Pumps & Systems Jan2017

J A N UA R Y 2 0 17
PUMPSANDSYSTEMS.COM
SYSTEMS
The Leading Magazine for Pump Users Worldwide
State of the
INDUSTRY
Are you ready for 2017?
INSIGHT F ROM UP DATE ON PUMP GLOBAL MARKET

INDUST RY EX PERTS EFFICIENCY RULES FACTORS IN 2017
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2 FROM THE EDITOR
EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
W
aarchibald@cahabamedia.com 205-278-2843
ith the arrival of 2017,
SENIOR TECHNICAL EDITOR: Mike Pemberton
the Pumps & Systems staff
mpemberton@cahabamedia.com
wishes all of our readers a happy 205-314-8279
and prosperous new year. The MANAGING EDITOR: Amelia Messamore
past year was marked by a volatile amessamore@cahabamedia.com
205-314-8264
business climate resulting from
MANAGING EDITOR: Martin Reed
ongoing concern over the oil and
mreed@cahabamedia.com 205-278-2826
gas market, as well as political
MANAGING EDITOR: Savanna Gray
unrest in the U.S. and overseas. sgray@cahabamedia.com 205-278-2839
What will 2017 mean for the CONTRIBUTING EDITORS: Lev Nelik,
business landscape? This State Ray Hardee, Jim Elsey
of the Industry issue of Pump & Managing Editor Amelia Messamore visits with women from
Big Concession Village in Zambia in March 2015 as part of CREATIVE SERVICES
Systems explores the challenges
Pumps & Systems Gift of Clean Water coverage. DIGITAL PROJECT MANAGER &
and trends that companies SENIOR ART DIRECTOR: Greg Ragsdale
can expect to face this year. More than 30 industry experts provided their insight in ART DIRECTOR: Elizabeth Chick
response to questions posed to them by our editorial staff. WEB DEVELOPER: Greg Caudle
Find a wealth of information throughout the 18-page State of the Industry section DIGITAL COMMUNITY MANAGER: Amy Cash
that features a Q&A with Hydraulic Institute Executive Director Michael Michaud PRINT ADVERTISING TRAFFIC: Lisa Freeman
explaining the development of U.S. pump efficiency regulations (page 32), the lfreeman@cahabamedia.com 205-212-9402
importance of industry training opportunities (page 35), global factors impacting
CIRCULATION
the worlds markets (page 39), and 2016 activity involving mergers and acquisitions
AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
(page 47). lmasaoay@cahabamedia.com 205-278-2840
This important issue provides other articles to help ring in the new year, including
columnist Jim Elseys outline of 12 resolutions for your pumps on page 20, a special ADVERTISING
section on food and beverage process pumps featuring articles by Trelleborg Sealing NATIONAL SALES MANAGER: Derrell Moody
dmoody@pump-zone.com 205-345-0784
Solutions and Iwaki America starting on page 24, and the debut of our monthly Flow
ACCOUNT EXECUTIVES:
Meters column on page 51. Mary-Kathryn Baker
The new year will bring exciting developments for not only our industry, but also our mkbaker@pump-zone.com 205-345-6036
editorial staff. After working on 29 issues of Pumps & Systems, Managing Editor Amelia Mark Goins
Messamore is beginning a new chapter of her career as development coordinator for mgoins@pump-zone.com 205-345-6414
Design Outreach, based in Columbus, Ohio. The humanitarian engineering nonprofit John Harris
jharris@pump-zone.com 205-561-2607
helps to deliver clean water solutions in developing countries around the world. Were
Garrick Stone
thankful for her contribution to this publication and industry, and we wish her the best gstone@pump-zone.com 205-212-9406
in her new endeavor.
MARKETING ASSOCIATE:
In this new year, the Pumps & Systems editorial staff remains committed to delivering Sonya Crocker
important and useful articles to help end users and others in their day-to-day jobs. My scrocker@cahabamedia.com 205-314-8276
door is always open to you, so please feel free to contact me at mreed@cahabamedia.com
to provide suggestions and comments.
Thanks for reading.
PUBLISHER: Walter B. Evans Jr.

VP OF SALES: Greg Meineke
Managing Editor Martin J. Reed CREATIVE DIRECTOR: Terri J. Gray
CONTROLLER: Brandon Whittemore
mreed@cahabamedia.com
P.O. Box 530067

Birmingham, AL 35253
Pumps & Systems EDITORIAL & PRODUCTION
is a member of the following organizations: 1900 28th Avenue South, Suite 200
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals Birmingham, AL 35209
postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the 205-212-9402
right to determine qualifications. 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 205-278-2840 inside or outside the U.S. POSTMASTER: Send changes of address and
form 3579 to Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253. 2016 Cahaba Media Group, Inc. No part of this publication may be reproduced ADVERTISING SALES
without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, 1806 6th Street, Suite 200
articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The
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to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 25, Issue 1.
J an uary 2 0 17 | Pum ps & S y st e m s

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This issue JANUARY Volume 25 Number 1
COLUMNS
COVER
SERIES STATE OF THE INDUSTRY PUMPING PRESCRIPTIONS
13 By Lev Nelik, Ph.D., P.E.
Pumping Machinery LLC
Case Study: Troubleshooting Seal
Problems in Cooling Water Pumps
PUMP SYSTEM IMPROVEMENT
16 By Ray Hardee
Engineered Software Inc.
Analyzing a Large Closed-Loop Service
System with Multiple Paths
COMMON PUMPING MISTAKES

20 By Jim Elsey
Summit Pump Inc.
12 New Years Resolutions for
Your Pumps
INDUSTRY INSIGHTS
23 By Mike Pemberton
Pumps & Systems
30
What Industry 4.0 Means for American
Manufacturing in the Coming Years
2 FROM THE EDITOR

32 9 CRITICAL QUESTIONS ABOUT PUMP INDUSTRY REGULATIONS 8 FROM THE READERS
IN 2017 9 NEWS
Michael Michaud, executive director of the Hydraulic Institute, spoke with Pumps 12 TRADE SHOW PREVIEW
& Systems about how end users can prepare for new Department of Energy rules
and policies. 69 ADVERTISERS INDEX
70 PUMP USERS MARKETPLACE
35 PREPARING TODAYS WORKFORCE FOR TOMORROWS CHALLENGES
By Martin J. Reed, Pumps & Systems 72 PUMP MARKET ANALYSIS
With large numbers of people retiring in the coming years, the industry is
emphasizing training opportunities more than ever.
39 6 GLOBAL FACTORS AFFECTING THE PUMP MARKET IN 2017 ON THE COVER SYSTEMS
J A N UA R Y 2 0 17
PUMPSANDSYSTEMS.COM
By Tom Angle, Hidrostal AG The Leading Magazine for Pump Users Worldwide
The Pumps Powering

& Chris Angle, Mechanics Bank State of the
INDUSTRY Possibilities image, created
Many of these factors relate to the ongoing instability in various parts of Europe,
Are you ready for 2017?
for the Hydraulic Institutes

but in todays interconnected global economy, innumerable current events and 100th anniversary, was
trends can impact the marketplace. designed by Strategy
INSIGHT F ROM
INDUST RY EXPERTS
Studio. The poster shows

UPDATE ON PUMP
EFFICIENCY RULES
GLOBAL MARKET
FACTORS IN 2017
42 LETS TALK ABOUT 2017 the hidden nature of pumps

More than 30 industry leaders answered key questions about the pump while reminding us all of their essential role in
marketplace in 2017. The Pumps & Systems editorial team selected excerpts from keeping the world moving and supporting life.
their responses to help you prepare for the new year. For more information or copies of the poster,
contact msilver@pumps.org. (Courtesy of
Hydraulic Institute)
J an uary 2 0 1 7 | Pum ps & S y st e m s

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6
This issue JANUARY
DEPARTMENTS
48 EFFICIENCY MATTERS
SSPECIAL
PECIAL
FOOD & BEVERAGE PROCESS PUMPS Designing Better Bearing Housings
SECTION By Heinz Bloch
Process Machinery Consulting
24 OPTIMIZING SEAL
DESIGN IN FOOD & 51 FLOW METERS
BEVERAGE PUMPS Ultrasonic Flow Meters Help Cool
By Thijs Menzel, Industrial Power Distribution Systems
Trelleborg Sealing Solutions By Pascual Espinoza
Understanding the Badger Meter Flow Instrumentation
manufacturing process that
produced the equipment, as 54 MOTORS & DRIVES
well as the production and The Power of Drives & Controls in
cleaning processes for which Increasing Reliability
24
the equipment is used, is vital By Kyle Schoenheit
for efficient operation.
Xylem Inc.
27 IP 67-RATED CHEMICAL PUMPS 56 MAINTENANCE MINDERS
WITHSTAND WASHDOWN & MORE
A Novel Way of Protecting Parallel
By Michael Price,
Centrifugal Pumps
Walchem, an Iwaki America Company
By Robert X. Perez &
The rating means they were tested under 3 Glenn Everett
feet of water for 30 minutes and continued
Enterprise Products
to run properly.
58 SEALING SENSE
Back to Basics: Expansion Joints
By Paul (Bud) Baltzer Jr.
PRACTICE & OPERATIONS FSA Member, Meccom Industrial
Products Company
& Stephen Cramb
65 HOSPITAL SAVES MORE THAN FSA Member, Garlock Sealing
$600,000 WITH RETROFITTED HVAC Technologies
VARIABLE SPEED COOLING SYSTEM
By Brent Ross, 62 HI PUMP FAQS
Armstrong Fluid Technology Containment Considerations for
Pumps played a key role in the facilitys
energy efficiency improvements. 27 Magnetic-Driven Pumps & Designs
for Integral Motors in Canned
Motor Pumps
By Hydraulic Institute
EDITORIAL ADVISORY BOARD

THOMAS L. ANGLE, P.E., MSC, Vice BOB DOMKOWSKI, Business TODD LOUDIN, President/CEO North SCOTT SORENSEN, Oil & Gas
President Engineering, Hidrostal AG Development Manager Transport American Operations, Flowrox Inc. Automation Consultant & Market
BRYAN S. BARRINGTON, Machinery Pumping and Amusement Markets/ MICHAEL MICHAUD, Executive Developer, Siemens Industry Sector
Engineer, Lyondell Chemical Co. Engineering Consultant, Xylem, Inc., Director, Hydraulic Institute ADAM STOLBERG, Executive Director,
Water Solutions USA Flygt Submersible Wastewater Pump
RUSSELL SMITH, Business Dev. JOHN MALINOWSKI, Senior Manager
Manager - Wastewater, Grundfos WALT ERNDT, VP/GM, CRANE Pumps of Industry Affairs, Baldor Electric Association (SWPA)
Americas Corporation & Systems Company JERRY TURNER, Founder/Senior
R. THOMAS BROWN III, President, JOE EVANS, Ph.D., Customer & WILLIAM E. NEIS, P.E., President, Advisor, Pioneer Pump
Advanced Sealing International Employee Education, PumpTech, Inc. Northeast Industrial Sales DOUG VOLDEN, Global Engineering
(ASI) LARRY LEWIS, President, Vanton LEV NELIK, Ph.D., P.E., APICS, Director, John Crane
CHRIS CALDWELL, Director of Pump and Equipment Corp. President, PumpingMachinery, LLC KIRK WILSON, President, Services &
Advanced Collection Technology, WILLIAM LIVOTI, Business HENRY PECK, President, Geiger Pump Solutions, Flowserve Corporation
Business Area Wastewater Solutions, Development Manager/Energy & Equipment Company JAMES WONG, Associate Product
Sulzer Pumps, ABS USA Efficiency Specialist, WEG Electric Manager Bearing Isolator, Garlock
Corporation MARIANNE SZCZECH, Director,
JACK CREAMER, Market Segment Global Marketing and Product Sealing Technologies
Manager Pumping Equipment, Management, Pump Solutions Group
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8 FROM THE READERS
Reader Raises Concerns about

Article on Pump Efficiency Rules
SYSTEMS
O C T O B E R 2 0 16
PUMPSANDSYSTEMS.COM
Get Ready for New Federal manufacturer of the pump to ensure compliance with
The Leading Magazine for Pump Users Worldwide
Pump Efficiency Rules the standardnot the end user or system owner. Whats
CONNECTING
THE INDUSTRY more, the rules do not include a requirement to audit the
OCTOBER 2016
efficiency of preexisting pumps or the systems in which
Peter Gaydon, Director of they are installed.
Technical Affairs at the Hydraulic The rules for general pumps (81 FR 4368 & 81 FR 4086)
CORPORATE
Institute, writes: define five equipment classes of clean water pumps that
2016
CAPABILITIES
are within scope and sets standard levels for these pumps.
While reviewing the October
TA K E O U R N E W 6 TIPS TO TROUBLESHOOT
PUMP NINJA QUIZ DIAPHRAGM PUMPS
In the rules, DOE defines a pump to be inclusive of a

2016 edition of Pumps & Systems
bare pump (pump wet end only) and, when applicable,
magazine, I came across the article Get Ready for
a driver (typically a motor) and controls (typically
New Federal Pump Efficiency Rules. I believe there
a variable frequency drive). The standard level power
are several points discussed in this article that should
consumption prescribed is based on the minimally
be clarified so that the published federal pump energy
compliant efficiency of the bare pump, but the test
conservations standards and ongoing rulemakings and
procedure rule (81 FR 4086) outlines methods to account
their requirements are fully understood by end users and
for the driver losses in the prescribed standard level power
manufacturers.
consumption. According to the product definition, a pump
The U.S. Department of Energy (DOE) has published
can be rated and certified with a driver and control when
a Federal Register final rule prescribing new energy
distributed in commerce with a driver or control.
conservation standards 81 FR 4368 (Jan. 26, 2016) and
The point to understand is that DOEs product
test procedures 81 FR 4086 (Jan. 25, 2016) for certain
definition for a pump can be inclusive to what industry
general pumps. Compliance by the manufacturer must be
terms the extended product (driver and control). At
on or before Jan. 27, 2020.
times, I have heard the extended product referred to as the
The article Get Ready for New Federal Pump Efficiency
pump system, which is misleading terminology because,
Rules referenced an ongoing negotiated rulemaking
as defined, a pump is rated and certified according to
for circulator pumps, docket EERE-2016-BT-STD-0004,
its pump/motor/drive configuration, not by the overall
but then discussed requirements of the rules for certain
system in which it is installed.
general pumps (81 FR 4368 & 81 FR 4086). In addition
In summary, the burden of compliance is on the
to the ongoing circulator pump negotiation, dedicated
manufacturer of the pump and not the end user. The end
purpose pool pumps (DPPP), docket EERE-2015-BT-
user should be aware of the rules pertaining to pumps
STD-0008, are in a rulemaking process. A Notice of
and use this understanding to make educated purchasing
Proposed Rulemaking (NOPR) pertaining to the DPPP test
decisions. And while not required by the DOE rule, system
procedure 81 FR 64580 was published on Sept. 20, 2016.
audits are a recommended practice in order to identify less
The article indicated that the general pumps rule and
efficient pumps, ready for replacement.
ongoing rulemakings cover or will cover the efficiency of
existing pumps, the systems they are installed in, and
that end users will need to audit the efficiency of their
pumps and systems. This is not the case, however, as the
Want to join the conversation? Become a member
DOE rules are prescriptive to products as distributed of the Pumps & Systems LinkedIn group to
in commerce. The rules do not extend to the overlying engage in discussions with more than 23,000
system that contains the pump. It is incumbent upon the industry professionals.

NEWS 9
NEW HIRES,
PROMOTIONS & RECOGNITIONS
TIMO IHAMUOTILA, ABB LARS RASMUSSEN, DANFOSS
ZURICH, Switzerland ABB announced that BALTIMORE, Md. Danfoss recently named Lars
Timo Ihamuotila has been named chief financial Rasmussen vice president of its heat exchangers
officer and member of the Executive Committee, business. In this role, Rasmussen will focus on
effective April 1. Ihamuotila succeeds current continuing to grow and develop Danfoss heat
CFO Eric Elzvik in an orderly transition process. exchanger product portfolio and research and
Elzvik will pursue career opportunities outside development efforts, as well as contribute to
of ABB after a thorough handover in the second Timo the growth of heat exchangers for refrigeration Lars
quarter of 2017, according to a statement from Ihamuotila and air-conditioning applications worldwide. He Rasmussen
the company. Ihamuotila is joining ABB from holds a masters degree in electrical engineering
Nokia, where he has held the position of CFO since 2009. Ihamuotila from the Technical University of Denmark as well as an Executive
brings with him 26 years of experience in the communications and MBA from Ivey Business School. danfoss.com
banking sector and has deep experience in finance, controlling,
mergers and acquisitions, commercial, and general management. KEN MOODY, ASAHI/AMERICA
He earned a Master of Science in economics and a post-graduate LAWRENCE, Mass. Asahi/America Inc.
degree in finance from the Helsinki School of Economics. abb.com announced the addition of Ken Moody to its
business development team. Moody joined
JUSTIN ARSENEAULT Asahi/America on Oct. 31, 2016, as business
& MARC LI, development manager for commercial piping
SINGER VALVE in the western region. Moody, who will promote
SURREY, B.C. Singer Valve Asahi/Americas new PP-RCT piping line, Ken
Inc. has added two new Asahitec, as well as the COOLSAFE and Air- Moody
members to its engineering Pro piping systems, will work closely with the
department: Justin Arseneault companys western sales team on pre-construction sales efforts
as instrumentation and Justin Marc and engineering specifications. Moody resides in the San Francisco
Arseneault Li area. asahi-america.com
automation engineer and Marc
Li as applications engineer. As instrumentation and automation
engineer, Arseneault designs and programs Singers Underwriters PATRICK TOMS,
Laboratories (UL)-approved industrial panels, provides customer WORLDWIDE ELECTRIC CORPORATION
support for electronic products, is involved in training and research ROCHESTER, N.Y. WorldWide Electric
and development, and does much of the technical manual writing. Corporation (WWE) named Patrick Toms as the
He has a bachelors degree in mechatronics. As applications companys vice president of sales for its Electric
engineer, Li is focused on designing and implementing the optimal Motor and Gearing Divisions. With more than 27
valve solution for specific customer requirements. Li has a masters years of industry experience, Toms will oversee
degree in engineering. singervalve.com the day-to-day activities of WWEs regional Patrick
sales managers. He most recently served as Toms
JOE VORIH, OMEGA ENGINEERING the companys vice president and general
NORWALK, Conn. OMEGA Engineering Inc. manager of the Gear Reducer Division, where he was instrumental
has announced the appointment of Joe Vorih in delivering significant revenue and profit growth.
as company president. Vorihs priority will worldwideelectric.net
be to transform OMEGA from a well-known
direct provider of process sensors into a web-
based global partner for complete process MERGERS & ACQUISITIONS
measurement and control solutions, including Joe
innovative wireless and IIoT-ready offerings. Vorih
A manufacturing and technology industry Trelleborg completes acquisition of CoorsTek subsidiary.
Nov. 28, 2016
visionary, Vorih holds bachelors and masters degrees in
mechanical engineering from MIT and an MBA from Rensselaer
U.S. Water acquires Water & Energy Systems Technology.
Polytechnic Institute. In addition to Vorihs appointment, the global
Nov. 18, 2016
manufacturer and supplier of process measurement and control
products will be operating out of a new world headquarters in Schneider Electric acquires software company MaxEAM.
Norwalk, Connecticut. omega.com Oct. 31, 2016
p u m p s a n d s y s te ms . co m | J a n uary 2017
10 NEWS
AROUND THE INDUSTRY

HI Unveils New Logo, Prepares for Xylem Secures Deal with EPA Names Pilot Cities for
Next 100 Years Scottish Water for Rental Long-Term Stormwater
PARSIPPANY, N.J. The Hydraulic Institute Dewatering Pumps Planning Program
(HI), which will celebrate its centennial in NOTTINGHAM, U.K. Xylem has been awarded WASHINGTON The U.S. Environmental
2017, announced a new logo as part of a larger a new five-year framework agreement with Protection Agency (EPA) announced tools to
initiative to position HI for the next 100 years Scottish Water, the body responsible for help communities plan long-term strategies
of service to the pump industry. water and sewerage services across Scotland, for managing stormwater pollution.
The new logo is a key element of HIs according to a statement from the company. EPA has released a step-by-step guide
overall brand refresh and redesign process, Under the agreement, Xylem will supply to help communities develop long-term
according to the organization. and install submersible and diesel pumps for stormwater plans, a web-based toolkit for
The logo includes a hidden H that Scottish Water rental applications across the the planning process and technical
reflects the nature of pumpsalways there, region. Xylem will provide its Flygt electric assistance for five communities to develop
working behind the scenesand arrows submersible pumps and Godwin diesel plans as national models.
that represent a pumps purpose: flow and pumps to support dewatering efforts as part This approach was built on input from
movement. This movement reflects the of capital projects and ongoing upgrades to states, communities, industry, academia
evolution over the past 99 years from when existing pump stations. xylem.com and nonprofits.
pump manufacturers first came together Initially the draft guide will be used by
to discuss common issues and develop Schneider Electric Recognizes five communities selected for $150,000 each
technical standards. pumps.org Customer Innovation in technical assistance to develop long-term
LAKE FOREST, Calif. Schneider Electric stormwater management plans: Burlington,
SKF Invests Nearly $17 Million in recognized several customers for their Iowa; Chester, Pennsylvania; Hattiesburg,
German Bearing Manufacturing innovative approaches to optimizing asset Mississippi; Rochester, New Hampshire; and
GOTHENBURG, Sweden SKF is investing utilization, reducing unscheduled downtime Santa Fe, New Mexico.
nearly $17 million in modernizing its and improving performance. These communities will also be the beta
cylindrical roller bearing (CRB) manufacturing Six Schneider Electric customers testers for EPAs web-based toolkit, which
in Schweinfurt, Germany, according to a won awards for uses of enterprise asset will be refined and released more broadly
statement from the company. This is the performance management solutions: next year. epa.gov
third significant manufacturing investment AEP received the Avantis PRiSM Fossil
announced by SKF in the last 18 months, Catch of the Year Award for early Global Water Pumps Market to
following the announcement of investments identification of damage to a turbine blade Exceed $67 Billion by 2025
in Gothenburg, Sweden, and Flowery Branch, in a power generation unit; this saved an NEW YORK Market research firm
Georgia, the company said. estimated $17.5 million in cost avoidance. ReportLinkers newly released report called
The investment in Schweinfurt will New York Department of Environmental Global Water Pumps Market By Type, By End
involve the implementation of the latest Protection was a co-recipient of the User, By Region, Competition Forecast and
technologies within machining, assembly Avantis Excellence Award for continuous Opportunities, 2011-2025 states that the
and packaging, and it will result in older improvement in optimizing best practices global water pumps market is projected to
production channels being replaced by and work order processing. cross $67 billion by 2025.
largely automated technologies. skf.com Rayonier Advanced Materials received the The report bases the projection on
Milestone Award for 25 years of Avantis increasing water scarcity and the growing
NI Partners With IBM & Partnership, having first deployed Avantis need to upgrade the existing water pump
SparkCognition to Advance the IIoT in 1991. base and replace older pumps.
AUSTIN, Texas NI (National Instruments) Tennessee Valley Authority received the Although centrifugal pumps dominate
announced that SparkCognition is Avantis PRiSM Nuclear Catch of the Year demand for water pumps across the globe,
partnering with NI and IBM to collaborate Award for early warning to detect a failing demand for positive displacement
on the Condition Monitoring and Predictive condensate booster pump, saving about pumps is projected to grow at a robust
Maintenance Testbed, according to a $1 million. pace because of their versatility of
statement from the company. Western Refining was a co-recipient application and low maintenance, according
The collaborations goal is to deliver an of the Avantis Excellence Award for to the report. Additionally, Asia-Pacific
unprecedented level of interoperability implementing several innovations that dominated global demand for water pumps
among operational technology and streamlined processes and operations because of growing industrialization in major
informational technology as organizations across refining and pipeline operations. developing economies.
search for better methods to manage and Wipro Limited received the eDNA Rapid industrialization and urbanization
extend the life of aging assets in heavy Innovation Award for developing several in developing countries is propelling demand
machinery, power generation, process advanced applications for National Grid for water pumps across various end user
manufacturing and a variety of other UKs gas transmission system. segments, according to the report.
industrial sectors. ni.com schneider-electric.com reportlinker.com
To have a news item considered, please send the information to Amelia Messamore, amessamore@cahabamedia.com.

