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AU G U S T 2 0 21
SYSTEMS
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FROM THE EDITOR
The Pumps & Systems team had a

chance to attend a trade show for
the first time in nearly two years in
June, as I visited the EASA show in
Fort Worth, Texas, with sales team
representatives Gannon Greene, EDITORIAL
Mark Goins and Derrell Moody. We EDITOR: Jennifer King
had our customary booth and were jdking@cahabamedia.com • 205-278-2826
able to visit with readers face-to- PRODUCTION MANAGER: Amy Hyde
face. It was the first show I had ahyde@cahabamedia.com • 205-314-8274
visited since the 2020 AHR Expo. MANAGING EDITOR: Drew Champlin
dchamplin@cahabamedia.com • 205-314-8264
Show attendance was Gannon Greene, Dave Stewart of Electrom Instruments and Drew ASSOCIATE EDITOR: Evi Arthur
down 30% from usual—the Champlin visit at EASA 2021. earthur@cahabamedia.com • 205-278-2839
show normally has around
CONTRIBUTING EDITORS: Lev Nelik, Ray Hardee,
5,000 attendees—but that was expected, as EASA President and CEO Linda Raynes told Jim Elsey
us. International attendance was nearly nonexistent as some countries have quarantine CREATIVE SERVICES
protocols following the coronavirus pandemic. But the vaccines have helped give the green DIGITAL PROJECT MANAGER &
light for large gatherings to return, and we’ll see you at a few more shows later this year. SENIOR ART DIRECTOR: Greg Ragsdale
Matthew Conville, technical support specialist at EASA, pointed out several talking points ART DIRECTOR: Elizabeth Chick
at this year’s convention. WEB DEVELOPER: Greg Caudle
For one, medium voltage motors are starting to get smaller in frame sizes, and that should CIRCULATION
continue as their price points become more reasonable. Conville said that as we continue to AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
see a rise in efficiency needs, the International Efficiency (IE)4 and IE5 machines will become lmasaoay@cahabamedia.com • 205-278-2840
more commonplace. These machines are typically permanent magnet or a reluctance variant ADVERTISING
design. These machines will take a much bigger place in the market in the future as they NATIONAL SALES MANAGER:
continue to go up in frame size and horsepower. Electric machines are also getting smarter.
Derrell Moody
OEMs have adjusted to the legislation and demand for smarter and more efficient dmoody@pump-zone.com • 205-345-0784
machines quite well, Conville said, and the supply chain will have to make adjustments. SENIOR ACCOUNT EXECUTIVES:
Read more from EASA representatives at: pumpsandsystems.com/trade-shows-making- Mark Goins
return-industry-travels-easa. mgoins@pump-zone.com • 205-345-6414
Normally, the August issue is the one we produce with a focus on pump system Gannon Greene
optimization and send to the Turbomachinery and Pump Symposia (TPS) in Houston. But this ggreene@pump-zone.com • 205-278-2876
year’s TPS was moved to December, so you’ll read more about that then. We focused more on Garrick Stone
the basics—terms like total dynamic head, cavitation, sizing a pump, best efficiency point gstone@pump-zone.com • 205-212-9406
and root cause failure analysis are discussed in-depth in our cover series. SALES DEVELOPMENT REPRESENTATIVES:
We hope to see more readers at shows such as TPS and WEFTEC later this year. Email us at Ross Wagner
rwagner@cahabamedia.com • 205-278-2828
pumpeditors@cahabamedia.com with anything else you’d like to read about.
CLIENT SERVICES COORDINATOR:
Sonya Crocker
As always, thanks for reading.
scrocker@cahabamedia.com • 205-314-8276
Managing Editor Drew Champlin PUBLISHER: Matthew G. Conroy

dchamplin@cahabamedia.com VP OF SALES: Greg Meineke
CREATIVE DIRECTOR: Terri McVey
CONTROLLER: Brandon Whittemore
Pumps & Systems P.O. Box 530067

is a member of the following organizations: Birmingham, AL 35253
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue S., Suite 200, Birmingham, AL 35209. EDITORIAL & PRODUCTION
Periodicals postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users.
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submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 29, Issue 8.
2 PUMPS & SYSTEMS AUGUST 2021

Improves uptime and
productivity
Increases safety for

employees and data
Reduces
maintenance cost
and time
—
Smarter and safer
mounted bearing health check
The new ABB Ability™ Smart Sensor for mounted bearings is an easy-to-use, condition
monitoring tool which provides a quick health indication on bearings in operation
without requiring employees to touch the equipment. Evaluating bearings on a regular
basis allows vibration and temperature trends to be analyzed and outliers to be
detected before a failure occurs.
Smart. Safe. Productive.

ABB Ability Smart Sensor for mounted bearings
Check 106 on index.

baldor.abb.com
IN THIS ISSUE
AUGUST 2021
14
COVER SERIES: 36 Proactively Avoiding Valve COLUMNS
THE BASICS Closure Water Hammer
By Nick Vastine, 12 PUMP SYSTEM
31 The Basics of Root Cause APPLIED FLOW TECHNOLOGY IMPROVEMENT
Failure Analysis A New Facility, a New Journey
By Torill Bigg, 39 How to Quickly Calculate By Ray Hardee,
TUNLEY ENGINEERING a Centrifugal Pump’s Total ENGINEERED SOFTWARE INC.
Dynamic Head
32 Best Efficiency Point & By Irene País Goyache, 14 COMMON PUMPING
Performance Curves GEIGER PUMP & EQUIPMENT MISTAKES
By Amin Almasi, Don’t Overlook This Basic
PRINCIPAL MACHINERY/ 42 What Is Cavitation? Advice, Part 2
MECHANICAL CONSULTANT By Peter Wolff, By Jim Elsey,
ARMSTRONG FLUID TECHNOLOGY SUMMIT PUMP INC.
34 6 Basic Rules of
Pump Piping Design 44 Do You Need to Pump Up 18 GUEST COLUMN
By Jeff Simpson & Dale Annoye, Your Pump Sizing Skills? The Hydraulic Performance of
CRANE ENGINEERING By Michael Kelley, Reciprocating Machines
ZOELLER By Gary Dyson,
36
HYDRO
EVERY ISSUE
2 FROM THE EDITOR

8 NEWS
69 ADVERTISERS INDEX
70 PUMP USERS
MARKETPLACE
72 PUMP MARKET ANALYSIS

TRIPLE PLY BELLOWS CARTRIDGE SEAL
FOR HIGH PRESSURE CRUDE OIL APPLICATIONS
Flexaseal’s HPCS is a true high pressure bellows

solution for one of the toughest oil and gas pipeline
challenges: sealing crude oil under high pressures.
EDGE WELDED BELLOWS TECHNOLOGY eliminates the

dynamic elastomer, a common failure point in dirty
crude oil services.
EXCLUSIVE TRIPLE-PLY, HIGH PRESSURE DESIGN

operates in pressures up to 1500 psig, accommodating
virtually all crude pipeline services.
API 682 4th ED. COMPLIANT, HEAVY DUTY DESIGN can

be used in conjunction with Piping Plan 65A/B.
FLEXdrive TORSIONAL DRIVE SYSTEM eliminates

torsional loads on the bellows, reducing stress and
increasing reliability and MTBR.
STEALTHtm PROACTIVE HEALTH TECHNOLOGY enables

real-time remote monitoring of seal status.
Check 102 on index.
Innovative Technology
Fast Delivery
Responsive Customer Service
Designed, Manufactured, and www.flexaseal.com

Tested in the USA 800-426-3594
IN THIS ISSUE
AUGUST 2021
SPECIAL SECTION:
MS
SEALS & BEARINGS
47
A L E S T E 20 The Small Adjustment That
U A S SY Makes a Big Difference
P S&
N N C
By Alex Gunkel,
W
SCHAEFFLER GROUP USA INC.
M
PU
1 A O
H
24 Mechanical Seal Repairs:
2 S
20
Making the Right Choice
CT By Stephen Shaw,
U
AESSEAL
O D 26 Avoid Premature Bearing
R
Wear With Long-Term
P Sealing Solutions
By Chris Tones & Jeff Blank,
GARLOCK
DEPARTMENTS 28 The Impact of Water on

Pump Bearing Life
By Mark Barnes,
58 BACK TO BASICS 64 MOTORS & DRIVES
DES-CASE CORPORATION
Selecting Grease for Powering Systems at Peak
Pumping Systems Efficiency With Permanent Magnet
By Greg Morris, Technology
PLUS
▲
SHELL By Paul Luarde & Chris Schantz,
FRANKLIN ELECTRIC
60 EFFICIENCY 101 54 Why a User’s Most
How to Achieve Pump Efficiency 66 SEALING SENSE Important Tool Is Safety
By Alan Jones, The Benefits of Split Seals By Sean Silvey,
XYLEM By Steven Bullen, FLUKE CORPORATION
FSA MEMBER, A.W. CHESTERTON
62 FLOW METERS 56 Coupling Selection for
Flow Measurement Experience 68 HI PUMP FAQS Dredge Pumps
By Dave Olson,
in Safety-Critical Heavy Friction Loss in Pump Bearings &
PSC COUPLINGS
Residue Applications How Viscosity Affects Pump
By Gerard Bottino, Performance
PANAMETRICS
EDITORIAL ADVISORY BOARD

THOMAS L. ANGLE, P.E., MSC, JIM ELSEY, General Manager, JOHN MALINOWSKI, Industrial SCOTT SORENSEN, Oil & Gas
Geschaeftsleiter (CEO), Swiss Flow Summit Pump, Inc. Motor Consultant Automation Consultant & Market
Solutions GmbH Developer, Siemens Industry Sector
JOE EVANS, Ph.D., Customer & MICHAEL MICHAUD, Executive
R. THOMAS BROWN III, President, Employee Education, PumpTech, Inc. Director, Hydraulic Institute ADAM STOLBERG, Executive Director,
Advanced Sealing International (ASI) Submersible Wastewater Pump
GEORGE HARRIS, President & CEO, LEV NELIK, Ph.D., P.E., APICS, Association (SWPA)
KEVIN CLARK, Vice President, Hydro International Center for Pumps
Industrial Strategy, Accruent Research and Development, Israel DOUG VOLDEN, Global Engineering
ROB LAIRD, Practice Leader, Director, John Crane
BOB DOMKOWSKI, Business Woodard & Curran HENRY PECK, CEO, Geiger
Development Manager/Engineering Pump & Equipment Company CHRIS WILDER, CEO, SEPCO
Consultant, Xylem, Inc., Water LARRY LEWIS, President, Vanton
Solutions USA – Flygt Pump and Equipment Corp. MICHELE SHAUGHNESSY,
Vice President Marketing & Sales,
JIM DRAGO, Principal Applications TODD LOUDIN, President/CEO PSG Dover
Engineer, Garlock Sealing North American Operations,
Technologies Flowrox Inc.

Equipment, wherever
and whenever you need it.
With the largest, most diverse fleet of construction and industrial equipment
in North America, we are a one-stop shop for whatever you need, delivered
on time and ready to go.
Visit UnitedRentals.com/PSM to browse the largest fleet in the industry.
UnitedRentals.com/PSM I 800.UR.RENTS
© 2021 United Rentals, Inc.
Check 107 on index.

NEWS
NEW HIRES, PROMOTIONS & RECOGNITIONS
DWIGHT WATERS specialist. In this role, Mathur will work responsibility for executing NSBE’s
PCM USA with all teams in the operations group refreshed strategic plan, titled Game
KATY, Texas – PCM USA, Inc., has promoted at Hayward Gordon. Her focus will be to Change 2025.
improve efficiencies, cost performance, Launched in February, Game Change
Dwight Waters to president. Waters has
quality and delivery. Mathur brings 16 2025 seeks to sustain and increase the
been with the company for the last three
years of engineering, design and process significant progress NSBE has made during
years as sales director, Americas.
improvement experience to the role. the past five years toward its primary
PCM USA is a global manufacturer of
haywardgordon.com strategic goal: to partner with higher
positive displacement pumps and fluid
handling equipment. PCM USA provides education institutions to graduate 10,000
CELESE PAULEY new Black engineers annually in the U.S.
solutions to three main sectors: food,
GASKET RESOURCES
general industry and oil and gas. by 2025.
HOUSTON – Gasket Resources announced
pcm.eu The plan builds on NSBE’s longstanding
the promotion of Celese Pauley to national
social justice consciousness and activism
sales manager.
JULIANA HERMAN to transform the organization, STEM
Pauley has more than 30 years of
VALVTECHNOLOGIES (science, technology, engineering and
experience in the gasket industry,
HOUSTON – ValvTechnologies, Inc., has mathematics) and broader society.
primarily growing sales in the Southeast
named Juliana Herman as its global nsbe.org
region and further developing the Durlon
marketing director. Most recently,
brand of products.
Herman served as senior product
gasketresources.com DANNY WOODLIEF
marketing manager for Emerson for WAGO
pneumatic valve actuation products. GERMANTOWN, Wis. – WAGO
JEFFERY L. TAYLOR
Herman holds an MBA in marketing and has hired Danny Woodlief as its
FRANKLIN ELECTRIC
international business from Rice University new electrical contractor and
FORT WAYNE, Ind. – Franklin
and a Bachelor of Science in clothing and Electric announced that Jeffery wholesale specialist for the Eastern U.S.
textiles from Virginia Polytechnic Institute L. Taylor has been appointed He holds a bachelor’s degree in aviation
and University. vice president and chief financial officer management from Southeastern Flight
valv.com (CFO). John J. Haines has retired as vice School and holds diplomas in industrial
president and CFO of the company. distribution, engineering technology,
AALAM CHEEMA Most recently, Taylor was the CFO of Blue marketing and voltaic energy.
GRAPHITE METALLIZING CORP Bird Corporation, a manufacturer of school wago.com
YONKERS, N.Y. – Graphite buses, since 2020. He was previously senior
Metallizing Corp. has hired vice president and CFO of Wabash National MICHAEL ROMANO &
Aalam Cheema as an inside Corporation from 2014 to 2020. DAVID MCMAHON
sales engineer for Graphalloy products. Taylor holds a bachelor’s degree in SUNDYNE
He began his career as a product chemical engineering from Arizona State ARVADA, Colo. – Sundyne
development intern for Flowserve. More University and an MBA from the University
announced that Michael
recently, he served as an applications of Texas.
Romano has joined the
engineer and then field engineer for Weir franklin-electric.com
Minerals in Canada. company as global strategic
account leader. Romano will
Cheema holds a master’s degree in JANEEN UZZELL
industrial systems engineering from shape the business strategy
NSBE
the University of Regina in Canada and grow the account teams responsible
ALEXANDRIA, Va. – The
and a bachelor’s degree in mechanical National Society of Black for expanding Sundyne’s chemical business
engineering from the University of Engineers (NSBE) has around the globe.
Leicester in the United Kingdom. announced the selection of veteran Sundyne also announced that David
graphalloy.com technology executive, engineer and McMahon has joined the company as C&I
longtime NSBE member Janeen Uzzell as market strategy leader. In this new role,
USHA MATHUR its chief executive officer (CEO), a newly McMahon will help shape business strategy
HAYWARD GORDON GROUP created position for the society. and expand the value creation for key
HALTON HILLS, Ontario – Hayward Gordon Uzzell moved from her current post as customers in the chemical and industrial
has announced the promotion of Usha chief operating officer of the Wikimedia market segments.
Mathur to the role of process improvement Foundation to join NSBE on July 7, taking sundyne.com

Check 104 on index.
NEWS
▲
Mergers & Acquisitions
Valmet Merges PSG Acquires Quantex Mueller Water Products Anderson Process to Acquire
With Neles June 24, 2021 Acquires i20 Water Premier Pump Inc.
July 6, 2021 June 15, 2021 June 11, 2021
Ingersoll Rand to Acquire Ingersoll Rand to Atlas Copco Compressors Pace Solutions Acquires
Maximus Acquire Seepex Acquires Compressed Glengarry Chemicals
June 30, 2021 June 21, 2021 Air Systems June 7, 2021
June 12, 2021
AROUND THE INDUSTRY
Guardiola Sala Foundation country is experiencing difficulties in 2021 impact different market segments
to Address Sustainable relation to water. Climate change and and their business. To register, visit bit.ly/
Water Management other factors are creating a number of MOW-2021. pumps.org
MANCHESTER, England – Pep water-related issues, so it’s up to us to do
Guardiola—former Spanish professional something about it now. That’s why the RevTwo Rebrands to InSkill
football player and current manager of Guardiola Sala Foundation is honored to BOSTON – RevTwo has rebranded,
Manchester City—along with his brother partner with Xylem and EarthEcho to give changing its name to InSkill. The
Pere, both representing their newly our youngsters a platform for making a change happened on May 28. “We chose
established Guardiola Sala Foundation, difference. If we all do our part, we can the InSkill name to better reflect our
have teamed up with global nonprofit, succeed in building a better world.” continued mission of delivering industrial
EarthEcho International and global xylem.com expertise to those who need it, when they
water technology company Xylem Inc. to need it, and where they need it,” said
encourage students to seek a sustainable HI, VMA Present Virtual Market CEO and co-founder Dale Calder on the
future for Spain’s water resources. Open Workshop InSkill website. “InSkill also represents
Guardiola joined the first in a series PARSIPPANY, N.J. – Hydraulic Institute a fundamental re-envisioning of our
of water education events at Casal dels (HI) and The Valve Manufacturers capabilities.” inskill.ai
Infants in Barcelona as part of a new Association of America (VMA) announced
initiative, Water Challenge Catalonia. that the 2021 Virtual Market Outlook Israeli Anti-Fouling Product Wins
The initiative, which closely aligns Workshop will take place virtually Water Council’s Tech Challenge
with the United Nations’ water-related Aug. 5-6. MILWAUKEE – PANI, an Israeli product
Sustainable Development Goals, seeks The Market Outlook Workshop is open that prevents biofouling in water
to inspire action to address Spain’s water to members and nonmembers of both equipment, has been selected by The
challenges. Water supply is expected organizations and brings together global Water Council’s corporate sponsors as the
to fall by up to 40% by the end of the and national economic experts, as well winner of the spring 2021 Tech Challenge.
century. Guardiola’s involvement stems as experts who research and follow the The prize was $10,000.
from his launch of The Guardiola Sala economic indicators for end-use markets The spring 2021 challenge sought
Foundation, which will raise funds for important to the fluid handling and flow solutions that reduce scale, corrosion
established charities in Britain and control industries. and fouling for pipes, tanks, valves
Catalonia. On his visit to the school, Industry experts will address economic and other equipment that encounters
Guardiola joined students of Casal dels trends and outlook, energy markets, water. The innovative preparation
Infants in learning about Catalonia’s infrastructure and specialized markets. and grafting method of polyaniline
water challenges and actions they can New segments added to the program (PANI) makes it a functional coating
take, such as monitoring the quality of this year include hydrogen, mining and that prevents biofouling—the
their local water resources. His visit is pharmaceutical. accumulation of biological material
one of several events planned by Xylem This event is open to anyone in the such as microorganisms and algae
Watermark and EarthEcho in Madrid industry and is ideal for those in the on surfaces—in water systems and
and Barcelona. flow control or fluid handling industries accessories. The product was created
Speaking at the Water Challenge looking for a greater understanding by Dr. Ran Y. Suckeveriene of Kinneret
Catalonia event in Barcelona, Pep of how economic, societal and other Academic College in Zemach, Israel.
Guardiola said: “It’s no secret that our implications from the events of 2020 and thewatercouncil.com

LEARN ABOUT
GOOD
Upcoming Events
OTC
Aug. 16-19
NRG Center
Houston, Texas
THE
2021.otcnet.org
BAD
MINExpo
Sept. 13-15
Las Vegas Convention Center
Las Vegas, Nevada
minexpo.com
Pack Expo
THE
Sept. 27-29
UGLY
Las Vegas, Nevada
packexpolasvegas.com
WEFTEC
AND THE
Oct. 16-20
McCormick Place
Chicago, Illinois
weftec.org
ADIPEC
Nov. 15-18
OF REDUCING WATER USAGE

Abu Dhabi Convention Center
Abu Dhabi, United Arab Emirates
adipec.com
Turbomachinery & Pump When the importance of saving water collides with the need
Symposium
Dec. 14-16 to seal effectively you have good, bad, and ugly options.
George R. Brown Convention Center Contact a SealRyt engineer today for honest and realistic advice
Houston, Texas
tps.tamu.edu on saving water in your plant. We know that it's easy to talk about
reducing water but hard to do on an operational level.
IPP Expo
Jan. 25-27, 2022 That's why this topic keeps popping back up.
Georgia World Congress Center
Atlanta, Georgia
ippexpo.org
THERE ARE PROVEN REDUCTION METHODS.
PowerGen International
Jan. 26-28, 2022
Kay Bailey Hutchison
Convention Center
Dallas, Texas
Check 108 on index.
powergen.com
ROTATING SHAFT SEALING EXPERTS
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Jan. 31-Feb. 2, 2022
MADE IN THE U.S.A.
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PUMPSANDSYSTEMS.COM 11
PUMP SYSTEM IMPROVEMENT
A New Facility, a New Journey

