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APRIL 2016
PUMPSANDSYSTEMS.COM
The Leading Magazine for Pump Users Worldwide
SYSTEMS
Strategies for advancing today’soil & gas facilities 4 WAYS TO PREVENT
Seal Failure
TAKE THE Valve
Maintenance Test
ON PAGE 70
TRADE SHOW PREVIEW:Houston’s OTC 2016
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April 2016 | Pumps & Systems
Just a couple of weeks ago, oil
prices were continuing to make
headlines—in a good way. As this April
issue of Pumps & Systems went to the
printer, the price of U.S. crude was right
around $38 a barrel. A few days earlier
it had reached its highest price of
$38.51 a barrel since Dec. 9, 2015. Brent
crude futures were around $40 a barrel
after reaching a high of $41.48 over the
same time.
Oil prices are still a far cry from the
$70-a-barrel range a year ago, making
the need to increase effi ciencies and
save money as important as ever in the
oil and gas industry. e cover series in
this issue of Pumps & Systems focuses
on operational advancements in refineries.
e series begins with an article on page 46 about how a preventive maintenance
program can reduce costs and increase reliability at refineries, while the benefits of
monitoring technology at these facilities are explained starting on page 54. An article on
page 50 showcases an example of a Texas refinery improving its water management with
reverse osmosis units and by reusing 100 percent of its water on-site.
An article about the benefits encountered at a Midwest refinery from using graphite-
metal alloy bearings begins on page 52, and the series concludes with an article on page
58 about a Southwest pipeline station and tank farm addressing vibration-related issues.
is issue’s special section dives into the topic of sealing challenges with four
educational articles. Check out the benefits of using dry gas seals to pump liquids on
page 32, followed by four ways to prevent seal failure starting on page 36. An article
on page 40 looks at how the right bearings and seals help in harsh conditions, while
advancements in seal ring and face materials are discussed starting on page 42.In addition, anyone who has questioned the right time for performing maintenance
on control valves must check out the article by Singer Valve on page 68. e article
concludes with a matrix and scorecard that can help keep your equipment operating at
optimal performance.
At Pumps & Systems, we strive to be your primary go-to source for information
pertinent to individuals working in numerous facets of the industries we cover. With
every issue, we are committed to delivering informative articles that can help end users
with their jobs on a daily basis.
We have an open-door policy for suggestions, ideas and comments, so please email me
Sincerely,
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicalspostage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves theright to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US andpossessions $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 andform 3579 to Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253. ©2016 Cahaba Media Group, Inc. No part of this publication may be reproducedwithout the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements,articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. Theopinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makesno 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 freeto publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 24, Issue 4.
Pumps & Systems is a member of the following organizations:
EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia [email protected] • 205-278-2843
SENIOR TECHNICAL EDITOR: Mike [email protected]
MANAGING EDITOR: Amelia [email protected]
MANAGING EDITOR: Martin [email protected] • 205-278-2826
MANAGING EDITOR: Savanna [email protected] • 205-278-2839
CONTRIBUTING EDITORS: Lev Nelik,Ray Hardee, Jim Elsey
CREATIVE SERVICES
DIGITAL PROJECT MANAGER: Greg Ragsdale
ART DIRECTORS: Melanie Magee, Elizabeth Chick
WEB DEVELOPER: Greg Caudle
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NATIONAL SALES MANAGER: Derrell [email protected] • 205-345-0784
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Managing Editor
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FROM THE EDITOR
Pumps & Systems Managing Editor Martin Reed,Senior Editor Alecia Archibald, Managing EditorAmelia Messamore and Vice President of Sales GregMeineke attend the Hydraulic Institute’s annualconference in Tucson, Arizona, in February.
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April 2016 | Pumps & Systems
This issue APRIL
46 IMPROVE ASSET PERFORMANCE WITH INNOVATIVE SERVICES By Harald Großmann, Sulzer
Preventive maintenance programs at refineries can result in reduced costsand better reliability.
50 TEXAS REFINERY REVAMPS WATER TREATMENT SYSTEM By Mike Jenkins, Progressive Water Treatment
e custom solution reduces supply and maintenance costs and provides aconsistent feedwater supply.
52 FACILITY CHOOSES GRAPHITE-METAL ALLOY BEARINGS By Eric Ford, Graphite Metallizing Corp.
e materials are able to withstand dry-run conditions.
54 SOPHISTICATED MONITORING SAVES LABOR HOURS& DOWNTIME IN REFINERIESBy Brian Phillippi, National Instruments
An industry with aging infrastructure and increasing demands needs bettermonitoring technology.
58 SOUTHWEST PIPELINE STATION EMPLOYS MODERN TOOLS TOIMPROVE PUMPING SYSTEM
By Jay Marchi, ProPump Services
Various analyses can identify problems and predict future systemvibratory responses.
COVERS E R I E S
2 FROM THE EDITOR
8 NEWS
88 PRODUCTS
92 ADVERTISER INDEX
92 PUMP USERS MARKETPLACE
96 PUMP MARKET ANALYSIS
OIL & GAS REFINERIESPUMPING PRESCRIPTIONS
16 By Lev Nelik, Ph.D., P.E. Pumping Machinery LLC
Letter from a Reader: Vibration Spectrum Analysis
PUMP SYSTEM IMPROVEMENT
20 By Ray HardeeEngineered Software Inc.
Examine Pump, Process & ControlElements to Solve Fluid PipingSystem Problems
COMMON PUMPING MISTAKES
24 By Jim Elsey Summit Pump Inc.
Guidelines for Submergence & Air Entrainment
INDUSTRY INSIGHTS
30 By Mike Pemberton Pumps & Systems
e Future of PredictiveMaintenance
COLUMNS
58
46
ON THE COVER
Petro Star’s North Pole Refinery processes petroleum from the Trans Alaska Pipeline and distributes diesel products across the state. (Photo © Judy
Patrick, courtesy of Petro Star)
Volume 24 • Number 4
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April 2016 | Pumps & Systems
DEPARTMENTS
62 EFFICIENCY MATTERSCompressors Assist in PropaneTransfer Transition
By Bill Holmes
Blackmer
68 MAINTENANCE MINDERSHow Reliable Is Your Control Valve Maintenance Program?
By Mark Gimson
Singer Valve
72 MOTORS & DRIVESHow Power Factor & InductionMotors Can Impact theBottom Line
By William Livoti
WEG Electric Corporation74 SEALING SENSE
Manage Rubber ExpansionJoints in Piping Systemsto Maximize Reliability &Effi ciency
By Lloyd B. Aanonsen, P.E.,
& Joshua Cocciardi
FSA Members
78 HI PUMP FAQS Air Pockets in a Piping System,Sealing Device Basics & Rotary
Pumping System LeakageBy Hydraulic Institute
S P E C I A L
S E C T I O N
SEALING CHALLENGES
This issue
THOMAS L. ANGLE, P.E., MSC, VicePresident Engineering, Hidrostal AG
BRYAN S. BARRINGTON, MachineryEngineer, Lyondell Chemical Co.
KERRY BASKINS, VP/GM, Milton RoyAmericas
R. THOMAS BROWN III, President,Advanced Sealing International(ASI)
CHRIS CALDWELL, Director ofAdvanced Collection Technology,Business Area Wastewater Solutions,Sulzer Pumps, ABS USA
JACK CREAMER, Market SegmentManager – Pumping Equipment,
Square D by Schneider Electric
BOB DOMKOWSKI, BusinessDevelopment Manager – TransportPumping and Amusement Markets/Engineering Consultant, Xylem, Inc.,Water Solutions USA – Flygt
WALT ERNDT, VP/GM, CRANE Pumps& Systems
JOE EVANS, Ph.D., Customer &Employee Education, PumpTech, Inc.
LARRY LEWIS, President, VantonPump and Equipment Corp.
