JULY PUMP

The Magazine for Pump Users Worldwide July 2012

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Pumps in

FOOD &FOOD &BEVERAGEBEVERAGEProcessing

Metering & Dosing PumpsS P E C I A L S E C T I O NS P E C I A L S E C T I O N

The Magazine for Pump Users Worldwide

pump-zone.com

July 2012

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2 JULY 2012 www.pump-zone.com PUMPS & SYSTEMS

Letter from the Editor

PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 110, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and additional mailing offi ces. Subscriptions: Free of charge to qualifi ed industrial pump users. Publisher reserves the right to determine qualifi cations. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call (630) 739-0900 inside or outside the U.S. POSTMASTER: Send changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. ©2012 Cahaba Media Group, Inc. No part of this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, articles or descrip-tions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media Group, Inc., permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.

is a member of the following organizations:

As industry standards get tougher, food and beverage processing continues to be a challenge. Formulation changes (with

FDA and USDA regulation updates) are a regular occurrence. Food safety and sanitary requirements are paramount.

Many pumps are used in food and bever-age processing—including centrifugal, positive displacement, fl exible impeller, air-operated dia-phragm, rotor, progressive cavity and peristaltic. h is issue of Pumps & Systems shows images of systems pumping everything from chocolate, to cookie dough to food pies and even wine.

Many companies have adopted clean-in-place (CIP) to clean the interior surfaces of pipes, vessels, process equipment, fi lters and associated fi ttings, without disassembly. Until the 1950s, closed systems were disassembled and cleaned manually. CIP’s advent was a boon to industries needing frequent internal cleaning.

h e benefi t to industries that use CIP is that cleaning is faster, less labor intensive and more repeatable, and poses less chemical exposure risk to people. CIP started as a manual practice involving a balance tank, centrifugal pump and connection to the system being cleaned. Since the 1950s, CIP has evolved to include fully auto-mated systems with programmable logic con-trollers, multiple balance tanks, sensors, valves, heat exchangers, data acquisition and specially

designed spray nozzle systems. Simple, manually operated CIP systems are also still used today.

If you have more information about CIP developments, please drop me an email and tell me about it. What are some of the challenges you face in food and beverage processing and how do you solve them?

In this month’s cover series, you can read about the food and beverage pump market (page 29), pumping delicate food products (page 31) and production at a California winery (page 35).

You will also fi nd an informative article on proper pump-pipe alignment in a 10-step pro-cess by Dr. Lev Nelik (page 13). Go to our web-site (www.pump-zone.com) for a slideshow and more information on this process. h is month, we also begin a three-part series on centrifugal radial thrust from Terry Henshaw (page 18) that you won’t want to miss.

We want to hear from you! Be sure to join the many conversations about these and other topics on the Pumps & Systems LinkedIn group.

Best Regards,

Michelle [email protected]

PUBLISHER

Walter B. Evans, Jr.

ASSOCIATE PUBLISHER

VP-SALES

George [email protected] • 205-345-0477

EDITOR/VP-EDITORIAL

Michelle [email protected] • 205-314-8279

MANAGING EDITOR

Lori K. [email protected] • 205-314-8269

CONTRIBUTING EDITORS

Laurel DonohoJoe Evans, Ph.D.Terry Henshaw

Dr. Lev Nelik, PE, APICS

SENIOR ART DIRECTOR

Greg Ragsdale

ART DIRECTOR

Terri Jackson

PRODUCTION MANAGER

Lisa [email protected] • 205-212-9402

CIRCULATION & MARKETING

MANAGER

Jaime [email protected]

CIRCULATION

Jeff [email protected] • 630-739-0900

SENIOR WEB EDITOR

Julie [email protected]

ACCOUNT EXECUTIVES

Derrell [email protected] • 205-345-0784

Mary-Kathryn [email protected] • 205-345-6036

Mark [email protected] • 205-345-6414

Addison [email protected] • 205-561-2603

Vince [email protected] • 205-561-2601

ADMINISTRATIVE ASSISTANT

WEB EDITOR

Ashley [email protected] • 205-561-2600

EDITORIAL INTERNS

Michael LambertJoel Langham

Savanna Lauderdale

A Publication of

P.O. Box 530067Birmingham, AL 35253

Editorial & Production1900 28th Avenue South, Suite 110

Birmingham, AL 35209Phone: 205-212-9402

Advertising Sales2126 McFarland Blvd. East,. Suite A

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

Editorial Advisory Board Thomas L. Angle, PE, Vice President Engineering,

Hidrostal AG

Robert K. Asdal, Executive Director, Hydraulic Institute

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

Kerry Baskins, Vice President of Sales, Viking Pump

Walter Bonnett, Vice President Global Marketing, Pump Solutions Group

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

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

John Carter, President, Warren Rupp, Inc.

Jack Creamer, Market Segment Manager, Schneider Electric

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

Joe Evans, Customer & Employee Education, PumpTech, Inc.

Ralph P. Gabriel, Chief Engineer—Global, John Crane

Bob Langton, Vice President, Industry Sales, GRUNDFOS PUMPS

John Malinowski, Sr. Product Manager, AC Motors, Baldor Electric Company, A Member of the ABB Group

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

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

Mike Pemberton, Manager, ITT Performance Services

Bruce Stratton, Product Manager, KLOZURE®, Garlock Sealing Technologies

Kirk Wilson, Vice President/General Manager, Integrated Solutions Group, & Vice President Marketing, Engineering & Technology, Flowserve Corporation



p Peristaltic Pumps in Caustic or Abrasive ApplicationsBy Russell Merritt, Watson-Marlow Pumps Group

New technology offers accurate metering without valves or ancillary equipment.

p Software and Control System Improves OperationsBy Balvinder Rai, Tajna River Industries

Specialized system automates a continuous process industry plant.

p Macro Trends Drive Market DynamicsBy Sonia Francisco & Anand Gnanamoorthy, Frost & Sullivan

Challenges in the food & beverage processing industry

p Hydro-Transport Food PumpsBy Dave Young, Cornell Pump

Correct pump confi guration solves product damage problems.

p Wine Industry PumpsBy Keith Evans, Xylem Inc., Jabsco Flexible Impeller Pumps

Many different pump types can move food and beverages.

Table of Contents

PRACTICE & OPERATIONS

p Seal Confi guration SelectionBy Glenn Schmidt, EagleBurgmann

Choose the correct seal to meet the application requirements.

p Advanced Technology Provides Control and Mobility

By Chris Suskie, PumpTech, Inc.Control via an iPad helps solve packaged pumping system problems.

July 2012

Volume 20 • Number 7

The Magazine for Pump Users Worldwide July 2012

pump-zone.com

Pumps in

FOOD &BEVERAGEProcessing

Metering & Dosing PumpsS P E C I A L S E C T I O N

The Magazine for Pump Users Worldwide

pump-zone.com

July 2012

22

25

35

46

50

29

31

DEPARTMENTS

Readers Respond. . . . . . . . . . . . . . . . . . . . . . . . . . 6

P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pump Ed 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10By Joe Evans, Ph.D., P&S Editorial Advisory BoardCentrifugal Pump Effi ciency—When Is Effi ciency Important?

Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . 13By Lev Nelik, P.E., Pumping Machinery, LLC10 Steps for Proper Pump-Pipe Alignment

Centrifugal Pump Hydraulics by the Numbers . 18By Terry HenshawRadial Thrust

Effi ciency Matters . . . . . . . . . . . . . . . . . . . . . . . . 38By Edison Brito

Latex Pumping Challenges

Maintenance Minders . . . . . . . . . . . . . . . . . . . . . 40By Peter CarlisleEasy Shaft Alignment

FSA Sealing Sense . . . . . . . . . . . . . . . . . . . . . . . . 43What are the current industry best practices for the assembly of bolted fl ange connections?

Advertiser Index . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Pump User Marketplace . . . . . . . . . . . . . . . . . . . 53

P&S Market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

COVER

SERIES

SPECIAL

SECTION Dosing Pumps

Pumps in Food & Beverage Processing

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Readers Respond

Centrifugal Pumps Hydraulics by the Numbers: Centrifugal Pump Axial ThrustEditor’s Note: In

“Centrifugal Pumps Hydraulics by the Numbers: Centrifugal Pump Axial h rust” (May 2012), Figures 1, 2 and 4 did not include their com-plete captions and credits. h e fi gures are provided below with their complete captions and credits. We apologize for any confusion this may have caused.

P&S Figure 1. A typical horizontal, single-stage, single-suction process pump with enclosed impeller and

wear rings, front and back

Figure 2. A typical vertical, inline, single-stage, single-suction process

pump with enclosed impeller and wear rings, front and back

Courtesy of Afton Pumps

Figure 4. Illustration of axial thrust created by back-to-back

impellers. Image provided courtesy of Flowserve Corporation.

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P&S News

NEW HIRES, PROMOTIONS &

RECOGNITIONS

EAGLEBURGMANN (HOUSTON) announced that John Dillon joined the company as a territory manager for the Southeast Region. He will report to David Fri, Southeast regional sales manager and will fi ll an open territory in the Southeast covering North Carolina, South Carolina and Georgia. His experience includes more than 11 years in industrial sales. EagleBurgmann is a sealing technology provider. www.eagleburgmann.com.

BJM PUMPS (OLD SAYBROOK, CONN.) announced that Steve Mosley has recently joined its team as an application engineer. Mosley will be the primary inside contact for help-ing customers, representatives and distributors size, price and select BJM Pump products for their pump applications.

Richard Bronson recently joined the BJM Pumps team as an assembly technician. Bronson brings a broad range of experience and training that fi ts in well with the goals of BJM Pumps. BJM Pumps manufactures pumps for chemical, pro-cessing and industrial applications. www.bjmpumps.com

TURBODESIGN TECHNOLGOY, INC. (NEW YORK) announced that Michael J. Dergance was named vice president of sales and marketing of TURBOdesign Technol-ogy, Inc., (TDT). He will apply his more than 30 years of leadership experience and global high-technology software business perspective to make fundamental changes.

TURBOdesign Technology, Inc., provides turbomachinery design and con-sulting and is the exclusive U.S. distribu-tor for the Advanced Design Technology (ADT) turbomachinery design software, TURBOdesign Suite. www.turbodesign-tech.com

BENTLEY SYSTEMS (PHILADELPHIA) presented Tom Lazear, chairman of California-based Archway Systems—the longest-serving Bentley Channel Partner—with the inau-gural Bentley Institute Lifetime Achievement Award for his steadfast commitment to inspiring students, architects and engineers to explore and apply computer technology in the service of design and engineering.

h e company also announced that it acquired InspectTech Systems, Inc., a Pittsburgh, Pa.-based provider of fi eld inspection applications and asset management ser-vices for bridges and other transportation assets.

Bentley provides architects, engineers, geospatial pro-fessionals, constructors and owner-operators with software solutions for sustaining infrastructure. www.bentley.com

AROUND THE INDUSTRY

BASETEK (NEWBURY, OHIO) celebrated the groundbreaking ceremony on a 26,000-square-foot facility located in Geauga County (Burton Township). h e new building will more than double its current manufacturing capacity.

BaseTek, LLC, designs and manufactures polymer com-posite foundations for a broad range of industries. www.basetek.com

EMERSON PROCESS MANAGEMENT (ST. LOUIS) announced that it has acquired ISE Magtech, enabling it to strengthen its level measurement solutions in the oil and gas, refi ning, chemical and power generation industries. Terms of the acquisition were not disclosed.

Emerson Process Management, an Emerson business, helps businesses automate their production, processing and distribution in the oil and gas, chemical, refi ning, pulp and paper, power, water and wastewater treatment, mining and metals, food and beverage, pharmaceutical and other indus-tries. www.emersonprocess.com

WÄRTSILÄ (HELSINKI, FINLAND) signed an operations and maintenance (O&M) agreement with Sasol New Energy Holdings, a wholly-owned subsidiary of Sasol, an energy and chemical company. h e three-year agreement covers the company’s gas engine power plant project in Sasolburg, South Africa.

Wärtsilä provides complete life-cycle power solutions for the marine and energy markets. www.wartsila.com

CLYDEUNION PUMPS (BURLINGTON, CANADA) has relo-cated its Canadian works to a new facility in Burlington, Ontario, almost doubling its manufacturing footprint. h e new site provides increased regional production capacity, allowing larger between-bearings-style pumps to be manufac-tured onsite. h e 6,500-square-meter (70,000-square-foot) facility will manufacture single- and multi-stage centrifugal pumps to API 610 standards and reciprocating power pumps to API 674 standards.

ClydeUnion is an SPX brand. h e SPX Flow Technology segment designs, manufactures and installs engineered solu-tions used to process, blend, meter and transport fl uids, in addition to solutions for air and gas fi ltration and dehydra-tion. www.spxft.com

Michael J.

Dergance

John Dillon

Basetek’s groundbreaking ceremony

PUMPS & SYSTEMS www.pump-zone.com JULY 2012 9

UPCOMING EVENTS

GROWTH, INNOVATION & LEADERSHIP 2012: SILICON VALLEY Sept. 9 – 12 Fairmont Jose / San Jose, Calif.www.gil-global.com/siliconvalley/

OIL SANDS CONFERENCESept. 11 – 12Suncor Community Leisure CentreFort McMurray, Alberta, Canada888-799-2545www.oilsandstradeshow.com

INTERNATIONAL PUMP USERS SYMPOSIUM/TURBOMACHINERY/CHEMINNOVATIONSSeptember 24 – 27George R. Brown Convention CenterHouston, Texas979-845-7417 / www.turbolab.tamu.edu

MINEXPOSeptember 24 – 25Las Vegas Convention CenterLas Vegas, Nev.www.minexpo.com / [email protected]

WEFTECSeptember 29 – Oct. 3New Orleans Convention CenterNew Orleans, La.www.weftec.org / 877-933-4734

POWER-GENDecember 11 – 13Orange County Convention CenterOrlando, Fla.918-831-9160 / www.power-gen.com

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

P&S

VERDER (VLEUTEN, THE NETHERLANDS) opened a Denmark offi ce on June 1, 2012, in the Copenhagen area. Verder A/S will sell diaphragm pumps, peristaltic pumps, other Verder brands and universal spare parts for progressing cavity pumps.

h e Verder pump trading companies are suppliers for the chemical, water treatment, food and process industries. www.verder.com

To have a news item considered for ‘P&S News,’ please send information to Lori Ditoro at Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253, 205-314-8269, [email protected].

