design and applications
for the military and several large
original equipment manufacturers
for 43 years in most industrial
markets around the world. Elsey
is an active member of the
American Society of Mechanical
Engineers, the National Association
of Corrosion Engineers and the
American Society for Metals. He is
the general manager for Summit
Pump Inc. and the principal of
MaDDog Pump Consultants LLC.
Elsey may be reached at
jim@summitpump.com.

30
INDUSTRY INSIGHTS
Trends & analysis for pumping professionals
By Mike Pemberton
Pumps & Systems Senior Technical Editor
The Future of Predictive Maintenance
rocess equipment represents

an enormous investment
for manufacturers, with
medium to large plants having
thousands of assets that support
the supply chain, production and
distribution. All equipment must
be managed efficiently to ensure
reliability and productivity. Th is
is a priority for industrial plants
as they seek to move from reactive
and preventive maintenance
approaches to predictive.
According to ARC Advisory
Group, the growing number of
plant assets coupled with the
reduction in skilled labor means
there are 500 to 2,000 process
control loops per technical staff
member. Maintenance personnel
are responsible for the associated
equipment for an individual loop,
including instruments, valves and
pumps, making it increasingly
difficult to manage plant assets
using in-house staff alone.
With baby boomers retiring
at the rate of 10,000 per day,
industrial plants are relying on
automation solutions to manage
assets. Th is dependence is also
driven by aging infrastructure,
competitive market pressures,
environmental regulations and
shrinking profit margins.
Predictive Maintenance
The growing use of predictive
analytic software, wireless sensors
and cloud computing, as well as
other information technology
advances, is a key enabler.
These technologies broaden the
scope of real-time performance
monitoring and machineto-machine communication,

which, in turn, supports
the evolution of predictive
maintenance approaches. In some
cases, equipment can also be
self-repairing.
Accurately predicting remaining
useful life helps streamline
the supply chain with the right
parts arriving for scheduled
replacement. Unscheduled
downtime and inventory costs
are minimized. Suppliers can
better support equipment using
remote diagnostics.
In the future, predictive
maintenance systems will collect
real-time and historical data, apply
analytics, and assess the health
of the equipment and the entire
production process. The systems
will prioritize maintenance
and operator actions based
on criticality and recommend
corrective actions. These expanded
capabilities will enhance
maintenance and operating
decisions while providing
critical equipment information
to process control and business
systems. Plant management
and engineering can make more
informed decisions related to
capital budgets and long-term
modernization plans.
Intelligent Pump Control

A common application of
intelligent pump control is a
parallel pumping system such as a
cooling tower. Parallel systems are
designed to provide incremental
flow by turning multiple pumps
on or off to meet changing system

demand. Cooling tower systems
are common across manufacturing
facilities that use heat exchangers.
These applications offer an
opportunity for industrial plants
to reduce energy consumption and
improve reliability.
For example, multi-pump
application of intelligent
variable frequency drives (VFDs)
represents the convergence of
pump and automation technologies
for predictive maintenance. The
pump intelligence embedded in the
drives microprocessor allows the
pump to identify conditions such
as dry running, dead-heading and
cavitation in real time. Conditions
can be communicated via a digital
bus back to the distributed control
system (DCS) for display and
alarming. The operator can quickly
take corrective action either
by making adjustments to the
system at the DCS console or by
automatically generating a highpriority work order requesting
system maintenance.
The individual drives are
interlinked and can be configured
to automatically change the
lead and lag pump(s) at regular
intervals to even mechanical
wear over time. If one pump fails,
the system can automatically
synchronize and adjust individual
pump speeds to ensure that flow
demand is maintained.
Multi-pump control maintains
stable process conditions, which
optimizes the number and speed
of pumps needed and offers
smooth startup and shutdowns
31
because there is no need for a

separate control logic in the
DCS. The drives intelligence
also operates the pumps in the
most energy-efficient manner,
allows redundancy and provides
the capability to mix pumps
of different sizes and powers
(although the ideal system
configuration has identical
pumps). While the multi-pump
intelligence is embedded in
the VFD microprocessor, the
intelligence could also be in
the DCS microprocessor or on a
server in the cloud. While this is
a special case of using embedded
intelligence to control a multipump system, the future will see
broader use of data to empower
predictive analytic software for

plant-wide asset management.
Facilities will be able
to implement mechanical
systems that self-diagnose
and automatically adapt to
equipment failure and process
upsets. Compared with fi xedspeed systems, the broader use
of variable speed pump systems
requires smaller motors, allows
removal of the control valves
at the pump discharge and
prevents the need for supporting
infrastructure such as pneumatic
lines and control wires. Wide
application of variable speed
technology will dematerialize the
process and reduce maintenance
and operating costs.
Innovative Pass-Through
Technology
In these scenarios, facilities

can continuously monitor assets
and make system adjustments
over a wireless or wired network.
Service technicians, whether
on or off site, will eventually
be able to use 3-D printing to
produce standard or custom
parts and ship them in a timely
manner. These advancements and
others will allow plants to work
within budgetary constraints
and overcome barriers caused by
limited resources.
Mike Pemberton is the senior
technical editor for Pumps &
Systems. He may be reached at
mpembertmp@gmail.com.
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32
SPECIAL SECTION
SEALING CHALLENGES
Using Dry Gas Seals

to Pump Liquids
This unconventional solution features bonding consisting of a
micro-crystalline layer that has attributes of natural diamond.
BY EMERY JOHNSON
EAGLEBURGMANN
ouston, Texas, gets hot during the summer,

with temperatures exceeding 95 F (36 C) in
August and 90 F (33 C) for an average of 102
days a year. While air conditioning helps to
make life tolerable during Houstons hot, humid days,
there is no such relief for pipelines that are pumping oil
and gas products.
Keeping pipeline components in optimal condition is
a constant challenge for oil and gas companies that must
contend with the effects of rising temperatures on liquid
pump seals.
Recently, one company solved a similar problem with
the seals on its ethane pumping system by incorporating
a dry gas seal in a liquid-pump application.
The end user, located in Houston, operates natural gas
liquid (NGL) fractionation facilities, where it processes
mixed NGL streams into purity NGL products including
ethane, propane, normal butane, isobutene and natural
gasoline. A crucial part of its operation is the ethane
injection pumps that pump ethane from 410 pounds per
square inch (psi), or 28 bar, to about 1,100 psi (76 bar).
While the ethane temperature at suction should be
approximately 60 F (16 C) on a typical warm, Houston
summer day, this temperature can increase dramatically.
The increased temperatures result in seal failure, which
can cause ethane to vaporizeresulting in product loss.
evaluated to ensure proper sealing fluid is being supplied

to the seals at all times.
Here is what to look for when evaluating proper liquid
seal function, highlighting some problems that can occur:
Startup: The pump is charged, but at or near suction

pressure. Liquid ethane at the seal faces is slowly
leaking and vaporizing. When the pump starts,
how long does it take to build the right pressure in
the stuffing box and get the pressure above vapor
pressure? Additionally, the heat generation between
the faces, although not significant, could be enough to
increase vapor pressure and vaporize the fluid across
the faces. Damage to sealing faces could be a telling
sign that this is occurring.
Why Liquid Pump Seals Fail

When operating rotating equipment, some end users
do not pay enough attention to transient conditions.
Startup, slow-roll and standby pump conditions must be
Image 1. Typical design of a dry gas seal (Image and graphic

courtesy of EagleBurgmann)
33
Slow-roll: The same situation as startup but

compounded. Without the right speed, the discharge
pressure is not generated. The pressure in the stuffing
box is not rising quickly enough to ensure the ethane
will reach a high enough pressure to overcome the
vapor pressure. Also, the heat generation between the
contacting faces is increasing, and damage is probably
taking place.
Standby: All conditions mentioned above are the
same, but the seals are sitting idle for many months
without a flush to the seals. During the standby
time, evidence has shown that debris has collected
at or around the seal faces, which, in turn, adds more
complication to the sealing environment.
Inefficient operation: Operating the pump too far
outside of the best efficiency range and with the wrong
operating parameters results in increased demand for
drive power and reduced discharge pressure. Both of
these negatively impact the vapor margin in the seal
area, which can result in dry running.
Other transients that play a role in evaluating sealing

fluid are temperature changes in the product, frequent
starts and stops, and operator error. These situations
can lead to seal failure. At the Houston facilitys ethane
pumping operations, mean time between failure (MTBF)
was averaging a little more than three weeks. Something
needed to be done to prevent seal failure and product loss.
Meeting the Challenge

Low vapor margin applications, such as ethane, have
one thing in common: The liquid would rather be a gas.
For this reason, many end users incorporate liquidlubricated gas seals. The manufacturer that supplied
the seals for the facility in Houston, for example, offers
pump seals that run on a gas fi lm between the faces
either a dual pressurized seal using an inert gas or a dual
unpressurized seal with the outboard seal operating on
a gas. A dual unpressurized seal works great in these
applications, but transients and other unknowns can
cause problems. Incorporating a clean gas at the seal faces
helps prevent failure, but certain problems can persist.
When the manufacturer was evaluating these
challenges, the Houston facilitys initial solution was to
use liquid-lubricated seals and take discharge pressure
directly into the stuffing box. But the liquid-lubricated
seals continually failed, especially on warm summer days
as the outside temperature rose. The reason had to do
with the inherent nature of ethane.
For ethane to remain in its liquid state, it must be
kept at a certain temperature and a certain pressure
(approximately 300 to 400 psi [21 to 28 bar]) at 60 F
[16 C]). If the pump is operating properly and the pressure
and temperature are at their ideal points, then the
ethane continues to flow as a liquid. But as the outside
temperature rises on a warm day, the pressure and the
temperature of the pump also increase. This causes the
ethane to vaporize at the seal.
Transient Conditions
Liquid-lubricated seals are designed to handle liquids
only; they will fail if they are suddenly confronted with
handling a gas, such as when ethane vaporizes from a
liquid. In reality, a liquid-lubricated seal can be successful
EXAMPLE OF TANDEM SEAL WITH INTERMEDIATE LABYRINTH

The details of this seal include:
1. Seal face, stationary
9. Split ring
2. Seat, rotating
10. Tension ring
3. Thrust ring
11. Cover
4. Spring
12. Process side labyrinth
5. Shaft sleeve and seat

retainer
GBI is gas buffer inlet, GBO

is gas buffer outlet and D is
drain. The yellow parts are
rotating, blue are stationary,
and gray represents pump shaft
and housing.
6. Intermediate sleeve
7. Housing (adapted in size to
the installation space)
8. Adjustable nut for axial
misalignment
34
SPECIAL SECTION
SEALING CHALLENGES
in an ethane application, but only

under conditions that do not change.
Because the seal environment kept
changing in the Houston application,
the liquid-lubricated seals could not
work properly.
Liquid-lubricated seals work best in

environments where the temperature
and pressure are at a consistent level.
For this end-users operations, it was
the transient conditions that caused
the problems.
For this application, ethane was

sealed. For ethane to become a gas,
it needs a pressure drop or a vapor
pressure increase above the sealing
pressure. Heating the fluid is a quick
way to achieve this, but using an
external heater adds complexity and
maintenance. Using a close-clearance,
multi-tooth labyrinth on the front
end of the seal causes the turbulent
flow during operation to create fluid
friction that will build heat. The
rotation of the seal faces also adds
heat. The closer the gap is between the
faces, the smaller the leakage and the
higher the heat generation. But the
transient conditions caused problems.
Relying on rotation to build heat
ignores the effects of startup, slowroll and the standby pump.
Dry Gas Seals

The solutiona dry gas sealwas
simple, though a bit unconventional.
This technology is usually not used
in liquid-pump applications, but it
seemed to be a good solution because
the ethane liquid wants to be a gas.
Dry gas seals delivered enhanced
reliability in operating modes
where the seal faces are in constant
contactturning, ratcheting, coastdown and other operating modes that
create critical conditions for standard
gas seals. Experience has shown that
unexpected operating situations,
such as the transient conditions
the end user was experiencing, can
compromise a gas seal.
Because seal faces are designed
primarily for non-contact operation,
they are subject to wear when there
is contact for sustained periods. This
can cause seal failure resulting in
downtime and production loss.
These seals featured bonding that
consisted of a micro-crystalline
layer that has attributes of natural
diamond. For example, it will
not fl ake or chip off, the coating
is extremely hard and wearresistant, and it offers excellent
35
heat conductivity and high chemical

resistance. These dry gas seals can be
ideal solutions for extreme operating
conditions. They can extend the
recommended repair intervals for
mechanical seals to at least five years.
This technology also provided
simplification of the sealing system.
In this application, the liquid ethane
is very clean. It is typical to fi lter
the ethane prior to injecting it back
in the seal area; otherwise, there is
a risk of damage to the dry gas seal
faces. A fi lter flush can increase the
stuffing box pressure, which increases
the vapor margin and makes it more
difficult to vaporize the liquid.
Instead of using a flush, if some
particles were in the liquid, the
special bonding would either crush
them, or if they are small enough,
the special dry gas seal groove
pattern would pass them along. No
fi lters were needed, which reduced
maintenance costs and downtime.
Emery Johnson is the product specialist, dry gas seals, for

g
EagleBurgmann NA. With more than 19 years of experience in the dry gas
dr
seal industry, Johnson leads the technical sales of EagleBurgmanns dry
Universi
gas seal and systems business. He is a graduate of Texas A&M University.
He serves on the API-692 committee for dry gas seals and systems.
Successful Application
The dry gas seals were installed in
July 2011. After several months,
plant operators reported that they
had seen at least an 83 percent
reduction of the ethane to their fl are
system. Today, it is above 90 percent.
Eight months into operation,
the end user took the pumps out of
service for an impeller re-rate. The
seals were removed and transported
to the manufacturers facilities for a
teardown and inspection. When the
seals were opened, the faces looked
new. The components were cleaned,
and the seals were tested. The leakage
rates were slightly lower than what
was originally recorded. The end user
decided to install the seals back into
their pumps and run them without
repair. Currently, the seals are still
running with no issues.
This technology is being used in
more types of services with different
light hydrocarbons and in a carbon
dioxide application.
36
SPECIAL SECTION
SEALING CHALLENGES
4 Ways to Prevent
Seal Failure
Take these precautions to maximize your investment.
BY ANDREW KALINEN
FLEX-A-SEAL INC.
he life expectancy of a mechanical seal is

determined by a wide variety of factors, most
of which are independent from the seal design.
Seal selection, installation technique, equipment
startup procedure, operation, seal storage conditions,
product variables and seal support systems all play a part
in how long a seal will last.
Even with so many variables, there are steps users can
take to prevent seal failure and increase seal life. Here are
four proven methods to ensure any seal operates in peak
condition for as long as possible.
Choose the Correct Seal

Lack of knowledge and information is an obstacle
in the seal selection process. Before deciding on a seal,
carefully consider the application and normal operating
conditions, as well as any potential off-design usage.
For example, selecting a seal to operate in hot water
may seem easy because the medium is not particularly
difficult. However, if the application is boiler feedwater,
this assumption is incorrect. Hot water at temperatures
above 190 F is unable to appropriately lubricate and cool
the seal faces. The sealing process is then compromised by
elevated friction between the two mating faces and will
culminate in premature seal failure.
To solve this issue, the user must determine if the
correct operating parameters are being maintained,
then talk with the seal supplier to verify the appropriate
American Petroleum Institute (API) flush plan and to
choose the correct seal face combination and elastomer
materials. Every application has unique requirements,
and the proper seals are designed specifically to overcome
application challenges.
MECHANICAL SEAL STORAGE

ENVIRONMENTAL CONDITIONS:
Room temperature between 5 C (40 F) and 25 C
(80 F) with humidity below 70 percent
Free of radiation, particularly sunlight
Free of contamination (pumped products,
solvents, oils, copper)
Free of ozone and ozone-generating devices
and equipment
Properly Install the Seal

Seal installation should be performed using the
steps outlined by the manufacturer and with great care
to avoid damaging the delicate seal faces and/or O-rings.
Common issues that may occur when installing a seal
include forgetting to tighten set screws before removing
setting clips, not tightening gland bolts evenly, damaging
O-rings, nicking seal faces or incorrectly using the piping
connections. Improper seal installation caused by a lack
of knowledge is a significant factor in most seal failures.
Component seal installation is inherently more prone
to installation errors when compared with cartridge seals
because of the extra steps and measurements needed.
This is why, if possible, users should choose a cartridge
seal over a component design. There is already enough to
be meticulous about when installing a mechanical seal;
why add additional opportunity for mistakes?
Prevent Excess Heat Generation

Excessive heat generation between seal faces will
drastically reduce seal life. Dry-running is the most
common example of this issue. It typically occurs when
37
Image 1. This sleeve is an example of catastrophic

seal failure that resulted, in part, from improper
installation. Errors in installation can cause
vibration and degrade the pressure between
the seal faces. Excessive vibration inhibits the
primary seal faces operation and fatigues other
components within the seal. (Images courtesy of
Flex-A-Seal Inc.)
a pump is flooded and/or the seal chamber is incorrectly

vented before pump startup. Other situations can also
lead to excessive heat generation and dry-running.
For example, the seal chambers pressure can exceed
the seals design parameters during upset conditions. In
this situation, contact the seal manufacturer. The seal
design may need to be altered if condition fluctuations are
an ongoing issue.
Shaft runout and elevated vibration levels may cause
interruption to the lubrication fi lm established between
mechanical seal faces during successful operation. A
mechanical seal is often the first visible point of a failure,
but the root cause of failure may be located in a different
part of the system. Using the correct piping system,

verifying sufficient net positive suction head available,
carrying out proper pump preparation and ensuring
that pump functions are within the original equipment
manufacturers (OEM) parameters are all important for
reliable seal performance.
In another scenario, the process fluid could be unable
to properly lubricate the seal faces. This could occur in
slurries with a high percentage of solids, media with
extremely high or low viscosity, or a process fluid being
pumped close to its vapor pressure. The seal manufacturer
can help the user choose the best sealing solution based
on the specific application and system details.