WILLIAM LIVOTI, BusinessDevelopment Manager/EnergyEfficiency Specialist, WEG ElectricCorporation
TODD LOUDIN, President/CEO NorthAmerican Operations, Flowrox Inc.
MICHAEL MICHAUD, ExecutiveDirector, Hydraulic Institute
JOHN MALINOWSKI, Sr. ProductManager, AC Motors, Baldor ElectricCompany, A Member of theABB Group
WILLIAM E. NEIS, P.E., President,Northeast Industrial Sales
LEV NELIK, Ph.D., P.E., APICS,President, PumpingMachinery, LLC
HENRY PECK, President, Geiger Pump& Equipment Company
MARIANNE SZCZECH, Director,Global Marketing and ProductManagement, Pump Solutions Group
SCOTT SORENSEN, Oil & GasAutomation Consultant & MarketDeveloper, Siemens Industry Sector
ADAM STOLBERG, Executive Director,Submersible Wastewater PumpAssociation (SWPA)
JERRY TURNER, Founder/SeniorAdvisor, Pioneer Pump
DOUG VOLDEN, Global EngineeringDirector, John Crane
KIRK WILSON, President, Services &Solutions, Flowserve Corporation
JAMES WONG, Associate ProductManager – Bearing Isolator, GarlockSealing Technologies
EDITORIAL ADVISORY BOARD
APRIL
PRACTICE & OPERATIONS81 SOLID FOUNDATIONS INCREASE
ROTATING EQUIPMENT RELIABILITYBy Scott Sapita, BaseTek LLC& Thomas Hines, Chemtrade Logistics Inc.
84 A NEW APPROACH TOPRODUCT DEVELOPMENT
By Bill Blankemeier & Bill TaylorPeopleFlo Manufacturing
32 USING DRY GAS SEALS TO PUMP LIQUIDS
This unconventional solution features bonding consisting of a micro-crystalline layerthat has attributes of natural diamond.
By Emery Johnson, EagleBurgmann
36 4 WAYS TO PREVENT SEAL FAILURETake these precautions to maximize your investment.
By Andrew Kalinen, Flex-A-Seal Inc.
40 ADVANCED BEARINGS & SEALSOFFSET HARSH CONDITIONSA large petrochemical plant increasedthe service life of its equipment from sixmonths to three years.
By Tom McDermott, SKF USA Inc.
42 SOLVING SEALING PROBLEMS BYKEEPING FACES CLOSE & PARALLELAdvances in seal ring and face materialscan improve basic design issuesassociated with mechanical seals.
By Mark P. Slivinski,Carbide Derivative Technologies Inc.
84
32
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Motors and drives, the key components of yfacility, can be prone to a number of unse
problems causing costly downtime.
Download Fluke’s most popular applicationote that discusses:
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8 NEWS
April 2016 | Pumps & Systems
BRYCE W. DAVIS
& JEFF KOEHLER
WATER PLANET
LOS ANGELES (Feb. 29, 2016)
Water Planet announcedthat Bryce W. Davis, Ph.D.,and Jeff Koehler, Ph.D.,
joined its growing team.Davis, who possesses a
doctorate in analytical chemistry, joined Water Planet as aresearch and development (R&D) scientist. Previously, he was aprincipal engineer at Polymer Group Incorporated, an applicationengineer for Fiberweb plc. and a materials scientist with FibeRioTechnology Corporation. Koehler is product development specialisttechnical liaison for commercialization of Water Planet’s PolyCeramembranes. Previously, Koehler was principal scientist anddirector of process development at NanoH2O Inc./LG NanoH2O, andprincipal scientist at Nanostream Inc. waterplanet.com
JOE ACCETTA, KALENBORN ABRESIST
URBANA, Ind. (Feb. 26, 2016) – Joe Accetta,president of Kalenborn Abresist Corporation,has announced that he will be retiring in May
2016. Accetta, a 1973 graduate of NorthwesternUniversity, was originally employed as vicepresident of sales in 1983 and was namedpresident in 1990. He has served in thatcapacity for 26 years. For 10 years prior to1983, Accetta was involved in the sales andAbresist product management for M.H. Detrick, an early jointventure partner in Kalenborn Abresist Corporation. abresist.com
CHRISTOPHER BRIDGEWATER
CORNELL PUMP
CLACKAMAS, Ore. (Feb. 25, 2016) – CornellPump has announced that ChristopherBridgewater has joined its team as Southwestagricultural regional manager, with
responsibilities for irrigation, farm dewateringand manure in California, the desert Southwestand the Mountain West. He has more than 20years of experience in the industries, workingin the supply chain process from manufacturing to installation.He has spent the last nine years as a territory manager, increasingsales in his area by more than 600 percent. cornellpump.com
JOHN TOMLJENOVIC, MIKE MURRAY & KEVIN MOLONEY
SUMMIT PUMP INC.
GREEN BAY, Wis. (March 1, 2016) – John Tomljenovic is SummitPump Inc.’s newest addition as Western regional sales manager.Tomljenovic is responsible for the Western region of the U.S.,
Western Canada and all of Mexico. He has more than 25 yearsof experience in direct sales and sales management in themechanical seal business. Mike Murray has transitioned fromdirect sales to Midwest regional manager. He has more than 30years of direct professional experience in pump sales, applicationsand troubleshooting. Kevin Moloney is the Eastern regional salesmanager and has responsibility for the Eastern U.S., Canada andportions of the Caribbean. He has more than 30 years of pump andmechanical seal experience. The regional sales managers report to
Jim Elsey, general manager for Summit Pump.summitpump.com
NATHAN OLDS, GRUNDFOS
DOWNERS GROVE, Ill. (Feb. 11, 2016) – GrundfosPumps Corporation has appointed Nathan Oldsas the vice president of Domestic BuildingServices (DBS) Trade for the U.S. In this role,Olds will manage wholesale distribution for thecompany’s heating and plumbing products. Hewill report to the DBS executive vice president,Terry Teach. us.grundfos.com
STEVE BASCLAIN, PSG EBSRAY
OAKBROOK TERRACE, Ill. (Feb. 10, 2016) – PSGhas appointed Steve Basclain to business
development manager for PSG Ebsray. In thisrole, Basclain will help drive new businessopportunities for the Ebsray brand and supportthe PSG sales teams globally while directing thefunctional areas of applications engineering,customer care, contracts, product managementand aftermarket. He will report directly to John Cosgrove, generalmanager for PSG Ebsray. psgdover.com/en/ebsray
ANTHONY MISIAK
& JEFF DAVIS
TSURUMI PUMP
GLENDALE HEIGHTS, Ill. (Feb.
4, 2016) – Tsurumi Pumphas announced that it hasadded two new regional salesmanagers to its staff. Joiningthe management team areAnthony “Tony” Misiak andJeff Davis. Misiak joined Tsurumi as a regional sales manager inDecember 2015. Misiak will be based in Byron Center, Michigan,and he will be responsible for the Midwest region. Also joiningTsurumi as a regional sales manager is Davis, who startedhis employment in January of this year. He will overseeTsurumi’s Western region and will be based in Lake Sherwood,Missouri. tsurumipump.com
Jeff KoehlerBryce Davis
NEW HIRES,PROMOTIONS & RECOGNITIONS
Nathan Olds
Steve Basclain
Jeff
Davis
Anthony
Misiak
Christopher
Bridgewater
Joe Accetta
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AROUND
THE INDUSTRY
Hydraulic
Institute
Recognizes
Four Industry Leaders
PARSIPPANY, N.J.
(Feb. 24, 2016)
The
Hydraulic Ins t i tute
(HI)
announced
the recip ients o f several awards
and honors during its 2016 Annual
Conference in Tucson , Arizona. Jack
Claxton , vice president of engineering ,
Patterson Pump Company , received HI's
Lifetime Ach ievement Award; Patrick
Hogg , product manager, Nidec Motor
Corporation ,
was
HI's Young Engineer
of
the
Year
award recipient ; Wil l iam
C.