AW-LAKE COMPANY (FRANKSVILLE, WIS.) announced its new partnership with POMTAVA, a manufacturer of gear pumps. AW-Lake Company will be POMTAVA’s fi rst Master Distributor serving North America.

AW-Lake Company designs, manufactures and services fl ow measurement technology for. www.aw-lake.com

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The power required by a pump is directly propor-tional to both the fl ow and the head that it produces. As fl ow and/or head increase(s) so does the power

required. Conversely, power is inversely proportional to hydraulic effi ciency. For the same fl ow and head, an increase in effi ciency reduces the power requirement. h e two equa-tions below illustrate this relationship:

P = (Flow x Head) / Ef

BHP = ((Flow x Head) / 3960) / Ef

Where:

P = Hydraulic powerBHP = Brake horsepowerEf = Pump effi ciency

Pumps that run continuously or for extended periods can experience a substantial reduction in energy costs with a relatively small increase in effi ciency. Figure 1 shows two, 3,000-gallon-per-minute pumps that operate 24/7. With effi ciencies of 87 percent and 84 percent, the horsepower required is 130 and 135 respectively. h e electrical cost per thousand gallons is 5.7 and 5.9 cents. Two-tenths of a cent is not a huge diff erence, but if you consider the annual cost of electricity, the lower effi ciency pump adds an additional $3,200 to the total electric bill.

Another factor that can increase the attractiveness of higher effi ciency is the cost of electricity. h e energy cost of 10 cents per kilowatt hour, used in Figure 1, is the average commercial rate for 2010. However, it can vary signifi cantly by state.

In some states, the cost of electricity can be as low as 6 cents, and in certain parts of Washington, cooperative

rates can be as low as 4 cents. New England states’ costs, however, are in the high teens. What is the worst case? Hawaii—with Oahu at 23 cents and some outer islands topping out near 40 cents.

As the cost per kilowatt hour increases, so will the savings due to increased pump effi ciency. Seeing what the average rates will be for 2011 will be interesting. I suspect that they have increased substan-tially. Another factor to consider when selecting a pump that will not run continuously is the actual fl ow rate required. Does the end user really need 3,000 gallons per minute, or can the same results be achieved by running a 2,000-gallon-per-min-ute pump longer?

If you have the same head and effi ciency at these two fl ow rates, the cost per thousand gallons pumped is the same for both. In most cases, reducing fl ow by 1,000 gallons per minute will result in a substantial decrease in friction head. Since BHP is directly proportional to head,

By Joe Evans, Ph.D., P&S Editorial Advisory Board

Centrifugal Pump Efi ciency—When Is Efi ciency Important?

Figure 1. The wire-to-water information for two, 3,000-gallon-per-minute

pumps that operate 24/7

Pump Ed 101

Sixth of Six Parts


an end user could see a substantial reduction in the cost per thousand gallons pumped with the lower volume pump.

When Is Effi ciency Not

As Important?Selecting the most effi cient pumps and motors will always reduce the cost of electrical power, but some-times, the payback versus initial cost does not pencil out. Examples include smaller pumps, pumps that are used infrequently and those installed for back-up or emergency use only.

In many industrial applications, effi ciency will take a back seat to a pump’s ability to reliably perform a particular process. A good example is a slurry pump, with which larger clearances increase useful life. Another is the vortex pump, which is pop-ular in both industrial and wastewater applications.

Figure 2 shows the H/Q curve for a 4-inch, vortex waste-water pump. At 800 gallons per minute, its hydraulic effi -ciency is just 48 percent. A standard 4-inch, non-clog pump with similar performance would have an effi ciency of 68 to 75 percent—20 to 27 points better. h e reason for the lower

effi ciency is that vortex action is a two-step process, and the overall effi ciency is the product of the two individual effi -ciencies. However even though effi ciency is much lower than normally desired, there is an extremely positive side. Almost anything that enters the suction of a vortex pump will exit its discharge.

h is is because the vortex impeller is recessed and seldom contacts any of the solids or other material in the pumpage. h is can be benefi cial when smaller wastewater pumps are required. h e more effi cient 4–inch, non-clog pump can plug frequently when rags and stringy material are present, and this

Figure 2. The H/Q curve for a 4-inch, vortex wastewater pump



Pump Ed 101

often results in removing the pump from service for cleaning on a weekly basis.

In these applications, a vortex pump can be far more reli-able, and the maintenance cost savings is much greater than the additional energy costs due to lower effi ciency. One of the seminars I present to specifying engineers is titled “How Lower Pump Effi ciency Can Reduce Costs.” It usually gets their attention.

If a pump is run by a gasoline engine, the case could be made that the pump’s effi ciency is not too important. Although an 80 percent effi cient pump should save quite a bit of energy over one that is 65 percent effi cient, the gas engine (approxi-mately 20 percent) brings their totals down to 16 percent and 13 percent respectively.

It may be hard to justify a higher initial pump cost for such a small energy savings, unless the pump is used frequently and for long periods of time.

Finally, some application design points exist for which reasonable effi ciency cannot be attained, but a pump is still required. Suppose some million-dollar process line cannot use a positive displacement pump but, instead, requires a centrifu-gal pump that can deliver 20 gallons per minute at 3,000 feet of head.

Would it really matter if a single-stage pump had to be driven at 23,000 rpm and that its effi ciency was less than 25

percent? Probably not, and there are far more of these types of applications than you might suspect.

h ere is defi nitely more than one side when it comes to pump effi ciency. Effi ciency is a good thing, and we should always consider a higher effi ciency pump if the return on investment pencils out.

Often, a peak effi ciency that adds one or two percentage points is not that important since few pumps operate at their best effi ciency points (BEPs). h e breadth of high effi ciency, on either side of BEP, can be far more benefi cial.

P&S

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

Read more articles from Joe Evans, including

the i rst i ve articles of this series.

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The initial version of this procedure was published several years ago by me. Since then, a large amount of feedback has

been accumulated. h e most recent refl ection appeared in the March 2012 issue of Pumps & Systems with discussion on how the thermal eff ects of pipe growth infl uence the supports, anchors and other restrictions. h e 10 steps outlined in this article refl ect modifi cations, corrections, your questions, challenges and practical considerations and limitations.

Piping issues directly aff ect a pump’s life and its performance. Bringing the pump to the pipe in one operation and expecting a good pump fl ange or vessel fi t is a diffi cult task. When bringing the pipe to the pump, the last spool (suction side and discharge side, each) should always be left until the pump has been leveled in place and rough aligned. h e fi nal alignment will be a free bolt condition, and no come-alongs would be needed, which may be a surprise to some readers. With an initial, common-sense investment and proper attention to details, the pumps will last longer, with fewer failures of seals, shafts, bearings and couplings. More equipment uptime and less lost production will result in signifi cant cost savings and fewer headaches.

Step 1Note: h is step is only for cases in which NO thermal growth is experienced—otherwise skip to Step 2.

At this point the pipe should be securely anchored just before the last spool, to prevent future growth toward the pump’s fl anges. h e piping lay out should not be fi nalized until certifi ed elevation drawings are received from the engi-neering group or from the pump vendor. Once the fi nal certifi ed drawings are received, the fi nal isometrics can be completed and the piping takeoff can be performed.

h e delivery of the equipment can either be early or it can be late in arriving at the site. When the equipment is late it is criti-cal to have certifi ed elevation prints of the equipment. h e certifi ed prints ensure that the isometrics required for the piping takeoff s can be made without impacting the construction schedule. If the equipment is early, it will arrive at the site before the con-struction team needs it for installa-tion. Preparations must be made for long-term storage. Using oil mist lubrication is customary to keep the equipment in as-shipped condition while it is stored. h e pressuriza-tion of the bearing housing and the casing with just 10 to 20 H2O pres-sure prevents moisture and contami-nants from entering the sealed areas

By Lev Nelik, P.E., Pumping Machinery, LLC

10 Steps for Proper Pump-Pipe Alignment

Pumping Prescriptions

Figure 1. Occasionally, anchors (only if NO thermal growth, which is rare) can be

used for the pump piping.

Figure 2. Rough alignment phase (note that the motor and the pump are not coupled yet

and the baseplate is still sitting free, not grouted)

A. Correct confi guration—Sliding support does not keep the piping from sliding up/away.

B. Piping is restrained (cannot slide up/away) with high thermal expansion loads.

C. “Anchor” will allow pipe to expand toward/into the pump. This is a problem, causing

high axial loading.



and damaging the components. In addition, early delivery of equipment to the site allows for the verifi cation of the actual measurements.

Step 2When the location of the equipment is set, the baseplate can be put in place, leveled and rough-aligned, with the equipment mounted. Rough alignment should happen prior to building the grout forms. To avoid stresses caused by the thermal expan-sion of pipes, expansion loops should be installed in the suction and discharge lines. h e “sliding” pipe supports near the pump suction and discharge are required to eliminate the weight loads of piping on the pump, which can cause excessive loads and misalignment, leading to seal, bearing and coupling failures.

However, anchors (three dimensional restraints) should not be used because they could cause signifi cant stresses and casing distortions from thermal expansion. Consider, an exam-ple (Figure 2, Example C) of an incorrectly placed anchor (restraining growth in ALL directions, not simply a vertical, sliding support), even 2 feet away from the pump suction, and the case of pipe expansion by only 30 F (morning to afternoon):

ΔL

L = αΔT = (6.9 x 10-6 in/in°F) x 30° = 0.0002 in/in

ΔL = LαΔT = (2' x 12") x 0.0002 = 0.0005"

Stress σ = ∑ ΔL

L = (30 x 106) x 0.0002 = 6,000 psi

Where:

L = Pipe lengthΔL = Change in pipe lengthΔT = Change in temperature

For the pipe, the area of contact between the pump and pipe fl anges depends on the pipe size. Assume, for example, a 20-square-inch contact area (or use the pipe/fl ange number). h e resultant force on the pump will be:

F (force) = 6,000 x 20 = 120,000 pounds

h is is high and will distort the pump casing, feet, shafts, etc., and cause problems. If, in addition to that, the pumped product is hot, the piping expansion could be worse. However, even the daily fl uctuations of ambient temperature alone could cause problems, as shown in the calculation above.

Step 3Once rough alignment has been completed, remove the equip-ment (pump, motor gearbox) from the baseplate. Level the baseplate to a maximum out of level of 0.025 inch (0.06 mil-limeter) from end to end in two planes. Use machined pads as the base for the leveling instruments. Inspect the foundation

for cleanliness, and if not clean, use a solvent to remove grease and oil.

Step 4Allow time for the cleaning substances to evaporate. Form the base using the appropriate techniques to allow for the weight, temperature rise and fl uidity of the grout material. Use epoxy grout to secure the base, and allow the grout to cure, follow-ing the grout manufacturer’s recommendations. h is normally requires 24 hours at 80 F (27 C). Remove the forms and clean all sharp residue and edges from the foundation.

Step 5h e rough alignment step, mentioned above, is critical to mini-mize the changes that will be required to appropriately fi t the piping to the pump. At the last stage, when the fi nal spools are installed, the fi nal alignment will be achieved with small

Figure 3. Baseplate leveling pads and grout location

Figure 5. Potential bolt-bound situation due to tight clearances

between bolt, feet and base

Figure 4. Typical anchor bolt and leveling wedges


adjustments. h is will minimize the adjustments required on the motor feet/bolts. Unfortunately, motor hold-down bolts are often too tight and allow for only small adjustments to the motor before becoming bolt bound.

Motor manufacturers could improve this situation signifi -cantly if motor feet were slotted by design rather than drilled for bolts. Figure 5 shows the tightness of space available to insert the foot hold-down bolt. h is illustrates once again why good alignment at Step 3 can save time and the cost of having to alter motor feet (which can be a night-mare) by slotting or reaming.

Step 6Reinstall the pump and the motor on the baseplate. Rough align the equipment again, using a reverse indicator, laser alignment or similarly accurate tech-nique. It should now be easy to fi ne-tune the motor movement within the allow-able alignment target without becom-ing bolt bound. h is is possible because of completion of the rough alignment during Step 4. Note: Never install shims under the pump feet. If the shims are lost or misplaced then alteration to the piping may be required to get the pump within the required alignment specifi ca-tion. h e normal procedure is to place 0.125-inch (3.2-millimeter) thick shims under the motor feet. h is allows for adjustments that will be required during fi nal alignment.

Step 7Make up the fi nal spool pieces for the suction and discharge spaces. Bring the piping to the pump now.

Step 8As a fi nal alignment step, bring the piping to the equipment. Take fi nal measurements, and tack weld the spools in place. At this time, the spools can be removed and taken back to the hot work permit area to fi nalize the weld. Leave a square and parallel gap between the fl ange faces. h e gap should be wide enough to accommodate the size of the gasket required, plus ⁄ to ⅛ inch, depending on the piping sizing. h is is the only distance through which the piping will be pulled. However, because it is properly anchored before the spool

pieces, this length is short, and stresses are minimized. Finally, align the equipment, considering hot and cold operating condi-tions, using two indicators on the pump shaft coupling area.

Step 9As the piping is tightened into place, the shaft must not be moved more than 0.002 inch (0.005 millimeter). Otherwise,

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modify the spool pieces until the piping misalignment is fi xed. Several conditions are common when piping is misaligned. Some of these conditions are the mechanical seal and/or the bearings running hot and other component failures. A quick analysis of the failed parts will clearly show the signs of piping misalignment. To make a fi nal confi rmation of the symptoms, unbolt the piping while measuring the movement in the verti-cal and horizontal plane. Again, piping that moves more than 0.002 inch (0.005 millimeter) must be modifi ed to correct the situation.

Step 10 Place an indicator in the horizontal and vertical planes, using the motor and pump coupling.

