Trade Show Preview

TPS 2019
Page 30

PUMP
SYSTEMS
for process plants
CIP rotary lobe pumps offer advantages
for hygienic applications

Also Inside

Design requirements of
multistream switching systems

Reducing friction in
hydraulic sealing systems

Best use cases for FMCW

technology in level measurement

AUGUST 2019 • Vol. XXV, No. 8

www.flowcontrolnetwork.com
 AHR EXPO
PREVIEW
Page 28

FLUID
Density
The effects of
temperature and
pressure

Also Inside

Automating custody transfer

level measurements

Ultrasonic flowmeters for

HVAC monitoring

Performing a storage
tank risk assessment

JANUARY 2019 • Vol. XXV, No. 1

www.flowcontrolnetwork.com

FC_0119_Cover.indd 1 12/14/18 8:24 AM

Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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GF Piping Systems

9950 Dual Channel Type 586 Pressure

SmartPro Transmitter/
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• Independent Dual Channel Multiparameter Flow, pH/ORP,
Conductivity/Resistivity, , Pressure, Temperature, Level/
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• 2 Passive 4-20mA Loop Outputs Standard
• Choice of up to 4 Relays – Dry contact or Solid State
• Optional Two mechanical relay module with four binary
inputs for up to four more sensing points
• Advanced Boolean Relay Logic
• Derived Functions : Ratio, Difference, Sum, % Rejection,
% Recovery
• Onboard Clock and Calendar for Scheduled Events
The 9950 SmartPro Transmitter takes a simple approach to
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system. The 9950 is ready to run out of the box with its standard
two 40-2omA passive outputs. Add optional relay modules and
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controller. With on board clock/calendar, derived functions,
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Regulating Valve
GF Piping Systems is pleased to introduce the innovative modular
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users to easily change configurations. The valve can be changed from
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• No re-torqueing needed
• Modular
• Online tool makes sizing a breeze
• 100% molded design means
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Union style bonnet
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Table of Contents | August 2019 • Vol. XXV, No. 8

Cover Series
Pump Systems
10 Simplifying pump maintenance
reduces downtime
By Peter Wright, Xylem
Rotary lobe pumps with clean-in-place (CIP) systems
offer cost-effective solutions for hygienic applications
in personal-care products and food processing.

14 The flow of fluid in vertical pumps

and intake systems
By Amin Almasi
10
Consider these guidelines when selecting a
vertical pump type and design to ensure reliability
and performance.

Features
18 Achieving better sample isolation and
analyzer responses with process stream
switching systems 18 26
By Randy Rieken, Swagelok Company
How to meet the three key design principles of sample
isolation, quick responses and minimal flow upset.
Departments
24 Fight friction and reduce costs with
4 From the Editor
lubrication management
By Beth Figliulo and Michael Cook, Trelleborg Sealing
Solutions Americas 6 News & Notes
Reduction in compression set behavior with new
hydraulic sealing systems reduces friction and creates 8 Application Corner & Quiz Corner
a better environment for seals.
30 Trade Shows & Events
26 How frequency modulation can improve
31 Advertiser Index
effectiveness of radar level measurement
By Ingemar Serneby, Emerson Automation Solutions
Lessons learned from FM and AM broadcasting can be 32 FlowControlNetwork.com
applied to tank level measurement, delivering better
performance in challenging applications. Cover: dusanpetkovic/iStock

Flow Control (ISSN #2641-6735) is published 12 times a year
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2 | August 2019 Flow Control

Simultaneous
flow, pressure and
temperature measurement
WATERFLUX 3070 – electromagnetic water meter with integrated
pressure and temperature sensor
• All data directly available via Modbus RTU
• Important input for e.g. district zoning (DMA) and leak detection
• Battery or mains powered with battery backup
• CT: MI-001, OIML R49 up to DN600 / 24“
• No inlet/outlet runs needed

us.krohne.com/en/waterflux-3070

products solutions services

 From the Editor
VICE PRESIDENT & GROUP PUBLISHER
MICHAEL C. CHRISTIAN
mchristian@endeavorbusinessmedia.com
ASSOCIATE PUBLISHER

L
ast month, I had the opportunity
to trade the hot Alabama weather
for cooler temps in Denver, Colorado,
for the annual Siemens Automation Summit
user conference. The theme: digitalization.
In the opening session, Raj Batra, presi-
dent of Siemens Digital Industries, U.S.,
discussed how trends such as artificial intel-
ligence, cloud, edge and advanced robot-
The technology café included booths JIM SEMPLE | 908-963-3008
jsemple@endeavorbusinessmedia.com
for discussions with experts about topics
EDITOR IN CHIEF
including: digitalization for the chemical
MOLLY ROGERS
and pharmaceutical industries, low-
mrogers@endeavorbusinessmedia.com
voltage drives and motors, process
CONTRIBUTING EDITORS
instrumentation and distributed control AMY W. RICHARDSON
systems. A well-received highlight of the arichardson@endeavorbusinessmedia.com
event was the announcement of the new MARIE MCBURNETT
Simatic PCS neo (read more about it in mmcburnett@endeavorbusinessmedia.com

ics will transform industrial facilities. Those this issue’s news briefs on page 6). GROUP ASSISTANT EDITOR

companies embracing new technologies And for this issue of Flow Control, we DANIEL GADDY
dgaddy@endeavorbusinessmedia.com
were recognized at the event with Customer focus on pump systems, presenting articles
COLUMNIST
Excellence Awards. Among the winners is from Xylem’s Peter Wright with a discus-
DAVID W. SPITZER
Air Products and Chemicals with its devel- sion on rotary lobe pumps commonly
ART DIRECTOR
opment of a proprie- used in applica- RYAN CARLSON
tary web-based pre- tions for process- PRODUCTION MANAGER
dictive monitoring and ing of personal-care AMANDA PORTER
fault diagnostic plat- products, food and aporter@endeavorbusinessmedia.com

form. The application pharmaceuticals. DISTRICT MANAGER

leverages Siemens' Also, Amin Almasi JAY HAAS | 281-980-5831

jhaas@endeavorbusinessmedia.com
cloud-based open returns to cover
WEST COAST SALES
IoT operating system the various types
MARK MALLOY | 224-234-8275
MindSphere. Others of vertical pumps mmalloy@endeavorbusinessmedia.com
can use the applica- and intake systems. ACCOUNT MANAGER
tion to monitor their Read about process LISA WILLIMAN | 518-322-6691
plant conditions, and with MindSphere, the stream switching systems by Swagelok’s lwilliman@endeavorbusinessmedia.com
data is securely connected and continuously Randy Rieken and lubrication manage- DIGITAL BUSINESS DEVELOPMENT MANAGER
shared in real time. Another winner, Dow ment in hydraulic systems by Trelleborg’s MICHAEL RING | 347-365-0641
mring@endeavorbusinessmedia.com
Performance Silicones, collaborates with Beth Figliulo and Michael Cook. Lastly,
MARKETING MANAGER
Siemens on best practices and knowledge Emerson’s Ingemar Serneby talks about
JOHNSON BAILEY
sharing of the Simatic PCS 7 for continued frequency-modulated continuous wave
DIGITAL OPERATIONS MANAGER
system reliability enhancements. technology for tank level measurement. MARY BETH ROMANO
For the 700 attendees, the event I hope you enjoy reading this issue of AUDIENCE DEVELOPMENT MANAGER
offered numerous breakout sessions that Flow Control — and hang in there, fall is ANNA HICKS
filled three days, including presentations just around the corner. SUBSCRIPTION & REPRINT REQUEST
on brewery automation, dry run protection flowcontrol@omeda.com
for pumps in hazardous liquid transfer Sincerely,
CORPORATE TEAM
systems, HMI/IPC/SCADA roadmap, gas
CHIEF EXECUTIVE OFFICER
detection systems and safety automa- CHRIS FERRELL
tion and a valve monitoring app solution. Molly Rogers CHIEF OPERATING OFFICER
Attendees also enjoyed hands-on training mrogers@endeavorbusinessmedia.com PATRICK RAINS
and many networking opportunities. @FlowControl_Mag EXECUTIVE VICE PRESIDENT
SCOTT BIEDA

EDITORIAL ADVISORY BOARD

Jeff Jennings: Equilibar LLC | Mitch Johnson: JMS Southeast | Gobind Khiani: Fluor Canada Ltd.
Jim Lauria: Mazzei Injector Company | John Merrill, PE: EagleBurgmann Industries
Steve Milford: Endress+Hauser U.S. | Tom O’Banion: Emerson Automation Solutions
David W. Spitzer, PE: Spitzer and Boyes LLC | George Weihrauch: ABB Motors & Mechanical
Andrew Yeghnazar: Blacoh Fluid Control | Jesse Yoder, Ph.D.: Flow Research