Livoti , business development manager,
WEG
Electric Corporation , received the
organization 's f irst
PSM
Leadership
Award; and Paul Ruzicka , global
COE
residential, commercial wastewater and
chief engineer at Xylem
Inc.
Applied
Water Systems, received the 2015
Member
of
the
Year
award. Claxton
has
more than 40 years of service in
the pump industry and
has
been an
instrumental
HI
mem ber for more
than
30
years.
Hogg has
been involved
with
HI since 2013, is a member of
10
commit tees ,
serves
as a webinar
instructor, and ho lds leadership posit ions
on three committees. Livoti
has
more
than 40 years in the pump indust ry ,
designing, f ield testing , repairing and
troubleshoo ting mechan ical seals ,
compressors , motors and pump ing
systems. The
HI
Board of Directors
selected Ruzicka for his commitment to
HI
in leading and actively participating
in numerous
HI
commit tees in the
advancem ent of the institute's technical
work and guiding young engineers
within the institute's extensive technical
organization. •
pumps.org
US Poll Finds 60 Percent of
Participants Would Pay More
for Secure W ater Service
ALEXANDRIA,
Va.
(Feb. 24,
2016)
-
The
Value of Water Coa lition
has
released the
results
of
a new nat ional po l l
on
publ ic
attitudes ab out water, which found th at
Americans
are
deeply concerned with
the state
of
water infrastructure and
are
will ing to sup port efforts to invest and
mode rnize these systems to ensure and
ma intain reliable water and wastewater
services. Of the part icipants , 9 5 percent
support investm ent in water systems,
and
60
percent said they would pay m ore
for secure water. • theva/ueofwater.org
Flex-Pro ®Peristalt ic
Metering Pumps
provide smooth,
quiet
pumping
act ion and del iver accurate amounts of chemical
to your
system. Three Flex-Pro mod els are of fered, featur ing a broad range
of
output
rates, electronics
options
and features .
Advanced Electronics- wi th Exclusive- Built-in, patented
Tube
Failure
easy access
to controls. Detection.
Mult iple Signal Input and Innovative, Heavy Duty Rotor : Single piece plastic
Output (4-20mA, etc.) . rotor means no flexing and increased accuracy
One Button Prime Mode. with no metal springs or hinges to corrode.
Flex A Prene
Heavy Duty Peris ta l t ic Pump Tubing
Flex-A-Prene ®
s
a mult ichannel pump
tube assembly designed by B lue-White
exclusively for Proseries-M
8
and Flex-Pro•
Peristaltic Metering Pumps . Flex-A-Prene•
is engineered for opt imum performance,
including up to four t imes longer
service l ife than othe r pump
tube assemblies.
pumpsandsystems.com
I
April
2016
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11
pumpsandsystems.com | Apri l 2016
The EcoFlow Seal Flush thermal relief valve automatically and
reliably controls seal water flow and temperature from your double
mechanical seals for a drastic reduction in water consumption
and significant cost savings. A simple installation reduces water
usage and waste water treatment while boosting cost savings:
Immediate, significant reduction in seal water consumption
with no outside power required
No more monitoring and manually adjusting flow
Avoids dry runs and protects seal life
Allows users to leave the water supply on and ensures
water flows only when needed
Reduces pump downtime
Find out how this little valve creates such BIG savings,
visit ThermOmegaTech.com/EcoFlow today.
Little thermal
relief valve.
Big waterconservation
savings.
(877) 379-8258
THE WORLD LEADER IN SELFACTUATED TEMPERATURE CONTROL SOLUTIONS
C i r c l e 1 1 9 o n c a r d o r v i s i t p s f r e e i n f o . c o m .
will help support community-based job creation in U.S. cities and establishnational standards for professionalsseeking to work on GI projects. This
joint effort will support DC Water’srecently announced legal agreement toconstruct large-scale GI to help controlcombined sewer overflows in the Districtof Columbia, according to the groups.wef.org
Private Water Players ReshapeGlobal Desalination, PoseidonEnters Top 25BOSTON (Feb. 3, 2016) – The top 25
desalination system owners, includingboth public and private companies,added a quarter (approximately 25percent) of total capacity additionsin 2015, representing an estimated524,000 cubic meters per day, accordingto a study. Private water players tookan active role in the desalinationmarket in 2015, representing nine ofthe top 10 biggest movers by capacityadditions, according to rankingsreleased by Bluefield Research. Withthe commissioning of its Carlsbad,California, desalination plant, PoseidonResources became the first U.S.company to rank among the top 25private water owners globally,according to Bluefield Research.bluefieldresearch.com
ISA Announces theContinuation of Beamexas its Premier StrategicPartner for CalibrationRESEARCH TRIANGLE PARK, N.C. (Feb.3, 2016) – The International Societyof Automation (ISA) announced thatBeamex, a calibration company withproducts, services and support in 80
countries, will continue to serve asits strategic partner for calibration.Over the past several years, throughthe partnership, Beamex and ISAhave collaborated to provide ISAmembers and customers with access toBeamex’s diverse calibration resources,including publications, case studies,webinars, expert advice and more. Thisannouncement signifies that Beamexwill continue to work with ISA to co-develop informational and educationalresources. isa.org
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12
April 2016 | Pumps & Systems
NEWS
Process Pumps & Steam Turbines
www.snm.co.jp
Generating Power for Human Life, SNM
TOTAL SOLUTIONS APPROACH
SNM is the only manufacturer in the world that produces
API610 process pumps and API611/612 steam turbines in
the same factory. This total solutions approach uniquelyaddresses the needs of the oil and gas industry.
ENERGY-SAVING SOLUTIONS
Mounting data confrms that
energy savings are realized when
old pumps in aging plants are
replaced with high eciency,
latest model pumps. At SNM our
pump products and solutions
address energy-savings concerns
facing clients across the globe.
FACTORY SALES OFFICES
TOKYO, JAPAN
+81-3-6737-2631
HOUSTON, TEXAS
+1-281-990-8594
GLENDALE, CALIFORNIA
+1-818-500-8165
BANGKOK, THAILAND
+66-2-262-0740
HIROSHIMA, JAPAN
+81-823-71-1111 C i r c l e 1 1 8 o n c a r d o r v i s i t p s f r e e i n f o . c o m .
Recommended Practice forMotor Repair Re-Approved asANSI Standard
ST. LOUIS (Feb. 1, 2016) – An updatededition of the only American NationalStandard for repair of motors andgenerators—ANSI/EASA AR100-2015:Recommended Practice for the Repairof Rotating Electrical Apparatus—wasrecently published for use by the repairindustry and its customers. The standarddescribes industry best practices forthe repair, rewinding and testing ofelectrical apparatus in order to maintainor enhance the energy efficiency andreliability of both alternating and directcurrent motors and generators. ANSIrequires that standards be re-approved
at least every five years, promptingthe review and approval of the AR100-2015 edition. The revision introducednew requirements, added or tightenedperformance tolerances in several criticalareas and expanded testing procedures.The standard now includes requirementsrelating to the machining of commutatorsand slip rings, and it establishestemperature limits for the process ofremoving motor windings. Additionalperformance tolerances were addedfor balancing motors rated above 2,500rpm. Finally, testing procedures wereestablished or clarified relating to bearinginsulation, winding surge comparisonand resistance, no-load performance andvibration. ansi.org
To have a news item considered, please
send the information to Amelia Messamore,
MERGERS &
ACQUISITIONS
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Houston Office: 8885 Monroe Road, Houston Texas 77061 USA
Toll Free: 1.888.405.0209 Fax: 713.956.2141
www.pumpworks610.com • twitter: @PumpWorks610
We do it fast and we do it right.
Most pump OEMs make you wait 30 to 50 weeks to deliver
their API 610 compliant single and multistage pumps.