Uncouple the pump and motor, while watching the indi-cators for movement. Start unbolting the fl anges, and continue watching for movement in the indicators. If the needle jumps more than 0.002 inch (0.005 millimeter) the piping has to be modifi ed to improve the pump’s performance.

References

1. AlChE Equipment Testing Procedure for Centrifugal Pumps (Newtonian

Liquids), 2nd Edition, AlChE, New York, 1984.

2. AlChE Equipment Testing Procedure for Rotary Positive Displacement Pumps (Newtonian Liquids), Second printing, New York, N.Y., 1968.

3. AlChE Equipment Testing Procedure, New York, N.Y., 1999.

4. API 610 Standard for Centrifugal Pumps, 8th Edition, American Petroleum

Institute, Washington, D.C., August 1995.

5. API 676 Standard for Rotary Pumps, 2nd Edition, American Petroleum

Institute, Washington, D.C., December 1994.

6. Nelik, L., Centrifugal and Rotary Pumps: Fundamentals with Applications, CRC Press, Boca Raton, Fla., March 1999.

7. Pump Standards, Hydraulic Institute, ANSI/HI 1.1 1.5 1994, Parsippany,

N.J., 1994.

8. Rizo, L., Nelik, L., “Piping-to-Pump Alignment,” Pumps & Systems, April

1999.

P&S

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

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topic. Also read other articles by Dr. Lev Nelik.

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This article is the fi rst of three on centrifugal pump radial thrust. It relates the author’s experience with the use of the traditional equation to calculate radial

thrust, subsequent measurements of radial thrust and com-parison of the two. Part Two will show a plot of measured radial thrusts imposed on a performance curve and will dis-cuss the pattern revealed. h e fi nal part will discuss varia-tions in impeller and casing designs which reduced radial thrust.

Stepanoff Radial Thrust EquationIt was 1958. I was fresh out of college and working in New York City for a major manufacturer of industrial machin-ery. One of my early assignments was to calculate the shaft defl ections of a number of pumps being bid for hydrocar-bon processing to a major contractor who required calcula-tions demonstrating that the wear rings would not rub when operated at low capacities. I calculated the radial thrust on the impellers probably using data from Stepanoff [1]. His book off ered the following equation for calculating the radial thrust:

P = KHD2B2

2.31 (1)

Where:

P = radial force, poundsH = pump head, feetD2 = impeller diameter [outside diameter—OD],

inchesB2 = impeller overall width including shrouds [at the

impeller OD], inchesK = a constant that varies with capacity, determined

experimentally

Notice that the product D2 x B2 is the projected area of the discharge of the impeller, and H/2.31 is the total dif-ferential pressure produced by the pump. h e product of pressure x area, therefore, calculates a force. h e K factor is intended to adjust that force to the actual radial thrust. h e absence of specifi c gravity in the equation indicates that its use was intended only for cool water. Although the Stepanoff data was precise and detailed, it reported thrust character-istics for only one size pump. In 1959, Agostinelli, et al,

reported radial thrust test results for 16 diff erent pumps [2], while continuing the procedure of considering the eff ective pressure area being the impeller OD x width (D2 x B2).

By Terry Henshaw

Radial Thrust

Centrifugal Pump Hydraulics by the Numbers

First of Three Parts

Figure 1. Radial thrust factor at shutoff for single-volute

(constant-velocity) pumps (From Reference 3. Courtesy of the

Hydraulic Institute, www.pumps.org, Parsippany, N.J.)

Figure 2. The current Hydraulic Institute radial thrust factor

graph for single-volute (constant-velocity) pumps (Courtesy

of the Hydraulic Institute, www.pumps.org, Parsippany, N.J.)


Hydraulic Institute CurveIn 1969, the Hydraulic Institute (HI) published a curve show-ing K values at shut-off for single-volute pumps as a function of specifi c speed [3] (see Figure 1). Although the HI values agreed with Agostinelli [2] in the higher specifi c speed range (around 3,000), they were almost twice the Agostinelli values in the lower range (around 600). h e current HI K value graph, as seen in Figure 2, shows shut-off K values lower than the 1969 graph, and which compare favorably with Agostinelli [2]. h e procedure continued to consider the eff ective area to be D2 x B2.

Actual Radial Thrust of Vertical,

In-line PumpsI learned that, using Equation 1—an accepted, published equation—and K values, produces signifi cantly inaccurate radial thrust values for some pumps. I was asked by a pump manufacturer to determine the actual radial shaft defl ection, at the mechanical seal, for a line of vertical, in-line centrifugal pumps, similar to that in Figure 3. h e pump shaft was rig-idly coupled to the motor shaft so that, when the pump was equipped with a mechanical seal, the motor bearings absorbed both axial and radial thrusts from the pump.

h e pumps were equipped with semi-open impellers. h e

impeller faces were machined at an angle of 20 degrees, result-ing in vanes that got wider (an increasing B2 dimension) as the diameter was reduced. Such design is common for impel-lers in pumps provided to the chemical industry, although uncommon for enclosed impellers and some semi-open impel-lers. Because the casings were volutes, maximum radial thrust occurred at shut-off (zero gallons per minute).

Figure 3. A vertical

in-line pump with

semi-open impeller

and rigid coupling



Centrifugal Pump Hydraulics by the Numbers

ANSI Specifi cation B73.2 [4] (partially written by this author) required that the cal-culated shaft defl ection not exceed 2 mills at the gland end of the stuffi ng box, under maximum radial load. Questions had been raised about a 3 x 2 x 11 single-volute pump, running at 3,500 rpm. To minimize the radial thrust, the impeller exit width (B2), at the 11-inch (maximum) diameter, had been designed at ⁄ inch. h e D2 x B2 area (see Figure 4) was, therefore, 2.06 square inches. h e shut-off head of 480 feet created a dif-ferential pressure, on cool water, of about 208 psi. Specifi c speed was about 650. Using K = 0.18, from Figure 1, the calculated radial thrust was 77 pounds. With the appropriate motor, the 77 pounds would produce a shaft defl ection, just above the mechanical seal, of an acceptable 2 mils. But two competitors reported that measured shaft defl ection was considerably higher. It was necessary that we measure the radial shaft defl ections.

Our test procedure was similar to that used by Stepanoff [1]. A rigid steel table was fabricated, to which was bolted a motor-coupling-shaft assembly. h e shaft position—one-half inch above the location of the seal faces—was measured by a pair of proximity probes, located at right angles. Force gages were used to pull on the end of the shaft (at the location of the impeller) to establish an accurate relation between the radial force at the impeller and shaft defl ection, ½ inch above the seal faces. We were able to accurately “calibrate” the motor-coupling-shaft assembly, even including the eff ect of looseness in the bearings.

When the pump was tested, we learned that the radial thrust imposed on the 11-inch impeller, at shut-off , was 240 pounds, more than three times the value calculated using the information in Figure 1—almost six times the value calculated using K values from the other references. Instead of using just the projected area of the impeller discharge, as illustrated in Figure 4, if we use the total projected area of the impeller, from the 3-inch diameter eye to the 11-inch outside diameter, D2, (see Figure 5) the area changes from the 2.06 calculated above, to 6.56 square inches.

Multiplying that by the 208 psi and by the 0.18 K value from Figure 1, results in a calculated radial thrust of 246 pounds, which is only 2 percent above the measured 240 pounds. h e closeness of the agreement indicates that we should consider using this procedure for impellers that get wider as the diameter is reduced (and it may well work for all impellers). More sizes of pumps should be tested to determine if this concept applies to all sizes.

References

1. Stepanoff , A. J., Ingersoll-Rand, Centrifugal and Axial Flow Pumps, John

Wiley & Sons, New York, 1948.

2. Agostinelli, A., Nobles, D., and Mockridge, C.R., Worthington, “An

Experimental Investigation of Radial h rust in Centrifugal Pumps,” Paper

59-HYD-2, Transactions of the ASME – Journal of Basic Engineering, American Society of Mechanical Engineers, 1959.

3. Hydraulic Institute Standards For Centrifugal, Rotary & Reciprocating Pumps, twelfth edition, 1969, Hydraulic Institute, New York, N. Y.

4. Specifi cations for Vertical In-Line Centrifugal Pumps for Chemical Process, ANSI B73.2 – 1975, h e American Society of Mechanical Engineers,

New York, N.Y.

5. Karassik, Igor J., Worthington, “Centrifugal Pump Construction,”

Section 2.2 of the fi rst edition of the Pump Handbook, edited by Karassik,

Krutzsch, and Fraser, McGraw-Hill Book Co., New York, 1976.

6. Lobanoff , Val S & Ross, Robert R, United, CENTRIFUGAL PUMPS: Design & Application, Gulf Publishing Co., Houston, 1985.

7. Hydraulic Institute Standards for Centrifugal, Rotary & Reciprocating Pumps, 2009, Hydraulic Institute, Parsippany, N.J.

P&S

Terry Henshaw is a retired engineer living in Magnolia, Texas. He worked for more than 50 years in the pump indus-try. He can be reached at [email protected].

Figure 5. A semi-open impeller showing the impeller suggested effective area to

calculate radial thrust

Figure 4. A semi-open impeller showing the impeller discharge area traditionally

used to calculate radial thrust

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In recent years, process engineers have increasingly turned to peristaltic pump technology for metering highly caus-tic and corrosive chemicals. Peristaltic pumps are especially

suited to dosing, metering and transferring chemicals—such as hydrochloric acid, sodium hydroxide, sodium hypochlorite and sulfuric acid.

In addition, new peristaltic pump technology is available that is designed specifi cally for chemical metering in industrial markets. h ese high-performance pumps accurately meter chemicals without valves or ancillary equipment, keeping costs minimal. In fact, the total cost of ownership is less than that of a typical solenoid or stepper-driven diaphragm pump.

New Peristaltic Pumps Meet Key

Selection CriteriaProcess engineers face a number of challenges. h ey must fi nd a pump that withstands chemical attack, runs reliably, meters accurately to optimize chemical usage and is quick and simple to maintain and operate. Meeting all these requirements, the latest peristaltic pumps help plants reduce life-cycle costs and drive gains in process effi ciency.

With no valves in the pump to clog, leak or corrode, the new peristaltic pumps can safely and securely handle fl uids that are caustic, abrasive, viscous, shear-sensitive, gaseous or slurries. It can also pump fl uids that contain suspended solids. h e fl uid is fully contained within the tubing, eliminating any risk of cross contamination. Such chemical process containment, in combination with accurate and linear fl ow, helps reduce chemi-cal use, providing cost savings.

h e pump’s range generates fl ow rates up to 7.9 gallons per minute at 100 psi, with speed control of 1,600:1 in ana-logue mode. h e pump also accepts 4-20 mA input and output analog signal control.

h e new technology boosts process effi ciency by providing accurate, repeatable and linear fl ow performance, even when transferring diffi cult fl uids with varying pressure, viscosity and solid content. Potential applications include: • Disinfection of drinking water • pH adjustment of drinking water• pH adjustment of industrial process water• Flocculation, industrial cooling water preparation• Reagent dosing in mineral processing and paper colorants

Simple OperationBased on the physiological principle of peristalsis, a term refer-ring to the alternating contraction and relaxation of muscles around a tube (for example, the throat or intestine) to induce fl ow, a peristaltic pump’s operation is elegantly simple. A fl ex-ible tube or hose element is compressed between rotating rollers or shoes and a track. Between each roller pass, the tube or ele-ment recovers to create a vacuum and draw in fl uid.

It is well documented that acids, caustics and solvents attack the valves, seals, stators and moving parts of diaphragm and progressive cavity pumps, causing disruptive downtime and high life-cycle costs. By contrast, the use of peristaltic pumps allows engineers to mitigate these costs because they contain no valves, seals or glands and have no mechanical parts contacting the product stream. h e fl uid only contacts the inside of the hose or tube, which is a low-cost, low-maintenance and easily-serviceable component.

Hose and tube materials, which in the past were the only prohibitive factor against the widespread adoption of peristal-tic pumps for caustic chemical applications, are now available in diff erent elastomers, formulated specifi cally to balance long mechanical pumping life with sustained resistance against con-centrated acids, bases and solvents.

Peristaltic Pumps in Caustic or Abrasive ApplicationsBy Russell Merritt, Watson-Marlow Pumps Group

New technology offers accurate metering without valves or ancillary equipment.


Metering & Dosing Pumps

For example, chlorosulfonated polyethylene (CSM), an elastomer available for hose pumps, can handle toluene and other corrosive sol-vents that are used to manufacture certain products—such as gaskets, aerosol paints, lacquers, paint strippers, adhesives, cosmetics, perfumes and anti-freeze.

Some of the latest chemical-duty elements are capable of thou-sands of hours of continuous service operating at fl ow rates up to 350 gallons per minute and 282 psi. Furthermore, peristaltic pumps have the ability to self-prime, dry-prime and self-clean. h ey are also revers-ible to dislodge blockages or drain lines.

h e lack of valves makes peristaltic pumps attractive to industries such as paper and pulp. For instance, one peristaltic pump is being used to handle sodium hydroxide for bleaching pulp and disinfecting water at a paper mill.

Precise Meteringh e inherent accuracy of positive displacement pumps is another reason that they are chosen whenever exact chemical metering or dosing is required. In peristaltic pumps, where metering accuracy is better than 1 percent, fl ow is proportional to pump speed. Complete tube element closure gives the pump its positive displacement action, preventing fl ow drop or erosion from backfl ow and eliminating the need for check-valves, which are typically the primary source of any metering inaccuracy.

A 350-gallon-per-minute hose pump


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Accuracy is particularly important at power plants, as dem-onstrated by a power generation servicing company that uses peristaltic pump technology to meter 65 gallons per minute of sulfuric acid when cleaning power plant condensers—driv-ing the pH down to less than 4.0 to break down scale. Precise control of acid fl ow is necessary to ensure that, after scale is dis-solved, the discharge to the municipal wastewater system will have a neutral pH.

With regard to turndown ratio, a high-quality peristaltic pump is capable of a fl ow range greater than 2,000:1 simply by controlling rotor speed. With the added versatility of inte-grating diff erent tube sizes into a single pump, fl ow range can expand to 1,000,000:1. Diaphragm pumps are normally lim-ited to 20:1.