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PUMPING PRESCRIPTIONS 13
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery LLC, P&S Editorial Advisory Board
Case Study: Troubleshooting Seal Problems in

Cooling Water Pumps
Second in a Series
Editors Note: Barry T. Brown of Spurlock Station, Unit 2, East Kentucky Power Cooperative contributed to this column.
T
he first part of this series best efficiency point (BEP), and and then all pumps shut off during
(Pumps & Systems, December no unusual internal flow-induced the outage. If a short-term outage
2016) introduced an disturbances or cavitation would be takes place, one pump will run
investigation involving three expected. Pumps 2B and 2C showed because the turbine will still be
double-suction horizontal split- similar results. Transposing the hot. Once the unit is fired back up,
case pumps (labeled 2A, 2B and data over the OEM curve revealed both pumps will be running.
2C) that have had mechanical the following information: During the earlier PREMS-2A
seal issues since their installation Pump 2A generally operated tests, the team deduced the flow
around 2009. Of the four power between 3,600 and 6,000 gpm. from the pressures, assuming
generation units at East Kentucky Pump 2B operated between non-degradation in performance.
Power, Unit 2 was the only one 4,000 and 5,500 gpm. That translated to a flow range
having these problems. Pump 2C operated between of 4,000 to 5,500 per pump. The
A pump reliability and 4,000 and 5,800 gpm. flow-measurement companys
efficiency measurement and data data, however, shows about 3,000
acquisition system (PREMS-2A) The ultrasonic flow meters to 4,000 per pump when two
was installed to troubleshoot this accuracy is 8 to 10 percent, and the run together, or 4,500 when one
case and track parameters related pitot tube is 1 to 2 percent accurate. runs. This implies roughly 1,000
to pump reliability (vibrations, Pitot tube meters generally read a gpm degradation of the flow from
temperatures) and performance somewhat higher (about 6 percent) what would be expected with the
(head-capacity, power and flow when compared with the OEM curve. The company stated
efficiency). This part will explore ultrasonic meter. that its ultrasonic meter tends
data trends and analysis. As shown in the data, the to read about 6 percent lower
bearing housing temperature than the actual flow, which was
Data Trends readings were not high, and confirmed by completing the pitot
Because the flow was not readable they exhibited a slow-changing test in conjunction with the flow
by the flow meter at the time of the trend, reflecting mainly ambient test. A typical 4,000 gpm reading
initial test, a simplified assumption temperature variations throughout would need to be corrected to
was made regarding the pumps the day/nightno smoking gun. approximately 1.06 x 4,000 =
actual head-capacity curve as 4,240; for example, a 300 gpm
supplied by the original equipment Separate Flow Test correction, or a 700 gpm deficit
manufacturer (OEM). A company that performs flow compared with the OEM curve.
As shown in Figures 1 and 2 measurements obtained a flow At roughly 140 feet of head,
(page 14), in 16 hours (8,279 data record, from Sept. 9-16, 2016. this equates to about $16,172 per
points), the pump head varied If the plant is running, both year running nonstop at $0.10 per
between 88 and 131 feet3,600 pumps are running; if the plant kilowatt-hour (kWh). Assuming
to 6,000 gallons per minute (gpm). is offl ine for an outage, one pump two pumps run nonstop most of
This indicated that Pump 2A runs until the turbine is cooled the time, this results in about
operated reasonably close to its down (about two to three days) $32,000 of wasted energy per year.
14 PUMPING PRESCRIPTIONS
Vibration
Vibrations fluctuated between
0.15 and 0.25 inches per second
(in/sec) (overall, root mean square
[RMS]) for Pumps 2A and 2C in
the direction along the flow axis
and remained less than 0.1 in/sec
in a direction perpendicular to the
flow direction. Pump 2B vibrations
were lower, less than 0.1 in/sec.
As a reference, 0.3 in/sec is
considered a warning, and 0.5 in/
Figure 1. A screenshot of the live data from the PREMS-2A system (Graphics courtesy of
sec is an alarm. The data indicated the author)
that there was no apparent
vibration concern. Some changes
in vibration fluctuations in
Pump 2C were noted, but those
levels stayed relatively low, never
exceeding about 0.25 in/sec.
Vibrations also were verified
manually by a hand-held Fast
Fourier Transform (FFT) analyzer
along the entire perimeter of each
pumps frame (each of the four
sides: at the three locations along
the top steel member, bottom and
Figure 2. Expanded data plot of pump head for Pump 2A (calculated from discharge and
both sides). As would be expected, suction pressures), temperatures, amps (left side scale) and vibrations (right side scale)
the upper member (cross bar)
showed higher vibration compared A speed of 1,778 revolutions piping loads to make sure the
with the sides or lower bars (0.08 per minute (rpm) represents pump is not warped by the
in/sec at the upper bar, gradually 29.6 hertz (Hz) running speed piping load deflections (dial
reducing to 0.02 in/sec at the frequency (1X). Significant indicators are used to see how
lower [foundation level] bar). vibration was present on side 1 of much load is on the pipe that
That indicated that the structural the lower bearing (below 15 Hz), could cause seal damage)
integrity of the supporting and virtually no vibration was seal condition, including
structure was adequate. present on the opposite side (just a venting arrangement (in
However, a detailed (also few inches away). vertical position, lack of
manual) traverse of the entire The structural detail of the lower venting may prevent air
pump in the axial direction bearing housing was suspected to from escaping from the seal
(starting from the top bearing be compromised (cracked, loose chamber; this could create
housing, moving down along bearing fits, etc.). In this case, air/liquid pockets and poor
the casing and eventually to the the hammering action of this low lubrication of the seal faces,
lower bearing) showed peculiar frequency could be a contributing which could lead to burn-up
results. While vibration was low factor to the seals compromised and failure of the seal faces)
throughout the pump and bearing integrity and failures. bearing bore dimensions and
housing body, vibration at the fits (outer diameter to housing)
lower bearing housing (Pump 2B) Pump Reassembly seal flush piping condition
was drastically higher at one side The next planned step was to to confirm seal flush is
(0.56 in/sec) than the other reassemble the pump(s) during active (no clogged tubing
(0.11 in/sec)essentially at the the upcoming outage and examine or cyclone separator
same elevation. them for the following: malfunction/clogging)
January 2017 | Pumps & Systems

15
Alternatives to Pump Repositioning

One alternative to mechanical seals is a simple packing
(with possible lantern ring/flush). This arrangement may
be enhanced if the packing chamber is designed to have a
follow-up chamber followed by a bushing to further restrict
any flow of leakage past the seals. The follow-up chamber
would slowly accumulate any small leakage past the packing
and, before exiting along the shaft toward the bearings, the
leakage from the packings would be directed to a drainnever
getting past the gland and into the bearings.
This arrangement would be simple, inexpensive and reliable.
Eliminating the weakest component (seal) and replacing it with
a more reliable component (packing) should be an alternative
for any installation that does not require a mechanical seal.
Next Steps
Because of the teams inability to read the flow at the initial
test, they could not determine the actual degradation of
efficiency. Instead, they used the original OEM curve to
estimate the flow so the deficiency (the opposite of efficiency)
impact was not calculated. Their suggestion was to follow up
with this additional test after the outage, with the PREMS-2A
assisted by the GE878 ultrasonic flow meter.
The next part of this series will discuss what happened:
inspection findings, fi xes and follow-up monitoring.
References
1. L. Nelik, Pumps & Systems, July, August, September, October 2015,
Efficiency Monitoring Saves Plants Millions in four parts
2. PREMS-2A Pumps On-Line Efficiency and Reliability Monitoring: http://
www.pumpingmachinery.com/pump_school/PVA/pva.htm (model #11)
3. L. Nelik, Analysis of the Thermal Behavior in the Sealing Cavity of an
Overhung API Process Pump, Proceedings of 8th International Pump
Symposium, Texas A&M, March 3-5, 1991
Dr. Nelik (aka Dr. Pump) is president of Pumping

Machinery LLC, an Atlanta-based firm specializing in
pump consulting, training, equipment troubleshooting
and pump repairs. Dr. Nelik has 30 years of experience
in pumps and pumping equipment. He may be reached
at pump-magazine.com. For more information, visit

pumpingmachinery.com/pump_school/pump_school.htm.
Barry T. Brown holds a B.S. in mechanical engineering from

Iowa State University of Science and Technology and a B.A.
in history and geography from Northwest Missouri State
University. He is a senior plant engineer for East Kentucky
Power Cooperative at Spurlock Station, Maysville, Kentucky,
where he acts as the system expert for condensers, cooling
towers, air heaters and pumps. He has been involved in coal-
fired power generation and engineering for 15 years.
16 PUMP SYSTEM IMPROVEMENT
A better understanding of complete system operation
By Ray Hardee
Engineered Software Inc.
Analyzing a Large Closed-Loop

Service System with Multiple Paths
P
ast Pump System (HVAC) chilled water cooling or regulate the flow rate through each
Improvement columns have hydronic heating, closed-loop circuit to the specified value.
focused on piping systems cooling systems to keep operating Each of the four circuits shares
made of one or two circuits. These equipment cool, and hot oil a number of common elements,
systems often are found in process systems to provide process heating. moving clockwise from the
systems where fluid is pumped Figure 1 shows a closed-loop common return header (RH-1)
from a supply tank acting as cooling system consisting of four through the water chiller and pipe,
the inlet boundary, through the circuits. As always, this system is back to Pump P-1, and out to the
systems process elements to make made of three elements working common supply header (SH-1). At
the product, and then through together. The pump elements this point, each circuit has its own
the control elements to adjust the (Pump P-1 and Pump P-2) provide combination of process and control
systems flow rate to maintain the all the hydraulic energy to the elements before rejoining at RH-1.
desired operating condition. system. The process elements Next, we will look at how the
This months column examines consist of a tank providing a fluid energy changes as it moves
multi-loop closed systems used to point of known pressure, the to the first circuit through Air
recirculate a heat transfer fluid to interconnecting pipelines and the Handler 1. At the suction side
heat or cool loads in the system. air handlers used to remove heat of the pump (P-1 In), the energy
These systems often are used in from the conditioned system. The grade is a little more than 45 feet
commercial buildings for heating, control elements consist of control of head. Pump P-1 adds 227 feet of
ventilation and air-conditioning valves CV1 through CV4, which head to the fluid, bringing the fluid
Figure 1. Closed-loop cooling system with four circuits (Graphics courtesy of the author)

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18 PUMP SYSTEM IMPROVEMENT
energy at the discharge to 272 feet. 65 feet, resulting in fluid energy of the energy level noted previously
The fluid travels through pipe P-1 Out more than 131 feet at the inlet of at the suction side of the pump.
and the common leg of the supply pipe L1-3. The fluid flows through If we work through the rest of
header SH-1, where the energy grade L1-3 and the common return header the circuits in the same manner, we
drops to a little less than 231 feet RH-1, resulting in an energy grade arrive at the results shown in Table 1.
because of friction Taking a look at
losses and elevation the overall data,
change. For installations where lowering operational we can make a few
Following the observations. First,
fluid through the
costs is a priority, further system analysis because the same
first loop, the head and optimization is possible to reduce energy pump element is
drops to less than driving the fluid
223 feet of fluid at
that is not being used directly through all four
the outlet of pipe for the process elements. loops (Pump P-1),
L1-1. The head the energy added
loss through Air for each loop is the
Handler 1 is 23 feet to a little more of less than 91 feet of fluid at the same: 226.7 feet of fluid. Second,
than 199 feet of fluid. inlet to the water chiller. The while the head loss in the process
At the outlet of pipe L1-2, going energy level drops 16 feet through elements and the head loss for the
into the control element CV1, the the chiller, then flows through control elements are different for
energy grade is 196 feet. Control three more pipe segments (C-Pipe 1, each loop, the total head loss for
valve CV1 has a head loss of almost C-Pipe 2 and P-1 In) to return to the control and process elements is
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19
Table 1. Energy used or added for each circuit by piping system element always equal to the pump head (the energy added to the
(all values in feet of fluid) fluid by the pump). Lastly, the control elementsthe
Circuit: 1 2 3 4 control valvesare consuming 10 to 30 percent of the
energy the pump adds to each loop.
Pump Element Total 226.7 226.7 226.7 226.7 For installations where lowering operational costs is
Pump P-1 226.7 226.7 226.7 226.7 a priority, further system analysis and optimization is
possible to reduce energy that is not being used directly
Process Element Total 162.1 176.2 200.5 205.6 for the process elements.
In a multi-loop system typical of HVAC and
Pipe: P-1 Out 9 9 9 9
other distributed service installations, each loop
Pipe: Supply Header 32.6 43.2 49.8 58.6 typically contains all three of the piping system
elements: pump, process and control. The head loss
Pipe: Load Piping 19.7 20.9 33.8 19.5
from the process and control elements in each of
Air Handler 23.1 14.8 13 14.8 these loops is equal to the pump head added by the
pump elements.
Pipe: Return Header 32.6 43.2 49.8 58.6
Chiller 16.1 16.1 16.1 16.1

Ray Hardee is a principal founder of Engineered
Pipe: C-Pipes+P-1 In 29 29 29 29 Software, creators of PIPE-FLO and PUMP-FLO software.
At Engineered Software, he helped develop two training
Control Element Total 64.7 50.6 26.3 21.1
courses and teaches these courses internationally. He may
Control Valve 64.7 50.6 26.3 21.1 be reached at ray.hardee@eng-software.com.
pumpsandsystems.com | January 2017

20 COMMON PUMPING MISTAKES
Simple solutions for end users
By Jim Elsey
Summit Pump Inc.
12 New Years Resolutions for Your Pumps
T
he famous Swiss psychiatrist
and psychotherapist Dr. NPSH A = H1 H2 + H3 H4
Carl Jung is often quoted as Equation 1
saying, What you resist persists. I Where (all values are absolute):
always took it to mean that because H1 = absolute pressure in feet
I had problems with calculus H2 = fluids vapor pressure converted to feet
in college, I would always be in H3 = static height of the fluid column above the pump impeller
professional positions that would centerline. This component has a negative value if the fluid is
require me to be proficient in the below the impeller centerline (suction lift).
subject. I was painfully correct. H4 = friction loss in the suction system in feet
If you do not set goals and face
these situations, the things that Note: If calculating NPSH A, you can ignore the velocity head. If
you resist will persist by repeatedly measuring NPSH A, you need to account for velocity head.
popping up, typically at the most
inopportune times. In this new Pumps & Systems has published impeller, installing a different size
year, I propose we work on items many articles on the subject pump or a different model pump,
on this resist list of common several in the last couple of years. A and/or changing something on
damage-causing issues for pumps. good starting place is my Pumps & the system that could be as easy as
1
Systems column from August 2015 installing a three-way control valve
NPSH A Mystery titled Rethinking NPSH. or an orifice.
The subject that requires the It all comes back to knowing the
3
most attention is understanding basic formula in Equation 1. Pipe Strain: The Silent
net positive suction head available Pump Killer
2
(NPSH A). Some people resist Best Efficiency Point A pump is the most expensive
learning about it because the name Operating the pump away piping hangar you can purchase.
and subject can be difficult and from the best efficiency point (BEP) It seems that piping systems
confusing. Others believe they is the second most common issue are often not properly designed,
know all about the concept, but affecting pumps. I acknowledge installed and/or anchored.
their calculations and applications that, in many applications, Provisions for thermal expansion
prove otherwise. Their pumps operators or owners are helpless and contraction are often
consequently cavitate, incurring to do anything about the situation not considered.
expensive damage and downtime. because of circumstances beyond I observed a situation where
The resisting category also their control. Others can look to pipe strain was the suspected root
includes anyone who thinks that change something in the system cause of bearing and seal issues.
NPSH A is purely a function of that allows the pump to operate After we instructed the mechanics
suction pressure, suction energy where it is designed to run. to remove the pump foundation
and/or static height (submergence), Just as someone should not drive bolts, the 3,200-pound pump was
as in having a flooded suction. a car down the interstate in first lifted several inches by the piping.
I propose that the subject is gear, end users should not operate For those who are not sure, that is
really not that difficult. There are a pump near the shutoff point. an example of severe pipe strain.
numerous sources of information Helpful options include variable Another way to check is to place
and instruction on this topic. speed operation, trimming the dial indicators on the coupling

21
in the horizontal and vertical

planes, then unbolt either suction
or discharge piping. If the dial
5 Alignment
The alignment of the driver
to the pump is critical. No matter
7 Running the Pump Dry
Submergence (simple
submergence) is defined as the
indicators show more than 0.002 how well the pump was aligned distance (D) measured vertically
inches of movement, there is too in the manufacturers facility, the from the liquids surface to the
much pipe strain. Repeat for the alignment was lost the second centerline of the inlet suction pipe.
other fl ange. The coupling should the pump was transported. If you A more important descriptive
have inserts/spacers removed. aligned the pump when it was set term is required submergence,
in place, it was likely lost when you also known as minimum or critical
4 Preparing for Startup

Pumps of any size, other than
connected the piping. submergence (SC).
Required submergence is the
fractional horsepower close-
coupled, rarely arrive at the final
site ready to start up. Pumps are
6 Oil Level & Cleanliness
More oil is usually not
better. In ball bearings with
vertical distancefrom the
fluid surface to the pump inlet
required to prevent fluid
not plug and play. End users must splash lubrication systems, the vortexing and fluid rotation
add oil to the bearing housing, set optimal oil level is when the oil (swirling and or pre-swirl).
the rotor and impeller clearances, is touching the very bottom of Vortexing will introduce unwanted
set the mechanical seal, and the bottom ball. Adding more oil air and non-condensable gases,
perform a rotational check of just increases friction and heat. which can cause pump damage and
the driver prior to installing the Remember this important point: reduce pump performance.
coupling. Read and understand the The biggest cause of bearing failure A centrifugal pump is not a
instruction book. is contaminated oil. compressor, and performance
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p u mp s a n d s y s te m s . co m | J a n ua ry 2 01 7
22 COMMON PUMPING MISTAKES
is significantly affected when For example, during an NPSH A Most pump problems are on the
pumping dual and/or multi-phase calculation involving a steam suction side of the pump. Think of
fluids (gas and air entrainment condenser, you will likely have a the whole system as three separate
in the fluid). There are simple case where there is 28.42 inches of systems: the suction system, the
formulas and charts to calculate mercury (inches Hg) of vacuum. pump itself and the discharge side
how much submergence is Even with this high vacuum, there of the system.
required. For more on this topic, is still 1.5 inches Hg of (absolute) If the suction side of the system
see my April 2016 Pumps & Systems pressure in that vessel. The adequately provides fluid energy
article titled Guidelines for pressure of 1.5 inches Hg converts to the pump, then the pump, if
Submergence & Air Entrainment. to 1.71 feet of absolute head. properly selected, will handle most
For background: A perfect of the issues that occur on the
8 Driving Blind
You cannot manage (or repair)
vacuum is about 29.92 inches
Hg. The difference is how much
discharge side of the system.
what you do not measure. Use

gauges or pressure transducers on
all pumps. Gauges will measure
pressure still exists in the vessel
(29.92 28.42 = 1.5 inches Hg). The
1.5 inches Hg (multiply by 1.139 to
12 Experience & Training
Do you have 30 years
of experience or one year of
pump performance and display convert) is equal to 1.71 feet. experience that is 29 years old?
the differential pressure across Stephen Covey, the author of 7
the pump. That information, along
with knowledge of the pump and
system curves, will provide details
10 Wear Rings &
Impeller Clearances
Pumps wear out. As clearances
Habits of Highly Effective People,
identifies the seventh habit as
sharpening the saw. The short
about the equipments health. wear and open, there are negative version of what he means is that
The differential pressure across effects on the pump (vibrations even the people at the top of any
the pump is key to knowing where and unbalanced forces). In general, profession are constantly working
the pump is on its operating curve. pump efficiency will decrease one to improve their knowledge.
Knowing where the pump is on point for every one-thousandth of Pumps will operate more efficiently
the curve is critical for managing an inch (0.001) for the first 0.005 and reliably if you know how to
the pumps health. Converting the to 0.010 inches the clearances accomplish the goal.
pumps differential pressure to open (from original settings). After
head will provide a location on the the clearances open by 0.020 to
curve. Convert pressure to head 0.030 inches from the original
by multiplying the differential clearance, the efficiency begins to Jim Elsey is a mechanical
pressure by 2.31 and divide the drop exponentially. At some point engineer who has focused on
product by the specific gravity. of gross inefficiency, the pump is rotating equipment design and
Compare your results to the just agitating the fluidkilling the applications for the military
manufacturers performance curve. bearings and seals in the process. and several large original
equipment manufacturers for
9 The Pressure of
Knowing Vacuum
Vacuum is a subject that
11 Suction Side Design
The suction side is the most
important part of the pump. Fluids
43 years in most industrial
markets around the world. Elsey
is an active member of the
causes confusion. A thorough do not have tensile properties/ American Society of Mechanical
understanding of the subject strength. Consequently, a pump Engineers, the National
is especially important when impeller cannot reach out and pull Association of Corrosion
calculating NPSH A . Remember that fluid into the pump. The suction Engineers and the American
even in a vacuum, there is some system must provide the energy to Society for Metals. He is the
amount of (absolute) pressure deliver the fluid to the pump. The general manager for Summit
however small. It just is not the energy may come from gravity and Pump Inc. and the principal of
full atmospheric pressure you have a static column of fluid above the MaDDog Pump Consultants LLC.
normally worked with at sea level pump, a pressurized container/ Elsey may be reached at jim@
of 14.7 pounds per square inch vessel (even another pump) or summitpump.com.
gauge (33.95 feet). simply from atmospheric pressure.