By comparison, the PumpWorks 610 Model PWH andModel PWV standard lead times are 16 weeks or less,
and PWM Multistage pipeline pumps are 28 weeks or less.
In addition, all of our pumps are manufactured in the USA.
PumpWorks 610 offers our online ePOD
Pump Selector to simplify pump configuration
by quickly providing you with pump selection
and performance curves right off of our website – no log in
required.
At PumpWorks 610, you can count on our knowledgeable
staff to ensure that your finished product meets or exceedsyour exact specifications.
Why wait longer to get the pump you need when you need
it? Visit www.pumpworks610.com or call
1-800-405-0209 for more information.
PWH API 610 OH2Pumps Deliveredin 16 Weeks
PW-11 API 610 OH2Pumps Deliveredin 2-4 Weeks
PWD API 610BB1Deliveredin 26-28
Weeks
PWI-BB API 610OH3 & PWI API 610OH3Deliveredin 16-18
Weeks
PWM API 610 BB3
Delivered in 26-28 Weeks
PWV API
610 VS6 & VS1 PumpsDelivered in16 Weeks
Now with offices in Dubai UAE
PumpWorks 610
delivers.
C i r c l e 1 0 9 o n c a r d o r v i s i t p s f r e e i n f o . c o m
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14 NEWS
April 2016 | Pumps & Systems
Reliable Plant 2016 April 5 – 7, 2016Kentucky InternationalConvention CenterLouisville, Kentucky 800-597-5460 / conference.reliableplant.com
PumpTec 2016(Advanced Training) April 6 – 7, 2016 Atlanta, Georgia770-310-0866 / pumpingmachinery.com/pump_school/pump_school.htm
Offshore Technology ConferenceMay 2 – 5, 2016NRG ParkHouston, Texas972-952-9494 / 2016.otcnet.org
2016 EASA ConventionJune 12 – 14, 2016Metro Toronto Convention CentreToronto, Ontario314-993-2220 / easa.com/convention
National Fire Protection AssociationConference & ExpoJune 13 – 16, 2016Mandalay Bay Convention CenterLas Vegas, Nevada800-344-3555nfpa.org/training/conferences/conference
American Water Works AssociationAnnual Conference & ExhibitionJune 19 – 22, 2016McCormick PlaceChicago, Illinois
800-926-7337 / awwa.org
World Nuclear ExhibitionJune 28 – 30, 2016Paris Expo - Le Bourget, Hall 2BParis, France33 147 56 65 37 / world-nuclear-exhibition.com
INDOWATER 2016July 20 – 22, 2016Grand City ConvexSurabaya (East Java), Indonesia+49-40-3999905-0 / indowater.com
(Image Courtesy of Corp orate Event Images)
The Offshore Technology
Conference (OTC) 2016,
the offshore energy industry’s
premier annual event, will
take place May 2-5 at NRG
Park, formerly Reliant Park,in Houston, Texas. is year’s
theme is “Endless Innovation.”
Sponsored by 13 nonprofit
technical societies involved
in the energy business, OTC
2016 is an opportunity to gain
technical knowledge, learn
more about best practices and
see new products and services.
More than 90,000
professionals—including
industry leaders, investors andentrepreneurs—from more
than 130 countries are
expected to attend. is year’s
event is expected to include
more than 2,100 exhibitors
from 45 countries and 18
international pavilions.
OTC offers learning
opportunities that include a
technical program featuring
global experts and topics
spanning risk management,
new and emerging markets, and
the operation of aging fields
and hardware.
e event will offer training
courses on deepwater riser
engineering, marine broadbandtechnologies and petroleum
geology for engineers. Courses
will be held at the George R.
Brown Convention Center on
the days before and the day
after the conference.
Other events and activities
at OTC 2016 include the
Distinguished Achievement
Awards Luncheon at the NRG
Center on May 3.
e second d5 conference—an OTC event designed to spark
creativity and innovation in
the industry—will be at Rice
University on May 6. Speakers
will include Helen Greine,
co-founder of iRobot and CEO
of CyPhyWorks; Ram Shenoy,
former chief technolog y offi cer
at ConocoPhillips; and Gindi
Vincent, an author, speaker and
counsel at ExxonMobil.
For registration or more
information about OTC 2016,
call 972-952-9494 or visit
otcnet.org.
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Monday, May 29 a.m. to 5:30 p.m.
Tuesday, May 39 a.m. to 5:30 p.m.
Wednesday, May 49 a.m. to 5:30 p.m.
Thursday, May 59 a.m. to 2 p.m.
EVENTS
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8/18/2019 PumpsAndSystems April
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Letter from a Reader:Vibration Spectrum Analysis
Regarding the vibration
spectrum on page 12 of
the February 2016 issue
of Pumps & Systems (“Using Pump
Effi ciency Monitoring to Make
Faster Decisions,” Figure 1), your
question of what the spectrum is
showing needs more information
to enable an accurate answer:
• Where is the sensor located?
• What kind of pump?
• What is the orientation of the
sensor? X, Y or Z axis?
• Is the data averaged, peak hold
or instantaneous?
• Is the pump speed constant
or changing?
• Is the flow steady or changing?• How many vanes are on
the impeller?
• Are the units root mean square,
peak or other?
• What is the power required by
the pump?
• Is this a Category I or II pump
per International Standards
Organization (ISO) 10816-7?
Making some assumptions
about the data, an unbalance
problem appears to be present. It
is not misalignment or cavitation.
However, if you look at the
spectrum, there is a slight peak
just above one time per revolution
at maybe 70 hertz (Hz). is could
be resonance. If so, the running
speed is less than 20 percent away
from this natural frequency, and
the response could be amplified by
this resonance. While unbalance
is indicated, it may be a resonance
problem, and balancing is not, in
my opinion, a permanent fix.
Assuming this is a small pump,
judging by the operating speed, the
amplitude is probably acceptableper ISO 10816-7. e overall level
of vibration is probably less than
0.098 in/s-RMS, which is the Zone
A/B boundary for new machines.
But if the small peak at 70 Hz is a
resonance, then all bets are off. If
I were the end user, I would not be
happy with a resonance less than
20 percent above running speed. As
the machine wears, the resonance
will drop in frequency, potentially
to the point where the running
speed will sit right on the natural
frequency. With the low amount of
damping present in the spectrum,
this would create amplitudes well
in excess of the ISO 10816-7 limit.
—Reader from California
Nelik’s Response
Let me start with your ending
notes first: very observant! e
small peak just past the 1X is a
potential problem. With wear and
lowered stiffness of the system over
time, the 70 Hz peak may creep
right onto the 60 Hz resonance.
Frequent or even continual
monitoring would be important.e values are still small, and the
unit is small, judging from data
shown on the performance curve
above the spectral plot. Unbalance
(1X) is small, but the proximity to
the possible critical frequency may
lead to issues—though it is hard to
predict how soon. While immediate
pump pull and fix is not necessary,
monitoring is.
Making some assumptions about the data, an unbalance
problem appears to be present. It is not misalignment or cavitation.
However, if you look at the spectrum, there is a slight peak just
above one time per revolution at maybe 70 hertz (Hz). This could be
resonance. ... While unbalance is indicated, it may be a resonance
problem, and balancing is not, in my opinion, a permanent fix.
16 PUMPING PRESCRIPTIONS
April 2016 | Pumps & Systems
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
Troubleshooting & repair challenges
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Circle 145 on card or visit psfreeinfo.com.
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PUMPING PRESCRIPTIONS
Regarding
your other points, the
location of
the
sensor is relevant,
but
they
are
most often on bearing housings.
The type of pump would
not
make much
difference,
although if it
is ver t ica l ,
then
any unbalance would be a serious i ssue .