RAY HARDEE | Engineered Software Inc.
My June 2021 article talked about taking

the first step of a digital twin journey for an
existing fluid piping system. This month,
we will look at a new project from its
Using data supplied by the equipment supplier, the
inception through the design and build computer modeling analysis can simulate
stages until the project is turned over
to the client. A major step in this task is
how equipment will operate in the total system.
the requirement to configure, procure
and quote (CPQ) all the required project
equipment. We will see how digital twin price of each item of equipment along better understanding of how the pumps
technology can be used to develop a smart with the manufacturer’s delivery schedule. were going to be used in the final system.
CPQ process. In the end, a winning supplier would The input data along with the sizing
be selected, and a purchase order would calculations can be performed in the CMA
CPQ History be developed and agreed to by the client/ applications. Often the CMA application can
Back in the day, the entire purchasing EPC and the equipment supplier. The export this information electronically using
process was done using paper documents specified equipment would then be built, an application programming interface
and drawings. It was a manual process the commercial requirements would be (API). This allows the specification data
where the client and the engineering validated, and the equipment would be sent to be electronically passed on to the
procurement and construction firm (EPC) to the EPC for use in building the system. equipment manufacturers.
would work together to develop project Over the years, these documents were The equipment manufacturer can then
specifications for all equipment items. The created using spreadsheets and word import the user’s specification information
next step was developing the bidders list processing programs. With the wide- directly into its CPQ application to
of prospective suppliers satisfactory to the scale use of email, these documents streamline the creation of its bid document.
client and the EPC. often replaced the mailing of paper Once the manufacturer’s bid documents are
The equipment specification documents documentation. finalized in the CPQ application, the specific
were sent to the manufacturers on the In 2005, many manufacturers started item of equipment is known along with all
bidders list. Each supplier would take the automating their price books by using the supporting data.
EPC specification documents and, using configuration software. Using the user’s Using the pump example, the
its equipment catalog data, determine specification document, the configuration manufacturer’s CPQ application provides
which of its products would meet the software could select the items that met the pump type, size, rotational speed,
user’s operational requirements. They the user’s needs and develop a price for motor size and the manufacturer’s supplied
would then apply special factors based each item. This streamlined the supplier’s pump curve, along with a host of supporting
on the user’s delivery requirements and task, but it still required the purchaser to information. Since the manufacturer’s CPQ
other proprietary items. Then would manually review each supplier’s bid. application was used to develop the bid
come the price book, where they would package, that information can be shared
develop a current price for the items under The Smart CPQ Process with other applications.
consideration. Using this information, the With the Digital Twin
supplier would provide the recommended My February and April 2020 Pumps & The EPC Review
item and the price in its bid package back Systems articles explained how front- The EPC then reviews the bids from
to the EPC. end engineering design was improved by each of the equipment manufacturers
The EPC and client would review each using digital twin technology to minimize on the bidders list. Many EPCs have
bid package and all discrepancies between oversizing pumps. In that article, we implemented applications to help in their
the specification and bid documents were saw how the computerized modeling equipment review process. If the EPC’s
identified and rectified. Most of the review and analysis (CMA) applications for fluid review application has access to an API,
process focused on the initial purchase hydraulics using existing rules provided a the bid data from the manufacturer’s

CPQ application can be imported further, pump with the CMA application is the user (ODBC) standard provides an independent
streamlining the EPC’s review process. can determine where it is operating on method and ensures the seamless flow of
In the past, the EPC’s review process the curve in relation to its best efficiency information among devices from multiple
focused on the capital costs, the point (BEP). vendors. Using an ODBC standard will
recommended spare parts and delivery provide even more power to the digital
schedules for various equipment items. The Future Value of the Digital Twin twin, which I will cover in future Pumps &
These commercial details are important Smart CPQ is based on seamless Systems columns.
when getting the best deal for the communications between the various
new purchase. applications. This can be done using API
One should not forget that when looking technology, but each application sending
▲
at the total system’s life cycle cost, the and receiving information must use the
equipment operating cost is typically 20 same data schema.
to 40 times greater than the initial capital As the number of supporting
cost. This is where smart CPQ can create applications increases, it makes it harder Get More Info
notable savings. to use the API method of data transfer. Read more columns
Using the equipment operating data Industry standards organizations are by Ray Hardee at
supplied by the equipment supplier, helping to define the various terms to pumpsandsystems.com/
author/ray-hardee
the CMA can simulate how each item of describe equipment. If every application
equipment will operate when placed into is using standard terminology, the data
the total system. Using the system power exchange is simplified.
cost feature of the piping CMA application, But the holy grail of software
Ray Hardee is a principal founder of Engineered
the annual operating cost of each pump applications is to define an interoperable Software, creators of PIPE-FLO and PUMP-FLO
can be determined, providing insight into standard for the secure and reliable software. At Engineered Software, he helped develop
two training courses and teaches these courses
the total system life cycle cost. exchange of data between applications. In internationally. He may be reached at
Another advantage of evaluating the computing, an open database connectivity sales@eng-software.com.
INNOVATION
THAT REVOLVES
AROUND YOU
Inpro/Seal® didn’t just invent the Bearing

Isolator. We’ve perfected it – again and
again – to meet the unique needs of
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www.inpro-seal.com/since1977
Check 113 on index.
COMMON PUMPING MISTAKES
Don’t Overlook This Basic Advice,

Part 2
JIM ELSEY | Summit Pump Inc.
Last month, we discussed that the system

(not the pump) dictates where the pump
will operate on its performance curve. We
also discussed “liquid personality” (the
properties of the liquid) such as specific
gravity, suspended solids, pH and viscosity
and the mostly negative effects on the
pump and system.
If you have been around the pump world
for more than a few days, I am sure you
have heard the term best efficiency point
(BEP). In essence, all centrifugal pumps
are designed for just one operating point of
flow and head on the curve. This one design
point for flow X and head Y is commonly
referred to as the BEP or best operating
point (BOP). All other possible operating
points are, to some varying degree, a
counter compromise with efficiency, IMAGE 1: Pump reliability/operating range (Images courtesy of the author)
cavitation, radial thrust (shaft deflection)
and recirculation issues. Ignoring these
stress issues will shorten the life of the curve was miscalculated? Assuming What’s the Big Deal With Operating
bearings and mechanical seals, making the pump selection was the best choice the Pump Away From BEP?
the pump less reliable and more costly compromise for the application, and since The simple answer is that if you run
to operate. many pump applications require operation too far right—that is, at or near the end
If time and money were not an issue, away from the design area of BEP, there are of the curve—the pump will cavitate and
the pump OEM would be happy to design methods to manage the negative effects. the result will be high vibration levels that
and build a pump specifically for the user’s All of the mitigation methods are burdened will damage the mechanical seal and
unique operating point. Yes, it does happen, with the added cost of pump efficiency bearings in quick fashion. The impeller
but not very often. reduction, but that increased cost may may also suffer cavitation damage that is
often be an acceptable trade-off for dependent on several variables not covered
Allowable Operating Region reliability and reduced maintenance costs. in this column.
Of course, most end users don’t have just You can explore the numerous methods to As I often state in my role as the master
one operating point—normally they want reduce or eliminate the negative effects of the obvious during my pump training
to operate in a wide area of the curve that with your pump salesperson, technician/ classes, “the end of the curve …is the end of
is commonly referred to as a safe or engineer or a knowledgeable systems the curve.” If pump manufacturers thought
allowable operating region (AOR). The design person. If you have no means to you could or should operate there, they
presumption is that the end user knows determine the differential pressure across would extend the curve. Everyone wants
where the pump is operating on its curve the operating pump, such as a set of simple more coverage, but the laws of physics keep
and fully understands that the pump will pressure gauges or transducers, then getting in the way.
operate where the system curve compels your first check box on the road to pump Another important factor to consider
it to perform. reliability will be to install a set (one on near the end of the curve is the radial
If you are experiencing pump failures, the suction side and one on the discharge thrust, which will increase exponentially
perhaps the problem is that the pump was side) and then calculate where the pump is as you depart from BEP and move toward
selected incorrectly and/or the system operating on the curve. runout. Depending on the shaft rigidity

factor (L3/D4 ratio or think robustness
Pump Reliability Compared to Radial Thrust
factor), the shaft may deflect some
amount. Shaft deflection is a dynamic
bending of the shaft while in motion
that occurs two times per revolution. 100
Understand that a shaft rotating at 3,550
Percent Thrust and or Reliability

rotations per minute (rpm) will have 7,100
deflections per minute. Shaft deflection will 80
damage mechanical seals and bearings.
More importantly, excessive deflection can
Th
often lead to shaft cyclic stress fatigue 60
ru
y
lit
st
and breakage. Also, be aware that the shaft
bi
Ra
would measure perfectly straight if you ia
el
di
al
stopped and removed it from the pump. As R
40
I mentioned before, deflection is a bending
phenomenon that may occur during
operation. If the shaft is already bent
and/or the impeller is out of balance, the 20
situation is critically exacerbated. For more
details, see my January 2021 column on 20 40 60 80 100 120
radial thrust and my February 2017 column
on shaft breakage.
Approximate based on single volute Percent of BEP
Operating the pump to the left side of IMAGE 2: Pump reliability compared to radial thrust
the curve also has negative consequences.
When we state operating to the “left,” we
mean operations between the BEP and One rudimentary way to think about from a thermodynamic aspect: At what
shutoff (sometimes just abbreviated as this is to convert the driver’s BHP to British point does the liquid convert/flash to vapor?
SO). Shutoff is the point of no (zero) flow thermal units (Btu), and then realize The pump OEM will determine a minimum
such as closing the discharge valve or a that much of that energy is working to continuous flow rate for the pump for both
blocked system component. Operating heat the liquid in the pump casing while mechanical and thermal factors—the
near shutoff will also increase the radial simultaneously the shaft is bending twice higher of the two will become the minimum
thrust and deflect the shaft—the same per revolution. flow rate for that pump. For more details,
phenomenon we discussed above at the far There are four factors to be calculated/ see my Pumps & Systems column from
right side runout condition and with the evaluated when determining the acceptable November 2015.
same penalties. The only difference from minimum flow point. For this column, we
the radial thrust experienced at runout will just examine the main two factors. By Design, the System Must Supply
(right) when compared to the left side of the The first is from a pump mechanical the Liquid to the Pump
curve is the thrust is now applied from the perspective: How much dynamic load Stated another way, centrifugal pumps do
opposite side (180 degrees of opposition). from a radial and axial thrust perspective not suck liquids. I mentioned in Part 1 of
The negative effects are the same. can the pump take? And the second is this series that most pump problems occur
Most pump manufacturers will advise on the suction side of the system due to
▲
you where the recommended minimum this misunderstanding about centrifugal

flow point is on the left side of the curve. pumps. “This is mostly due to a common
This is frequently referred to as the misunderstanding that pumps will ‘suck’
minimum continuous stable flow (or A Note About MCSF the liquid into the pump—they do not. The
allowable flow). Minimum continuous suction portion of the system must supply
Note that for a given size pump, the required energy to move the liquid to
stable flow (MCSF) is defined as that flow
if one manufacturer states its
rate below which the pump should not be the pump; this is typically accomplished
minimum continuous stable flow is
operated for any length of time. What is by gravity or atmospheric pressure.” (Some
lower than another manufacturer,
not defined is the amount of time, and this does not mean it is necessarily external source other than the pump.)
I would suggest minimizing the time as a better pump. It may just mean the Note from a technical perspective that
much as possible. The higher the pump manufacturer is more conservative in the pump impeller does create a small
energy (brake horsepower [BHP]) the shorter its approach to reliability. differential pressure directly in front of
the time. the impeller, but that energy level is in no
COMMON PUMPING MISTAKES
▲
Notes on Cavitation
1. You may think the liquid is not hot
enough to form vapor bubbles and
likely it is not at ambient pressure,
but remember from science class
that you can boil water at room
temperature if you reduce the
pressure sufficiently. You can boil
water at 70 F if you reduce the
pressure to 0.363 absolute
pressure (psia).
2. Do not confuse vapor bubbles
with air bubbles. The collapse of IMAGE 3: Examples of cavitation damage
entrained air bubbles in the liquid
stream does little damage to the
impeller. It is possible to air-bind
the pump where the air bubbles way sufficient to overcome gravity and Conversely, for any given system
block the flow of liquid. Vapor the friction required to initiate and sustain design and corresponding flow rate, there
bubbles, on the other hand, possess the flow rate. Also, note that liquids do will be an amount of NPSHa. It is the
high energy and can severely not possess tensile properties, and so the responsibility of the system designer to
damage an impeller in a short pump is not capable of pulling the fluid accurately determine/calculate the NPSHa.
period of time. Actual damage will
into itself. There must be more NPSHa than NPSHr,
vary with the energy level, liquid
One way to describe the energy and the margin required will vary based
properties and impeller materials.
required on the suction side of the system on several circumstances not covered here
3. Just because you have adequate
NPSH margin does not mean at the pump suction flange is called net but can be referenced in American National
that there will be no cavitation or positive suction head available (NPSHa). I Standards Institute/Hydraulic Institute
damage. Even with high margins, understand this is a return-to-pump-basics Standard 9.6.1 (2012).
there may still be cavitation column and many neophytes will dismiss If there is insufficient NPSH margin,
occurring, albeit probably not of a and ignore this uncomfortable subject for the pump will cavitate and be short-lived.
very destructive nature. as long as possible. I would suggest that the Cavitation is the formation of vapor bubbles
4. You may also see what appears as sooner you can wrap your head around the in the liquid stream (normally just in front
cavitation damage on the convex subject, the better off you will be. of the impeller) and then the subsequent
side (aka, the working side or For reference and assistance, please collapse of those bubbles some distance
high-pressure side) of the impeller refer to a detailed series of five columns I along the impeller vane. Normally the
vanes and this is typically due authored on this subject starting in bubbles collapse within the first 25% to
to recirculation cavitation. This July 2018. 33% of the vane length. The bubbles will
damage is not due to insufficient collapse on the underside (concave side) of
NPSH margin, but to operating
NPSH: A Primer the vane.
the pump in a nonstable region
Yes, the pun is intended. The pump Next month, we will discuss suction and
between BEP and approaching
OEM/manufacturer will design and discharge recirculation, submergence and a
shutoff. The actual operating point
(area) where this will occur is a test its pump to determine net positive few more basic pump topics.
function of the impeller’s suction suction head required (NPSHr).
specific speed (Nss). Nss in its That is, for several condition points
on the pump curve there is a Jim Elsey is a mechanical engineer with more than
simplest form is an expression of 50 years of design and operating experience, primarily
the design geometry for the suction corresponding amount of energy focused on rotating equipment reliability in most
side of the impeller. Consider the required at the pump suction that must industrial applications and markets worldwide. Elsey
number of vanes, inlet vane angle, is GM of Summit Pump and an active member of
be satisfied by the system. It is the the American Society of Mechanical Engineers, the
curvature and pitch of the vane, pump manufacturer’s responsibility American Society of Metals, the National Association
the amount of vane overlap and to conduct this test and report/ of Corrosion Engineers and the Naval Submarine
effective impeller eye diameter, to League. Elsey is also the principal of MaDDog
publish the results in accordance with Pump Consultants LLC. He may be reached at
name a few factors. industry standards. jim.elsey@spiohio.com.

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GUEST COLUMN
The Hydraulic Performance of

Reciprocating Machines
GARY DYSON | Hydro
Pump engineers are familiar with the

performance curve of a centrifugal pump.
For a fixed speed, the head varies with
flow and the performance envelope can
be clearly defined, although this envelope
is often ignored to the detriment of
reliability (Image 1).
Engineers intuitively use the mental
image of the pump performance curve to
evaluate the operating position and the
interaction with the system. This has been
widely discussed and has become second
nature to many. However, reciprocating
machines have different characteristics
compared to centrifugal pumps. IMAGE 1: Centrifugal pump performance curve (Images courtesy of the author)
There is no HQ curve for this type of
machine as there is with centrifugal pumps. number of available volumes means that fixed volume. Image 2 depicts 100%
If we were to draw a capacity curve, it would the reciprocating machine is, in principle, a volumetric efficiency, and the other
simply be a straight line from zero capacity constant flow machine. line depicts the pump at the actual
and speed to maximum capacity and speed The reciprocating pump engineer has in application volumetric efficiency.
(Image 2). For a fixed rotations per minute his or her armory several tools that can get Volumetric efficiency measures how
(rpm) value, the flow is consistent. the flow required by the process: much of the swept liquid passes through
• Plunger diameter: One pump can to the discharge based on the valve
Hydraulic Design of accommodate a range of plunger sizes. effectiveness. The analogy that can be
Reciprocating Machines Changing the size changes the swept applied from centrifugal pumps is the
While centrifugal pump hydraulic engineers volume. The stroke length is fixed, volumetric efficiency considered when
spend time and effort understanding but the diameter can be tuned to the evaluating the effectiveness of the wear
impeller blade design and the transfer of process need. ring landings.
energy between rotating and stationary • Pump speed: Belt and chain drive • Number of plungers: Plungers can be
components, the reciprocating pump systems are not uncommon to set the arranged in parallel in one machine
principles are more straightforward. speed to the correct level, and variable so one complete revolution sweeps all
Reciprocating pumps function by frequency drives (VFDs) are also popular. the plungers. Three to five plungers are
displacing liquid through a volume—the The volume displaced varies directly commonly used.
size of the volume and the number of times with the number of revolutions, i.e.,
per minute the volume is swept. Plus, the increase the number of sweeps of the As can be seen from the variable
available, there is not one answer to getting
the correct flow. Small plungers at higher
speeds will have the same flow as large
plungers at slower speeds. Mechanical
limitations dictate which is most
appropriate and possible.
IMAGE 3: Swept Key Tips for Using

volume—diameter Reciprocating Pumps
IMAGE 2: Fixed displaced volume capacity curve x stroke length
• Reciprocating pumps are well suited to

lower flow rates. Certain combinations • Because of the fixed volume of Standards from the American Petroleum
of flow rate and pressure can make fluid displacement, a more precise Institute (API) and Hydraulic Institute
centrifugal pumps inherently less capacity can be achieved. A positive (HI) limit the maximum speed of
efficient. A reciprocating pump in a displacement reciprocating pump has a applications. Many are tempted to choose
high-head, low-flow application could constant flow regardless of pressure. smaller, faster-running pumps that
have a high efficiency (90%) compared • Using a reciprocating pump, a different approach or surpass these limits as a less
to the single-digit efficiency of an capacity can be achieved by changing expensive alternative. This causes wear and
equivalent centrifugal machine. the pump speed. reliability issues.
• Positive displacement reciprocating • A positive displacement reciprocating Due to the nature of the reciprocating
pump net positive suction head required pump can be used if the application motion of the plungers, the system
(NPSHr) varies as a function of flow that has variable pressure conditions. A experiences pressure pulsations on the
is determined by speed. The lower the centrifugal pump will be forced up and suction and discharge side. System
positive displacement reciprocating down the performance curve varying interactions are stronger. Poor system
pump speed, the lower the NPSHr. The the flow. A positive displacement design drives down reliability, and the
engineer often can run the pump slower reciprocating pump can give near- system designer must deal with the
to improve the NPSH margin. This is constant flow, making it possible to potential problems caused by pulsations.
true in centrifugal machines, but there match the flow rate to the process
are often compromises on operating requirements. A reciprocating pump’s
condition that can limit reliability. variable capacity can be achieved by
• The operating range constraints of changing the pump speed.
a centrifugal pump do not apply to Gary Dyson is managing director with Hydro
a reciprocating machine. Using the A Word of Caution Global Engineering Services. He has a doctorate
plunger/speed/number of plungers, the Misapplication is one of the main causes from Cranfield University and 30 years of experience
in senior positions with many pump industry
pump can run efficiently and reliably of poor reliability in reciprocating pumps. manufacturers. For more information, visit
where centrifugal machines struggle. Reciprocating pumps should run slowly. hydroinc.com.
Check 117 on index.
SEALS & BEARINGS
The Small Adjustment