38
SPECIAL SECTION
SEALING CHALLENGES
The use of API 682 flush plans and seal support systems
is generally recommended for all applications. Piping
plans such as Plan 11 (flush line from pump discharge),
Plan 13 (recirculation to pump suction) or Plan 53A
(pressurized barrier fluid with a seal reservoir) can be
simple or highly complex, but they all have the same goal:
to keep the seal faces clean, cool and well-lubricated.
The correct seal support system (based on API 682
flush plans) will have an overwhelming impact on the
overall success of production. For example, if abrasives
are present in the product, the seal manufacturer may
recommend changing a softer carbon face to either
silicon carbide or a tungsten carbide face. This hard face
combination has proven to be successful in abrasive
services. However, if there are no abrasive solids or
chemical issues with the process fluid, the carbon versus
silicon carbide face may be the best seal face combination
to achieve long seal life. In all cases, it is easy to
remember: A cool-running seal is a happy seal.
Maintain Proper Storage Conditions

Mechanical seals are composed of many unique
parts formed from a variety of materials. Because of
the diverse properties and the precise, delicate nature
of these components, it is important to understand
how long a seal can be stored safely without
compromising function.
If the following procedures are followed and the
seal is stored in a clean, temperature/humiditycontrolled environment, a seal can be stored effectively
for five years.
To store a new seal for less than two years, store it in
a clean, cool environment. Prevent face lock and loss
of face flatness by rotating the seal faces against each
other (by rotating the sleeve or shaft) two turns every
three months if the seal is not used in operation during
that time.
To store a new seal on a shelf for more than two years
or to store a seal that has been in service already and will
be stored for more than one year:
Disassemble the seal and store all parts as individual
components. Ensure that O-rings are in a relaxed
state and meet the appropriate environmental
conditions. For a seal that has been in service, clean
and dry all components before storage.
Plug all openings in the seals gland as well as the

unused pumps seal chamber.
Do not store seal faces (silicon/carbon/tungsten)

together in the same packaging. Faces are best
separated into individual, protective, bubblewrapped packages.
Image 2. This sleeve shows how excessive heat and poor product
circulation resulted in seal failure. Accumulated thermal
damage and the resulting product solidification compromised
the secondary sealing surfaces. An appropriately rated flush
and/or steam quench plan would have dramatically extended
this seals useful life.
To reassemble the seal after storage:
Check O-rings for cracks, cuts and wear, and

lubricate O-rings for easier assembly.
If O-rings are damaged or have experienced

compression set, replace them.
Check mating ring/seal ring for cracks or chips,

especially on the sealing faces. If they are damaged,
contact the vendor for a replacement.
These are just a few of the basic recommendations for

storage, maintenance and reintroduction to service for
a mechanical seal. For more details, see international
standards such as Deutsches Institut fr Normung (DIN)
7716 and International Organization for Standardization
(ISO) 2230, which detail fundamental instructions on the
storage and maintenance of elastomeric seal elements.
A facilitys needs are best served when the users
capitalize on the seal manufacturers knowledge and
assistance to choose the right seal for the application.
In addition, it is crucial to ensure that the equipments
operating parameterssuch as shaft end and radial play,
shaft runout, seal chamber face runout and seal gland
register measurementsall fall within the acceptable
tolerances as specified by the OEM. Replacing a failed
or damaged seal is significantly more costly than taking
time at the beginning of the process to ensure the seal is
right for the environment.
Andrew Kalinen is a manufacturing and design
engineer at Flex-A-Seal Inc. He may be reached at
akalinen@flexaseal.com or 802-878-8307. For more
information, visit flexaseal.com.
40
SPECIAL SECTION
SEALING CHALLENGES
Advanced Bearings & Seals

Oset Harsh Conditions
A large petrochemical plant increased the service life of its
equipment from six months to three years.
BY TOM MCDERMOTT
SKF USA INC.
umps operating in harsh conditions will come

under attack from many influences that can
threaten a systems performance and service
life. The good news is that advances in design
engineering and high-performance materials offer viable
defenses that can optimize uptime and productivity.
Among the more extreme examples of harsh
applications in the world of industrial pumps, cryogenic
pumps that handle various liquefied gases can be
subjected to temperatures as low as minus 250 C,
particles in the gases, high rotational speeds, elevated
vibration and stray electrical currentsall of which are
problematic without safeguards. As another industry
example, slurry pumps are often exposed to severe
abrasives, which can result in wear and damage to a
pumps impeller and cause imbalance that will affect
other components.
Across industries, pumps are put to the test every day
unless operating conditions are offset with technologies
to withstand assault. Manufacturers and suppliers have
made significant strides to provide robust bearing and
seal technologies designed to keep pumps up and running
as intended without interruption.
Bearing Down on the Challenges

In general, pump bearings support hydraulic loads
imposed on the impeller, the mass of the impeller and
shaft, and loads caused by couplings and drive systems.
They additionally keep axial and radial deflections of
shafts within acceptable limits for the impeller and
shaft seal. But when severe operating conditions arise,
standard bearings can become targets and casualties.
Using cryogenic pumps as an example, bearing service

life often is less than six months because of attacks on the
bearing arrangement. When bearings fail, overhaul and
repair operations for a pump can be expensive and even
dangerous. Specially engineered cryogenic pump bearings
represent one solution.
Compared with standard bearings, cryogenic pump
bearings benefit materially from specially heat-treated
stainless steel, which delivers improved protection
against corrosion, wear and fatigue. The bearings
integrate low-friction ceramic rolling elements, while
the silicon nitride ceramic material prevents electrical
erosion by insulating against stray currents and
resists surface fatigue, even under the poor lubrication
conditions inherent to cryogenic pumps.
Cryogenic pump bearings are designed with singlepiece, glass, fiber-reinforced polyetheretherketone
(PEEK) cages. Unlike conventional rigid and riveted steel
and brass or polymer counterparts, a PEEK cage allows
liquefied gases in cryogenic applications to flow easily
through the bearing. At the same time, the cage will
flex away from the dynamic movements of the bearings
rolling elements to help improve operational efficiency.
A large petrochemical plant was experiencing repeated
bearing failures with its cryogenic pumps. The pumps
with high revolutions per minute (rpms) were submerged
in and used to pump minus 100 C liquid ethylene through
start-stop cycles around the clock. Issues involving
the extremely low temperature of the liquid, ingress of
contaminants, cycling, lubrication and other factors
were combining to cause severe damage to bearing
components, leading inevitably to their failure.
41
With a need to increase pump reliability and eliminate

expensive maintenance in the high-risk areas of the plant
where the pumps were located, operators equipped the
pumps with high-performance cryogenic pump bearings
that would mitigate the ongoing risk factors. After
more than two years in service, the bearings continue
to perform well with no signs of damage. Today, the
projected realistic service life of the newly installed
bearings is at least three years, compared with less than
six months for standard bearing counterparts.
Thrust-taking bearings in American National
Standards Institute (ANSI) style pumps also routinely
face threats to performance. High loads and poor
lubrication can result in higher bearing temperature,
lubricant degradation and, consequently, premature
bearing failure. In response to these common threats, a
special family of double-row angular contact ball bearings
has been engineered to deal with the extreme conditions
and serve as complements to conventional double-row
angular contact ball bearings typically specified to
perform as thrust-taking bearings in ANSI-style pumps
(and some older American Petroleum Institute [API]
style pumps).
Design innovations integrated into this special family
of bearings include machined brass cages, which can
withstand extremely high temperatures, poor lubrication
conditions and rough operation more effectively than
conventional plastic or pressed-steel cages. Steeper
40-degree contact angles impart increased thrust
capacity. Reduced axial internal clearances promote load
sharing between the two rows of balls and a reduced
possibility of unloading the inactive ball set. Annular
Bearing Engineering Committee (ABEC)-3 (P6) tolerances
promote smoother and cooler bearing operation. All these
improvements increase ruggedness.
Sealing the Deal

Bearings are not the only precision components in the
crosshairs when harsh conditions take aim. Effective
sealing of pumps and systems is essential. Otherwise,
contaminants can invade lubricant and infl ict damage on
bearings and the system and have catastrophic results.
As an application example, slurry pumps must
be properly sealed in the face of unforgiving pump
conditions. Whether a slurry pump is heavy-duty, lightduty, horizontal or vertical in design, abrasive solids,
corrosives and voids in the fluid can cause excessive
impeller wear and severe damage within a pump system.
Impeller damage from abrasives may cause a chain
reaction that directly targets bearings.
Image 1. Specially engineered thrust-taking bearings for

pumps integrate machined brass cages, among other features,
to effectively withstand extremely high temperatures, poor
lubrication conditions and rough operation.
(Courtesy of SKF USA Inc.)
Impeller wear from abrasives may create an imbalance,

causing excessive vibrations and, eventually, shaft
deflections. These effects may increase the loads on
bearings and seals, while unpredictable flow and elevated
temperatures stress the system, which may cause a seal to
leak and the bearings to fail. Proper sealing is critical.
But what type of seal is appropriate? If standard offthe-shelf technologies fall short in especially demanding
applications such as slurry pumps, customized machined
seals can be engineered.
Advances in the production of customized machined
seals allow them to be manufactured practically
on-demand to meet exact specifications required by
original equipment manufacturers or maintenancerelated pump applications. Virtually any type of rotating,
reciprocating or static seal can be developed, drawing
from hundreds of standard profi les and engineered to
counteract the most aggressive operating conditions.
Seals can be developed from rubber-like
elastomers, polyurethanes, thermoplastics and
polytetrafluoroethylene or from specialty materials, such
as a type of thermoplastic polyurethane exhibiting high
abrasion-resistance, low compression set and excellent
strength. Other options include materials complying with
specific industry standards and regulations and specially
formulated proprietary materials. When size matters,
continuous one-piece seals can be machined up to 157
inches outside diameter, and larger versions can be made
using a welding technique allowing on-site fitting.
Tom McDermott is a senior applications
engineer for SKF USA Inc. and is based
at the SKF Solution Factory in Houston,
Texas. He may be reached at 281-9252855 or tom.l.mcdermott@skf.com. For
more information, visit skfusa.com
42
SPECIAL SECTION
SEALING CHALLENGES
Solve Sealing
Problems By Keeping
Faces Close & Parallel
Advances in seal ring and face materials can improve basic
design issues associated with mechanical seals.
BY MARK P. SLIVINSKI
CARBIDE DERIVATIVE TECHNOLOGIES INC.
he mechanical seal was invented in the 1940s as

a replacement for packings. The device needed
to fit in the same cavity (i.e. the stuffing box)
as the packing because of volume limitations.
Advantages over packings included reduced wear
against the pump shaft and elimination of the need
to periodically tighten the packing nut to keep it tight
against the shaft. Mechanical seals were more expensive,
so the purchase cost had to be offset by low maintenance
costs and increased life expectancy of the seal.
Fast forward 75 years, and it is clear the mechanical
seal has successfully met these challenges. As a result,
mechanical seal design has not changed very much. One
could argue that the basic design has not changed at all.
The device is still basically two faces in sliding rotation
relative to each other. They must be smooth, optically flat,
and in parallel and close to one another.
That last feature is where the rub comes in. Ring
smoothness and fl atness can be routinely accomplished
in manufacturing. The parallel/proximity is determined
by many factors including the seal assembly, the
environment in which it operates and the size constraints
of the stuffing box. Every seal application poses a
different set of these circumstances to the rotating
rings. Careful engineering is directed at the operating
environment of sealed fluid, temperature, pressure,
pump speed, seal configuration, seal ring material and its
running surface characteristics.
Figure 1. A diagram of a single mechanical seal at rest (Graphics

courtesy of Carbide Derivative Technologies Inc.)
Pump Housing
Rotating Ring
Rotating/Sliding
Interface
Stationary
Ring
Rotating Shaft
Balancing these competing parameters is essential to

achieve the parallel/close proximity required for proper
seal operation and wear life. Leakage is proportional to
the proximity of the ring faces. If they remain parallel,
a well-behaved hydrodynamic lubricating fi lm will form
between them with minimal leakage.
Figure 1 shows a simple diagram of a single seal
arrangement with a rotating primary ring. This seal is at
restthere is no fluid pressure nor rotation. In this state,
the seal rings are parallel with and in proximity to each
other; they are touching. When the seal is pressurized,
the primary ring will deform under the pressure.
Two other effects happen when the seal rotates. First,
the seal faces separate due to the effects of hydrodynamic
lubrication (lift) caused by the pressure of the sealed fluid
trying to escape through the gap. Second, friction causes
43
the faces temperature to increase,

creating thermal deformation. Figure
2 shows how the seal faces can deform
and the effects of temperature (see
page 47). The rotating ring angle
of deflection has been exaggerated
to show where the two faces can be
overstressed from operational effects.
The real trick in all seal application
engineering is to keep the sealing
faces parallel and in close proximity.
Figure 2 shows the two deleterious
effects of getting this wrong. First, the
pressure deformation causes a nonparallel situation called radial taper
that will cause leakage. If this effect
is large enough, the outer diameter
edge of the rotating ring will come
in direct contact with the stationary
ring, violating the close proximity
requirement. One can think contact
means very close proximity, which is
a good thing, but no lubricating fi lm
can be established in this condition,
and the result is dry friction that can
drastically reduce seal life. An area
of temperature increase also results,
which can be seen by the temperature
contours. Thermal expansion will
happen in this area and cause a
dimensional increase in the ring
surface (i.e. a bump) that worsens the
premature wear.
grades of carbon, carbon phenolics and

graphites that would run against hard
materials such as tool steel, Stellite
and tungsten carbide. Ceramics such
as alumina were introduced, and later
silicon carbide.
Until the 1990s, combining hard

materials against themselves or
other hard materials was considered
impossible because they were not
able to withstand the operating
deformations without damage.
Seal Ring & Face Materials

Decades ago, the prevailing wisdom
was to combine a soft material that
had some lubricating qualities and
rotate against a harder material. This
method was used specifically to cope
with the situation shown in Figure
2. This situation would be mitigated
after a certain period of run-in,
where the soft material was compliant
and eventually wore at an angle
to establish the necessary parallel
condition. The worn-in angle would
only be parallel at nominal operating
conditions. Any process upset would
disrupt the parallel situation, and
the seal would leak. This issue led
to extensive development of several
44
SPECIAL SECTION
SEALING CHALLENGES
In a process upset, the contacting edge of the deformed

ring could machine itself into its counterface, causing
catastrophic failure.
Sophisticated computing technology and finite
element modeling enabled engineers to make more
precise application calculations and control designs to
more accurately establish the parallel/proximity of the
sealing faces in operation. Silicon carbide was also being
perfected, and its hardnessnext to that of diamond
helped to increase seal life through reduced wear. Finite
element modeling enabled engineers to combine it against
itself with confidence that it would operate with adequate
parallelism and lubrication.
After 20 years of application experience, silicon
carbide against itself has become a standard seal ring
combination in industrial applications.
Industry Advances
The next levels of seal performance improvement beyond
silicon carbide included diamond coatings, which were the
only material harder than silicon carbide.
Industrial diamond coatings emerged in the 1990s
with varying degrees of success. Early applications to
mechanical seals were plagued by adhesion failures and
Figure 2. Mechanical seal rings in operation with induced

deformations from pressure and temperature
surface morphologies that were more applicable to cutting

tools. Adhesion risk is inherent when a coating of one
material is applied to a substrate of a different material
due to the adhesion between them at the bond line,
plus differences in their thermal expansion coefficients.
The mechanical stress on the adhesive bond line from
operation (in Figure 2) combined with the thermal
expansion differences can cause delamination.

45
Other state-of-the-art surface treatments include those

not involving a coating process. One treatment starts
with a finished silicon carbide component and involves
etching the silicon out of the carbide surface, leaving the
carbon behind. Because no dissimilar material is added,
there is no adhesive bond line, and the resulting part
is dimensionally the same as before treatment. A cross
section of treated surface can show where the treatment
undergoes a natural transition into the carbide substrate,
with no adhesive bond line and no stress concentrations.
The microstructure is not disturbed in this process, and it
is as strong as when originally sintered. A unique aspect
of this new surface is that it is functionally graded, not
homogeneous. The first several microns are composed
mostly of graphite and free carbon. Closer to the
transition to the virgin carbide, nanocrystalline diamond
emerges, mixed with the graphite and carbon.
The result is a hard component with a hard surface that
is also self-lubricating, compliant and able to deal with
the radial taper that results from the process upset shown
in Figure 2. It basically gives the best of both hard and
soft surfaces without delamination risk. In one case, only
1.7 micrometers (m) of wear resulted from a 100-hour
accelerated wear test in fl ashing hot water that caused
s
low
F
n
re
e
Wh
tio
va
o
Inn
190 m of damage to an untreated silicon carbide ring.