INDUSTRY INSIGHTS 23
Trends & analysis for pumping professionals
By Mike Pemberton
Pumps & Systems Senior Technical Editor
What Industry 4.0 Means for American

Manufacturing in the Coming Years
T
he need for manufacturing Leadership Coalition has been Intelligent motor systems
jobs in the U.S. was a selected to foster the next integrated into software allows
significant issue in the generation of advanced process the distributed control systems
2016 presidential election. Since control, which will support the and computerized maintenance
2000, the U.S. reportedly has lost implementation of advances in management systems (CMMS)
about 5 million manufacturing sensors, controls, Internet of to merge and eliminate what was
jobs. In 2011, President Obama Th ings (IoT) platforms, modeling formerly islands of information.
initiated the Council on Jobs and big data analytics. With less staff to manage and
and Competitiveness to develop An important component of this maintain process assets today,
recommendations to improve initiative is the development of this bodes well for the future by
manufacturing employment. new and improved variable speed allowing more reliable production
The council, led by GE CEO motors and drives plus refi nements assets that self-report and, in
Jeff rey Immelt, provided in motor system assessment some cases, self-correct.
recommendations that have techniques. Pump assessment and The plant of the future will have,
contributed to the formation online sensor technology also will for the fi rst time, fully integrated
of several government-funded support the implementation of information systems within the
institutes. The mission of predictive analytic modeling. plant and across the enterprise.
these institutes is to provide With up to 90 percent of Plant servicessafety, regulatory
a mechanism for research, fossil power plant energy compliance, life cycle, modeling
development and deployment lost because of inefficiency, and morewill be integrated with
of new technologies and significant improvements are the process control system to allow
methodologies to transform needed in electrical generation, rapid adaptation to change.
energy-intensive industries. transmission, distribution and The energy-intensive industrial
Efforts that include the system efficiency. plants of today could see a
federal governments smart While often viewed as separate reduction of 50 percent or more
manufacturing initiatives are domains within industrial plants, in electricity usage. More energy-
expected to enable the next phase pump system energy efficiency, efficient systems have greater
of industrial growthtouted as equipment reliability and process reliability, which reduces energy
Industry 4.0to achieve quantum control are all interconnected. costs by decreasing or eliminating
leaps in performance. A more holistic approach will be human activities and related
As part of this latest industrial required in order to achieve total processes required by plant staffs
revolution, new and existing plant process management. to maintain process assets such
industries will become highly With digital communication, as pump systems. Product quality
energy efficient while improving pumps are increasingly will increase, and less waste will
the reliability and sustainability becoming part of the automation be generated. All of this is part of
of their operations. With these architecture. Embedded fostering clean energy enterprises
improvements, plants can reduce intelligence in the pump itself, the and ushering in Industry 4.0.
their environmental impact and use of variable frequency drives
carbon footprint. that act as a brain for the pump Mike Pemberton is the senior
In alignment with U.S. system, and the growing use of technical editor for Pumps &
Department of Energy goals, for IoT and predictive analytics are Systems. He may be reached at
example, the Smart Manufacturing integrating all three domains. mpembertmp@gmail.com.
24 SPECIAL SECTION FOOD & BEVERAGE PROCESS PUMPS
Optimizing Seal
Design in Food &
Beverage Pumps
Understanding the manufacturing process that
produced the equipment, as well as the production
and cleaning processes for which the equipment is
used, is vital for ecient operation.
BY THIJS MENZEL
TRELLEBORG SEALING SOLUTIONS
T
he food and beverage industry is highly regulated, Seals that Meet Standards
and equipment used in these facilities must meet Pump seals are particularly tricky to produce in a
a variety of standards and regulations that ensure hygienic-design environment because O-rings usually
consumer safety. In the past, being familiar fit into a groove. Those grooves can collect and trap food
with either U.S. or European regulations for hygienic after cleaning, causing food-spoiling microorganisms and
design was sufficient for pump manufacturers and their bacteria to grow.
suppliers selling to food and beverage producers. Todays As a result, special designs for seals and surrounding
global economy has changed that ability. equipment are needed to ensure hygienic integrity and
For instance, the end user of an American-made pump maximum cleanability.
could be located in Europe or vice versa. China has its own Depending on the pumps function within the
complex regulations for food-contact materials that differ manufacturing process and how it will be cleaned,
from those in the West and that tend to change more the potential sealing solution may be an ethylene
frequently than those in other countries. An awareness of propylene diene monomer (EPDM) sealing material for
global regulations and requirements is necessary to offer an aseptic seal, a fluoroelastomer (FKM) material for
compliant products in various markets. increased temperature stability, a perfluoroelastomer
To satisfy hygienic design standards, each component (FFKM) with increased chemical resistance or a
of a pump must be fully compliant with regulations polytetrafluoroethylene (PTFE)-based seal with a fully
regarding the material used and the way the part was enclosed activation spring.
manufactured. The manufacturer of each component
must carefully document the entire production process, Choosing Materials
including all materials used and the exact conditions The more a supplier knows about the use of the pump, the
under which the part was produced. That documentation greater the opportunity to optimize material costs. When
may be scrutinized during regulatory audits of any pump suppliers know nothing about the processes or cleaning
containing the component. methods that will be used, they tend to over-specify.

25
Component manufacturers typically choose

a sealing material that can be used in a wide
range of manufacturing processes and can
withstand any type of cleaning, including
clean-in-place/sterilize-in-place (CIP/SIP), to
ensure sealing integrity.
This tendency, however, often leads to
unnecessary expenses. To optimize the cost of
seals within a food and beverage application,
end users and their specifiers must match the
sealing material to the process materials and
cleaning regimes that will be used in each
specific application.
For instance, FFKM is the ultimate rubber Image 1 (top). It is important to choose the right seal for the ultimate
for processing applications because it can performance at the lowest cost.
Image 2 (bottom). To comply with hygienic design standards in food and
withstand virtually any aggressive media, even beverage processing, all components must meet regulatory requirements.
at elevated temperatures. (Images courtesy of Trelleborg Sealing Solutions)
The ultimate materials, however, can come
with a high cost. If the supplier knows the react differently in various media. A sealing material that
process media and the type of cleaning that is involved, is suitable for dairy processing may be unsuitable for use
he or she can safely provide a lower-cost material that with beverages containing acetic acid.
will perform well in the processing conditions. Another issue with food and beverage processing
The type of media processed is also a critical factor that pumps is hygienic design. Many sealing systems designed
affects seal life. For example, different types of materials to minimize dead space can lead to bacteria buildup.
Pumps that are designed according to state-of-the- Working with a component supplier that has an
art hygienic standards can be cleaned much faster than in-depth understanding of current global regulations
traditional pumps. This reduces the length of the cleaning and that has developed materials to meet specialized
process and elongates the intervals between cleaning requirements for a variety of temperatures, pressures
treatments, decreasing downtime. and cleaning agents is one way to ensure the finished
On the other hand, the use of higher-concentrated pump will work as expected on the line while adhering to
cleaners with cleaning intensifiers at increasing hygienic design standards.
temperatures in order to shorten cleaning time challenges This three-pronged approachconsisting of the
elastomer materials. As a result, suppliers of elastomeric relationship between the supplier, the end users
seals are forced to keep up with that trend, developing engineering team and the purchasing departmentto
high-performance materials in every material class to meet the stringent requirements of a highly regulated
meet these challenges. industry should result in maximized production and
minimized downtime, no matter how complex the
Internal & External Collaboration production line.
The final important factor in successfully navigating
the strictly regulated food and beverage industry is
collaboration between the end user and sealing supplier,
as well as between the different departments within the Thijs Menzel is market research director and food,
end-user facility. To ensure materials meet regulations, beverage and water segment manager at Trelleborg
the users engineers must collaborate with the purchasing Sealing Solutions. He has an extensive background
department. The user should make the supplier aware of in market research, data analysis and business
the manufacturing process used to make the pump, as development within a number of different industries. For
well as the manufacturing and cleaning processes to be more information, visit tss.trelleborg.com.
used on the food or beverage line.
E
E M PS
FRL P
U
HEAVY DUTY
TR
IA
SLUDGE PUMPS
Pumps with no rotors, stators or lobes to replace,
providing superior abrasive handling
Just one wearing part - the hose
Flows to 300 GPM
Suction lift to 30 feet, dry running and reversible
Eliminate ancillary equipment
Ideal for centrifuge and belt press feed
No mechanical seals or packing to leak
wmftg.com
800-282-8823

FOOD & BEVERAGE PROCESS PUMPS SPECIAL SECTION 27
IP 67-Rated Chemical
Pumps Withstand
Washdown & More
The rating means they were tested under 3 feet of
water for 30 minutes and continued to run properly.
BY MICHAEL PRICE
WALCHEM, AN IWAKI AMERICA COMPANY
C
hoosing the correct metering pump involves
many considerations. Among them are accuracy,
repeatability, chemical output, material
compatibility, line pressure, control input, off-
gassing of the chemical and the environment where the
pump will be placed.
Even for pumps that meet the requirements for a
particular application, the environment in which the
pump operates can pose a significant challenge. Metering
Image 1. An example of a metering pump installation (Images
pumps often are used in wet conditions and require daily courtesy of the author)
washdowns of the equipment.
To choose the best pump for an application, end users risk of failure because it operates in the same
must consider the applications environment and how environmental conditions. In some cases, end users
water will affect the equipment. replace these pumps with a waterproof version that can
handle the washdown procedures.
Water Intrusion There are pumps available with a rating of Ingress
Manufacturing a food or beverageas well as Protection (IP) 67 (NEMA 6 equivalent), which means
maintaining a hygienic work area during the process they were tested under 3 feet of water for 30 minutes and
requires copious amounts of water. Washing down the continued to run properly.
equipment requires either raw water or water containing For example, one manufacturers line of these types
chemicals such as oxidants. of metering pumps have been used extensively in
The inundation of water during the washdown process the produce disinfection market where washdowns,
frequently causes pump failure because of water intrusion condensation from low temperatures and perpetually
into the electrical drive or control. wet surfaces exist.
Repairing these pumps is time-consuming and requires In this specific example, these pumps also can be
a replacement pump to keep the line producing. If the used in many environments and processes where water
pump is replaced, the new equipment also faces the intrusion, flooding or washdowns occur.
IP 67 Pump Benefits
Chemical metering pumps are the workhorse in produce THE DEFINITION OF IP 67, ACCORDING TO
applications because all produce must be disinfected to THE SIEMON COMPANY1
remove or kill disease-causing pathogens. The process
typically requires an oxidizing disinfectant such as Enclosures constructed for either indoor or
chlorine, chlorine dioxide or peracetic acid to be pumped outdoor use to provide a degree of protection
to personnel against incidental contact with
into the water that comes into contact with the produce.
the enclosed equipment; to provide a degree of
The residual oxidant must be maintained during the
protection against falling dirt; against hose-
process for the required contact time to ensure that the directed water and the entry of water during
microorganisms are killed and cannot reproduce. This occasional temporary submersion at a limited
usually requires an accurate, reliable and waterproof depth; and that will be undamaged by the external
chemical metering pump in conjunction with a controller formation of ice on the enclosure.
and an appropriate chemical sensor. 6 = Totally protected against dust
The produce disinfection process places pressure
on chemical pumps because of the constantly wet 7 = Protected against the effects of temporary
immersion between 15 cm and 1 m. Duration of
environment. Several tools and accessories can protect
test 30 minutes.
these pumps, but they often pose their own challenges.
Pump covers, for example, can make the pump difficult to
access for adjustment or servicing. Pump boxes also make
pump adjustments difficult, and they can contain heat, more than six years has a complete gasket surrounding
which may cause a heat overload or failure. the cover, which mates with the faceplate to create a
The pumps can be moved to a dry location, but this waterproof seal.
makes it difficult to monitor the performance and make With this equipment, the glands used for wiring the
adjustments. The pump also may require lengthy runs of pump are waterproof when used as described in the
tubing, which can cause loss of prime and chemical feed. manual. In addition, the cabling used for control must
One of the simplest solutions to this challenge is an have a tight fit to ensure it stays waterproof. If the cable
IP 67-rated chemical metering pump. Manufacturing a diameter does not have a snug fit, water can seep into
pump to this specification is not an easy task, but some the drive.
technology can meet the challenge. One companys pump The bolts on the cover plates also must be tight and
that has been in the produce processing market for in the correct position. It is advisable to tighten them
diagonally to ensure that the seal has equal pressure on
all sides.
All pumps must be secured, preferably to a bracket or
a shelf. If a pump is placed on top of a chemical tank, it
may be dislodged during washdown or when the tank is
moved. This is probably the second leading cause of pump
failures in food and beverage plants.
Other Pump Considerations

There are other important installation points users must
consider to ensure that these pumps work as specified.
When pumping an oxidant that off-gasses, it is
important to install an auto-degassing valve. This valve
purges gases from the pump head through a low-pressure
line so that the pump does not lose prime because of a
vapor lock. The purge line returns to the chemical tank.
Vapor lock occurs because gas is compressible and liquid
is not.
When the pump is unable to purge the gas, the gas in
the head is continually compressed and decompressed, so
no liquid moves through the lines. It is always advisable
Image 2. Metering pumps installed in a facility to have the shortest suction line possible, so gas cannot

29
accumulate. This will reduce the time required for the change of the wetted parts that come into contact
pump to purge the gas from the tubing, which will help with the chemical, such as the diaphragm, seats and
keep the chemical residual consistent. ball checks. This procedure can be performed in about
The pump also may be outfitted with a chemical feed 15 minutes.
verification device that will alert end users to the loss of The selected pump has given us superior performance
chemical feed from the pump. The device sends a signal and reliability, said Ben Vogt, national technical support
to a controller or programmable logic controller with an manager for Pulse Instruments and Aqua-Pulse Systems.
alarm when this deviation occurs. With the IP 67 waterproof rating and wide range of
dosing capabilities, the pump can be utilized in a variety
Produce Disinfection of environments and applications.
Pulse Instruments, a California company that
specializes in produce disinfection nationwide, has References
1. siemon.com/us/standards/nema_comparison.asp
used a specific type of metering pump in many of its
accounts over the last six years, significantly reducing
the number of pump failures.
Previously, Pulse Instruments had encountered
issues with water intrusion in its equipment. When Michael Price is the Western U.S., Western Canada and
the pumps failed, the process lines had to be shut down, Australian regional sales manager for Walchem, an Iwaki
and sometimes produce needed to be discarded. The America Company. Price has a degree in chemistry and
specific type of metering pump the company chose did has worked with water and associated systems for more
not fail and has reduced downtime and maintenance in than 30 years using controls, chemicals and biological
the plants. solutions. Price has experience in food and beverage,
The pumps require low maintenance and need to high-purity water, environmental, municipal and
be serviced every two years. The servicing only requires a industrial systems.
STATE
of the
30 INDUSTRY
2017
Y FOR 2017?
AD
RE
U
YO
ARE

STATE OF THE INDUSTRY 31
STATE
of the
INDUSTRY
2017
F
rom new political leaders taking office, to the ongoing evolution
of technological advancements that are improving the way
machines and end users operate, to the development of
regulations affecting the equipment that is used daily, change remains
a critical factor for the pump industry in 2017. This State of the Industry
issue of Pumps & Systems spotlights the important challenges impacting
all facets of the business. More than 30 managers and leaders from
companies representing a cross section of the pumps and related markets
provided their valuable insight into what 2017 could bring to the business
landscape. There is no doubt that operations will continue to integrate
smart technology, which will improve efficiencies by delivering real-time
data for analysis. Speculation is rampant about what will happen to the
oil and gas market in 2017. Changes in the political environment, not
only in the U.S. but also in Europe and elsewhere, are raising questions in
the industry as well. Additionally, companies are preparing for a surge of
retirements involving longtime, experienced and highly valuable workers in
the coming years. The Pumps & Systems editorial team remains dedicated
to addressing the important subjects that impact readers by showcasing
informative, educational articles within the magazines pages each month
and online every day. The tagline, The Leading Magazine for Pump Users
Worldwide, represents a commitment by Pumps & Systems to our readers.
STATE
of the
32 INDUSTRY
2017
9 Critical Questions
about Pump Industry
Regulations in 2017
Michael Michaud, executive director of the Hydraulic Institute, spoke
with Pumps & Systems about how end users can prepare for new
Department of Energy rules and policies.
Take us through what we know and dont new models incorporating more efficient technologies or
know about the federal governments pump designseither completed internally or acquired through
efficiency regulations, their impact and what some of the recent merger and acquisition activity you
we can expect this year. have reported on. So I know the pump manufacturers will
be ready in 2020.
Early in 2016, the U.S. Department of Energy
(DOE) released its commercial and industrial clean
water pump (CIP) Energy Conservation Standard and Does this affect currently installed pumps or
Test Procedure for Pumps, essentially requiring that by only new pumps?
2020, pumps within scope that are sold into the market
will need to be redesigned or reconfigured to meet new The next few years will present some very
efficiency standards. interesting options for end users. The DOE energy
We estimate that these requirements will eliminate conservation standard does not require any change to
some 25 percent of the pumps currently available. currently installed equipment or pumps. However, as
Certainly for pump manufacturers, this is not news as more highly efficient pumps become available in the
they have been preparing for this for some time. marketplace and utility incentive programs become
This is relatively new to most of the end users I speak available, end users will have some interesting choices.
with, however. They are wondering how it will affect When you do a life-cycle, cost-accounting analysis of
themif there will be a significant change to the pumps pumps, most end users find that more than 75 percent
available in the marketplace and if they will need to of the lifetime cost of ownership is various operating
change their procurement practices. costs. Energy costs alone represent the largest share at
40 percent. The upfront cost to purchase the new pump
is generally only around 10 percent, with installation
What do we know now about the impact of coming in at 7 percent.
these changes? Incentives will further reduce the upfront expense,
making it even more affordable to purchase a new,
Manufacturers are already starting to implement more efficient pump, which will have the added effect of
the changes. Many have rolled out or will be rolling out producing more energy savings.