That Makes a
Big Difference
Improve centrifugal pump reliability by
optimizing bearing clearance.
ALEX GUNKEL | Schaeffler Group USA Inc.
Centrifugal pumps are among the most seal against the shaft, prematurely wearing IMAGE 1: Typical bearing arrangement inside a
centrifugal pump (Images courtesy of Schaeffler
commonly used devices for transferring the seal material. Reducing this shaft
Group USA Inc.)
fluids in industrial applications. Although deflection will extend the life of the seal,
quite rugged by design, centrifugal pumps which will lead to a longer system life for angle that the bearing experiences. This
typically suffer mechanical failure due to the pump. additional spin leads to a phenomenon
excessive seal wear, skidding damage in the The second common failure mode for known as skidding, which can be recognized
bearings and/or bearing cage failure. This centrifugal pumps—skidding damage in by slippage tracks on the raceway and
article explores these three failure modes the bearings—is caused by insufficient rolling elements. Reducing the clearance or
and, using proprietary bearing calculation loading on one of the locating bearings. even preloading the locating bearings can
software, explains how proper bearing axial Because the axial force of the pump help avoid this failure mode.
clearance can mitigate these problems to typically only acts in one direction, only Skidding can also lead to cage fracture,
extend the service life of the bearings and, one of the locating bearings takes the the third common failure mode for
ultimately, the pump itself. majority of the load while the other bearing centrifugal pumps. Within a lightly loaded
Looking inside a centrifugal fluid pump, is used to support any additional radial load bearing, the load zone makes up a smaller
two separate bearing positions can be and overturning moment. Depending on portion of the raceway. This can cause the
found. The front position closest to the the operating conditions, this may lead to rolling elements in the bearing cage pocket
impeller is usually the nonlocating bearing the unloading of one bearing, whereby the to decelerate or brake as they enter the
that reacts to the radial loads of the system. rolling elements tend to spin off their axis unloaded zone in the cage pockets and then
A deep groove ball bearing or a cylindrical rather than roll along the intended direction accelerate when they reenter the load zone
roller bearing is most commonly used for in the raceway. ACBBs and DRACBBs are and begin rotating normally again. If these
this purpose. The rear position is typically especially vulnerable to this mechanism accelerations and decelerations are drastic
the axially locating bearing pair, which under lightly loaded conditions. Moreover, or frequent enough, then the cage can
sets the axial end clearance and reacts to the centrifugal force exacted on the balls experience fatigue and eventually fracture
while they are outside the load zone can in the pocket as a result of the higher-than-
axial as well as radial load. Most centrifugal
further exacerbate the change in contact normal stresses.
pumps employ either a double-row angular
contact ball bearing (DRACBB), a pair of
angular contact ball bearings (ACBBs) or a
pair of tapered roller bearings.
Failure Modes
As mentioned above, the three common
failure modes in centrifugal pumps are seal
wear, skidding damage in the bearings and
bearing cage fracture. The first of these
failure modes—excessive seal wear—is
caused by a deflection of the main shaft,
which increases the contact force of the IMAGE 2: Seal deflection at different bearing axial clearance settings (shown at BEP)

ULTRACHEM¨ SEALLESS
Analysis
To investigate these failure modes,
CHEMICAL PROCESS PUMPS
a bearing manufacturer selected a
user-provided pump and monitored the
displacement at the seal, the balls’ roll/
spin ratio as well as the cage acceleration
across a best efficiency point (BEP). To
simulate normal operating conditions,
all load cases were run at 1,780 rotations
per minute (rpm) with a temperature
differential of 10 C (50 F) between the
inner and outer ring. Three different pairs
of 7313-series ACBBs were simulated
in the locating position under the
aforementioned conditions with varying
clearance ranges. All tested pairs were of
universal design (meant for use as a pair
in either X or O arrangement) and featured
the following clearance classes: UA (small
axial clearance), UB (smaller than UA
axial clearance) and UO (clearance-free).
The clearance in the front 6313-series
bearing was set to normal clearance (CN)
for all calculations. Based on the loading
provided, the motor-side bearing in the
locating pair supports the axial load in
the system, while the bearing on the
impeller side supports any radial load and
overturning moment loads.
Using these test parameters and
three different pairs of ACBBs, the shaft
displacement at the seal location was the
first condition to be investigated. These
deflections can be seen in Image 2. At
0% BEP, the pair of UA-clearance ACBBs
resulted in the largest shaft displacement.
Meanwhile, the UB-clearance bearings
deflected 13 micrometers (µm) less than
the UA-clearance versions, while the pair
of UO-clearance bearings deflected 27 µm
less than the UA pair at the seal location.
Similar results were seen at 25% BEP: The
UB-clearance pair deflected 11 µm less
than the UA pair, while the UO-clearance Finish Thompson products are manufactured
pair deflected 24 µm less than the UA pair on site in Erie, Pennsylvania, U.S.A.
at the seal location.
Although similar results were seen
Check 109 on index.
at 50% BEP, it should be noted that the

overall deflection of the shaft decreases Finish Thompson Inc.
as BEP increases. The pair of UB-clearance 921 Greengarden Road Sealless Pumps
ACBBs deflected 2 µm less than the UA Erie, PA 16501 USA Sealed Pumps
Tel: (800) 934-9384 Drum Pumps
pair, while the UO-clearance bearings Vertical Pumps
www.finishthompson.com
deflected 4 µm less than the UA pair at
the seal location. At 75% and 100% BEP,
SEALS & BEARINGS
the UA pair deflected less than both the

UB and UO bearings. At 75% BEP, the UB-
clearance bearings deflected 1 µm more
than the UA-clearance bearings, while the
UO pair deflected 2 µm more than the UA
pair at the seal location.
Similarly, the UB-clearance bearings
deflected 2 µm more than the UA pair
at 100% BEP, while the UO-clearance
bearings deflected 3 µm more than the UA
pair at the seal location.
IMAGE 3: Roll/spin ratio as a function of bearing axial clearance There are only marginal differences in
deflection at a more optimal BEP range,
but there is an advantage at lower BEP
with respect to minimizing seal wear due
to less shaft deflection.
Following the shaft deflection analysis,
the roll/spin ratio was the next condition
to be investigated. A roll/spin ratio
greater than 0.5 has been linked to a
higher likelihood of skidding damage in
bearings, although this may depend on
the lubrication in the system. For this
part of the analysis, the bearings in the
IMAGE 4: Cage speed difference as a function of bearing axial clearance motor- and impeller-side locations
p o d c a st
Episode 53
Challenges of Process Flow
Control with Ken McHenry
of Custom Valve Concepts
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were monitored, and a full output of results With regard to the third common failure Using a bearing with less clearance
can be seen in Image 3. mode for centrifugal pumps—bearing limits the deflection at the seal, which,
With respect to the UA-clearance bearing cage failure—the cage speed variation of in turn, can help improve seal life of the
pair, the roll/spin ratio is greater than 1.1 for the bearings showed results similar to the pump—especially when operating further
all BEP cases in the impeller-side bearing; roll/spin condition. This was determined from optimal BEP ranges. Moreover, the
this indicates that skidding would be likely. by calculating the orbital speed of each reduced clearance minimizes the amount
While the motor-side bearing fairs better ball in the cage pockets and then using of potential skidding in the bearings,
once the BEP is increased, skidding is still the variance between the maximum and particularly in the unloaded bearing that is
likely when operating under 50% BEP. minimum values to generate the cage primarily used for moment and radial load.
Meanwhile, the impeller-side bearing of speed difference seen in Image 4. Choosing the proper clearance can
the UB pair showed a roll/spin ratio greater Since greater cage speed differences put also reduce the stresses in the cage
than 0.9 for all BEP cases—once again, more stress on the pockets, this condition due to accelerations, which can extend
indicating that skidding would be likely. may lead to fractures. Per Image 4, the UA- the life of the bearing and the overall
Skidding is still a concern at 0% BEP and clearance bearing pair exhibits the highest system. If, however, damage is still seen
25% BEP in the motor-side bearing; the cage speed difference; this phenomenon is in the bearings even with a reduced
skidding condition is borderline at 50% BEP. particularly evident as the BEP decreases. clearance range, then it may be necessary
Finally, the impeller-side bearing of the While the UB pair performs better, the to move to a preloaded bearing to further
UO-clearance bearing pair showed a roll/ lowest cage speed variations are achieved reduce the likelihood of skidding and
spin ratio greater than 0.6 for all BEP cases. using UO-clearance bearings. cage stress.
This indicates skidding would be likely at As the preceding investigation into the
0% BEP and 25% BEP; at higher BEP, the three common failure modes for centrifugal
skidding condition is borderline. Skidding pumps has shown, selecting the proper Alex Gunkel is an application engineer at Schaeffler
is still a concern at 0% BEP and 25% BEP, bearing axial clearance should improve the Group USA Inc. for the fluid power and pneumatic
sectors in North America. He holds a Bachelor of
although the roll/spin ratio is under 0.5 at life of the bearings and, consequently, the
Science in mechanical engineering from Clemson
higher BEP. pump itself. University. For more information, visit schaeffler.com.
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Check 112 on index.
SEALS & BEARINGS
Mechanical Inside Diameter (ID) Outside Diameter (OD) Minimum Diametral

Clearance
Seal Repairs: ID seal chamber bore

and gland plate
OD rotating seal
part
CW seal type
NC seal type
6 mm (0.25 in)
3 mm (0.125 in)
Making the ID stationary seal part OD rotating seal

part
shaft ≤ 60 mm 1 mm (0.039 in)
shaft > 60 mm 2 mm (0.079 in)
Right Choice ID stationary gland

part
OD internal
circulation device
shaft ≤ 60 mm 1 mm (0.039 in)
shaft > 60 mm 2 mm (0.079 in)
ID containment OD rotating seal shaft ≤ 60 mm 1 mm (0.039 in)
There are important factors fixed bushing 2CW-CS, part shaft > 60 mm 2 mm (0.079 in)
2NC-CS
and regulations to consider
when choosing to repair rather IMAGE 1: API 682 table (Image courtesy of AESSEAL)
than replace a mechanical seal.

Part Compatibility directive. The repairer should work with
International Electrotechnical Commission the user to ensure the mechanical seal has
STEPHEN SHAW | AESSEAL System for Certification to Standards been repaired in accordance with the health
Relating to Equipment for Use in Explosive and safety requirements and standard.
Atmospheres (IECEx) regulations stipulate Atmosphere explosible (ATEX) Zone 0
that a repaired seal must perform mechanical seals require certification
exactly as stated in the documentation relating to design and assembly processes
Mechanical seals often seal hazardous,
for the original seal, including seal face such as QAR/QAN certificates.
toxic and flammable products and have to
temperature rise data and misalignment
perform under extreme conditions such as
high speeds, temperatures and pressures. capability. Imprecision is unacceptable. API 682 Edition 4 Compliance
It is therefore inevitable that some It is not enough to say a seal will have Failure modes due to contact between
mechanical seals become worn and, a certain amount of axial misalignment the rotating and stationary parts inside
particularly when driving to achieve capability unless the tolerance stack-up a mechanical seal are more common
maximum operational efficiency within prevents it. Repaired seals have to do what than many users may realize. American
strict financial margins, opting for a it says on the box. Petroleum Institute (API) 682 Edition 4
potentially quicker and cheaper repair is Repairing a mechanical seal to such stipulates the clearances between rotary
understandable. strict standards presents a challenge even and stationary components to be
The repair process may differ slightly when OEM parts are used, as the same 1 millimeter (mm) for seals up to 60 mm
but, on the whole, following safe seal types may have been manufactured and 2 mm for seals larger than 60 mm.
disassembly, some parts can simply be in different locations using different plant Where seal vendors employ an Archimedes-
cleaned while others can be reworked— equipment. To guarantee identical levels type screw pumping circulation device, it is
seal faces being relapped, for example— of performance in the repaired seal, the not unusual to see clearances that are less
and some, such as elastomers and end user should establish that the seal than those stipulated in API 682 (Image 1).
metalwork, replaced. The end product manufacturer has strict engineering It is also important to note that the
should always be a mechanical seal that controls in place across its global API 682 air test does not guarantee that
performs as good as new. operations to ensure total compatibility a mechanical seal meets the emissions
Legislation such as the Right to between parts. requirements of API 682—it is an integrity
Know law, which requires proof of a test to ensure the mechanical seal has
decontamination certificate before a Health & Safety Requirements been assembled correctly. An air test “pass”
seal can be accepted into a repair center, To comply with the health and safety allows for leakage at up to 7,500 grams per
can serve as a disincentive to those requirements of IECEx or similar legislation, hour of water (g/hr). Compare this to the
considering off-site repairs for seals that a risk-based approach is often taken. This qualification test pass criteria of no more
are used in “hazardous to health” chemical requires manufacturers of equipment than 5.6 g/hr and one can see that passing
applications. However, even where this is operating in hazardous or explosive the air test might not equate to seal
obtained, a number of challenges remain. atmospheres to identify ignition hazards performance in operation.
Therefore, it is advisable to take several and ignition sources and take protective
factors into account before deciding measures to reduce or eliminate risks. Positive Material Identification
whether to turn to a third-party repairer or When repairing IECEx certified seals, do Non-OEM repair may require a repair
OEM for seal repairs. not presume conformity with the relevant facility that can identify metallic and

nonmetallic materials and understands the construction
materials of the mechanical seal and its tolerances. If necessary,
testing should be carried out to ensure the repaired seal performs
at least as well as the original OEM one. That requires a huge
amount of investment and many years of knowledge that has to
be captured, stored and disseminated among global repair center
networks. Extensive knowledge of product media and associated
compatibility is invaluable.
Some mechanical seal parts also need heat treatment
and stress relieving and complex surface coatings (such as a
polycrystalline diamond-like coating or hard chrome oxide or
tungsten carbide facing) to ensure adequate wear characteristics
and functionality.
For a repaired seal to be considered good as new, there
should be rigid reporting and data retention with every repair
documented with full traceability, including replacement parts.
Testing should be completed to ensure a mechanical seal has
What would happen if
been assembled correctly and meets recognized international
standards before it is shipped. your pump ran dry?
Overheating and seizure or meltdown?
Design Competency
A non-OEM repair often requires reverse engineering of parts,
Unplanned downtime? Costly repairs?
which requires clear design standards and precise measurement With its seal-less design and patented diaphragm
and manufacture. Computer-aided design activities should position control technology, Hydra-Cell pumps can
be subject to International Organization for Standardization run dry without damage. Indefinitely.
(ISO) 9001 certification and even local manufacturing,
including subcontract processes, should be subject to ISO 9001 Seal-less also means no seals or packing to leak,
certification. Mechanical seals comprising gas-lift noncontacting adjust or replace, so Hydra-Cell pumps have less
designs and face groove technology can be difficult to measure downtime, less environmental containment costs,
and replicate. Engineers must understand complex issues such as and less yearly maintenance costs than other types
spring force, face balance, preferential lapping and face shape. of pumping technologies.
Selecting the Right Repair Provider
A user seeking a safe and reliable repair for high-technology
mechanical seals should check that the repairer:
• has the necessary plant, machines, equipment, tooling and
infrastructure such as air handling, lifting equipment and
decontamination
• has sufficient inspection equipment and test facilities
• can evidence employee competence with detailed
supporting records
• has written procedures and standards such as ISO standards
and associated risk documentation
• has an in-depth understanding of the seal materials Contact us today for details and pricing –
• can demonstrate competence and approvals in component and a dry run.
and assembly design
Check 118 on index.
For a user seeking optimum reliability and cost-efficiency,

selecting a quality-assured and experienced repairer is the surest
guarantee of receiving a “good as new” mechanical seal.
Stephen Shaw is the global engineering director at AESSEAL. He may be

reached at stephen.shaw@aesseal.co.uk. For more information, visit aesseal.com.
www.Hydra-Cell.com • 612-332-5681
SEALS & BEARINGS
Avoid Premature Bearing Wear With

Long-Term Sealing Solutions
Noncontact seals can help provide maintenance and protect bearing life.
CHRIS TONES & JEFF BLANK | Garlock
“Problems of output are problems of input.”

It is a helpful takeaway to remember
that users get out what they put in.
For those familiar with rotating and
reciprocating equipment—such as pumps,
motors and gearboxes—this certainly
rings true, especially when problems arise.
Considering the high demands (and high
stress) placed on such intricate machinery,
time is of the essence. Therefore, when
things go wrong, it can be more beneficial
to seek out a lasting solution instead of a
temporary fix.
For process industries and applications,
oil lubrication is used in rotating equipment
to reduce friction and minimize the wear of
bearings and components during operation.
In these arrangements, particularly
in gearboxes and gear reducers, it is
common to encounter oil lubrication that
has been filled to a level that could leak
outside of the unit. Often, there are two IMAGE 1: Example of bearing failure (Image courtesy of Garlock)
main types of seals being used to help

protect the bearings, each having its own And in these aggressive, flooded lubrication creating an abrasive slurry that eventually
considerations and limitations. environments, those repairs are not cheap. leaves a wear spot on the rotating shaft
Traditionally, an oil seal (or lip seal) Luckily, there are some things users can do, surface. Once this wear has occurred, it may
has been used to retain oil within these and some key indicators to look for, to help also prevent a new oil seal from making
configurations. Unfortunately, extended use avoid trouble along the way. proper contact to retain oil lubrication,
tends to lead to shaft wear and grooving, thus increasing the chances of additional
which affects the seal’s overall performance Trouble Ahead equipment failure or damage.
and causes oil to leak from the system. When it comes to red flags, the most
In contrast, some end users prefer to use common signs to be aware of are frequent Compounding Problems
a noncontact seal, like a traditional bearing or premature failure of the bearings, Bearing failure can result in a costly
isolator labyrinth seal, to prevent wear frequent oil seal failure and shaft wear replacement and, depending on the extent
in certain arrangements. However, these from oil seal contact. Further, a failed seal, of the damage, other internal components
noncontact seals will not retain oil filled or inadequate seal design, can also allow could suffer as well—requiring additional
to this flooded level. This poses a problem contamination to enter the oil lubrication, repairs. Yet, residual problems can stretch
because without proper or sufficient which might degrade the properties of the far past the equipment. For instance,
lubrication, internal rotating components oil and cause equipment damage. This oil spreading and leakage soon become
can fail, causing extensive damage that happens when the abrasive contaminants Environmental Protection Agency (EPA)-
might require repairs or replacement. embed in the seal lip and mix with the oil, related issues. Not only that, but the

same also can raise safety concerns when corners can lead to more repairs and more even if the seal is in contact with abrasive
factoring in related slips and falls. Both costly downtime later. contamination. This ensures protection
can lead to steep fines and regulatory Rather, when equipment begins to fail, of the internal oil seal element from
violations. Perhaps worst of all, in addition and when some of the aforementioned contaminants in the application, providing
to the fines and repair costs, is the lost problem indicators are noticed, it is better a pristine running condition and extended
revenue due to the production downtime. to identify the why-behind-the-what of seal life. And with minimized loss of oil
For some businesses, depending on equipment failure and downtime. Getting lubrication, users can expect extended oil
the amount of time consumed by such to the root cause of the issue is worth the life and a longer overall run time of the
maintenance requirements, the pain can effort (and cost), versus merely placing a bearing. There can also be the added cost
become crippling once it starts affecting Band-Aid on the wound, so to speak. savings of improved safety and overall
the bottom line. process efficiency.
Considering a Longer-Lasting High demands and high stress are
Discover What’s Best Suited Noncontact Seal Solution manageable when all is well, but when
for the Application Using an improved noncontact seal, problems arise, it is important to fight
What can be done? For starters, users designed to retain oil filled to a flooded the temptation of a quick, easy remedy.
have to decide what works best for their level, can help provide better outcomes Remember: Users get out what they put
situation. Many plant managers choose the by solving these problems. There are a few in. Consider a longer-term solution that will
previously stated options and stay on top of additional benefits to consider. save money, protect the bottom line and,
the maintenance schedules that come with First, these improved designs can in most of all, provide peace of mind.
it. Neither choice is foolish. many instances be installed on a damaged
However, a quick fix may not be the or grooved shaft surface. Such versatility
best route to take and the incorrect seal eliminates the need for a user to resurface
design for an existing application is bound or replace a worn shaft.
Chris Tones is a senior product engineer and Jeff
to cause more harm than good eventually. Second, this type of design also will Blank is a product engineer for Garlock. For more
While costs may be saved up front, cutting not further wear at the shaft surface, information, visit garlock.com.
Check 120 on index.
SEALS & BEARINGS
The Impact of Water on Pump Bearing Life