Similar tests have resulted in no measurable wear, while
also exhibiting the unique ability of this surface to selfpolish. The self-lubricating qualities enable dry gas seals
to withstand the dry running conditions involved with
start/stop, reverse rotation and slow roll.
New surface treatments present a paradigm shift
because they are not homogeneous and do not involve
adhesion mechanisms. The non-homogeneity provides
self-lubricating compliance in both nominal and process
upset conditions, including fl ashing or dry running. Such
performance overcomes the most significant sealing
challenges that impact mean time between failures and
mean time between maintenance. They are also amenable
to batch processing in large quantities, which enables
widespread application at an affordable cost.
Mark Slivinski is president of Carbide Derivative
Technologies Inc. and former vice president of global
technology for John Crane International. He may be
reached at mslivinski@carbidederivative.com. For
more information on CDT treatment for silicon carbide
surfaces, visit carbidederivative.com.
Here
...
From
The
Beginning
Griswold 811 ANSI Series centrifugal pumps have exceeded the requirements of
ANSI B73.1 since its original release in 1974*. As a member of the Hydraulic Institute,
the Griswold Pump Company has continued to refine and improve the 811 ANSI Series
to offer industry-leading performance and reliability that includes:
A full line of ASME/ANSI B73.1-2012-compliant pumps with an

outstanding 5-year warranty
Unrivaled quality and delivery at a competitive price
Dedicated application and design engineering team on staff
State-of-the-art in-house QC laboratory & testing facility
For more information, visit:

http://psgpumps.com/ps416g
OHSAS 18001
* Griswold 811 ANSI Series pumps are founded on the technology

of TRW Mission Stan-Met I
ISO 14001
ISO 9001
22069 Van Buren Street

Grand Terrace, CA 92313-5607
USA
O: +1 (909) 512-1262
F: +1 (909) 783-3440
griswoldpump.com

46
Improve Asset
Performance with
Innovative Services
Preventive maintenance programs at reneries can
result in reduced costs and better reliability.
BY HARALD GROMANN
SULZER
he high density of rotating equipment used

in refineries means that effective asset
management of pumps, turbines, compressors,
motors and generators can play a vital role
in maintaining plant uptime and achieving overall
equipment effectiveness targets. Diligence in this area
can also ensure high safety levels and profitability.
Because every refinery operates with steadily aging
equipment, these facilities, including petrochemical
refineries, must execute the most cost-effective
maintenance programs possible to improve asset
performance and reliability. Daily production costs
within refineries can escalate quickly, so keeping
production equipment and components running at
optimum performance levels is crucial for delivering a
positive bottom line.
Understanding the Costs

Rotating components within any production process
will eventually wear and require service or replacement.
The type of maintenance program that is used can
mean the difference between a good investment and
unnecessary expenditures.
The costs associated with a breakdown include the
price of the new parts and the additional labor required
to install them. In most

cases, these costs will be
insignificant compared with
the costs associated with
lost production and process
restarts. For this reason,
any maintenance program
must focus on preventing
breakdowns, which means monitoring and ensuring
quality repairs.
In industries where high-value or high-volume
commodities are produced, the failure of a seemingly
insignificant component can have enormous effects
that can bring someeven allproduction to a halt. In
some instances, facilities benefit from having standby
equipment that can be brought online to quickly return
production levels to normal; however, breakdowns still
lead to a period of lost productivity.
In addition, when the process is restarted, the facility
may be unable to use a significant quantity of final
product because of reduced quality. The overall costs will
depend on the piece of equipment and the process in
which it operates, but being able to quantify these costs
enables the maintenance team to prioritize the assets
within the facility.
47
Image 1. The global network of many service provider engineers has considerable
experience in maintaining and managing mature equipment by applying experience
and the latest technological innovations. (Images courtesy of Sulzer)
Reactive & Preventive Maintenance

Historically, many refineries have employed a reactive
maintenance policy by which assets are replaced or
repaired on a fi x-as-fail basis. This method may deliver
some cost savings in the short term, unless a more serious
failure occurs. Reactive maintenance relies on the skills
of the on-site maintenance team and the availability
of spare parts. If either of these factors fails to meet
expectations, substantial losses may result because of
lost production. The purpose of preventive maintenance is
to use all available information and techniques to identify
assets that require service intervention and schedule
the work to be completed as a preventive measure. In
this way, the work can be scheduled to cause minimal
disruption, and countermeasures can be used to reduce or
even avoid lost production costs.
Image 2. Service providers can provide design improvements

to a number of larger rotating components such as pumps,
compressors, motors and generators.
Thousands of assets are used across a refinery site, and

some are more important or expensive than others. In
a number of cases, regular maintenance and inspection
schedules overlook smaller, seemingly less important
equipment, but this can lead to higher costs in the long
term. Developing even the most rudimentary scheme for
preventive maintenance can pay dividends in terms of
reliability and productivity.
Refineries commonly have well-developed relationships
with local service and maintenance providers that can
offer skills and services that are not available within
48
COVER
SERIES
With so many production processes involving a multitude of pumps,

compressors, turbines and motors, refineries must have welldeveloped asset management systems in place to reduce the amount
of reactive maintenance within the plants.
the facility itself. These service providers often have

in-depth knowledge of the demands within the
refinery sector and extensive experience providing
engineering technology to the industry. Developing
the relationship between the refinerys technical
engineering department and the local service agent is
crucial for improving the operations and maintenance
processes within the facility.
A preventive maintenance program that reduces
costs associated with repairs caused by unexpected
failures can be developed to include all key assets
within the refinery, and it may involve procedures such
as thermography and vibration analysis.
Some service providers can also provide design
improvements to a number of large rotating
components such as pumps, compressors, motors
and generators that will deliver improved reliability
and efficiency.
Process-Specific Solutions
Many pieces of equipment within a typical refinery
could benefit from design changes or upgrades to more
modern materials.
Improvements to bearing designs on larger pieces of
equipment, for instance, can increase service life and
reduce time spent on regular maintenance. Impeller
design in many multistage compressors could also be
improved as part of a scheduled maintenance program.
These changes could deliver greater output, which
would allow a more flexible working envelope and
improve efficiency.
Many facilities within the petrochemical industry
could apply innovative solutions to their huge numbers
of installed pumps. Remanufacturing of impellers,
balancing, and bearing overhauls can be accomplished
within scheduled maintenance intervals, and the
application of surface treatments can be used to extend
the pumps operational life.
Service Providers
For the majority of cases involving component failure,
many service providers can offer reduced lead times for
a completed repair. For example, an emergency repair
to a steam turbine that had a cracked low-pressure
casing saw a team of engineers on-site within 24 hours.
The overall shutdown period was just nine weeks,
compared with the 14 months that had been offered by
the original equipment manufacturer.
Even when replacement parts appear to be
unavailable, service providers often have the necessary
technology to reverse-engineer new components,
manufacture them from the latest materials and
correct design fl aws in the original.
Improving Long-term Reliability

With so many production processes involving a
multitude of pumps, compressors, turbines and motors,
refineries must have well-developed asset management
systems in place to reduce the amount of reactive
maintenance within the plants. As assets mature, an
increased amount of intervention will be required. The
site engineering team must ensure that the most costeffective solution is implemented.
See parts manufacturers and

repair service providers in our new
Manufacturers Directory online at
pumpsandsystems.com/manufacturers
Harald Gromann is service center

manager for Sulzers Neuss Service
Center in Germany.
for WATER AND

WASTEWATER APPLICATIONS
The Most Complete Line of Swing

Check, Ball Check, and Plug Valves.
TOLL FREE 1-800-833-2040

www.flomatic.com
FAX (518) 761-9798
E-mail: flomatic@flomatic.com
MADE IN GLENS FALLS NEW YORK
50
COVER
SERIES
Texas Renery Revamps

Water Treatment System
The custom solution reduces supply and maintenance
costs and provides a consistent feedwater supply.
BY MIKE JENKINS
PROGRESSIVE WATER TREATMENT
he oil and gas business has always been a water

business, with water-oil ratios averaging 8-to1. Oil and gas operations consume 82 billion
barrels (bbls) of water and produce more than
2.5 billion bbls of polluted wastewater each year. That is
1,300 times the City of San Franciscos annual water use.
With water management becoming an ever-larger
proportion of industrial operations, oil and gas operators
are beginning to look for advanced wastewater treatment
technologies that can mitigate this cost center. Across the
U.S., three key pressures are driving these upgrades.
1. Aging infrastructure and regulations. Without
proper infrastructure, industries cannot
efficiently perform at scale. According to the U.S.
Environmental Protection Agency (EPA), there is
a $500 billion gap in water investment in the U.S.
alone. Environmental concerns also drive strict water
disposal regulations to protect natural resources,
which can add stress to complicated water treatment
protocols. Many facilities that had previously used
internal wastewater treatment systems now struggle
to keep pace. As water use is more closely tracked
and increasingly strict wastewater regulations are
created, many oil and gas facilities are looking to
update their treatment systems.
2. Regional water pressure. Extreme drought is
affecting residential and industrial water use in
several regions, especially California where new
standards are cropping up to better manage water
across the value chain. For example, Senate Bill 1281,
passed in 2015, requires all oil and gas operators
to provide a monthly water use statement to the
3.
state board for approval. To add to the complexity

of efficiently managing industrial processes, falling
oil prices are leading to tighter budgets across the
oil and gas industry. As legislation continues to
change and oil prices continue to drop, operators
are searching for an environmentally friendly water
treatment alternative that wont break the bank.
Lack of in-house resources. Purchasing a water
treatment facility or equipment requires a
substantial investment of time and resources, and
many refineries are no longer hiring dedicated
in-house water managers. Companies must find the
resources to complete water analyses, technology
evaluation, scope development, vendor evaluation,
capital budgeting, and proposal requests and
evaluation. They must then perform final design
work, equipment fabrication, environmental
permitting, field installation and process
optimizationwork that detracts from their core
operations. Outsourcing can take care of those tasks
in a comparatively short time span.
A Texas-based refinery represented an example of

an industrial facility in need of water infrastructure
upgrades. In December 2015, the company decided to
update an aging ion exchange system, which had become
inefficient and costly to maintain. Waste from the system
was generated every two days, and chemical and treatment
costs were high. The plant desired higher-quality water to
feed the high-pressure boilers, and the system upgrade
had to comply with strict suspended and dissolved solids
quality requirements for boiler feedwater in Texas.
51
Engineering Challenges
Image 1. A 750-gallon-per-minute wastewater treatment system

with fully automated controls operates at a facility in McKinney,
Texas. (Courtesy of Progressive Water Treatment)
High Costs
The refinerys boiler feed system, called an ion exchange
system, used resin beads to exchange good ions for bad
suspended-solid ions in a water supply. The process
requires constant regeneration and uses many costly
chemicals. The aging ion exchange system was also
highly inefficient during treatment, and regeneration had
become too costly to maintain. The cost to treat the waste
and water effluent with the faulty ion exchange hardware
was a major pain point for the companys operators,
causing the refinery to lose significant revenue.
The refinery also wanted a higher-quality water to
feed its high-pressure boilers. The municipal feedwater
pumped into the refinery did not meet regulations for
maximum contaminant levels and would have to be
pretreated for use in the refinerys boiler system. Refinery
operators needed an efficient and precise system upgrade
that would comply with strict suspended and dissolved
solids quality requirements for boiler feedwater.
Waste from the boiler feed system was generated every
two days, meaning constant management for operators.
The wastewater had to be treated with heavy chemicals
before it could be trucked and disposed of with the rest
of the plant waste. According to Jefferies analysts, the
industrial water management process costs operators, on
average, $9 to $26 per barrel of water.
To address these key concerns, the refinery outsourced
its new boiler feed system to a Texas-based water services
company. The company replaced the outdated system with
a reverse osmosis technology designed and engineered
to comply with regulations, reduce chemical costs and
require little to no maintenance.
With on-site space constraints, engineers were brought

in to design and install a safe and user-friendly water
treatment system at the refinery. In order to use a small
area in the heart of the facility, the engineering team
designed the system so that three complete 250-gallonper-minute reverse osmosis units could be mounted on
one 37-foot-by-39-foot painted steel skid.
The company creatively engineered a system that would
reuse 100 percent of the water on-site, with the option of
utilizing the reverse osmosis reject water as feed for the
cooling towers and the reverse osmosis product as boiler
feedwater, to improve efficiency and reduce costs.
The new treatment system included multimedia
fi lters, water softeners and single-pass reverse osmosis
with required chemical treatment systems. Some
existing equipment, such as tanks and chemical pumps,
were used in the overall plant scheme to further save
on capital cost.
The improved system included a program logic
controller and human machine interface for completely
automated controls. The new system was easy to access
for any necessary repairs, used little space at the facility
and required little manpower to operate, further reducing
maintenance and operational costs.
Refinery Refresh
The water services company designed and built a custom
system that combined all three units onto one common
frame. This enabled it to fit in a non-hazardous location
of the plant, saving on capital costs for a new building as
well as associated engineering and design labor.
The company employed a team of creative engineers
that were able to design and locate the system in an ideal
part of the plant. With limited options, the system could
have been located in a hazardous area of the facility, and
equipment costs could have soared to two to three times
the refinerys capital costs for the project.
Installed in December 2015, the system is projected
to reduce supply costs, improve operating efficiency,
decrease maintenance costs and provide a consistent,
quality boiler feedwater supply at the refinery.
Mike Jenkins is the vice president of sales and

Treatme
applications for Progressive Water Treatment,
where he manages sales, engineering and
project development. He is also responsible
for a team of engineers that designs and
sells water treatment systems.
52
COVER
SERIES
Facility Chooses GraphiteMetal Alloy Bearings

The materials are able to withstand dry-run conditions.
BY ERIC FORD
GRAPHITE METALLIZING CORP.
ometimes saving money can be expensive.

Ads showing that an appliance is more energy
efficient than its competition can be convincing,
but perhaps spending $800 on a new refrigerator
would only save $10 a year. The problem is not limited to
consumer goods. Selecting the wrong replacement parts
for industrial equipment can also prove to be costly.
One Midwest refinery encountered this issue when it
replaced the original graphite-metal alloy bearings on
two butane cavern pumps with bronze bearings. While
the original bearings lasted almost a quarter of a century,
the new bronze bearings failed within four years. Just the
labor to remove the pump ended up costing far more than
purchasing higher-quality bearings would have.
Limestone Cavern
The refinery was built in the early 1900s. Over the past
century, it has undergone extensive reconfiguration and
expansion. It can process 125,000 barrels per day (bpd)
of sweet or sour crude. Four hundred feet beneath the
refinery lies a limestone cavern used for butane storage.
In 1980, the plant purchased a pair of 13-stage, deepwell cavern pumps to move product out of the cavern.
Designed to fit on the existing 16-inch, 300-pound
flanges with mechanical seals and rigid fl ange couplings,
the pumps came with 408 feet of column and stainlesssteel shafting. Originally, they were designed to pump
350 gallons per minute of propane, but this later changed
to butane. Although butane is slightly heavierwith a
specific gravity of 0.58 versus propanes 0.51it was
well within pump specifications. The equipment was also
designed to pump water if it infi ltrated the cavern. The
pumps operate one at a time in a balanced mode so that
they have the same number of operating hours, rather
than operating as the primary and the other as a standby.
Both pumps were initially fitted with self-lubricating

graphite-metal alloy composite bearings. These
composites consist of a metal impregnated into a graphite
substrate under high temperature and pressure. This
process gives the material its strength. Such components
can be manufactured with tighter-than-normal
clearances. Any wear or contact exposes the graphite,
providing a low-friction surface. Depending on the
intended use, these composites can be made using metal
alloys including Babbitt, bronze, copper, iron, nickel and
silver. The graphite does not have a melting point and
does not soften at high temperatures, so it can be used
in non-oxidizing temperatures up to 1,000 F (538 C)
and up to 750 F (400 C) in air. It does not get brittle at
temperatures as low as minus 450 F (minus 268 C).
The original graphite-metal alloy bearings lasted
from initial installation in 1980 until 2004. However,
the pump original equipment manufacturer (OEM)
recommended using bronze as replacement bearings,
which was a less expensive option. In many instances, it
makes sense to go with the lower-cost bearings. However,
this was not one of those times. While bronze performs
well under normal operating conditions when moving
product, it does not do well during dry-run conditions.
The problem is one of lubricity.
In these deep-well pumps, the product lubricates the
bushings on its way up and out of the pump. During
startup, the pump has to run dry for 10 to 15 seconds
before product is moved to the top of the pump. Because
bronze is not self-lubricating or non-galling, the pumps
would seize during this time, and the bearings needed to
be replaced after an average of just nine months.
With an above-ground pump, repairs might be fairly
straightforward. That was not the case with these cavern
pumps. To repair them, technicians had to pull each
53
pump out of the ground, one 10-foot

section at a time, and disassemble it
along the way. Forty bearings needed
replacement, one for each section. Each
pump then had to be assembled and
lowered, section by section, before it
could be put back into service. The cost
of doing this just one time was more
than 20 times the cost differential
between the self-lubricating bearings
and the bronze bearings.
When engineers with experience
at this plant returned to work at the
refinery, they observed the situation
and recommended the plant return to
the approach that had worked before.
In this case, it was an easy financial
decision now that replacement labor
costs were well-known.
The first pump had its bronze line
shaft bearings and bowl bushings
replaced with graphite-Babbitt grade
bearings. Five years later, both pumps
continue to operate without issue,
allowing maintenance personnel to
put time and budget toward improving
other aspects of the refinery.
Eric Ford is vice president of Graphite Metallizing Corp., a maker of graphitegraph metal alloy materials under the Graphalloy brand name. He may be reach
d
reached
at eric.ford@graphalloy.com. For more information, visit graphalloy.com.
Beyond Cavern Bearings

Bronze or other materials with short
dry-run capabilities are a good fit in
some situations, but not for vertical
pumps operating under possible dryrun conditions, especially with low
specific gravity fluids. These vertical
pumps are not limited to hydrocarbons
or refinery operations. They are also
used in potable water service in places
that require deep-well pumps.
Twenty years ago, pump operators
would install a food-grade bearing
grease drip system that an operator
could turn on five or 10 minutes before
startup that would ensure bearings
were lubricated all the way down the
shaft. Now regulators do not allow
anything to be introduced into these
water wells. As a result, some operators
have switched to graphite-metal alloy
bearings that can withstand these
startup conditions.

54
COVER
SERIES
Sophisticated
Monitoring Saves
Labor Hours &
Downtime in
Reneries
An industry with aging infrastructure and increasing
demands needs better monitoring technology.
BY BRIAN PHILLIPPI
NATIONAL INSTRUMENTS
etween 2009 and 2012, the U.S. faced more than

1,700 refinery shutdowns, an average of over
1.16 shutdowns per day, and almost 92 percent
of the maintenance-related shutdowns were
unplanned.1 So a proper maintenance strategy is critical.
The goals for any maintenance strategy are to:
boost revenue through increased uptime and asset

maintenance optimization
reduce costs by decreasing warranty repair expenses,
extending mean time between failures, reducing the
frequency of unscheduled downtime and optimizing
the workforce
manage risk and increase safety by minimizing worker
contact with dangerous machines and environments
and preventing catastrophic failures
Increasing production while decreasing the total

number of refineries in the U.S. makes these goals even
more important.2 Creating a maintenance strategy with
the appropriate investment in the right maintenance
techniques is not easy.