4 | August 2019 Flow Control

News & Notes
Company news
Siemens develops web-based
process control system
Siemens announced it is developing
Simatic PCS neo, a system software that
offers companies global web-based col-
laboration in engineering and operation
and a user interface that displays all rel-
evant information in a single workbench.
Users have a graphical user interface (GUI)
that allows them to reach any applica-
tion with a few clicks. Simatic PCS neo’s
workbench allows toggling between the
Engineering and the Monitoring & Control
views at any time. The object-oriented data
model increases efficiency and quality over
the entire plant lifecycle. The system allows
multiple users to work in parallel and does
not require local software installation.
Rawson/Industrial Controls
partners with Forum
Rawson and Industrial Controls, distributors
of instrumentation, valve and control prod-
ucts, signed a distribution partnership
agreement with Forum Energy Technologies’
valve solutions business. The agreement
enables Rawson/Industrial Controls to offer
comprehensive valve and control solutions
for a wide range of industries. In partner-
ship with Houston-based Forum, Rawson/
Industrial Controls’ distribution network will
add valve solutions from brands including
ABZ Valves & Controls, Cooper Valves, DSI
Valve, PBV Valve and Quadrant Valve &
Actuator. With the partnership, Rawson/
Industrial Controls can provide Forum
products across its entire geography, from
the Gulf Coast and Southeast to the mid-
Atlantic and Midwest regions of the U.S.
Leslie Controls offers
replacement for Kylie-
Mueller control valves
Leslie Controls, a CIRCOR International
brand, announced that replacement Kylie-
Mueller’s GTB and GTW control valves are
available through CIRCOR’s international
channel partner network. Previously, main-
tenance managers at facilities with aging
Kylie-Mueller valves could service the inter-
nal components of the valve with CIRCOR’s
Rotable Critical Trim Refurbishment Program
6 | August 2019 Flow Control
or replace the units with a different CIRCOR
product. Now, customers can replace
their Kylie-Mueller valves with an identical
Kylie-Mueller replacement — completely
new, including direct-from-factory body
and bonnet.
Air Liquide signs agreements
with Marathon Petroleum
Air Liquide signed two long-term supply
agreements with Marathon Petroleum
Company for a total of up to 900 met-
ric tons per day of oxygen for Marathon
Petroleum’s refineries in Texas City, Texas,
and Garyville, Louisiana. At Marathon
Petroleum’s Galveston Bay refinery in
Texas City, Air Liquide will increase its
current oxygen delivery by 400 metric
tons per day. And in Garyville, Air Liquide
will increase oxygen delivery by up to as
much as 500 metric tons per day.
Honeywell launches
enterprise performance
management software
Honeywell introduced the availability of
Honeywell Forge for Industrial, an enter-
prise performance management software
for operational technology that leverages
process and asset digital twins, advanced
data analytics and decades of process
industry domain knowledge to help indus-
trial manufacturers achieve and sustain
peak performance. With Honeywell Forge
for Industrial, a business can use instant
insights from real-time benchmarking to
help make better decisions that have an
impact equipment performance, reliability,
safety and profitability. Honeywell Forge
for Industrial collects and integrates infor-
mation from a manufacturer’s operations,
analyzes and helps determine the achiev-
able optimal performance and augments it
with predictive analytics to identify oppor-
tunities for improvement. It then provides
recommendations in real time that help
industrial producers close performance
gaps and operate at peak performance.
Rand Simulation launches
turbomachinery solutions
Rand Simulation (Rand SIM), a new divi-
sion of Rand Worldwide that provides
ANSYS software solutions and consulting
services — computational fluid dynam-
ics (CFD), finite element analysis (FEA)
and electromagnetic simulation (EMAG)
— launched new capabilities to help
manufacturing organizations leverage the
benefits of simulation to drive innovation.
For companies in fields related to turboma-
chinery, Rand Simulation’s team can offer
proof of concept, problem detection and
baseline comparison/benefit quantification.
Ohio Transmission
Corporation acquires pump
and engineering companies
Ohio Transmission Corporation, an indus-
trial equipment service provider and
distributor headquartered in Columbus,
Ohio, acquired Furey Filter & Pump and
its subsidiary, PSI Engineering. Based
in a suburb near Milwaukee, Wisconsin,
Furey Filter & Pump provides pumps,
filtration, service and full-system engi-
neering and fabrication, including certi-
fied welding capabilities. PSI Engineering,
headquartered in the Minneapolis/St.
Paul, Minnesota, area, is an industrial
equipment distributor for pumps, filters,
mechanical seals and valves. The com-
pany offers a full range of services for
repairs of fluid handling equipment.
People news
Peppiatt of Hallite Seals
inducted into Fluid Power
Hall of Fame
Hallite Seals International announced that
Dr. Nick Peppiatt was nominated into the
first Fluid Power Hall of Fame hosted by
the International Fluid Power Society
(IFPS). Peppiatt was selected alongside
four other inductees for his dedication
and innovative contributions to fluid power
technology. Peppiatt will accept his award
at a dinner honoring the Fluid Power
Hall of Fame inductees on Wednesday,
September 25, in Seattle, Washington.
Peppiatt, a Chartered Engineer and a
Member of the Institution of Mechanical
Engineers, is a graduate of the University
of Bristol. During his time at Hallite, Peppiatt
managed the design, development, testing
and application of several innovative sealing
solutions for fluid power cylinders. Included
among his many achievements is design for Indiana. Wiedemann has been with Tuthill president for sales and marketing. Tuthill
seals used in mining applications that helped since 2015, when he joined Tuthill Vacuum Transfer Systems manufactures Fill-Rite
push the industry to new heights and into and Blower Systems in Springfield, and Sotera Systems fuel and chemical
more efficient operations, such as longwall Missouri, as director of global busi- transfer pumps. FC
roof supports using high-water based fluids. ness development and Americas sales.
His work also helped enhance the fluid power Previously, Wiedemann worked at CST Send news and events for consideration
industry’s understanding of wiper seal tech- Industries in the Kansas City area where to Molly Rogers at mrogers@
nology for hydraulic cylinders, the application he held positions of vice president for busi- endeavorbusinessmedia.com.
of CAD-to-seal design and numerous addi- ness and product development and vice
tional topics. This enabled him to present
several conference papers and publish more
than 40 technical articles on a wide range
of fluid power sealing subjects. BEHIND EVERY GORMAN-RUPP
Peppiatt is extensively involved in the INDUSTRIAL PUMP PACKAGE
IS A SUPERIOR PUMP
development of reciprocating and related
seal standards and has chaired the British
Fluid Power Association committee TC7
“Seals and their housings” (Incorporating BSI
MCE/11) since 1992. He is also the conve-
nor of ISO TC131/SC7/WG2 “Dimensions for
seal housings” and holds several patents. In
2013, his essay on “Reciprocating Lip Seals”
was published in the Springer Encyclopedia
of Tribology — a reference book relevant to
researchers and industry covering all aspects
of the science and engineering around fric-
tion, wear and lubrication.

Tuthill Transfer Systems

names new president
Rick Wiedemann became president at
Tuthill Transfer Systems in Fort Wayne,

Upcoming events Gorman-Rupp offers a complete line of A reliable pump system package depends
pumps that can be packaged for industrial on the precise matching of all components,
Turbomachinery & Pump Symposia applications to provide you a total pumping so you can be assured that Gorman-Rupp
Sept. 9–12 solution that meets your industrial fluid- pump packages are designed for maximum
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testing of the most efficient and serviceable will be there to support service and supply
WEFTEC packages available in the market place today. parts for your entire system.
Sept. 21–25
Chicago FASTER, TROUBLE-FREE INSTALLATION EQUALS
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Chicago SEPTEMBER 10-12, 2019

VISIT US AT BOOTH #1206
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P.O. BOX 1217 l MANSFIELD, OHIO 44901-1217 l USA
New York City 419.755.1352 l GRSALES@GORMANRUPP.COM l GRPUMPS.COM
Oct. 22–24
509 © 2019 The Gorman-Rupp Company Gorman-Rupp Pumps USA is an ISO 9001:2015 and an ISO 14001:2015 Registered Company
chemshow.com

www.flowcontrolnetwork.com August 2019 | 7

 Application Corner
By David W. Spitzer
Part 3: Measuring downward flow:
Considerations for accuracy
and vibration
W
e continue the discussion of
three important situations to
carefully consider: operation
under vacuum, measuring downward liq-
uid flow and gravity flow. Operating under
vacuum was discussed in the previous two
columns, so let’s move on to measuring
downward flow.
When selecting a flowmeter for liquid
service, it is common to consider its
upstream pressure, downstream pressure
and the pressure drop to ensure that the
flowmeter will pass the design flow in the
process piping system. Interestingly, under
no flow conditions in downward flow, the
pressure actually increases through the
flowmeter as a result of static pressure
due to decreasing elevation. This pressure
increase gets smaller as flow is increased
and may eventually become a pressure
drop at higher flow rates when the pres-
sure drop across the flowmeter becomes
larger than the static pressure increase
due to elevation.
It is not clear how this pressure rise
might affect flowmeters — if at all.
However, some years ago, I was charged
with fixing a particular vortex shedding
flowmeter installed in downward flow
that consistently differed from process
calculations by approximately 10% since
its installation approximately a decade
8 | August 2019 Flow Control
prior. This particular flowmeter design
had exhibited problems in other plant
locations subject to high vibration, but
vibration was not an issue in this loca-
tion, and similar vortex shedding flow-
meters of the same design not subject
to vibration performed accurately. Being
pragmatic, we purchased a new vortex
shedding flowmeter of a different design,
but installed it with upward flow, and it
performed accurately. Given the poten-
tial vibration problem, it is not clear
whether this measurement issue can
definitively be assigned to downward
flow. Reinstalling the existing flowme-
ter in upward flow would have reduced
this doubt but might have compromised
plant operation.
Read more on this topic next month. FC
David W. Spitzer is a principal at Spitzer
and Boyes, LLC, which offers engineering,
focused market research, writing/editing
white papers, strategic marketing consult-
ing, distribution consulting, seminars and
expert witness services for manufacturing
and automation companies. Spitzer has
written more than 400 technical articles
and 10 books about flow measurement,
instrumentation and process control. He
can be reached at 845-623-1830 or via
spitzerandboyes.com.
 Quiz Corner Which of the following flowmeters can measure 0 to 100 kg/min
of liquid flow?