Maintaining a low level of moisture and humidity in pump bearing housings is critical.
MARK BARNES | Des-Case Corporation
350%
In industries that rely on process pumps, 300%

water in the form of free water, steam
250% Dissolved Saturated (free & emulsified)
Relative bearing Life
or airborne humidity is a pervasive
contaminant. Water not only leads to
rust and corrosion but can also lead to a 200%
reduction in oil film strength, resulting in
!"" ".%
overall poor lubrication conditions that can 150%
L** =
reduce the life expectancy of bearings by as #
much as 50%. As such, maintaining a low 100%
level of moisture and humidity in bearing
housings is critical to overall pump life. 50%
Why Is Water So Impactful? 0%

Most pumps use rolling element bearings. 0 100 200 300 400 500
In an element bearing, the separation of the Water Content in ppm
bearing raceway from the rotating elements
IMAGE 1: The impact of water on bearing life (Images courtesy of Des-Case Corporation)
occurs due to elastohydrodynamic
lubrication (EHL). Under EHL conditions, the
oil trapped between the moving elements the molecular levels throughout the oil. rust and oxidation (R&O) inhibited pump
and raceway is subjected to extremely All oils will hold a certain amount of water fluid. Based on this curve, which arbitrarily
high, localized pressures, often in the range in the dissolved phase. Even though there set a water-in-oil concentration of 100 ppm
of hundreds of thousands of pounds per is water in the oil, an oil with dissolved as a baseline for 100% bearing life, one can
square inch (psi). Under these pressures, moisture will appear clear and bright. The see that once water concentrations exceed
the oil will exhibit a rapid increase in amount of dissolved water depends on the saturation point of the oil, bearing life
viscosity due to the oil’s pressure-viscosity the type of oil, the temperature and the can be significantly reduced. In fact, at only
coefficient. This viscosity increase causes condition of the fluid. 300 ppm, equivalent to just 3 milliliters
the mating bearing surfaces to elastically Most pump oils at operating (ml) in a 10-liter (L) oil sump, bearing life
deform. As a result, this distributes the load temperatures will hold between 100 to expectancy is cut in half.
across a wider surface area. If any water is 150 parts per million (ppm) (0.01% to The effects on water and other
present in the load zone, it will impact the 0.015% volume per volume [v/v]). Once this contaminants on pump life are well known
elastohydrodynamic oil film and, under concentration is exceeded, the oil is said to and primary reasons why bearing isolators
some circumstances, can cause flash be saturated with moisture and additional have become standard on many American
vaporization of the water. water will be present as either free water, National Standards Institute (ANSI) and
sitting on the bottom of the bearing American Petroleum Institute (API) pumps.
Water & Oil Do Mix housing or emulsified, causing the oil to Modern bearing isolators that are designed
While conventional wisdom says that polar appear milky or hazy. While all forms of to provide both dynamic and static sealing
fluids like water do not mix with nonpolar moisture are harmful to bearings, free and have proven effective at increasing pump
fluids such as oil, in pump oils and other emulsified water are the most damaging. life. However, studies have shown that
lubricants, oil and water can mix under Image 1 shows the results of an using bearing isolators does not completely
certain conditions. When water and oil mix, empirical study of bearing life as a function negate the impact of water on pump life.
the water can exist in three distinct phases: of water-in-oil concentration1 for a standard The reason for this is due to the way
dissolved, emulsified and free. Dissolved mineral-based International Standards that water and humid air interact—an
water refers to water that is dispersed at Organization Viscosity Grade (ISO VG) 68 effect that can be explained by Henry’s

160
Law. Henry’s Law states that at a constant port, allowing the silica 140
temperature, the amount of a given gel to dehumidify the 120

gas (water vapor) that dissolves in each headspace. Both pump
100
ppm of water
type and volume of liquid (oil) is directly bearing housings
proportional to the partial pressure of that were equipped with 80
gas in equilibrium with that liquid. Put a leading brand of
another way, if the air above an oil has bearing isolator. The 60
a relative humidity of 60%, the oil will test was conducted in 40

also be 60% saturated, meaning a water Central Florida in the
concentration of 60 to 100 ppm. Image 2 summer with average 20
shows how the humidity of air affects the ambient humidity 0

water concentration in the same ISO VG of 74% relative 0% 20% 40% 60% 80% 100%
68 R&O fluid. The inference in Image 2 is humidity and daytime Realtive Humidity of Headspace
clear: Exposing pump oil to higher levels temperatures around IMAGE 2: Water absorption of an ISO VG 68 R&O oil at 100 F
of ambient humidity will result in higher 93 F (34 C).
water-in-oil concentrations, effectively The results of the study are shown in with silica gel protection showed a low level
lowering bearing life expectancy. Image 3. As shown, the pump with no of humidity, despite identical conditions to
To study the influence of ambient headspace protection shows high levels the reference pump. Based on this data, the
humidity on pump headspace humidity of humidity in the headspace, varying pump oil saturation graph shown in Image
levels, two pumps were fitted with desiccant from 50% to 65% relative humidity. 2 and the relative bearing life projections
breathers equipped with smart humidity Interestingly, humidity levels were shown shown in Image 1, it is reasonable to
sensors. One breather was sealed and the to fluctuate across a 24-hour period, conclude that the pump without headspace
silica gel desiccating media removed to reflecting the impact of daytime/nighttime humidity protections might be expected to
serve as a reference, while the second temperature fluctuations on pump have as much as a 20% to 40% reduction in
breather was installed in the bearing fill headspace humidity. By contrast, the pump bearing life.
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Check 115 on index.
SEALS & BEARINGS
sitting idle in oil in resealable containers when not in use.

70 contaminated with 2. Installing bearing isolators is a
60 free or emulsified strategy to exclude particles and
Sensor RH reading
50 water. This is gross moisture during normal operation

40 prevalent in process and shutdown.
30 industries such 3. Using a desiccant breather that has
20 as petrochemical silica gel in contact with the pump
10 or refining where headspace will help to reduce headspace
0 it is common to humidity and, in doing so, increase
-10 have both duty and bearing life.
0 24 48 72 96 120 144 168
Test Time in Hrs standby pumps.
Under these References
Sealed Breather Without Silica Gel With Silica Gel
circumstances, 1. R. E. Cantley ASLE Transactions Vol. 20. 3.
IMAGE 3: The influence of temperature and ambient humidity on pump controlling 244-248, 1977
headspace humidity headspace
humidity should be
Which Pumps Are Most Affected? considered a priority to prevent unexpected
The impact of headspace humidity on failures during pump startup.
Mark Barnes is the vice president of the Des-Case
pump life is perhaps most pronounced reliability services team. Barnes has 25 years of
when pumps operate intermittently. Since How Can Headspace Humidity experience in the fields of lubrication management,
oil analysis and contamination control and has
relative humidity is temperature dependent, Be Controlled?
published more than 175 technical articles and white
pumps that operate in stop/start mode or Controlling headspace humidity is a three- papers. Barnes holds a doctoral degree in physical
are shut down for long periods of time are step process. chemistry from the University of Southampton in
the United Kingdom and is a Certified Maintenance
often found to be completely saturated 1. New oil should be prefiltered to remove and Reliability Professional (CMRP). For more
with moisture, meaning the bearings are both particles and moisture and stored information, visit descase.com.
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COVER SERIES: The Basics
The Basics an alternating duty/standby arrangement

or identical but differently located pumps
answer might be, “the pump was blocked”
and ceasing the maintenance activity
of Root
completing comparable operations, can once the blockage has been cleared is
be compared by calculating the ratio of a sure route to a return visit. So, it is
pump flow rates. If both pumps are running necessary to ask further, “Why is the pump
Cause Failure efficiently, the ratio will be between 0.9 and
1.1. Outside of this ratio and one pump—in
blocked?” It could be that a macerator is
broken, or it may be that inappropriate
Analysis the same setup—is running inefficiently

relative to the other. In addition, investigate
material is entering the system further
upstream. Ask the third why, “Why
the relative frequency of starts for each is the macerator broken?” and so on
Find out why a system failed pump. If one is starting more frequently, until a root cause is arrived at and then
and what could be done to this can indicate a problem downstream of address that. Always take a step back to
the pump such as an inoperative nonreturn consider what has happened and consider
prevent repeated failures. valve (NRV). Far too often, a pump will be FRETT—force, reactive environment, time
reset and the NRV is ignored, but having and temperature. Typically, this method
TORILL BIGG | Tunley Engineering
investigated the root cause, the NRV can be requires asking why five times, hence the
maintained, repaired or replaced. name of the method.
Work Order Data Fishbone Diagrams

Another set of data that is informative if This may require a meeting between
All too often, pumps fail. The same it is available is work order data. This may managers or can be conducted by an
pumping system is attended to time and take the form of a count of the number individual, but it is more strategic than the
time again, and the maintenance costs of jobs raised to an asset, the type of five whys. It can even be used to provide
mount up. This is a sure sign that the root job raised per asset, the amount of time the five why questions to be asked by a
cause has not been addressed. Instead, the required to repair the asset, or the reason technician responsible for interventions.
symptoms are overcome, and the operation the job was raised. This is likely to be the The bones of the fish may begin with
is set going again—until the next time. impact of the service failure such as a leak generic areas of investigation such as:
Performing an analysis of the root cause of or a loss of pressure, mean time between • faults in the design—pump selection,
the failure will pay dividends. Once the root failures and spares required. Combining impeller selection, pumps used at an
cause is found, long-term solutions can be operational and work order data provides inefficient point of the pump curve
planned, documented and implemented. powerful data-driven and statistical root • material defects
But which root cause analysis tools or cause indicators. Consider, for example, • machining errors
methods should be used? A little knowledge using Pareto analysis. • assembly or installation defects
goes a long way. Both data methods are assisted by • operational conditions outside of the
accurate data recording which, in turn, design intention
Operational Data requires a cultural understanding for the • maintenance or lubrication deficiencies
In root cause failure analysis (RCFA), usefulness of recording accurate data as • improper operation
experience has cultivated a preference well as a comprehensive asset list.
to start with operational data. In many Systematic examination and elimination
circumstances there is not much data, The 5 Whys of each hones in on where the root cause
and what does exist may be unreliable. Keep it simple. There are statistical exists. RCFA does not have to be glamorous.
Where available, it is best to use data methods for RCFA. However, an analysis Take a step back and consider what has
from systems such as telemetry systems, method that is an everyday tool able to happened, look into why it happened
supervisory control and data acquisition be used by everyone in maintenance is at and drill down to the root cause—what
(SCADA) and programmable logic control its most useful and effective. A tool that is system failed, which component failed,
(PLC) data. Where this is unavailable, used is always more useful than a tool that what combination led to a service failure
there are methods by which data can be is rare and can only be used by an expert. from a component or a multicause effect.
derived or deduced. For example, in the The five whys involves asking a series of Then, solve the root cause, document and
absence of a flow meter, forward flow can questions to drill down to the root cause. implement a solution for today, and build
be derived from the pump running time A user might stop at one why such in planned prevention for tomorrow.
and the volume of liquid passed forward. as, “Why has the pump stopped?” They
This can be compared to the pump curve, get symptomatic relief and repeat
Torill Bigg, Ph.D., is chief carbon reduction engineer
which can reveal if the pump is suitable for breakdowns—which is an expensive way at Tunley Engineering. For more information, visit
the application. Paired pumps, such as in to operate pumping systems. The first tunley-engineering.com.
Best Efficiency Point & head will tend to just slightly decrease.
In other words, because the pump’s curve
Performance Curves
is relatively flat, in the event of a larger
flow rate than expected, the head will
decrease only a small amount, which
means that the pressure at the consumers
How to ensure your centrifugal pump is operating efficiently. will drop only a small amount. Therefore,
for such applications where many different
AMIN ALMASI | Principal Machinery/Mechanical Consultant consumers can come on and off, a relatively
flat curve works better. A good example of
such an application is the fire water pump.
A drooping curve shape should usually
be avoided because it is possible for the
pump to hunt between two operating points
The best efficiency point (BEP) is the • So-called normal curves, where the head that both satisfy the head requirement of
point along a pump performance curve decreases as the flow rate increases. the system. This is known to happen when
where efficiency is the highest. In other A typical (normal) performance curve two pumps are operated in parallel. When
words, BEP is the point at which the pump head decreases relatively rapidly as flow the second pump is started, it may fail to
efficiency peaks. In any pumping system, rate increases. get to the operating point or hunt between
operating at or around BEP of the pump is • Steep curves, where the head decreases two points that are at equal head.
desired. However, there are many things rapidly as flow rate increases.
to consider and issues to avoid in order to • Flat curves, where the head decreases Theory vs. Practice
achieve this ideal operation. slowly as the flow rate increases. These The BEP data and the pump performance
curves are actually relatively flat. curve are usually only theoretical values
BEP & Performance Curve • Drooping curves, similar to the normal until the shop or site performance test. The
The performance curve shows how profile except at the low flow end, the actual BEP data and performance curve are
deviation from BEP, working to the left head rises then drops as it gets to the determined by the pump test. They may be
side or right side of the BEP, would affect shut-off head point. slightly different than the theoretical BEP
the operation and performance of the and curve.
pump. The pump characteristic curve is the A normal curve has an angle, say 25 or There have been many sources for such
head (discharge pressure) versus flow rate 35 degrees on average; therefore, it is more deviations or differences. For instance,
(capacity) curve. The preferred operating or less inclined. A steep curve has a steep actual dimensions and details of the
range is typically defined as 70% (or 75%) angle (just as indicated), say above 40 or 50 impeller and casing might be different
to 110% (or 115%) of flow at BEP for most degrees on average. A relatively steep curve from theoretical ones, or the simulation
centrifugal pumps. However, this is just can be desirable from the control point of of the liquid flow inside the pump was not
an indication, and the actual pump curve view for some pump applications since a accurate. The impeller details play a major
and its behavior in the system should be small reduction in the flow will result in a role in the BEP and curve. Any change or
carefully considered. large pressure rise. Therefore, it can help to modification of the impeller will change
There have been various types of recover the lost flow. For example, if there the BEP and curve of the pump. The casing
curves for different centrifugal pumps. is a flow restriction by partial plugging usually has less of an effect.
However, there are typically four different in the downstream, this large pressure Trimming of the impeller, or slightly
curve profiles: rise can help to overcome the problem changing the impeller (slight modifications
(partial plugging in this case) and restore on vanes, etc.), can be used to make some
the desired situation. The steepness of changes on the performance curve and BEP.
the curve depends on many details of the However, these changes need to be made
Any change or pump, such as the number of vanes and the with great care.
modification of the specific speed. However, a steep curve is not
suitable for every application. Control Valves in Pumping Systems
impeller will change A relatively flat curve is sometimes The flow rate through a pump is usually
desirable, such as when a change in flow determined by the pressure (head) in the
the BEP and curve
should only result in a small change downstream (discharge) of the pump. A
of the pump. in head. In some applications, as more control valve in the pump discharge piping
liquid consumers are turned on, added is most often used to control the flow rate
or connected in the discharge side, the and overall operation. If the system is set

up properly, the control valve might help
to keep the pump operating near BEP.
However, there are some important factors
that should be considered. The control
valve has a pressure drop across it, which
represents a waste of energy. Operational
conditions regulated by the control valve
may push the pump to operate sometimes
far from its BEP if the system is not
designed and operated properly. This can
directly affect the reliability, performance
and efficiency of the pump.
BEP, Vibration, Heat & Noise

Vibration of a centrifugal pump almost
always varies with flow and operating point.
Usually, the vibration is the minimum in
the vicinity of BEP and increasing as flow is
increased or decreased. The rise of vibration
as the operating point is moved from BEP
to another point depends on many factors
such as the pump’s energy density, its
specific speed (Ns) and its suction specific
speed (Nss). Higher energy consumption
per unit of capacity is one of the key
effects of inefficiently operating far from
BEP. The wasted energy shows itself as
heat, unwanted vibration, noises,
damaging forces inside the pump and
other adverse effects.
Pumps should be selected and operated
to work as close to BEP as possible.
However, there are many practical
considerations and challenges to overcome
in order to achieve this goal. When a pump WASTEWATER PUMPS
PS SURFACE PUMPS, PACKAGES,
AGES, SUBMERSIBLE & VERTICAL
operates at BEP, it is at its most efficient. AND PACKAGES AND CONTROLS LINESHAFT TURBINES
This means it uses the driver power as
efficiently as possible and reduces energy
costs, energy waste and potentially PERFORMANCE
PERFORM
RMAN
NCE BEYON
BEYOND
OND THE
HE PUMP
damaging effects. When a pump operates Franklin Electric is
i your single
siingle source for engineering,
engiin ering manufacturing
manufacturing,
at BEP, it usually produces the lowest
packaging, and technical support for water pumping appli applications
ications in
vibration readings and lowest temperature
readings. Therefore, pump reliability/ municipal,
munici
ipal, industrial, and commercial markets. Maximize performance
availability is increased and maintenance beyond the pump and choose Franklin as your partner for water systems.
costs are decreased.
Check 110 on index.
Amin Almasi is a principal machinery/mechanical

consultant in Australia. He is a chartered professional
engineer of Engineers Australia (MIEAust CPEng–
Mechanical) and IMechE (CEng MIMechE). He has
a Bachelor of Science and Master of Science in
mechanical engineering and is a RPEQ (Registered
Professional Engineer in Queensland). He has
franklinengineered.com
Visit us at MINEXPO
authored more than 200 papers and articles
dealing with pumps, rotating equipment, mechanical BOOTH C4631
equipment, condition monitoring and reliability.
6 Basic Rules IMAGE 1: The pipe
of Pump diameter on the suction

side should be equal to
Piping Design
or one size larger than
the pump inlet. (Image
courtesy of Crane
Engineering)
Why users need a piping

expansion joint.
as low as possible. The straight-run pipe and elbow. This helps to eliminate the “side
gives users a uniform velocity across the loading” of the pump impeller and creates
JEFF SIMPSON & DALE ANNOYE | pipe diameter at the pump inlet. Both are uniform pump axial bearing loading.
Crane Engineering
5
important to achieving optimal suction.
2
Eliminate Potential for
Pipe Diameter on Suction Side Air Entrapment in the
Should be Equal or One Size Suction Piping
Larger Than Pump Inlet Maintain adequate levels in supply tanks
Installing a new centrifugal pump? Pipe sizing is a balancing act between cost to eliminate vortices from forming and air
After carefully selecting the right size and friction loss. Larger pipes cost more, entrapment. Avoid high pockets in suction
and materials, make sure the new pump whereas smaller pipes impose greater piping, which can trap air. Keep all pipe and
is set up for success with proper friction losses on the system. In terms fitting connections tight in suction vacuum
installation. Setting the base correctly of diameter, discharge pipe diameter conditions to prevent air from getting into
and aligning the pump is crucial. It is should normally match the discharge the pump.
6
also important that piping to the pump flange on the pump but can be larger to
is done properly. reduce friction losses and decrease Ensure the Piping
Pump piping design is sometimes system pressure. Arrangement Does Not Cause
overlooked when setting up new On the suction side, the diameter can Strain on the Pump Casing
installations. The focus is more on the be the same size, but often engineers Pumps should never support the suction
equipment than the pipes that supply it. select a size or two bigger, thus requiring or discharge piping. Any stress on the
However, when installed with inappropriate an eccentric reducer. Larger suction piping pump casing by the piping system greatly
piping arrangements, pumps can on the suction side is usually preferred if reduces pump life and performance.
experience premature and repeated failures the liquid viscosity is greater than water. Keep in mind that increasing the
during the life of the pump. Maintenance This also helps produce an even flow to the performance of the pump will help to
teams will regularly repair the pump, pump and avoid cavitation. make up for piping mistakes made on the
3
effectively treating the symptom instead of discharge side of a pump. Problems on the
the true problem. Use Eccentric Reducers suction side, however, can be the source
Knowledge and resources are limited on the Suction Side of repetitive failures, which could cause
on this topic, except what is found in the Consider using eccentric reducers on the problems for years to come if not
installation, operation and maintenance suction side of the pump when a pipe size addressed appropriately. Suction side
(IOM) manual (which is minimal). But by transition is required. Install the flat side piping problems cause the majority of
following these six simple rules, users can of the reducer on the top when fluid is pump issues.
avoid premature pump failure and related coming from below the pump. If the fluid Piping design is an area where basic
pump piping pitfalls. comes from the top, the flat portion of the principles are frequently ignored, resulting
1
reducer should be mounted on the bottom in increased vibration and premature failure
Keep Suction Piping of the pipe. The flat portion is designed to of the seals and bearings. Incorrect piping
as Short as Possible discourage an air pocket from forming at has long been disregarded as a reason for
Include a straight-run pipe length equal to the pump suction. these failures because of the many other
4
five to 10 times the pipe diameter between reasons this equipment can fail. Many
the pump inlet and any obstruction in the Eliminate Elbows Mounted experienced engineers may argue that
suction line. Obstructions include valves, on or Close to the Inlet pumps with incorrect piping still function
elbows, “tees,” etc. Nozzle of the Pump and operate as they should. This argument,
Keeping the pump suction piping short Include five to 10 pipe diameters of although valid, does not make questionable
ensures that the inlet pressure drop is straight-run pipe between the pump inlet piping practices correct.