Impeller
wear
way below the soleplate
is
not
often detectable by
the
analyzers
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I Pumps
Systems
Circle
34
on card or visit psfreeinfo.com.
at the top of the structure motor
area),
and
vertical turbine vibrations are
not easi ly detectable
by
the
vibration
instruments at the
top.
Your point on
sensor
location has
another important
aspect. If
the
signal
comes
from
the axial direction,
then
the
angular misalignment
may
be
an
i ssue , which is often
shown
not as a
2X but a
lX
component. In such cases,
having
another
sensor direction
is
important. f it is
at the
offset direction
(para l le l
of
vertical,
for
example)
and
s h o w s 2X (twice
running
speed) , then
misalignment
is l ike ly (presence
of
lX
and 2X).
The pump
speed
is constant in this
case, but
the
cloud of higher head
data
is
an
indication of
the second pump
joining
in at some
time,
with two of
them
now
generating higher head,
but at a flow
only slightly
higher-a
typical situation
with
two pumps
running in para l le l .
Vibration data are
at
RMS, as shown
at the vertical
axis . The
pump
is
small,
and vibrations are wel l within
the
limits, as you
noted.
Interest ingly, the
resonance
concern was expressed
in
this
particular case, which is why
continual
monitoring is planned .
Thank you for
your insightful
comments and observations . f you
want
to be
involved in
our committee
work, let me know, and we wi l l get you
involved . For more
information, visit
pumpingmachinery.com . •
Dr. Nelik
(aka
Dr.
Pump ) is president
of Pumping Machinery,
LLC, an
Atlanta-based firm specializ ing in
pump consult ing, t ra in ing, equipment
troubleshooting and pum p repairs.
Dr.
Nelik has 30 years of experience in
pumps and pumping equipment. He
may be reached at pump-m agazine.
com. For more in format ion, v is i t
pumpingmachinery .com/pump_school /
pump_school .h tm.
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Circle 103 on card or visit psfreeinfo.com.
8/18/2019 PumpsAndSystems April
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Examine Pump, Process & Control Elements toSolve Fluid Piping System Problems
My past Pumps & Systems
columns have dealt with
using basic engineering
principles to better understand the
interaction of pump, process and
control elements in fluid piping
systems. e articles demonstrate
how to hone your troubleshooting
skills while improving the
operations of piping systems.
is month, we will start
demonstrating how to use this
knowledge to work through
problems on real-life systems.
I am not calling them case
studies because case studies
provide a system description,
as well as information on the
company, the plant facility, theproblems encountered and maybe
even the people involved. is
degree of detail requires multiple
levels of permission—even before
the lawyers take a look at it.
Instead, I will use the line
from the movies: “Based on an
actual event.” In this column, all
the names and places have been
omitted, but the other pertinent
facts are presented. ese columns
are based on actual systemproblems I have encountered in
my 45-year career in operating,
designing, testing and supporting
fluid piping systems. Many of the
examples come from technical
support questions from our
software users and feedback from
our piping system training classes.
Increasing System Flow Rate
In the late ’90s, I was working
with an electrical utility in British
Columbia that had a program to
help its large utility customers
reduce their plants’ energy
consumption. e utility would
evaluate a customer’s pump
systems to see what could be done
to reduce energy consumption.
I got a call from the consultant
performing the analysis on a water
makeup system in a nickel mine,
where water was pumped from
a river to the mill through a
5-mile pipeline.
Over the years, the plant’s river
water requirements increased.
e sales engineer for the vertical
turbine pump manufacturer was
called in each time. e increased
A better understanding of complete system operation
Figure 1. Flow diagram showing the mine water piping system with calculated results(Graphics courtesy of the author)
Figure 2. Pump curve for one of four identical 10-stage vertical turbinesfor the river water system
20 PUMP SYSTEM IMPROVEMENT
April 2016 | Pumps & Systems
By Ray Hardee
Engineered Software, Inc.
8/18/2019 PumpsAndSystems April
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system capacity was accomplished byadding stages to the existing vertical
turbine pumps, as well as adding
new pumps. When I was called, four
10-stage vertical turbine pumps
were providing approximately 4,100
gallons per minute (gpm) of river
water to the mine with a fifth pump
on standby.
e Total System
e utility’s consultant modeled
the river water system using acommercially available piping
system simulation program. e
river water level was 100 feet above
sea level, and the elevation of the
mine reservoir liquid level was 435
feet. e supply header was 12-inch
steel schedule 40 pipe with a length
of 21,000 feet from the river to the
mill. e consultant built the system
model and asked me if I would look
at his results (see Figure 1).
e first thing I asked was if hehad an accurate pump curve for the
installed vertical turbine pumps. He
did and provided me with a copy (see
Figure 2).
I then asked how the model’s
calculated results matched the
physical system. He said the only
system instrumentation was
a pressure gauge on the pump
discharge header reading 430
pounds per square inch (psi), which
closely matched the simulation’scalculated results. He also
mentioned that he double-checked
the river and tank elevations, pipe
lengths and pipe diameters based on
existing design documents, and they
were correct.
e fact that he had a
manufacturer’s supplied pump curve
and that the actual pump discharge
pressure closely correlated with the
calculated pump pressure indicated
that the model closely resembled
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21
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the physical system. With an accurate system model,
proposed system changes could be evaluated.Each of the four pumps were supplying 1,043 gpm,
which is within the manufacturer’s allowable operating
range. But with the pump’s best effi ciency point (BEP)
flow of 2,600 gpm, this represents only 40 percent
of the pump’s BEP flow—well outside the preferred
operating range recommended in the American
National Standards Institute/Hydraulic Institute
(ANSI/HI) 9.6.3-2012 Rotodynamic (Centrifugal and
Vertical) Pumps – Guideline for Allowable Operating Region
standard. Running a pump this far from its BEP can
cause premature bearing and seal failure.
Next, I looked at the flow rate through the supply
header. With 4,200 gpm through the 12-inch diameter
pipeline corresponding to a fluid velocity of 12 feet per
second, the result was a dynamic head loss of 660 feet
in the pipeline. is head loss added to the 335 feet of
system static head results in a required pump head of
1,000 feet.
Considering the Options
e flow rate in the river water system needed to be
increased to 4,500 gpm. As previously stated, a fluid
piping system is made of the pump, process and control
elements. Increasing the flow rate to 4,500 gpm in the
existing system resulted in a head loss in the supply
header of 767 feet, or a total pump head of 1,102 feet.
Each element affects the total system operation, and
when users need to increase the system flow, their first
thought is to call the pump manufacturer.
Pump Option
When the pump manufacturer was called, he stated that
the existing pumps could not meet the head required for
the new flow rate because the installed vertical turbine
pumps were not designed for more than 10 stages.
Additional pumps were not an option because there
was no space in the pump house for the added pumps. As a result, the pump sales representative suggested
replacing the existing pumps with higher-capacity
pumps. e plant’s utility manager was concerned the
larger pumps would increase the site’s electrical utility
demand charges.
Process Option
In this system, the process elements consist of the river,
mine reservoir and the interconnecting piping complete
with valves and fittings. Because the fluid velocity in
the 12-inch supply header was so great, installing a new
C i
r c l e 1 3 7 o n c a r d o r v i s i t p s f r e e i n f o . c o m .
22 PUMP SYSTEM IMPROVEMENT
April 2016 | Pumps & Systems
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pipeline parallel to the existing pipe was considered.
is would allow for a greater flow rate and minimizethe head loss in the supply header.
System Evaluation
e cost to operate the existing system with four pumps
running 8,000 hours per year with a power cost of $0.03
a kilowatt/hour was approximately $358,000 per year.
Installing a 20-inch pipeline in parallel to the existing
supply header resulted in a head loss in the supply
header of only 51 feet. As a result, the new pump head
requirement was only 406 feet.