A. Coriolis mass B. Differential pressure C. Magnetic D. Positive displacement

E. Turbine F. Ultrasonic G. Vortex shedder

A
nswer A is the straightforward answer to the literal
question because kg/min is a mass flow, and Coriolis
mass is the only flowmeter technology in the list that
measures mass flow.
A less literal interpretation of the question would focus
answers on what the flowmeter displays — not on what the
Additional complicating factors
The measurement of some fluids may be traditionally dis-
played in certain units. For example, reactor feed flows are
often expressed in kg/min or lb/min — independent of what
the actual flowmeter measures. This can be confusing, so we
displayed mass units in our plant when the flowmeter actu-
DanielAzocar/iStock

flowmeter measures. In this interpretation, all of the flowme- ally measured mass flow, except where a strong precedent
ters listed can display the flow in kg/min. However, with the applied, such as steam flow.
exception of Coriolis mass, displaying the flow will typically be
the result of a calculation based on a fixed density of the liquid.

www.flowcontrolnetwork.com August 2019 | 9

Cover Series: Pump Systems
Figure 1. The design of the Hy-Line Plus
minimizes CIP setup time. Bolts on the
ports also reduce the number of tools
required to install and maintain the pump.
All images courtesy of Xylem
Simplifying pump
maintenance
reduces downtime
Rotary lobe pumps with clean-in-place (CIP) systems offer cost-effective
solutions for hygienic applications in personal-care products and food processing.
By Peter Wright, Xylem
O
perating within today’s competi-
tive business environment, com-
panies need efficient, effective
and reliable technology solutions that
support smooth operations. Simple, user-
friendly maintenance that keeps down-
time and labor costs to a minimum is
highly desirable for pump operators work-
ing in the pressurized industrial and food
and beverage sectors. Simultaneously,
businesses within these regulated sectors
must ensure that operations are regularly
and effectively maintained and serviced.
Rotary lobe pumps are widely used
within many industries including the food
and beverage, dairy, personal care and
health care industries. The popularity of
these pumps across diverse industries is
due to their sanitary qualities, high effi-
ciency, reliability, corrosion resistance and
good clean-in-place/sterilize-in-place (CIP/
SIP) characteristics. Rotary lobe pumps
with front-loading single-shaft seals are
simple in design and fully accessible with-
out disturbing the process pipework, so
they are quick and simple to service and
maintain. Ease of maintenance delivers
benefits including reduced downtime,
increased production time and easy clean-
ing using minimal water/cleaning agents.
10 | August 2019 Flow Control
When selecting a pump, considerations
for price, effectiveness and efficiency are
all important factors, but these should not
overshadow the importance of user-friendly
maintenance that contributes to increased
production time and reduced downtime.
Cleaning in place versus
manual cleaning (strip clean)
In many applications — such as food,
pharmaceutical, chemical and industrial
— fast and effective cleaning is impor-
tant. Living contaminants such as bac-
teria and other organisms must not be
introduced or allowed to multiply, and all
traces of fluid must be removed at the
end of a batch, process or at product
changeover to prevent any intermixing.
In order to clean a pump or other piece
of “closed” equipment, it must either be
dismantled (manual cleaning), or cleaned
in place as part of the procedure for clean-
ing the entire process. The type of clean-
ing required depends on the needs of the
process. For example, organic materials
such as oils, fats and proteins require a
different cleaning system compared to
inorganic materials such as mineral salts.
Detergent manufacturers can give
advice on the correct use of chemicals
and temperature. CIP usually needs a
velocity of 1.5 meters/second (5 feet/
second) through the pipeline to achieve
the turbulent flow required.
An advantage of manual cleaning is
that no special pipework or equipment
(tank, heater, etc.) is needed. However,
CIP is becoming more common as it
offers advantages over manual cleaning,
including the aforementioned benefits of
reduced downtime, more time to dedicate
to production and a quick and simple
cleaning process that any team member
can carry out.
Step-by-step cleaning in place
The following steps occur in a CIP process.
Step 1. Rinse through system with a suit-
able liquid, usually water at approximately
50°C (120°F), as soon as possible after
completion of process to remove the bulk
of residues before they dry onto surfaces.
Step 2. If CIP will not be carried out imme-
diately after rinsing, leave pump and sys-
tem full of rinse liquid.
Step 3. Choose chemical cleaning agents
to suit the nature of the contamination to
be removed, and use them in accordance
with manufacturers’ recommended dilu-
tion, temperature and circulation time. Do
not exceed 90°C (195°F). Confirm compat-
ibility with pump materials of construction.
Step 4. CIP fluid flow should result in a
mean pipeline velocity of at least 1.5
meters/second (5 feet/second). Note
that all pumps are more susceptible to
cavitation when pumping hot liquids.
Ensure that adequate net inlet pressure
is available. If using a separate pump to
circulate CIP fluids, the lobe pump may
need to be rotated at a speed sufficiently
high enough to allow the fluid to pass
through freely. If sufficient pipe velocity
cannot be achieved, fit a bypass loop to
divert excess flow past the pump.
CIP fluid pressures must equal or exceed
process pressure at all points in the sys-
tem to ensure fluid reaches all contact
surfaces. To achieve this, it may be neces-
sary to restrict flow in discharge pipework,
but do not exceed differential pressure
or temperature suitable for the pump. A
minimum differential pressure of 1 bar is
recommended for effective cleaning.
Step 5. After CIP, rinse through with neu-
tralizers and clean water to remove all
traces of cleaning agents. Do not pass
cold liquid through the pump immediately
after hot; allow the temperature to change
slowly. Failure to observe can result in
pump seizure.
Application example:
Confectionery manufacturing
The global confectionery market is one
of the strongest performing sectors glob-
ally and expected to reach $232,085 mil-
lion by 2022, according to Allied Market
Research. In Europe, chocolate confec-
tionery, specifically, showed the highest
growth rate in recent years, accounting
for more than one-third of the market.
When one of Europe’s leading chocolate
confectionery companies needed to find an
innovative and hygienic solution for a chal-
lenging glucose pumping application, the
company turned to Xylem. Pumping delicate,
viscous fluids can be a daily challenge for
confectionery producers. If an ill-performing
www.flowcontrolnetwork.com August 2019 | 11
pump is used, the effects on productivity
and product quality can be costly.
Chocolate processing and seal selection
Double mechanical seal arrangements
with a high-pressure food grade* barrier,
or flush, are recommended for applica-
tions handling premium-quality chocolate
products. Alternatively, packed gland
seal arrangements can be used where a
controlled amount of product leakage is
acceptable at the back of the rotor case.
The level of cocoa content in the choco-
late product may also determine which
arrangement is most suitable, e.g., high
cocoa content products are more valuable
and place a higher demand on sealing
methods than lower cocoa content choco-
lates due to the abrasive nature of cocoa.
Throughout chocolate processing, tem-
perature control is key to maintaining
quality; temperature is also important to
maintaining the pump head. Temperature
control jackets are recommended to pro-
tect pump head temperature variation
from sources such as low ambient tem-
peratures and thermal transfer from the
pump gearbox.
The project
Many confectionery manufacturers use
high quantities of glucose, transporting
it from tankers to internal canisters for
use in the production processes.
In this case, the manufacturer had been
using a legacy gear pumping system for this
purpose, but wanted to upgrade to a more
reliable, efficient and hygienic solution.
External gear pumps are widely used
in hydraulic fluid power applications as
well as in chemical installations to pump
high viscosity fluids. These pumps use
two meshing and contacting gears to
pump fluid by displacement — the gear
in the pump head turns the other gear.
Despite their popularity, gear pumps can
have a downside: the potential wear of
gear material into pumped media.
The solution
The manufacturer chose two Xylem
Jabsco Hy-Line Plus hygienic rotary lobe
pumps specifically designed for the food
industry and ideal for tank filling and emp-
tying. Unlike with external gear pumps,
the lobes do not make contact, and
their gentle pumping action preserves
the quality of ingredients, while the AISI
316 stainless steel construction makes
them durable and food-grade compliant.*
The pumps include a front-loaded
mechanical seal system that offers time
Figure 2. The Hy-Line
Plus is equipped with
front-loaded mechanical
seals that are simple in
design and fully accessible
without disturbing the
process pipework.