Why You Need to move in three different ways: axial flexible or metal liners are not technically
a Piping Expansion Joint compression or extension, lateral offset or an expansion joint, more of a flexible
The same pump failed again. A angular deflection. connector. They work well in high
manufacturer experienced repeated failures They typically come in three different pressure and temperature applications
on the same pump, and even though the materials to cover a variety of applications. requiring vibration dampening or pipe
pump had been properly repaired, Metal: Metal expansion joints are misalignments. These are often used
installed and aligned, it still experienced mostly used in applications where on pumps and other equipment to help
chronic vibration issues. thermal expansion is an issue. When the eliminate thrust load on the equipment
A closer look determined that the temperature of the pipe increases, the nozzles due to thermal expansion.
vibrations were not being emitted from metal expansion joint compresses to Eliminating that load is critical to
the pump, instead it was being affected compensate for the movement, taking pump performance. Braids provide
by vibrations from other equipment as it stress off the anchors and the pipe. A metal lateral and angular movement. They also
traveled along the pipes. What can be done expansion joint is a prime example of how absorb vibration.
to stop rogue vibrations from affecting the to handle expanding hot pipes. The entire process is intertwined, and
pump? A piping expansion joint might help. Rubber: Rubber can be used for thermal each piece affects the next. Having a
expansion, and it also absorbs vibration reliable piping system is key to a process
What Is a Piping Expansion Joint? and shock waves well. That is why this that maximizes uptime. Carefully managing
An expansion joint is installed in piping type of expansion joint is great for a piping system will keep the pipes in great
systems for a couple of reasons. They can minimizing the transmission of noise, working condition and also extend the life
be used to absorb vibrations and shock vibration from other equipment to protect of the equipment attached to them.
and to relieve anchor stress, reduce noise equipment like pumps. They also work
and compensate for misalignment. as shock absorbers to minimize trauma
Certain expansion joints are also caused by water hammer, pressure surges Jeff Simpson is a fluid process engineer and
Dale Annoye is a senior application engineer at
designed for thermal expansion in hot and seismic events. Crane Engineering. For more information, visit
applications. Expansion joints allow pipes Braided: Braided stainless hoses with craneengineering.net.
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Check 114 on index.
Proactively Avoiding Valve Closure

Water Hammer
The more gradually a system can slow its flow, the better a pressure surge is mitigated.
NICK VASTINE | Applied Flow Technology
Water hammer, or surge, is a notable

change in pressure due to rapid
acceleration of a fluid. The most universal
cause of water hammer is a valve closure,
in which fluid flow is rapidly decelerated
causing a large increase in pressure.
During a valve closure, the kinetic
energy of a flowing fluid is converted
into potential energy in the form of
pressure. This increase in pressure can
be significant, potentially exceeding
designed pipe pressure ratings. The faster
the valve is closed, the more aggressively
kinetic energy is converted into pressure,
resulting in a higher pressure surge. The
more gradually a system can slow its flow,
the better a pressure surge is mitigated.
Imagine gradually applying the brakes in a
car compared to slamming on the brakes.
IMAGE 1: A flow rate reduction comparison for different valve closure times, showing increasing valve closure
By slowing down gradually, the energy is time, does not necessarily reduce flow and, therefore, surge pressure, proportionally. (Images courtesy of
better dispersed through the system. Fluid Applied Flow Technology)
is slowed smoothly by gradually closing
valves, with a few caveats. as an emergency shutdown, the fastest the process, the effective closure time
Generally, the longer the valve closure, possible closure within the allowable is only 10 seconds. The effective closure
the less pressure surge will occur. Often pressure surge is ideal. time can be defined as the amount of time
there are design heuristics to “close spent actively reducing flow rate during
X seconds for every X amount of pipe Instead, if the focus is on a system’s a transient. In the example, if the same
diameter” or based on other parameters. reaction to a transient event and predicting valve is instead closed over 40 seconds, the
However, these simplified rules of thumb to a response through modeling, an engineer effective closure time only increases to
mitigate a water hammer event have two can mitigate (or ideally, completely avoid) 20 seconds.
potential pitfalls. the pitfalls of heuristic-based closures. A real-life example explored water
1. A design heuristic is not always hammer surge from a subsea pipeline
conservative, meaning a suggested What Is Effective Closure Time? valve closure. The engineer compared a
valve closure may not effectively While lengthening a valve closure time 20-second valve closure to a 600-second
prevent surge. This can be caused by should theoretically mitigate a surge event, closure in water hammer modeling
several different factors a simplified it is not always a direct relationship to software, but as seen in Image 1, the
heuristic does not account for. slow flow. effective valve closure time was still short.
2. While a rule of thumb may prevent Remember, a valve closure’s pressure The rapid deceleration of the fluid resulted
surge, it may be overly conservative increase is caused by decelerating the fluid. in a drastic pressure response in each
and lead to unnecessarily long closure If a 20-second valve closure does not begin tested case, despite the longer overall
times. In emergency conditions, such decelerating the fluid until halfway through closure time.

What Causes Effective Closure Time
to Differ From Overall Closure Time?
Valve closures are impacted by two major
factors: the valve’s inherent characteristics
unique to how the valve is constructed and
the valve’s installed characteristics—how a
valve interacts with a system.
A valve’s inherent characteristics inform
two things about a valve closure. First is
the shape of a valve’s closure in the form
of a characteristic curve. For example, the
rate at which flow is reduced as a ball valve
closes will be drastically different from
the rate as a globe valve closes. Image 2
isolates these characteristic curve effects
by closing valves over the same amount
of time from the same starting point. It is
clear how a valve’s construction impacts its IMAGE 2: A characteristic curve comparison for valves with equal overall closure time, leading to drastically
ability to slow flow over a closure, which in different pressure responses as flow rate is reduced.
turn impacts its pressure response.
The second factor for a valve’s inherent valves were closed over the same time, the informed by the overall system, making it
characteristics is the starting loss of the globe valve would create more loss earlier an installed valve characteristic dependent
valve at full open. For example, globe valves and, thus, start reducing flow sooner, on the system. For example, take a garden
generally cause higher losses than similarly resulting in a longer effective closure time. hose that users can cover with their thumb
sized gate valves. Thus, if both types of This necessary loss to control flow is to control flow. When the hose is not kinked,
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Check 119 on index.
IMAGE 3: Valve losses relative to system losses, indicating the valve begins
controlling flow through the system at nearly 40% open in this example.
the thumb causes most of the overall system losses and users
can easily control the flow. However, if the hose is kinked and
the normal system losses are quite high, the same thumb
covering will less effectively reduce flow, if at all. This is the
relationship of valve-specific losses to overall system losses, and
the result on flow rate is found in Image 3.
These nonvalve system losses can be caused by many
things, such as overcoming elevation change, fittings in a
pipeline, and pipe parameters like increasing length and
reducing diameter. When a system has losses elsewhere, it
takes more loss through a valve for it to start controlling and
reducing flow. This means the first part of the closure is often
Check 128 on index. ineffective, reducing the effective closure time.
What Is a Be er Valve Closure Design?

With effective closure time in mind, there are many approaches
to quickly close valves without causing a large surge event.
1. Determine where a valve starts reducing flow and reach that
point as early in the closure as possible. Since flow should
not be reduced through this initial part of the closure, there
UNMATCHABLE EXPERIENCE IN
is not a pressure surge to worry about.
FLOW CONTROL TRANSACTIONS
2. Consider the valve’s characteristic curve to stage a closure
event. How a globe valve and ball valve should be closed may
be drastically different.
Jordan Knauff & Company is a knowledgeable and
experienced provider of a comprehensive line of
investment banking services to the pump, valve and While design heuristics and rules of thumb are a good first
filtration industries (“Flow Control”). approximation, the most reliable way to predict a system
response is through modeling. Modeling a system allows for
Our lines of business include: selling companies, rapid iteration and design alternative testing before field
raising debt and equity capital, and assistance implementation or purchasing components. Modeling provides
on acquisitions.
confidence in a design while avoiding the typical pitfalls
To learn more about Jordan Knauff & Com- of heuristic-based design. Especially since a valve closure
pany, contact any member of our Flow response is highly dependent on the valve’s surrounding
Control team. Access our Flow Control research system, creating a curated closure is easier in software where a
at www.jordanknauff.com/research-library.
model is customizable.
G. Cook Jordan, Jr. David A. Kakareka

Managing Principal Vice President References
cj@jordanknauff.com dkakareka@jordanknauff.com 1. waterhammer.com/blog/86-system/145-effective-closure-time
312.254.5901 312.254.5907
Nick Vastine is a business applications engineer at Applied Flow Technology

MEMBER FINRA, SIPC (AFT). Vastine holds a Bachelor of Science in chemical engineering with a
minor in economics from the Colorado School of Mines. For more information,
visit aft.com.
Check 127 on index.

How to Quickly Calculate a Centrifugal

Pump’s Total Dynamic Head
Learn safe assumptions when calculating the total head of a pump and how
to deal with an oversized or undersized pump.
IRENE PAÍS GOYACHE | Geiger Pump & Equipment
As an engineer, there are times when

calculations need to be done quickly,
even when all of the desired inputs are not
readily available, to determine the best
solution. With centrifugal pumps, these
calculations typically deal with calculating
a pump’s total head to select the optimally
sized pump required. While referencing the
existing pump and how it works would be
the easiest, there are scenarios where a user
cannot access that data. Here are solutions
for those on-the-fly situations, as well as
the best assumptions to make to accurately IMAGE 1: Example system where water is transferred from point A to point B (Image courtesy of Geiger Pump
estimate the total head of a system. & Equipment)
Calculating Pump Total Head Basics Total Head Calculations being compared to the energy needed at
To select a right-sized centrifugal pump, Centrifugal pump manufacturers the discharge to produce the desired flow,
a design or pump sales engineer needs to commonly present performance curves and the pump is then selected to add the
know the desired flow rate and total head. with units of pump head shown in feet of additional energy required at the discharge
While flow rate is relatively intuitive (or liquid. An ideal pump with a given impeller most efficiently. This is the head routinely
customer-driven), determining pump total diameter and operating speed will raise a specified for pumping applications.
head can be more challenging and lead to liquid to a certain elevation in the discharge
serious issues if calculated incorrectly. pipe, regardless of the density (or specific Calculating Centrifugal Pump
For example, if too many safety factors gravity) of the fluid. By using feet of liquid TDH for a Water-Like Fluid
are integrated into the calculation, the as the unit of pressure, the fluid’s density is Image 1 shows an example system in which
result can be an oversized and more eliminated as a variable. water (or a similar low-viscosity fluid) must
expensive pump. Alternatively, if not The Hydraulic Institute (HI) defines head be transferred from Tank A (suction) to Tank
enough are considered, the risk is an as the expression of the energy content of B (discharge). In this example, both tanks
undersized pump that cannot handle the a liquid in reference to an arbitrary height, are open to the atmosphere and the water
work. One result of miscalculating the or datum—typically the pump centerline. level in these tanks is kept constant. The
pump total head is incorrect sizing of the Further, HI defines total dynamic head datum is the centerline of the pump.
motor and related electrical components. (TDH) as the measure of energy imparted to To quickly estimate the required TDH,
Other consequences can include: the liquid by the pump. More specifically, despite the presence of other nuances,
• too much or too little flow TDH is the difference between discharge focus on the two primary components that
• the pump running out of the best head and suction head as measured are going to affect the TDH in Image 1 of
efficiency point (BEP) and the preferred between the inlet and outlet of the pump, the centrifugal pump system:
operating range (POR) including the energy required to overcome • the static head, or height difference,
• cavitation static elevation, friction and other losses. between the liquid level in Tank A and
• vibration When calculating TDH, the energy the liquid level in Tank B
• bearing issues available at the entrance of the pump is • the friction head, or the pressure losses
caused by the flow of liquid through For a fast, manual estimate of a simple need for an external programmable logic
the pipe and fittings, between Tank A system, one recommended method is the controller (PLC) or to calculate the pump
and Tank B. equivalent length method, which considers flow without a flow meter.
friction loss of various fittings as an • Partially close the discharge valve to
In the example, the velocity head will equivalent length of straight pipe. Using throttle the pump. This is a way to
balance out to zero, as centrifugal pumps commonly published tables, determine the artificially create additional friction
provide pulsation-free flow. The example equivalent length of fittings, then add those losses in the piping system. For
tanks are also both open to atmosphere, lengths to the estimated actual length of example, if the pump is cavitating,
so there is no additional pressure head pipe at each diameter. From there, total closing the discharge valve slowly will
to consider as well. When calculating the friction head can be determined using cause the pump to run back on the
TDH for a water-like fluid, these and other friction loss per 100 feet of pipe data. curve to a point where the cavitation
additional components are not required and Safety factors discussed earlier include stops. This is a quick way to check if the
a basic calculation is shown in Equation 1. pipe roughness, laminar versus turbulent cavitation is corrected, and then proceed
Net static head, or the elevation flow (especially in high flow or small pipe with any of the other methods to fix the
difference between the surfaces of A and diameter applications) and fluid viscosity. situation on a more permanent basis.
B, should be easy to estimate in most Their application is a judgment call in this
cases. However, if these are variable exercise, but remember that more is not In cases where TDH was underestimated,
over time, start with the largest possible necessarily better. Typically, a safety factor the pump will likely be unable to produce
difference. Also, note the impact of suction between 10% and 15% is applied. sufficient flow from A to B, as the pump will
lift versus flooded suction applications. The sum of the net static head and the be running closer to shutoff conditions. The
In applications where the fluid source is total friction head will give the TDH value options for remedy include:
below the pump (suction lift), the suction for a given flow rate requirement. • Increase the impeller diameter. This
elevation is presented as a negative would likely mean higher horsepower
number—such that static discharge minus How to Fix an Undersized or required and, therefore, a larger
static suction (net static) is additive. Oversized Centrifugal Pump motor. The larger motor may not fit
Despite best efforts, pumps are often on the same baseplate, or the motor
found to be operating away from their starter may be too small, so these
pump TDH = (±) net static head + optimal hydraulic rating. While these considerations must be evaluated.
friction head assumptions and computations will provide • Increase the pump speed with a VFD.
Equation 1 an approximate value of the pump total While it is not common to run a motor
head and will provide a reasonable duty over 60 hertz (Hz), VFDs and some
point (flow rate and total head), there are motors are capable of doing so. However,
The friction head calculation for the solutions available for correcting operations. this may still result in the need for
pipe and fittings between A and B requires a In cases where TDH was overestimated, more horsepower.
more detailed characterization of the piping the pump will have excess flow and will • Survey the system for opportunities
system, including: operate closer to runout conditions. Aside to reduce required head, such as a
• How long is the pipe? from getting additional flow, which is not control valve that is usually at least
• What is the pipe diameter? always a bad outcome, the pump may partially closed. Substituting a VFD and
• What is the pipe material and how cavitate as the net positive suction head control logic can be an opportunity to
old is it? required (NPSHr) drastically increases save energy and solve the issues of an
• How many fittings and accessories are toward runout. In some cases, the motor undersized pump. A professional pump
between A and B? (The number and may also overload if a borderline selection system assessment can help determine
type of elbows, tees, valves, reducers was taken. The options for remedy include: the best option.
are typically required to determine the • Decrease the impeller diameter.
friction losses.) • Decrease the pump speed with a A safety factor between 10% and 15%
• What is estimated, or target flow rate, of variable frequency drive (VFD). This is useful as the result of overestimating
liquid through the pipe? solution offers a short payback time, pump head is less of a headache than
in some cases only a few months, and underestimating. The use of VFDs provides
There are multiple reference sources a VFD can simplify controls elsewhere. increased flexibility as well, in addition to
that describe the calculations to derive a Some VFDs can offer pump-specific typical energy savings.
reasonable friction head value. There are control and protection features,
also many websites offering handy online providing the option to also add process Irene País Goyache is an environmental sales
engineer for Geiger Pump & Equipment. She may
calculators to calculate the friction loss instrumentation for speed control (such be reached at ipais@geigerinc.com. For more
with some simple inputs about the system. as a pressure transmitter), without the information, visit geigerinc.com.

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What Is Cavitation? What is happening in the pump
▲
when it is cavitating?
Understand how cavitation can damage your system. Bernoulli’s theorem states that static water
pressure in a pipe multiplied by its velocity
is a constant. It follows then that if velocity
PETER WOLFF | Armstrong Fluid Technology is temporarily increased, water pressure
must drop.
As the water passes through the impeller
it accelerates, moving from a larger
Cavitation is a condition that can affect any from pumps, are ships’ propellers, control diameter pipe into a smaller diameter
fluid flow system. Despite it being an ever- valve seats and small-bore orifice plates in as it approaches the impeller, leading to
present threat, it is not well understood. water pipework. a reduction in the static pressure. If the
In the simplest possible terms, cavitation vapor pressure of the water is higher than
the static pressure at this point, water gas
▲
involves the formation of water vapor What causes cavitation
bubbles that damage metal components in pumps? bubbles will form.
when they collapse back to the liquid As the water makes contact with the
phase. Here are some common questions Cavitation in pumps is caused by vanes of the impeller, pressure is increased
and answers that relate to cavitation. excessively low pressure at the pump inlet. and the bubbles implode quickly as the
A blockage or restriction such as a clogged static pressure now exceeds the vapor
Does a pump sound differently filter or part-closed valve mounted on the pressure. All is now liquid again, at a
▲
when it cavitates? inlet to the pump can cause it. It can also price. Depending on the impeller material,
happen when the pump is having to source damage can be extensive. Cast iron
Yes. Cavitation has been described as its water supply from a sump installed impellers are the worst affected. Stainless
sounding like gravel or coffee beans in below the pump—called a “suction lift.” steel impellers are less affected, due to the
the system. Finally, hot water, close to boiling point, is a toughness of the material.
likely contributor.
How can I predict if a pump
▲
How does cavitation damage
▲
system components? Why does hot water allow is going to cavitate?

▲
pumps to cavitate more easily?