Considerations vary widely
but can include inconsistent
diagnostics, lack of insight,
aging plants, postponement
of new equipment, aging
workforce, safety, and time
or money spent manually
collecting data rather than
analyzing it. Against this
backdrop, maintenance
managers are increasingly focused on reducing
costs and optimizing efficiency, equipment utilization and
worker safety without spending more money.
The sheer volume of refinery shutdowns should be
enough to spark a change in the traditional maintenance
mix, but other factors are in play as well. Refinery age
has become a legitimate factor. The average age of the
15 newest refineries in the U.S. is more than 31 years
old, with the newest 100,000 barrel-per-day producing
refinery being 37 years old.3 This advanced age, among
55
Image 1. Between 2009 and 2012, the

U.S. faced more than 1,700 refinery
shutdowns, which is an average of
more than 1.16 shutdowns per day.
(Courtesy of National Instruments)
other factors, can lead to unplanned or uncontrolled

shutdowns, which cost the company millions in lost
production and potentially millions in fines.
Further increasing the complexity of the issue,
the reasons for shutdowns are not always the same.
Maintenance causes 23 percent of shutdowns, mechanical
issues cause 46 percent and electrical problems lead
to 19 percent (more than 60 percent of electrical were
from unspecified causes).1 Traditional measurements
are no longer enough to account for all of these types of
shutdowns; electrical measurements are also necessary.
56
COVER
SERIES
4 COMMON MAINTENANCE APPROACHES

1. Reactive. Using this approach, facility
employees wait until something breaks to fix
it. Although the upfront costs for this approach
are low, hidden costs such as safety, unplanned
interruption and ripple effects to other
machines in the critical path can be high.
2. Scheduled/preventive. This has become
the default strategy in many industries, and
for good reason. Most professionals think this
is the best approach because it is popular and
recommended by many machine providers
to ensure the integrity of the machine. The
maintenance intervals are clear and defined,
but facilities risk fixing a machine that is
not broken and stopping production more
often than necessary. This approach also
runs the risk of excessive tinkering that could
damage the machine being maintained while
increasing operational costs.
3. Preventive with manual/route-based
measurements. This involves periodically
measuring key performance indicators such
as vibration, temperature, proximity and
power. This technique is a good first step to
achieving maintenance objectives, but it has
its shortcomings. Human error, diagnosing
skill, disparate systems and the inability to
scale prevent this from being a great solution.
4. Automated or online automated
diagnostics. Smart equipment on machines
can help predict issues before they wreak
havoc on your budget, safety, efficiency or
yield. In an ideal world, an automated solution
would be the optimal maintenance strategy.
But, as often is the case, it is too expensive
and does not have the promise of return
on investment for all but the most critical of
assets. However, that notion has begun
to change.
Measurements such as power, power quality,

transformer oil temperature and motor current
signature analysis on electric motors can give greater
insight into the health of the refinery. Traditional
maintenance methods are not sufficient to deal with the
volume and myriad of measurements and measurement
types required to increase efficiency and prevent
unplanned shutdowns.
Collecting more data and information about machine
health is only part of the answer. A recent article by
International Data Corporation indicates that out of all
the data collected, only 22 percent is documented well
enough to be analyzed. Of this data, only 5 percent is
actually analyzed.4 It is no wonder that 78 percent of
maintenance managers are unhappy with their current
maintenance approach, according to a survey conducted
by Allied Reliability Group. Too much time and money are
spent with a lack of results to show for it.
Another challenge that arises is how to scale a
maintenance strategy to incorporate all vital assets.
Hiring more people is not always a fi x. According to the
Bureau of Labor Statistics, growth in vibration specialists
will only be 4 percent over the next few years. So finding
the right people will be a challenge.
Spending more money on traditional automated
measurement systems will not work either, because those
systems are too expensive and inflexible to measure
several different types of signals.
But according to Bernie Cook, director of maintenance
and diagnostics at Duke Energy, Without additional
resources or new equipment condition monitoring
technologies, the risk of equipment failures will increase.
In other words, plants must find a better way to detect
problems earlier, because it can mean the difference
between a $5,000 bearing replacement and a $150,000
catastrophic bearing failure.
Now is the time to invest in a new strategy. Facilities
need a predictive maintenance strategy that integrates
with their existing enterprise infrastructure and
automates the collection of data on more machines to
predict machine failure in advance of catastrophic and
costly repairs. A study by researchers at the Electric Power
Research Institute found that a predictive maintenance
strategy costs about one-third of a preventive or
scheduled maintenance strategy and all but eliminates
the possibility of catastrophic failure.5 This evidence
is buoyed by findings of researchers at McKinsey &
Company: When companies inject data and analytics
deep into their operations, they can deliver productivity
and profit gains that are [5] to [6] percent higher than
those of the competition.6
57
Oil refineries often require both traditional

measurements and power measurements. Refineries
need a platform that is flexible enough to incorporate
different measurements yet economical enough to
produce a return on investment. Some platforms can
even be flexible enough to perform both control and
monitoring to further simplify systems.
Some products provide a platform-based, ready-torun integrated hardware and software solution for
online condition monitoring that helps companies
gain insight and improve operations and maintenance
programs by understanding the health of their
machinery and equipment.
This extensible suite acquires and analyzes
measurements, generates alarms, provides the
ability to visualize and manage data and results, and
simplifies remote management for large numbers of
monitoring systems. It offers:
built-in analytics and alarming capabilities and

remote interactive visualization of waveform data
scalability to hundreds of acquisition devices per
server
support for vibration and process measurements
using integrated hardware options
remote management of monitoring systems
and users
IT-friendly security features that include user and
device authentication
References:
digitalrefi ning.com/article_1000773.pdf
eia.gov/dnav/pet/pet_pnp_cap1_dcu_nus_a.htm
eia.gov/tools/faqs/faq.cfm?id=29&t=6
EMC Digital Universe with Research & Analysis by IDCThe
Digital Universe of Opportunities: Rich Data and the Increasing
Value of the Internet of Th ings
5. The Electric Power Research Institute has calculated
comparative maintenance costs in US dollars per horsepower
(hp) for each maintenance strategy.
6. mckinsey.com/insights/business_technology/
big_data_whats_your_plan
1.
2.
3.
4.
Brian Phillippi is product marketing manager

for embedded control and monitoring at
National Instruments. Learn more about
predictive maintenance and condition
monitoring techniques for oil and gas
at ni.com/mcm.
58
COVER
SERIES
Southwest Pipeline Station

Employs Modern Tools to
Improve Pumping System
Various analyses can identify problems and predict future system
vibratory responses.
BY JAY MARCHI
PROPUMP SERVICES
pipeline station and tank farm in the

Southwest uses four identical fourstage vertical booster pumps driven by
300-horsepower (hp) electric motors to
transfer crude oil between various storage tanks. The
piping systems and support structures are identical. To
expedite the process, the facility made plans to increase
pump output by adding a fifth stage and a larger 400-hp
motor. Before moving forward with
the planned upgrades, the facility
had to identify and resolve several
questions concerning ongoing
vibration-related issues. It needed to
determine if the planned upgrades
would exacerbate current or create
new vibration-related anomalies.
Using vibration signature analysis,
operating deflection shape (ODS)
and experimental modal analysis
(EMA), the end user was able to
identify the cause of the current
vibratory forces. In addition,
structural dynamic modification
(SDM) software was used to analyze
the dynamic effects the planned
upgrade and increased pump output
would have on the system.
Background
The operations team chose Booster Unit (BU) 3 and BU 4
(see Image 1) to be the subject of this study.
The first study (Study 1) was conducted to investigate
reported vibratory energies measured on the motor and
deflection of the associated piping in various locations.
In addition, recommendations were made to alter the
structure to accommodate the additional dynamic
Image 1. Booster Unit 3 and 4 (Image and graphic courtesy of ProPump Services)
59
The computer deforms the models

accordingly and combines them into
animations, providing insight into how
the system elements perturb at discrete
frequencies under normal operation.
loads that could result from the planned system upgrades. These
recommendations included increased pump output, a more robust
discharge head and a heavier 400-hp motor.
A second, post-modification study (Study 2) was conducted to
determine how well the predicted effects on the system matched the
actual responses of the modified system. The decision to proceed
with modification of the other three units was based on the results
of Study 2.
After Study 1, it was recommended that the end user consider the
installation of a concrete pier under the discharge block valve and
an optional additional support under the check valve. A new pier
under the BU 4 discharge block valve was installed. The optional
recommended support under the check valve was not installed.
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Method of Testing
Basic vibration analysis: High-resolution vibration measurements

were acquired at the locations identified in Image 1. The data is
presented in terms of velocity. The velocity of the signature is
a measure of the maximum speed at which the mass is moving
or vibrating during its oscillations. The faster the flexure, the
sooner a system will fatigue. Vibration velocity is directly
related to failure.
ODS analysis: The ODS models presented were generated from
the measurement of 120 triaxial vibration signatures while
the pumping system was operating under typical speeds and
loads. The deflection of the models is the result of the vector
summation of the triaxial measures at each point, which
produces a force vector that includes amplitude and phase.
The computer deforms the models accordingly and combines
them into animations, providing insight into how the system
elements perturb at discrete frequencies under normal
operation. The perturbations of the models are a combination
of the reaction to the forcing functions and the amount of
mechanical damping at the specific point on the model.
Complete stator & rotor analysis detect early faults in AC & DC

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Auto diagnosis within
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The data acquired for both studies included signatures for the basic
vibration, ODS and EMA analysis. Each data acquisition method is
summarized below:
60
COVER
SERIES
EMA: Similar to the ODS, the same 120 triaxial

signatures were taken. However, the difference is
that the system was not operating and a measured
excitation force was appliedin this case, by a tuned
model hammer. This type of force response testing
identifies the systems natural frequencies. When a
forcing function coincides with a natural frequency,
the vibration amplitude at that frequency can be
significantly amplified. Vibration signatures were
recorded at the locations in Image 1.
During the data capture, BU 4 was operating near full

load, recirculating through a tank pumping crude oil. A
comparative review of the amplitudes for Studies 1 and 2
was presented. As indicated, the majority of the overall
amplitudes decreased or remained the same.
The vibration signatures produced by the operation of
the motor and pump were presented in the representative
MOH. The spectra of the two motors are similar. However,
noted was the change of amplitude in the subharmonic
0.33 x revolutions per minute (rpm) component.
The higher order frequencies of the new motor are near
rotor bar and slot pass, which is common with highefficiency motors.
motor was as anticipated. The structure of the new motor

did have some effect on the mass distribution of the
model (the original SDM equations include a cylindrical
National Electrical Manufacturers Association [NEMA]
frame motor), but the mass-to-stiff ness ratios were very
similar, hence the similarities of their deflection shapes.
As predicted, the torsional forces on the discharge nozzle
were eliminated because the weight of the discharge
block valve was fully supported by the new concrete pier.
Additionally, the flexure of the piping at the check valve
was less than indicated in the SDM model, suggesting the
optional valve support structure was not required.
Comparison of Study 1 to Study 2

The comparison of the SDM modified structural
resonance modes to the actual measured modes was
presented in an interference diagram, also called a
Campbell plot. This type of graphic is a convenient
method of displaying a systems natural frequencies as
they relate to the primary and harmonics of running
speed. The plot can show where an increase in vibration
amplitudes that result from resonance may occur.
As indicated, the first response of concern was
the predicted first mode at 1,992 rpm. After the
Study 1 ODS at 1,788 RPM

The animations revealed that the torsional forces
generated by the motor rotor were twisting the discharge
head. This motion was imparted to the discharge nozzle,
which also produced a torsional force. At the nozzle, force
transitioned to the discharge block valve, forcing the
valve toward the right angle discharge piping. The force
reversal, due to the spring constants of the discharge
head and nozzle, resulted in a rocking motion of the valve
perpendicular to the pump. The valve motion imparted
the torsional force into the attached T-junction, forcing
the straight run piping to twist, drawing it back toward
the pump and driving the right-angle section downward.
Acting as a moment arm, the right-angle piping imparted
a torsional force into the attached piping, resulting in a
torsional motion that changed direction as it transitioned
through the check valve. This produced a sinusoidal
motion along the long axis of the pipe.
Study 2 ODS at 1,781 RPM

Using the modal data from Study 1, the team animated
a predicted SDM deflection shape and then compared it
to the actual shape animated with the data from Study
2. By comparison, the predicted and actual shapes were
very similar in magnitude and direction to the structural
perturbations. The parallel-to-discharge oscillation of the
Figure 1. Typical vibration data points identification
61
An engineering design firm helping pump manufacturers
modifications, the new first mode

increased to a more comfortable
2,376 rpm, or 33 percent above
the nominal running speed of
1,781 rpm. The higher order
second and third modes shifted
down most likely because the
omission of the additional support
under the check valve changed
the system stiff ness from what
was predicted in the SDM model.
None, however, coincided with
any frequencies of concern.
Modification and upgrades
to existing systems can be
expensive because of engineering
and material costs and loss of
productionall adding up to
increasing the payback period.
Depending on the extent of
the modifications, end users
must understand the system
and consider the effects of
the modifications prior to
implementation. System upgrades
intended to eliminate design
problems can introduce a new
set of structure-related issues.
Using the tools and techniques
presented in this article can help
eliminate problems and ensure the
reliability of new systems.
Jay Marchi is a 1985 graduate

of Pennsylvania State
University with a Bachelor of
Science in electrical design
engineering technology and
is employed by ProPump
Services (PPS), an engineering
and diagnostic consulting
firm located in Bethlehem,
Pennsylvania.
Marchi may be
reached at jmarchi@
propumpservices.c
propumpservices.com.
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62
EFFICIENCY MATTERS
Compressors Assist in
Propane Transfer Transition
When the Cochin pipeline stopped delivering propane into the U.S., Minnesota-based
Alliance Midstream established a new rail-supplied facility.
By Bill Holmes
Blackmer
new era in how propane

would be transported,
supplied and distributed
in Minnesota dawned in May
2012. Thats when Kinder Morgan
Energy Partners, L.P., announced
the launch of its Cochin Reversal
Project, which would see the
reconfiguration of its Cochin
pipeline from one that supplied
propane to the U.S. and eastern
Canada to one that would ship
diluents (light condensates/C5/
Pentane) from Kankakee County,
Illinois, to the oil sands region of
Alberta, Canada.
First placed in service in 1978,
the 12-inch, 95,000-barrels-perday Cochin pipeline was used
to transport propane and other
light hydrocarbon liquids 1,900
miles from Fort Saskatchewan,
Alberta, to Windsor, Ontario, with
intermediate distribution points
located in seven U.S. states: North
Dakota, Minnesota, Iowa, Illinois,
Indiana, Ohio and Michigan.
Over the years, the Cochin had
become the largest single source of
propane supply in Minnesota, with
38 percent of the states annual
propane supply delivered through
the pipeline.
We use between 400 and
500 million gallons of propane
in Minnesota annually.
Approximately half of that is
used for residential home heat,

40 percent is used for agriculture,
and the remaining 10 percent is
a mix of commercial, industrial
and motor-fuel applications, said
Scott McClelland, engineer at LPG
& NH3 Supply Inc., a supplier of
equipment and services for use in
the propane market in Minnesota.
When they shut down the Cochin
pipeline, it was imperative to find
new ways to get propane into the
state to keep up with demand.
Filling The Void