Figure 3. The keyway drive of the Hy-Line Plus
helps keep the pump shaft and motor aligned,
reducing the risk of repairs.
and cost savings if maintenance is required
on the pump. Changing a seal on a front-
loaded pump can be completed within 15
minutes, compared to three or four hours
on a non-front-loaded seal pump.
The hygienic rotary lobe pumps can be
used for ingredient unloading and transfer,
tank filling and emptying, recirculation and
12 | August 2019
mixing, portion and container filling and
sampling and filtration — suited for food
and dairy applications as well as breweries.
Pleased with the results, the manu-
facturer is also considering using the
technology for its chocolate processing
applications with the packed gland version
of the Jabsco Hy-Line Plus lobe series.
The packed gland is a convenient, cost-
effective sealing solution used in chocolate
manufacturing. It is ideal for processing
chocolate in its thick liquid form and trans-
ferring it throughout the whole produc-
tion process — from chocolate liquor to
the conching process, to the molding of
chocolate bars. FC
Footnote
*All food contact materials fall within the
scope of two pieces of European legislation:
1. Regulation (EC) 1935/2004 on mate-
rials and articles intended to come
into contact with food, also known as
the Framework or FCM Regulation.
2. Regulation (EC) 2023/2006 on good
manufacturing practices for materi-
als and articles intended to come
into contact with food, also known
as the GMP Regulation. Any material
considered to be an FCM will need
to comply with this legislation.
Peter Wright is director of product man-
agement and engineering for Xylem’s
Specialty Flow Control business, which
includes the Jabsco, Rule and Flojet
brands and serves the marine, indus-
trial and beverage sectors. Since joining
Xylem in 2005, Wright has held posi-
tions in product management, market-
ing, business development and strategy.
He earned a bachelor’s degree in physics
from Bristol University and an Executive
MBA from Henley Business School in
the U.K.
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Cover Series: Pump Systems
The flow of fluid in vertical
pumps and intake systems
Consider these guidelines when selecting a vertical pump type
and design to ensure reliability and performance.
By Amin Almasi
W
hile horizontal pumps are
commonly used in many ser-
vices, other applications can
best be served by vertical pumps — with
various types and configurations for a
wide range of applications.
Vertical pumps are often used in plants
and locations where there are space or
weight restrictions. Another advantage
of vertical pumps is that the alignment
between the driver, usually an electric
motor, and pump is easier to maintain
than many horizontal pumps. Vertical
pumps use a unique set of shaft and
bearing support configuration that allows
vertical configuration — with the driver
at the top and the pump components
at the bottom. While horizontal pumps
generally require a firm foundation for
mounting, vertical pumps need a smaller
foundation or, alternatively, may not
require such a foundation. For example,
inline vertical pumps can be attached to
the piping with minimal support beneath
the pump. Vertical pumps can also be
used in some high pressure or extreme
temperature applications.
Configurations and types of vertical
pumps include inline vertical pumps, sub-
mersible vertical pumps, can-type vertical
pumps and others. Vertical pumps in dif-
ferent arrangements and configurations
can have many stages or impellers —
sometimes up to 40 stages or more. The
14 | August 2019 Flow Control
following discusses vertical pump types
and the flow of fluids in them, as well as
intake systems, which are important for
many vertical pumps.
Considerations for selecting
a vertical pump
There are many models and designs of
vertical pumps including inline vertical
pumps, high-speed integrally geared ver-
tical pumps, submersible vertical pumps,
different models of wet pit suspended ver-
tical pumps and can-type vertical pumps,
among others. Can-type vertical pumps
have the driver above the liquid surface;
submersible vertical pumps are enclosed
packaged pumps, operating deep inside
the liquid.
Owing to the diverse types and applica-
tions, numerous options of vertical pumps
are available. While this provides a high
degree of flexibility, less expensive
pumps are not always the best choice.
It is important to ensure that the verti-
cal pump is accurately specified, care-
fully selected and purchased to reflect
the requirements of the application. The
best pump type should be selected for
each service.
Another consideration is the quality of
the selected pump. Material selection is
important because vertical pumps are
usually in closer contact with the pumped
liquid than other pumps.
 The assurance and reliability of part
straightness, concentricity and paral-
lelism throughout the life of the pump
should also be considered. Particularly,
the shafting should be concentric with
the pump assembly and driver (elec-
tric motor), and these two assemblies
should also be fully aligned with each
other and with their own individual parts.
Although this involves a lot of accu-
racy needed during both installation
and maintenance of a large pump, it
will be rewarded with high performance
and reliability.
The assurance and reliability of part straightness,
concentricity and parallelism throughout the life of
the pump should be considered.
www.flowcontrolnetwork.com August 2019 | 15
Can-type vertical pumps
Can-type pumps are used to lift liquids
from storage tanks, reservoirs or liquid
sources. The pump driver (usually an
electric motor) is located at or above
the liquid surface, and the shaft extends
from the driver to the pump, which may
be located some distance below the
liquid surface.
This type of pump contains a vertical
series of impellers. In other words, a
series of impellers or stages are used
to take the pump liquid from the low-
est impeller and pressurize it to the top.
A series of large vertical pumps
during installation.
Image courtesy of Amin Almasi
Multiple impellers are together in a series
so that an impeller’s discharge is directed
into the next impeller’s suction and so on.
The same flow rate passes through all
the impellers, and each adds a particu-
lar amount of head. Therefore, the total
pressure gained is theoretically the sum
of the pressure added by each impeller.
Can-type vertical pumps, particularly
those with many stages, are long and nar-
row with a single electric motor driving at
the top. The electric motor is accessible for
operational inspection and maintenance.
Submersible vertical pumps
A submersible pump is an integral pump-
motor unit in a sealed enclosure. This
pump is inserted inside the liquid in a
reservoir, sump, bay or tank. An elec-
tric cable runs to the electric motor.
These pumps are used for lifting liquid
from almost any depth. For applications
where the pump is installed deep into
the liquid, the submersible pump offers
many advantages. This is often the best
option for such deep liquid services, but
there are also disadvantages. The electric
motor is not accessible for inspection or
maintenance without pulling up the entire
pump. Also, there is much less oppor-
tunity for operational observations and
condition monitoring.
This type of pump as a package is
rather simple in concept but its parts
and components should be capable of
supporting the pump assembly, electric
motor and others in harsh, challenging
operating conditions deep inside the liq-
uid. A critical point is the reliable opera-
tion of the electric motor and bearings in
an enclosed configuration. The reliability
and life of a submersible pump depend
greatly on the electric motor and qual-
ity of the bearings. The pump bearings
are lubricated with the pumped liquid
because there is no practical way to sup-
ply lubricants of any kind from an outside
source. The bearings of the electric motor
are sealed in the motor and, depend-
ing on the motor, are lubricated with the
pumped liquid or grease. The hydraulic
axial thrust and the weight of the pump
and the motor rotor are usually carried
by the motor thrust bearing.
 A poor intake system can result in operational
problems, as well as capacity and efficiency losses
and even damages due to vibration and cavitation.
There are different types and models of
submersible pumps in many configurations
and arrangements. Some are installed on
a structure or similar installation; others
are installed with a small clearance at the
bottom of the reservoir or liquid tank.
Vibration in vertical pumps
Vertical pumps have intrinsically weak
structures for dynamic, vibration and
resonance. One reason is their long,
slender shape. Another is their relatively
weak and thin shell structures, particularly
for large vertical pumps, which are prone
to dynamic excitations and resonances.
Even if best analytical and experimental
methods are used, sometimes, unex-
pected resonances arise after installa-
tion. The unexpected resonance can be
due to many reasons and root causes,
for example, the difference between rigid-
foundation test operation and jobsite real
flexible-foundation operation. Another
reason is the variation in the liquid eleva-
tion, which can change natural frequen-
cies of the vertical pump.
The general shape of a vertical pump
usually consists of a long column with a
large mass at each end. Too often, this
configuration is weak for external or inter-
nal vibrations, thus has a tendency for
resonance and high vibration. To prevent
these vibrations of a vertical pump, any
resonance should be avoided, and the
natural frequencies of the total pump
assembly should be calculated and veri-
fied. It is important to predict the natural
frequencies and mode shapes of a vertical
pump analytically and to confirm them
experimentally in a realistic and accurate
test — preferably at the jobsite with all
final attachments. Accurate simulations,
realistic experimental verifications and
parametric studies should be used to fully
investigate resonance cases. Particularly,
parametric studies should be employed to
investigate the effects of all operational
variables on the dynamic characteristics
of vertical pumps and to propose proper
16 | August 2019 Flow Control
operational parameters and strategies for
lower vibration and better dynamics.
Centrifugal versus mixed flow
Many vertical pumps use centrifugal impel-
lers in a vertical arrangement. The impel-
lers used in vertical centrifugal pumps are
similar to those in horizontal centrifugal
pumps. However, some vertical pumps,
such as turbine-type vertical pumps, use
mixed flow or axial flow impellers. This can
develop significant operational differences,
particularly in the larger sizes and high
flow services.
There are some disadvantages for these
impellers. For example, in the performance
curve for a typical mixed flow impeller,
the shutoff head is usually high; it may
be more than twice the head at the best
efficiency point (BEP). An axial flow impel-
ler will produce an even higher difference
at the shutoff condition. The power draw
is at its maximum at the shutoff for these
pumps, and the required power is very
high at or near the shutoff. Therefore, a
provision such as an automatic bypass
will be needed if the discharge is clogged
or restricted by the valve. Otherwise, the
driver will be overloaded.
Intake of vertical pumps
Some vertical pumps, such as inline verti-
cal pumps, have suction piping, but many
vertical pumps take liquid from a kind
of intake system. The performance and
reliability of a vertical pump is dependent
on the intake system and flow of liquid at
the intake/suction. This is closely related
to where the pump is installed, such as
the sump, reservoir, column or tank.
For horizontal pumps, there should be
proper suction piping. Compared to ver-
tical pumps, the design of such suction
piping is easier than proper configuration
and arrangement of an intake system
such as a sump or suction intake area.
Proper configuration of an intake system
in a vertical pump is challenging, which
frequently results in performance and reli-
ability problems. The layout of the intake
system and the relative positioning of the
pumps, if multiple vertical pumps are used
within that intake system, are important to
the reliability, performance and operation of
vertical pumps. For many vertical pumps,
thorough analytical studies and even model
testing are needed prior to the design and
construction of the intake system.
A poor intake system can result in not
only operational problems, but also
capacity and efficiency losses and even
damages due to vibration and cavitation.
The effects of disturbed approach flow
on operational behavior increase with
the high specific speed and the size of
the vertical pump. Therefore, this is more
challenging for large vertical pumps that
use mixed flow or axial impellers.
The objective of an intake system is mini-
mal hydraulic turbulences and no nega-
tive influence from the incoming liquid flow
lines. The velocity distribution at the impel-
ler entry should be as uniform and calm
as possible. This is achieved by suitable
management of the approaching flow to
the pump; the entire flow path in the intake
should be considered and managed.
A key element is the velocity of the
approaching liquid. Roughly, this velocity
should be about 0.25 to 0.4 m/s. The
location of each pump to the other(s)
and to the side and back walls of the
sump, tank or reservoir is also impor-
tant. These distances are related to the
entrance velocity of the pump, which can
be a function of the suction bell diameter.
In addition, the clearance of the bottom of
the pump to the floor (bottom) is critical.
Roughly, this clearance should be more
than half the suction bell diameter of the
pump. Note that bell diameters for the
same size and type of pump may vary
with different manufacturers.
Arrangements of pumps and accom-
panying baffles are used in different situ-
ations. Many installations are now using
dividing walls between each pump to
contribute to the smooth flow of liquid
to the suction bell of each pump, as this is
usually necessary for optimum operation.
It is particularly important to avoid any
cascading effect from incoming liquids
that might create air/gas entrainment or
vortexing that will detrimentally affect
pump performance and reliability.
Formation of vortices in the approach-
ing flow upstream of a vertical pump
should be prevented. This applies to
all kinds of vortices, for instance, air-
entraining or hollow vortices proceeding
from the liquid surface, bottom or wall
vortices and vortices resulting from flow
separation or skewed velocity profiles in
the approach flow. Air-entraining vortices
should be avoided by suitable configu-
ration of the pump intake area immedi-
ately upstream of the entry and adequate
immersion depth (or minimum submer-
gence). Vortices due to flow separation in
the approach liquid should be prevented.
Asymmetric approaching flow can
induce preswirl and vortices. This source
of preswirl should be prevented. Every
impeller is subject to flow recircula-
tion at the impeller suction. The liquid
recirculating from the impeller induces
a strong pre-swirl that can lead to the
formation of cavitating or noncavitating
vortices. To avoid detrimental effects on
performance, cavitation and vibrations,
this type of preswirl should be suppressed
to a large extent by swirl-breaking ele-
ments upstream of the impeller such as
ribs or floor splitters.
Typically, the design and configuration
of the intake for vertical pumps is a com-
promise between the structural con-
straints, hydraulic requirements and pump
specific mandates. Only close collabo-
ration between the design team of the
purchaser and pump manufacturer can
lead to reliable, optimum installation. The
requirement for undisturbed approaching
flow to the impeller can be met by dif-
ferent provisions, such as with a proper
pump bay, suitable suction bell or a good
inlet bend. For larger capacity pumps,
such as large vertical pumps involving
heavy construction costs, the design and
final setting of the intake system should
be reached after thorough technical and
commercial studies and assessments.
Conclusion
Vertical pumps are special classes of
pumps for many specific applications.
When selecting a vertical pump, take
into consideration the environment and
requirements for best pump performance
and reliability. FC
Amin Almasi is a senior
machinery and equipment
consultant. He is a chartered
professional engineer of Engineers Australia
and IMechE. Almasi is an active member of
Engineers Australia, IMechE, ASME and SPE,
and he has authored more than 150 papers
and articles on rotating equipment, condi-
tion monitoring, offshore, water treatment,
wastewater treatment and reliability.