One aspect of cavitation that is not widely First, by looking at the net positive suction
understood is why these apparently When water temperatures are low, the vapor head required (NPSHr) curve of the pump.
harmless bubbles are so destructive when pressure of water is also low. For example, This is a calculation of how much absolute
they implode. The answer is in the release at 32 F, the vapor pressure is a fraction of pressure is needed at the inlet to keep the
of latent heat energy of condensation 1 pound per square inch (psi). As water system from cavitating.
when the water vapor returns to its liquid temperatures rise, the vapor pressure Second, calculate the NPSH available
phase. The collapse of the bubble and the climbs. At 212 F, the vapor pressure is the (NPSHa). This value represents the absolute
energy released creates a small pressure same as standard atmospheric pressure. At pressure available at the pump inlet. If the
jet that can strike a nearby solid surface, this temperature, when the vapor pressure NPSHa is 3 feet more than the NPSHr, the
potentially damaging it. Because of the is the same as the atmospheric pressure, pump will not cavitate. Be aware, NPSHr
large number of bubbles formed in a the water will begin to vaporize—turn to is measured under ideal conditions for
cavitating system, these bubbles of water gas, in layman’s terms. The commonly repeatability and accurate benchmarking.
vapor can cause extensive damage to known term for this is boiling. Pumps connected to a short radius elbow
system components over time. Because on the inlet are hardly ideal. When this type
cavitation takes place on the entry to a What is wrong with a of poor inlet pipe is in place, up to 50% may
▲
pump, the first system component that the suction lift? need to be added to the declared value of
bubbles encounter is the pump impeller. NPSHr to be on the safe side.
A suction lift adds more vertical height from
Where else can cavitation the water level in the sump up to the pump.
▲
happen? This subtracts from the static pressure How do I calculate NPSHa?
available to the water, making it easier for
Virtually anywhere that water is moving the water to turn to vapor and generate NPSHa is the sum of three values:
fast. The most well-known locations, aside damaging bubbles. 1. The vertical static suction head. If the

pump is on a suction lift, it will be a the air. They operate the pump across
negative number. a range of flow rates and, at each flow
2. The friction loss on the inlet pipework. rate, start the vacuum pump and observe
This is also a negative number. the inlet pressure falling on a compound NTN
3. The temperature advantage, which gauge. They also closely look at the
is calculated using an equation discharge pressure gauge. When the MEGAOHM™
where temperature advantage equals pump-generated pressure falls by 3%, the Bearings
atmospheric pressure minus vapor pump is cavitating according to the pump
pressure. Cold water in the system industry’s common standard and the inlet Reduce the
lends a temperature advantage that pressure—the NPSHr—is recorded. Shock of
can help avoid cavitation. Hotter As touched on earlier, to ensure
system water reduces this advantage. repeatable results, the inlet pipe has to
Downtime
be 15 straight pipe diameters in length.
In summary, Equation 1 shows: However, this a rare sight in most pump
installations. Hence, the safety margin.
NPSHa = +/- static head/ As a side note, the drop in pressure is the
lift – friction loss + temperature start of the process called “pumping on
advantage the break” where a cavitating pump will
cease to generate any head. Pressure
Equation 1
falls all the way to zero. The 3% is at the
beginning of it cavitating.
So, if there is enough
static head available when
▲
pumping hot water, will the What is ‘false’ cavitation?

pump be OK?
This is a situation in which a pump sounds
If static pressure in the system is high
as if it is cavitating, but is not. Instead, the
enough, yes. When the pressure falls as
pump is having to deal with entrained air
the water interacts with the impeller, if the
bubbles, which present no damage to the
pressure level is still higher than the water
pump impeller.
vapor pressure, no gas bubbles will form.
Entrained air is a nuisance, but it is
not actually cavitation. It happens most
And if there is not enough
often on cooling tower applications when
▲
static head available, are we

there is a vortex in the tower pond near
in trouble?
the exit pipe, where the water leaves. The
If the static pressure in the system is too vortex can allow air to be sucked into the
low, when the pressure falls as the water condenser cooling tower pump.
interacts with the impeller, the pressure
level will fall below the level at which Is there hope for preventing
▲
water vaporizes. In this situation, bubbles the damage caused by

will form and cavitation will occur. cavitation?
The pressure level at which water
Yes. In recent years, technology for
will vaporize is an important aspect of
tracking pump performance has evolved to
cavitation because it changes based on
the point that cavitation can be identified
the temperature of the water.
early, or even predicted so that issues can
be addressed before substantial damage
Check 125 on index.
is caused.
▲
How is NPSHr measured?
Pump manufacturers measure NPSHr

most often by using a closed-circuit test Peter Wolff is regional sales enablement specialist
rig with a sealed water tank with an air for Armstrong Fluid Technology. Wolff graduated
with a degree in engineering and applied sciences
blanket at the top and a vacuum pump from Sussex University in 1977. For more
connected to the top, ready to suck out information, visit armstrongfluidtechnology.com. ntnamericas.com
Do You Need to Pump Up static head because at a flow of zero gallons

per minute (gpm) there is no friction loss,
only static head. If there is an additional
Your Pump Sizing Skills? operating head requirement, such as tying
into a force main, the additional operating
head can be modeled by shifting the
Why users need to understand system head curves and Y-intercept up (static plus operating head).
their benefits in proper pump selection. See Image 1 for an example of the various
components of a system head curve.
There are multiple benefits and
MICHAEL KELLEY | Zoeller
information that can be provided by
the system head curve that cannot be
addressed in a single article. This article
will address some of the benefits the
Introductory pump sizing courses provide Pump sizing software calculates the system system head curve can provide such as
foundational knowledge and familiarization head curve based on user inputs, though it determining operating points, analyzing
with terms but do not provide the full can be calculated in workbook applications simultaneous operation, piping design,
picture. A design point, though critical in like Excel or estimated by calculating the variable frequency drives (VFDs), varying
selecting a pump, is only one piece of the total dynamic head (TDH) at various flow design conditions and comparison of
puzzle. To fully understand the relationship rates and drawing a line of best fit conservative and expected performance.
between flow and pressure in a system and through them. In the wastewater industry,
how a pump interacts with that system, system head curves are most commonly Determining Operating Points
additional information is needed. The calculated using the Hazen-Williams A pump will only operate along its
system head curve gives the full picture equation; however, other methods and performance curve. However, many times
that a single design point fails to and equations do exist. the design point used to select a pump is
provides additional information to select System head curves are unique to not on the pump’s performance curve. The
the best equipment for each application. each application, but understanding how question may be asked, “what flow will the
For the purpose of this article, the they are created can give some quick pump produce?” The system head curve
system in system head curve is defined information. Generally, they are in the provides the answer. The intersection of
as the pipe, number and type of valves, shape of a half-parabola. The magnitude the system head curve and the pump’s
static head, and any other aspects of the of the exponential curve is related to performance curve is the operating point.
design that may affect the pressure on the the friction loss. The more friction loss a The operating point defines the system
pump. The system head curve is a graphical system has, such as in undersized pipes, head and flow rate, the flow and pressure
representation of how the pressure changes the steeper the system head curve is. The the pump will produce in that system. In
as flow changes through the system. In less friction loss a system has, such as in Image 1, the design point is 20 gpm at
a sense, the system head curve is the oversized pipes, the flatter the system head 82 feet TDH. Without the system curve,
performance curve of the piping network. curve is. The Y-intercept of the curve is the it could be determined that the pump in
IMAGE 1: System head curve with operating head (Images courtesy of Zoeller) IMAGE 2: System head curves and simultaneous operation

DON’T RISK
DAMAGING YOUR
reduce the number of starts, quickly VERTICAL PUMP
adapt to varying incoming flow rates,
reduce wear and tear with soft starts—the WITH HARD
list goes on. So, why not use them on all SURFACE
pumps? The first reason is cost and the
second is application-based. The system BEARINGS!
head curve will help with the latter. Bearings made of hard
Image 3 is a representation of a pump’s plastic or graphite
IMAGE 3: System head curves and VFDs performance at varied frequencies. The often claim extraordinary
system head curve and operating points performance. However,
the graph would be acceptable, but the look ideal at first (however, in sewage that’s not telling the
flow produced by the pump would not applications the velocity must be greater whole story. Hard
be known. However, the system curve than or equal to 2 feet per second [ft/s]). surface bearings are
indicates the operating point of 24 gpm The operating point when running the just that – hard. This
at 91 feet TDH. The operating point is pump at 30 hertz (Hz) will drop the hardness causes scoring
another valuable piece of information velocity below that minimum. This does and increased wear to
not mean a VFD is not viable in sewage your rotating shaft.
that should be used in place of the design
flow in other aspects of system design applications, but the minimum frequency Cutless® Rubber Bearings
such as control set points (off, lead, lag should be set so that the pump can are resilient and allow
and more), cycle times, basin sizing, etc. exceed the minimum scouring velocity. abrasives and grit to pass
The operating point will also define the Additionally, VFDs can be less viable in through leaving the shaft
estimated efficiency point. systems where the static head is greater unharmed. The proprietary
than 50% of the TDH or on systems with rubber promotes fluid-film
formation increasing rotor
Simultaneous Operation flat system head curves.
stiffness and damping
It is commonly mistaken that two pumps resonant vibrations.
operating in parallel will double the flow of Applications With Varying
Cutless® Bearings are
what a single pump can produce by itself. Design Points engineered to provide
This would only be true if both pumps System head curves are also great for maximum protection,
had independent and identical piping evaluating applications with varying reducing “Total System
networks between the pump and outfall. design points. Some examples of Wear” (TSW™).
However, it is common in multipump lift applications with varying design points
stations to have a single, common header are pipe systems that partially, or entirely,
and discharge for all pumps. To fully drain between pump cycles (high points, BRAND
understand and compare the performance pumping downhill, etc.), deep basins INDUSTRIAL GRADE
of a single pump and multiple pumps with varying water levels and static head,
operating simultaneously, the system pressure sewer (peak flow versus nonpeak
head curve must be used. Image 2 shows flow), and other specialty applications.
the performance curve of a single pump, a In the event an application has varying
composite curve of two pumps operating design points, it is best to select a pump
simultaneously and three system that can safely and adequately operate
curves at various diameters. Image 2 at each design point. The system head
demonstrates the system head curve curve provides the clarity needed. For
and allows users to better understand example, Image 1 has two system head Cutless® brand
how a single pump compares to multiple curves, one that models the static and water-lubricated rubber
bearings, trusted by industry
pumps operating simultaneously. friction loss from the pump to a force
professionals for over 75 years.
Additionally, Image 2 demonstrates the main (lateral losses only) and another that
Only from Duramax® Industrial,
Check 126 on index.
ways manipulating the piping network models the static, friction and operating
an ISO 9001:2015
can affect operating points and allows head of the force main (lateral losses plus Certified Company.
the designer to dial in a more favorable force main pressure). In the event there
operating point. is no pressure on the force main, which
DuramaxIndustrial.com
is possible in off-peak times, the pump
440.834.5400
Variable Frequency Drives will operate at the higher flow, lower head
VFDs are great in the proper applications. operating point. In the event the pressure
VFDs can reduce energy consumption, in the force main is at its peak, the pump
EXCELLENCE – MADE TO LAST

will operate at the lower flow, higher head
operating point. The two separate system
FLOW OPTIMIZATION head curves and pump curve establish the
extreme operating points. Since the extreme
SECOND TO NONE operating points and the entire pump curve
in-between is at a safe operating point on
the pump curve, this pump is a viable option.
If either of the system curves does not
intersect the pump’s performance curve at a
desirable flow or operating point, a different
pump should be analyzed.
Conservative vs. Expected

THE NEW BLUELINE NOVA Performance
It can be helpful to evaluate a design
ROTARY LOBE PUMP
condition versus the expected condition.
The BLUEline Nova sets new standards in
pump technology. With or completely with Many regulating authorities require the use
BLUEline
NOVA
out casing protection – the BLUEline Nova of conservative values, such as a C-value of
achieves unrivaled volumetric efficiencies. 120 for friction loss calculations, which can
Made for one another – the newly developed have a significant impact on designs with
DIUS rotors in combination with the flow extended runs of pipe or high friction loss. It
optimized pump chamber ensure perfectly is generally best practice to buffer a design
smooth running at pressures of up to 12 bar. www.newblueline.com
with conservancy and factors of safety, and
it is not the author’s recommendation to
Check 123 on index. abandon this practice. It is recommended
for those designing pumping stations to
reach out to their local regulating authority
to ensure their design complies. However,
TITAN ¨
it is beneficial to look at the expected,
nonconservative case as well. If only the
conservative case is analyzed, once installed,
the pump may run further out on its curve
than anticipated due to lower pressures. The
actual operating point could be less efficient
and increase amp draw. It may be beneficial
to evaluate the pump selection with two
system head curves, one with conservative
values and one with expected values, and
select a pump that can operate adequately at
both operating points.
In conclusion, the system head curve
can provide many insights into proper pump
selection. System head curves provide a
deeper understanding of how the piping
network influences the performance of the
pump and the system. When sizing a pump,
be sure to check the system head curve to
fully understand how the system will
operate and what can be adjusted to provide
the best solution.
Michael Kelley is an application engineer at Zoeller.

He can be reached at michaelk@zoeller.com. For more
information, visit zoeller.com/en-na.
Check 122 on index.

M S
S T E
A L E
S Y
U A S
P S&
N N C
PUM A OW
2 1 S H
2 0 T
U C
O D
P R
Innovative products,
technologies and solutions
from our partners
ALIGNMENT/ FLOW METERS

VIBRATION
INSTRUMENTATION/
BEARINGS CONTROLS
CENTRIFUGAL PUMPS MOTORS & DRIVES
COATINGS ROTARY PUMPS
CONDITION SEALS
MONITORING
SLUDGE/
DIAPHRAGM PUMPS SLURRY PUMPS
FILTRATION VERTICAL PUMPS
A SPECIAL ADVERTISING SECTION
ALIGNMENT/VIBRATION BEARINGS
Condition Monitoring Unit Fluid Pivot Bearing
The VCM-3 is a new dimension of automatic machine With decades of
fault detection and diagnostics. It uses specially defined proven reliability,
measurements that not only automatically detect Pioneer Motor Bearing
developing faults earlier but also give a diagnostic Company handles
indication on the type of fault and its severity. dynamic misalignment
VCM-3 is among the most powerful data acquisition up to an astonishing
and processing field units in the market, and it is cyber- 5 degrees. Harness
secure. Schenck USA has packed more than 20 years all the advantages
of condition monitoring experience in that little box to of a tilting-pad
make a user’s life easier. bearing with none of
the harmful effects
like pivot damage, wear or fretting. The secret of the
bearings is the combination of pad design with fluid
pivot technology—pads continuously floated by
self-generated hydrostatic oil films. Supported by a
hydrostatic oil film, the pads have more tolerance for
operational misalignment, thermal distortion and
load stresses. The line of fluid pivot bearings is custom
designed to fit equipment.
Schenck USA Corp. Pioneer Motor Bearing Co.
631-242-4010 704-937-7000
sales@schenck-usa.com sales@pioneer1.com
schenck-usa.com pioneer1.com
Check 153 on index. Check 155 on index.
CENTRIFUGAL PUMPS CENTRIFUGAL PUMPS

Multipurpose Sewage Electrical Pump High Pressure Pitot Tube Pump
The K+ Energy range is now Thomas T-GTO pumps are made for high-pressure, low-
being expanded, including flow applications and widely used in the food processing
models for both small and industry for sanitation and wash-down. Other key
medium flow rates. Caprari’s applications include boiler feed, pulp and paper and
K+ Energy electric pump for mill descale operations. This product line is made in the
wastewater management offers U.S. and can outperform both centrifugal and positive
truly revolutionary features. displacement pumps in operating range with excellent
This is thanks to its exclusive quality and unparalleled service. These pumps are
and internationally patented backed by a guaranteed 24-hour
dry wet system: a truly unique pump replacement in the
cooling system that allows event of any
one electric pump model to malfunction.
be used for both submersed
installations and applications
in dry chambers, guaranteeing
excellent reliability even when liquid levels inside the
tank are unknown.
Caprari Thomas Pump & Machinery

+39 059 897611 800-256-7867
info@caprari.it tpump@thomaspump.com
caprari.com thomaspump.com

COATINGS CONDITION MONITORING
Composite Paste Grade Rebuild Material & Oil Sight Glass
Brushable Ceramic Coatings
A critical tool in early detection
Resimac specializes in offering high-performance of contamination, the Hex-
composite paste grade materials and industrial Duty Oil Sight Glass by Esco
coatings combating abrasion, wear, impact, chemical Products, Inc., allows for constant
attack, corrosion and heat loss on process systems and monitoring of oil conditions.
equipment. The Resimac material range is ideal for Applications include pumps,
repairs to corroded or eroded cast iron or steel surfaces. gearboxes or any piece of
Worn pumps and valves can first be rebuilt to original lubricating equipment that has
dimensions and then protected against subsequent a drain valve. The innovative,
damage by the application of Resimac coatings. hexagonal bottom allows for easy
The Resimac materials have been designed to resist installation and disassembly, and
cavitation, abrasion the single-piece bottle design is
and corrosion and to stronger and more durable, with
enhance fluid flow, double the pressure rating at
thereby reducing 400 psi. The Hex-Duty Oil Sight
the risk of premature Glass is a recommended, best
failure or a reduction practice addition to increase equipment life, view
in efficiency. presence of sediment, and view and purge accumulated
water contamination.
Resimac Esco Products, Inc.
386-309-9912 877-525-0924
info@resimacamericas.com info@esco-inc.com
resimacamericas.com escopro.com
DIAPHRAGM PUMPS DIAPHRAGM PUMPS

High-Volume Diaphragm Pump AOD Slurry Pump Replacement Parts
Air-operated diaphragm (AOD) pumps were developed
more than 30 years ago and initially serviced the mining
industry. These pumps were, and continue to be, a true
workhorse, with thousands sold. 20th Century Pumps
offers exact replacement parts for what was once known
as the Dorr-Oliver ODS pump and replacement parts for
the old-style gorator pump as well. Beyond parts, AOD
Pumps 2000 was established to offer pumps capable slurry pumps are offered for industrial and municipal
of handling abrasive, solid-laden and corrosive fluids applications and self-priming centrifugal pumps. To
in mining environments and to create an alternative provide a broader range of products, 20th Century
to heavy, maintenance-intensive diaphragm pumps. Pumps has partnered with IMBIL Pumps of Brazil.
Pumps 2000 introduced one of the first high-volume
designs delivering maximum flow rates to 540 gpm. The
advantages of Pumps 2000 are now being realized in all
industries: longer maintenance-free operation, no end of
life, fewer wear parts and lower air consumption.
Pumps 2000 20th Century Pumps Ltd

412-963-9200 888-281-7774
info@pumps2000america.com sales@20thcenturypumps.com
pumps2000.com 20thcenturypumps.com
FILTRATION FLOW METERS

Breathers Next-Generation Gear Meters
Pumps without AW-Lake’s next-generation gear meters build on the
headspace performance expected from a PD meter and take
humidity ease-of-use and durability to the next level. Built with
protection could upgraded materials for better resistance to corrosion,
have as much next-generation gear meters are designed to provide
as a 20% to 30-plus years of service in the field while maintaining
40% reduction ±0.5% accuracy, even under extreme or hazardous
in bearing life. conditions. When paired with the EDGE family of
However, significant improvements to pump reliability flow electronics, next-gen gear meters are even more
and longevity can be achieved through the application of accurate (±0.25%), delivering flow data seamlessly
precision lubrication practices, most easily by adding a to a PLC, PC,
desiccant breather. Des-Case VentGuard Series breathers remote display
can extend the life of pumps by removing contamination or smartphone
in virtually any environment or application including to help users
humidity and extreme moisture. With check-valve maintain
technology that isolates the system and only “breathes” complete
when necessary, Des-Case VentGuard breathers ensure a awareness of
clean, dry headspace and are an ideal solution to protect operations.
low-flow applications with intermittent operations.
Des-Case Corporation AW-Lake
615-672-8800 414-574-4300
sales@descase.com info@aw-lake.com
descase.com aw-lake.com
INSTRUMENTATION/CONTROLS INSTRUMENTATION/CONTROLS
Smart Transmitters IIoT Device
Winters WinSMART family of pressure, differential Cornell Co-Pilot connects
and temperature smart transmitters offer a powerful to the pump to monitor
combination of analog and digital communications. temperature, vibration
The LY16 Series offers pressure ratings from compound and location. Co-Pilot
up to 14,500 psi, with all SS wetted parts with pressure also connects with
monitoring. The LY36 Series is the differential external sensors to track
transmitter rated from inches of water to 1,450 psi with additional parameters
differential pressure monitoring. The TY52 Series is the and interface with
temperature transmitter with a PT100 RTD sensor. All control systems. The
configurations include 4/20mA, 4/20mA + HART, 1/5VDC Co-Pilot brand stands
or MODBUS communication options, allowing users for Pumps Industrial
to connect to Internet of Things and represents a commitment to
any PLC or PAC innovative design and user satisfaction. Use the Co-Pilot
device. Approvals, to plan maintenance, check operation, reduce manual
CSA hazardous inspections, track pump location, demonstrate run
locations and conditions to users on warranty claims, and improve
Intertek listing runtime through maintenance programs.
for intrinsically
safe areas.
Winters Instruments Cornell Pump
416-444-2345 503-653-0330
sselim@winters.com bjwarren@cornellpump.com
winters.com/whywinsmart co-pilot.cornellpump.com

MOTORS/DRIVES ROTARY PUMPS
Power Quality New Chocolate Solution
Product Line
Viking pumps are
Mangoldt offers a complete used throughout
range of power quality the production of
products for drives, chocolate, including
including “5-in-1” line/load chocolate processing
Reactors, PolyGap Sinewave (bean to bulk), making
Filters, L-C-L Filters for confections (bulk to bar) or
active front ends, and VFD both (bean to bar). Whether the
input harmonic filters. Mangoldt’s award-winning line/ task is transferring cocoa mass
load reactors maximize the power quality and protection from a ball mill across the plant
at either the input or output of an adjustable speed to a blending tank or to recirculate
system to prevent nuisance tripping, reduce harmonics yogurt coating in a closed loop to
and protect motors. Mangoldt filters are offered to feed a series of panners, or 100 other
system integrators, panel builders and OEMs as kits. Sine possibilities, Viking’s gentle, reliable pumps will improve
wave filters convert PWM voltage to a sine wave. Input operational efficiency. These are new with the O-Pro
harmonic filters offer 5%, 8% and 12% THDi and can be Barrier Seal, a combination of O-rings and lubricating
a lower cost when the VFD includes an internal reactor. fluid provide a robust seal preventing process fluid from
These products are reliable, flexible and affordable. leaking out of the pump.
Allied Industrial Marketing, Inc. Viking Pump

262-618-2403 224-298-7562
info@alliedindustrialmarketing.com info.vp@idexcorp.com
alliedindustrialmarketing.com vikingpump.com
ROTARY PUMPS SEALS

New Asphalt Solution Mechanical Seal Rings
Viking Pump is Metcar manufactures self-lubricating carbon/graphite
providing a new components and machines them to user specifications.
solution to the Metcar’s material grades are suitable for use up to
Asphalt market: the 1,200 F in an oxidizing environment and 6,000 F in
1224A-ASP Series a nonoxidizing environment. Select material grades
pumps. Asphalt has are suitable for use in cryogenic applications and
traditionally been sealed with can withstand a wide range of chemicals. Metcar’s
packing, which must continuously primary ring seals are used in many of today’s most
leak to stay lubricated. The ASP sophisticated and reliable mechanical seals for
asphalt series pumps come standard industrial, aerospace and military applications. With
with Viking’s O-Pro Cartridge seal, more than 150 grades of Metcar’s proprietary carbon/
which uses O-rings in combination with a lubricating graphite material, engineers will work with users to
grease to provide a robust seal that keeps process fluid select the optimal grade for the application. Contact
from leaking out of the pump. The O-Pro Cartridge Metcar’s application engineering
seal improves operational efficiency by not requiring department today
periodic repacking or retensioning of the seal gland, for assistance on
and the leak prevention avoids loss of product and next carbon/
cleanup costs. graphite
application.
Viking Pump Metcar
910-855-0648 914-941-3738
info.vp@idexcorp.com sales@metcar.com
vikingpump.com metcar.com
SEALS SEALS
O-Pro Seals Seals & Pump Components
Viking Pump’s latest development is the patented O-Pro For more than 30 years,
seal technology. O-Pro seals use a series of O-rings to Hi-Tech Seals has been
create a robust seal and lubrication chamber, all in one. recognized as a leader in
O-Pro Barrier seal functions as both a seal and bracket industrial seals, gaskets
bushing; O-Pro Cartridge and Guard seals are simple and rubber and plastic
retrofit options. As an alternative to packing, these solutions. The high-
solutions provide leak defense and help the user reduce quality seal and pump
product loss, maintenance costs and repair costs. components are used
across various industries
to meet and exceed users’
requirements. Hi-Tech
Seals’ pump offerings
include, but are not limited to, O-rings, gaskets, oil
seals, braided packing, mechanical seals, shims, vee
packing stacks and custom carbide and ceramic
components. For custom components, the Hi-Tech
Seals’ team of professionals collaborate with users
from design to production.
Viking Pump Hi-Tech Seals Inc.