Tell me more about the Utility The Energy Rating Label has some administrative
Incentive programs. requirements as well, including test data coming from an
HI-approved pump test lab. This step is very important
The Utility Incentive programs are designed to for the utilities that require an additional level of
transform markets quickly. Utilities like to think of these assurance that the performance on the label will actually
programs as building nega-watt plantsessentially be seen when the pump is in use.
taking a negative amount of energy off the grid. Utilities
have been doing this successfully with lighting and
variable speed drive (VSD) rebates. What is the timing on this? When can we
Some pump-related programs already exist, but they expect these to transform the market?
tend to be what the industry calls custom programs.
These are generally used for a larger pump installation Timing is a great question. Obviously, the earlier
where there is a lot of engineering, testing, data collection these programs are put in place (prior to 2020), the
and validation larger the impact. HIs Pump Test Lab Approval Program
and obvious energy (PTLAP) has
Figure 1. Typical life-cycle cost for a pumping system (Courtesy of Hydraulic close to a dozen
savings. Institute)
More recent manufacturers/
activity is moving Installation 7%
labs involved now.
Pump 10%
toward deemed The Energy Rating
Environmental 5%
incentives. This Label program is
approach collects the Downtime 3% set to launch in Q1
data to analyze and 2017. We have been
validate the energy Operating 10% working with utility
savings up front. groups for several
Doing this allows years already and
public utilities to put have been sharing
in place a prescriptive data all along, so the
rebate program utility program side
that can be adopted should also be ready
everywhere. The to go in early 2017.
savings have been The early adopters
predetermined, and will start to see
Maintenance 25%
the administrative Energy 40% some impact in 2017,
process is essentially and we expect the
streamlined. The program to be well-
Hydraulic Institute established in 2018.
(HI) is providing the
data so this testing and validation can be done now, but
more fundamentally, we have also developed an Energy What will happen after 2020? Will market
Rating Label specifically for this purpose. incentives still be available?
The general consensus is that there will still be

incentives in the marketplace. Pump systems account for
Tell us more about the Energy Rating Label.
25 to 30 percent of the electricity usage, so it will take a
while to replace or upgrade that amount of equipment.
HI worked with the DOE to develop the test And even if the regulatory or incentive levels change, the
methodology that manufacturers use to measure Energy Rating will still be the yardstick used.
performance. The Energy Rating Label is essentially HI is proud to develop a system that could meet the
HI 40.6 (the pump test standard that also happens to strict technical requirements of the regulated utilities
be a requirement by the DOE) plus some additional but also be able to grow with the industry. Of course,
calculations consistent with the CIP regulation. it also helps that HI is working in concert with the
STATE
of the
34 INDUSTRY
2017
HI is fortunate to have great support from the entire

pump industry, our suppliers, partners and a
growing group of end users. We have always come together
at meetings to collaborate on standards.
trade organizations for motors (National Electrical specifically designed to circulate water with motors that
Manufacturers Association), compressed gas (Compressed must be mounted horizontally. These types of pumps are
Air and Gas Institute) and fans (Air Movement and most prevalent in hydronic heating and domestic hot
Control Association) to align our efforts and streamline water recirculation.
the process for all our applications. As far as DPPPs are concerned, a process similar to
No matter how good the incentive program, for it to that described for circulator pumps was used. A NOPR
be truly effective, it still has to be easy for the utilities to for the test procedure, which also defines the scope, was
quantify and manage. Adopting a common framework for published in the Federal Register on Sept. 20, 2016, and
all will help this effort. was open for comment until Nov. 21, 2016.
It is expected that a test procedure final rule and
standard level direct final rule will be issued in 2017
Are there other upcoming regulatory changes for DPPPs.
we should be aware of?
There are two additional regulatory processes A lot is changing in the pump industry in
related to clean water pumps that are active at the terms of regulations. How is HI keeping up?
moment. They cover circulator pumps and dedicated
purpose pool pumps (DPPP). HI is fortunate to have great support from the
These pumps were excluded from the CIP entire pump industry, our suppliers, partners and
regulation because of their unique designs for those a growing group of end users. We have always come
specific applications. together at meetings to collaborate on standards. Now we
HIs Circulator Pump Committee started working are sitting down with end users to develop training and
with energy advocates in 2014. In early 2016, based on certification programs to help them understand
recommendations from advocates and the HI committee, their systems.
the DOE approved an Appliance Standards Federal Working closely with end users has also helped HI
Rulemaking Advisory Committee (ASRAC) working re-engage with members in a whole new way. This is
group (a similar process that led to the CIP regulation) to exciting, particularly this year as we celebrate our
recommend a test procedure and standard level. centennial. So look for a few more new programs in 2017,
The 15-member ASRAC working group met more and keep your eye out for our new anniversary logo,
than 20 times to negotiate and complete the term which will bring the industry together even more and
sheet by December 2016. The term sheet included carry HI well into the next century.
recommendations on scope, test procedures and standard
levels for the Secretary of Energy to consider.
We are now waiting for a Notice of Proposed
Rulemaking (NOPR), expected in 2017, with a final rule Michael Michaud is the executive director of
to follow. the Hydraulic Institute, the largest association
In general, the term sheet recommends standard levels of pump original equipment manufacturers
for inline pumps up to 5 hydraulic horsepower that are and supplier companies in North America.

Preparing Today s Workforce

for Tomorrow s Challenges
With large numbers of people retiring in the coming years, the industry is
emphasizing training opportunities more than ever.
BY MARTIN J. REED
PUMPS & SYSTEMS
W
hen Zoeller Company started
planning the development
of its Center for Excellence
training facility at its Louisville,
Kentucky, headquarters a few years ago,
educating its employees and others throughout
the pump-related industry was the goal. But
there was another important reason driving the
need to increase training opportunities.
We recognize that about 20 percent of
our workforce (at the Louisville offices) would
be able to retire in the next 10 years, Zoeller
Company Corporate Human Resources Director
Dwight Newton said in a recent interview.
Corporate-wide, Newton put the figure at about
15 percent. That represents our most seasoned
and knowledgeable staff, experience from Image 1. Zoeller Companys Center for Excellence is a 12,000-square-foot training facility
all realms of both hands on the line all the that opened in September 2015 at the companys headquarters in Louisville, Kentucky.
(Courtesy of Zoeller Company)
way through senior management. It covers
the gamut.
He added, Its exciting, but it puts us in a position to have Many large, older companies are caught up in a tsunami of
to think about, How do we transfer the knowledge? And that baby boomers retiring and are unaware of how much tribal
is what the Center for Excellence was built for. knowledge they are taking with them, Harvard Business
Zoeller is not alone. Numerous industriesnot just within School Professor Emerita Dorothy Leonard was quoted as
the pump-related worldare facing challenges associated saying in a January 2016 BloombergBusinessweek article.
with an aging workforce as members of the baby-boomer The concern is felt throughout the pump-related industry
generation (those born between 1946 and 1964) are reaching as companies anticipate the retirement of experienced
retirement age at a reported rate of about 10,000 every day. workers and place an extra emphasis on training
STATE
of the
36 INDUSTRY
2017
This gap also branches beyond end users and includes

local industrial product distributors who have been
viewed as product experts throughout the years for
industrial plants. With the combined loss of knowledge
at both the end user and distributor level, more time
and effort are required than ever before to get industry
professionals up to speed on the various industrial
technologies, Sandlin said.
Center for Excellence

Industry organizations such as the Hydraulic Institute
and the Submersible Wastewater Pump Association are
offering a host of educational opportunities for clients,
while many pump-related companies are focusing on
training as they prepare for the future. Zoeller and its
Center for Excellence, a 12,000-square-foot facility that
opened in September 2015, are a prime example of a
company focused on education.
This is not a new processthis is something we
have been doing as long as we have been in business,
John Enyard, director of the Center for Excellence,
said about providing education. But we have seen its
something that needed to be elevated to a different level.
What we looked at is doing training, taking people into
the shop, showing them whats going on. This has
all been going on for a number of years. About three
years ago, we decided we had to do it better at a more
permanent location.
Zoeller started construction in early 2015 on the
Image 2. More than 300 people attended Geiger Pump Center for Excellence and completed the facility in
& Equipments Mid-Atlantic Pump & Process Equipment September 2015. The companys entire workforce has
Symposium XI on Oct. 6, 2016, in Aston, Pennsylvania. The
daylong event included educational sessions involving been through classes at the training site, and about 600
centrifugal pump repairs, pump system optimization, wastewater other people have received training at the facility. Its
challenges and more. Representatives from several companies something that we have to do, Enyard said.
attended to inform attendees about their products and services.
(Photo by Martin J. Reed/Pumps & Systems) This is some of the stuff in the last two weeks that we
have done: We have our customer support people, our
opportunities for their employees and others within their product support people, come into a training, and they
business spheres. We have identified the impending would take a pump apart to install a new switch in
departure of longtime, knowledgeable employees due it, so when they talk to customers on the phone, its not
to retirement, etc. for several years, Flowserve Vice that theyre just reading it out of a manual. They have
President of Product Management Eric Van Gemeren said physically done it themselves, Enyard said. Theres
in an email to Pumps & Systems. We have implemented nothing better than that to train somebody.
training to transfer this knowledge (especially tribal During the same time frame, Zoeller provided safety
knowledge) to younger associates. training for the companys shop personnel, while a group
At Graco Inc., the pump manufacturer has observed from Alaska traveled to the facility to learn.
impacts from departures around the industry. As Were using a lot of technology, doing videos, using
more and more long-term, experienced maintenance screens, but one of the main things we try to do here is
technicians are leaving the field, we see the skills for every hour in the class, we want an hour of hands-on,
gap increasing quite dramatically, Mike Sandlin, the Enyard said. The technology is great, but Im old-
companys global product marketing manager for the schoolif you dont pick it up, if you dont touch it, if you
process division, said in an email. dont smash your hand on it, you dont learn.

Demand for Training

At Grundfos, Steve Schmitz, the companys director
of technical education for the Americas, has seen a
booming demand for training offered by the Grundfos
Technical Institute, which provides a range of courses
from the beginning through the advanced level.
Absolutely, its been growing since we started it in
2015, Schmitz said in an interview.
I dont see anything changing thats going to lessen
it. With rules and regulations in industry becoming
more paramount and restrictive, people who are putting
buildings up and designing systems that are going into
them have their hands full, he said. We view our job
here as a way to help them along in that process.
The Grundfos Technical Institute addresses the
growing need to provide qualified, educated workers
throughout the industry, Schmitz said. It does touch
on whether you have a lot of retirements in your system
or not. It does touch on if you have the most qualified
people in your positions that youre fi lling, he said.
People who are more knowledgeable about the
products and applications they can go into can first of
all realize the issues the customers have and give the
most correct answer to the problem, Schmitz said. Its
always been very important for Grundfos that we have
people who are properly trained in the marketplace.
The Grundfos Technical Institute serves workers
in North and South America by providing virtual
classroom courses and webinars that are 100 percent
free, Schmitz said. The only thing we charge for is face-
to-face courses, he said, but in the last couple of years,
we have really moved away from the traditional model
thats out on the marketplace, the face-to-face training.
The virtual courses allow anyone with an internet-
connected tablet or computer to learn about a myriad
of subjects at their own pace. Courses are available in
Spanish and English. Visitors to the website grundfos.
us/training can register for courses in categories
including agriculture and irrigation; commercial and
residential plumbing; heating, ventilation and air

conditioning; fire pumps; municipal water systems;
water treatment and dosing systems; and more.
If you look at the courses some of these students are
taking coming out of the engineering schools, theres not
as much focus as you would see on basic foundational
blocks, Schmitz said. Our approach is very much an
application-based approach, what is the best-practice
way to accomplish what is trying to be done.
Considering the courses are free and students can
take them at home or from an office, the demand at the
Grundfos Technical Institute continues to increase.
STATE
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2017
i-ALERT2 device that provides

up-to-the-second condition
reporting on a pump or other
machine.
Geigers Symposium is a
biennial event that offers a
host of classroom sessions on
pump repair, pump system
optimization, wastewater
challenges and more. At
the 2016 event, more than
300 people representing
100 customer organizations
attended, along with
representatives of several
manufacturers who discussed
their latest products.
Geiger President Henry Peck
said the educational events
are an important way to help
train customers and learn
about their needs. It gives us
an opportunity to understand
Image 3. Geiger Pump & Equipments Rebekah Macko talks about pump system optimization their business as well because
during the companys Mid-Atlantic Pump & Process Equipment Symposium XI on Oct. 6, 2016, in
Aston, Pennsylvania. (Photo by Martin J. Reed/Pumps & Systems)
now you have a forum, Peck,
who serves on the Pumps &
Systems Editorial Advisory
Its expensive to travel and even more so having Board, said in an interview at the Symposium. We learn
people out of the office for several days, said Schmitz, from them, and they learn from us.
noting that thousands of people have taken courses With many longtime workers retiring in the coming
since 2015. Grundfos employees, depending on their years, the need for reliable training opportunities is more
job positions in the company, are required to do a critical than ever, said Chris Brown, Geigers executive
certain number of courses every year. Outside of the vice president. I think there is a huge need, and there are
companyoverwhelmingly where we see the usageit not enough people generating that content, Brown said.
comes from all spectrums across the board as far as titles Thats a big piece where we can fit. We see a position
and positions. for ourselves where we can play a role in that next
generation of training.
Hands-On Learning Jeff Warden, a maintenance technician with NuStar
One day last October, beneath one of the four big-top Energy in Baltimore, Maryland, said training sessions,
tents temporarily set up at Geiger Pump & Equipment including those organized by Geiger, help provide
Companys facility in Aston, Philadelphia, the companys valuable knowledge for workers. Theyre very important
Todd Jenner led a class on centrifugal pump assembly because of the various applications, Warden said.
and repair. The bustling activity at the facility signaled Everything we do is hands-on. The more hands-on we
the arrival of Geigers Mid-Atlantic Pump & Process get, the better we can be.
Equipment Symposium XI.
Dozens of end users from a broad spectrum of
industrial applications gathered around workbenches as Martin J. Reed is managing editor of
they received instructions about disassembling pumps Pumps & Systems. He may be reached at
during Jenners hands-on class. As he talked about mreed@cahabamedia.com or
condition monitoring, Jenner likened the real-time 205-212-9402.
monitoring provided by a Fitbit tracker to the Goulds

STATE
of the
INDUSTRY
39
2017
6 Global Factors Aecting the

Pump Market in 2017
Many of these factors relate to the ongoing instability in various parts
of Europe, but in today s interconnected global economy, innumerable
current events and trends can impact the marketplace.
BY TOM ANGLE, HIDROSTAL AG

& CHRISANGLE, MECHANICS BANK
A
s 2017 commences, several new factors have Trumps apparent mercurial personality makes it difficult
come into play in Europe and around the world for pump companies to plan their European strategies given
that have the potential to impact the U.S. pump that the range of potential outcomes is much larger than
industrys business significantly in the coming what the U.S. would likely have with a more traditional
years. Many of these factors relate to the ongoing political/ president-elect.
economic instability in various parts of Europe, but in todays
interconnected global economy, innumerable current events
and trends can impact the industry. While this is not an
exhaustive list, end users can expect the following six factors
2 Brexit
The second major factor affecting the industry is Brexit.
The vote of the British to leave the European Union (EU) sent
to affect the pump marketplace. shock waves throughout global markets. While the economic
doomsday predictions that followed were overblown, the
1 U.S. Presidential Election

The first major factor that could affect the industry
in 2017 is Donald Trumps election as U.S. president. As
impact on European-American trade has yet to be determined
and will largely depend on the final Brexit negotiations.
American pump companies doing business in Britain and
the nation awaits inauguration day, it is difficult to know the rest of Europe will face the challenge of operating in two
how Trumps administration will affect the economy in different regulatory environments. Exactly how different
the long-term. they will be depends on the negotiationsthe outcome of
While it appears that a Trump White House could be less which remained unknown at press time. The Brexit vote has
committed to maintaining the global business system that depreciated the British pound substantially, and this has
has existed in some capacity since World War II, how far made American exports into the U.K. less competitive at the
the administration deviates from the status quo will help very least (all things being equal).
determine how the business climate in Europe will change.
If the Trump administration makes trading with Europe
more difficult, the U.S. pump industry could face unforeseen
consequences. On the other hand, if Trumps policies treat
3 Anti-Globalist Trends
Another issue is the rise of hard-right/anti-globalist
parties in various parts of Europe. The free-trade paradigm
European partners more as traditional allies with whom good that has been more or less in place in Western Europe since
relations are paramount, they could end up benefitting trade. the end of World War II is being called into question. In 2017,
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2017
France could end up with a president from the National implemented likely in the next three to five years. U.S.
Front, an anti-globalization party that, up until a few pump manufacturers must be aware of the ramifications
years ago, was not largely taken seriously. The migrant regarding exporting product into the EU.
crisisand Germanys unpopular response to itis Other recent EU regulation changes and
fueling segments of the German political spectrum that implementations will affect pump manufacturers.
are less sympathetic to open borders and free trade. Recently new ATEX rules took effect. The changes
Across Europe, right-wing/anti-globalist parties that basically modify definition and paperwork procedures,
either were not taken seriously or maybe did not even but it is important to be aware of the new requirements.
exist 10 to 15 years ago are helping to set the agenda in Important for those manufacturers that supply
many countries. The result is likely to be a Europe less transmitting equipment with their pumps and motors, a
open to free trade, which means that doing business in new Radio Equipment Directive (RED) became applicable
Europe may be more difficult in the future. on June 12, 2016. New equipment placed on the EU
market after this date must be in compliance with this
4 Resurgence of Russia
The fourth major factor is the resurgence of Russia.
One of the major foreign policy challenges for the West
directive. Equipment currently being marketed has until
June 13, 2017, to meet the requirements.
Several other items on the horizon could affect pump
is how to manage Russias attempts to flex its political manufacturers, but currently neither details nor hard
and military muscle. A consequence is that Russian implementation dates are in place.
movements, which can be unpredictable, may have Materials in Contact with Drinking Water: This is an
impacts on foreign currency markets for years to come. attempt to standardize the allowable materials used
in pumping, controlling and conveying drinking water
5 U.S. Commitment to NATO

There is some question regarding Trumps
commitment to the North Atlantic Treaty Organization
across the EU. Currently, each member state has its
own requirements, and exporters into Europe face
an extremely complex situation. Studies have been
(NATO). While Trump may have been hyperbolic on the ongoing for more than a decade, and no consensus
campaign trail, any indication (true or not) that he is has been reached concerning the standard and an
softer on NATO than prior U.S. presidents could cause implementation date.
Russian President Vladimir Putin to be more aggressive Product Environmental Footprint (PEF): This
than he otherwise might have been. To the extent that is a carbon footprint defined as the total set of
the Russian threat to the Eastern European Union seems greenhouse gas emissions caused by the production,
to be growing, this could cause a depreciation in the euro lifetime operation and disposal of a product. There
and make U.S. products sold in Europe more expensive. is ongoing work on this initiative, and the pump
The converse is also true. These currency fluctuations industry, through Europump, is participating in the
are likely to complicate planning for U.S. companies doing development of the calculation procedures to comply
business in Europe. While many factors cause currency with an eventual European directive in this area.
fluctuations, Russia has not been a factor in the past but Practical implementation of such a directive is several
is likely to be one for the foreseeable future. years away.
Waste Electrical and Electronic Equipment (WEEE):
6 Regulatory Environment
Both current and possible future regulations for
energy savings are themes on which the pump industry
This directive that became European law in February
2003 set goals for recycling all types of electrical
and electronic goodsincluding all pump motors.
in Europe will remain focused. Currently, building Because it did not meet its goals, the initiative has
circulators and certain other pumps have regulations been amended and now places the responsibility for
in place regarding minimum efficiency requirements. a products final disposal on the manufacturer or
Working groups in Europump (the European Association distributor. At this point, only consumer goods are
of Pump Manufacturers) are involved in defining covered, but there is discussion regarding expansion
proposed efficiency standards for wastewater and other into industrial products. At this time, pump
types of pumps. manufacturers are excluded, but the pump industry
While getting agreement and implementing and in Europe is keeping a close eye on this issue. If the
enforcing these regulations across the EU can be industry does come under this directive, the costs will
challenging and time-consuming, these new rules will be be quite high.