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Features: Valves

Achieving better sample isolation

and analyzer responses with
process stream switching systems
How to meet the three key design principles of sample
isolation, quick responses and minimal flow upset.

By Randy Rieken, Swagelok Company

P
lants often use multistream sam-
pling systems to monitor as many
process streams as possible with
a single process analyzer. Such systems
allow a plant to select a single process
stream for analysis and block all others.
To achieve the best results, system
designers should ensure their multistream
switching systems follow three primary
design requirements, including:
• Properly isolating samples to prevent
cross-stream contamination
• Ensuring fast responses so final
measurements are representative
of real-time process conditions
• Minimizing flow upset to mitigate
pressure spikes and potential sample
phase changes

This article reviews design strategies for

meeting these objectives to help plants
effectively use multistream switching sys-
tems to optimize their analyzer networks.

Proper sample isolation

It is necessary to isolate each sample to
prevent a stream not selected for analy-
sis from contaminating the stream that
is being analyzed. Using reverse flow or
reverse pressure ensures that a leak
across a valve seat will flow away from
the stream under analysis and therefore
not contaminate it. Avoiding dead legs
— areas of reduced flow that trap older Courtesy of Swagelok Company

18 | August 2019 Flow Control


Figure 1. The reverse flow technique used
to prevent dead legs in this block-and-bleed
assembly featuring three-way valves allows the
selected sample to flow into the entire flow path.
Figure 2. An integral flow loop inside a ring
manifold helps maintain a constant flow to
the analyzer when switching streams.
Figure 3. A continuous bypass loop added
to the sample line close to the stream
switching system helps the sampling system
better maintain a consistent flow for more
timely and accurate analyses.

sample material — is also critical to pre-
vent older samples from contaminating
a new sample.
The reverse flow technique prevents
dead legs by ensuring every tee in the line
to the analyzer is flowing in all its legs.
For example, the block-and-bleed system
in Figure 1 allows the selected sample
to flow into the entire flow path and out
from two outlets — one flowing to the
analyzer and one to a bypass line or vent.
The reverse pressure technique pre-
vents dead legs by ensuring every closed
valve seat has a lower pressure — typi-
cally atmospheric — on the other side
of the seat. Therefore, any seat leakage
flows to a vent and cannot contaminate
the sample. Every tee in the flow path for
the double-block-and-bleed (DBB) system
(discussed later in more detail) becomes
a three-way valve, leaving no dead legs.
Quick responses
Time delay represents the total time from
the sample being drawn to producing an
analyzer result. Shorter delays enable
operators to make any necessary pro-
cess adjustments sooner. Minimizing the
presence of dead legs, mixing volumes
could damage sampling system compo-
nents. In addition, a sudden flow and
pressure increase may cause a gas
sample to condense.
It can be challenging to minimize flow
rate changes because stream selector
systems differ in how they treat lines
not selected for analysis. For instance,
systems that completely stop the flow of
unselected inlet lines leave old samples in
upstream lines that will need to be purged
before the next analysis. On the other
hand, systems that ensure a continuous
flow, even when the stream selector valve
is closed, do not maintain constant flow,
as flow in the transport line will increase
when selecting a stream.
Systems that maintain the same flow
Figure 4. A valved bypass configuration can
at all times offer the best potential. To help a sampling system maintain consistent
achieve constant flow, the stream selec- flow and produce fast analyzer responses.
tor valves must simultaneously shut off a
stream’s line bypass flow when selecting
that stream for analysis via the common
flow path to the analyzer.
Configuring stream
selector valves
Some key design configurations can help
enhance system reliability and achieve some
“Industrial Sampling Systems,” ©20131

and potential adsorption surfaces, such or all of the three primary design objectives.
All figures courtesy of Swagelok,

as filters, in the common flow path to the

analyzer promotes quick responses after
stream switching, as does ensuring all lines
are flowing, even when not being analyzed.
Minimum flow upset
When selecting different streams for
analysis, avoid drastic flow changes, as
they may create pressure spikes that
Ring manifold: A simple manifold design
has dead legs at each tee junction.
However, a ring manifold design (see
Figure 2) reduces the volume of dead
legs, especially if tee fittings can screw
directly into the valve bodies. With an inte-
Figure 5. Every tee in the flow path in this
gral flow loop and ports for various pro- reverse pressure DBB system becomes a
cess and analytical stream connections, three-way valve, eliminating dead legs.

www.flowcontrolnetwork.com August 2019 | 19

 Double-block-and-bleed systems are highly
effective at eliminating dead legs and isolating
samples to avoid contamination.