319-595-4858 936-206-3124
info.vp@idexcorp.com info@hitechseals.com
vikingpump.com hitechseals.com
SLUDGE/SLURRY PUMPS VERTICAL PUMPS

Disk Pumps Immersion Sump Pump
Tesla Disk Pumps feature pulsation-free, smooth laminar Series 800 immersion
flow, enhancing gentle processing of fragile products sump pump applications
and eliminating costly damage while reducing wear include sump drainage,
to pump, related piping and instrumentation. No tight flood control and process
internal tolerances means they can pass large/irregular drainage to meet EPA and
hard solids as well as a variable solids stream without OSHA requirements. Heads
plugging. NPSH ranges are from approximately 1/3 to go up to 230 feet,
1/2 that of conventional centrifugal pumps in the same temperatures to 350 F, pit
service due to the smooth depths to 26 feet and up to
laminar flow generated 3,000 gpm. Other features
by this design. Pump include: semiopen impeller,
design is capable of being external adjustment, standard
operated indefinitely with NEMA C face motor, cast iron, 316 SS or Alloy 20
zero process fluid. The construction. Series 700 sewage ejector pump
low radial and axial loads applications include industrial wastes, sanitary wastes,
generated by the disk process wastes, rendering wastes and pollution control.
rotor result in extended Heads are up to 100 feet, pit depths to 26 feet and up to
pump life. 1,500 gpm. Pump is cast iron construction.
Tesla Disk Pumps Vertiflo Pump Company

870-444-5155 513-530-0888
sales@tesladiskpumps.com sales@vertiflopump.com
tesladiskpumps.com vertiflopump.com

where the
community comes to connect

Learn, explore, network, grow professionally,
and strengthen your connection to the water
community at WEFTEC 2021.
October 16–20 I Conference

October 18–20 I Exhibition
#WEFTEC McCormick Place, Chicago, IL
November 16–18 I Online
In Person + Online REGISTER NOW at weftec.org

SAFETY
Why a
User’s Most
Important
Tool Is Safety
Tips and tricks for maintaining
safety in any work environment.
SEAN SILVEY | Fluke Corporation

IMAGE 1: Safety is more than a process, it is a
culture. (Images courtesy of Fluke)
Electricians and technicians know the Pettinger suggests taking time during shift
power of electricity, but safety procedures startup meetings to discuss potential risks
can sometimes soften under day-to-day and how to mitigate them.
3
workloads. To make sure everyone follows
appropriate safety practices, management Think Long Term
and workers need to communicate At many companies, new initiatives
effectively about safety, get employees can start strong but then lose momentum IMAGE 2: Tools that send data outside the arc flash
engaged in safety programs, and think and get ignored. To build a culture of safety, zone increase safety.
strategically about the long-term safety users need to think in both the short and
culture of their companies. Safety culture long term. When starting a new initiative,
expert Chuck Pettinger of Predictive set short-term goals so more progress is
Solutions has found three key changes that being made. Individual employees will feel
companies can make to build a successful like they can make more of an impact and
culture of safety. management can track what changes have
1
begun. Once people see the value of the
Communicate new process, it becomes a long-term, self-
Effective safety communication can sustaining part of the safety culture.
take many forms, including goal setting
and incentive programs. Pettinger suggests Safety Commitment Checklist
concentrating on positive metrics; focusing Safety culture requires a commitment IMAGE 3: Using an electrical tester, users can make
measurements easier and safer without needing to
on accidents and injuries “drives a lot of from everyone—from management to line touch live wires.
safety reporting underground. And it may workers—to value and maintain safety
unintentionally hurt the culture.” Instead, throughout the operation. This checklist the job is crucial—Class 2 electrical gloves
track the quality of safety inspections can help users avoid losing the original are not necessary if a user never gets into
or how many employees participate in a intent of essential safety standards. equipment over 480 volts, for example.
safety initiative. People are generally more Take the time to put on the proper Thick gloves can reduce dexterity, which
motivated by trying to improve something personal protection equipment (PPE) for may cause users to drop a tool or a test lead
rather than trying to avoid or reduce the job—follow the table method to see when working with an energized panel.
something—like injuries. what level of gear is needed based on the In addition to choosing the right PPE,
2
National Fire Protection Association (NFPA) select handheld test tools are designed
Make It Personal 70E Standard for Electrical Safety in the to be easier to operate with heavy gloves.
Making safety an individual Workplace. Remember that wearing PPE It is also possible to reduce the amount
responsibility helps keep it top of mind rated for a higher hazard level than the of PPE required in some instances by
throughout the workday. Instead of environment calls for will not necessarily equipping workers with noncontact tools,
focusing on where the previous shift left off, make users safer. Having the right PPE for such as thermal imagers, infrared (IR)

Thousands of Pumps
thermometers and wireless or remote tools
that allow workers to capture data from
outside the arc flash zone—which increases
Have Never Seized
overall safety.
Once appropriately geared up, match the
measurement category (CAT) rating of the
test tool and test leads to the work ahead,
and check that the tool and its accessories
are safe to use. Today’s safety standards
require some electrical tools to include
special high-energy fuses designed to keep
the energy generated by an electrical short Pumps fitted with
inside the fuse enclosure, protecting the
GRAPHALLOY® wear
parts survive upsets.
user from electric shock and burns. When it
is time to replace fuses, always choose the
high-energy fuses approved by the meter’s • Self-lubricating
manufacturer; cheap generic replacement • Non-galling
fuses can increase the risk of serious injury. • Won’t swell
Matching the tool to the job also means • Corrosion resistant
replacing outdated equipment. The safety • Dimensionally stable
• Improved efficiencies GRAPHITE METALLIZING
features in today’s test tools were unheard of • -400˚F to 1000˚F (-240˚C to 535˚C) CORPORATION
even a few years ago; even if “old reliable” is Yonkers, NY USA P1
still working, the new safety and test features
+1.914.968.8400 • www.GRAPHALLOY.com
can be well worth the cost of an upgrade.
Use lockout/tagout when necessary. Check 121 on index.
Follow the steps in NFPA 70E to remove power
from an electrical circuit or panel and lock
out and tag the panel or circuit so that no one
can re-energize it while work is in progress.
In situations where it is not feasible to shut
down the power, follow the Occupational
Safety and Health Administration (OSHA)
rules for qualified electricians and
technicians working on energized systems.
RELIABLE POWER
When working with live circuits, remember
the old electrician’s trick: keep one hand in
your pocket. It lessens the chance of a closed When your engine package powers your business, you
need a reliable source of power that you can depend on
circuit across your chest and through your
under the harshest of conditions. That’s why we use John
heart. Hang or rest the meter if possible; Deere PowerTech™ engines which are durable, fuel efficient,
avoid holding it in your hand to minimize and easy to maintain. They are also backed by one of the
strongest engine and equipment companies in the World.
exposure to transient charges.
Anyone who works with electricity quickly At engines, inc., we engineer solutions for pump packagers
for a variety of industries, including: water/wastewater;
develops a healthy respect for anything with chemical; oil/gas; and mining. We stand behind our
even a remote chance of being “live.” The packages with the most reliable
pressures of getting a job done on time or support structure in the business. Our
skilled staff is always available to you
getting a mission-critical piece of equipment on our 24-Hour Service Line to give
back online can result in mistakes by even you the support you need, when you
need it, wherever you are. We are
the most seasoned engineer or electrician,
your power source.
but a strong culture of safety helps every
project get done efficiently and correctly.
24-HOUR SERVICE LINE
870-268-3799
Sean Silvey is a product specialist at Fluke Jonesboro, AR | 800-562-8049 | www.enginespower.com
Corporation. For more information, visit fluke.com.
Check 124 on index.
COUPLINGS
Coupling blasters and jet-assist if needed. The

service pump is either a vertical turbine or
environments with sand and grit often
surrounding the pumps. In-hull pumps have
a centrifugal pump. There are also various cleaner environments on the outside, but
Selection for hydraulic pumps used on a dredging vessel. the environments the pumps experience on
Dredging vessel manufacturers are the inside are just as harsh. Along with the
Dredge Pumps focused on designing and manufacturing
dredges that offer high value and strong
material going through the pumps, which
act like aggressive sandblasters, there can
return on investment. To achieve this, also be large rocks, tree branches and other
Answer these 4 questions the manufacturers often partner with miscellaneous material that can impact
when specifying a pumping suppliers to bring different areas of the pumps.
system for a dredge. expertise together to arrive at an optimal
solution. This is especially true for driveline Selecting the Drive System
development for dredge pumps. After the style of dredge and pump are
DAVE OLSON | PSC Couplings determined, the driveline can be selected.
Specifying the Pumping If the dredge is in-hull, there are several
Requirements options: use a direct drive through a
It is helpful to answer several questions gearbox; use a marine transmission; or
when specifying a pumping system for use a belt drive. If the dredge is a ladder
Dredging is the removal of sediments and
a dredge. design with the pump on the ladder, the
debris from the bottom of lakes, rivers and
driveline design will require torque tubes
1
other bodies of water. Dredging is often
How deep does the dredge need with couplings on either end of the tubes
focused on maintaining or increasing the
supported by bearings, all suitable for
depth of navigation channels to ensure the to operate?
underwater usage.
safe passage of boats and ships. Dredging For shallow depths, it is most efficient to
is also performed to reduce the exposure of install a pump in the hull of the vessel. For
Ladder Dredge: Driveline
fish, wildlife and people to contaminants deeper requirements when a ladder dredge
is used, a jet-assist for the suction of the
Considerations for the Dredge Pump
and to prevent the spread of contaminants
The driveline allows mechanical power to
to bodies of water. pump may be required. Alternatively, the
be transferred from the engine or motor
The pumps on a dredging vessel are pump can be placed near the end of the
to the dredge pump. During operation, the
critical to the operation of a dredge. The ladder, so the pump does not have to work
driveline faces a harsh environment just
main pump of a dredge is a heavy-duty as hard to get the material up the ladder.
like the dredge pump. The driveline needs
2
slurry pump. The dredge also has at least
to operate under conditions with periodic
one service pump that is used for main How far does the material
shock loading, dynamically changing
pump packing, hydraulic cooling, water need to travel to reach the
misalignment, and a sandy, abrasive
processing plant?
underwater environment. In addition to
If there is a long distance between the
operating reliably in a harsh environment,
dredge and the processing plant, a second
the installation of the driveline needs to be
or third pump called a booster pump may efficient and cost effective.
be needed to help move the material to
the plant.
Coupling Selection for the Driveline
3
Disc couplings are the primary couplings
How much material is required to chosen for driving a dredge pump on a
move through the plant? ladder dredge. The nonlubricated design
This usually determines the size of the of the disc coupling does not require any
pump. The material flowing to the plant is special sealing. In addition, the use of
measured in tons per hour. corrosion-resistant materials and coatings
4
is relatively economical. The following are
What type of material is several areas considered when selecting a
being pumped? disc coupling to drive a dredge pump on a
The type of material can affect how well the ladder dredge.
material flows through the piping.
1. Torque density
IMAGE 1: Couplings used in a dredging application Challenging Operating Environment The torque density of the disc coupling is
(Image courtesy of PSC Couplings) Underwater pumps operate in wet, dirty an important factor to consider. The most

common definition of torque density is the continuous torque
rating of the coupling divided by the mass of the coupling. The
higher the torque density, the lower the coupling mass for a given
torque. With higher torque density and resulting lower mass,
the coupling causes less of a bending moment on the driveline.
This reduces vibration levels and can increase the life of
bearings and seals. Torque density is critical to ensuring the
driveline has a long, useful life and the uptime of the dredging
vessel is maximized.
2. Durability
The disc coupling must be able to handle the shock loading and
vibratory torque the driveline will experience. At the same time,
the coupling must be able to handle the dynamic misalignment
of the driveline during operation. The disc coupling must do this
while operating underwater, so proper materials and corrosion-
resistant coatings must be selected. The disc coupling also needs
to be sized appropriately. The torque rating of the disc coupling
along with the appropriate service factor are important when
selecting a coupling size.
3. Ease of installation & ease of service

Ease of installation and service of the disc couplings are also
critical aspects to consider. The first consideration is how the
disc couplings will be integrated into the torque tubes. The disc Check 132 on index.
couplings will either be welded to the tubes or attached to the
tubes with fasteners. Fasteners offer several advantages over
welding during initial installation. These advantages include
improved driveline quality with less material deformation due
to heat and less installation time. Also, a coupling installed with
fasteners is significantly easier to manage in the field if the
driveline ever needs to be serviced. It is preferred to use standard
fasteners in these applications since standard fasteners are
readily available and relatively inexpensive.
4. Cost factors
Cost is an important factor when making the driveline design and
disc coupling selections. The opportunities to improve costs can
CRITICAL
be seen in several areas such as initial coupling cost, installation
time, driveline quality and field maintenance of the driveline.
Collaborative Driveline Design & Vessel Integration

BOLTED
With new dredge applications, it is helpful for the dredge JOINTS? HEICO has the solution!
manufacturer and the disc coupling manufacturer to work
together to integrate the disc couplings into the driveline design.
This will ensure the performance, reliability, cost and all other HEICO-LOCK® HEICO-TEC®
requirements of the driveline are considered. It is important to Wedge Lock Washers Tension Nuts
analyze the driveline as an entire system since all components
Keep your equipment running! HEICO fastening
must work together seamlessly. This includes the disc couplings
systems are an easy, fast, and reliable way to reduce
as well as the other components of the driveline. maintenance and costly downtime due to dynamic
shock loads and/or high vibration environments.
Dave Olson is the president of PSC Couplings. He holds master’s degrees in

engineering and business. He may be reached at dwo@psccouplings.com. For HEICO-LOCK.US • 888.822.5661 • HICKORY, NC
more information, visit psccouplings.com.
Check 131 on index.
BACK TO BASICS
Selecting Grease for Pumping Systems

How to use the National Lubricating Grease Institute’s high-performance multiuse
grease specification for pump maintenance.
GREG MORRIS | Shell
Pumps are critical in moving fluids, slurries

or gases (compressors) in industrial plants,
municipal water and wastewater systems
and chemical processes. The compressed
or pumped fluids move from high pressure
to low pressure with the energy assist
provided by the mechanical action of the
IMAGE 1: Grease selection is more than the color of the grease. (Images courtesy of NLGI)
pump. Whether the pump is a rotating or
positive displacement pump, the goal is
the user is well-versed in lubrication. manufacturing conformance/quality and
to change mechanical energy into fluid
For example, the pump OEM may say, application performance expectations.
energy. In most cases, the prime mover is
“Lubricate with a high-quality National Since lubricating greases are
an electric motor or engine turning a shaft
Lubricating Grease Institute (NLGI) 2 manufactured by chemical reactions and
at high speed that adds energy to the fluid
lithium grease.” In any given plant, there mechanical processes, it is important to
to be moved.
may be multiple greases that are lithium ensure the finished product meets the
The bearings that support that shaft
or lithium complex thickened. But how is “a manufacturing standard for mechanical
must be lubricated to reduce friction,
high-quality NLGI 2 grease” defined? stability, oil separation and NLGI
increase efficiency and prevent wear. When
Experienced maintenance professionals consistency. The HPM specification sets
that lubricant is a grease, the lubricant
may rely on previous practice or hard- constrained limits that define expectations
also performs the critical role of sealing the
learned lessons from the trial and error that the user can rely on when buying
bearing from the ingress of contamination
school that have led to a working solution. greases that carry the HPM specification.
from particulates from the environment
Just because a grease solution has worked Performance expectations vary
or fluid from the high-pressure side of
in the past, does that guarantee future depending on the intended application
the pump.
success? Is the working solution optimal?
The NLGI recently launched a new grease NLGI High-Performance
Multiuse Grease
specification designed to provide guidance
and support in determining a level of
Manufacturing
Performance Criteria
quality and performance that maintenance Conformance
and operations staff can use to select a

grease that is fit for the purpose and Mechanical Stability Seal compatibility
instill confidence.
Load Carrying
Oil Separation Capacity
NLGI’s HPM Grease
Specification Detail
NLGI Consistency
Torque
The NLGI high-performance multiuse (HPM) Classification
IMAGE 2: NLGI’s HPM grease specification puts
the science into grease selection.
grease specification is a performance
standard for industrial applications that Water resstance
parallels NLGI’s long-running GC-LB
Which Grease Is the Right Grease? classification system introduced in the late
Corrosion Protection
Sometimes the pump OEM provides 1980s specifically for automotive chassis
guidance on grease selection. Generally, and wheel bearing lubricating greases. The IMAGE 3: Grease performance is a combination of
the language is vague and unhelpful unless HPM specification contains two broad areas: manufacturing criteria and physical properties.