Alliance Energy Servicesthrough
its subsidiary Alliance Midstream
LLC in Benson, Minnesota, which
owns, operates, acquires and
develops midstream assets used
in the transportation and storage
of energy productsknew that
creative thinking would be required
to replicate the delivery volumes of
propane that would be lost.
Now that the Cochin has ceased
the shipment of propane from
Image 1. When it was announced that the Cochin pipeline would no longer be used to deliver propane
into the U.S., Minnesota-based Alliance Midstream LLC saw this as an opportunity to establish a new
rail-supplied facility. But for this plan to work, all of the components used at the facility needed to
operate at their full effectiveness and reliability, including Alliances compressors of choice.
(Images courtesy of Blackmer)
63
Canada into the U.S., our industry

has a large void in distribution,
said Jason Doyle, founder and
president of Alliance Energy Services,
in a July 2014 report in ButanePropane News. The area that will
be most affected will be the Upper
Midwest, and Minnesota is ground
zero since it relied on approximately
40 percent of its propane supply from
the pipeline. Supplying the market
during peak demand periods will be
very challenging. The industry must
work together, more than ever,
to plan and adjust to these
distribution challenges.
Seeing the opportunity to fi ll the
propane-supply void in the state,
Alliance purchased Kinder Morgans
propane terminal in Benson, which
is served by the Cochin pipeline and
located about 120 miles west of the
Twin Cities near Interstate 94. It
was the first major acquisition for
Alliance Midstream.
Most of the infrastructure
at the Benson terminal was in
place, including 17 90,000-gallon
propane storage tanks, which
provided a storage capacity of
1.53 million gallons. Alliance
determined that, in the absence
of the Cochin pipeline, rail would
be the best way to deliver propane
to the facility, and the company
constructed a rail spur that would
be serviced by BNSF.
The terminal in Benson has
a lot of storage capacity, but we
needed a way to get product into
the facility, said Chad Cain,
dealer account manager with
Alliance Midstream, who helped
oversee the facilitys buildout.
Alliance Energy decided the best
way to do that was by rail, so we
installed the railroad spur off the
BNSF mainline.
As the rail spur was being built,
Alliance contracted with LPG &
NH3 Supply Inc. to construct and
outfit a propane rack and unloading

system that could unload up to 16
railcars at a time.
With the average LPG railcar
possessing a capacity of 33,000
gallons, this would be as much as
530,000 gallons of product flowing
into the facilitys storage tanks at
once. The propane would be sourced
mainly from Canadian suppliers
with smaller volumes acquired from
the growing production areas in
neighboring North Dakota.
They worked with us to design a
system that could unload 16 railcars
at a time and get the propane into
storage, McClelland said.
What theyve got now is a large
monolithic structure, one long
continuous platform with eight
unloading stations on each side that
can unload eight cars on each side at
one time. Whats unique about the

setup is that this was an existing
pipeline asset that has started fi lling
from rail after they built a rail spur,
switch and platform for unloading.
The site layout was approved by
the Army Corps of Engineers in July
2014, with operations commencing
before the end of the year, just in
time to fi ll the storage tanks with
propane that was to be used in
Minnesotas important crop-drying
and heating seasons.
Weve got many carriers that come
into the facility, said Jake Johnson,
transload operator at the facility.
In one recent week, we unloaded 46
railcars (1.52 million gallons) and had
204 (approximately 2 million gallons)
trucks come in. Thats quite a bit of
propane considering its August and
its not yet the busy season.
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64
EFFICIENCY MATTERS
Lending A Hand
An important piece of equipment
in the propane-railcar unloading
process is the compressors that are
used to remove the propane from
the tankers and transfer it into the
storage tanks.
Weve got four compressors
total, which are good for unloading
two railcars at a time, McClelland
said. What theyre doing is
hooking up the railcars, using the
compressors to unload the liquid
and perform vapor recovery. The
terminal runs all the time, and
with those compressors they can
turn their 1.5 million gallons of
storage, fi ll it and pump it out, all
in 24 hours. They can offload 16
cars in only six or seven hours.
The compressors, which
feature 30-horsepower motors
and a mounting configuration
that includes pressure gauges, a
structural steel base and welded
or flanged piping, are ideal for the
Alliance terminals needs because
they provide single-stage, oil-free
operation and have been designed
specifically for propane transfer
and vapor recovery with flow rates
up to 125 standard cubic feet per
minute (212 cubic meters per hour,
935 gallons per minute).
Design features of the
compressors include high-efficiency
valves, ductile-iron pistons, selfadjusting piston-rod seals, head
and cylinders sealed with O-rings,
heavy-duty crankshaft, pressurelubricated bearing, pressureassisted piston rings and wearresistant crosshead assemblies.
They also feature American Society
of Mechanical Engineers liquid
traps, which have a mechanical
float to protect the compressor by
preventing liquid from entering.
Our compressors have to be
operating in all weather conditions
at all times and be fail-safe with
no problems. If were shut down,

weve got a line of trucks that
are waiting, and that just cant
happen, said Johnson, who likes
that the products are Americanmade. Im very pleased with the
product. Theyre very quiet, they

run amazingly; we havent had any
problems. I like them because I
push the buttonits almost like
the commercial, Set it and forget
it. Thats what it reminds me of.
Image 2. Running the day-to-day operations at the Alliance Midstream

terminal includes providing transloading and logistical support, along with rail
and truck services.
Image 3. The compressors are ideal for the Alliance terminals needs because they
feature single-stage, oil-free operation and have been designed specifically for
propane transfer and vapor recovery.
67
You push the button, and its going to

work all dayno problem.
With the compressors playing a
prominent role, the operation has
been so successful already that
Alliance has purchased additional
land around the 17-acre facility with
an eye toward eventually adding
more track to handle more railcars
and building additional storage
tanks. Any unloading rack or storage
additions would also increase the
need for compressors.
Theres no question that the
propane-supply market in Minnesota
was knocked for a loop in 2012
when Kinder Morgan announced
that the Cochin pipeline would no
longer be used to deliver propane.
But great change can bring with
it great opportunity. Alliance
Midstream recognized this and
immediately responded by finding a
solution to what could have been an
overwhelming challenge.
The solutionconverting the
Benson propane terminal into a
rail-supplied facilitywas a smart
move, but the plan could only work if
all of the facilitys components were
operating to their full effectiveness
and reliability. That includes the
compressors that must operate on a
24/7 basis.
This is the largest propane facility
in three states, so everything needs
to be state-of-the-art, Johnson said.
To operate at the level that we are
going to operate at, we need top-ofthe-line equipment, and they spared
no expense when they bought
those compressors. Theres no way
theyre going to let us down.
Bill Holmes is director of sales North

America Energy & Transfer Group
for PSG in Oakbrook Terrace, Illinois.
He may be reached at 847-726-7565
or bill.holmes@psgdover.com.
68
MAINTENANCE MINDERS
How Reliable Is Your Control Valve

Maintenance Program?
Read these guidelines, and use the scorecard on page 70 to find out.
By Mark Gimson
Singer Valve
ll mechanical equipment
requires maintenance,
and control valves are no
exception. With the guidance of
a regular maintenance plan, you
should be checking for leaks in the
tubing, monitoring pressure gauges
and inspecting equipment for any
abnormalities. In most cases, this
process should only take 20 to 30
minutesa small price to pay for
peace of mind.
In case a problem is detected,
always have the correct instruction
manual for the valve. Today, many
manufacturers provide these on
their websites, which operators can
access from a mobile device.
The following guidelines can help
you keep your valves operating at
optimal performance. As a note of
caution, valves are under pressure,
so be sure to bleed pressure off the
valve before taking any valve apart.
Ball Valves
Plated steel handles on ball valves
often rust away and leave a valve
without means of closure, so try to
ensure that you have solid stainless
handles for longevity. Ensure that
ball valves are open. If a ball valve
is meant to be left closed, it will
typically have a tag to inform you
of that. Give each ball valve a quick
turn to ensure it still moves, but
leave them in the same position
you found them.
Pilot Systems
Pilots typically sit in the same
position with little internal
movement for years of troublefree operation, but certain factors
can cause sluggish behavior or
fl awed readings. To check your
pilot, make slight adjustments to
the pressure settings while the
valve is in operation.
By slowly adjusting the setting
screw clockwise and observing
the downstream pressure gauge,
you can see if the pilot still has
operation of the valve. A small
move on the adjustment screw
should be seen on the pressure
gauge needle. Increase the setting
by approximately 5 pounds per
square inch (psi). Then, assuming
the pilot has performed this,
turn the adjustment screw
counterclockwise and lower the
pressure past the normal set point
so the gauge reads 5 psi lower
than normal.
Did the pilot and gauge work
together? If so, slowly bring the
pressure back to normal by turning
the adjusting screw clockwise and
setting the lock nut.
This simple exercise proves
the pilot is still working and
controlling the valve. If the gauge
did not track your adjustments,
then take a closer look internally to
ensure that nothing has worn out
in the pilot.
Another thing to look for is pilot

diaphragm leakage. If your pilot
has water leaking out of a vent hole
or through the adjusting screw
threads, you have a problem. First,
make sure that the water is not just
condensation by wiping the water
with a cloth. If after a few minutes
it starts to drip, then you know you
have a leak.
Water leakage indicates that you
have water in the spring casing;
that means there is a problem with
the pilot diaphragm. If this is the
case, you will have to take it apart
and replace that part.
The one exception where a
leaking pilot is acceptable is for an
altitude pilot, which is installed
with a copper tail tube designed
to relieve water during valve
operation, so water will drip
from it.
Leaks and cracks in a pilot
system will also affect how a
valve operates. Because the valve
pilot system relies on a supply of
pressurized water, it is susceptible
to damage from simple accidents.
Over-tightening of fl are fittings
often results in a small crack that,
over time, will cause failure.
When you check the valve, look
at the entire pilot system to see if
the fittings are tight and to ensure
that no water is seeping from a
joint. The small bore tube and
fittings can also break.
69
In some areas, minerals in the

water will wear out copper tubing
in the bends, so make sure the
system looks like it will still
hold pressure.
Air rises to collect at high points,
which are usually the pilots and
tubing in the control valves. Air is
also compressible and, if allowed
to remain in the pilot system,
it will alter readings and lead to
instability. If the valve is installed
with a wet type position indicator,
air will collect in the sight glass,
and the water level will be partially
down the glass tube.
The small plug or bleed valve
installed on the top of the indicator
can be opened or removed to
vent the air. When venting the
indicator, you are venting the main
valve bonnet, so the main valve
will begin to open.
Valve Diaphragms
Main valve diaphragms rarely
tragically fail unless something
is in the line that does not belong
there. They typically wear out over
time or get fatigued because of
mineral buildup.
A simple test can ensure that the
diaphragm is intact.
First, isolate the pilot system
so no water can get into the valve
cover. Then remove the bonnet top
plug or open bleed valve on top of
the position indicator. The main
valve will open, discharging all the
water in the bonnet as it does so.
Once the valve is wide open, the
water should stop flowing. If water
continues to flow, the diaphragm is
leaking. This will require removing
the main valve bonnet and closely
inspecting the diaphragm.
TAKE THE MAINTENANCE TEST

on page 70 to see how your
control valves score.
Mark Gimson is the business

development and marketing
manager for Singer Valve. He has
an engineering background with
extensive experience in valve
mechanics. He has worked around
the globe in the valve industry for
more than 35 years.
operato
He also runs operator
training sessions
around the world and
speaks at industry
conferences.
Strainers
A plugged strainer screen will
choke the water supply to the
main valve bonnet, causing the
main valve to have trouble closing
or not close at all. Most strainers
are installed with a plug, which
allows for a blowdown of the screen
without removing it. Remove the
plug and install a nipple and ball
valve, which allows for simple
blowdown. Keeping a screen clean
usually takes just a few seconds.
Fittings
Depending on the mineral quality
of your water, restriction fittings
small orifices that all pilot systems
rely oncan also get blocked. Clear
them by drilling them out, soaking
them in a solution or replacing
them altogether. If you have a valve
that struggles to open or close and
the strainer has been cleanedand
assuming all needle valves are
functionala plugged or partially
blocked line could be the problem.
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Control Valve Service Matrix

Courtesy of Singer Valve
Instructions
1. In the Summary section (in yellow below), insert your score for each of the eight variables.
2. Add your eight variable scores to get your Total Score.
3. Check your Total Score against the Scorecard (bottom of page) to determine the required action.
1. Size of area
Number of properties in the zone?
Score
4. Differential Pressure
Inlet press - Outlet press = Diff
pressure (P)
Score
7. Last minor service

PRV disassembled, cleaned &
visual inspection done?
Score
More than 2,500
Above 145 psi (10 bar)
Less than 4 years
1,800 to 2,499
116 psi to 144 psi (8 bar to 10 bar)
Less than 3 years
1,200 to 1,799
Less than 2 years
800 to 1,199
Less than 1 year
Less than 800
Below 42 psi (3 bar)
Less than 6 months
2. Critical nature of zone / area

How critical is the zone fed by the
PRV?
Score
5. Age of control valve

When was the PRV installed?
Score
8. Sizing factor
Is the PRV sized correctly?
Score
Medical facilities
Older than 15 years
Oversized - PRV opening 10%

and below
Older network - prone to bursts
Between 11 and 14 years
Undersized - PRV opening 70%

and more
Sensitive - manufacturing,
critical users
Correctly sized
Single feed zone
Domestic
Less than 1 year
SUMMARY
3. Size of pressure reducing valve

What is the bore of the PRV?
Score
6. Last major service

PRV had parts replaced: diap,
disc, seals, etc.
Score
1. Size of area
12 (300 mm) and larger
More than 4 years
3. Size of PRV
8 to 10 (200 mm to 250 mm)
4. Differential pressure across PRV
6 (150 mm)
5. Age of control valve
3 to 4 (80 mm to 100 mm)
6. Last major service
2.5 (65 mm) and smaller
Less than 1 year
7. Last minor service
2. Critical nature of zone
8. Sizing factors
TOTAL SCORE
TOTAL ACTION SCORECARD

43 to 56
High risk
Immediate review of valve operation required and preventive maintenance program to be generated. Inspection and major
service required in the next 1 to 2 months.
29 to 42
Medium to high risk

Check for high scores indicating a lack of maintenance. Where no major service has been done in more than 2 years, treat as
above (High risk - major service required between 1 and 2 months). If major service has been done, perform minor service on
valve in the next 2 to 6 months.
15 to 28
Medium to low risk

Normal range of operation. Without any major critical factors existing (which would then require a major service), perform a
minor service on the valve in the next 6 to 12 months.
0 to 14
Low risk
If the valve has not had a major service in more than 4 years, a major service is required. If it has been serviced, then a minor
service is required in the next 12 to 18 months.
72
MOTORS & DRIVES
How Power Factor & Induction Motors

Can Impact the Bottom Line
Corrections can be a sustainable, cost-saving measure and should be considered by companies
with a large installation of these types of motors.
By William Livoti
WEG Electric Corporation
hat is power factor, and

how does it impact your
bottom line? Anyone
with large induction motors in
their plants or those who have
been the recipients of power factor
correction charges from their
electric power utilities should read
this article carefully.
The Institute of Electrical and
Electronics Engineers and the
International Electrotechnical
Commission define power factor as
the ratio between the applied active
(real) power and the apparent
power (see Equation 1).
Circuits containing purely
resistive heating elements such as
strip heaters and electric stoves
have a power factor of 1.0 (unity
power factor). Circuits containing
inductive or capacitive elements
such as induction motors have a
power factor below 1.0. Induction
motor power factor is determined
primarily by the construction
material. Higher permeability
PF = P / S
Equation 1
Where:
PF = power factor
P
= active (real) power (kW)
S
= apparent power (VA,
volts amps)
material results in better motor

performance, lower current and
a higher power factor, so the
motor stator contains a majority
of this material. Power
factor varies from one motor
manufacturer to another because
of varying construction materials.
Besides the power factor
correction charge, there is the
ongoing cost for less-thanunity power factor due to the

permeability of materials. Some
might call it the gift that keeps
on giving. Low/poor power factor
continues to impact your plant
bottom line (month after month)
as noted in Equations 3 and 4.
Failure to correct power factor to
near unity can be very costly.
Figure 1. The graphic shows how the power factor

is derived. The kW, or real power, is what a user
receives. The kVAr, or reactive power, is the extra
power transmitted to compensate for a power
factor less than 1.0. The combination of the two
is called apparent power (kVA or volt-amperes).
(Graphics courtesy of WEG Electric)
Figure 2. At reduced load, power factor drops off

much quicker than efficiency.
(measured amps) x (measured voltage) x (1.732) x PF x hours x rate

1,000 (watts to kW)
Equation 2
Where:
Measured amps = average of three phases
Measured voltage = line-to-line voltage
PF
= power factor
Hours
= annual hours of operation
Electric Rate
= electricity cost in $/kWh
73
(340) x (460) x (1.732) x (0.85) x 4,160 x $0.07

1,000
= $67,049 per year
(340) x (460) x (1.732) x (0.75) x 4,160 x $0.07

1,000
= $59,161 per year
Users also need to be aware of

motor load. Unlike motor efficiency,
power factor drops off much quicker
than efficiency when a motor operates
at reduced load, as noted in Figure 2.
Notice how the power factor (green
line) begins to drop off at around 80
percent load. Equation 2 shows the
cost of power factor in an induction
motor. It can be used to calculate
annual electrical cost.
When performing the calculation,
use the name plate power factor, as
shown in Equation 3. The equation
uses measured amperage (340)
and measured voltage (460), while
1.732 is the square root of three,
0.85 is the name plate power
factor, 4,160 is the operating
hours, and $0.07 is the cost per
kilowatt (kW). Performing the
same calculation using corrected
power factor 0.75 based on the
motor performance data sheet,
Equation 4 shows using the actual
power factor. The savings can be
calculated by subtracting Equation
4 from Equation 3. The savings
with power factor correction
(unity) equals $7,888 per year.
Advantages of correcting power
factor include:
The electrical load on the
utility is reduced, allowing the
utility to supply surplus power
to other consumers without
increasing generation capacity.
Most utilities impose low power
factor penalties, which can be
substantial. By correcting the
power factor, this penalty can
be avoided.
Equation 3
Equation 4
High power factor reduces the load

currents, so considerable savings
are made in the cost of hardware.
There are several ways to address

power factor, including variable
frequency drives (limited to a specific
piece of equipment), static var (volt
amphere reactive) compensators
and dynamic var compensators (also
known as synchronous condensers).
Which method to use should be
evaluated based on total cost of
ownership. For example, variable
frequency drives are only cost-effective

under certain operating conditions.
Static compensators require regular
maintenance and must be sized
to the specific piece of equipment.
Synchronous condensers can be sized
to meet plant requirements, but this
comes at a price.
Less-than-unity power factor
can cost a company thousands of
dollars. Power factor correction is a
sustainable, cost-saving measure
and should be considered by any
company with a large installation of
induction motors.
William Livoti is the power
generation business development
manager for WEG Electric
Corporation. Livoti may be reached
at wlivoti@weg.net.
2196
SN
Model SN
Green Bay, WI
Model 2196
www.SUMMITPUMP.com
Celebrating Over 30 Years