One Certainty
Overall, doing business in Europe has been challenging
over the last few years amid the financial crisis as one
over-leveraged country after another has caused worry
in the markets and the euro to depreciate. Many of
those factors remain, and some new macro-factors have
arisen that can add instability to the euro in the coming
years. While companies experienced in doing business in
Europe likely will not be forced to abandon the market
(as some Brexit doomsayers have predicted or advised),
their activities probably will be more challenging.
There are many unanswered questions and
uncertainties. The political, economic and regulatory
environments point to a future that can seem to be
incomprehensible, and it is easy to fall into doom-
and-gloom thinking. Steve Schofield, director and
chief executive of the British Pump Manufacturers
Association, provides important advice for the industry:
Nobody knows what effect Brexit or Donald Trump
becoming U.S. president will have on global markets.
The current predictions are for growth across Europe to
be around 0.5 to 1 percent for 2017 and 18. The low oil
price affects many sectors, and growth looks stagnant
for the foreseeable future. Areas such as commercial,
building service, water, and water and wastewater are
expected to retain their current levels of business, and
in some countries they are expected to grow further.
The majority of pump manufacturers are now truly
international with businesses set up in the majority of
continents around the globe, so they can have a negative
effect in one location and a positive effect in another.
One thing is for sure: If you wish to move a liquid from A
to B location, a pump will be required.
Tom Angle is chief engineer for Hidrostal AG in

Neunkirch, Switzerland. He has more than 40 years
of experience in the pump industry. He has BS
and MS degrees in engineering and is a Registered
Professional Engineer in California. He is also a
member of the Pumps & Systems editorial advisory

board. He may be reached at tom.angle@hidrostal.ch
or +41 526870687.
Chris Angle is the equipment finance manager

for Mechanics Bank in Walnut Creek, California.
He has management experience in multiple
industries including agriculture, international
logistics and finance. Angle has a bachelors degree
in international relations and a masters degree in
international economics and finance.
STATE
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2017
Let s Talk About 2017

More than 30 industry leaders answered key
questions about the pump marketplace in
2017. The Pumps & Systems editorial team
selected excerpts from their responses to
help you prepare for the new year.
MORE COMMENTS AND ANSWERS CAN BE FOUND AT PUMPSANDSYSTEMS.COM.
What are the most important innovations for 2017 in

instrumentation, controls and monitoring?
SCADA systems have been around for decades. Much data has
been collected, but most goes unused, sitting in data silos. The
advent of smart water systems marks a change in direction of
how data can help further improve decision support. Look to
see these types of intelligence-gathering investments better
leveraged in 2017, driven in part by the use of advanced
analytics from data collected via the IIoT from pumps, valves
and bearings. Information acquired from these devices will
increasingly let operators visualize what is happening in the
field and, when things are not in order, provide alarms faster to
elicit an appropriate response.
Rudy Engert
Business Development Manager for Infrastructure, Schneider Electric
The Internet of Things (IoT) will continue to deliver increased

efficiencies, fewer product defects and improved customer
satisfaction for those companies that implement an IoT
system. For 2017, this will be significant as recent market
research indicates that 87 percent of manufacturers still have
not implemented an IoT system, and 95 percent of companies
plan to in the next three years. While IoT is significant for the
manufacture of the IoT architecture, more important is the
intrinsic commercial value for companies who deploy IoT. The
unique value-added services that an IoT system offers customers
improve intimacy and brand loyalty than any single product can
deliver on its own.
Michael Robinson
National Marketing Manager - Projects, Solutions & Services, Endress+Hauser
As industrial manufacturing instrumentation and control systems have

increased in complexity, optimizing performance or solving problems with
these modern systems is becoming a bigger challenge. Innovations in modular
measurement sensors and cloud data analysis are just beginning to help make
sense of these systems.
Hilton Hammond
Power Quality Business Unit Manager, Fluke

Much of the market is eager to In 2017, pump distributors are benefitting

see continued development and Our industry has experienced an from an ever-increasing offering of better
implementation of equipment fitted with influx of technology from advanced products from pump manufacturers.
interactive instrumentation for controlled Most of those product offerings are in
design softwares communication
operations. A goal for many of our clients the controls and monitoring of pumps to
technologies to the ability to monitor
especially those who operate multiple units provide more efficient operating conditions
spread across a large areais to reduce applications from anywhere in and advanced predictive maintenance
operational costs and increase their own the world with handheld devices. solutions. Additionally, the natural turnover
efficiency by: The industry has grasped these in the generations of employees has paved
advancements. We are seeing the way for new, highly capable pump
Eliminating the need to hunt for changes in our mature industry people to join our industry. And the benefit
mechanical failures that may have every day. End users must educate of that is showing. We are beginning to
already occurred in the field by zeroing themselves, explore and embrace show significant gains in productivity
in on problems via remote monitoring these technologies in order to through more efficient communication
technology before ever deploying a remain competitive. The next and supply chain tools with customers
technician to the field and suppliers.
generation of end users will require
Scaling back 24-hour pump watch Henry R. Peck
more information faster with fewer
on less critical pumping systems by President, Geiger Pump & Equipment Co.
collecting and monitoring operational challenges from old technologies.
data from afar, and responding to issues Application and product convenience
Capital investment requirements (in) the
only when they arise is the future, and as manufacturers,
U.S. wastewater systems are estimated to
Utilizing remote technology to activate we must adapt and prepare to be total almost $300 billion over the next 20
a pump on standby or to deactivate a successful in the coming year. years. Pipe repair represents the largest
pump that no longer needs to operate need to address combined sewer overflows.
without the need to deploy personnel Deron Oberkorn
Director of Business Development, There are roughly 800,000 miles of sewer
Managing preventive maintenance mains in the U.S., and many of these
Zoeller Company
and fueling operations by using the pipes are over 70 years old and in terrible
information gathered and reported back shape. The aging sewer pipes are the main
electronically The most interesting innovations are in the cause of combined sewer overflows. In
Avoiding disastrous system failures areas of how information is being handled. lieu of repairing their existing combined
on unmanned operations due Digital information platforms continue to sewer overflows, many municipalities
to mechanical breakdowns via reshape our business. We are seeing much are beginning to separate combined
instrumentation-driven messaging when more activity in the areas of preventive sewers into purely sanitary sewers and
certain pre-determined triggers are met, and predictive maintenance, which leads separate storm sewers. When new
allowing rapid operator response time to to new products being developed with the systems are built, most municipalities
mitigate potential damages. Industrial Internet of Things in mind. prefer to construct a separated system to
Randy Breaux prevent future combined sewer overflow.
Devices such as the Global Messenger Senior Vice President of Marketing, Distribution As wastewater separation continues,
Device allow clients to have this kind & Purchasing, Motion Industries Inc. manufacturers supporting municipal
of functionality on any pump they rent wastewater systems will need to design
or purchase. They can set certain their products to support more viscous
operational parameters, maintain a What trends and challenges wastewater with less volume flow.
database online to track performance do you foresee for the future?
data and track a pumps physical location Walt Erndt
Vice President & General Manager Municipal
using GPS technology or by establishing I believe that aftermarket services will
Market, CRANE Pumps & Systems
geofences to trigger an alert when a pump continue to increase in importance.
is relocated. All information captured Servicesengineering, education, training,
The Internet of Things, which is driving
by the instrumentation is available plant assessments, testing and field
innovation from the connectivity of smart
to customers on an exclusive, secure supportwill continue to grow. Pumps
devices, is beginning to make its way
and password-protected web page for suppliers will not be just vendors but will
into industrial equipment. End users of
immediate remote access. I would expect work together as partners with pump users
industrial machines and equipment are
the demand for this type of technology to in all industries to enhance operations and
now seeing advantages and benefits to
only grow over time. reduce total cost of ownership. acquiring real-time data to assess machine
Gino Mersino George Harris health remotely. The integration of
President & CEO, Global Pump President & CEO, Hydro Inc. condition monitoring devices to handheld
STATE
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44 INDUSTRY
2017
mobile devices and remote systems may opportunity for end users to use them in The water/wastewater industry is a huge
hopefully allow end users to more actively places they never thought possible before. growth area and will continue as long as our
ensure pump efficiency and reliability. Melissa Stiegler population continues to grow. I see power
The challenges faced will be to achieve Director of Wireless Product Marketing, Emerson generation and water/wastewater to be the
this level of integration and mobility two most active industrial sectors, assuming
without sacrificing security of the the EPA doesnt add any additional
industrial plants network(s). What trends are you seeing in regulations. If the Keystone pipeline is
David R. Mikalonis chemical processing? approved, I see oil and gas coming back.
Vice PresidentApplication Engineering, I would also expect advancements in
SKF USA Inc. Digitalization: There is more integration desalination as aquifers are depleted.
globally with devices and machines
William C. Livoti
We are seeing moves in the emerging generating massive amounts of data,
Power Generation, Business Development
world to supply 24/7 water; i.e., water that which is leading to an increased focus on Manager, WEG
is available all the time as opposed to a integrated engineering and operations as
time-restricted supply. This is opening well as cloud-based data analytics.
Modularization: There is an increasing What can end users expect to
opportunities for innovative solutions
in new distribution systems, where urgency to bring products to market see in 2017, and what should
historically everything had been a manual faster by building plants in multiple they do to prepare?
operation. (In 2017, end users can pieces in parallel and in the most optimal
locations possible. Assembling process Water will be a key focus for Blacoh
expect to see) a move from mechanical
lines from modular components enables Industries globally in 2017. India and
to automated controls, upgrades and
manufacturing to be brought online China are the fastest areas for growth in
maintenance to aging infrastructure for
faster and also provides the flexibility to the water/wastewater markets where the
developed countries, and rapid expansion
rapidly transition between grades or types total global market is expected to grow
of water distribution systems in fast-
of products. Standardization: (This) ensures by 7.4 percent. The U.S. water treatment
growing developing nations.
that, regardless of production location, the equipment market is forecast to be up
Mark Gimson almost 6 percent, making the market worth
Business Development & Marketing Manager,
result will be consistency and high quality.
$13 billion in 2017. Where else do we see
Singer Valve Inc. Doug Child growth like that? In the global water
Director of the Chemical Industry for the US,
Customers are pushed these days by a Siemens sector, we are seeing aging infrastructure
very competitive global marketplace to with piping systems failing in large part
reduce prices and costs. ... Our customers (due) to transient pressure waves resulting
cannot afford to keep engineering or What trends are you seeing in shutdowns and waste. It is amazing
maintenance talent for the occasional in water and wastewater, that in a day and age where everyone
project in their facilities. What outside mining, desalination, pulp talks about being responsible for the
engineering firms used to do is now and paper, etc.? environment, we stand by as we lose over
expected from capital equipment suppliers. 7 billion gallons a day in the U.S. and 1.7
We have to supply complete, timely and Given what has happened in Flint, trillion gallons globally due to leaks, main
responsive solutions to address the whole Michigan, and California, a more breaks, meter errors or theft. It is reported
problem. If we need to supply electric widespread focus on water and wastewater that globally, up to 60 percent of water is
panels, we do it. If we need to supply is increasing. After emerging from the lost due to leaking pipes, costing water
piping, we do it. If we need to supply economic downturn, which undercut utilities $14 billion globally. ... I do believe
volumetric feeders and eductors to make public spending in water infrastructure by we will see mining begin a comeback over
up a solution, we do it. Being responsive almost 15 percent from 2009 to 2014, we the next few years with a gradual uptick
to customer needs, solving problems, and anticipate a surge of network upgrades starting in 2017. Similarly, we see a rise in
eliminating production downtime, upsets that will usher in a range of infrastructure the chemical process industry as oil prices
technology, equipment and financing will likely hover around $50 barrel in 2017,
or scrap is what is required.
solutions. More broadly, several trends coupled with a small increase in CAPEX
Michael L. Dillon to watch will be in the markets ability to spending. Still, if the Russians continue
President, SEEPEX Inc.
stay ahead of deteriorating infrastructure, to meddle in the Middle East and the U.S.
There is going to be a trend of sensors supply a growing population with clean continues to back out, oil prices may rise
everywhere and more and more points to water and mitigate wastewater effluent more quickly than anticipated, impacting
monitor. We see a big opportunity around impacts on water bodies. the chemical processing industries as well.
corrosion monitoring. Because the sensors Reese Tisdale Andrew Yeghnazar
are wireless and non-intrusive, there is an President, Bluefield Research President, Blacoh Industries

With the consolidation of resources at global regions including Africa, Asia and The anticipated gradual rebound of the
suppliers, there are bound to be gaps South America are witnessing continued oil and gas sector this year coupled with
in service, and end users are going to strong population growth, living standards growth in chemical and processing sectors
struggle to fill in the gaps themselves or are improving, and industrialization will boost the pump industry and allow
find alternates. Suppliers focused on the continues apace. At the same time, existing for more competition and growth. This
aftermarket and providing complete service water resources are becoming scarcer will fuel more innovations and support
are going to be the highest-value providers also in the Middle East. In the upcoming further expansion in the industries that the
to end users. This leads to long-term decades, the tasks of sourcing, processing pump industry supports. Further economic
relationships where both the end user and and supplying water to residential and resurgence will support demands of the U.S.
the supplier are committed to collaborating industrial areas will become increasingly infrastructure improvements, which will
to provide goods and services that result crucial. Equally vital will be the treatment leverage the pump industry.
in the highest value proposition. It makes of wastewater. Many emerging and Keith Grgurich
economic sense in the long run. developing economies still need to build Director of Sales, BJM Pumps LLC
Eric Van Gemeren the requisite infrastructure, and this is
Vice President, Product Management and R&D, where we see the most significant potential We are doing some interesting things
Flowserve for growth. In the U.S., it is clear (that) the with control panels. Were seeing greater
aging infrastructure as well as the impacts connectivity capabilities and giving
End users can expect product innovation of a changing wastewater are resulting in customers the ability to monitor and even
targeting communication and energy control pumps remotely. These factors
the need for upgrades and improvements to
efficiency. System monitoring via PLC, allow for more efficient pumping systems,
the existing systems and hence a need for
SCADA and DCS require products capable as well as fleet and jobsite management.
investment. This represents excellent sales
of delivering real-time information to After the shake-up caused by Tier 4
opportunities for our products.
increase production efficiency and provide Final, there is more certainty in product
a clear view into current process conditions. Thomas Belledin designs. We are now starting to see real
Additionally, manufacturers are tuning VP Global Business Development, KSB Inc.
benefits from these new engines and
equipment to operate more efficiently controls, as well as lower emissions. Pump
to reduce energy consumption at the manufacturers are better poised to deliver
plant level. Smarter pumping solutions with the right solutions.
Mike Sandlin more emphasis on reducing or
Bobby Zitzka
Global Product Marketing Manager, Process eliminating nuisance call-outs, National Sales Manager, Thompson Pump and
Division, Graco Inc. spills and under performance. Manufacturing Company Inc.
More emphasis of total integration
Expect a mirror result of 2016 In challenging times, there are always
in water and wastewater networks
unless you make moves to improve pockets of opportunities that exist in our
to reduce power consumption and
your market position. Focus on reducing dynamic markets. In order to capitalize on
COGS to improve margins, advertise
enhance process capabilities. these opportunities and fully maximize
the same amount or more in 2017 to Peter Diffley company efficiency and productivity, you
improve your market share compared U.S. Monitoring and Controls Manager, need to be smarter, quicker and more agile.
with competitors and carefully guard the Xylem Strategies need to be clearly defined, razor-
addition of new employees and operating sharp and fine-tuned along the way in order
costs to ensure positive profitability. to prime consistent organic growth. As we
Motivate your sales staff to be active and move into 2017, we will look to accelerate
focused on target customers. our growth, optimize our cost structure,
Global trends such as aging infrastructure, and increase our customer interface and
Todd Loudin
urbanization, increasing energy costs installed base connectivity by globalizing
President, Flowrox Inc.
and the need for sustainable solutions and localizing the sales and manufacturing
are driving the need for smart water capabilities of our portfolio in the Asia and
What kind of year will this be technologies and intelligent water devices. EMEA regions. Our brands and technology
for water/wastewaterboth Our recently launched Flygt Concertor are market leaders. We will continue to
intelligent wastewater pumping system is invest in them and the innovation pipeline.
in existing and emerging
a good example of new, smart technology Talent acquisition/development, both
markets?
developed to address these challenges. internal ... and external with our various
The global water and wastewater market Kristel Zaman partners, is key for achieving our goals.
is on the rise. A number of important North America Flygt Product Marketing Gennaro A. DAlterio
megatrends point in this direction. Several Manager, Xylem Global President, CECO Environmental
STATE
of the
46 INDUSTRY
2017
How do you see could help too. Carbon taxes could the over-inflated prices that we have
governmental regulations spill over into the U.S. with some states seen in previous years. Increases in
impacting the market in adopting them. fracking are not anticipated to be
extremely positive, but I believe the
the coming year? John Malinowski
Senior Manager of Industry Affairs, bleeding has stopped and that trend
Given what has happened in Flint, Baldor Electric Company will not continue in 2017.
we have several U.S. DOE regulations Mike Pulley
in play at this time. Revised rules for Product Support Manager,
electric motors went into effect June Bartlett Bearing Company Inc.
2016 for integral HP motors. OEMs We are seeing additional
continue to adjust to these as old opportunities in the power market
How is the departure of
inventory is used up. Almost all three- and particularly in the coal-fired
knowledgeable employees
phase motors will now be premium plants, which are being forced
efficiency. DOE issued two proposed due to retirement affecting
to reduce their coal combustion
rules in 2016; one is for collection your company, and what
residuals as part of the EPAs
of import data on DOE-regulated steps are you taking to fill
Resource Conservation and
products. For the pump industry, that the resulting skills gap?
Recovery Act. Also, the loosening
would mean that any importer of a
pump and motor would need to file of EPA regulations could have a With the ongoing retirement of
paperwork for each shipment certifying positive impact on the oil and long-time employees with knowledge
the motor is compliant with DOE rules. gas industry and specifically the of pumps and rotating equipment,
This is supposed to be done through pipeline and shale drilling sectors our customers are looking to
the Customs and Border Protection going into 2017. partners like ITT Goulds Pumps and
system. Once pump regulations go ITT PRO Services to help them fill
into effect, certification paperwork will David Aldrich the gap. ... For us, its been a great
Product Manager-Floway, opportunity to further partner with
need to be submitted for pumps and Weir Flow Control
our customers and to also introduce
extended systems as well. Another DOE
them to some new technologies that
proposed rule was issued that affects
have tremendous potential to help
the marking and compliance limits on
them drive improvement in areas
electric motors. This one is still under
comment and could effectively raise the
What are your predictions ranging from uptime to total cost
efficiency level on existing single- and for the oil and gas market of ownership.
three-phase motors currently regulated. in 2017? Aris Chicles
Natural Resources Canada is expected President, ITT Industrial Process
I think the oil and gas market is
to adopt similar regulations to the DOE
going to be relatively stable. It will be One of the ways Vanton has
Small Motor Rule that went into effect
comparable to where it is right now in been proactively preparing for this
in 2015. This may go into effect mid-
my estimation. Saudi Arabia and Iran inevitable turnover was by embracing
2017. Motor regulations for the European
Union are changing for 2017 where are competing for output and pricing newly available technologies.
covered motors need to conform to at the time of this interview, but I think We are, however, acutely aware of
IE3 levels on 0.75-370 kilowatt (kW) prices will be relatively stable moving the limitations of technology and
designs. IE2 motors are still allowed forward. I dont see it going up to $100 we continue to encourage open
to be sold but must be used with an a barrel, but I dont see it going down to communications, the exchange of
adjustable speed drive. Additional $30 a barrel, either. ideas, data and individual experience
countries are developing and revising Glenn Wieczorek among our employees in the effort to
Minimum Efficiency Performance Managing Director, Tsurumi America Inc. ensure these valuable resources are
Standards (MEPS) for electric motors. preserved. This allows us to continue
Pump manufacturers should be aware Unlike coal, the oil and gas market to manufacture premium chemically
of regulations for each country where will rebound by a fair amount as a resistant, non-metallic fluid-handling
they export products. Pending carbon result of the slowed production in products and to provide unsurpassed
taxes for Canada could renew interest 2016. It does not have much more personal service on a global basis to our
in energy efficiency with higher utility room to go down with current demand. valued customers.
costs, shortening the payback time for Price per barrel of oil is already Larry Lewis
system upgrades. Cheap money supplies climbing slightly, but it will not reach President & CEO, Vanton Pump & Equipment

STATE
of the
INDUSTRY 47
2017
Who Changed Hands in 2016?

Several companies were involved with mergers or acquisitions during the year. While
not comprehensive, this list, compiled by Jordan, Knau & Company along with Pumps &
Systems, shows some of the major activity that occurred over the last 12 months.
2016 Pump and Related Equipment Transactions

Announced Target Acquirer Announced Target Acquirer
Date Date
1/12/16 Jiangsu Xinghe Valve Co. Ltd. Ham-Let (Israel Canada) 7/28/16 SFC Koenig AG IDEX Corporation
Ltd.
8/2/16 Emerson Electric Co. Motors, Nidec Corporation
1/14/16 PumpTek LLC Ohio Transmission Drive and Electric Power
Corporation Generation Business
1/27/16 Advanced Pneumatics Hartfiel Automation Inc. 8/15/16 SW Controls Inc. FCX Performance Inc.
Company Inc.
8/15/16 Sensus Worldwide Ltd. Xylem Inc.
1/28/16 R.W. Lyall & Company Inc. Hubbell Inc.
1/28/16 Mitsubishi Heavy Industries Fuji Oozx Inc. 8/18/16 Pentair plc, Valves & Controls Emerson Electric Co.
Machine Tool Co. Ltd., Solid Business
Valve Business 8/26/16 Dixie Pump & Machine Tencarva Machinery Company
2/1/16 Diverse Energy Systems LLC Cimarron Energy Inc. Works, plus part of Predictive LLC
Maintenance Consultants
2/4/16 Tideland Signal Corporation Xylem Inc. 8/29/16 Morrison Pump Company Inc. Gorman-Rupp Company
2/16/16 Gatlin Group Inc., Seal Group Hydradyne LLC 8/31/16 Specification Seals Co. LTI Boyd Corporation
2/17/16 Missouri Power Transmission Motion Industries Inc. 9/2/16 Bently Pressurized Bearing New Way Air Bearings
Inc. Company
3/1/16 Atlanta Powertrain & FORCE America Inc. 9/5/16 Schafer HPS GmbH, High OHE Maschinenbau GmbH
Hydraulics Inc. Pressure Business
3/10/16 Nichols Portland LLC Altus Capital Partners 9/7/16 RL Stone Inc. FCX Performance Inc.
3/28/16 Bluffton Motor Works LLC WEG Electric Corporation 9/8/16 Anderson Seal LLC Trelleborg Sealing Solutions
4/6/16 Fluid Controls Ltd. Indutrade AB 9/9/16 Total Hose Inc. Air Hydro Power Inc.
4/12/16 China Automation Group Ltd. Ascendent Capital 9/15/16 Michigan Pipe & Valve, Lansing Ferguson Enterprises Inc.
Partners and Flint, Michigan Meter
Technology Group
4/29/16 Power Service Inc. NOW Inc.
9/30/16 Norvalves AS Ham-Let (Israel Canada) Ltd.
4/29/16 Mastergear Worldwide Rotork plc
10/5/16 Braas Company Inc. Motion Industries Inc.
5/19/16 FMC Technologies Inc. Technip SA
10/31/16 Baker Hughes Inc. General Electric Company
5/24/16 Atlantic Supply & Equipment Fortiline Waterworks 10/31/16 MaxEAM Schneider Electric
Company Inc.
11/18/16 Water & Energy Systems U.S. Water, an ALLETE
6/17/16 Hydro International plc Hanover Investors
Technology Inc. Company
Management LLP
6/20/16 Esspump AB AxFlow Holding AB 11/25/16 PCI FCX Performance Inc.
6/23/16 Weir American Hydro Wartsila Services 12/1/16 Rotecs gas turbine maintenance Sulzer
Corporation business (Rotec GT)
Designing Better Bearing Housings