Discussions with the pump supplier determined that
two of the existing pumps with only five stages per
pump could deliver 2,350 gpm with 390 feet of head,
resulting in a total system flow rate of 4,700 gpm. e
existing pumps have an effi ciency of 83 percent at
this flow rate, resulting in an annual operating cost
of $106,000. is created an annual energy savings of
more than $250,000 across the existing system.
e cost to replace the five existing pumps with new,
larger pumps to meet the increased system flow rate
and head was in the same price range as adding the
20-inch pipeline. Because the addition of the pumps
would do nothing to reduce the energy consumption
of the existing system, the client decided to install the
pipeline instead of considering pump replacements.
After the client had instal led the pipeline in parallel,
I called to see how the system changes had turned
out. He sent me an as-built model of the system, and
I noticed that the last 3,000 feet of the new pipeline
was 24 inches in diameter. I asked if there was a reason
for the larger pipe diameter in the new pipeline. He
responded that they had purchased all the 20-inch pipe
in Western Canada and wanted to get the improvement
made as quickly as possible, so they purchased 24-inch
diameter pipe for the remainder. In addition, the utility
documented the $250,000 savings in energy cost.
As you can see, there are three elements in a fluidpiping system. As they all work together, they have an
effect on how the system operates. It is best to consider
all options when looking at any piping system.
Ray Hardee is a principal founder of Engineered
Software, creators of PIPE-FLO and PUMP-FLO software.
At Engineered Software, he helped develop two training
courses and teaches these courses internationally. He may
be reached at [email protected].
C i r c l e 1 3 3 o n c a r d o r v i s i t p s f r e e i n f o . c o m .
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COMMON PUMPING MISTAKES
Submergence is a
commonly overlooked
pump suction side issue
that can create mechanical and
hydraulic performance problems.
Insuffi cient submergence can leadto increased vibration, a broken
shaft, shortened mechanical seal
life, premature bearing failure,
lower flow rates and diminished
discharge heads (pressure) for the
pump. In the worst cases, these
issues will cause surging and will
actually stall (air block) the pump.
Submergence (simple
submergence) is defined as the
distance (D) measured vertically
from the surface of the liquid to thecenterline of the inlet suction pipe.
A more important term is required
submergence, also known as
minimum or critical submergence
(SC). Required submergence is
the vertical distance—from the
fluid surface to the pump inlet—
required to prevent fluid vortexing
and fluid rotation (swirling and
or pre-swirl). Vortexing will
introduce unwanted air and non-
condensable gases, which can causepump damage and reduce pump
performance. A centrifugal pump is
not a compressor, and performance
is greatly affected when pumping
dual and/or multi-phase fluids (gas
and air entrainment in the fluid).
A common misconception is that
inadequate submergence issues are
found only on vertical and/or very
large pumps. is issue, however,
can and will occur on small and/or
horizontal pumps.
When a centrifugal pump
operates at a given flow rate (Q),
there is a corresponding fluid
velocity in the suction line (V). You
can calculate this velocity easily
by using Equation 1 or by simply
looking it up in references such as
Cameron Hydraulic Data (Chapter 3)
or Crane Technical Paper No. 410,
Flow of Fluids.
e velocity of the fluid is an
important value to know because
it will determine the correct
submergence required to prevent
the formation of vortices.
Figure 1 shows two separate
cases; both are for a flow rate of
300 gallons per minute (gpm),
but the suction pipe diameter is
4 inches in one case and 6 inches
in the other.
Using Equation 1 and Figure 1,
we can see that the 4-inch pipe
yields a velocity of 7.7 ft/s, and
By Jim Elsey
Summit Pump Inc.
Guidelines for Submergence & Air Entrainment
Figure 1. General guide for minimum submergence based on fluid velocity(Courtesy of the author using data from Hydraulic Institute)
V =
Equation 1
Where:
V = velocity in feet per second (ft/s)
D = suction pipe diameter in inches
(GPM) X (0.4085) ÷ (D) 2
April 2016 | Pumps & Systems
24
Simple solutions for end users
D = (0.0744 Q) 0.5
Equation 2
Where:
D = recommended suction inlet pipe size in
inches
Q = the flowrate in gpm
8/18/2019 PumpsAndSystems April
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the 6-inch pipe yields a velocity of 3.4 ft/s. Note the
difference in velocity between 4- and 6-inch piping
for a flow rate of 300 gpm. Figure 1 indicates thatthe required minimum submergence for the 4-inch
pipe at a velocity of 7.7 ft/sec will be about 4.5 feet.
e minimum submergence for the 6-inch pipe at a
velocity of 3.4 ft/sec will be less than 2 feet. In other
words, for a given flow rate of 300 gpm and a suction
pipe diameter of 4 inches, a minimum of 4.5 feet of
liquid above the inlet pipe will be required at all times
to prevent the risk of air entrainment due to vortex
formation. But if the suction line diameter is 6 inches,
2 feet of submergence will be required to preclude
vortex formation. at is a difference of more than
2.5 feet.If you have the 4-inch diameter suction pipe at 300
gpm but cannot raise the suction side fluid level to
mitigate air entrainment, you can add a 6-inch suction
bell to the 4-inch pipe inlet to reduce the velocity
at the entrance and, in essence, fool the system to
prevent vortexing. Addition of the 6-inch suction bell
will reduce inlet velocity to 3.4 ft/sec and reduce the
minimum required submergence to less than 2 feet. If
a suction bell cannot be added, then a barrier (anti-
vortex device such as floating or submerged rafts or
fixed baffl e plates) that presents a torturous path may
also be installed.
Note that, while the barrier may preclude vortices,
swirl and turbulence in the fluid stream can still
present unbalance issues with the impeller. e size
of the barrier can be calculated by knowing the added
submergence required and then sizing the barrier to
make the fluid take that same length of travel. Proper
placement and location of the barrier is important;
if you are not comfortable or experienced with this
subject, please consult someone who is. I am reminded
of an incident at a nuclear power plant 36 years ago
when I, as the factory field engineer for the pump
manufacturer, advised the user not to place a 12-foot
A common misconception is that
inadequate submergence issues
are found only on vertical and/
or very large pumps. This issue,
however, can and will occur on
small and/or horizontal pumps.
C i r c l e 1 2 1 o n c a r d o r v i s i t p s f r e e i n f o . c o m .
25
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COMMON PUMPING MISTAKES
I-beam near the suction of the vertical pump.
e user determined that I was wrong andsought to block any vortices while measuring
flow. He securely attached the flow meter to the
large beam and placed it near the pump suction.
Less than 3 seconds after the pump was started,
the beam became an integral part of the suction
bell and the impeller.
Besides inadequate submergence issues,
air and non-condensable gases can enter the
fluid in other ways. Liquid can fall from above
the suction tank/sump (e.g. cooling tower), or
agitation can occur in the upstream process.
Sometimes air or gases are introduced on
purpose as part of a process requirement (e.g.
pulp slurry recycling). An additional issue is
having a suction tank/sump that is not sized
properly. A properly sized tank/sump will, by
design and with respect to volume and geometry,
allow for suffi cient transient time (hold time) for
the fluid to facilitate the escape of entrained air
prior to entering the pump suction.
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Circle 130 on card or visit psfreeinfo.com.
12 TIPS TO REMEMBER
1 Critical submergence (SC) must be greater than simplesubmergence to prevent vortex formation, but it is still not aguarantee of vortex preclusion.
2 Pumps that are larger, vertical and/or with impellers of higherspecific speeds are generally more sensitive to submergenceissues, but all centrifugal pumps are susceptible.
3 Opening impeller clearances by a factor of three to four timesthe normal measurement can allow air and gas to pass throughthe pump with fewer negative effects, but the efficiency, relatedbrake horsepower and cost of operation will be greatly affected.Do not open clearances without consulting the OEM first.
4 There are various stages, strengths and states of vortex
generation including incipient, invisible, surface and subsurface.Just because the vortex is not visible to the naked eye does notmean it is not present. The vortex size is a function of the residualangular momentum of the fluid at that point.