74
SEALING SENSE
Manage Rubber Expansion Joints in Piping

Systems to Maximize Reliability & Efficiency
By Lloyd B. Aanonsen, P.E., & Joshua Cocciardi
FSA Members
t has long been recognized

that rubber expansion
joints (REJs) provide critical
design functions that impact
the reliability of the entire
piping system. This has led some
industry professionals to an overly
conservative calendar-based
replacement program and others
to a somewhat reckless approach
based on running equipment
to failure.
Maximizing an expansion
joints functional benefits while
minimizing its inherent risk has
always been a goal for the industry.
Until recently, end users have
addressed this concern by using
performance replacement REJs
along with best practices for
maintenance, reliability and
operations (MRO).
These strategies should not be
minimized. However, significant
advancements have been made
using a failure modes and effects
analysis (FMEA) program and
improved technologies related to
the detection of failure modes.
Specifically, synthetic
aperture radar (SAR) has shown
significant promise in improving
nondestructive inspection of the
inner construction of REJs.
Combining performance
replacement REJs with traditional
and advanced inspection methods
in an FMEA program can help
end users to improve the

management of REJs in piping
systems in order to maximize plant
reliability and efficiency.
The critical design functions
of REJs include their ability to
accept all directional movements
and to reduce noise and vibration
in the piping system. These pieces
of equipment are also designed
to have a cycle life in the tens of
millions of cycles, compensate for
misalignments, provide access to
piping and equipment, and relieve
pipe and anchor stresses.
However, the characteristics of

rubber lead to degradation over
time, which is accelerated by stress
and temperature. These conditions
are common in power and process
systems. Unchecked degradation
can lead to a catastrophic failure
that could cause a plant shutdown.
However, rigid piping systems
designed without REJs or a means
of handling the thermal growth
and other external movements
can lead to the same catastrophic
consequences despite inspection or
maintenance frequency.
Image 1. Inspection of REJ body blister as a failure mode (Image and graphic courtesy of FSA)
75
Improved Technologies
Improved materials and manufacturing
technologies have led to increased
design function and have minimized
the inherent risk of the REJ. For
example, fabric reinforcement, which
was traditionally square-woven cotton
or polyester weave, can be upgraded to
tire cord.
Square-woven implies that the fabric
strands are perpendicular to each
other and have approximately the same
strength in each direction. If a greater
strength is needed in only one direction,
the design requires an increase in the
overall number of plies, which increases
body thickness, reduces movement
capability and increases overall stiff ness.
A thicker body also reduces the projected
flange sealing area and can increase the
risk of REJ flange leakage.
The use of tire cord allows the bias
angle to be changed to increase the
strength in one direction over the other.
This is significant because, depending
on the application, the static forces in an
REJ can be considerably different in the
axial versus the radial direction.
Tire cord also ensures a superior
rubber-to-fabric bond because it is
coated with a specially formulated
adhesiveresorcinol formaldehyde
latex (RFL). The tire industry developed
the RFL coating to improve adhesion
and prevent ply separation and
delamination. The combination of an
improved elastomeric bond as well as
an optimal number and angle of plies
creates a homogeneous composite
with consistent and predictable
engineering capabilities.
Greater flexibility in todays REJs
minimizes their own internal stresses
as well as external stresses to the piping
system. The reduction of internal stress
minimizes the effects of aging and
leads to a longer service life. System
stress reduction is achieved when
the expansion joint accepts thermal
movements, relieving thermal stresses
that can quickly exceed allowable pipe
with varying overall lengths and built-in

lateral offsets. It is relatively inexpensive
for a qualified REJ manufacturer to
incorporate these field dimensions into a
performance replacement.
In a not-so-unusual case, the
installation crew spent a great
deal of time and effort forcing a
nonperformance REJ into an offset
and misaligned location. After an
exhaustive installation process, the
nonperformance replacement REJ had
a substantially reduced life because of
permanent stresses imposed on it. In
some cases, the actual field dimensions
exceed the allowable movement
capabilities of the joint, resulting in
rapid aging.
Building an REJ to exact field
dimensions ensures that the full
allowable movement capability and
useful life are maintained while also
stresses. Other advanced materials have

made it possible for REJs to be used with
a wider range of chemically abrasive and
erosive mediums under higher system
temperatures and pressures.
Building the REJ to exact field
dimensions is another example of
improving performance and reducing
risk. Over time, piping and equipment
settle and offset at different rates. For
example, a large diameter condenser
REJ may develop nonparallel fl anges and
a lateral offset in excess of 2 inches over
the course of its useful life. While the
condenser and piping system as a whole
have many years of use left, the problem
becomes how to bridge this offset with a
replacement REJ.
When replacing a valve and REJ,
it is often cost-prohibitive to realign
the piping or equipment. It is also
unrealistic to order a replacement valve
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76
SEALING SENSE
Figure 1. Cross sections of bi-directional REJ (left) vs. unidirectional REJ (right)
been compromised, and failure

is imminent.
Performance replacement
REJs and traditional inspection
methods are the primary
benefits of a plant reliability and
efficiency program offered by
a qualified REJ manufacturer.
Such a program provides direct
training and support and is
MRO-focused. Additionally, it
Traditional Techniques
can avoid catastrophic system
Through traditional preventive
failures, reduce U.S. Environmental
maintenance techniques such as
dimensional verification and visual Protection Agency liabilities
and physical inspections, end users and negative news cycles, and
and technicians can predict failures increase overall plant safety
before they pose a serious threat to factors. Industry best practices
have shown the importance of
the plant.
on-site training and inspection
Dimensional verification is
services, technical resources, and a
critical for understanding current
transparent relationship with the
stresses in the joint and ordering
REJ manufacturer.
an optimal replacement part. The
lower the stress the REJ is under,
the longer its useful life will be.
Nondestructive Evaluation
As mentioned above, ordering a
Despite the relative success of
joint to the field dimensions will
traditional inspection methods
ensure longer useful life of the
and industry best practices, there
part and lower stresses on the
remains significant ambiguity
piping and equipment. Visual and
in judging internal degradation
physical inspections are critical
without performing destructive
to reveal the effects of aging and
testing. The Electric Power
joint degradation. For example,
Research Institute (EPRI) had been
aging rubber will be hard and
tasked by the nuclear industry
brittle to the touch, often showing to improve the management
cover cracking. Blisters indicate
of REJs, so the organization
the tube has been compromised
formed a rubber expansion
and fluid is wicking through the
joint Technical Advisory Group
fabric reinforcement layers. In
consisting of utility sponsors,
some dramatic cases, ballooning
EPRI representatives, academic
is observable; this would indicate
researchers and representatives
that a significant number of the
from REJ manufacturers and/or
fabric reinforcement plies have
inspection vendors. The groups
minimizing installation and
maintenance costs. Performance
replacement REJs also offer
ease of installation and greater
installation tolerances because
of their improved flexibility, and
they provide zero leakage because
of optimal body thickness and
improved flange design.
main intent was to better manage

REJ components and prevent REJ
failures. The resulting technical
report, Microwave and Millimeter
Wave Evaluation of Rubber Expansion
Joints, applied well-studied and
readily available technologies in
a breakthrough nondestructive
evaluation (NDE) methodology for
REJs. The technical report explored
in detail mm-microwave SAR
techniques, which better visualize
the internal degradation of REJs.
Previous NDE methods for internal
inspection had proven unsuccessful
because ultrasound attenuates too
easily and radiography requires
access to both sides of the REJ.
In the field, this SAR
technology is applied using a
dual detector probe that is moved
circumferentially along the part,
creating a line scan measuring
voltage changes. Any internal
defects will result in a change in
voltage and are plotted on the line
scan. Any significant changes in
voltage that cannot be reconciled
because of surface geometry are
noted for further evaluation.
The report concluded that the
technology shows significant
promise as a safe, inexpensive
and reliable way to visualize
internal REJ degradation that was
previously unobtainable.
Failure Mode & Effect Analysis

FMEA programs are welldocumented and recognized as
effective reliability tools. They
quantify process failure risks by
77
considering their causes, effects and

failure modes. Additionally, they provide
a risk-priority number based on severity
of failure, likelihood of occurrence
and ability to detect. A qualified REJ
manufacturer can recommend corrective
actions and timelines to significantly
reduce the identified system risks and
corresponding risk-priority numbers.
The manufacturer also should have a
comprehensive failure assessment table
for the design, installation, operation
and retrofit phases of REJ applications.
Example REJ failure modes include
cracking, delamination, blisters,
ballooning and leaking fl anges.
An REJ experiencing body blisters
as a result of a compromised tube,
for example, would have a high riskpriority number based on the difficulty
to detect, severity of the failure and
the relatively high likelihood of failure
occurrence. Corrective actions can be
taken at the next scheduled outage and
should include using a performance
replacement REJ. This will minimize the
risk-priority numbers associated with
the severity of failure and the likelihood
of occurrence. Implementing traditional
and advanced inspection methods also
will reduce the risk-priority number
associated with the ability to detect the
failure mode.
REJ programs can maximize plant
reliability and efficiency, and allow the
industry to confidently transition to
condition-based maintenance with a
predictable replacement cycle.
Next Month: Why is bolted flange

connection training so important, and
what is a good source to acquire it?
We invite your suggestions for article topics as well as
questions on sealing issues so we can better respond
to the needs of the industry. Please direct your
suggestions and questions to
sealingsensequestions@fluidsealing.com.

78
HI PUMP FAQS
Air Pockets in a Piping System, Sealing Device

Basics & Rotary Pumping System Leakage
By Hydraulic Institute
the pump outlet (discharge) and

the outlet discharge check valve.
It is important to size and adjust
the air-release valve to evacuate
most of the air on startup. A
small volume of air is desirable
Air-release valves are an
to cushion the water as it slams
essential component in the design
against the check valve on pump
of system piping. These valves are
hydro-mechanical devices that vent startup. A vacuum valve is usually
pockets of air as they accumulate in desirable on vertical turbine wet
a system. In general, as the liquid is pit/well pumps to release the
vacuum accumulated during pump
pumped, entrained air will bubble
up to the high points in the system shutdown when the water in the
column pipe returns by gravity
piping. If the pipeline slopes
to the wet well. If the vacuum
upward, the liquids velocity will
in the column is not released to
move the air bubbles to stagnate
atmospheric pressure when the
at a high point. In contrast, if the
pipeline is fairly fl at and the inside pump is shut down, it may result in
a damaging water slam against the
surface of the pipe is very rough,
or if the pipeline slopes downward, check valve.
On initial fi lling of piping
the fluid velocity may not be sufficient to keep the bubbles moving. systems or after a shutdown that
results in draining of the system,
As a consequence, it is possible
caution is required to prevent
for a pocket of air to collect at
damage to air-release valves.
these high points and gradually
During fi lling of the pipeline
reduce the effective liquid flow
area, which may create a throttling with liquid, there can be a sudden
change in momentum forces on
effect similar to a partially closed
valve. Also, sudden compression of the air-release valves when the
fluid flowing in the pipe changes
these air pockets can set up severe
from all low-density gas to the
shock waves when released, with
the potential for serious equipment higher-density liquid. When this
interface passes a high point with
damage. When pumping into a
an air-release valve, the valve can
pressurized system, an automatic
undergo the same sudden change
air-release valve may be required.
in momentum. The resulting forces
For vertical wet pit pumps
may exceed the strength of the airon water service, it is usually
release valve housing.
appropriate to use both an airFor horizontal pumps that are
release valve and a vacuum valve.
not self-venting (trap air at the
The valves should be located on
top of the volute), a valve should
the high point of the pump outlet
be located at the highest point
(discharge) nozzle and between
What are the effects of air

pockets in a pump piping
system, and how can they
be eliminated?
on the volute case. Additionally,

air-release valves may be installed
on pipeline high points, changes
in grade and at periodic intervals
on long horizontal runs that lack a
defined high point.
For more information on
specialty piping components and
applications, refer to ANSI/HI 9.6.6
Pump Piping for Rotodynamic Pumps.
What are the basic

operating principles of
sealing devices?
Sealing devices can be
classified as static seals, such as
gaskets, and dynamic seals, such
as rotating interfacial axial seals,
also known as end-face mechanical
seals. Mechanical seals are used in
many types of pumps of various
sizes and pressure ratings and are
used to transport many different
fluids in numerous industries.
For this reason, mechanical
seals are available in a variety of
Figure 3.1. Essential elements of a mechanical seal

(Graphics courtesy of Hydraulic Institute)
79
A dynamic seal is achieved when the two rings contact

perpendicularly to the pump shaft. These rings are called seal faces,
one the rotating face and the other the stationary face.
configurations. Their selection
depends on the application
conditions; however, regardless
of the service conditions, all
mechanical face seals operate on
the same basic principle. Figure 3.1
shows a simple mechanical seal.
A seal consists of two sealing
rings, either of which rotates
relative to the other. One of the
rings is mounted rigidly, and the
other is arranged so that it can
move freely and align radially,

axially and angularly with the
rigidly mounted ring. A dynamic
seal is achieved when the two rings
contact perpendicularly to the
pump shaft. These rings are called
seal faces, one the rotating face and
the other the stationary face.
The faces are lapped fl at, which
results in low levels of leakage
while providing long life on the
basis of normal wear. Besides
the two faces, the mechanical

seal contains a set of secondary
sealing elements and several metal
parts. These serve the function of
sealing dynamically and statically,
loading the faces and transmitting
rotation. The secondary seals
provide sealing between the seal
faces and the metal parts, such as
mating ring housing, sleeve and
gland. The metal parts transmit
the torque and provide an axial

80
HI PUMP FAQS
Table 9.6.9.3.2.5. Application guidelines for leakage monitoring systems

mechanical seals
Seal Arrangement
Dual
Monitoring
Method
Single
Pressurized (double)
Unpressurized (tandem)
Inboard
Inboard
Outboard
Pressure
buildup in
seal reservoir
Barrier fluid
flow increase
or change in
reservoir level
Outboard
X
X
Pressure buildup in secondary

containment areas of sealless
pumps may also be used to
indicate leakage past the primary
containment.
Another form of monitoring
leakage is noting a change in
barrier fluid flow. Leakage
through the inboard seal of a dual
unpressurized seal arrangement
How can leakage in
may be detected by monitoring
a rotary pumping
the gas/liquid flow from the seal
system be detected and
to the vent system or collection
monitored for possible
system. Leakage through the
pump failure?
inboard seal of a dual pressurized
Leakage from installed
seal arrangement may be detected
pumps is detected in a number
by measuring the change in the
of ways depending on the hazard
level of barrier liquid from the
posed by the liquid being pumped
circulation system and reservoir
and the surrounding environment. (see Table 9.6.9.3.2.5).
Leakage is monitored to identify
For a complete list of means of
the failure of the seal or pressure
monitoring leakage, refer to ANSI/
boundary. These leaks may be in
HI 9.6.9 Rotary Pumps Guidelines
the form of liquid or vapor.
for Condition Monitoring.
Pressure buildup is one form
of monitoring leakage. Leakage
through the inboard seal of a dual
HI Pump FAQs is produced by the
unpressurized seal arrangement
Hydraulic
Institute as a service to pump
may be detected by a change in
users,
contractors,
distributors, reps
pressure in the seal reservoir
and OEMs. For more information, visit
containing the buffer fluid. This
pumps.org.
is accomplished by blocking off
the reservoir from the vent for at
least 10 minutes and noting the
increase in pressure.
mechanical force by means

of a spring element to load the
lapped faces.
For more information on
mechanical seals, refer to HIs
guidebook Mechanical Seals for
Pumps: Application Guidelines.
Solid Foundations Increase

Rotating Equipment Reliability
Baseplate failures are often difficult to identify in the field but can be
correlated to reoccurring performance issues in mounted equipment.
By Scott Sapita, BaseTek LLC
& Thomas Hines, Chemtrade Logistics Inc.
he success of rotating
equipment often can be
traced directly to the surface
and structure quality on which
it is mounted. The useful life of
seals and bearings in most process
pumps is compromised when shafts
are misaligned or excess vibration
is present.
Some estimate that more than 80
percent of sealed centrifugal pumps
are pulled from service for an issue
with a mechanical seal or bearing.
A solid foundation can increase
the mean time between planned
maintenance for pumps and most
other types of rotating equipment.
While many features and
options can be incorporated into
a pump baseplate, experts will
typically agree on the following
minimum requirements:
Figure 1. Damping ratio of typical baseplate materials

(Graphic and image courtesy of BaseTek)
Mounting surfaces should

support the entire pump and
driver continually through
the operating range of the
equipment.
Baseplates should be stiff
enough to resist distortion
and deflection and maintain
alignment of the pump and
motor when installed properly
per design.
Driver and pump mountingpad surface fl atness should be
parallel within 0.002 inch per
foot (0.15 millimeters [mm]
per meter).
Final alignment should be
maintained by allowing up to a
0.125-inch shim pack (3 mm).
Mounting hole requirements,
including size and location,
should never present a boltbound condition that inhibits
final alignment procedures.
Typical equipment baseplates

and foundations can easily
become compromised for a number
of reasons.
Incorrect or failed grouting
systems common with a hollow
metal or cast-iron base can quickly
cause excess vibration frequencies
that vary by rotational speed,
temperature, and equipment forces
and moments.
Less expensive, non-reinforced

metal bases can also warp and
bend during shipment, requiring
additional labor to straighten,
or they are often installed with
such deviations.
Corrosion and other forms of
environmental deterioration of
the mounting base or underlying
foundation can create an unstable
and varying mounting surface that
can result in excess vibrations
and cause misalignment of
installed equipment.
Baseplate failures are often
difficult to identify in the field but
can be correlated to reoccurring
performance issues in the mounted
equipment. Identifying and
eliminating hidden mechanical
defects in baseplate systems can
save time and frustration in rootcause evaluations.
Historically, baseplates have been
constructed of metal and either
cast or fabricated to meet specific
design requirements. Inexpensive,
hollow, cast-iron designs along
with channel and bent/formed
steel options often twist or
diaphragm during shipment and
may require surface preparation
or large amounts of grout to
complete the installation. Rarely
do these designs maintain a tight
fl atness tolerance. More complex
81
82
Image 1. Pumps at a sulfuric acid regeneration facility in Toledo, Ohio
metal-fabricated designs provide

increased rigidity and surface
flatness but may still require a
significant amount of grout to
complete a reliable installation.
A popular alternative gaining
ground in the pump industry is
the use of solid polymer concrete
baseplates. They provide the
benefits that reliability engineers
desire at an economical installed
price point.
In addition to a fl at vibration
damping surface, the corrosionresistant solid material can
easily incorporate drip pans,
containment rims, higheralloy threaded hole inserts and
alignment devices.
Often referred to as a polymer,
granite or mineral cast baseplate,
this material is a special
combination of well-defined
grain size aggregates bound to a
thermoset epoxy or vinyl ester
resin. Manufactured in a controlled
environment during a transfer
molding process, these materials
can be cast to precision tolerances
and offer high mechanical
properties suitable for most
industrial applications.
Polymer Concrete Benefits