Figure 6. The line bypass in this double-block

system maintains flow in the inlet lines to help
achieve faster analyzer responses.

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Figure 7. A two-way primary block and a

three-way secondary block-and-vent in this
double-block assembly isolates the sample.
A ring manifold maintains consistent flow.

a ring manifold generates about the same

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flow resistance for each stream to help
maintain a constant flow to the analyzer
when switching streams. Unfortunately, the
design in Figure 2 does not protect against
possible valve leakage, making it unsuit-
able for switching process streams alone.

Line bypass: Adding a continuous bypass

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loop to the sample line at a location close
to the stream switching system is the sim-
plest way to maintain flow (see Figure 3).
The bypass line may include a needle valve
and flowmeter or a critical orifice to main-
tain flow. This design offers a fast response
when switching streams. However, sample
contamination from valve leakage may
still occur. In addition, because the line
selected for analysis flows more rapidly

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than the unselected lines, the sample flow
is not constant.

20 | August 2019 Flow Control

Valved bypass: The three-way valves
shown in Figure 4 maintain flow in
the lines not selected for analysis and Adding a ring manifold to a vented double-block
achieve two of the three design objec-
tives. By setting the analyzer flow to
valve system provides additional two-way and
equal the bypass flow, flow changes three-way valve arrangements.
can be eliminated during switching.
Responses will also be fast in this
design. However, sample contamination
is still possible from valve seat leakage
and small dead legs.

Double-block-and-bleed system: System

designers can address — but not nec-
essarily fully meet — the three design
objectives by using various configurations
of a DBB system. Such systems are highly
effective at eliminating dead legs and iso-
lating samples to avoid contamination.
A DBB arrangement (see Figure 5) has
dual block valves driven by a common
actuator. First, a primary valve blocks the
incoming sample stream and bleeds the
connecting tube to a vent. Next, a sec-
ondary valve blocks the connecting tube
and opens a cascaded path that allows
the selected sample to flow to the ana-
lyzer. Dead legs are thereby eliminated.
The common vent header, which is at a
lower pressure than the stream flowing to
the analyzer, disposes of any valve leak-
age, making cross-stream contamination
virtually impossible.
Regarding response times, designers
need to watch for time delay with some
DBB assemblies. The DBB’s cascad-
ing valve path causes each sample to
encounter a small but finite flow resis-
tance. Therefore, streams passing through
more valves have lower sample flow and
higher time delay.
Adding a line bypass to maintain inlet
line flow (see Figure 6) will help designers
achieve a faster response from the ana-
lyzer when switching samples. However,
it will not keep the sample line flow con-
stant, as additional flow occurs when
selecting a stream for analysis.

Double-block system with a ring mani-

fold: Adding a ring manifold to a vented
double-block valve system provides
additional two-way and three-way valve

www.flowcontrolnetwork.com August 2019 | 21


Figure 8. Whether a stream is selected or not,
this double-block assembly uses three-way valves
with a bypass in the primary block position to
hold each stream at a constant flow rate.
arrangements that can help address the
three design objectives.
The basic valve circuit in Figure 7 uses
a ring manifold with a two-way primary
block and a three-way secondary block-
and-vent. The dual valves block each
unselected stream in two places and
vent the line between them to prevent
cross-contamination. However, the ring
manifold may introduce small dead legs
at each connection.
The design in Figure 8 uses three-way
valves in the primary block position to
maintain continuous flow in the inlet
lines whether a stream is selected or
not. However, it is necessary to include
an initial bypass or fast loop upstream
of the stream selector if the streams all
have different flow rates. The sample
from each sample takeoff point flows to
the stream selector and passes through
the primary block valve and out via the
bypass line. By setting each bypass flow
to equal the flow rate taken by the ana-
lyzer, each stream will have the same
flow rate whether its selection valve is
open or closed.
Finally, fast response times are likely
with a double-block valve system fea-
turing a ring manifold because flow
resistance is essentially the same for
each stream.
Modular stream selection valves:
Another viable option for meeting the
design objectives is a compact stream
selector valve assembly (see Figure 9),
which combines DBB functions into one
compact valve body. It has an integral
actuator that operates three two-way
valves in unison. Bolting multiple stream
selector valves together can manage
numerous streams. The compact assem-
blies enable faster analyzer response times
even at lower flows due to their minimal
flow paths and low internal volumes.

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FEATURES AND BENEFITS
• Multiple mounting options
• 1/4": 4.3 m (14.2') of dry suction
lift for better priming
• 1/2": 5.1 m (16.9') of dry suction
lift for better priming
• Startup pressures as low as 1.03
bar (15 psig)
• Bore-seal design eliminates leaks
that result from torque decay
• Interchangeable footprint with
previous Wilden designs (P.025,
P25 and P1, P100)

PSG | 22069 Van Buren Street

Grand Terrace, CA 92313-5651 USA
P: +1 (909) 422-1730 | F: +1 (909) 783-3440
wildenpump.com

19-WILD-1871 Flow Control - August 2019.indd 1 7/3/19 4:28 PM

22 | August 2019 Flow Control


Figure 9. Stream selector valves combine DBB
functions into one compact valve body and
can be bolted together to create a multistream
switching system.
Connecting several stream selector
valves together automatically deploys a
ring manifold that extends the length of
the valve assembly. This pathway helps to
maintain a constant flow to the analyzer
when switching streams.
With a stream selector valve, a DBB
function isolates samples by ensuring
any leaking fluid from other streams
escapes via a vent and cannot contami-
nate the stream being analyzed. The
valve’s internal design also preserves
the analytical purity of the sample by
Figure 10. An integral ring manifold inside this
assembly of three stream selector valves helps
to maintain a constant flow to the analyzer
when switching streams.
www.flowcontrolnetwork.com August 2019 | 23
eliminating unswept tees and cavities
along the internal flow path. The three-
stream design in Figure 10 is a good
example, as it mitigates a potential
deadleg at the vent valve by purging
the vent valve seat with a continuous
flow of sample fluid. The design also
minimizes dead legs in the ring manifold
by purging all the closed outlets with
the selected sample flow.
Meeting the primary design
objectives to optimize
process analyzers
Multistream sampling systems are an
effective way for plants to reduce their
total number of process analyzers.
However, designers should only use mul-
tistream switching when measuring the
same analytes at about the same concen-
tration in each stream. When multistream
switching is a viable option, following
the primary design objectives of sample
isolation, quick analyzer responses and
minimum flow upset will help to enhance
analyzer reliability. FC
References
1. “Industrial Sampling Systems:
Reliable Design and Maintenance
for Process Analyzers” (2013),
authored by Tony Waters and pub-
lished by Swagelok Company. www.
industrial-sampling-systems.com.
Randy Rieken is market manager for
chemical and refining for Swagelok
Company. He is responsible for the
development and implementation of
chemical and refining market-driven
strategies. Rieken joined Swagelok in
November 2014 and has more than
25 years of global business develop-
ment experience. He can be reached
at randy.rieken@swagelok.com.
Features: Sealing Systems

Fight friction and reduce costs

with lubrication management
Reduction in compression set behavior with new hydraulic sealing
systems reduces friction and creates a better environment for seals.
By Beth Figliulo and Michael Cook, Trelleborg Sealing Solutions Americas

from years of experience with issues caused

by friction in hydraulic systems, including:
• Increased pressure and speed in
today’s smaller, lighter machines
have pushed polyurethane seals to
their material limits.
• Coatings on counter surfaces are
added to ease friction, but they are
often chosen for technical reasons
without considering the seal system.
As a result, they may severely limit
the lifespan of the seals and/or the
entire machine.
• Tiny imperfections on interfacing
surfaces (e.g., embedded holes or
uneven textures) act like a knife on
seals, compromising their integrity.
• Modifications designed to prevent
seal wear are common, but they
come at a cost high enough to affect
a company’s competitiveness.
Figure 1. Common cylinder application injection molding machine
All images courtesy of Trelleborg Sealing Solutions Lubrication management addresses all
these issues by providing a better envi-

D
esigners have a healthy respect
for the role of lubricants in boost-
ing the service lives of hydraulic
systems; however, with the increased
complexity, efficiency and precision of
today’s systems, more is required of a
lubrication system.
Studies have shown that lubricants aver-
age about 1% of overall plant operating
costs (overhead is 35%, maintenance is
30%, utilities are 19% and depreciation
is 15%).1 That 1% seems low, and taking
into consideration that poor lubrication is
the primary cause of premature machine
bearing failure, it may even seem deficient.
This discrepancy between money spent
and the potential effect on machines
should be seen within the context of
the larger challenge facing designers.
Machines must work reliably for longer,
but economic pressures result in a never-
ending quest for cost effectiveness.
A solution to this conundrum is lubrica-
tion management, which takes a holistic
approach to machine maintenance to
reduce friction and create a better envi-
ronment for seals, significantly extending
the life of the system.
Understanding lubrication
management
In a holistic solution, each element of the
system is viewed as a complementary com-
ponent of the whole. This approach stems
ronment for both seals — primary and
secondary — in today’s popular tandem-
seal systems. It is especially important
in applications where seals play a criti-
cal safety and operational role. In these
cases, the challenge of friction and wear
can be multiplied exponentially.
In traditional systems, the primary seal
prevents all lubricant from getting past it,
maximizing pressure on the primary seal and
creating dry-running conditions for the sec-
ondary seal, which can reduce its lifespan.
Lubrication management combines
superior lubrication with a rounded-edge
seal to completely change the system’s
dynamics. The thicker, high-quality film of
oil passes underneath the pressure-loaded