5 In respect to suction tank or sump design, if the intake pipe ishorizontal, a vertical wall (90 degrees) is better than one with aslope (less than 90 degrees).
26
April 2016 | Pumps & Systems
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6 When referencing charts for calculating minimumsubmergence, keep in mind that the assumption is thatno obstructions or asymmetrical geometries are in thetank/sump.
7 Do not confuse submergence with net positive suctionhead available (NPSHA). I always recommend that bothvalues be calculated for the worse expected condition.You can have adequate NPSHA and still not have propersubmergence and vice versa.
8 Critical submergence is a function of factors besides thevertical distance and the acceleration of gravity. Otherfactors are surface tension, viscosity, density and thediameter of the suction pipe opening, especially if there
is a transition to a smaller-diameter pipe shortly afterthe initial opening. Pay specific attention to the ratio ofthe diameter changes. With surface tension, it is a verysmall factor. In the case of viscosity, it will depend onthe Reynolds number, which is defined as the ratio ofmomentum forces to viscous forces and quantifies therelative importance of these two types of forces for givenflow conditions. Think of it as the amount of turbulence.
9 In some cases, you can have too much submergencefor a given system design, from the aspect of siphoneffects. This is rare.
10 Suction (pipe) velocities to the pump should be keptbetween 5 and 8 feet per second. I recommendnot more than 6 feet per second unless there is arequirement for suspended solids (critical carryvelocity) and other slurry rheology concerns.
11 The suction tank/sump should be sized and designedso that the volume has five to eight minutes of holdtime. For example, if the pump is designed for 200gpm then the tank should be 1,000 to 1,600 gpm in
effective volume. Proper addition of barriers, bafflesand weirs can reduce the required size.
12 As a general guideline only, the recommended suctioninlet pipe size (D) can be calculated using Equation 2(see page 24). I always recommend rounding D up tothe next pipe size, not down.
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COMMON PUMPING MISTAKES
Dissolved air and gases will come
out of solution at the eye of the
impeller because that is typically the
lowest pressure area. e amount of
dissolved air and gases coming out of
solution will be a function of suction
pressure. e higher the pressure, the
less likely the gases will be released.
Note that many manufacturers have
successfully injected 1 percent air
into the pump suction to address
chronic cavitation problems. At air or
gas amounts higher than 1 percent,
performance issues will occur. As a
general guideline, 2 percent free air
will reduce pump flow by 10 percent,
and 4 percent air will reduce the
flow by more than 40 percent. e
degradation in pump performance
is dependent on the fluid properties,
pump design, impeller geometry and
clearances. Pump performance will
not get better with more entrained air
and gas. As a guide, most centrifugal
pumps will lose the majority of their
performance between 6 and 12
percent air entrainment. e average
pump will likely fail to operate at 14
percent air entrainment. Some pump
designs that use vortex impellers,
recessed impellers, separation
chambers or air escapes can handle air
entrainment up to 24 percent.
References
Hydraulic Institute and ANSI Specification 9.8
Hydraulic Intake Design
Ingersoll-Rand Cameron Pump Division white
paper: Pump Intake Design
e Pump Handbook, 4th ed ition, Paul Cooper
& Charles Heald et al.
Jim Elsey is a mechanical engineer
who has focused on rotating
equipment design and applications
for the military and several large
original equipment manufacturers
for 43 years in most industrial
markets around the world. Elsey
is an active member of the
American Society of Mechanical
Engineers, the National Association
of Corrosion Engineers and the
American Society for Metals. He isthe general manager for Summit
Pump Inc. and the principal of
MaDDog Pump Consultants LLC.
Elsey may be reached at
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April 2016 | Pumps & Systems
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Process equipment represents
an enormous investment
for manufacturers, with
medium to large plants having
thousands of assets that support
the supply chain, production and
distribution. All equipment must
be managed effi ciently to ensure
reliability and productivity. is
is a priority for industrial plants
as they seek to move from reactive
and preventive maintenance
approaches to predictive.
According to ARC Advisory
Group, the growing number of
plant assets coupled with the
reduction in skilled labor means
there are 500 to 2,000 process
control loops per technical staff
member. Maintenance personnelare responsible for the associated
equipment for an individual loop,
including instruments, valves and
pumps, making it increasingly
diffi cult to manage plant assets
using in-house staff alone.
With baby boomers retiring
at the rate of 10,000 per day,
industrial plants are relying on
automation solutions to manage
assets. is dependence is also
driven by aging infrastructure,competitive market pressures,
environmental regulations and
shrinking profit margins.
Predictive Maintenance
e growing use of predictive
analytic software, wireless sensors
and cloud computing, as well as
other information technology
advances, is a key enabler.
ese technologies broaden the
scope of real-time performance
monitoring and machine-
to-machine communication,
which, in turn, supports
the evolution of predictive
maintenance approaches. In some
cases, equipment can also be
self-repairing.
Accurately predicting remaining
useful life helps streamline
the supply chain with the right
parts arriving for scheduled
replacement. Unscheduled
downtime and inventory costs
are minimized. Suppliers can
better support equipment using
remote diagnostics.
In the future, predictive
maintenance systems will collect
real-time and historical data, apply
analytics, and assess the healthof the equipment and the entire
production process. e systems
will prioritize maintenance
and operator actions based
on criticality and recommend
corrective actions. ese expanded
capabilities will enhance
maintenance and operating
decisions while providing
critical equipment information
to process control and business
systems. Plant managementand engineering can make more
informed decisions related to
capital budgets and long-term
modernization plans.
Intelligent Pump Control
A common application of
intelligent pump control is a
parallel pumping system such as a
cooling tower. Parallel systems are
designed to provide incremental
flow by turning multiple pumps
on or off to meet changing system
demand. Cooling tower systems
are common across manufacturing
facilities that use heat exchangers.
ese applications offer an
opportunity for industrial plants
to reduce energy consumption and
improve reliability.
For example, multi-pump
application of intelligent
variable frequency drives (VFDs)
represents the convergence of
pump and automation technologies
for predictive maintenance. e
pump intelligence embedded in the
drive’s microprocessor allows the
pump to identify conditions such
as dry running, dead-heading and
cavitation in real time. Conditions
can be communicated via a digitalbus back to the distributed control
system (DCS) for display and
alarming. e operator can quickly
take corrective action either
by making adjustments to the
system at the DCS console or by
automatically generating a high-
priority work order requesting
system maintenance.
e individual drives are
interlinked and can be configured
to automatically change thelead and lag pump(s) at regular
intervals to even mechanical
wear over time. If one pump fails,
the system can automatically
synchronize and adjust individual
pump speeds to ensure that flow
demand is maintained.
Multi-pump control maintains
stable process conditions, which
optimizes the number and speed
of pumps needed and offers
smooth startup and shutdowns
The Future of Predictive Maintenance
30 INDUSTRY INSIGHTS
April 2016 | Pumps & Systems
By Mike Pemberton
Pumps & Systems Senior Technical Editor
Trends & analysis for pumping professionals
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because there is no need for aseparate control logic in the
DCS. e drive’s intelligence
also operates the pumps in the
most energy-effi cient manner,
allows redundancy and provides
the capability to mix pumps
of different sizes and powers
(although the ideal system
configuration has identical
pumps). While the multi-pump
intelligence is embedded in
the VFD microprocessor, theintelligence could also be in
the DCS microprocessor or on a
server in the cloud. While this is
a special case of using embedded
intelligence to control a multi-
pump system, the future will see
broader use of data to empower
predictive analytic software forplant-wide asset management.
Facilities will be able
to implement mechanical
systems that self-diagnose
and automatically adapt to
equipment failure and process
upsets. Compared with fixed-
speed systems, the broader use
of variable speed pump systems
requires smaller motors, allows
removal of the control valves
at the pump discharge andprevents the need for supporting
infrastructure such as pneumatic
lines and control wires. Wide
application of variable speed
technology will dematerialize the
process and reduce maintenance
and operating costs.