New Pump Head TechnologyAn interesting feature of the new peristaltic tube pump technol-ogy is a new pump head—a sealed, single component, no tools maintenance element that is at the core of the pump range. h is ensures the delivery of accurate, linear and repeatable fl ow for fl uids of wide-ranging viscosities. It also maximizes valu-able process uptime by facilitating quick and easy pump head removal and replacement. h ere is no need for tools, training or maintenance technicians. h e contained pump head design also eliminates safety concerns.

Low Life-Cycle CostsWhile the initial cost of a peristaltic pump can be slightly higher than other positive displacement pumps, a quick assess-ment of life-cycle costs quickly tips the scale in favor of peri-staltic pumps. For instance, no seals, ball valves, rotors or sta-tors need replacement, and hose/tube replacement usually takes only a few minutes. h e low-cost tube or hose can be replaced in-situ and without special tools or skills, making the process extremely economical in comparison with conventional posi-tive displacement pumps where replacement parts can cost up to 75 percent of the pump’s initial purchase price and take sev-eral hours to fi t.

For example, the new pump technology delivers fl ow rates up to 7.9 gallons per minute at 100 psi, while maintenance intervals are up to six months, at typical usage, reducing the impact of downtime.

Another added cost is the need for a separate control panel or variable frequency drive to achieve variable fl ow meter-ing, with the incremental cost if high turndown is required. Peristaltic pump manufacturers, however, build high turn-down, closed-loop speed control capability and expansive I/O connections for DCS, SCADA and PROFIBUS systems into standard pumps for simplifi ed integration.

Process-duty pumping is being taken to the next level with a new, integrated PROFIBUS networking capability that has been added to a peristaltic pump. With two-way, real-time communications, the new technology off ers increased diag-nostic capability and faster response, helping optimize process control and minimize plant downtime.

Pumping Abrasive FluidsFrequently, fl uids contain corrosive and abrasive material. Peristaltic pumps stand up well to the challenge, as a U.S.-based construction product manufacturing plant can verify. A peri-staltic hose pump was used in the manufacture of fi ber cement siding products. h e cement mixture had little eff ect on the hose, despite being highly abrasive and strongly alkaline.

Peristaltic pumps are also used for other abrasive fl uids, including lime slurry and underfl ow in mining operations, alum in wastewater treatment and titanium dioxide for pig-mented inks and paints.

In contrast with peristaltic pumps, abrasion takes a toll on other positive displacement pumps. Abrasive fl uids may cause the erosion or clogging of valves in diaphragm pumps. h e same eff ect in progressive cavity pumps widens clearances between the rotor and stator, which may cause internal slip.

A Growing Choiceh e advantages peristaltic pumps off er mean that they repre-sent a rapidly growing percentage of the positive displacement pump market. Plant managers tasked with reducing pump life-cycle costs embrace the functionality and benefi ts of peristaltic pumps, which are fast becoming the fi rst choice for chemically aggressive and abrasive applications.

P&S

Russell Merritt is the marketing manager for Watson-Marlow Pumps Group. He can be reached at [email protected].

Peristaltic pumps are also used for other abrasive

fluids, including lime slurry and underflow in mining

operations, alum in wastewater treatment and

titanium dioxide for pigmented inks and paints.



Tajna River Industries is a continuous process chemical industry that manufactures bleached lac, shellac fl akes, shellac wax and seedlac. In addition to production

fl oors, the plant also has a water treatment plant, chiller units, a steam producer, a sodium hypochlorite preparation plant, a gasifi er (wood to producer gas) and diesel generator (DG) sets.

To improve its system by reducing inputs, manpower, power consumption and downtime, Tajna River Industries decided to automate and control the manufacturing unit with a custom system. h e chosen system was National Instruments’ LabVIEW software that created an automation and control system that met the plant’s application needs. h is article sum-marizes the improvements provided by the new software.

Speed Control of Diesel Generator Setsh e DG sets are powered by a mixture of diesel and producer gas created in an 80-kilowatt gasifi er. h e engine speed increases as more gas is input, so the diesel fuel intake must be reduced to

achieve constant engine speed and line frequency. h e engine speed is detected by using the software to fi nd the frequency of the tone generator output attached to the engine shaft. h e closed-loop control system generates signals through the mul-tifunction software system’s data acquisition (DAQ) device to control diesel fl ow in the engine. h e output from the DAQ device is applied to a small DC motor through a DC regulator IC that screws or unscrews the generator’s fuel control screw.

Power Factor Controlh e system performs power factor sensing through the analog signal from a power factor transducer. h e signal is fed from the multifunction I/O DAQ device to the control system built into the software. h e control system has a set of digital outputs that switches 24 relay switches on and off . h e relay switches control

Software and Control System Improves OperationsBy Balvinder Rai, Tajna River Industries

Specialized system automates a continuous process industry plant.

Figure 1. Closed-loop speed control of DG set Figure 2. Closed-loop power factor control


SPECIAL SECTION

contactors that add or remove 15 capacitors in a capacitor bank. h e power factor remains near the desired 0.92 set point.

Automatic

Control of

Chiller MachinePreviously, the system used a programmable logic controller (PLC) for the chiller machine, but spare parts were costly and problems occurred with the PLC main card. h e deci-sion was to replace it with a software system. Operators monitored the temperature at fi ve points in the machine. h e chiller machine is energized by steam and controlled by fi rst gen-erating a ramp output during a 12-minute span from the DAQ device attached to a system that supplies steam to the high-temperature generator of the chiller machine. Using the software, operators implemented automatic switch con-trol to open and close the steam valve from 100 percent to 0 percent. Water is cooled to 4 C, and the steam control valve is modulated depending on the current temperature.

Electric Load Managementh e total connected load is 75 kVA and 85 kVA in two units. h e plant operators must manage the load to avoid going beyond the maximum limit or exposing the system to instability. h e same load management system that was used to remove the possibility of sudden loading on the DG sets (125 kVA, 110 kVA, 40 kVA, or 20 kVA depending on load needs) when attempting to start several loading units at the same time was used in this process. h e plant runs 80 subunits through this power supply. h e operators introduced a scheme in which each piece of equip-ment released a pulse for a duration of its startup. h is varied depending on the type of equipment—fans, centrifuges, pumps or motors. Sequence starting was implemented on a fi rst come, fi rst serve basis using digital I/O cards. h e software system was used to log the starting and stopping of diff erent units.

Figure 4. Sample VI

Figure 3. Electric load management

Figure 5. Sample VI

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Maximum Demand ControlWith maximum demand control, overload of the multiple power sources is prevented. Before starting a load, operators verifi ed the running load and load limit of the power supply. h e load that added to start a particular load, the running load of the source and the load limit of a power source were known. Based on these simple calculations made in the software, the system accordingly gives permission to start on a particular source. If the power supply changes, then the changed load limit and running load are updated. Following a similar algorithm to account for frequency considerations for DG sets, a starter cannot start a DG set if it is running on low frequency.

Plant Maintenance

SchedulingBecause the system keeps a record of the starting and stopping of each unit, oper-ators can easily calculate the number of run hours for each piece of equipment. Plant maintenance can be scheduled based on the run hours. A maintenance alarm activates after a set number of run hours. Online condition monitoring is used in other areas, as well. For example, the temperature and vibration of bear-ings and motors can be checked to deter-mine if they need maintenance.

System Benefi tsh is system had several benefi ts—such as cost reduction, improved monitoring and control of the plant and machinery, manpower reduction, power system sta-bility, savings in power tariff and better care of the equipment through the plant maintenance system. All these benefi ts could be achieved through the system. It also made it possible to use the exist-ing hardware which otherwise would not have been used.

System SuccessLabVIEW training taught the opera-tors good programming practices, which drastically reduced development time (see Figures 4 and 5 for sample VIs). h e schemes can be applied to any con-tinuous process industry—such as paper, textile and chemicals and off er many benefi ts.

P&S

Balvinder Rai is technical director for Tajna River Industries Pvt. Ltd. Rai can be reached at +91 33 22483299. For more information about the LabVIEW system, visit www.ni.com.

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COVER

SERIES

PS & SYSTEMS

CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEERRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRR

SSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEERRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEESSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS

COVER

SERIES

222828282828 JULJULULULULYYYYY 2020202020112121212 wwwwwwww ppu.pump-mp-p zonzonzonzonee ce.comomm PUMPUMPUMPUMPUMUMUMPUMPUMPUMPP

Pumps in

FOOD &FOOD &BEVERAGEBEVERAGE Processing



The food and beverage industry, key users of pumps, is expected to be a dynamic sector during the next 5 to 10 years, based on several critical, top-level trends infl u-

encing the market. h ey include:

It has never been tougher to build and sustain a successful food and beverage business. Even with a recovering economy, conducting business is challenging in North America due to regulatory changes, dynamic societies and diseases, raw mate-rials pricing, corporate sustainability goals and changing con-sumer demands, among others. Globally, challenges include

establishing foreign operations, safety and reliability of off shore suppliers, impact of currency fl uctuations and competition for talent. h e list continues with a growing global population put-ting immense pressure on food security and supplies.

A renewed focus on healthy foods means “pure” is the new natural. Natural products are becoming the rule rather than the exception in many western markets, despite ongoing issues with a clear defi ni-tion of what “natural” encompasses. h is trend is also spreading to the developing regions. Increasing eco-nomic prosperity will enable the BRIC countries of Brazil, Russia, India and China, as well as Mexico, Poland and South Korea, to expand and diversify their food and beverage off erings, including nutraceutical products. Naturally-derived substances—consist-ing of herbal and botanical extracts and animal- and marine-based derivatives—will be the fastest growth among the major groups of nutraceutical ingredients.

While these ingredients have earned their eff ects as indispensable substances, they can be diffi cult to handle for transfer equipment, such as pumps. For example, glucose is an abrasive and fast drying sub-stance and puts stress on the pump, leading to wear-ing and eventual breakdown of the pump. New prod-ucts, such as nutraceuticals, may also put a strain on pumps because they are complex and time consum-

ing when adhering to the current good manufacturing practice (CGMP) regulations.

Hygiene, convenience and fl exibility play a critical role in the industry, while ensuring the highest quality. Product con-sistency is the key to maintaining brand equity. At the same time, keeping costs low forces operators to looking at energy costs and the effi ciency of their production lines. While main-taining hygiene during food processing is important, it is also important to focus on the hygiene and sanitary implications of waste management and disposal. For example, bird or animal waste from processing is highly viscous, making pumping the material a challenge.

Macro Trends Drive Market DynamicsBy Sonia Francisco & Anand Gnanamoorthy, Frost & Sullivan

Challenges in the food & beverage processing industry

Clockwise from top: Kinnerton Confectionary uses MasoSine SPS-3

to pump caramel, photo courtesy of Watson-Marlow Pumps Group;

cookie dough in a custom hopper of a seepex BTCS food-grade pro-

gressive cavity pump, photo courtesy of seepex, Inc.; photo cour-

tesy of Cornell Pump; and Pukka Pies relies on the MasoSine SPS-4

to pump pie fi lling, photo courtesy of Watson-Marlow Pumps Group.


COVERSERIES

Market Metrics

Figure 1 shows the forecasted growth for pumps in the global food and beverage sector. h is segment is expected to witness one of the highest growth rates of all pump-user segments, rivaled by the water and wastewater and pharmaceutical segments. Trends described in this article are driving strong growth in the food and beverage segment throughout the mid and long term.

Regional analysis shows that the Asia Pacifi c region is expected to march ahead of all the regions with double digit growth, closely followed by Latin America, then the Middle East and Africa. Increasing economic prosperity, foreign direct investments (FDIs), foreign institutional investor (FII) investments and a keen focus on government infrastructure investments, are driving growth in these regions. Pump manufacturers cannot aff ord to under serve these regions.

Fuelled by continuing economic woes, Europe is the slowest growing market, even in the mid and long term. While Western Europe continues to face fi nancial diffi culty, Eastern European countries enjoy a more optimistic economic climate and, therefore, more pump manufacturers are expand-ing into these regions.

North America is expected to witness a nominal growth rate (around 5 percent) through the mid and long term. While the food and beverage sector is expected to be fairly stable in North America, pump manufacturers are seeing more oppor-tunities in maintenance and repair aspects of the value chain.

Conclusion

Driven by mega trends, the food and beverage industry is one of the fastest growing end-user segments across the globe. End-user preferences are con-stantly shifting, requiring pump manu-facturers to be able to support end-user agility in production requirements. As North American pump manufacturers go global, they need to adapt to regional market conditions, requiring further innovations. Food and beverage is an exciting vertical segment due to expected growth rates, but innovation is a key suc-cess factor.

P&S

Sonia Francisco is a Frost & Sullivan Research Analyst track-ing the pumps market. She can be reached at [email protected].

Anand Gnanamoorthy is a Senior Research Analyst for Frost & Sullivan, covering various prod-ucts in the industrial segment. He can be reached at [email protected].

Figure 1. Pumps used in the food and beverage industry




Processing plants look for continuous and trouble-free operation from a pump that is capable of transporting even the most delicate whole food products or processed

foods, while keeping product damage to a minimum. Pumping food products has an overriding issue—any food product damage can result in degradation to the fi nal product and profi t losses at the plant.

While damage is a concern, hydro-transport systems do provide an advantage lacking in other mechanical conveyance. h ey can be used, with a consistent level of product safety, to convey and clean many foods—carrots, cranberries, pickles, cherries, onions, beans, peppers, leafy vegetables, crawfi sh, shrimp and hatchery fi sh. Many food products are hydro-trans-ported. In fact, most packaged salad producers use food han-dling pumps to process and transport their products, without damage, for the fresh pack industry.

System ComponentsA hydro-transport system involves several components that must function together to safely process and transport food.

Vortex TankIn a hydro-transport system, the vortex tank is where the product fi rst comes in contact with the hydraulic conveyance medium. It is traditionally constructed of stainless steel to min-imize clean-up time and enhance sanitation levels. h e tank is designed to receive product on its return from the reclamation system and mix it with water, reducing air injection and entrap-ment. Solids are mixed with the liquid at a uniform rate—to minimize loss of prime—and vortexed into the pump suction.

h e pump must be located suffi ciently below the liquid level in the suction bay to ensure that adequate suction head is maintained. h e vortex should draw the product uniformly into the pump’s suction. Product vortexing is especially impor-tant with light foods that normally fl oat.