If the old saying Build something better and people will buy it is correct, then a new bearing
housing design will be of interest to those focused on reliability.
By Heinz Bloch
Process Machinery Consulting
W
hen MPP (not his real third bearing if one were to Had I ever experimented with
initials), a manager maintain the oil level below the different shapes of fl inger
for a process pump lowermost rolling element? discs? MPP considered having a
manufacturer, told me his company They were considering raising curved disc made, arguing that
was working on the thrust chamber the oil level to midpoint on the the curvature would help splash
design for its new horizontal pump, lowermost rolling element in oil directly onto the bearing.
I was interested. After all, millions the bearing. Would a fl inger Understanding that the oil
of process pumps would benefit disc provide enough splash to splash (or flow rate) decreases
from improved lubricant delivery cool the oil? with speed when using a fl inger
and better bearing housings. So,
in early 2016, I was pleased to
Figure 1. Simplified view of a pump bearing housing with oil splash provided
respond to his query. by flinger disc. The large disc diameter makes it necessary to place the thrust
MPP mentioned that the bearing set in a removable cartridge. Notice the bearing housing protector seals
companys pump speeds varied at both ends. (Courtesy of the author)
from about 1,800 revolutions per
minute (rpm) to 4,200 rpm. Typical
operation is at 3,600 rpm.
The manufacturers goal was
to design a superior ball bearing
thrust chamber that could handle
a force of up to 10,000 pounds
(44,482 Newtons) of axial load.
MPP and his team were
considering three angular contact
(7315) ball bearings to achieve
this unusually high load capacity
for a process pump. The inboard
bearing could be either a typical
deep-groove radial or an angular
contact type to handle any
minor short-duration reverse
thrust action in the normally
inactive direction.
MPP communicated the
following five other questions
related to lubrication:
Would a fl inger disc provide
enough lubrication for the

disc, MPP also had considered adding holes in the
disc to provide additional oil splash. What were
my thoughts on this? Plan B for his design would ENGINEERED
be to use only two rear bearings with an oil splash
or bath. Suppose the third bearing would be
for performance
required: Should MPP provide an oil mist system? WE COVER IT...
Does anyone still make my Vi ton flinger disc FROM DESIGN TO RELIABILITY,
patent? The original manufacturer of this TO ZERO IMPACT ON
technology no longer offered the flexible disc THE ENVIRONMENT.
flinger. Did I know if these flexible discs were not
profitable, or were there issues with reliability?
A Partial Answer
Because I know the end user's mode of operating
and maintaining pumps, I hesitated to recommend
triple angular contact bearing sets 1 for MPP's new
horizontal process pump. I imagined the purchaser's
hard-pressed reliability technicians trying to
ascertain and supervise the proper installation
of matched-bearing triple sets after explaining
ThorPios-Biue
their cost to the global vice president of modern
supply chain management. Triple sets require the
Q ThorPio s-White XL
e Composite PTSO
expenditure of much more than the customary
training, educational effort or maintenance money
allocated to pumps at most plants.
Flexible flinger discs were developed for snap- Thordon Vertical Pump Bearing Benefits
open insertion into bearing housings with openings/
At Thordon we manufacture high performance,
bores slightly smaller than the disc diameter. The
long lasting bearings that require no oil or grease.
original manufacturer of the Vi ton flinger disc later
discontinued this product for economic reasons. Our vertical pump bearings have proven performance
The plastic discs that allow high peripheral speeds in various industrial facilities- power plants, water
will not deflect much, and the ones that allow much treatment, refineries, mining, agriculture
deflection will not permit high peripheral speeds. and any industry moving water.
In contrast, contoured metal discs similar to the
Abrasion resistance ThorPiasWhite
straight one shown in Figure 1 are found in a number
Extended wear life complies with
of thoroughly engineered pumps.
Dry start up NSF/ANSI 51, 61
Usually made from stainless steel, flinger discs
Easy to design, and WRAS
are commonly used in Europe and require different machine & install approval (UK)
contours for particular pump models, sizes or shaft
speeds. Because these discs are partially immersed
in the lube oil, a number of variables influence Thordon Bearings Inc. is on the
which contour and geometry to select. The wrong Approved Materials list
contour will agitate and shear the oil and can cause of top 10 global pump OEMs
temperature increases and thinning of the oil.
Curved discs, in particular, provide a refresher
on the laws of physics . A droplet of oil moving T H ()R D 0 N
toward the tip of a quasi "rotating frisbee" will have
THORDON BEARINGS INC.
a small axial velocity component. However, gravity
will ensure that centrifugal force- and the radial For your Local distributor, visit us at
component-predominates. www. ThordonBearings.com
pumpsandsystems.com I January 20 1 7
Putting it bluntly, our hopes and In 63 years of owning all sorts Unfortunately, that was all the
expectations are (again) overruled of automobiles, I have never time I could find to communicate
by the immutable laws of physics. experienced the failure of an with MPP. Perhaps working with
Sir Isaac Newton was right. oil pump. a knowledgeable consulting
Regrettably, many end users Either oil mist or pressurized oil engineer would reduce his
(and a few manufacturers) in the delivered through a small nozzle development cycle.
U.S. put considerable faith in the will serve a set of 75-millimeter I did not dare recommend
one-size-fits-all approach, which is bearings at 4,200 rpm with little four hours of reading, which,
found in many oil ringsperhaps risk. In this case, I would not nevertheless, might shorten the
the lowest cost and least reliable advocate anything similar to MPPs development time by several
means of transporting oil from a proposal. We can only hope that orders of magnitude and save
static sump into sets of bearings. someone will do it right instead of tons of money.
Well-engineered fl inger discs simply tweaking components here If the old saying Build
may require the bearings to be or there. something better and people
located in a removable cartridge, A set of truly advanced and well- will buy it is correct, then a new
which increases the initial cost engineered bearing protector seals bearing housing design will be of
of the pump, but they can pay for should be part of doing things interest to those who are focused
themselves in a short time. right the first time. on reliability.
A set of truly advanced and well-engineered

bearing protector seals should be part of
doing things right the first time.
References
Radical Improvement Finally, no process pump with
1. Bloch, Heinz P., Petrochemical
If I had any say in the matter of rolling element bearings still Machinery Insights, (2016) Elsevier
reliability-improving pumps, the requires the oil to be cooled. With a Publishing, Oxford, UK, and Waltham,
shaft portion located between the reasonable pump bearing housing MA; 750 pages; ISBN 978-0-12-809272-9
pumps thrust bearing set and its oil sump capacity and the proper
deep-groove radial bearing would oil, the many thousands of pipestill
drive a small pump. bottoms and other hot service Heinz P. Bloch has authored or
This small pump would be pumps in modern refineries have co-written nearly 700 publications,
internal to the bearing housing. yet to see oil temperatures above among them 20 comprehensive
The pump would take suction 190 F (88 C). The product in some books on practical machinery
from the oil sump and force the oil of these pumps is at 750 F (399 C), management, failure analysis,
through small nozzles directly into and still not a single one will ever failure avoidance, compressors,
the bearings. need a properly selected synthetic steam turbines, pumps, oil
Anticipating user concerns oil to be cooled. mist lubrication and practical
regarding the reliability of such In some pump bearing housings, lubrication for industry. Bloch
a housing-internal small oil cooling introduces water vapor holds a B.S. and M.S. (cum laude)
pump drive, I would ask these condensation. Many major oil in mechanical engineering. He is
skeptical individuals to study the refineries discontinued cooling an ASME Life Fellow and maintains
reliability statistics of shaft-driven water on rolling element bearings registration as a Professional
mechanical governors in small in the 1960s. Books and articles Engineer in New Jersey.
steam turbines. have been written on the subject.

FLOW METERS 51
Ultrasonic Flow Meters Help Cool

Industrial Power Distribution Systems
The flow measurement solution provides valuable data and visibility of hydronic cooling performance.
By Pascual Espinoza
Badger Meter Flow Instrumentation
T
odays industrial facilities
rely on power distribution
systems to maintain stable
and efficient operation. Plant
systems have greater power
demands than ever. In most cases
where electric installations and
devices shut down or malfunction,
the problem is thermal.
Ultrasonic flow measurement
can be used to optimize hydronic
cooling of integrated power
distribution systems. Ultrasonic
meters monitor flow conditions
throughout the system and provide
data to help determine if fluid
volumes are consistent and meet
Image 1. Plants utilize distributed power technologies to ensure a robust energy
the necessary coolant demand. supply and increase productivity. (Image and graphics courtesy of Badger Meter)
Increasing awareness of limited
energy resources, coupled with Need for Effective Cooling meaning it absorbs heat easily
the drive to minimize operational Plants use distributed power more so than air. It is effective for
costs, has focused attention on technologies to ensure a robust cooling power supply equipment.
energy management. For industrial energy supply and increase Water cooling transfers heat
organizations, enhanced power productivity. However, heat from each part to a radiator that
distribution systems are necessary generated by electronic devices dissipates the heat and cools the
to keep pace with technology and circuitry must be dissipated liquidsimilar to a cars radiator.
improvements and support a to improve reliability and prevent In any hydronic cooling
fully integrated solution that premature failure. Traditional application, the liquid medium
maximizes the efficient use of techniques for heat dissipation must flow at designed flow rates
installed power generation. include heat sinks and fans, as within the system.
Electrical power is used in every well as other forms of automated It is also important to assess
aspect of plant operations. A cooling such as liquid cooling. load variations. Load is calculated
constant power supply is crucial Hydronic cooling (i.e., the use of by using the flow rate as well as
for plants to operate safely and water as a heat-transfer medium) the associated supply and return
economically. A shutdown or is commonly employed to keep fluid temperatures.
malfunction of the electrical plant power systems within the Hydronic cooling systems can
installation can have majoreven proper temperature range. Water be difficult to balance because of
catastrophicrepercussions. has a high thermal conductivity, the presence of multiple system
52 FLOW METERS
Figure 1. For power distribution system cooling applications, the use Figure 2. A transit-time ultrasonic meter uses two transducers
of clamp-on ultrasonic flow meters meets crucial accuracy, reliability functioning as both ultrasonic transmitters and receivers.
and cost requirements.
branches, changes in cooling that can easily attach to piping to because there is no need to cut
demand, and pressure differences gather flow data without disrupting the line, interrupt service or drain
among the various supply the systems configuration and the pipe. The meters do not require
and return lines. Inclusion of normal operation. the installation of bypass piping
balancing valves and flow meters Certain flow metering and valves for removal, and there
at each terminal or branch circuit techniques lack the accuracy and/ is no pressure drop as with some
facilitates balancing. To help or responsiveness to optimize other technologies.
reduce the cooling systems energy hydronic cooling operation. Poor Unlike Doppler-type ultrasonic
requirements, system designers meter performance can lead to flow meters that depend on large
also seek to minimize the cooling large fluctuations in the coolant particles or bubbles in the flow
system pressure drop. flow rate. This, in turn, results in path to read a flow rate, ultrasonic
Measuring the bidirectional excessive energy consumption devices employing a transit-time
flow of liquid circulating in the at pumps because of continuous measurement method provide an
hydronic system is critical in loading and unloading. accurate output without modifying
order to monitor proper cooling Mechanical meters used the coolant flow.
performance. Flow measurement in liquid flow measurement
instruments are used to detect applications face an increased Putting the Solution to Work
reduced flow rates, leakage and likelihood of deteriorating For a wide range of power
other conditions affecting the accuracy caused by wear and tear distribution applications, the use
robustness of cooling equipment. on the device. Additionally, the of clamp-on, solid-state ultrasonic
need for mechanical meters to be flow meters meets key accuracy
Selecting the periodically tested, recalibrated and bidirectional measurement
Right Flow Meter and repaired means they have to criteria with an installation
Companies that design power be removed from service, forcing approach that satisfies cost,
distribution systems for industrial the user to replace the meter with a
facilities count on precise flow temporary device.
measurement instrumentation to Some power system designers V = K * D * (t)
monitor flow through hydronic focus on transit time ultrasonic Equation 1
system piping and ensure that flow measurement as an alternative Where:
coolant volumes remain consistent. to in-line metering. Externally V = liquid velocity
Flow readings are needed at mounted, clamp-on ultrasonic K = a constant
strategic locations to give a general meters are suited for use with D = the distance between
overview of coolant supply and coolant distribution lines. They the transducers
demand. This often necessitates are quick, easy and less expensive t = the difference in time of
a non-invasive metering solution to install than in-line flow meters fl ight

53
reliability and uninterrupted the difference in time of fl ight output to a data acquisition
operation needs (see Figure 1). calculated. The liquid velocity (V) system that corresponds to the
A transit-time ultrasonic meter inside the pipe can be related to instantaneous volumetric flow
uses two transducers functioning the difference in time of fl ight (t) rate of the coolant. The meters
as both ultrasonic transmitters using Equation 1. offer low energy consumption,
and receivers. It operates by Transit-time ultrasonic flow and their accurate measurement
alternately transmitting and meters have no moving parts to data is used to help reduce cooling
receiving a frequency-modulated maintain or replace, making fluid system variability and maximize
burst of sound energy between compatibility and pressure head operational efficiency.
the two transducers. The burst is loss a non-issue. Their rugged
first transmitted in the direction aluminum enclosure also promotes Pascual Espinoza is Badger Meter
of fluid flow and then against fluid a long service life. The meters Flow Instrumentations technical
flow (see Figure 2). have a large measuring range sales manager. He is responsible
Because sound energy in a that enables reliable readings at for supporting technical sales
moving liquid is carried faster all designed alternating-current efforts throughout North America.
when it travels in the direction of integrated fight-through power (AC Espinoza has an electrical
fluid flow (downstream) than it IFTP) system flow rates. engineering degree and
does when it travels against fluid Integrated in the cooling more than 15 years of
flow (upstream), a differential in apparatus for an industrial sales and application
the times of fl ight will occur. The power distribution system, the experience in flow
sounds time of fl ight is accurately ultrasonic meters provide an instrumentation.
measured in both directions and analog 4-20 milliamps (mA)
54 MOTORS & DRIVES
The Power of Drives & Controls in

Increasing Reliability
Bundling technologies leads to enhanced system efficiency for a Connecticut water supply.
By Kyle Schoenheit
Xylem Inc.
A
s corporate citizens, to the pump and change the Hydraulic shock is a brief
businesses must evaluate operating speed, enabling pumps increase in pressure inside a pipe
their impact on the to respond smoothly and efficiently caused by a sudden change in
environment and assess how to fluctuations in demand. These direction or velocity of water in the
their product applications affect robust, reliable and cost-effective pipe. This phenomenon can lead to
the communities in which they solutions help users avoid the wear complete pipe failure.
operate and serve. To address aging and tear of repeated on-off cycling. VSDs are often applied to
infrastructure and conserve water, In a variable-speed application, existing systems to increase
a growing number of operators as the flow decreases and the efficiencies. When a VSD is
are bundling existing pumps potential pump pressure increases, installed properly, pumps can work
and vertical turbines with more the drive slows the pump to match more efficiently, extending product
advanced solutions to drastically a constant discharge pressure. life, reducing energy consumption,
cut energy costs while meeting VSDs provide additional benefits and decreasing mechanical and
their increasing water needs. otherwise unattainable in a fi xed- electrical system stress.
Advanced solutions such as
variable speed drives (VSDs) and
intelligent pump controllers (IPCs)
are two ways operators can vary Some estimates suggest that VSDs can lead to
pump speeds to reduce overall
operating costs and extend product a 50 percent reduction in hydraulic shock, often
life. Proper selection of pumps, referred to as water hammer.
motors and controls is essential to
ensure pumping systems operate
efficiently and reliably.
Integrated Pressure Boosting speed application for operations Optimizing the System
The goal of boosting water is to with large flow variations and low A solution involving an IPC and
match the load profi le precisely, static head. VSD can be an economical
reducing the energy required to Static head, in its most simple answer for municipal and
run the system when water use is form, is the difference in the industrial water systems that
low. A booster system operates at supplys height and the destination have low water pressure.
20 percent capacity or less nearly of the liquid being moved, or the The extended hydraulics and
80 percent of the time. As a result, pressure into which the pump advanced technology of one IPC
many pumping systems benefit is discharging. can provide a distinct role in
from variable flow to minimize Some estimates suggest that automating the regulation tasks of
power during reduced demand. VSDs can lead to a 50 percent todays superior systems because
VSDs are electric controllers reduction in hydraulic shock, often of its ability to withstand incoming
that vary the speed of the current referred to as water hammer. power issues.

55
These capabilities make it The system also used a

well-equipped to provide variable chlorinator when the VSD ran at
frequency control of speed, full speed, and the chlorinator was
pressure, flow and level over a wide hooked up to the relay output. This
range of submersible and above- meant that the sites replacement
ground applications. IPC units would require a unique
VSDs and other optimized setup. The team configured the new
systems boost water for end users controller before visiting the site.
who need to maintain water Because the power loss was
pressures when demand is high or irregular, the teams pinpointed
fluctuating. Greater flow and more an abnormality with incoming
friction lead to a reduction in the power as a possible cause. D&S
systems water pressure. As water installed the new enhanced IPC on
use increases, the IPC changes the input of the pump controller
pump speed to keep line pressure to provide a more robust line fi lter
constant. Systems built on hills (3.6 percent versus 3.0) for when
or at the end of the water line are electrical impedance is required.
susceptible to fluctuating water Meanwhile, the technology Image 1. By monitoring data from
supply and reduced pressure. providers applications experts pump controllers, the product
manufacturer and local suppliers were
discovered that the drives were able to find the source of intermittent
Connecticut Case running without a pressure pump failure in a rural Connecticut
In a rural Connecticut community, transducer to sense the water community. (Courtesy of Xylem Inc.)
a VSD was faulting on a phase loss pressure in the system.
and experiencing random pump While on-site at Foleys on product features, data analysis
failure issues. This problem was in Danbury, Connecticut, and maintenance. Since installing
similar to a drive running a pump the manufacturer and D&S the new drives, performance with
and a motor when one of the legs employees monitored data with the bundled systems has improved,
of incoming power unexpectedly the pump controllers running and the community is receiving a
becomes lost or disconnected. at full speed and again with reliable water supply.
Experts from the equipment the increased 3.6 percent line The Connecticut community
manufacturer teamed up with reactor. The manufacturers installation is an example of
distributors D&S Pump Supply experts recommended that the the importance of selecting
Co. and Foleys Pump Service to user continue to use the new 3.6 and bundling the proper pump
provide a reliable water source to percent line reactor and monitor applications to provide a reliable
the community. to see if the issue returned during and efficient water source.
At the time, two variable speed peak usage. For the other pump
pump controllers were installed to and motor, IPCs were installed to Kyle Schoenheit is a global
work independently to pump water provide an optimum solution for product manager and global
uphill from a 100-foot well into this application. engineering manager, with
large storage tanks for distribution In the event of a failure, the expertise in monitoring and
to the community. Because the community could switch over from controls. For more than eight
two controllers were working the variable speed pump controller years, he has worked for Xylem
independently, the end user had to the new controller, ensuring the Inc. and its Goulds Water
to manually rotate from one drive customer will never be without Technology and Bell & Gossett
to the other. In a power failure, a water, said Ken Capuano, product brands as global product
backup generator kicked in. The specialist for the manufacturers manager on multiple new product
lapse of operation was sporadic and VSD line. developments and projects.
would happen in certain weather After successfully setting up Schoenheit holds a Bachelor of
conditions and at peak demand. the new pump controllers, the Science in mechanical engineering
This intermittent operation was experts remained on-site to test from Rochester Institute of
detrimental to the community. the controllers and train the user Technology.
56 MAINTENANCE MINDERS
A Novel Way of Protecting Parallel

Centrifugal Pumps
One application used a pump flow algorithm in place of a conventional
flow meter to protect pumps in parallel operation.
By Robert X. Perez & Glenn Everett

Enterprise Products
P
arallel operation is a setup in After the pumps had been flow using motor power and pump
which two or more pumps take operating for some time, personnel differential pressure. Because digital
suction from the same suction discovered that one pump was not pressure transmitters were already
header and deliver liquids into the sufficient to handle all the liquids. installed and a local programmable
same discharge header. In theory, Operators sometimes had to shut logic controller (PLC) was available,
if the two pumps and piping are down the compressors downstream all the team needed was local power
identical in design, they should pump of these pumps because of the high meters to estimate pump flow.
at approximately the same flow rate. risk of damage resulting from liquid The team began their analysis using
However, differences in piping, pump carryover. For this reason, facility Equation 1, which was developed
performance and internal wear often personnel decided to operate both to approximate the efficiency of a
lead to flow discrepancies in pumps pumps simultaneously in order to centrifugal pump in the field. This
operating in parallel. handle upset conditions. equation can determine a motor-
Indiscriminate parallel On paper, these pumps driven centrifugal pumps efficiency
operation of centrifugal pumps may appeared to be identical, so personnel under process conditions. This
lead to significant flow imbalances believed that parallel operation equation does not require the fluids
that can result in pump vibration, would result in a balanced flow specific gravity, which is useful when
pulsations, overheating and failure. condition. However, the team knew the specific gravity of the pumped
Pump users should always that one or both could operate at liquid is not known.
confirm that pumps are similar in unsafe conditions because of internal Rearranging terms produces
performance capabilities before wear, slight differences in pump Equation 2, which allows operators to
operating them in parallel. Individual construction, changing process estimate the pumps ideal flow using
flow meters can help ensure that conditions and other factors. So the kilowatt (kW) load on the motor,
pumps are operating at a safe flow personnel allowed parallel operation
when in a parallel arrangement. A only when flow measurements were Table 1. Pump performance data (Graphics
courtesy of Enterprise Products)
total flow meter for a group of pumps available for each pump.
is more common. To properly protect the pumps, Flow Delta P Eff Flow/Eff
In one scenario, two centrifugal the team needed to install individual 150 410 0.49 306.12
pumpsnine-stage, 125- flow meters. Personnel considered 200 400 0.56 357.14
horsepower (hp) vertical turbine different pump flow measurement
250 382 0.64 390.63
pumpsare installed side by side. options including an orifice flow
They transfer pipeline liquids meter, a compact flow meter such 300 360 0.69 434.78
collected upstream of a compressor as an Annubar flow meter, and 350 325 0.7 500.00
station into another pipeline. These calculated flow using motor power 400 286 0.685 583.94
pumps were never intended to and pump differential pressure.
450 249 0.66 681.82
operate in parallel. Normally, one Because of the lower cost and
of the pumps can handle all liquids minimal impact on the site, the 500 210 0.62 806.45
reaching the station. team elected the option of calculated 550 160 0.52 1057.69