24 | August 2019 Flow Control


Figure 2. Standard sealing system
Figure 3. Lubrication management sealing system
primary sealing element to reduce the load
on the seal and create a better environ-
ment for the secondary seal. In certain
configurations, the film volume can also
be controlled to the contact area of the
secondary seal and the counter surface
through an integrated check valve.
As previously mentioned, the rounded
edge of the seal and backup ring, where
applicable, is what drives the lubrication
management behavior of the system. The
edge shape gives the seal a more neutral
or inverse contact pressure when compared
to the standard, sharper sealing edge seen
on most seals. The rounded edge ensures
the primary seal will still hold the system
pressure while enabling the lubrication
film to pass underneath. Additionally, the
backup ring’s rounded edge prevents it from
scraping away the optimized lubrication film
during dynamic movement.
In tests using a polyurethane buffer
seal with a polyurethane U-cup, com-
pression set behavior was reduced by
almost 50%. In some circumstances,
www.flowcontrolnetwork.com August 2019 | 25
tests showed a reduction of up to 70%.
Another promising test involved short-
stroke applications that are often seen in
pitch-control cylinders. The short stroke
means that the running surfaces of the
primary and secondary seals will not
intersect, which can create a lubrication-
starved environment for the secondary
seal that is further exacerbated by the
heat generated from the rapid movement.
Test results using the optimized lubrica-
tion management sealing arrangement
showed very little wear on both seals
and counter surface, even after 1 million
cycles. The lack of wear on the counter
surface that was exclusively in contact
with the secondary seal was especially
promising since, in normal conditions,
significant run-in can be seen in this area.
Note that lubricant choice is an impor-
tant element of this approach. Although
industry has increased the use of min-
eral oil, synthetic lubricants and greases
carry a number of real-world benefits,
including increased wear protection, wider
temperature range, longer oil life and
lower costs. The optimal lubricant choice
will vary from system to system, affected
by factors such as temperature and overall
pressure within the system.
Benefits of lubrication
management
In a casual customer survey, 86% of
respondents said increased life of the
system was the most important goal
of improved lubrication management.
Respondents were allowed to choose
as many benefits as they liked, and they
mentioned lower wear (50%) and lower
friction (50%), alongside increased robust-
ness of counter-surface quality (36%) and
less smoothing of counter surfaces (36%).
The described holistic approach dove-
tails with consumer desire. When the load
on elements within a sealing system are
reduced, both performance and lifetime
are optimized.
Furthermore, because lubrication man-
agement decreases the limitation of seal
performance in relation to roughness spec-
ifications, the potential exists to lower the
total cost of the hydraulic system.
However, achieving this requires
designers to work hand-in-hand with an
experienced seal supplier. Successful
lubrication management involves consid-
ering not only lubricant choice and control
mechanisms, but also maintenance plan-
ning and a host of other issues. Thus, it
is recommended to choose a supplier
with considerable experience in wear-
resistance testing, leakage limitation and
lubrication management. FC
References
1. Bickley, J., Proper Lubrication Practices
Improve Plant Operations, https://www.
powermag.com/proper-lubrication-
practices-improve-plant-operations.
Beth Figliulo is the fluid power segment man-
ager at Trelleborg Sealing Solutions Americas.
Michael Cook is a fluid power technical
specialist at Trelleborg Sealing Solutions
Americas. Go to tss.trelleborg.com for
more information.
Features: Level Measurement

How frequency modulation

can improve effectiveness of
radar level measurement
Lessons learned from FM and AM broadcasting can be applied
to tank level measurement, delivering better performance in
challenging applications.
By Ingemar Serneby, Emerson Automation Solutions

I
n 1933, radio pioneer Edwin
Armstrong demonstrated a new
technology that would transform
broadcasting: frequency modulation
(FM) transmissions capable of delivering
higher-fidelity sound and less interfer-
ence than amplitude modulation (AM).
Eventually, FM broadcasting became
standard for radio and television with
a form used in today’s digital wireless
communications. AM remains but FM
is preferred for most purposes.
Creative engineers have found ways to
adopt FM for a variety of applications,
including radar for tank level measure-
ment. The basic radar approach takes
advantage of an electromagnetic wave’s
ability to bounce off surfaces, including
liquids. If it is possible to measure the
time required for a signal to travel to the
surface of the liquid, reflect and return to
the device at the top of the tank, then it
is possible to calculate the distance trav-
eled and therefore level. This is the work-
ing concept of both noncontacting radar
(NCR) and guided-wave radar (GWR) level
measurement. Radar level instruments
provide a top-down, direct, accurate and
reliable measurement of the distance to
the surface of liquids, sludges, slurries
and some solids.
GWR transmits a pulse down a wave-
guide probe (see Figure 2), which might
extend all the way to the bottom of the Figure 1. New FMCW level instruments are compact and can operate on a standard 4-20 mA
tank. This guides the pulse and helps con- two-wire loop. Safety-certified models are also available.

centrate the reflection, so it is unaffected All images courtesy of Emerson Automation Solutions