In addition, the vortex—which should be limited to mini-mize air entrainment—causes long foods, such as string beans, to enter the stream with their length parallel to the fl ow. h e pump must have an adequate and uniform supply of water to minimize loss of prime and prevent surge.

Materials of ConstructionFood handling pumps are traditionally constructed of all iron with stainless steel shaft sleeves. Applications associated with abrasive or aggressive pH values often warrant the use of optional construction materials. Optional materials can also be used to resist attack by soaps, detergents and the germicidal agents used to clean the system. Table 1 shows the recom-mended materials for each pH value range.

Stainless steel should be avoided for salt brine applications. Monel metal can be used for brines. However, monel metal should be avoided when corn, lima beans or peas are pumped since copper may darken the product. Bronze is fairly corrosion resistant but is not recommended for conveying brines in which foods are canned because of possible product discoloration.

Optional materials for applications associated with abra-sive material traditionally include hardened ductile iron. h e impeller commonly wears 200 percent faster than the back plate or volute. A hardened impeller with a cast iron volute and back plate will normally sustain a similar life cycle.

PipingIn principle, the transport line should be as short as possible and free of sharp bends, protruding edges and rapid increases or decreases in pipe size. h e piping coeffi cient should be strongly considered to avoid abrasion to the product by the pipe wall. h e pipe length is traditionally determined by the retention time required for disinfection, hydro cooling, blanching, etc., or the shortest available route. For practical purposes, horizon-tal and vertical pipe length should be limited to 250 feet and 65 feet respectively. h e fi rst part of the evaluation should focus on determining the appropriate line size, which will allow the

Hydro-Transport Food PumpsBy Dave Young, Cornell Pump

Correct pump confi guration solves product damage problems.

pH Range Recommended Material

0 – 4 Corrosion resistant alloy steels

4 – 6 All bronze

6 – 8 All iron

10 – 14 Corrosion resistant steels

Table 1. pH value of the materials of constructions


COVERSERIES

engineer to design a system with optimum line velocity. Water volume should be determined in gallons per minute. h is is accomplished by determining the product to be transported in pounds per minute. h en the recommended volume-to-product ratio is applied, which provides the designer with an equivalent volume of water. h e water-to-product ratio should be as great as economically possible and should vary depending

on the type of food being transported. Traditionally, highly sensitive products require a greater water-to-product ratio. h e piping confi guration should be designed to maintain optimum line velocities to prevent the product from falling out of sus-pension, dragging along the bottom of the pipe or stacking up. High line velocities should also be avoided to reduce product impact. Short radius ells, rough pipe joints or heads inside the

welded pipe can cause more damage to the product than the pump.

System Design and Pump Selectionh e speed of the pump should be selected to meet the head requirements of the system. h e system should be designed to keep the head as low as pos-sible. Excess pump speed produces an excess volume of water used. h is results in excess line velocity and increases the possibility of impact damage. Pumping excess water is a needless waste of power.

A pump that is too slow produces insuffi cient water volume, and as a result, a loss of lift capacity, retention time, etc., which may further damage the product.

Although the pump capacity required will depend upon the tonnage to be handled, the pump preferably should be selected so that it will operate at its point of peak effi ciency or slightly to the left of this point on the character-istic curve.

Consideration should be given to the choice of a food handling pump with either a standard or expanded volute. Typically, the expanded volute is selected for leafy, stringy, large or fragile products. If a water knife will be used in the system, the product will need to be accelerated considerably for the slicing action to be eff ective.

At the dewatering screen, products should be carefully separated from the liquid, since this is a common point of product damage. Deceleration prior to dewatering may be required. Careful motor selection is also needed to ensure a non-overloading operating environ-ment. h e horsepower characteristics included on a traditional performance curve can be used.

h e mounting confi guration of hydro-transport food handling pumps is traditionally an overhead V-belt mount. h is allows the end user to employ the food handling pumps in diff erent


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operating environments while maintaining relatively slow oper-ating speeds. Variable frequency drives are also commonly used. h is option allows end users to address dynamic operating environments in an automated way.

Selection Guidelines

h e following suggestions, based on fi eld experience, are off ered as a guide in pump selection and applications.• h e vortex should be controlled so

that air is not drawn into the pump. • Although the pump capacity required

will depend on the tonnage to be handled, the pump should be selected so that it will operate at its point of peak effi ciency or slightly to the left of this point on the pump curve. h is induces a pre-rotation in the suction eye that results in reduced product damage on the leading edge of the impeller.

• h e speed of the selected pump should meet the system head require-ments. Heads up to 110 feet have been successful with some foods. h e system should be designed to keep the head as low as possible.

• h e ratio of water to food solids should be as great as is practical or economical. One to 3 gallons per pound is the general range.

• A pump with a single port food han-dling impeller is recommended for most foods. A pump with a bladed impeller can cause damage.

• Food solids should be carefully sepa-rated from the liquid at the dewater-ing screen because this is a common point of product damage.

• For new uses, the fi rst pumping unit should be installed with a provi-sion for variable speed operation and observation of the product’s condition after passing through the pump. Evidence shows that short radius elbows, rough pipe joints or beads inside the welded pipe can cause more damage to foods than the pump. A velocity in the pipe of 5 feet per second should be tried fi rst, because this velocity appears to be above the critical for movement of food suspensions without clogging. When pumping food with hot water, contact the pump manufacturer for

the required minimum suction head to obtain performance comparable to pumping with cold water.

Case Study—Onion DamageA food processor was experiencing signifi cant product damage with the 8-inch pump handling whole onions. Not only was the system plugging, but much of the fi nal product was also too



COVERSERIES

damaged to sell. h is waste and ineffi ciency cost the processor thousands in lost revenue.

In examining both the pump and the design of the system, three issues were identifi ed: • Incorrect pump type—h e pump in service was consid-

ered a non-clog style pump, with an enclosed, multiple vane impeller and a volute cutwater. While this style of pump can work well in some food waste applications, it is not recommended for delicate, whole-food products.

• Low water-to-product ratio—h e water-to-product ratio was low, causing inadequate pipe velocities and clogging. h e system only pumped approximately 20 percent of the recommended 1 to 3 gallons per pound of product. h e onions fell out of suspension and were damaged.

• Discharge pipe would be too small for potential solu-tions—Altering the water fl ow to achieve correct water-to-product ratio would make the existing discharge pipe diameter too small, causing higher than recommended pipe velocity. h e high velocity would keep the onions suspended in the pipe, but could lead to damage when the product reached the dewatering screen.

Possible Pump Solutionsh ree possible solutions were examined to mitigate the product damage and plugging. h e fi rst option was to replace the whole

system with a more expensive mechanical conveyer. h is would have taken the plant offl ine for a signifi cant amount of time compared to other options and cost the most money to imple-ment. h e second option was to keep the existing pump and replace the discharge pipe to accommodate the recommended fl ow based on the water-to-product ratio. h e concern was that the existing pump would still produce a high product damage rate. It did, however, have the advantages of being the fastest fi x with the least initial expense.

h e third option was replacing the existing pump with a new pump designed to handle whole foods. h is pump design allows food to pass through the pump and exit through the center of the discharge nozzle, minimizing contact with any pump surface. Along with the new pump, replacing the dis-charge pipe to the correct diameter would be required.

Solution—Hydro-Transport Food Pumph e third option was deemed the most advantageous, in terms of time, design and overall cost.

h e food processor recalculated the correct gallons per minute needed to transport the desired pounds per hour of onions and recalculated the total dynamic head of the system with the correct discharge pipe diameter. After this assessment, a 10–inch, hydro-transport food pump with a single port impel-ler and expanded off set volute was chosen for the job. h is size

pump was needed to handle the system’s fl ow and pressure requirements and to ensure that the largest onions would not plug the pump.

With the new pump in place and following the guidelines for handling food products—including water-to-product ratio and pipe velocity—the food processor reduced damage to onions by more than 90 percent. h e up-time of the pump and energy effi -ciencies have been working well since 2010—saving tens of thousands for nearly two years.

P&S

Dave Young is the northwest regional manager for Cornell Pump Company—a Clackamas, Ore., manufacturer of centrifugal pumps

for industrial, agricultural, mining, oil, gas and municipal applications. Young has more than 17 years of experience in food and agricultural pump solutions. He can be reached at [email protected] or 503-653-0330.




Pumps are used in many beverage and food process appli-cations. For example, egg whites, honey, food oils, apple sauce, apple juice, donut glaze and pancake batter are all

moved using pumps. Pumps can also be used to gently circu-late fl uid when fermenting high alcohol beer where oxygen is injected into the process to signifi cantly reduce the fermenta-tion time.

Pumps can provide a winemaker with the ability to trans-fer just-harvested grapes from a de-stemmer/crusher to the tank for fermentation. h ey can also be used for pump overs in fermentation tanks to allow for color enhancement on red wines and providing a way to move the juice from the tank to barrels for aging.

Pumps are also used to move the wine to the fi ltering pro-cess to remove sediment or solids and then to move the wine to the bottling line for packaging. Regardless of the style, pumps provide time savings to the winemaker and should be consid-ered part of the wine production lifeline.

h e winemaker should choose a pump that has the greatest versatility for the par-ticular operation. A versatile pump—one that can run at vari-able speeds and provide a winery with multiple task fulfi llment capabilities—is a cost advantage to a winemaker. Some other advantages of a versatile pump are self-priming, reversible fl ow, portability and ease of cleaning.

h is article discusses some typical pumps found in the wine industry. However, they can also be used in other food and bev-erage industry segments. Pump styles can be off ered in fl ow ranges from a trickle to hundreds of gallons per minute and with AC or DC voltages.

Pumps can be obtained as a pump alone, with the motor

attached and or mounted on a cart for ease of movement within the winery. Some pumps off er low pressure and some can produce high discharge pressures. Picking the fl ow and pressure to meet the needs of the application is important for successful and continuous production.

Flexible Impeller PumpsFlexible impeller pumps (FIPs) are self-priming with either wet or dry at start up. h ey off er gentle, smooth and variable fl ow rates. h is design includes a fl exible impeller that rotates in a fi xed cavity. h e use of an off set cam causes the vanes on the impeller to defl ect, decreasing the cell volume initially.

When the vanes leave the cam contact, the volume increases between the vanes, and fl uid is drawn into the larger cell cavity with the help of atmospheric pressure. As the impel-ler rotates, it reduces the cell volume at the discharge port on contact with the cam.

Wine Industry PumpsBy Keith Evans, Xylem Inc., Jabsco Flexible Impeller Pumps

Many different pump types can move food and beverages.

A portable, fl exible impeller pump used in wine production


COVERSERIES

Each cavity then produces a nearly-even and perfect smooth fl ow and is repeated on each revolution of the impel-ler. h ese pumps can transfer solids suspended in liquid. h ey are reversible and can be mounted above or below the liquid source. h e fl uid has contact with the rubber fl exible impeller and the interior of the body housing. Pump bodies and mate-rials, preferably, should be manufactured from sanitary stain-less steel with sanitary rubber compounds. h ese are positive displacement pumps.

Rotary Lobe Pumps & External

Circumferential Piston Pumps Rotary lobe pumps and external circumferential piston (ECP) pumps, positive displacement pumps, off er high effi ciency, gentle pumping action and corrosion resistance. h ese pumps are reliable and can be cleaned in place (CIP) or steamed in place (SIP). Rotary lobe pumps are capable of handling thick or thin solids, liquids and paste products. Some models of rotary lobe pumps perform well on self-priming if wetted. h ey can produce signifi cant pressure.

h ese pumps, like FIPs, can have the direction of fl uid fl ow reversed. Run dry capability is possible if the seals are wetted during the run dry timeframe. Rotary lobe pumps have two alternating direction rotating rotors that mesh in

operation. h e fl uid or product fl ows into the pump and is captured by the rotating lobes. h e product is transferred in the cavities around the outside of the lobe body. h e product does not eff ectively travel between the meshing actions of the two lobes.

Centrifugal PumpsCentrifugal pumps use gravity to push water into the pump cavity, and the high speed of the pump impeller then dis-charges the fl uid from the discharge port. h ese pumps tend to be the most effi cient with a smooth, pulse-free delivery. Minimal wear is associated with the pump components, the impeller and pump head are generally easily disassembled.

Most centrifugal pumps are small, but can produce a high volume of fl ow. Most can be obtained in AC and DC versions and are relatively inexpensive. h e main draw back to centrifu-gal pumps is that they are not self-priming and may cavitate easily. h e most common form of centrifugal pumps is a radial fl ow design.

Air-Operated Diaphragm PumpsAir-operated diaphragm (AOD) pumps use air to power them. h e pump design is self-priming, capable of handling high solids content, can run dry, is portable, explosion proof, has




Keith Evans, of Xylem Inc., is product manager, Americas, for Jabsco Flexible Impeller Pumps. He can be reached at [email protected].

a high pumping effi ciency and can deliver a variable fl ow rate and discharge pressure. One disadvantage is the requirement to have an air compressor on hand for use. h is is a positive displacement pump.

Peristaltic PumpsPeristaltic, or roller, pumps are positive displacement pumps that transport fl uid inside a fl exible tube or hose in a circular casing. A rotor rolls inside the tube, not making any contact with the fl uid or product transferred. Operation of the pump powers a piston through a chamber, opening a one way check valve drawing fl uid into one part of the pump cavity. When the air drives the piston back to its fi rst position, it opens another one way check valve and discharges the fl uid from the cavity. h is type of pump can also handle solids.

Progressive Cavity or Eccentric

Screw Pumps Progressive cavity or eccentric screw pumps transfer fl uids by using a progressive cavity where the helical rotor turns inside an inner housing. h e stator, which is typically made of rubber, is where the fl uid is contained in the cavity of screws until it reaches the discharge end of the pump housing. h e fl uid con-tacts the screw and the rubber inner housing. h is is a positive

displacement pump and is a good choice when pumping vis-cous fl uids or at high pressures.