57
Figure 1. Plot of ideal versus estimated pump with best fit equation Figure 2. Comparison of manufacturers predicted performance versus
the actual field data
Es#mated Flow versus the Ideal Flow
9 Stage Ver,cal Turbine Pump Test
600
Data from 6/24/2014
450
500
400
400
Es#mated Pump Flow (gpm)
350
Pump P (psi)
300
300
200
250
100 Best Fit Equa,on for Manufacturer's Performance Curve

y = 8.2198E-07x3 - 2.4246E-03x2 + 2.5808E+00x - 4.3935E+02 200
y = 1.515152E-06x3 - 2.586580E-03x2 + 5.724242E-01x + 3.772511E+02
R = 9.9837E-01 R = 9.993994E-01
0
0 200 400 600 800 1000 1200 150
Ideal Pump Flow (gpm) 100 150 200 250 300 350 400 450 500 550 600
Pump Flow (GPM)
Calculated Flow Manufacturer's Data Poly. (Manufacturer's Data)
the motors efficiency and the pumps by plotting Q versus Q/p from the agreement between the calculated flow
differential pressure. The ideal flow is performance data. (In this case, a third data and the pump performance curve.
the expected flow for a pump with 100 order polynomial is used. The R 2 value Preliminary results prompted the
percent efficiency. To obtain an actual of 0.9983 indicates that there is an team to continue with their plan
pump flow, an equation that relates the excellent fit between the data and the of embedding this new pump flow
ideal pump flow to the estimated pump best fit equation.) algorithm into the overall pump
flow must be derived. To perform the complete flow control scheme. Because the ideal-
First, begin with the pump calculation in the field, operators in flow-to-estimated-flow equations will
performance data in a tabular format the example needed a power meter to change as the pumps degrade, a long-
(see Table 1). Next, create a column provide the true power to the electric term strategy to handle calibration
titled Flow/Eff with a calculated motor driver, pressure transmitters on errors and internal wear must be put
value of flow divided by efficiency, the pumps suction and discharge, and in place. The team will continue to
which will be called ideal flow. Using a PLC to perform the calculations. look for chances to use the pump flow
Excel, plot the flow (Q) versus the ideal The PLC calculates the ideal algorithm in place of a conventional
flow (Q/p). Finally, insert a trend line flow using Equation 2, then uses the flow meter to protect the pumps in
with the equation for the relationship best fit curve equation to estimate parallel operation.
between flow and ideal flow. Figure the pump flow. If the estimated flow
1 shows a best equation obtained is below the minimum flow value, the
Robert X. Perez is a
PLC will return a low-flow reading and
rotating equipment
Q(Pd-Ps) shut down one of the pumps. If the
p = engineer working for
2,298mkW estimated flow is above the maximum
Equation 1 Enterprise Products
value, the PLC will return a high-flow
Inc. He has 30 years
reading and start up one of the pumps.
Where: of experience in the
Q = flow (gpm) petrochemical industry
Results in the Field
Pd and Ps = pressure (psi) and is a licensed professional engineer
Two new power meters were installed
p = pump efficiency in Texas.
in the field, and their outputs were
m = motor efficiency tied into a local PLC, along with pump
kW = true kilowatt power from Glenn J. Everett is a controls training
suction and discharge pressures. The
the electric motor specialist with Enterprise Products.
PLC was programmed to perform all
He has 34 years
calculations for an estimated flow rate.
of experience in
Figure 2 shows calculated pump
the petrochemical
Q 2,298kWm data (represented by red diamond
industry, working with
p = = ideal flow
data points) taken from the site and
(Pd-Ps) PLCs, controls systems
superimposed on the manufacturers
Equation 2 and plant automation.
performance curve. The data shows
58 SEALING SENSE
Back to Basics: Expansion Joints

Last in a Series
By Paul (Bud) Baltzer Jr., FSA Member, Meccom Industrial Products Company
& Stephen Cramb, FSA Member, Garlock Sealing Technologies
M
any members of the Fluid Figure 1. Typical expansion joint construction (Graphics courtesy of FSA)
Sealing Association (FSA)
Non-Metallic Expansion
Joints Division and of the
Expansion Joint Manufacturers
Association (EJMA) feel that
expansion joints are the forgotten
components of many piping
systems. Other piping system
componentsfl anges, gaskets,
strainers, valves, pumps and the
pipe itselfseem to get most of the
design time.
In many ways, expansion
In Europe, the term expansion one-and-a-half times this rate.
joints are the most important
joint is not used. They are referred The polyvinyl chloride (PVC) pipe
components of a well-designed
to as compensators, which best thermal expansion coefficient
piping system. They are the living
describes them. is more than three times that of
and breathing dynamic part of the
Thermal growth of pipe stainless steel. Even pipe runs of
whole system.
materials will cause serious only 30 to 40 feet can be a problem
Without well-designed and
problems if ignored or disregarded. if an expansion joint is not used.
well-placed expansion joints,
Carbon steel pipe, with a coefficient For expansion joints to perform
parts such as pump nozzles,
of thermal expansion of 6.4 x10 -6 properlycompress when the
valve bodies and pipe anchors
inches per inches-Fahrenheit pipe growsthey must be located
could face excessive loading and
(in/in-F), grows almost 2 inches between two fi xed points or
vibrational fatigue. Without proper
per hundred feet for a 260 F anchors. An anchored piece
compensation, thermal growth
temperature rise, and T-304 of equipment is considered a
at elevated temperatures can
stainless steel grows about fi xed point.
damage some pipes, reducing their
operating life.
Expansion joints are sometimes FThrust = PA
misunderstood. Despite the name, Equation 1
expansion joints normally do not Where:
expand during operation. They
FThrust = pressure thrust force
compress in most applications.
Expansion joints provide stress P = internal pressure (system pressure)
relief from thermal and mechanical Dm2
A = effective area =
vibrations and/or movements in 4
Dm = mean diameter of expansion joint
piping systems.

59
Figure 2. Axial extension and compression (in inches), lateral or parallel movements (in inches), and angular movements
(in degrees).
Axial Elongation. The dimensional increase or lengthening of face-to-face parallel

length of the joint measured along the longitudinal axis.
Axial Compression. The dimensional reduction or shortening of face-to-face parallel

length of the joint measured along the longitudinal axis.
Lateral or Transverse Movement. The movement or relating displacement of the two

ends of the joint perpendicular to its longitudinal axis.
Angular Movement. The angular displacement of the longitudinal axis of the expansion
joint from its initial straight-line position, measured in degrees. This is a combination of
axial elongation and axial compression.
With these points in place, Under axial deformation, Non-Metallic

the pipe will grow toward the the expansion joint spring rate Expansion Joints
expansion joint from each anchor, also must be considered. In this Non-metallic expansion joints
compressing the joint. Without example, a spring rate of 500 typically consist of three layers:
expansion joints or some relief pounds per inch (lb/in) would not the tube, body and cover. The tube
mechanism of complex and be uncommon. is a leak-proof protective inner
expensive pipe flexing design, the For a compression of 1 inch, liner made of synthetic or natural
stress from thermal growth is another 500 pounds of axial force rubber. It extends seamlessly
taken up by the anchors and the must be added to the resultant through the ID of the expansion
pipe itself, causing excessive strain forces on the anchors. These factors joint from outside flange to
and potential failure. often are overlooked. outside fl ange.
Fixed points (pipe anchors) One important consideration The cover is the exterior surface
are designed to withstand the when dealing with these types of of the expansion joint, and it
resultant forces imposed on them movements is the use of control is made of synthetic or natural
by the expansion joint and the rods, which are essential pieces of rubber. It is designed to protect the
system pressure. hardware added to the expansion inner portions of the expansion
The pressure thrust force of joint during installation. joint from external conditions.
an expansion joint is defined in Contrary to widespread belief, The bodyor carcass as it is
Equation 1. control rods are not designed to sometimes calledis the internal
For example, a 12-inch internal keep the expansion joint in line reinforcement encapsulated by
diameter (ID) expansion joint could and prevent the joint from the tube and cover. The body
have a mean diameter of 13 inches. moving in excessive lateral provides the expansion joints
Calculating the effective area and offset. They are designed to limit structural strength under
multiplying by an internal pressure the amount of movement the varying system pressures and
rating of 100 pounds per square expansion joint is exposed to vacuum conditions.
inch gauge (psig) would result in during operation. The body can have two
13,273 pounds of thrust force. These movements can result types of reinforcement: fabric
Without properly designed anchors, from large forces, so the joint reinforcement consisting of
this force could cause the piping to and the control rods must be quality synthetic fabrics and metal
move, leaving the expansion joint designed to withstand all reinforcement in the form of wire
to counteract the forces. stresses involved. or solid steel rings.
60 SEALING SENSE
All layers contribute to the Non-metallic joints are also Application: This refers to how
overall strength and protection superior to metallic joints when the expansion joint will be used.
of the expansion joint while used to absorb vibration. They Where will the joint be installed?
maintaining flexibility. possess inherent damping Additionally, what type of
Non-metallic expansion joints capabilities. Metallic joints equipment is it attached to? Pipe,
are superior to metallic joints typically fall short of acceptable pump or other equipment? Are
in most chemical applications. life when dealing with high- there force/moment limits on the
Elastomers are generally more amplitude and high-frequency equipment connections?
resistant to acids, solvents and oils vibrations. Elastomeric expansion Also, what type of construction
than metallic joints. joints are ideal for pump suction is required? Is the purpose to
In corrosive chemical and discharge applications because compensate for dimensional
applications, high-priced exotic of their ability to absorb axial variations, thermal expansion/
materials such as Inconel, and lateral movements along contraction or to reduce vibration
Hastelloy or Carpenter 20 might with vibration. transmission? Of the many
be required for metallic joints.
Polytetrafluoroethylene (PTFE) is
resistant to nearly all chemicals but
hydrofluoric acid.
In many applications, Non-metallic expansion joints are superior to
elastomeric expansion joint
spring rates are lower than those metallic joints in most chemical applications.
of metallic joints, especially for Elastomers are generally more resistant to acids,
higher-pressure applications. Non-
metallic joints can handle some solvents and oils than metallic joints.
higher-pressure conditions better
than metallic joints.
Lower spring rates are critical
in new PVC piping systems where
the pipe is weaker than standard Selection & Specification variations in expansion joint
metallic pipe. Using non-metallic When choosing the correct designs, which is most appropriate?
softer expansion joints can result expansion joint for a given Media: This refers to operating
in lower pipe and anchors loads, application, end users must know media that may come in contact
so PVC pipe will be less likely the accurate design conditions of with the expansion joints
to fail. the area where the expansion joint inner liner as well as external
Metallic expansion joints will be installed. atmospheric conditions that
have restrictions in terms of life Experts agree that many non- could be incompatible with the
cycle. It is necessary to know how metallic expansion joint failures cover material.
many cycles a joint can move the result from incorrect information Movements: This refers to the
predicted movement. Certain or lack of information. amount of movement an expansion
programs can be used to predict The most important information joint is expected to experience
when fatigue metal fracture is required can be described by during operation. Movements
expected to occur. the acronym STAMP, which is include axial extension and
Non-metallic expansion detailed below. compressions, lateral movements
joints, on the other hand, are Size: Size includes the expansion and angular movements. This
not limited by cycling fatigue. joints ID as well as face-to-face differs from misalignment, which
In general, non-metallic joints (F-F) or overall length (OAL). is a condition that occurs when
can withstand axial compression Temperature: This refers to the piping is misaligned prior to
and lateral offset movement minimum and maximum operating the initial installation.
combinations better than metallic temperatures of the application, Pressure: This refers to the
expansion joints because material both internal and external to the anticipated operating pressure and/
fatigue is not a factor. expansion joint. or vacuum of the application.

Figure 2 (see page 59) shows interpretation of the data, ensures We invite your suggestions for article topics as
the four most common motions a successful piping system. Some well as questions on sealing issues so we can
better respond to the needs of the industry.
encountered in expansion joints. general back-to-basics information
Please direct your suggestions and questions to
They include axial extension can help. sealingsensequestions@f/uidsealing.com.
and compression, lateral or
parallel movements, and
angular movements . As usual,
Next Month: Discover the New
Edition of the Expansion Joints
Fw1o sEAuuc
ASSOCIATIONr
vr ~
Vi.
"""--o--l~""
accurate data, along with correct Technical Handbook
Paul (Bud) Baltzer Jr. has been involved in "Flexible Pipe

and Duct Components" for more than 43 years, specializing
mostly in power, automotive paint shops, steel and pollution
control. He has been a member of FSA for more than 10
For more information
years and currently serves on the Board of Directors.
about expansion joints,
visit the FSA product
Stephen Cramb is product engineer at Garlock Sealing
locator at fluidsealing.
Technologies. Cramb has been in the engineering field for
com/product-locator, or
six years, and his experience includes product development,
contact a manufacturer.
applications engineering and material development for
expansion joints.
SOLUTIONS
for your process piping needs
Rubber Expansion Pinch Rubber Pump

Joints Valves Connectors
Let us show you the

benefits of screw
centrifugal pumping
over clogging Check Pressure Rubber Elbows
Valves Sensors & Hose
"non-clog" pumps.
~Products
' T " 'E;asto-Valve Rubber Products Inc.
www.hidrostalpumps.com sales@evrproducts.com 1705-523-2026 1www.evrproducts.com
Circle 225 on card or visit psfreeinfo.com. Circle 224 on card or visit psfreeinfo.com.
pumpsandsystems.com I January 2017

62 HI PUMP FAQS
Containment Considerations for Magnetic-

Driven Pumps & Designs for Integral Motors
in Canned Motor Pumps
By Hydraulic Institute
T
Figure 1. Magnetic-driven pump (Graphics courtesy of Hydraulic Institute)
he HI Pump FAQs published
in the October 2016 issue of
Pump & Systems addressed 71 231
a question related to secondary 236
63
containment considerations 230
for canned motor pumps and a 3
232
separate question related to design 73 78
considerations for magnetic- 239
1 234
driven pumps. Following that
publication, it was requested that
HI answer the same questions
but for the opposing technology. 2
Those questions and responses are
presented in this months column.
What primary and

61
secondary containment 17
considerations are 1 Casing 63 Bearing, axial thrust, 232 Magnet assembly,
recommended for 2 Impeller outboard outer
magnetic-driven pumps? 3 Shaft, stationary, 71 Adapter 234 Bushing, bearing,
pump 73 Gasket inboard rotating
17 Shaft, support 78 Spacer, bearing 236 Bushing, bearing,
The principal design 61 Bearing, axial thrust, 230 Magnet assembly, outboard rotating
consideration for sealless pumps inboard inner 239 Cover, casing
231 Shell, containment
is to prevent leakage to the
atmosphere. A magnetic drive
pump (MDP) (see Figure 1) is a Secondary containment is a Primary and secondary
type of sealless pump that uses an secondary pressure boundary that containment will have design
outer ring of permanent magnets provides absolute containment of pressure ratings equal to or greater
to drive an internal rotating the pumped liquid in the event of a than the maximum working
assembly through a corrosion- breached containment shell. pressure of the pump at rated
resistant containment shell. The The construction material of conditions. For MDPs, when
torque transmission by a magnetic the secondary pressure boundary primary or secondary pressure
coupling eliminates the need for a must be evaluated to ensure it is barriers are metallic, they are
traditional shaft seal. compatible with the pumped liquid. designed for the maximum
Because the primary The requirements and solutions allowable working pressure
containment could develop for secondary containment vary within stress values for the
leakage as a result of wear by based on the application and pump materials in Section VIII of the
adjacent rotating parts, corrosion configuration, so the purchaser American Society of Mechanical
or abrasion, secondary leakage and pump supplier must discuss Engineers (ASME) Boiler and
containment may be required. these points. Pressure Vessel Code.

63
Nonmetallic primary or secondary

containment shells are substantiated
through design and test to have a minimum
ratio between bursting pressure and
design pressure of 2-to-1 for the pressure/
temperature range.
The secondary containment is designed
to contain leakage for a minimum of 48
hours in the event of containment shell
leakage and have a minimum standby
life of three years. In the event of
leakage through the containment shell,
pump operation must be immediately
discontinued. The pump user is responsible
for providing shutdown devices and
procedures required for safety.
For more information, refer to the newly
revised standard ANSI/HI 5.1-5.6 Sealless
Rotodynamic Pumps for Nomenclature,
Definitions, Design, Application, Operation,
and Test.

What are the design
recommendations for
integral motors used in
canned motor pumps?
A canned motor pump (CMP) (see

Figure 2, page 64) is a type of sealless
pump that combines a centrifugal pump
and induction motor into one hermetically
sealed unit. The motor rotor is typically
2196
supported by hydrodynamic bearings at
SN
each end, and the stator windings and rotor
bars are protected from the process liquid
by corrosion-resistant and nonmagnetic
liners. The fluidtypically taken from the
pump discharge or a flush introduced from
an external sourceis used to cool the
motor and lubricate the bearings.
The circulation of pumped fluid in the
motor must remove heat generated by
eddy current losses, rotor windage loss and Model SN Model 2196
motor electrical losses. The stator winding
temperature must be maintained at or
below values established for the grade of
wire insulation used in the stator windings.
Thermal protection of the stator windings
is provided along with the temperature Green Bay, WI | www.SUMMITPUMP.com | Celebrating Over 30 Years
setting. Additionally, the purchaser can
64 HI PUMP FAQS
Figure 2. Canned motor pump
237 243 223 235

specify a motor winding
73
temperature rise test to verify
2 that the motor windings will
not exceed the maximum
1
251 insulation temperature at
design motor load and motor
73 liquid cooling temperature.
For satisfactory life of the
207 CMP, it is necessary to provide
2A clean liquid (not vapor) for
internal bearing lubrication and
motor cooling over the intended
pump operating range. This
is done through unit design
33 6 217 222 201 221 31 73
and selection of the proper
1 Casing 73 Gasket 223 Assembly, stator
circulation plan. Selection
2 Impeller 201 Housing, stator 235 Bushing, bearing, inboard of a circulation piping plan
2A Impeller, auxiliary 207 Cover, motor end 237 Bushing, bearing, depends on knowledge of liquid
6 Shaft, Pump 217 Shell, containment outboard
31 Housing, Inboard bearing 221 Can, rotor 243 Box, electrical connection properties such as cleanliness,
33 Housing, Outboard bearing 222 Assembly, rotor 251 Tube, circulation volatility, viscosity, specific
gravity, toxicity, temperature,
corrosiveness and any tendency
to form solids.
Intended flow rates, net positive suction head
available (NPSH A), frequency of starts, cooling or
heating availability, and potential loss of suction
liquid also should be considered. The purchaser must
supply this application data for the manufacturer
U N M AT C H A B L E E X P E R I E N C E
to recommend the most suitable circulation
I N F L OW C O N T RO L
TRANSACTIONS plan. Because internal flow is critical for reliable
operation, instrumentation and controls to detect
loss of flow through the drive unit are desirable.
Jordan, Knauff & Company is a knowledgeable and When explosion-proof units are required,
experienced provider of a comprehensive line of the manufacturer and purchaser must select
investment banking services to the pump, valve and the approved design that meets temperature,
PXVEXMSRMRHYWXVMIW*PS['SRXVSP
pressure and appropriate division, group and class
Our lines of business include: selling companies, requirements. Information on external motor
raising debt and equity capital, and assistance temperature may be required by the manufacturer
SREGUYMWMXMSRW
for proper selection.
To learn more about Jordan, Knauff & Company, For more information about centrifugal canned
contact any member of our Flow Control motor pumps, refer to the newly revised standard
XIEQ %GGIWW SYV *PS[ 'SRXVSP VIWIEVGL EX ANSI/HI 5.1-5.6 Sealless Rotodynamic Pumps for
[[[NSVHEROREYJJGSQS[GSRXVSP
Nomenclature, Definitions, Design, Application,
Operation, and Test.
+'SSO.SVHER.V (EZMH%/EOEVIOE
Managing Principal Senior Associate
GN$NSVHEROREYJJGSQ HOEOEVIOE$NSVHEROREYJJGSQ HI Pump FAQs is produced by the Hydraulic Institute as
a service to pump users, contractors, distributors, reps and
OEMs. For more information, visit pumps.org.
MEMBER FINRA, SIPC