Vibration damping: The polymeric
matrix of the material provides
damping ratios that are 20 to
30 times greater per identical
geometry than steel or cast-iron
materials (see Figure 1). Rotating
equipment is often associated with
stability under the influence of
various disturbances, and polymer
bases can effectively minimize
vibrations without increasing the
components mass size.
Precision mounting: Cast
mounting surfaces are typically
fl at within 0.002 inches per
foot, which reduces soft-foot
and speeds alignment. Threaded
insert holes are typically cast in
place or located with a computernumerical-controlled machine
to ensure precise location and
perpendicularity, which eliminates
bolt-bound conditions often
occurring with inexpensive
metal bases. Difficult-to-machine
features can easily be cast in place,
and maximum design flexibility
allows for retrofit to any existing
concrete foundation.
Corrosion resistance: Advanced
resin systems along with inert
natural aggregates provide

excellent protection from many
fluids that would otherwise require
an expensive alloy or corrode
standard cast iron or steel. Polymer
concrete systems eliminate the
need for additional protective
coatings or periodic upkeep and
maintenance activities.
Faster installation: Polymer
concrete baseplates will not twist,
bend or diaphragm like some
metal designs. This eliminates the
need for field adjustment during
installation. Most designs also
incorporate threaded leveling
inserts along with a bottom surface
ready for adhesion to grouting like
in a conventional hollow design.
Grouting a polymer concrete
baseplate requires considerably
less labor and material. Grouting a
hollow steel frame often requires
greater skill to ensure that all
voids are eliminated as grout is
intended to be in 100 percent
contact with the underside surface
for proper performance and
vibration damping.
Because the solid pre-cast
polymer concrete base will
maintain structural integrity
83
without requiring grout, many potential

installation errors can be avoided.
Stilt mounting a polymer concrete
assembly takes advantage of the
structural stability of the mounting
surface while allowing the equipment to
react to the forces and moments of the
piping system.
Polymer concrete materials also offer
low levels of heat conduction, act as an
excellent electrical insulator, are nonmagnetic and resist water absorption.
Mechanical properties are suitable for
most indoor-outdoor environments
found in process industries.
Case Study
Chemtrade Logistics operates a sulfuric
acid regeneration facility in Toledo,
Ohio, with more than 96 process
pumps in service. Four years ago, its
annual seal replacements were in
the range of eight to 10 per month. A
concentrated program was initiated to
focus on both equipment alignment and
vibration reduction.
The first step was to ensure a reliable
foundation. The facility made numerous
upgrades to convert to polymer concrete
baseplates. The material is impervious
to the acid, and installers who used the
threaded leveling inserts were impressed
at how easily they could use a minimal
amount of thin-set grout material to
adhere the new base to the existing
concrete pad. Minimal surface prep was
only required on the concrete pad.
The team completed proper alignment
between pump and motor shafts
according to the pump manufacturers
recommendations, not the coupling
manufacturers, which typically allow
for successful coupling operation at
much larger tolerances. While upgrading
baseplates, the installation team took
care to eliminate excessive forces
and moments in the piping, install
expansion joints and ensure a minimum
of five pipe diameters of straight piping
preceding the pump.
Accurate equipment hole locations

along with an extremely fl at mounting
surface made Bluetooth-enabled
precision laser alignment quick
and easy. Quarterly, handheld, fivepoint vibration monitoring confirmed
and reinforced all foundation and
equipment mounting changes that
were made.
After completion of these upgrades,
seal life increased dramatically. The
change-out dropped from a monthly
average of between eight and 10 units to

between 0.5 and one. The plant realized
sizeable reduction in seal cost and was
able to shift labor to other critical areas.
Chemtrade Logistics is continuing
its evaluation and replacement of
baseplates in conjunction with proper
alignment techniques.
A department emphasis has been
placed on precision maintenance
training to continually reinforce these
solid plant practices.
Scott Sapita is managing partner and co-founder of BaseTek LLC in

Middlefield, Ohio. Sapita has 29 years of experience in the rotating
equipment market. He may be reached at scott@basetek.com.
Thomas Hines is the maintenance supervisor at
Chemtrade Logistics Inc. in Toledo, Ohio. Hines has
more than 20 years of experience overseeing the precision maintenance
and reliability of rotating equipment. He may be reached at thines@
chemtradelogistics.com.
SEAL AND SYSTEM

REPAIR & REDESIGN
Specializing in rotating seals in high speed and critical equipment.
Petrochemcial Power Gen Oil & Gas
Stein Seal Industrial

50+ Years Experience
2 67-2 03-9 03 0 steinsealind.com

84
A New Approach to
Product Development
An iteration-based process allows for greater creativity.
By Bill Blankemeier & Bill Taylor
PeopleFlo Manufacturing
roduct development is arguably

one of the most important
pump industry processes.
For pump original equipment
manufacturers (OEMs), it accelerates
organic growth and complements
mergers and acquisitions. For end
users, product development presents
new opportunities to solve problems
and lower life-cycle costs. Despite
these benefits, developing innovative
new products can be daunting.
Successful product development,
especially in todays dynamic process
equipment industry environment, is
more demanding than ever. It requires
solving end-user problems with a
compelling value proposition that
drives down costs in tangible ways.
It requires meeting new demands
for greater energy efficiency and
lower environmental impact while
developing highly differentiated
products that enable OEMs to gain
competitive advantage and achieve
targeted return on investment in
record time.
To meet this challenge, many
companies are modifying the
traditional phase-gate product
development structure to incorporate

an iteration-based approach designed
to drive innovation through rapid
learning cycles. They are combining
this approach with systematic ways to
generate and develop ideas. For end
users, these new approaches to product
development are leading to more
innovative product solutions.
Traditional
Phase-Gate Structure
In the traditional phase-gate
development structure, a project is
divided into phases and separated by
gates. Each gate serves as a formal
decision point for management to
decide if and how the project will
progress to the next phase. The
traditional phase gate provides
structure to the product development
process, helps managers select the best
projects and reveals major problems
so they can be addressed before
further investment.
But in many cases, the traditional
phase-gate structure can stifle
the creativity needed to develop
innovative products. The time
allocated for creativity comes
earlyand only oncein the process

before it shifts to the next phase.
However, opportunities to generate
high-impact ideas are available
throughout the entire project.
Iteration-Based Approach
An iteration-based approach combines
the best elements of a phase-gate
structurehigh-level structure and
management review pointswith an
iteration strategy. This combination
enables development projects to
become a series of mini-project cycles
that includes comprehensive ideageneration with a design-make-test
cycle of the complete product.
History of Pump Innovation

2000 B.C. The shadoof is
invented in Egypt. It uses

a long suspended rod with
a bucket at one end and a
weight at the other.
200 B.C. The water organ is invented in Greece. It is an

air pump with valves on the bottom, a tank of water in
between them, and a row of pipes on top. This principal
design is now known as the reciprocating pump.
200 B.C. Archimedes invents the screw pump, considered
by some to be one of the greatest inventions of all time.
1475 A centrifugal pump

design for lifting mud is
published in Italy.
1588 A sliding vane
water pump design is

published.
1593-1636
Gear pumps are

developed in France
and Germany.
Image 1. The computerized numerical control (CNC) machining

section of a make-to-order production cell designed
concurrently with a new centrifugal pump product line.
Innovations included a flexible work-holding system combined
with parametric CNC programs that enable production of
high-mix, low-volume pump products. (Images courtesy of
PeopleFlo Manufacturing)
Image 2. Prototypes from four iterations involved in designing a sealless hygienic centrifugal pump. From left to right: cardboard and
tape concept prototypes, aluminum concept prototype, aluminum functional prototype and stainless steel functional prototype
Each iteration builds on the

in-depth learning, discoveries and
results of the previous iteration. The
lessons learned from one iteration are
used as a starting point for the next
iteration to drive improvements and
spark new ideas.
In the early phases, these iterations
are quick and typically involve creating
1650-1675
Piston pumps are developed

in Germany and England.
concept prototypes from materials

such as wood, plastic, cardboard,
clay or other inexpensive quick-build
materials. As the product design
advances to the next iteration, the
developers build prototypes with
more refined and functional features
that converge with higher resolution
to the final design. When combined
1687 The first true
centrifugal water
pump is developed.
1830 The
modern screw
pump is
introduced.
1849 All-
metal pump
construction is
introduced in
the U.S.
1859 The
diaphragm
pump is
introduced.
with a systematic way to generate

and develop ideas, the iteration-based
approach becomes a powerful way to
compete based on innovation.
Idea Generation
Each iteration provides a structured
yet flexible way to generate ideas,
converge these ideas to the best
1874 The
vane pump is
introduced.
1900 The liquid ring vacuum pump

is developed in Germany.
1901 The vertical turbine pump is

developed in the U.S.
1905 Multistage centrifugal

pumps are developed.
86
Image 3. Visual displays used during a centrifugal pump brainstorming session
alternatives and model the top ideas to

bring them to life with further clarity.
The idea-generation process starts
with establishing the core product
development challenge that will solve
major end-user problems and enable
OEMs to accelerate profitable growth.
Only by raising the bar to seemingly
impossible levels across several key
success drivers can the idea-generation
process have the foundation and
context necessary for product
line breakthroughs.
Developers can design an ideageneration process, tailored
to engineered machinery, to
systematically find innovative
solutions to the product development
challenge. The process can be applied
across a wide range of development
activitiesfrom high-level product
design architecture to specific
component designand throughout
1911
The internal
gear pump is
introduced in
the U.S.
1916
Submersible
pumps are
invented in
Russia.
1921 The use
of corrosionresistant alloys
for pumps in the
chemical industry
is commercially
introduced.
all iterations of product development.

The result is an ongoing flow of ideas
that continuously improves the
products design, performance and
cost in creative ways and allows the
incorporation of late-breaking ideas.
Brainstorming activity fuels the
idea-generation process, and a visual
environmentsketches, pictures and
engineering drawingsdisplays ideas
in full view so new ideas are inspired
through cross-pollination.
Idea Development
Each iteration also provides the ideal
environment for an idea-development
process to bring the best ideas to life
through a complete design-maketest cycle of a product. A design team
co-located with a comprehensive
prototype shop is advantageous
because of rapid part turnaround and
the agility required to make quick
1926 The first
inducer design is
patented for use
with centrifugal
pumps.
1930 A progressive
cavity pump design
is patented.
1936
The
metering
pump is
invented
in the
U.S.
changes. This end-to-end process

drives learning through a hands-on
experience that inspires creativity
and often leads to valuable new,
unforeseen innovation.
This learning-by-doing process is
perhaps the best way to build critical
innovation capabilities because it
is based on experiential learning.
Developing innovative new pump
products is complex and loaded with
tacit knowledge. This is hard to learn
through traditional training and
learning channels. Multiple iterations
of idea generation and development
help build critical skills in a rapid
hands-on learning environment.
Holistic Iteration-Based
Innovation
The opportunity to create value for
both end users and pump OEMs
through new product development
1949 The
magnet
drive
centrifugal
pump is
invented in
the U.K.
1955 Air-
operated double
diaphragm
pumps are
invented in
the U.S.
1962 High-speed
centrifugal pumps
are introduced in
the U.S.
87
Positive Displacement Pumps

Centrifugal Pumps
Specialty & Other Pumps
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Custom Research
White Papers
Frost & Sullivan evaluates and implements

effective growth strategies. We employ 50
years of experience in partnering with Global
1000 companies, emerging businesses and
the investment community from more than
40 offices on six continents.
Visit us at www.frost.com
For more information, contact Liz Clark
at 210.477.8483 or liz.clark@ frost.com
Bill Taylor is the VP of business development and

board member for PeopleFlo Manufacturing. With
more than 30 years of pump and
related industry experience, Taylors
past roles include president of
Sundyne Corporation and president
of ITT Industrial Products (Goulds).
He may be reached wtaylor@
peopleflo.com or at 714-856-7222.
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Comprehensive
Industry Coverage
Bill Blankemeier is the founder

and president of PeopleFlo
Manufacturing, an engineering
design and innovation firm focused
on helping pump manufacturers
create new products and processes.
Blankemeier has more than 30 years
of pump and valve industry experience with ITT and
Tuthill Pumps. He may be reached at
wblankemeier@peopleflo.com or at 630-862-1602.
Po
goes beyond what is possible through innovative

product design alone. How a product is madethe
production technologyis just as important as how a
product is designed.
End users not only want a new product that saves
money, but they also want an affordable upfront price
that provides quick payback and quick delivery lead times.
Pump OEMs want to hit product gross margin levels that
provide quick return on investment, and they aim to
deliver quickly without infl ated inventory levels.
A holistic development strategy that applies the
iteration-based innovation approach to production
technology with as much rigor as it is applied to product
design leverages the value creation opportunity. This can
be done without compromising seemingly confl icting
interests of OEMs and end users.
Creating an innovative make-to-order production cell,
developed concurrently with and tailored to the new
product line, has resulted in significant breakthroughs
up to 50 percent lower cost, 65 percent less upfront capital,
75 percent less floor space and outstanding delivery lead
times with relatively low inventory levels.
IGEL Electric GmbH Industrieweg 1315 48324 Sendenhorst Germany

Phone +49 (0)2526 9389-0 Fax +49 (0)2526 9389-22 info@igelelectric.de igelelectric.de

88
PRODUCTS
New & Notable Technology

Products selected by the Pumps & Systems editors:
1 PULSATION DAMPENERS
GRIFFCO VALVE INC. has issued a new line

of pulsation dampeners to enhance the
performance of chemical feed systems. The
pulsation dampener can reduce harmful
shock waves and deliver continuous chemical
dosage at the injection point. Nine volumetric
sizes are offered ranging from 6.0 to 125.0
cubic inches with a dampening effect of
+2.5 percent. The new pulsation dampeners
have a maximum operating pressure of
250 psi (17 bar) at 70 F (21 C).
2 ULTRASONIC FLOW METER
KROHNE INC. has introduced the

OPTISONIC 8300 ultrasonic flow meter for
superheated steam, which delivers 1 percent
measuring accuracy, high repeatability
and a large dynamic measuring range with
maintenance-free operation. The two-beam
ultrasonic flow meter is capable of handling
high flow rates of superheated steam, making
it ideal for power plant boiler and plant
efficiency monitoring, energy balancing, and
inter-company steam billing. The flow meter
is rated for pressure up to 200 bar/3,625 psi
and temperature up to 540 C/1,004 F, with
higher-rated units available on request.
PUMPING MACHINERY LLC has

released its custom-designed and -built
multichannel vibration monitors line.
Designed for engineering, maintenance
and operating plant personnel, the unit
includes a computer, hardware, software,
sensors, support and startup training. The
base unitthe PumpVib-9monitors
multichannel vibrations (overall, spectral,
and diagnostics) to pinpoint issues such
as unbalance, misalignment, blade pass,
cavitation and recirculation, and bearing
faults. An enhanced modelthe PREMS2Acovers vibrations, temperatures and the
pump performance curve (head, flow, power,
efficiency) and tracks it live remotely online.
4 DIGITAL OSCILLOSCOPE
AEGIS new Shaft Voltage Tester Digital

Oscilloscope is designed to check in-service
motors for damaging variable frequency
drive-induced shaft voltages and head off
bearing damage and costly unplanned
3 VIBRATION MONITOR
equipment downtime. The digital oscilloscope is

specially designed and configured to take and capture
highly accurate voltage measurements from the
spinning shafts of motors. The oscilloscope is capable
of sampling rates of 1 GSa/s to 50 GSa/s.
5 SLIDING VANE PUMP
BLACKMER, PART OF PSG, has added the NPH and XH

Series sliding vane pump models to its NP and X Series
product families. Both the XH Series pumps, which are
designed to handle non-corrosive and non-abrasive
industrial liquids and petroleum products, and the
NPH Series pumps, which are ideal for handling viscous
or shear-sensitive fluids, feature the same performance
characteristics as the NP and X Series models. They are
available in 2-, 2.5-, 3- and 4-inch sizes.
6 DEWATERING PUMP
XYLEM INC. has announced enhancements to its Flygt

2000 drainage pump range. The Flygt 2190 mid-sized
submersible dewatering pump is built to handle tough,
abrasives-laden liquids. The Flygt 2201 shares the same
technology and provides customers with a superhigh-head alternative with its two-stage hydraulics
version. The Flygt 2400 stainless steel pump provides
customers in the mining sector with a durable, superhigh-head pump suitable for transporting chemically
aggressive mine water.
To have a product considered for our Products page, please send the information to Martin Reed, mreed@cahabamedia.com.
89
8 END SUCTION PUMPS
ARMSTRONG FLUID TECHNOLOGY

has expanded its horizontal end suction
design envelope pumps that feature
sensorless integrated controls for greater
energy savings. Both the DE 4200H and
DE 4280 Series include Armstrong Design
Envelope technology, with easy-to-use
sensorless control and enhanced connectivity
to BAS to achieve significant efficiency
improvements. The DE 4200H pumps are
supplied with split-couplings and outside
balanced seals, while the DE 4280 pumps use
a close-coupled design.
9 COUPLINGS
7
7
7 SENSOR
S SO ASSEMBLIES
ASSEM
S
ENDRESS+HAUSER
E
SS
USER has released its Cleanfit CPA875
a CPA871 sensor assemblies that allow pH, ORP,
and
o yg n and NIR sensors to be installed or removed
oxygen
during operation. By moving the sensor from the
measuring position to a service position, these
retractable assemblies allow the sensor to be cleaned,
calibrated or replaced without interrupting the process.
The Cleanfit CPA875 is ideal for pharmaceutical and
food and beverage applications where sensors must be
removed for cleaning, calibration or maintenance on a
regular basis.
BALDOR ELECTRIC COMPANY has

introduced the BaldorDodge Raptor
coupling featuring the patented WingLock
Technology. With a fi nite-element optimized
winged elastomeric element design, the
Raptor can improve driven equipment life
and reliability. Raptors patented WingLock
technology increases surface area at the most
critical regions of the element, which can
result in higher bond strength, improved
fatigue resistance and longer life than
some urethane designs. A non-lubricated
natural rubber element results in lower
stiff ness, improved vibration damping and
misalignment capabilities.
Your Premier Manufacturer of
ANSI Pumps &