Motor- or Cam-Driven Diaphragm PumpsMotor- or cam-driven diaphragm (MDD) pumps use a mul-tiple diaphragm that is driven by an off set cam. h e cam positions one way valves to draw in fl uid on one cycle and on the next cycle pushes open another one-way check valve to discharge the fl uid. h ese positive displacement pumps are ideal for the home winemaker packaging reasonable volumes. MDD pumps can handle high pressures, run dry, are self-priming and are available in AC and DC versions.

The Final DecisionTo make the best choice for the operation, consider the cost and the value return. Often, a higher initial investment on a pump will be benefi cial because it will last longer. If possible, go with the best. If a winemaker produces small volumes, a good low-cost pump can take care of the production needs.

P&S


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Handling emulsions can be challenging. Even their basic defi nition—a mixture of two or more liq-uids that are normally unblendable—hints at the

diffi culties involved in creating and handling them. Still, examples in which emulsions have been successfully cre-ated—ranging from common milk to cutting fl uids used in metal working—can be found everywhere.

Latex is a complex but stable emulsion consisting of polymer microparticles contained in an aqueous medium. Like emulsions in general, latex—the most recurring image of which is a latex glove—is present in many common prod-ucts (paints, balloons, fl oor polishes and carpeting). Most latexes begin as simple emulsions in which droplets of the substance are added to water. h is initiates a process known as emulsion polymerization in which the fi nal product can be called latex.

h ough latexes are versatile and can be used to enhance a product’s performance characteristics—such as durability, dimensional stability and chemical resistance—they require precise manufacturing and handling processes. h is article identifi es and explains why air-operated double-diaphragm (AODD) pumping technology is ideal for the demands of latex handling.

The ChallengesTwo basic challenges exist when pumping latex:• Latex emulsions are extremely shear-sensitive, requiring

pumps that reliably deliver a low shear rate.• Any contact with air will further polymerize the latex,

making it imperative that the pump feature a sealless design. Also, pumps with mechanical seals usually require fl ushing, which can create a possible leak path or dilution of the latex solution.

Other pump characteristics that are desirable when han-dling latex emulsions include dry-run capability, ability to handle liquids with varying viscosities, from thin to high-grade, self-priming operation, portability and easy cleaning and maintenance.

A lesser consideration, but still important, is the climac-tic conditions in which the latex emulsion will be created and handled. Since most types of latex are incapable of with-standing repeated freezing or thawing, they need to be stored at temperatures above 40 F (5 C). h ey should also not be kept in temperatures above 100 F (30 C) for extended peri-ods because they can become susceptible to surface drying that will compromise their performance.

h rough the years, the search for the perfect pump to handle latex emulsions has led manufacturers to experiment with a number of diff erent technologies, most of which feature operational blind spots that negatively aff ect their performance in latex-handling applications. Some of these competitive technologies and their respective operational drawbacks are:Gear Pumps• h ey are not recommended for shear-sensitive fl uids.• If used, they must be oversized and operate at low speeds.• Seals are prone to leakage.• A pressure relief valve is required on the discharge side of

the pump.

Centrifugal Pumps• h ey are not recommended for, but known to be used

with, thin emulsions.• h e seals must have a fl ush pan and/or be cooled to pre-

vent product buildup around the pump shaft.• A double mechanical seal or water seal with a packing

gland is required.• Low-fl ow operation can cause pump failure.• h ey may require priming.

Progressive Cavity/Rotary Screw Pumps• h ey can be expensive to maintain.• h ey are diffi cult to disassemble.• A pressure relief valve is required on the discharge side of

the pump.• Viscous materials require an oversized pump operating at

low speed.

Effi ciency Matters

Latex Pumping ChallengesBy Edison Brito

Air-operated double-diaphragm pump technology delivers the shear-sensitivity and

leak-free operation required in this application.


• h ey have tight internal clearances.• h ey cannot be run dry.• h e seals are prone to leakage.

Circumferential Piston Pumps• h ey are not recommended for shear-sensitive fl uids.• h e multiple seals are prone to leakage.

Peristaltic (Hose) Pumps• h ey are only suitable for low-fl ow applications.

The Solution

Positive displacement, air-operated double-diaphragm (AODD) pump technol-ogy does not have the disadvantages of other technologies. Some AODD pumps are ideal for latex-handling applications because they feature a sealless, bolted con-fi guration that ensures total product containment. h e design of the wetted path reduces internal friction, enabling the pump to deliver the level of shear-sensitive operation that is mandatory when working with latex. h e AODD pump’s positive-displacement operating principle also guarantees that the product fl ow rate will remain volumetrically consistent.

AODD pumps are available in several materials of construction—including aluminum or 316 stainless steel, which is generally preferred when handling latex, with PTFE elastomers. Some AODD pumps have other benefi ts, including:• Air-Distribution System (ADS)—Provides operational fl exibility through an

effi ciency management system that allows the user to optimize the ADS for any application demands.

• Drop-in Pump Coni guration—Allows a pump to be installed in an existing footprint without the need to disturb the piping. h ey have a larger fl ow path, resulting in increased fl ow rates and decreased energy consumption.

• Full-Stroke PTFE Diaphragms—h e full-stroke design results in increased product displacement per stroke, which translates into greater fl ow rates and higher effi ciencies.

• Easy Install Diaphragms—Some pumps’ diaphragms that are made of ther-moplastic elastomer are easy to install and are a low-cost alternative to PTFE diaphragms when used in abrasive-handling applications. h ey have a fl at-profi le design that eliminates the need to invert the diaphragm when rebuilding a pump, allowing for easy, cost-eff ective installation.

h ese benefi ts also equate into energy savings because lower amounts of com-pressed air are needed to maintain the desired fl ow rates and pressures. Latex emul-sion is, and will continue to be, a crucial component in many industries and prod-ucts, some of which are as common as the adhesive on the back of a postage stamp. Sensitive handling characteristics make latex a diffi cult substance to pump. h rough the years, manufacturers and handlers of latex emulsions have found that AODD pump technology reliably provides the required operational principles.

P&S

Edison Brito is chemical market manager for Pump Solutions Group (PSG) based in Downers Grove, Ill. He can be reached at 714-396-1502 or [email protected]. PSG is comprised of several pump brands, including Almatec, Blackmer, EnviroGear, Griswold, Maag, Mouvex, Neptune, Quattrofl ow, RedScrew and Wilden. Wilden is the manufacturer of AODD pumps. For more information, visit www.wildenpump.com.

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Successful alignment of rotating machinery depends sig-nifi cantly on how much emphasis is put on the align-ment preparation and planning stages. Proper machin-

ery alignment reduces the chance of an equipment failure, helping end users avoid unnecessary downtime and exces-sive maintenance time and costs. Preparing thoroughly and choosing an appropriate alignment method can help ensure a smooth process.

Prepare for AlignmentBefore starting the alignment process, follow these steps:• Make sure that the mounting faces of the bedplate and

the rotating machine are free from paint, rust, weld spat-ters, burrs or other debris.

• h row away any shims used during previous alignments that are rusty, painted or damaged.

• Check to see if the holes for the holding-down bolts are large enough to allow adequate movement for alignment. h is helps avoid unnecessary delays later in the process.

• Check the distance between the shaft ends and align the machines approximately. You can do this by laying a straight edge against the machines and ensuring that the hub faces are parallel.

One issue that end users often overlook during align-ment is the presence of a soft foot, where the machine is not sitting evenly on the bedplate. h is can twist the machine frame, putting an unexpected load on the bearings and, ulti-mately, causing the frame to fracture.

End users can detect a soft foot by mounting a bracket carrying a dial indicator on one shaft and placing the plunger on the second shaft, with all the holding-down bolts lightly tightened. Next, work around the machine, fully tightening the bolts and then slackening them one at a time. Any exces-sive movement on the indicator signifi es the presence of a soft foot, which will require that the end user fi t shims to the machine before starting the alignment. Modern laser align-ment equipment also often contains a program that can check for soft foot without undergoing this manual procedure.

Preparation Checklistsh e following checklists can help end users prepare thor-oughly for alignment. h e lists can be adjusted as needed to suit specifi c machinery and the chosen alignment method.

Of -Site Checklist

❏ Safety regulations ❏ Working permits ❏ Time limits for stopping production ❏ Alignment tolerances ❏ h ermal off sets ❏ Available space ❏ Shaft rotation ❏ Shim sizes ❏ Alignment system ❏ Batteries, if required for laser equipment ❏ Specifi cations for the machine setup

Easy Shaft AlignmentBy Peter Carlisle

Thorough preparation and the right alignment method are critical.

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On-Site Checklist ❏ Machine serial numbers ❏ Safety conditions ❏ Available space ❏ Foundation condition ❏ Bedplate condition ❏ Bolt condition ❏ Adjustment capacity ❏ Shim condition ❏ Presence of leaks

Pre-Alignment Checklist ❏ Machine temperature ❏ Gross soft foot check ❏ Replacement of old shims ❏ Coupling assembly ❏ Adjustment of any mechanical looseness ❏ Run-out conditions ❏ Pipe strain ❏ Final soft foot check to adjust small errors after removing gross soft foot

❏ Repeatability test to ensure that tightening and loosening the feet bolts gives consistent results; this test also checks the condition of any shims or binding of bolts

Choose an Alignment MethodAfter preparing for alignment, end users must choose an align-ment method appropriate for their machinery. Many align-ment methods require brackets and arms for mounting the measuring equipment. As the length of the arms increases, the arms become more susceptible to sagging, which can cause sig-nifi cant measuring errors if end users do not take the sagging into account. Figure 1 illustrates the typical method to check for sagging arms. End users should add the values they record to the readings they take during alignment. h e major methods for checking alignment are discussed in this section.

Method 1—Face and Periphery h e face and periphery method is the oldest and most widely used dial indicator method. Figure 2 illustrates the correct setup for this method, which is good for large-diameter hubs with a short distance between shaft ends.

Advantages:• h e end user only

needs to rotate one shaft.• Visualizing shaft positions is easier compared to other

methods.

Disadvantages:• It is diffi cult to obtain face readings if there is any axial

fl oat.• An end user typically has to remove the coupling.• It is more complicated to make the graphical calculations

compared with other methods.• Any out-of-roundness in the hub periphery or out-of-

squareness in the hub face—meaning the hub fl ange is not round or fl at and square relative to the shaft—will aff ect the readings.

Method 2—Reverse Periphery (Indicator) Methodh e reverse periphery (indicator) method is becoming increas-ingly popular and is the optimal method for most alignments. Figure 3 illustrates the correct setup for this method.

Advantages:• It is generally more accurate than the face and periphery

methods.• Axial fl oat, or out-of-roundness or out-of-squareness in the

hub, does not aff ect the readings.• It is easier to plot graphically compared with other methods.• It is possible to make measurements with the coupling in

place.

Figure 2. Open lineshaft, product-

lubricated

Figure 1. Check bracket and arm sag

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Disadvantages:• End users must rotate

both shafts.• It is not accurate for

close-coupled shafts.

Method 3—the Laser Systemh e modern laser system (see Figure 4) consists of either two laser/detec-tor units or one laser and one mirror/prism refl ector unit. One unit is attached to each shaft, and the laser/detectors are connected to a key-board/display unit by a cable or via a wireless Bluetooth system. h e system operates using the principles of reverse periphery, detecting the movement of the laser beams as a measure of the misalignment.

Advantages:• h e system fi ts a variety of shafts.• End users do not have to remove the coupling.• End users can measure long spans with no sagging issues.

• It is not aff ected by axial fl oat.

• h e system detects the soft foot condi-tion easily.

Disadvantages:• h e system is

not suitable for couplings with backlash.

• Heat or steam can aff ect its accuracy.

• h e system is expensive.

Other Alignment MethodsOther alignment methods include shaft-to-coupling spacer, optical systems and electronic indicators. For equipment with long distances between the shaft ends, it is possible to fi t the coupling and check the alignment of one shaft to the spacer and then check the spacer’s alignment with the second shaft.

P&S

Figure 3. Reverse Periphery Method

Figure 4. Laser Alignment

Peter Carlisle is John Crane’s global product line direc-tor for couplings. He joined Flexibox in 1978. His work with the company

has included design, application and research on the fundamentals of power transmission couplings. He served as group engineering manager and has held roles in sales management and operations man-agement. He has a bachelor’s degree in mechanical engineering from the University of Manchester, U.K., and a diploma in marketing. Carlisle can be reached at +44 161 886 6290 or [email protected].

John Crane is a provider of engi-neered products and services for major process industries, including oil and gas extraction and refi ning, power generation, chemical produc-tion, pharmaceutical manufactur-ing, pulp and paper production, and mining. For more information, visit www.johncrane.com.


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Current directives to control fugitive emissions and eliminate leakage altogether in piping and pressure vessel assemblies have led to activities geared toward

fully understanding the intricacies that impact bolted joint performance. While a bolted fl ange joint assembly appears relatively simple in nature, joint integrity relies to a large extent on the skill and application of the installer. Proper inspection and selection of materials, along with a con-trolled, safe, documented assembly technique are fundamen-tal to ensuring a reliable bolted joint assembly. Currently, industrial facilities and organizations are commonly develop-ing general process and specifi c service bolting procedures and practices. A common thread in the method is a six-step approach:1. Clean and examine assembly components2. Align the fl anges3. Install the gasket4. Control fastener friction5. Control bolt tightening6. Compensate for relaxation

Clean and Examine

Assembly Components Remove all foreign materials from the fl ange seating surfaces, fasteners, nuts and washers using tools that will not damage the equipment. Flange cleaning must take place in a path or direction that corresponds with the serration path and not across the serrations. Examine fl ange surfaces for any pitting, corrosion, cracks, radial scores, heavy tool marks or anything that could prohibit proper gasket seating.

Where possible, use a straight edge to check for warp-ing. Remove old paint and lubricant from the nut-bearing surface of the fl anges. Examine the fasteners, nuts and wash-ers for defects, such as burrs or cracks. Nuts should run freely past the point on the fastener where it will come to rest after it is installed and tightened. If possible, repair equipment

that is out of optimal condition. Extensive out of tolerance conditions may require equipment replacement.