26 | August 2019 Flow Control


by objects inside the tank that might cause
an undesired reflection. The downside is
the potential for the probe to interfere with
moving objects such as an agitator.
NCR technology (see Figure 3) sends
a signal through the open head-space in a
tank down to the stored product surface.
Since it does not touch the contents, it is
unaffected by many process conditions
such as density, viscosity, conductivity,
coating and vapor. It is also an ideal
choice for tanks with moving objects, cor-
rosive products, wide temperature range
and difficult pressure conditions, since
these have no impact on measurement
accuracy. With built-in diagnostic capabili-
ties, straightforward commissioning and
no moving parts, NCR instruments offer
both ease-of-use and low maintenance
requirements.
Moving into the FMCW age
Given that the distance from a radar
instrument to the surface of a tank’s con-
tents could be a little more than a foot or
two, the amount of time required for the
pulse to travel is virtually instantaneous.
Getting an accurate measurement of
something so quick requires some clever
engineering. NCR uses one of two meth-
ods: pulse or frequency-modulated con-
tinuous wave (FMCW). GWR uses pulse,
www.flowcontrolnetwork.com August 2019 | 27
Figure 2. (Left) GWR sends a pulse down a
wave guide to minimize dissipation of the signal.
Figure 3. (Below) NCR minimizes extension
into the tank and does not touch the product.
FMCW has higher receiving sensitivity and uses
higher-strength signals than pulse systems, helping it
perform better in situations such as turbulence or foam.
Figure 4. The ability of FMCW to use frequency change for determining distance can help avoid
problems that affect pulse measurements.
but the more focused signal provided by
the wave guide creates different operating
characteristics than NCR.
Pulse systems use time expansion to
convert these extremely short intervals
to a slower timescale. The surface echo
is built up of tens of thousands of short
radar pulses transmitted from the instru-
ment at the tank top and aimed directly
at the process material below. The instru-
ment measures the time delay between the
transmitted and received echo signal, and
an on-board microprocessor then calcu-
lates the distance to the material’s surface
and, consequently, the level measurement.
FMCW uses the same reflected signal
concept but applies it differently. Instead
of measuring time-of-flight of a specific
pulse, an FMCW instrument transmits
a continuous signal from the antenna
at the tank top, but with a constantly
changing frequency (see Figure 4). After
the signal is reflected by the surface of
the contents, the echo is picked up by
the antenna. Since the transmitted sig-
nal constantly varies in frequency, the
echo has a slightly different frequency
compared to the signal being transmitted
at that moment. The difference between
these frequencies is directly proportional
to the echo delay, enabling distance to
be accurately measured.
 The difference between these two
approaches is analogous to AM versus
FM radio broadcasting. Pulse systems are
more like AM in that the signal is more
susceptible to interference from sources
such as internal tank structures, foam,
high vapor concentrations and turbulence.
For example, if turbulence is bad enough, a
pulse may be scattered and effectively lost
due to a poor reflection. The instrument
may incorrectly assume the reflection from
the next pulse is actually the lost pulse,
but with a much later return time, causing
it to read a distance greater than actual.
Measurement accuracy can also be influ-
enced by any drift of the pulse frequency
and even temperature inside the tank.
FMCW captures its process variable
information in the frequency domain,
which supports more accurate signal
conversion. Its signal processing can
ignore the common interference sources.
Moreover, FMCW has higher receiving
sensitivity and uses higher-strength sig-
nals than pulse systems, helping it to
perform better in difficult situations where
there may be turbulence and foam.
Why we still have both —
pulse and FMCW
Just as FM radio has not eliminated AM,
there are still lots of pulse technology
radar instruments available. Why have
these not been replaced by FMCW?
FMCW isn’t new — in fact, the technol-
ogy has been around for decades, and its
technological advantages have been rec-
ognized since the beginning. The reason so
many pulse instruments remain is largely
related to power consumption. Pulse
instruments are efficient to the extent that
GWR instruments using WirelessHART can
operate for years at a time on batteries.
As for FMCW, the working assumption
all along was that they were, by definition,
big, bulky four-wire devices and would
consume, at least by instrumentation
standards, a lot of power. If a power
source was not convenient, many users
stuck with pulse instruments unless some
process condition demanded the more
sophisticated approach.
That situation has changed. Like many
electronic devices, FMCW instruments
28 | August 2019 Flow Control
have become far smaller and more effi-
cient with improved power utilization.
Therefore, two-wire FMCW NCR instru-
ments (such as the one shown on page
26) have emerged on the market and are
growing in popularity.
Types of applications
where FMCW shines
The following are a few examples of the
types of applications that lend themselves
well to FMCW instruments.
Foam: Foaming liquids can disrupt echo
reflection, and the extent to which this
interferes with an accurate measurement
can be difficult to predict and depends
largely on the foam’s properties. One kind
may dampen out the signal completely,
while other types may be transparent. The
thickness, density and dielectric constant
are key factors that need to be analyzed.
Dry foam tends to be transparent, so
the instrument reads the actual liquid
surface. If the foam is wet or especially
dense, the microwaves are often reflected
from the foam surface, and the top of
the foam is seen as the level. The latest
FMCW instruments have a double-surface
handling function, allowing the user to
select either the foam layer surface or
underlying product surface as the output.
This enables the product surface to be
measured rather than the foam layer.
Condensation: FMCW technology is gen-
erally unaffected by condensation and low-
pressure steam, but heavy condensation
on the antenna can affect the measure-
ment. When this is a problem, air purging
may be required to prevent clogging of the
antenna. In high-temperature applications,
mounting the transmitter in an insulated
tank spud is recommended. Insulation pre-
vents the nozzle from becoming a cold
spot, causing condensation and liquid
buildup on the antenna. In extreme situ-
ations, heat tracing may be necessary to
keep the spud above the dew point.
Storage, buffer and blending tanks:
FMCW technology delivers highly reliable
and accurate level measurements when
applied to both metallic and nonmetallic
vessels containing any liquid, including oil,
gas condensate, water or chemicals. As
these transmitters have no moving parts
and do not contact the product, they
reduce maintenance and improve safety.
If agitators are necessary, sophisticated
FMCW instruments can use software to
see past false echoes so measurement
accuracy is unaffected.
Reactor vessels: Chemical reactions can
create a variety of conditions inside tanks
— often resulting in vapors, foam and
turbulence — while density can change
as part of the reaction, and pressure can
vary from vacuum to positive pressure.
FMCW instruments can cope with these
factors to provide measurement accuracy
and reliability.
Still pipes: When a tank’s content is
turbulent — whether from agitation, prod-
uct blending or splashing — an effective
return signal can be disrupted. Adding a
still pipe can reduce the effect by isolat-
ing the surface and reducing turbulence.
These situations often call for GWR, but
FMCW instruments can also provide accu-
rate readings within the confined space
of the pipe.
Conclusion
The two main modulation techniques for
NCR instruments — pulse and FMCW —
are both effective, but with its greater
sensitivity and accuracy, FMCW is suited
for challenging applications. Today’s
FMCW products are more compact and
provide high energy efficiency, allowing
operation with the low power supplied by
a two-wire loop. This eliminates the need
for additional power infrastructure and
enables these devices to provide accurate
and reliable level measurement in a wider
range of challenging applications. FC
Ingemar Serneby is a senior appli-
cation specialist with Rosemount
Tank Radar, Emerson Automation
Solutions. He has an electrical and elec-
tronics engineering degree from Chalmers
University of Technology and has worked for
Emerson for nearly 30 years.
 P R O D U C T
FOCUS
Send products for consideration in this section
to mrogers@endeavorbusinessmedia.com
1
1 | control valve
CIRCOR RTK’s REflex
Quick Change Seat Control
Valve with REact 30 DC-
PoP smart actuator is an
all-in-one solution for noise
reduction and high pressure
drop applications. The valve
assembles in four steps
without special tools. With
high-capacity flow paths and
interchangeable trim, the
two-way valve supports a
variety of media and meets
NACE standards for use with
abrasive liquids and gases. It
is customizable for lower flow
and higher pressure drop and
available in a range of sizes.
www.flowcontrolnetwork.com August 2019 | 29
2 | surge dampener
Wilden’s bolted plastic
Equalizer Surge Dampeners
Integrated SD Series are
engineered to help extend
the life and reduce the noise
of Wilden 13 mm and 25
mm Pro-Flo Series AODD
pumps. The dampeners use
an integrated design that
allows them to be directly
incorporated in the manifold
design. They screw onto the
top of Wilden pumps without
additional hardware. They
feature temperature ranges
from -51°C to 138°C for
EPDM and 10°C to 137°C
for PTFE.
3
3 | flowmeter
Azbil Corporation’s
enhanced Thermal Micro Flow
Rate Liquid Flow Meter Model
F7M offers an increased
measurement range of up
to 50 mL/min. The extended
measurement range will
enable users to control micro
flow rates and monitor optimal
flow in liquid transfer devices
and equipment to a greater
degree, which can contribute
to preventing process failure.
Other enhancements include
automatic configuration of
the flow rate correction factor
as well as measurement of
two liquids with a single unit.
4 | flow sensor
AW-Lake Company’s HUB-
40EX Hazardous Area Rated
Flow Sensor is available with
either sinking or sourcing
digital output and either 316
stainless steel or aluminum
junction box or a version
with no junction box at all.
Compatible with any stainless
steel AW-Lake flowmeter, the
sensor is ideal for applications
that require an explosion-proof
sensor. The sinking digital I/O
provides a ground connection
to the load while the sourcing
digital I/O version provides an
active voltage source for PLCs
designed for source output.
Trade Shows & Events
Turbomachinery and Pump Symposia
offers technical program and exhibition for
rotating equipment engineers and technicians
T
he 48th Turbomachinery and
Pump Symposia (TPS) — at the
George R. Brown Convention
Center in Houston on Sept. 10–12 — will
offer a forum for the exchange of ideas
between rotating equipment engineers
and technicians worldwide. The Symposia
is organized by the Turbomachinery
Laboratory, part of the Texas A&M
Engineering Experiment Station (TEES)
and The Texas A&M University System.
Now surpassing 47 years, TPS is known
for its impact on turbomachinery, pump,
oil and gas, petrochemical, power, aero-
space, chemical and water industries
through two pathways: the exhibition
and the technical program. The exhibit
hall will host leading international compa-
nies from across the globe, and industry
experts will demonstrate full-size equip-
ment and products and share insights
on current practices and future trends.
The event will stretch out over 216,000
square feet with 365 exhibiting compa-
nies from 45 countries. Organizers expect
4,750 people to attend.
Educational sessions
TPS also hosts a professional continuing
education program relied upon by rotat-
ing equipment engineers and technicians
worldwide, spanning the oil and gas, pet-
rochemical, power, aerospace, chemical
and water industries. The program —
consisting of short courses (that begin
30 | August 2019 Flow Control
Monday, Sept. 9), case studies, discus-
sion groups, lectures and tutorials — is
hand-picked by two advisory committees
and is made up of recognized leaders
in the turbomachinery and pump com-
munities. Topics include maintenance,
reliability, troubleshooting, instruction
on emerging designs, technology and
best practices that include case studies
on problems solved and lessons learned.
Short course topics include:
• Vibration Problems and Solutions
in Pumps and Turbomachinery
• Lateral Rotordynamics of
Petrochemical Equipment –
Review, Examples and Problems
• Vibration Problems and Solutions
in Pumps and Turbomachinery
Lecture topics include:
• Direct Head Measurements for
Turbomachinery Design
• Sand Management and Erosion
EXHIBITION SCHEDULE
All images courtesy of TPS
Tues., Sept. 10, 7:30 a.m.–5 p.m.
Wed., Sept. 11, 8 a.m.–6:30 p.m.
Thurs., Sept. 12, 8 a.m.–2 p.m.
tps.tamu.edu
• Cavitation Sensing and
Optimization in Rotary Positive
Displacement Pumps for
Transfer Duties
• Prediction in Subsea
Multiphase Pumps
Tutorial topics include:
• Dry Gas Seal Failure Simulation
Methodology
• Fundamentals of Fluid Film Thrust
Bearing Operation and Modeling
• Methods to Determine and Specify
Pump Dynamic Analysis
Case study topics include:
• Catastrophic Failure Diagnosis
with Modal Analysis of Generator
Endwindings
• Valve Seat Failure on Steam Turbine
• Acoustic Resonance in a
Progressive Cavity Pump
Discussion group topics include:
• Turbomachinery Bearings and
Annular Seals
• Improving Mean Time Between
Pump Failures
• Vertical Pump Problems and
Solutions
The proceedings from TPS will be avail-
able to the public at no cost six months
after the event at turbolab.tamu.edu/
proceedings. FC
 Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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 Featured
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In this case study, a U.S.
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sealing, including mechanical seals, pump and valve packing,
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GFO is a registered trademark of WL Gore and Assoc.

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