Centrifugal Mud
Pumps
In stock, ready to ship

Numerous makes and
models
Service and repair on
existing pumps
1113 Howard Avenue | Houston, TX 77536 | 281-479-5000
curflo.com
90
PRODUCTS
10 MODBUS DIN MOUNT GATEWAY
SIGNALFIRE WIRELESS TELEMETRY

is offering a Modbus DIN Mount Gateway
that combines a high-power radio with
gateway electronics in a compact DINmounted module with external SMA antenna
connections for use in remote monitoring
applications. SignalFires Remote Sensing
Systems consist of a gateway and nodes that
connect to remote assets and extract data
from or send control data to those devices
through other nodes and/or the gateway.
The SignalFire Gateway serves as a two-way
interface, connecting asset managers to
a remote mesh network of assets using
industry-standard Modbus protocol.
11 SOLIDS-HANDLING PUMPS
CRANE PUMPS & SYSTEMS has announced

the release of pumps and motors that expand
the range of its Barnes SH Pump line. The
Barnes SH Series now includes 3-, 4-, 6-,
8- and 10-inch discharge sizes along with
motors ranging from 2 to 150 hp. The SH
Series provides flows to 4,000 gpm and heads
to over 240 feet including low-flow, highhead pumps with steep performance curves
designed for low-flow connections to existing
pressure mains.
10
10
11
12 CONDENSATE PUMPS
HARTELL, a brand of Accudyne Industries, has

introduced its high-temperature, low-profi le
commercial-grade condensate pump series. The
addition to the PlenumPlus series has been designed
for applications where installation space is restricted.
The pump stands 4.75 inches high and can handle
temperatures up to 212 F with a maximum lift of
18 feet. The 1-quart reservoir is 1.75 inches tall and
comes standard with an auxiliary safety switch.
12

91
14
14 KNIFE GATE VALVE
15
13
LINED
NED VALVE COMPANY has unveiled its
h avy-duty stainless-steel resilient seated
heavy-duty
k ife gate valve, known as Figure 77,
knife
recommended
commended for pump isolation. Figure
7 resists corrosion with cast stainless77
steel
eel body, gland and yoke, and precisionmade stainless-steel gate and stem.
Figure
gure 77 is bi-directional with drip-tight
shutoff
utoff. The field replaceable seat is flush
w th bottom of port eliminating pockets.
with
Figure
gure 77 is MSS SP-81 and AWWA C520
certified
ed.
C cle 203 on card or visit psfreeinfo.com.
Circle
15 PROXIMITY
13 AC DRIVE
SIEMENS has released its Sinamics G120C drive

in AA size, which replaces the previous G120C
frame size A in power ratings up to 2.2 kW (3
hp), including communication variants for USS,
PROFIBUS, PROFINET and EtherNet/IP. Offering
high-power density in a smaller footprint, the new
drive offers fully compatible replacement for the
equivalent power ratings on the previous version.
The tiny drive offers machine builders another
economical, space-saving and easy-to-operate
standard AC drive with a wide range of functions.
MEASUREMENT SYSTEM
METRIX is offering its new Digital

Proximity System (DPS) line that
combines the performance of a fully API
670-compliant proximity measurement
system with the flexibility of digital
configurability. The Metrix DPS allows a
user to configure a 200-mV/mil (8mV/m)
linear output for almost any combination
of probe target material, system length
and manufacturer for a proximity probe
thrust, radial vibration or speed system.

92
NEW: Hydraulic Institutes Wastewater

Treatment Plant Pumps Guidebook
U N M AT C H A B L E E X P E R I E N C E
I N F L OW C O N T RO L
TRANSACTIONS
This new guide provides the

guidance necessary to select
pump types, pump materials,
and auxiliary components so the
wastewater pumping system
performs effectively, efficiently,
and reliably in various plant
operations. Find out whats
inside by visiting the link below.
Jordan, Knauff & Company is a knowledgeable and

experienced provider of a comprehensive line of
investment banking services to the pump, valve and
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Our lines of business include: selling companies,
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To learn more about Jordan, Knauff & Company,
contact any member of our Flow Control
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MEMBER FINRA, SIPC
Advertisers
A.W. Chesterton
Company .......................... 25 ...... 121
AE Pumps ............................. 95 .......173
AIGI Environmental Inc..... 28 ...... 122
All-TEST Pro, LLC. .............. 59 .......141
Apex Engineering .................................
Products Corporation. .... 92 ...... 160
Ashcroft ............................... 57 ...... 138
AutomationDirect.com ...... 29 .......102
AWWA ..................................90 ...... 123
Baldor Electric Company.... 19 ...... 103
BaseTek................................. 67 ...... 153
BBA Pumps Inc. ................... 67 .......142
BBA Pumps Inc. ................... 94 .......161
Blackmer, part of PSG......... 63 .......148
BLACOH ...............................BC ...... 104
Blue-White Industries .......... 9 .......117
Boerger ................................. 55 ...... 139
Grundfos .............................. 17 .............
CURFLO ............................... 89 ...... 154
Dan Bolen &
Associates, LLC ............... 94 .......162
EASA ..................................... 66 ...... 106
Electro Static Technology .. 43 ...... 125
Flomatic ............................... 49 .......116
FLSmidth ............................. 61 .......143
FLUKE .................................... 7 .......114
Friendly Acquirer ............... 95 .......179
Frost & Sullivan .................. 87 ...... 155
Fulflo Specialties Inc. .........44 ...... 126
FREE PRODUCT INFORMATION

Visit psfreeinfo.com to request more
information from these advertisers.
General Rubber Corp. ......... 27 ...... 127

Graphite Metallizing
Corp. ................................. 89 ...... 156
Griswold, part of PSG ......... 45 ...... 128
Hatz Diesel of
America, Inc..................... 39 .......107
Hydraulic Institute ............. 92 ...... 157
Hydro Inc. .......................... IFC ...... 100
IGEL Electric ........................ 87 ...... 158
JDA Global LLC ................... 35 ...... 129
Jordan, Knauff
& Company ...................... 92 ...... 159
KTR Corporation................. 77 ...... 144
Liberty Pumps ..................... 15 ...... 108
Load Controls, Inc............... 26 ...... 130
Load Controls, Inc............... 94 ...... 163
LobePro ................................ 93 ...... 164
Magnatex Pumps, Inc. ........ 77 .......145
Master Bond Inc. ................. 94 .......165
Meltric Corporation............ 93 ...... 166
Milton Roy ........................... 37 ...... 131
National Pump Company ... 53 ...... 132
PeopleFlo ...............................................
Manufacturing ................ 61 .......146
Pinnacle-Flo, Inc. ................ 69 .......147
Proco..................................... 79 .......140
PumpWorks 610 .................. 13 ...... 109
Rotech .................................. 95 .......174
RuhRPumpen ...................... 23 ...... 133
Schaeffler Group USA Inc. .... 3 .......110
SealRyt Corporation ........... 21 ...... 120
SEPCO .................................. 18 ...... 134

SERO Pump Systems .......... 93 .......167
Shin Nippon Machinery
Co., Ltd. ............................ 12 ...... 118
ShinMaywa
(America), Ltd. ................ 31 ...... 135
Sims Pump Valve
Company, Inc. ................. 95 .......176
Sims Pump Valve
Company, Inc. ................. 95 .......177
Sims Pump Valve
Company, Inc. ................. 93 .......178
Sims Pump Valve
Company, Inc. ................. 65 ...... 115
Skinner Power
Systems, LLC ................... 34 ...... 136
SPM Instrument.................. 95 ...... 168
St. Marys Foundry .............. 94 .......169
Stein Seal Company ............ 83 ...... 152
Summit Pump, Inc. ............. 73 .......149
SWPA .................................... 91 .......124
Fast & Effective

Biodegradable
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Non-Hazardous
Non-Corrosive
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ThermOmegaTech ............... 11 .......119
Thordon Bearings Inc. ........ 22 ...... 137
Start saving money today.
Titan Manufacturing Inc. .. 80 .......151

Titan Manufacturing Inc. .. 93 .......170
Tuf-Lok International ........ 95 .......175
Vaughan ............................. IBC ...... 111
Vertiflo Pump Company ..... 93 .......171
Vesco ..................................... 94 .......172
WEG Electric Corp. ............. 71 ...... 113
Xylem Water Solutions ......... 5 ...... 112
* The Index of Advertisers is furnished as a courtesy, and no responsibility is assumed for incorrect information.
Water Scale Can Be Costing

You Thousands of Dollars
Contact us at 630-820-8888
www.ApexEngineeringProducts.com
93

REPS WANTED
Sims Pump, a fast growing structural
composite pump, pump parts, and
mechanical seal manufacturer is
seeking ambitious, aggressive, and
self-motivated representatives for
both the marine and industrial
markets around the world. Sims
focuses on sales to customers with
corrosive environments, such as
marine, cruise, power generation,
public utility, wastewater facilities, oil
and gas, as well as chemical and
industrial markets. A background in
pumps, mechanical seals, or any
rotating equipment is required.
Please fax your resume to
1-201-792-4803, or email to
Simsite1@aol.com.
Office: 1-201-792-0600
WWW.LOADCONTROLS.COM
If:. BBA Pumps

www.bbapumps.com
Pumps, Pipes and Couplings for the

wellpointing, construction and rental market.

EXECUTIVE SEARCH/RECRUITING
Dan Bolen & Associates, LLC

__..........
"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 JULIAN MUELLER
9741 North 90'h Place, Suite 200

Scottsdale, Arizona 85258-5065
(480) 767-9000 Fax (480) 767-0100
Email: dan@danbolenassoc.com
www.danbolenassoc.com
April 2016
I Pumps
& Systems
For repair and protection against:

Corrosion Abrasion
High/low temperatures
~ ~!~X~L!!r~'?o~!?s Hackensack, NJ 07601 USA

main@masterbond.com
+ 1.201.343.8983
www.masterbond.com
95
Distributors of Mechanical Seals and other Rotating Equipment
Replacement ANSI Pumps/Parts

Self-Priming Pumps
Vertical Inline/Multistage Pumps
End Suction Pumps Ball Check Valve
Mechanical Seals
A growing, cash rich international manufacturer seeks acquisitions

of distributors / resellers active in the mechanical seal market.
The ultimate friendly acquirer, its integrations process is deliberately
slow and based around employee and customer retention. Ultimately, any
acquired business will form a part of a national sales network. Acquirer
values continuity, is a great home for loyal staff and is a succession
planning solution that leaves in place what you have created.
Discretion and confidentiality assured.
Please contact
FriendlyAcquirer@gmail.com
Inventory/ Shipping: USA/ Canada
1-866-217-PUMP (7867)
sales@rotechpumps.com | rotechpumps.com
U-iv>}}Eiv
}`}
U}ii
>i`
U->i
`ii
UV
U}i`
Tuf-Lok International
*i\ n{n U www.tuflok.com

96
PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

Figure 1. Stock Indices from March 1, 2015, to Feb. 29, 2016
By Jordan, Knauff & Company
he Jordan, Knauff &

Company (JKC) Valve Stock
Index was down 22.1 percent
over the last 12 months, while the
broader S&P 500 Index was down
8.8 percent. The JKC Pump Stock
Index also decreased 27.8 percent
for the same time period.1
In February, the Institute for
Supply Managements Purchasing
Managers Index (PMI) increased
to 49.5 percent from the January
reading of 48.2 percent but
remained in contraction territory
for the fifth month in a row. The
New Orders Index, a forwardlooking component of activity,
remained positive at 51.5 percent
for the second consecutive month.
Twelve of 18 industries reported
growth in new orders, including
textile mills, wood products,
furniture and related products,
machinery, plastics and petroleum.
A chemicals producer noted that
U.S. business demand is solid, but
international demand is soft.
The U.S. Department of Labor
reported that the U.S. economy
added 242,000 jobs in February
and revised Januarys nonfarm
payroll number up to 172,000.
Job gains in December and
January were revised up by a
combined 30,000 jobs. Sizable
job gains were observed in retail,
education, health care, and
leisure and hospitality, while

manufacturing employment
lost 16,000 jobs and mining
was down 19,000 jobs in
February. The unemployment
rate remained stable at
4.9 percent. The ongoing
pace of solid job growth
Source: Capital IQ and JKC research. Local currency converted to USD using historical
implies continued support
spot rates. The JKC Pump and Valve Stock Indices include a select list of publicly-traded
to economic growth from
companies involved in the pump and valve industries weighted by market capitalization.
consumer spending. The labor
averaged 9.3 million barrels per
force participation rate has
day, which was down 166,000
risen 0.5 percentage points
Reference
barrels per day from December
since September to 62.9 percent
1. The S&P Return
2014. Lower crude oil prices,
in February.
figures are provided
which have declined more than
The number of drilling
by Capital IQ.
70 percent since the summer of
rigs actively exploring for or
2014, have contributed to the
developing oil or natural gas in
decline in both production and
the U.S. averaged 532 in February,
Jordan, Knauff
drilling activity.
according to Baker Hughes Inc.
& Company is an
On Wall Street, the S&P 500
This figure is down from the 654
investment bank
based in Chicago,
reported in January and down 816 Index decreased 0.4 percent and
Illinois, that
the NASDAQ Composite fell 1.2
rigs from the 1,348 reported last
provides merger and
percent in February, while the Dow
February. The worldwide rig count
acquisition advisory
Jones Industrial Average increased
for February was 1,761, down
services to the
pump, valve and
from the 1,891 counted in January 0.3 percent.
filtration industries.
The indices were down
and down 1,225 from the 2,986
Please visit
because of mixed economic data,
counted in February 2015.
jordanknauff.com for
discouraging quarterly reports and
Along with the decline in active
further information.
the volatility of oil prices following
drilling rigs, U.S. oil production
Jordan Knauff &
Company is a member
uncertainty regarding production
has generally declined month to
of FINRA.
cuts by Russia and Saudi Arabia.
month since April of last year,
Wal-Mart Stores Inc., Cognizant
when it reached a 44-year peak
Technology Solutions Corp., Yahoo!
of almost 9.7 million barrels per
These materials were
day, as reported by the U.S. Energy Inc. and Exxon Mobil Corporation
prepared for informational
purposes from sources that
all reported lower than expected
Information Administration. In
are believed to be reliable
earnings results.
but which could change
December, crude oil production
Figure 2. U.S. energy consumption and rig counts
Source: U.S. Energy Information Administration and

Baker Hughes Inc.
Figure 3. U.S. PMI and manufacturing shipments
Source: Institute for Supply Management Manufacturing

Report on Business and U.S. Census Bureau
without notice. Jordan,

Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or completeness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
any investment offering or
deployment of capital.
Vaughans Rotamix System sets the standard for hydraulic mixing, providing the customer with
lower operating and maintenance costs, more efficient breakdown of solids and Vaughans
UNMATCHED RELIABILITY. Its perfect for digesters, sludge storage tanks, equalization basins
and other process or suspension type mixing applications.
- Over 1000 installations worldwide
- Optimizes solids contact with its unique dual rotational zone mixing pattern
- 10 Year Nozzle warranty
See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP

PumpsAndSystems April

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A P R I L 2 0 16

The Leading Magazine for Pump Users Worldwide

Circle 100 on card or visit psfreeinfo.com.

FROM THE EDITOR

ust a couple of weeks ago, oil

AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay

PUBLISHER: Walter B. Evans Jr.

P.O. Box 530067

Pumps & Systems

1900 28th Avenue South, Suite 200

2126 McFarland Blvd. East, Suite A

Circle 110 on card or visit psfreeinfo.com.

OIL & GAS REFINERIES

Letter from a Reader:

PUMP SYSTEM IMPROVEMENT

Engineered Software Inc.

COMMON PUMPING MISTAKES

Summit Pump Inc.

Guidelines for Submergence &

46 IMPROVE ASSET PERFORMANCE WITH INNOVATIVE SERVICES

Preventive maintenance programs at refineries can result in reduced costs

50 TEXAS REFINERY REVAMPS WATER TREATMENT SYSTEM

The Future of Predictive

By Mike Jenkins, Progressive Water Treatment

52 FACILITY CHOOSES GRAPHITE-METAL ALLOY BEARINGS

The materials are able to withstand dry-run conditions.

54 SOPHISTICATED MONITORING SAVES LABOR HOURS

By Brian Phillippi, National Instruments

FROM THE EDITOR

An industry with aging infrastructure and increasing demands needs better

58 SOUTHWEST PIPELINE STATION EMPLOYS MODERN TOOLS TO

By Jay Marchi, ProPump Services

Various analyses can identify problems and predict future system

Circle 112 on card or visit psfreeinfo.com.

Compressors Assist in Propane

32 USING DRY GAS SEALS TO PUMP LIQUIDS

This unconventional solution features bonding consisting of a micro-crystalline layer

By Emery Johnson, EagleBurgmann

How Reliable Is Your Control

36 4 WAYS TO PREVENT SEAL FAILURE

Take these precautions to maximize your investment.

72 MOTORS & DRIVES

40 ADVANCED BEARINGS & SEALS

How Power Factor & Induction

OFFSET HARSH CONDITIONS

A large petrochemical plant increased

42 SOLVING SEALING PROBLEMS BY

Manage Rubber Expansion

KEEPING FACES CLOSE & PARALLEL

Advances in seal ring and face materials

PRACTICE & OPERATIONS

ROTATING EQUIPMENT RELIABILITY

Air Pockets in a Piping System,

By Scott Sapita, BaseTek LLC

EDITORIAL ADVISORY BOARD

BOB DOMKOWSKI, Business

TODD LOUDIN, President/CEO North

SCOTT SORENSEN, Oil & Gas

WILLIAM E. NEIS, P.E., President,

DOUG VOLDEN, Global Engineering

LEV NELIK, Ph.D., P.E., APICS,

KIRK WILSON, President, Services &

HENRY PECK, President, Geiger Pump

JAMES WONG, Associate Product