Align the FlangesAlign the fl ange faces and bolt holes without using exces-sive force, reporting any misalignment in which more force than can be exerted by hand or spud/pin wrenches. Where alignment is not possible without excessive force, acceptable aligning methods include replacement by removing and rein-stalling the equipment in the properly aligned position or using uniform heat to relieve the stresses.

Proper alignment of all joint members is at the core of bolted fl ange connections. Proper alignment enables maxi-mum seating surface contact, maximum opportunity for even gasket loading and reduced friction between the nut and the fl ange.

Install the GasketEnsure that the gasket is the specifi ed size and material for the assembly. Make sure that the gasket is free from defects. It should be transported to the job site in a way that keeps it protected, up to and including the time of installation.

Fasteners and washers should be checked for proper diameter, length, threads per inch, grade and condition. Carefully insert the gasket, centering it appropriately between the fl anges. Do not force the gasket into place.

Some large gaskets may require the use of an adhesive to hold it in place. h e adhesive should be approved by the manufacturer, the process engineers and the metallurgist. Grease, tape, petroleum, gasket compounds or release agents are not recommended for this purpose. Care should be taken to keep any unwanted materials out of the process.

Fasteners should be placed into the bolt holes in a way that protects the threads. Nuts should be assembled with the fl at bearing surface against the fl ange or washer. When assembled, the fasteners should have the same profi le on both

What are the current industry best practices for the assembly of bolted

fl ange connections?

This month’s “Sealing Sense” was prepared by FSA member Joel Baulch.

From the voice of the fl uid sealing industry

SEALING SENSE


FSA Sealing Sense

sides, passing through the fl ange at right angles. h e washers should rest paral-lel to the fl ange surface. Bring the fl anges together slowly, squarely and gently, ensuring that the gasket is not pinched or damaged.

Control Fastener FrictionUse a specifi ed or approved lubricant suited to the service. Apply the lubricant generously and uniformly to all contact-ing thread, nut and washer load-bearing surfaces. Except when installing into tapped holes, apply lubricant after the fastener is installed in the fl anges to ensure that contamination of the fl ange or gasket face does not occur. Always lubricate an end where a nut is to be turned, and always apply enough lubri-cant to ensure that the nut does not run dry before it is tight. Apply lubricant to the side of the washer that is against the nut. Applying lubricant to both sides merely ensures that the correct side is lubricated.

Bolt Tightening Controlh e use of manpower to tighten the bolts, by sledgehammer,

striking wrenches and pieces of pipe on the end of the wrench is not recommended, since this off ers no accuracy. Consult the torque or tightening specifi cations

from the gasket manufacturer or the company’s engineering department for guidance. First, contact the gasket using only suffi cient force to lightly tighten the fasteners and stabilize the assembly.

Tighten the fasteners in a star or cross-bolt pattern (see Figure 1), checking to ensure that the fl ange remains even at ninety-degree intervals. No signifi cant gasket compression should be occurring at this stage.

Once the assembly is stabilized, apply only a medium tightening force (30 to 50 percent of the target load) using the same star or cross-bolt pattern. In the next pass, increase the force to an ample but restrained force (60 to 70 percent of the target load) using the same star or cross-bolt pattern. h en increase the force to approach full force (90 to 100 percent of the target load) using the same star or cross-bolt pattern. Apply full target load to all nuts in a circular pass, continuing until all the nuts no longer turn.

For safety reasons, any retightening of

bolts must be done with the system off

and the gauge pressure at zero.

circle 133 on card or go to psfreeinfo.com circle 132 on card or go to psfreeinfo.com

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Practice & Operations

This article discusses the operating conditions and design limits; applications for single seals, tandem seals, tandem seals with intermediate labyrinth and

double seals. It also explains tandem seals versus double seals.To select a dry gas seal confi guration, the operating con-

ditions and design conditions must be determined. Both the operating conditions and the design conditions will infl uence the type of seal used for an application. To ensure a depend-able dry gas system, seal conditions that must be identifi ed are normal sealing pressure, maximum sealing pressure, oper-ating temperature, seal design temperature and process gas.

Normal Sealing Pressure h e fi rst factor to be identifi ed is the normal sealing pres-sure. h is is the pressure that the seal must contain within the compressor during normal operation. For beam-style com-pressors, this is typically suction pressure. However, some confi gurations, such as back-to-back compressors, can have higher–than-suction sealing pressures. For overhung-style compressors, the sealing pressure is somewhere between suc-tion and discharge. h e discharge pressure gas decreases in pressure as it moves down the backside of the compressor impeller to the seal location.

h erefore, based on the design of the compressor, the actual sealing pressure must be confi rmed with the compres-sor manufacturer. Knowing the actual sealing pressure will provide accurate leakage information to reference during operation and for designing the seal monitoring system.

Maximum Sealing Pressureh e next pressure information needed is the maximum seal-ing pressure, typically the design pressure for the seal. Since the discharge pressure is the maximum pressure identifi ed for the compressor, this could be used for the maximum sealing pressure. Seals will typically never seal the discharge pressure of the compressor, so the pressure rating will be much higher than the maximum operating pressure of the seal. Designing

the seal to discharge pressure can also be expensive.For example, there is usually a price change for seals at

about 1,500 psi to 1,700 psi, depending on the manufac-turer and then another price change at about 3,000 psi to 3,300 psi. Verifying the maximum sealing pressure required for the application can lower the cost of the seal. Usually, the seal will never operate at higher than the settle-out pres-sure of the compressor, estimated at the mid-pressure point between suction and discharge pressure. Normally, this is an estimate since the volume of gas upstream and downstream of the compressor to the unit valves will infl uence the settle-out pressure.

A larger volume of gas from compressor to discharge valve compared to the volume of gas from the compressor to suction valve will result in a higher than midpoint settle-out pressure. If the larger volume of gas is on the compressor to suction-valve side, then the settle-out pressure will be below the midpoint. If the discharge pressure is below the 1,500 psi to 1,700 psi for lower-pressure applications or 3,000 to 3,300 psi for higher-pressure applications, then using dis-charge pressure as design pressure is not a big concern. If settle-out and discharge pressures straddle the identifi ed pres-sure, then more time may be required to identify the actual design pressure for the seal.

Settle-out pressure can also eff ect the decision to use a tandem seal or a double seal. h erefore if the application is low-pressure and/or for a dirty gas, identify the true settle-out pressure. Choosing a double seal for these services can provide a much more reliable seal. For dry gas seal applica-tions, low pressure is below 100 psi.

Operating Temperature and

Seal Design Temperatureh e next step is to identify the actual operating temperature and the seal design temperature. On a beam compressor, the suction-end seal and discharge-end seal will operate at diff erent temperatures. No compressor original equipment

Seal Confi guration SelectionBy Glenn Schmidt, EagleBurgmann

Choose the correct seal to meet the application requirements.

Fourth of Six Parts


manufacturer (OEM) can provide an exact temperature for the seal operating temperature because typically no temperature probes are at the seal, so the operating temperature is assumed to be somewhere between the process gas temperature and the bearing temperature.

Standard seals, from most manufacturers, can manage temperatures of 300 F to 350 F. If the discharge temperature is below this, then use the discharge temperature as the seal design temperature. If the discharge temperature is above this, then more time may be required to identify the actual design temperature if eliminating unnecessary costs is a concern.

h e other point about seal design temperature is seal supply gas temperature. If there is an issue with the dew point of the seal supply gas, then the gas should be heated to manage the dew point. h e temperature of the seal gas should be consid-ered when identifying the seal temperature rating. As indicated, seal temperatures are somewhere between process gas and bear-ing temperature. If the seal experiences discharge temperature, the bearing must be designed to handle this temperature as well because the seal is not far from the bearing.

For minimum seal temperature, identify both the ambi-ent temperature and the minimum compressor suction tem-perature. Use the lower of these temperatures as the minimum seal temperature. Typically, fl uorocarbon O-rings (the standard material used in dry gas seals) have minimum temperature rat-ings of -4 F to -20 F. Diff erent types of vendor-specifi c fl uoro-carbon O-rings are available to manage minimum tempera-tures. If the minimum seal temperature is -4 F or lower, make sure that the O-rings used are suitable for the application. h is is also why it is important that the O-rings in a seal are provided

by the seal manufacturer rather than purchased from an O-ring supplier. Features in the O-ring material or even diff erent types of fl uorocarbon must meet the demands of the seal and appli-cation. Using the incorrect material or a diff erent fl uorocarbon than originally specifi ed can result in seal failure.

As indicated previously, the seal operating temperature is somewhere between process temperature and bearing tem-perature. If a minimum-rated process temperature is identifi ed below -50 F, the low-temperature rating should be confi rmed with the seal vendor and compressor manufacturer.

Process Gas

Now that the operating and design temperatures have been identifi ed, the process gas must be analyzed. Is the process gas hazardous or fl ammable? Is the gas toxic? Examples of non-haz-ardous gases are air, nitrogen and carbon dioxide. Examples of hazardous or fl ammable gases are methane, ethylene or propyl-ene. Toxic gases, such as gas with hydrogen sulfi de, are defi ned as gases composed of components dangerous to humans and the environment.

Once the gas is identifi ed, the next questions are: • Is full containment of the process gas required? • What environmental or safety concerns must be considered? • Can an outside gas be introduced into the process from the

seal supply? • What is the minimum pressure available for the outside gas?

An outside seal-gas source is benefi cial if the process gas is toxic, dirty or wet. If a reliable source, at suffi cient pressure, is available and compatible with the process, using an outside seal-gas source can eliminate an expensive conditioning system.

Figure 1. Single seals feature a single set of seal faces in a car-

tridge or component seal and are ideal for use in non-hazardous

applications.

Figure 2. Tandem seals have two sets of seal faces in the seal car-

tridge and are typically used in hazardous pipeline applications.



Seal Confi gurations and ApplicationsTemperature, pressure and process gas will change the features and sealing elements in a dry gas seal cartridge. h ese elements can also aff ect the type of seal selected, the cost of the seal, the system and the reliability of the system. h erefore, the seal fea-tures and the benefi ts provided by seal vendors must be known to understand how they will impact dry gas seal reliability and support the sealing application through all operating condi-tions. Carefully analyze the sealing application and work with a knowledgeable seal vendor to make sure the best seal confi gura-tion is selected for your application. h is section outlines each seal type and where it is typically used.

Single SealsSingle Seals (see Figure 1) are a single set of seal faces in a car-tridge seal or a component seal. Single seals are the only seal confi guration that uses components, as all other seal confi gu-rations are too complex to install with components. Because they only have one set of seal faces, single seals are used in non-hazardous processes—such as moving air, nitrogen and carbon dioxide.

Sometimes, single seals are used with integrally geared compressors due to space constraints for hazardous applica-tions, but only after all other options have been eliminated. For integrally geared compressors, the gas is typically non-hazardous—such as air or nitrogen. A less effi cient lower-cost seal can be used for these applications because the loss of nitro-gen or air is not a concern. When selecting equipment, if total life-cycle costs are part of the company’s philosophy, it should pay attention to the seals used in non-hazardous applications. h e energy savings from improved compressor effi ciency and reduced seal-gas consumption can easily pay for the cost of dry gas seals and systems.

Tandem SealsTandem seals (see Figure 2) are typically used in pipeline appli-cations. A tandem seal confi guration has two sets of seal faces in the seal cartridge. h e second set of seal faces (the secondary seal) backs up the fi rst set (the primary seal) if the primary seal fails. h is allows containment of the process gas, so that the compressor can be safely shutdown and vented.

In a tandem seal, the secondary seal will operate on a small portion of the gas leakage from the primary seal, so small amounts of process gas will leak out of the primary and second-ary vent ports on the compressor.

h e fi rst type of dry gas seal installed was a tandem seal confi guration. h is was in a pipeline application where tandem seals are most commonly used, even today. h e other appli-cation where tandem seals are commonly used is low-pressure hydrogen applications.

Tandem Seals with Intermediate LabyrinthsTandem seals with intermediate labyrinths (see Figure 3) are the most commonly used seal. An additional port and labyrinth,

between the primary seal and secondary seal, allow for the supply of inert gas to the secondary seal. Any leakage from the primary seal is fl ushed out the primary vent, allowing for easier management of the gas leaking from the primary seal.

h is feature makes these seals ideal for hazardous or toxic service. h e intermediate labyrinth also provides a restriction in the event of a primary seal failure or catastrophic/total-seal failure (primary and secondary seal failure). h is allows for safer operation in high-pressure applications. h is confi gura-tion should be used for all high-pressure applications. h ese seals also provide higher safety when used in standard sealing applications.

Double SealsDouble seals (see Figure 4) are usually used in low-pressure applications (100 psi is defi ned as low pressure for compressor seal applications) and dirty, wet process gas applications. h eir confi guration consists of two sets of seal faces opposing one another. Because tandem seals were the fi rst dry gas seal confi g-uration to be installed, end users are hesitant to specify double seals. h e argument is that tandem seals are the proven tech-nology, but double seals are the better technology in specifi c applications. h ey can provide a reliable compressor seal when applied correctly and can prevent failures from reverse pres-sure, which results when a tandem seal is used in low-sealing-pressure applications. Reverse pressure for a tandem seal results when the vent pressure is higher than the sealing pressure. If the sealing pressure is a vacuum then reverse pressure can occur. If the vent pressure can increase to a pressure greater than sealing pressure, reverse pressure in a tandem seal will occur.

Figure 3. Tandem seals with intermediate labyrinths have an

additional port and labyrinth that supply inert gas to the second-

ary seal to allow for use with hazardous and toxic gases.


An example is when the primary seal vent line is connected to the fl are. h e fl are line conditions can result in the seal vent pressure being higher than the sealing pressure. Under these conditions, a tandem seal will be reverse pressured, and a seal failure will occur. With the double seal, this can be eliminated. h e pressure of a double seal is limited to the seal-gas supply pressure that is available.

Because double seals are typically used for dirty/wet ser-vices, the seal needs an outside source of seal gas. h is seal gas must always be approximately 50 psi higher than the process gas pressure being sealed. Since the source pressure is seal-vendor and application specifi c, always contact the seal vendor about seal-gas supply pressures. When the dry gas seal has been set-up correctly, double seals can off er many years of reliable operation in dirty/wet service.