In these scenarios, facilitiescan continuously monitor assets
and make system adjustments
over a wireless or wired network.
Service technicians, whether
on or off site, will eventually
be able to use 3-D printing to
produce standard or custom
parts and ship them in a timely
manner. ese advancements and
others will al low plants to work
within budgetary constraints
and overcome barriers caused bylimited resources.
Mike Pemberton is the senior
technical editor for Pumps &
Systems. He may be reached at
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April 2016 | Pumps & Systems
32
ouston, Texas, gets hot during the summer,
with temperatures exceeding 95 F (36 C) in
August and 90 F (33 C) for an average of 102
days a year. While air conditioning helps to
make life tolerable during Houston’s hot, humid days,
there is no such relief for pipelines that are pumping oil
and gas products.Keeping pipeline components in optimal condition is
a constant challenge for oil and gas companies that must
contend with the effects of rising temperatures on liquid
pump seals.
Recently, one company solved a similar problem with
the seals on its ethane pumping system by incorporating
a dry gas seal in a liquid-pump application.
e end user, located in Houston, operates natural gas
liquid (NGL) fractionation facilities, where it processes
mixed NGL streams into purity NGL products including
ethane, propane, normal butane, isobutene and natural
gasoline. A crucial part of its operation is the ethane
injection pumps that pump ethane from 410 pounds per
square inch (psi), or 28 bar, to about 1,100 psi (76 bar).
While the ethane temperature at suction should be
approximately 60 F (16 C) on a typical warm, Houston
summer day, this temperature can increase dramatically.
e increased temperatures result in seal failure, which
can cause ethane to vaporize—resulting in product loss.
Why Liquid Pump Seals Fail
When operating rotating equipment, some end users
do not pay enough attention to transient conditions.
Startup, slow-roll and standby pump conditions must be
evaluated to ensure proper sealing fluid is being supplied
to the seals at all times.
Here is what to look for when evaluating proper liquid
seal function, highlighting some problems that can occur:
• Startup: e pump is charged, but at or near suction
pressure. Liquid ethane at the seal faces is slowlyleaking and vaporizing. When the pump starts,
how long does it take to build the right pressure in
the stuffi ng box and get the pressure above vapor
pressure? Additionally, the heat generation between
the faces, although not significant, could be enough to
increase vapor pressure and vaporize the fluid across
the faces. Damage to sealing faces could be a telling
sign that this is occurring.
SPECIAL SECTION
SEALING CHALLENGES
Image 1. Typical design of a dry gas seal (Image and graphiccourtesy of EagleBurgmann)
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33
• Slow-roll: e same situation as startup but
compounded. Without the right speed, the discharge
pressure is not generated. e pressure in the stuffi ng
box is not rising quickly enough to ensure the ethanewill reach a high enough pressure to overcome the
vapor pressure. Also, the heat generation between the
contacting faces is increasing, and damage is probably
taking place.
• Standby: All conditions mentioned above are the
same, but the seals are sitting idle for many months
without a flush to the seals. During the standby
time, evidence has shown that debris has collected
at or around the seal faces, which, in turn, adds more
complication to the sealing environment.
• Ineffi cient operation: Operating the pump too far
outside of the best effi ciency range and with the wrongoperating parameters results in increased demand for
drive power and reduced discharge pressure. Both of
these negatively impact the vapor margin in the seal
area, which can result in dry running.
Other transients that play a role in evaluating sealing
fluid are temperature changes in the product, frequent
starts and stops, and operator error. ese situations
can lead to seal failure. At the Houston facility’s ethane
pumping operations, mean time between failure (MTBF)
was averaging a little more than three weeks. Something
needed to be done to prevent seal failure and product loss.
Meeting the Challenge
Low vapor margin applications, such as ethane, have
one thing in common: e liquid would rather be a gas.
For this reason, many end users incorporate liquid-
lubricated gas seals. e manufacturer that supplied
the seals for the facility in Houston, for example, offers
pump seals that run on a gas film between the faces—either a dual pressurized seal using an inert gas or a dual
unpressurized seal with the outboard seal operating on
a gas. A dual unpressurized seal works great in these
applications, but transients and other unknowns can
cause problems. Incorporating a clean gas at the seal faces
helps prevent failure, but certain problems can persist.
When the manufacturer was evaluating these
challenges, the Houston facility’s initial solution was to
use liquid-lubricated seals and take discharge pressure
directly into the stuffi ng box. But the liquid-lubricated
seals continually failed, especially on warm summer days
as the outside temperature rose. e reason had to dowith the inherent nature of ethane.
For ethane to remain in its liquid state, it must be
kept at a certain temperature and a certain pressure
(approximately 300 to 400 psi [21 to 28 bar]) at 60 F
[16 C]). If the pump is operating properly and the pressure
and temperature are at their ideal points, then the
ethane continues to flow as a liquid. But as the outside
temperature rises on a warm day, the pressure and the
temperature of the pump also increase. is causes the
ethane to vaporize at the seal.
Transient ConditionsLiquid-lubricated seals are designed to handle liquids
only; they will fail if they are suddenly confronted with
handling a gas, such as when ethane vaporizes from a
liquid. In reality, a liquid-lubricated seal can be successful
EXAMPLE OF TANDEM SEAL WITH INTERMEDIATE LABYRINTH
1. Seal face, stationary
2. Seat, rotating
3. Thrust ring
4. Spring
5. Shaft sleeve and seat
retainer
6. Intermediate sleeve
7. Housing (adapted in size to
the installation space)
8. “Adjustable” nut for axial
misalignment
9. Split ring
10. Tension ring
11. Cover
12. Process side labyrinth
GBI is gas buffer inlet, GBO
is gas buffer outlet and D is
drain. The yellow parts are
rotating, blue are stationary,
and gray represents pump shaft
and housing.
The details of this seal include:
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April 2016 | Pumps & Systems
34 SEALING CHALLENGESSPECIAL SECTION
in an ethane application, but only
under conditions that do not change.
Because the seal environment kept
changing in the Houston application,the liquid-lubricated seals could not
work properly.
Liquid-lubricated seals work best in
environments where the temperature
and pressure are at a consistent level.
For this end-user’s operations, it wasthe transient conditions that caused
the problems.
For this application, ethane was
sealed. For ethane to become a gas,
it needs a pressure drop or a vapor
pressure increase above the sealingpressure. Heating the fluid is a quick
way to achieve this, but using an
external heater adds complexity and
maintenance. Using a close-clearance,
multi-tooth labyrinth on the front
end of the seal causes the turbulent
flow during operation to create fluid
friction that will build heat. e
rotation of the seal faces also adds
heat. e closer the gap is between the
faces, the smaller the leakage and the
higher the heat generation. But thetransient conditions caused problems.
Relying on rotation to build heat
ignores the effects of startup, slow-
roll and the standby pump.
Dry Gas Seals
e solution—a dry gas seal—was
simple, though a bit unconventional.
is technology is usually not used
in liquid-pump applications, but it
seemed to be a good solution because
the ethane liquid wants to be a gas.Dry gas seals delivered enhanced
reliability in operating modes
where the seal faces are in constant
contact—turning, ratcheting, coast-
down and other operating modes that
create critical conditions for standard
gas seals. Experience has shown that
unexpected operating situations,
such as the transient conditions
the end user was experiencing, can
compromise a gas seal.
Because seal faces are designedprimarily for non-contact operation,
they are subject to wear when there
is contact for sustained periods. is
can cause seal failure resulting in
downtime and production loss.
ese seals featured bonding that
consisted of a micro-crystalline
layer that has attributes of natural
diamond. For example, it will
not flake or chip off, the coating
is extremely hard and wear-
resistant, and it offers excellent
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35
heat conductivity and high c