PRACTICE & OPERATIONS 65
Hospital Saves More Than $600,000 with

Retrofitted HVAC Variable Speed Cooling System
Pumps played a key role in the facilitys energy efficiency improvements.
By Brent Ross
Armstrong Fluid Technology
G
aining an average of $200,000 Based, in part, on the reviews Although the facility managers
a year in heating, ventilation findings, facility personnel decided to were interested in the estimated
and air-conditioning (HVAC) upgrade the HVAC system. energy savings, they were concerned
energy savings would be important about the equipments upfront costs
to any organization. For Methodist The Solution and skeptical that the proposed
Dallas Medical Center (MDMC), With the goal of upgrading to a more technology could provide the
it means being able to direct more energy-efficient system, the MDMC proposed improvements. This was the
money toward criticaleven life- facility managers met with RushCo hospitals first exposure to variable
savinghealth services. Energy Specialists, an energy- speed technology.
Serving North Texas since optimization contractor in the To address their concerns, the
1927, MDMC includes a Level III region. In addition to recommending pump and IPC manufacturer provided
Neonatal Intensive Care Unit and the installation of a new chiller and a written commitment regarding
the Methodist Dallas Transplant cooling tower, RushCo recommended the systems performance. With
Institute, one of the largest and converting the system to a variable that assurance in hand, the hospital
most active agreed to
multi-organ the proposed
transplant While keeping these critical-care patients system.
centers The facility
in the comfortable at all times is a priority at the managers
Southwest hospital, the existing cooling system had become had never
U.S. While worked with
keeping increasingly inefficient. vertical
these in-line (VIL)
critical-care pumps, but
patients comfortable at all times speed format, featuring new chilled based on the recommendation from
is a priority at the hospital, the water and condenser water pumps the contractor, they agreed to design
existing cooling system had become controlled by an integrated plant the system around a specific type of
increasingly inefficient. controller (IPC). VIL pumps.
A 2012 review of the mechanical The contractor advised that a new Because the old equipment had to
system indicated that opportunities variable speed pumping system would be removed and preparations had to
for energy savings were available and provide the hospital with significant be made to accept the new equipment,
that some components, including cost savings. According to Tim Rusher the retrofit project involved several
a 30-year-old cooling tower and a at RushCo Energy Specialists, his weeks of on-site work. This prep work
25-year-old chiller, were outdated. company had used the proposed included cutting a hole to install the
The review also revealed that the chilled water pumps for years and new chiller. The final system included
original installation included piping was comfortable recommending them a new cooling tower, a new chiller,
irregularities that led to inefficient and the IPC, which was made by the improved piping and the following
operations. same company. key components:
PRACTICE & OPERATIONS
SUMMITTM
three 250-horsepower (hp) VIL pumps
to serve the chilled water system
five 100-hp VIL pumps to serve a
condenser water system
aniPC
The Results
The installation was completed in late
March 2012, and the system performed
reliably from the outset. In April, the first
month of operation, the hospital saved
more than $15,000 compared with April
2011 through reduced energy costs that
could be directly traced to the upgraded
HVAC system.
Managers knew the real test of energy
efficiency would come in June, July
and August, the hottest months of the
summer. Savings for those three months of
operations, compared with the prior year of
PUMP, Inc operations, were $15,000 in June, $50,000
www.SUMMITPUMP.com
in July and $27,000 in August.
Circle 219 on card or visit psfreeinfo.com. From the installation in April 2012
through the end of 2015, MDMC has
realized more than $600,000 in energy
savings, an average of more than $200,000
a year.
The new system not only saves energy
but also creates a more comfortable
environment for hospital staff and
patients. The hospital has experienced
sharp reductions in "hot calls," and the
maintenance staff has commented that the
new system is easier to operate, monitor
and adjust.
The dramatic improvements in energy
efficiency because of these updates have
allowed the hospital to invest some of the
savings into critical care programs that
benefit the entire community.
Brent Ross is the global director of

configured building equipment with
PIPELINE FABRICATIONS Armstrong Fluid Technology.
Temporary Strainers Spectacle Blinds Open/Closed Blinds He has served on committees
Plate Strainers Restriction Orifice Plates Ring Spacers with various industry
organizations such as
Basket Strainers Duplex Strainers Tee Strainers
ASHRAE and the Hydraulic
WEFABRICATE@TITAN FCI.COM 910 . 345 . 0 I 0 I Institute.
Ja nu a ry 201 7 I Pumps & Systems

PRODUCTS
New & Notable Technology

Products selected by the Pumps &. Sldstems editors
1 CONTROL VALVES
VICTAULIC is offering the latest line of
BERM AD hydraulic control and air valve
offerings to the North American mining
industry. Designed and engineered
specifically for mining applications, these
durable, cost-effective automatic flow-control
solutions can improve supply and distribution
system efficiency. Together, Victaulic and
BERMAD are leveraging their strengths to
offer control valve technology, engineering
leadership and a broad distribution network.
2 FLUID COUPLING
VOITH has unveiled its new TurboBelt 500 TPXL 4
fluid coupling. The fill-controlled coupling
is the first model in the new TPXL family,
which combines the advantages of the proven
hydrodynamic drive principle with intelligent
control technology. The integrated controller
makes it possible to adapt the output torque of
the coupling exactly to the startup parameters
of the belt conveyor system. The Turbo Belt 500
TPXL requires half the volume of conventional
coupling types for the same force transmission.
3 WATER NETWORK SOFTWARE

SCHNEIDER ELECTRIC has introduced the
Water Network Optimization (WNO) Suite,
a water and wastewater industry solution
powered by Aquis 7.0 and built on Wonderware
System Platform. Water network operators can
use WNO to acquire and centralize real-time
data from network critical points for complete
visibility and control of their water distribution
5
network. WNO is able to trigger alarms
associated with potential anomalies detected
by simulations so immediate actions to prevent
or mitigate service disruptions can be taken
with enough lead time.
Circle 103 on card or visit psfreeinfo.com. 5 PERISTALTIC METERING PUMPS 6 IMPELLER
BLUE-WHITE INDUSTRIES has released KSB INC. has debuted in the U.S. its state-
the FLEXFLO A-lOON Polymer Pump that of-the-art F-max impeller technology. The
4 PUMP CONTROLLER handles high-viscosity polymers used in F-max incorporates different distances
GRACO INC. has announced enhancements water and wastewater treatment. A-lOON between its blades, which are arranged
to its Cycle Flo pneumatic pump controller, peristaltic metering pumps are equipped with in groups with two small and two large
now offering one unit operating on 100 to 240 Blue-White's exclusive, built-in Tube Failure distances. Because of this asymmetrical
VAC input power. The new Cycle Flo controller Detection system (TFD). If TFD senses tube blade arrangement, the F-max offers wide
has the functionality of two units in one, failure , the pump will automatically shut off free passages, ensuring that even larger rigid
simplifying installation for end users. The and energize a relay or switch, permitting solids pass easily and are reliably handled
CycleFlo controller is designed to control pump communication with external equipment, by the pump. Because the radial forces and
speed and run time to deliver precise batching , such as a backup pump or alarm. This vibrations created by the new impeller are
metering and dosing of fluids at low and high eliminates costly polymer spills and cleanup. usually lower than those of single-channel
pressures and flow rates. It features 32 batch No false triggering is caused by condensation impellers, the service life of shaft seals and
presets and an intuitive programming interface. and wash down procedures. rolling element bearings is increased.
Circle 104 on card or visit psfreeinfo.com. Circle 105 on card or visit psfreeinfo.com. Circle 106 on card or visit psfreeinfo.com.
To have a product considered for this section, please send the information to Martin Reed, mreed@cahabamedia.com.
pumpsandsystems.com I January 2017

PRODUCTS
7 ELECTRIC CARTRIDGE PUMP

SKF has announced the introduction of the
Electric Cartridge Pump ECP. Developed to
lubricate bearings and linear guides in small 8 ECCENTRIC DISC PUMP 9 WASTEWATER PUMPS
machines, the pump includes an integrated France-based JUMP has certified its eccentric disc GRUNDFOS' SL and SE range of wastewater
pressure-relief valve that enables its use in pump range JE Series for ATEX Zone 1 to meet the pumps include "medium," "high" and "super high "
single-line lubrication systems such as SKF growing needs of handling flammable liquids or hydraulic offerings from 12 to 42 horsepower that
MonoFlex. Utilizing easy-to-exchange 380-milliliter combustible materials. Now available for use in are designed to handle raw, unscreened sewage,
cartridges, it is compatible with both oil and fluid Zone 1 potentially explosive atmospheres, the JE effluent, and large volumes of surface and process
greases. This electrically driven piston pump Series pump is made to be conductive to prevent water. With its simple yet hydraulically efficient
uses 24-volt DC and is controlled by an external electrical hazards and is designed to protect Stube impeller, the extended range enables free
programmable logic controller for convenience. The against internal and external explosions. It also passage of solids up to S inches, which is ideal
Electric Cartridge Pump ECP is capable of manually prevents overheating. The JE Series technology for large flows of raw sewage. Intelligent and
activating a lubrication cycle and can be used with allows transfer of various fluids for many industries self-adaptive controls allow the pump to adjust
an optional, integrated level switch to monitor the such as food , chemical, pharmaceutical, cosmetics, to changing operating conditions, while high-
fill level of the cartridge. energy, mining and more. efficiency motors meet or exceed global standards.
Usually Ships In 1/2 The Lead Time

Horizontal and Vertical Pumps
RUN DRY, AND

KEEP ON RUNNING.
Pumps fitted with GRAPHAUOY
wear parts survive upsets.
GRAPHALLQYbushings
and case rings:
I~
Our vertical sump pump line offers up to 3000 GPM, 230' Heads and 26' Run hot, cold, wet or dry
depth. The horizontal end suction pump line offers up to 3000 GPM,
Reduce maintenance
300' Heads, back pullout construction and semi-open impellers.
v EA Rs Standard construction is Cast Iron, 316 Stainless Steel fitted, or all New pumps or retrofits
IIIJllil 316 Stainless Steel , and the self-priming pump is available in CD4MCu. Non-galling
lliJII View our complete catalog and pump selection software on-line. Self-lubricating
GRAPHITE METALLIZING
-400F to 1,000F
~/if)PUMP -240C to 535C+ CORPORATION
D""""""
Hydraulic ~VJ"i.!!.!;!JCOAfPANY Corrosion resistant Yonkers, NY 10703 U.S.A.
ISO 9001:2008
The Industrial Pump Specialists PS09b
Phone: 513-530-0888 sales@vertiflopump.com www.vertiflopump.com TEL. 914.968.8400 WWW.GRAPHALLOY.COM/PS

January 2017 I Pumps & Systems

PRODUCTS 69
Advertisers
10
11
Advertiser Name RS# Page
AutomationDirect.com .................201 ......... IFC

Advanced Ceramics
& Carbon, Inc. ...........................237 ...........71
AE Pumps .......................................240 ...........71
Badger Meter Inc. ..........................212 ...........53
Baldor Electric Company ..............207 ............. 7
11 PORTABLE SAMPLERS Blue-White Industries. .................208 ...........11
10 COMPRESSOR YSI, a XYLEM brand, is expanding its process Boerger ...........................................213 ...........41
An honorable mention winner in the 2017 monitoring and control equipment offering to Cat Pumps ...................................... 217 ...........21
AHR Expo Innovation Awards green building the wastewater market. The YSI ProSample
category, DANFOSS Turbocor TG compressors Series of fully automated portable samplers are Crane Pumps & Systems ...............210 ...........15
are the first oil-free, variable speed, magnetic lightweight and easy-to-use and provide a unique Dan Bolen & Associates, LLC .......238 ...........70
bearing centrifugal compressors to operate with combination of design and technology. The Elasto-Valve Rubber Products......224 ...........61
refrigerants that have an extremely low global compact samplers contain a customized
warming potential. Designed for air- and water- peristaltic pump that provides highly accurate
Graphite Metallizing Corp. ..........223 ...........68
cooled chillers ranging from 40 to 500-plus tons sampling, with measuring increments that can Hidrostal Pumps ...........................225 ...........61
when manifolded and/or used in multiple circuits, be preset based on time intervals, flow rates or Hydraulic Institute........................242 ...........29
the Turbocor TG compressor series provides weather events. The robust and insulated plastic
Jordan, Knauff & Company.......... 241 ...........64
optimum energy efficiency at full- and part-loads housing is ideal for field use, keeping samples
in a compact and lightweight footprint. intact and at the proper temperature. Load Controls, Inc. ........................215 ...........18
Circle 110 on card or visit psfreeinfo.com. Circle 111 on card or visit psfreeinfo.com. LobePro ..........................................230 ...........71
Magnatex Pumps, Inc. ..................236 ...........71
REPS WANTED
MasterBond Inc. ............................227 ...........70
NSK Americas ................................216 ...........12
Sims Pump, a fast growing structural ProSpec Technologies Inc. ............228 ...........70
composite pump, pump parts, and Schenck Trebel Corporation ......... 214 ...........37
mechanical seal manufacturer is SEEPEX ...........................................209 ...........19
seeking ambitious, aggressive, and Sims Pump Co. ...............................233 ...........70
self-motivated representatives for
Solve
Sims Pump Co. ...............................234 ...........71
both the marine and industrial Sims Pump Co. ...............................235 ...........69
dry start markets around the world. Sims
focuses on sales to customers with
Singer Valve ...................................221 ...........63
problems with corrosive environments, such as

Smith & Loveless Inc.....................204 ............. 1
Sulzer Management Ltd
Vesconite Hilube marine, cruise, power generation,
public utility, wastewater facilities, oil
Rotating Equipment Services. .231 ...........70
bushings and gas, as well as chemical and

industrial markets. A background in
Summit Pump, Inc.........................219 ...........66
Summit Pump, Inc.........................220 ...........63
Increase MTBR pumps, mechanical seals, or any Thordon Bearings Inc. ...................211 ...........49
No swell rotating equipment is required. Titan Flow Control ........................222 ...........66
Low friction = reduced Please fax your resume to
Titan Manufacturing Inc. .............232 ...........71
electricity costs 1-201-792-4803, or email to
Topog-E Gasket..............................229 ...........70
Vanton Pump & Equipment .........206 ............. 3
Quick supply. Simsite1@aol.com.
Vaughan .........................................203 .......... BC
No quantity too small Vertiflo Pump Company Corp. .....226 ...........68
Tollfree 1-866-635-7596 Vesco ...............................................239 ...........69
vesconite@vesconite.com Watson Marlow Fluid
www.vesconite.com Office: 1-201-792-0600 Technology Group .....................218 ...........26
Yaskawa America, Inc ...................202 ............. 5
The Index of Advertisers is furnished as a courtesy,
and no responsibility is assumed for incorrect
FREE PRODUCT INFORMATION information.
Visit psfreeinfo.com to request more information from these advertisers.
70 PUMP USERS MARKETPLACE
Technologically
Advanced Epoxies
One and Two Component
Systems Feature:
Protection against
corrosion
Toughness
High Tg
Resistance to cyclic
fatigue
Hackensack, NJ 07601 USA

+1.201.343.8983
main@masterbond.com
www.masterbond.com
1034LK_2.25x4_TechnologicallyAdvancedEpoxies.indd 12/3/14 9:34 PM
EXECUTIVE SEARCH/RECRUITING
Join our distribution
MEGGA network for dewatering
Pumps for Industry pump solutions!
Serving the Pump &

Rotating Equipment, Valve,
and Industrial Equipment
Industry since 1969
Looking for a quality yet economical pump?
Domestic & International
MEGGA Series PC is your answer.
Specializing in placing:
Full line of horizontal end-suction General Management Engineering
centrifugal pumps in rugged all iron
construction utilize standard mechanical Sales & Marketing Manufacturing
seals and motors. Our design features
a quality 316 stainless o-ring sealed slip fit DAN BOLEN JASON SWANSON
sleeve, casing taps and an optional steel
sub-base. Available close-coupled to a JM CHRIS OSBORN JULIAN MUELLER
frame motor or as a pump end kit less motor.
9741 North 90th Place, Suite 200
Currently seeking qualified Distributors! Contact miningandconstruction@sulzer.com
Scottsdale, Arizona 85258-5065
(480) 767-9000 Fax (480) 767-0100
1-888-797-PUMP
www.meggapumps.com Email: dan@danbolenassoc.com
www.danbolenassoc.com

71
Since 1985 your process reliability and

profitability have been our number one priority!
IN STOCK, READY TO QUICK SHIP.
Phone: 713.972.8666 | Toll Free: 866.624.7867

FAX: 713.972.8665
3575 West 12th Street, Houston, TX 77008
www.magnatexpumps.com
www.ceramicscarbon.com
Products Materials
Seal Faces Graphite
Bushings / Bearings Carbon Graphite
Steam Joints Resin Bonded Carbon
Rotors and Vanes Reaction Bonded, Sintered and Slip
Resin and Antimony Carbon Blanks Cast Silicon Carbide
Hot Glass Fixtures Tungsten Carbide Adding various impregnations such
Industrial Brushes Zirconia as resins and metals can enhance the
Electrical Components Alumina Ceramic strength and temperature capabilities.
ADVANCED CERAMICS & CARBON, INC. 808 South Michael Road | Saint Marys, PA 15857 | 814-834-0060
Go with the PRoS!! LoBePRo RotaRy PumPS
Important Properties of
LobePro Rotary Lobe Pumps
Low maintenance - Space-saving,
in place wear part compact design
replacement Self priming to 25 wet Circle 240 on card or visit psfreeinfo.com.
Pump Capacities up to 2,656 GPM (604 m/hr) with
discharge pressure ratings to 175 psi (12 bar)
To learn more or get a custom quote, email PumpSales@lobepro.com
912-466-0304 www.LOBEPRO.com Made in USA
72 PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

Figure 1. Stock indices from Dec. 1, 2015, to Nov. 30, 2016
By Jordan, Knauff & Company
T he Jordan, Knauff &

Company (JKC) Valve Stock
Index was up 12.4 percent
over the last 12 months, while the
broader S&P 500 Index was up
of U.S. economic activity,
increased at a 2.8 percent
rate, a slowdown from
the second quarters 4.3
percent pace. Business
4.5 percent. The JKC Pump Stock spending on equipment
Index increased 9.7 percent for the fell at a 4.8 percent rate,
same time period.1 marking four straight
The Institute for Supply quarters of decline in
Managements Purchasing equipment spending. Source: Capital IQ and JKC research. Local currency converted to USD using historical
Managers Index (PMI) increased to Investment in residential spot rates. The 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.
53.2 percent in November, up 1.3 construction fell at a 4.4
percentage points from October, percent annual rate. Spending international sanctions. Russia,
growing for the third straight on nonresidential structures, the largest non-OPEC producer,
month. The Production Index rose including oil and gas wells, also agreed to cut its production Reference
1.4 percentage points to 56, the increased at a 10.1 percent rate, the by as much as 300,000 barrels per 1. The S&P Return
highest level since January 2015. fastest pace since the first quarter day. Benchmark oil prices gained figures are provided
The New Orders Index improved of 2014. as much as 10 percent on the by Capital IQ.
to 53 percent from 52.1 percent in At the end of November, the news and share prices of energy
October. Survey respondents were Organization of Petroleum companies around the world
positive, with a plastics and rubber Exporting Countries (OPEC) agreed jumped along with the currencies Jordan, Knauff
& Company is an
product manufacturer noting, We to its first crude oil production of large export countries. investment bank
are foregoing our shutdown over cuts in eight years, hoping to On Wall Street, all three major based in Chicago,
Christmas break due to an increase reduce record global oil inventories U.S. indices were up for November. Illinois, that
in customer orders. Another that have contributed to record The Dow Jones Industrial Average provides merger and
acquisition advisory
manufacturer wrote, Business low oil prices. OPEC will reduce was up 5.4 percent (its largest services to the
conditions are good. oil output by 1.2 million barrels monthly gain since March), the pump, valve and
The Commerce Department a day by January, cutting its S&P 500 Index gained 3.4 percent filtration industries.
reported that U.S. gross domestic production to 32.5 million barrels and the NASDAQ Composite Please visit
product (GDP) rose at a 3.2 percent a day. Saudi Arabia, the groups jordanknauff.com for
increased 2.6 percent. Solid further information.
annual rate in the third quarter largest producer, will reduce economic data including consumer Jordan Knauff &
of 2016. Following the second output by 486,000 barrels per day, confidence, housing starts and GDP Company is a member
quarters 1.4 percent annual rate, while its second largest producer, gains, along with OPECs decision, of FINRA.
this was the strongest growth Iraq, will cut output by 210,000 bolstered investors sentiment.
since the third quarter of 2014. barrel a day. Iran was allowed to Third quarter corporate earnings
Consumer spending, which raise output to about 3.8 million These materials were
were also positive, up 4 percent prepared for informational
accounts for more than two-thirds barrels a day as it recovers from over the same period last year. purposes from sources that
are believed to be reliable
but which could change
Figure 2. U.S. energy consumption and rig counts Figure 3. U.S. PMI and manufacturing shipments without notice. Jordan,
Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or com-
pleteness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
any investment offering or
Source: Institute for Supply Management Manufacturing deployment of capital.
Source: U.S. Energy Information Administration and Baker Hughes Inc.
Report on Business and U.S. Census Bureau

CANT GET SCREW PUMPS
OR PARTS FROM
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From municipal wastewater to food processing to industrial
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which deliver the reliability, efficiency and durability you
expect from Vaughan.
4 to 6 week delivery on standard materials

Parts inventory on the shelf
Multiple configurations available
Special materials available
312 discharge
Call Vaughan today to find out which configuration will work best for your project.
ChopperPumps.com | 360.249.4042 | info@chopperpumps.com

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J A N UA R Y 2 0 17

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J an uary 2 0 17 | Pum ps & S y st e m s

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pumpsandsystems.com 1 January 2017

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Pumps & Systems Jan2017