Double seals can also be used for pressures greater than 100 psi, when a seal supply gas is available at suffi cient pres-sure. Do not rule out discharge gas as a seal gas source. If the discharge gas can be fi ltered economically and eff ectively, it can be a reliable source to use for the double seal and provides a much more dependable dry gas seal system. h is eliminates the concern of injecting nitrogen or another gas that may not be compatible with the process.

Seal Selection Guide

h is section covers the pressure, temperature, speed and appli-cation for each seal confi guration. Keep in mind, the limits for seals continue to be pushed. Contact a qualifi ed seal vendor when applications are close to or beyond the limits identifi ed. Advancements with sealing technology continues. Also, each

seal vendor will have diff erent limits for their seal designs. h e limits listed in this section are only general guidelines.

Single Seals• Non-hazardous applications—air, nitrogen, CO2

• Pressure capabilities to 1,750 psig (Possible for use with higher pressures, but there are safety concerns with using a single seal at higher pressures.)

• Temperature: -270 F to 410 F• Speeds to 660 feet per second

Tandem Seals• Hazardous applications—pipeline, hydrogen or high-pres-

sure, non-hazardous gas• Pressures to 8,700 psig• Temperature: -270 F to 410 F• Speeds to 660 feet per second

Tandem seals with intermediate labyrinth• Hazardous and toxic applications or high-pressure

applications• Pressures to 8,700 psig• Temperature: -270 F to 410 F• Speeds to 660 feet per second

Double Seals• Low-pressure applications (Hazardous or toxic—coker

compressors, wet gas compressor, sour gas)• Typical application pressure of - 250 psig (Possible pressure

to 1,000 psi for standard seals and systems or 1,500 psig with special considerations)

• Temperature: - 40 F to 350 F• Speeds to 460 feet per second

Author’s Note: For more information on identifying maximum sealing pressure, please reference, “Calculating Settle-out Pressure in Compressor Loops,” Hydrocarbon Processing, November 2006, or discuss it with your engineering company.

h e fi fth article in this series will discuss the instrumentation systems used with dry gas seals.

P&S

Glenn Schmidt is EagleBurgmann’s regional compressor seal specialist support-ing the American region with technical and sales support for designing, servicing, repairing, troubleshooting and upgrades of dry gas seals and systems. His 16 years of experience with dry gas seals includes

instructing a Texas A&M dry gas seal systems course and providing input as a member of the API 692 committee developing the standards for dry gas seals and systems. He can be reached at [email protected] or 713-939-9515.

Figure 4. Double seals consist of two sets of seal faces oppos-

ing one another and are used in low-pressure and wet or dirty

applications.



Late in 2010, a packaged pumping system manufacturer provided a packaged pump sta-tion unlike anything it had built in the past.

Scappoose, Ore., needed to upgrade its wastewater treatment plant. h e consulting engineer required a pump station that would provide continuous, vari-able fl ow from its existing clarifi ers while maintain-ing an operating range of 12 inches when pumping to a new fi lter station.

The Design SolutionBecause of geological restraints, the only avail-able site for the pump station was a narrow space between an existing road and previously installed process equipment. h e packaged system provider proposed a version of its system used for submers-ible pumps, buried below grade. h e wetwell with an integral valve vault was made from fi berglass and included an aluminum lid with access hatches. Because the station was only partially buried, the company was able to include safety handrails around the top perimeter for operator safety and a jib crane for equipment removal inside the station.

An Issue with the Sunh e package was completely assembled at the provider’s facil-ity and delivered to the jobsite in one piece. h e contractor provided installation, and the city was pleased with the qual-ity of the station and the operation of the equipment.

However, one small problem existed that no one had considered—the sun. In Oregon, when the sun shines most people are happy. At the Scappoose WWTP, when the sun shone it meant that the operators had to wait for a dark cloud

or dusk before they could work on the control system for the station.

h e control panel provided was well optioned with a PLC and touch screen human machine interface (HMI) that was enclosed in a NEMA 4X stainless steel, dead front enclo-sure. However, once the dead front was opened to access the PLC’s HMI, it was diffi cult to read on a sunny day. Since this panel faced virtually due east, even on slightly overcast days, reading the display was diffi cult. Working with pumps or other equipment with a touch screen control system that is located outside can be problematic. Sun glare, driving rain, panels located remotely from the equipment are just a few

Advanced Technology Provides Control and MobilityBy Chris Suskie, PumpTech, Inc.

Control via an iPad helps solve packaged pumping system problems.

Testing the Scappoose fi lter lift station with the mobile HMI.


extenuating circumstances that will make a nice installation dif-fi cult to operate.

A Solution for the Glare

For this reason, the packaged system provider decided to solve these control problems and unlocked a new way to establish

onsite mobility and document manage-ment. h is HMI fi ts right into the opera-tor’s hands and can be taken anywhere and used at anytime. h is was the beginning of a roving HMI and document management system designed to run on Apple’s iPad platform.

h anks to the evolution of PLC technology for pumping control systems, control panel novices have a much easier time operating, maintaining, adjusting and understanding their control systems. h is is in large part due to a general understand-ing of how to operate a personal computer. Computers make more sense to end users than ice cube relays, wire, switches and schematics. A PLC gives much the same feeling as a computer and many more options for controlling a system than a row of relays. However, all this technology is

useless if the end user cannot see the screen to operate it. Many PLC manufactures have a remote access program

that can be used on a laptop computer to connect to the PLC. h e problem is that most of these programs provide the data that the PLC has collected and some ability to change the operating

Testing the Mobile HMI in the sun


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parameters, but the end user experience is much diff erent than standing in front of the control panel and operating the system. h e screens look diff erent—not to mention a laptop is not a touch screen. h e biggest problem is that a laptop computer, while easier to carry than a desktop computer, is still not ideally mobile. Walking around with a laptop while typing is not easy.

h e goal was to use a mobile device that more closely resembled the PLC’s touch screen HMI so that the opera-tors felt as if they were holding the HMI in their hand. h is would also give operators onsite mobility that eff ectively cut the umbilical cord between control panel and operator.

h e Apple iPad was the best choice for making this happen since it is currently the most widely used tablet on the market. h e packaged system provider’s team and an application pro-grammer made the idea a reality. One year later, the application for the iPad was completed. During the year, several features were added and a second application was developed for man-aging and sharing the important documents pertaining to the pump system.

h e HMI allows end users to use their iPads to connect to the PLC in their control systems. It works exclusively with certain color touch panel PLCs. It connects to the PLC via a local WiFi router that does not require an internet connection. h e onsite mobility allows operators to move freely through-out their plant or station while monitoring or controlling the application. h ey can watch diff erent parts of a process while maintaining full control of the PLC. Never again will they have to stand outside in the rain to access their system. Sunlight will not aff ect the visibility of their iPad as it does with outside, panel mounted screens. h e best part of this system is that the iPad becomes the HMI and the graphics and controls render-ing are the same as on the actual PLC. h is allows the operator to switch from the mobile HMI to the PLC’s HMI and back seamlessly.

h e document management application works directly with the mobile HMI to create a document management

system unique for each piece of equipment to which the PLC is connected. It is a dynamic system because the operator and the pump station manufacturer share important documents regarding the pump station. h e documents in the document management system are cached or stored on the iPad for offl ine use. h is ensures that the operator will always have schematics, operation and maintenance checklists, photos, spread sheets, Microsoft Word documents and pdf fi les that are pertinent to each piece of equipment when and where they need it.

h e HMI and document manager can be connected to as many PLCs as the owner has and can be expanded to con-trol each future PLC. h is allows for a cost-eff ective expansion when the operator decides to upgrade or add additional equip-ment. Additional options are also available that give end users off site or remote access to each PLC.

The Freedom of MobilityFor Scappoose, the roving HMI for the iPad has solved a major problem that did not have many cost-eff ective solutions. By putting the PLC’s HMI on an iPad, the operators can now con-trol and monitor their fi lter lift station and enjoy the freedoms of onsite mobility. h ey are able to check the system without opening the dead front panel, move directly over the wet well and watch the pumps operate while reviewing the trending chart rendering on the iPad. Also, they can sit at their desks and log in the pumps’ hours of operation.

P&S

Chris Suskie is the vice president of PumpTech, Inc. He can be reached at [email protected] or 503-659-6230. For more information about pack-aged pumping systems and onsite mobility, visit www.pumptechnw.com.

Advanced Sealing International (ASI) 110 19

Advanced Engineering Pump, Inc. 140 53

Baker/Haight Pump 118 32

Bartlett Bearing Company 141 54

Blacoh Fluid Control, Inc. 120 9

Blue-White Industries 111 15

Boerger LLC 142 55

Cashco, Inc. 112 12

Dan Bolen & Associates 143 53

Darby Electric Company 144 55

EagleBurgmann 121 37

Frost & Sullivan 130 51

Graco, Inc. 122 34

Graco, Inc. 126 42

Hayward Flow Control 107 1

Hydraulic Institute 131 51

John Crane Inc. 113 40-41

Jordan, Knauff & Company 132 44

Junty International LLC 145 54

KNF Neuberger 123 26

Load Controls, Inc. 114 23

Load Controls, Inc. 147 55

LobePro 146 54

Maag Automatik, Inc. 133 44

MasterBond Inc. 148 55

Meltric Corporation 149 53

MET Motors 134 45

MINExpo International 100 21

Nidec Motor Corporation 101 3

NSK Americas 102 7

Primax Pumps 103 IBC

Pump Pros 124 30

Pump Solutions Group 125 39

Pumping Machinery 150 55

R+W America Technology 115 33

Scenic Precise Element, Inc. 151 54

seepex, Inc. 116 11

SEW-Eurodrive, Inc. 104 5

Sims Pump Co. 108 17

Sims Pump Co. 108 54

Smith & Loveless, Inc. 105 IFC

Summit Industrial Products 119 27

Thomas Pump & Machinery, Inc. 157 53

TouchSensor 152 53

Trachte, USA 135 36

Tuf-Lok International 153 54

Varisco 154 55

VERTIFLO 155 54

Vesco 156 53

Watson-Marlow Pumps Group 136 45

Worldwide Electric Corp. 117 16

Xylem USA 106 BC

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

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P&S Market


P&S Market

The Jordan, Knauff & Company (JKC) Valve Stock Index was down 4.2 percent over the last 12 months, below the broader S&P 500 Index

which was down 0.3 percent. h e JKC Pump Stock Index was down 27.6 percent for the same time period.

h e Institute for Supply Management’s Purchasing Managers Index (PMI) registered 53.5 percent in May, a modest decrease from April, indicating that manufac-turing sector growth continues but at a slightly more modest pace. h e New Orders Index continued its growth trend registering 60.1 percent, increasing 1.9 percentage points over April. h e Prices Index fell to 47.5 percent, dropping 13.5 percentage points. New orders increased for 13 out of 18 sectors including fabricated metals, electrical equipment, computers, machinery and chemicals. In addition, 13 sectors reported growth in employment.

h e U.S. economy grew slower during the fi rst quarter than previously reported. h e Bureau of Economic Analysis revised the real gross domestic product (GDP) growth in the fi rst quarter from 2.2 percent to 1.9 percent.

h e Bureau of Labor Statistics reported that the economy added 69,000 net new jobs in May, the smallest increase in a year. h e private sector added an average of 105,000 jobs during the past three months. However, the gains remain disappoint-ing compared to prior economic recoveries. h e unemployment rate edged slightly higher to 8.2 percent.

Global oil markets have loosened in recent months, as world oil production outpaced consumption by 0.7 million bar-rels per day (BPD) in the fi rst quarter of 2012. h e U.S. Energy Information Administration expects world oil production to exceed consumption by 1.2 million BPD in the second quarter of 2012. West Texas Intermediate (WTI) crude oil spot prices

averaged more than $100 per barrel during the fi rst four months of 2012. h e WTI spot price fell from $106 per barrel on May 1 to $83 per barrel on June 1, refl ecting market concerns about oil demand growth due to poor economic indicators in Europe, China and the U.S.

On Wall Street, the Dow Jones Industrial Average and the S&P 500 Index dropped more than 6 percent in May, while the NASDAQ Composite Index declined more than 7 percent. h e weakness was fueled by fears of a slowing U.S. economy and escalating concerns about the Eurozone debt crisis, with Spain

and Greece keeping contagion worries front and center. h e Dow and NASDAQ logged their worst monthly performances since May 2010, and the S&P 500 posted its biggest monthly loss since September 2011.

P&S

Wall Street Pump and Valve Industry WatchBy Jordan, Knauff & Company

Jordan, Knauff & Company is an investment bank based in Chicago, Ill., that provides merger and acquisition advisory services to the pump, valve and fi ltration industries. Please visit www.jordanknauff .com for further information.

Figure 2. U.S. Energy Consumption and Rig Counts

Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates. h e JKC Pump and Valve Stock Indices include a select list of publicly-traded companies involved in the pump and valve industries weighted by market capitalization.

Source: U.S. Energy Information Administration and Baker Hughes Inc.

Figure 3. U.S. PMI Index and Manufacturing Shipments

Source: Institute for Supply Management Manufacturing Report on Business® and U.S. Census Bureau.

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Figure 1. Stock Indices from May 1, 2011 to April 30, 2012

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result is Flygt Experior, a uniquely holistic experience that combines state-of-the-art

hydraulics, motors, and controls.

Today, Flygt Experior combines N-technology hydraulics and its adaptive functionality,

premium efficiency motors and SmartRun – the all-new intelligent control. Flygt Experior

comes from years of listening to you and applying our knowledge and expertise, to

develop the most reliable and energy-efficient wastewater pumping. It is therefore the

ultimate in our commitment to you.

Flygt Experior™. Inspired by you. Engineered by us.

flygt.com/FlygtExperior

Flygt is a brand of Xylem, whose 12,000 employees are dedicated to addressing the most complex issues in the global water market. Let’s solve water. circle 106 on card or go to psfreeinfo.com

Date post:	16-Apr-2015
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