Slurry and water
could contaminate
for the lubricating grease. The HPM In addition, consideration is given to the pump bearings
Outdoor pump
specification sets a baseline performance fretting protection via two other methods Pump bearings could bearings run
be exposed to intermittently
standard with respect to seal compatibility, (ASTM D7594 and D4170). corrosive throughout the
contamination winter in cold
load carrying capacity, starting torque (at LT (low temperature)—Because outside Midwestern winters
-20 C/-5 F) and the closely interdependent installations expose pumps to low-
HPM Grease
water resistance and corrosion protection. temperature startup, greases that have the
+WR +CR
To maximize efficiency and component LT endorsement have starting torque that + HL +LT
protection, the viscosity of the chosen meet or surpass bearing OEM guidance
grease’s base oil is the most important at -30 C/-22 F. These criteria reduce the
IMAGE 4: Selection process for pump
consideration. That is driven by bearing potential for bearing damage at startup due bearing grease
size, rotational speed and operating to excessive torque.
temperature. If the OEM has taken those As an industry body, the NLGI is brand-
operate intermittently. Plant operations
items into consideration, users can follow and marketer-neutral. While the NLGI
staff wishes to increase plant uptime,
its lead and find success. If the guidance is membership is made up of representatives
reduce maintenance spend and simplify
vague or specific operating conditions are from grease manufacturers and marketers,
lubrication tasks. Based on this scenario,
difficult, users may have to look deeper to it has additive and raw material suppliers
what should the operations staff do? The
find the best solution. among its members that bring balance
selection process might look like this.
and perspective in many cases. The HPM
Once the maintenance staff identifies
HPM Enhancements for Various specification process was inclusive of
the potential performance challenges,
Operating Conditions these membership classes. Marketing and
the HPM basic grease is a good choice.
Again, users can consult the NLGI HPM manufacturers include major integrated
However, a better choice would be to
specification to provide guidance. The HPM oil companies as well as specialty grease
pick a grease that provides performance
specification includes endorsements for companies and third-party manufacturers.
even when exposed to corrosive process
enhanced performance that may apply It was mutually agreed that the HPM
chemicals (HPM + CR) and excessive water
to specific pump situations—corrosive specification should be challenging but
(HPM + WR). Considering the pumps may
media, excessive water ingress potential, achievable, setting a common performance
face cold temperatures at startup, a low-
vibration or extreme temperatures. The expectation that gives guidance to the end
temperature grease may be a wise choice
endorsements are: user. The process involved several iterations
(HPM + LT). By choosing to reference the
WR (water resistance)—In order among the NLGI members and consultants
NLGI HPM specification, base performance
for a lubricating grease to meet these to establish the performance limits and
is established. Additional endorsements
endorsement criteria, the water resistance acceptance criteria.
for CR, WR and LT will allow the staff to
must be measurably better in standard Grease selection may include many
choose one product that can mitigate all
American Society for Testing and Materials facets—brand, value, availability and local
of its performance hurdles and simplify its
(ASTM) tests such as water washout (ASTM service, for example. Sales and marketing
lubrication routine by consolidating to one
D1264) and water spray-off (ASTM D4049) materials from various sources can be
product for all of the pumps.
than the requirements of the baseline confusing or even overwhelming. The
Protecting pump components, reducing
HPM specification. HPM specification is intended to provide a
operational expense and simplifying grease
CR (corrosion resistance)—Similarly, common performance expectation for the
selection are all worthy and attainable
the CR endorsement builds on the HPM end user that provides a level of confidence
goals. Using the NLGI HPM grease
base requirement, and then places that the product will perform in a specific
specification helps users reach those goals.
additional performance requirements for pump application. The other criteria can
By consulting a lubricant provider and
greases when exposed to corrosive media help to narrow down a user’s product
challenging them to provide quality and
such as seawater or salt solutions via selection and purchase decision.
performance that meets the NLGI HPM
combined static and dynamic ASTM tests standard, grease users can set and exceed
(ASTM D6138). Real World Example Using
expectations when selecting greases for
HL (heavy load)—Some pump HPM Grease Specification lubricating their systems.
installations may be exposed to vibration A water treatment facility has multiple
and dynamic loading from adjacent centrifugal pumps that move water,
equipment. The HL endorsement is handling corrosive treatment chemicals Greg Morris is the Americas grease product
application specialist for Shell. He has a Bachelor of
intended to certify greases that have and waste sludge. The facility is in Science in chemistry from West Virginia University
enhanced load carrying capacity as the Chicago area where the pumps and 30 years of industry experience. He currently sits
illustrated by performance under extreme are in-service both inside and outside, on the board of directors of the NLGI, serving on the
research and education committees and participates
pressure (ASTM D2596 and D5706) exposed to the elements. The sludge in the technical committee. For more information, visit
and wear resistance (ASTM D2266). pumps have redundancy built-in, so they bit.ly/hpm-pumps.
EFFICIENCY 101
How to Achieve Pump Efficiency

A look into the testing considerations when selecting a pump for hydronic applications.
ALAN JONES | Xylem
In a world filled with so many choices, it is

not surprising that the decision on how to
maximize energy savings on a new project
or retrofit is not an easy one.
There are important considerations when
evaluating published pump performance
and different testing options to achieve
performance levels acceptable for an
application. Guarantee point efficiency,
part-load efficiencies, motor efficiencies,
drive efficiencies and control strategies
all come into play when determining the
energy required to operate a system from a
pumping standpoint.
Just like the materials of construction,
the seal type and the impeller trim have
an impact on pump performance. Even
if a performance test is requested in
accordance with Hydraulic Institute/
American National Standards Institute (HI/
IMAGE 1: Expected performance based on published curve (Images courtesy of Xylem)
ANSI) 14.6 for a specified guarantee point,
if the actual test grade is not specified
in the order/quote, the manufacturer will
likely apply the default test grade for the
intended service. It is important to review
While every project cannot justify the additional cost
the current revision of HI/ANSI 14.6 to
understand the default acceptance grades of a certified performance test, it does not mean users
per application and shaft power along with
the current grades and their associated
cannot ensure the application requirements are met.
test bands. It will be easier and more
economical for the manufacturer to comply
with requests that align with published
standards as opposed to a custom intended service or what grade they would magnitude of these variations will vary
specification developed for a specific certify to. Why is this important? Many directly with the degree of precision applied
project or user. factors influence how close to the published to manufacturing processes, the test
curve a pump will actually perform. equipment and test procedures. The higher
Pump Performance vs. According to HI, variations in the precision used in manufacturing and
Published Curve hydraulic performance are the result testing, the smaller the expected variations
A reasonable assumption is that a pump of manufacturing tolerances, testing in test results. The published curve will
would perform closely to its currently instrument fluctuations and accuracy, likely represent an average of the historical
published curve. But many curves, whether driver (motor) variation, and the inherent performance of similar units.
published in a booklet or displayed on instabilities in the pumped media near If a pump is specified as requiring
selection software, do not specify the the pump suction and discharge. The compliance to a grade higher than what

the manufacturer assumed in its published
curve, a quote from the manufacturer may
come with a trim that is different from the
published curve used to make the original
selection. In fact, if the specified duty point
falls on the maximum trim for a pump,
the manufacturer’s quote may come with
a different pump or motor than originally
specified in order to achieve the guarantee
point at the tighter performance tolerance.
This is different from a scenario where no
performance tolerance was specified, and
the pump was either not tested or was
tested to a general standard in the case
that the manufacturer was not specifically
informed about the type of application and,
therefore, standard to apply.
Even if a performance test and grade
are specified, it should be noted that many
only ensure testing of head and flow to IMAGE 2: Here, the actual performance curve is passed through the tolerance cross hairs of the guarantee
point. Efficiency is measured at the intersection of the curve with a straight line from the origin through the
that grade at the specified guarantee
guarantee point.
point. The testing standard is specific and
should be consulted to understand what
will be included in a normal test and what perform to a specified grade at a minimum ensure compliance and schedule the
must be additionally specified. Power or and all submittals should include a curve testing. Balance these short-term
efficiency may not be guaranteed without to meet that grade. If the order contains issues with the longer-term issues of
being additionally specified. Another a certified test requirement, be explicit pump performance. Understand
consideration is that some grades may have in the test specification for head, flow exactly what is needed to make the
a bilateral (positive and negative) tolerance and/or efficiency. It is up to users as the project successful and then specify the
or a unilateral (positive only) tolerance for specifiers to include this information in requirements precisely.
head and flow. the specification. As an alternative, a A good specification maximizes project
It is important to understand what tighter tolerance for head and flow can outcome and provides clear guidance
aspects of pump performance will be be specified, with a lower tolerance for on expectations to the manufacturer.
most critical for the application and efficiency. A cut and paste of old specifications
match requirements accordingly. Will the If users are concerned about overloading risks disappointment and a last-minute
pump be operated with a variable speed the motor, consider specifying a maximum scramble to make system adjustments at
drive (VSD)? Is maximum pressure or horsepower and flow range to be evaluated. commissioning.
maximum horsepower a concern? Is If users are going to be operating the
the net positive suction head available pump with a VSD, the duty point may be
▲
(NPSHa) a concern? achieved at other than the typical motor

test speed. Remember to either specify the
Ensuring Application reduced test speed or provide a guarantee
Requirements Are Met point that will fall on the constant speed Get More Info
The good news is that there are steps curve of the pump. Read more articles about
that can be taken to ensure future pumps These are all important agreements efficiency at
satisfy requirements. While every project to have upfront. It will be difficult to start pumpsandsystems.com/
tags/efficiency
cannot justify the additional cost of a adding or changing criteria once there is a
certified performance test to the tightest completed test report and the manufacturer
tolerance band on pump flow, head and is waiting for approval to ship.
efficiency, it does not mean that users A tighter performance specification Alan Jones is the director of product management,
cannot ensure that the application or additional test requirements typically global residential and CBS/HVAC Americas for
requirements are met. equate to additional costs for the pump. Xylem. He holds a Bachelor of Science in systems
engineering from the United States Military Academy
When creating a pump specification, It can also extend lead times as the at West Point and an MBA from Syracuse University.
make sure to include that the pump must manufacturer takes additional steps to For more information, visit xylem.com.
FLOW METERS
SPONSORED CONTENT
Flow Measurement
Experience in Safety-Critical
Heavy Residue Applications
Learn what factors make this technology popular in
today’s environment.
GERARD BOTTINO | Panametrics

IMAGE 1: Transit time ultrasonic flow
measurement principle (Images courtesy
of Panametrics)
Today, many refineries have been connected to the emergency shutdown lines as there is no flow restriction
upgraded or constructed with advanced (ESD). The safety logic is often one out of nor obstruction thanks to its full-bore
processing units able to refine so-called two, or two out of three, out of order to trip design.
heavy feedstock and heavy oil residue fluid the unit depending on the user- or licensor- • It is not prone to drift as the primary
to get the most profitable products out recommended setup. Some operators measurement is time.
of it. Heavy residue can be defined as the require compliance with International • There is full and actual redundancy
remaining hydrocarbon oil after distillates Electrotechnical Commission (IEC) 61508, of the measurement since each
have been removed. It is typically also known as the safety integrity level transmitter is connected to an
measured at high temperatures—above (SIL) standard. Irrespective, all operators independent pair (or pairs) of sensors
400 C or 750 F—to break the long-chain require the same safety voting logic. to the ESD, meaning the redundancy
molecules. It often contains asphaltene There are several technical options for is on the flow transmitter and the flow
and fines (particles) that are abrasive. Plus, flow measurement on these applications. sensor(s). This is unlike alternative
heavy residue is prone to clog, which is a One of them uses ultrasonic transit time technologies as when the primary
problem for operators. technology, which has gained traction over element is drifting or out of order: all
Processing units that use furnace feed the last couple of decades. the flow transmitters linked to it
lines include crude and vacuum distillation, Image 1 illustrates the transit time become irrelevant.
coker and other cracking processes. These ultrasonic flow measurement principle. It • SIL certification is typically SIL2, but
are safety-critical flow measurements. If an calculates the acoustic signal time of flight up to SIL3 with hardware failure test
operator experiences line blockage due to difference. This time is shorter when going above zero, which depends on the ESD
heavy residue clogging, there must be an with the flow (green arrow, time down). setup (like for one out of two or two out
alarm. If there is no alarm, the furnace feed The flight difference time is longer in the of three examples). Their safe failure
rate could decrease too much compared to opposite direction as it is decelerated when fraction is > 97% and their diagnostic
the furnace capacity to such an extent that going against the flow (blue arrow, time up). coverage > 94.5% for a single channel
it triggers a blast risk. This time difference is proportional to the flow meter.
The flow measurements on these lines velocity of the measured fluid, whether it is • There are low operational expenditures
are often redundant and broken down a liquid or a gas. and even more so when there are
between control (with one flow transmitter The primary measurement is about purging lines that are no longer
connected to the plant digital control time, which will determine the velocity of required.
system [DCS] for control purposes) and the fluid based on the distance between • It is easy to maintain with safe
safety with up to three flow transmitters the transducers and the angle needed to sensor (transducer) online retraction
generate this time shift. Once the velocity capability without needing to shut down
is known, it is then multiplied by the cross- the line.
sectional area of the pipe to get to the
volumetric flow as per Image 2. The technology has helped users
Why is this technology so popular in improve their process units’ safety,
critical measurement environments? There reliability and increased availability. And
IMAGE 2: Velocity multiplied by cross-sectional are many factors: more users are opting for this technology
area of pipe gets to the volumetric flow. • It is not prone to clogging the feed based on the positive outcomes it has

SPONSORED CONTENT
delivered to users who drastically reduced the absence of pressure drop. That being
their operational expenditure. said, this setup can be used on relatively
The flip side is that this solution easy-to-measure applications like cooling
represents a slightly higher initial water lines. In the example, these lines
investment than traditional technologies were safety-critical and the users were
even if the payback can be achieved in aiming to protect critical assets like
less than 12 months in some instances. compressors from unexpectedly tripping.
Also, during the turnaround, it is strongly The setup required had a fully redundant
recommended to clean up the meter line system with a safety logic of two out of
and the meter buffers so they can be three to stop the compressor.
Where: Whether customers use them or not,
restarted for another production cycle.
T = time ultrasonic flow meters have many useful
Based on successful experiences in
P = the path length diagnostics to assess performance. For
delivering positive user outcomes on these
C = the velocity of sound example, velocity of sound, signal to noise
heavy residue applications, this design
has been expanded for other challenging
of the fluid ratio, signal quality, gain, etc. Some of
applications. Some still relate to refineries V = the velocity of the fluid the diagnostics have upper and lower
with molten sulfur measurement that A i = the cross-sectional area of thresholds that when going outside the
require permanent steam heating to keep the line preset limits can trigger alarms to let the
the temperature constant and get the Q = the volumetric flow rate user know that something is not going as
sulfur to freely flow with no obstruction expected, enabling early intervention.
nor restriction, or for viscous fluid such as Equation 1
asphaltene on solvent de-asphalting units. Gerard Bottino is global flow commercial
At the opposite end of the temperature liquefied natural gas (LNG) handled at development leader and technical support at
Panametrics. He may be reached at
spectrum, one case study example is a cryogenic conditions (-160 C/-256 F) and
gerard.bottino@bakerhughes.com. For more
large install base using this solution on close to its vapor pressure point thanks to information, visit panametrics.com.
PanaFlow HT SIL Flow Meter

can help operators:
• Avoid periodic calibrations
• Reduce maintenance
• Provide accurate and reliable flow
measurements in extreme temperatures
• Reduce operational expenditure
Improve safety Scan here to learn more about

Panametrics’ Ultrasonic
in hazardous areas in-line flow meters or visit us at

Panametrics.com to learn more.
Check 116 on index.

MOTORS & DRIVES
Powering Systems at Peak Efficiency

Efficiency
With Permanent Magnet Technology
These motor systems can run at a synchronous speed,
providing improved hydraulic performance.
PAUL LUARDE & CHRIS SCHANTZ | Franklin Electric
As natural and human resources get efficiently using rare earth magnets that
stretched, the need for equipment that runs perform with no slip. This translates into
efficiently has become more critical than lower input power for the same output
ever, whatever the job. This is especially power, saving on operational costs every
true in pumping systems, where water time the motor runs. Also, lower current
management plays an essential role in means that specific components of the
various industrial, commercial, municipal system—including variable frequency IMAGE 2: When it comes to submersible
pumping systems, the overall installation features
or agricultural operations. Efficient drives (VFDs), motor cables and filters—
fewer moving parts than those required for jobs
solutions deliver positive financial benefits, might result in smaller size requirements with VLSTs.
yet system reliability—including steady and, consequently, become less costly.
operation and consistent performance—is The advancement and use of variable consumption goes toward powering water
still nonnegotiable. speed technology within the pumping and wastewater plants. Higher efficiency in
A growing solution for delivering higher industry coupled with the benefits provided pumping operations can lead to long-term
efficiency with proven reliability is a by PM motors means engineers can trust benefits and major cost savings for not only
system built around a permanent magnet that this system solution provides cost- municipalities but pump operators in any
(PM) motor. PM rotors are magnetized at all effectiveness and efficiency. industry. PM motors run with an efficiency
times due to the raw material selection and rate of about 90%.
require no electrical power, making them How Do PM Motors Perform in They run this efficiently since the
more efficient, especially at reduced speeds Submersible Applications? rotor does not need to be magnetized,
and partial loads. PM motors operate more PM motors provide benefits in submersible concentrating all the power into motor
applications. A PM motor in a submersible shaft rotation. No energy is lost due to
pump may lead to lower total cost of magnetization of the rotor, concentrating
ownership (TCO), more efficient operation, more power into motor shaft rotation.
better performance and less downtime. Because of this power concentration, PM
Consider that PM motors run with an motor systems can run at a synchronous
efficiency rate of about 90% to 94%; PM speed, providing improved hydraulic
motors deliver strong performance across performance. With no slip, the motor
a range of speeds for longer motor life speed is consistent and will not vary
and they operate with no slip. Their speed regardless of load.
is constant regardless of load, delivering According to field trial data for PM
consistent water distribution. When paired motors, typical high-duty rate systems
with a pump in submersible installations, can have a payback of one to two years.
PM motors offer high-efficiency operation Paired with a VFD, a system can optimize
and speed. performance and maximize system life
while relying on real-time monitoring,
PM Motors Deliver Peak Efficiency protection and customizable application-
According to the Environmental specific programming software as needed
IMAGE 1: Interior permanent magnet construction Protection Agency (EPA), about 30% to to cover all user requirements. These
(Images courtesy of Franklin Electric) 40% of a municipal government’s energy efficiency savings also position owners and

Monitor Vibration
Stop paying too much for reliability!
operators for the future. Energy efficiency across a broad range of
operations and infrastructure-related equipment is continuing to
be prioritized. PM motors ensure energy-saving benefits to meet
compliance considerations now and as regulations evolve. Fixed System & Network Connected Solutions.
4 or 8 accelerometer channels. 24 VDC (relay drive) switched output
Efficiency Over a Spectrum of Speeds and 4 to 20mA output for each channel. Temperature & tacho input.
VFDs are a popular electronic device used to vary the speed of a
pump. A PM motor paired with a VFD delivers energy savings and
advanced speed control. An induction motor will run at the slip
speed at its rated voltage. If a user tries to increase the speed of
an induction motor above 60 hertz (Hz), it will run in a weakened
field, thereby lowering efficiency. In contrast, PM motors have no
slip and are designed to run with a synchronous speed at their
rated voltage. This means users are not compromising speed
for efficiency. When running a PM motor with a VFD, users can
enhance and expand the pump envelope by gaining optimized
efficiency. Last but not least, when a pumping system runs with
PM motors, users can experience a flatter efficiency curve over a
larger range of horsepower (hp), allowing users to cover various Smart Vibration Monitors
ranges without needing to stock dozens of different motors. This TPI 9034 & 9038
can reduce inventory, overhead and costs. Starting at $995.00
Noise Reduction & More

PM motor systems also offer maintenance advantages and noise-
800-368-5719 testproductsintl.com
reduction benefits, along with cost savings in installation. When it Check 130 on index.
comes to submersible pumping systems, the overall installation
features fewer moving parts than those required for jobs with
vertical lineshaft turbine systems (VLSTs). Having fewer parts can We pioneer motion
lead to a smaller overall size. This may save owners on installation

time, shipping expenses and other costs. Schaeffler X-life ®
PM motors used in submersible applications offer more silent Angular Contact Ball Bearings
operation and reduce noise pollution. Environmental or natural
damage is also less of a concern with submersible motors since
they are protected underground and away from heavy equipment,
lightning and other potential hazards.
One final, often overlooked, benefit is the ability of PM motors
to work in complex applications where submersible pumps
are preferred. For example, if a user is installing a pump in a
misaligned well, a submersible pump is typically the better
solution, thought it will experience wear, tear and reduced
longevity. Does a user need high flow from a reduced diameter
borehole? Submersibles are typically operated at higher speeds
since the pump and motor are close-coupled, enabling them to
move more water with a slimmer diameter pump. This changes
the pump size and, therefore, can offer the opportunity to drill
a smaller borehole for the installation of the smaller diameter
Featuring our exclusive X-life seal of quality
pump and motor.
that delivers up to 30% higher dynamic load
rating, as much as 50% longer rating life,
and up to 10% less friction vs. conventional
Paul Luarde is a senior applications engineer at Franklin Electric. He can be bearings.
reached at pluarde@fele.com.
Better performance. Better reliability.
Chris Schantz is the global director of vertical pumping systems at Franklin Better bearing.
Electric. He can be reached at cschantz@fele.com. For more information, visit
www.schaeffler.us
franklinwater.com or franklinengineered.com. ©2021
Check 129 on index.
SEALING SENSE
The Benefits
of Split Seals
The newest generation of split
seals offers cost savings, self-
alignment and eliminates need
for equipment disassembly.
STEVEN BULLEN | FSA member

IMAGE 1: USS Nautilus during initial sea trials (Image courtesy of Fluid Sealing Association)
Sealing device maintenance on large

rotating equipment, such as large pumps,
can be a time-consuming and costly
It should be noted that properly installed
exercise. As asset owners, maintainers and
operators, users want to find out if using and applied split seals are known to operate
split seals can enable their teams to spend
less time on maintaining equipment and
leak-free for more than 10 years.
sealing devices, and if they can help to
reduce operating costs, increase equipment
availability and maximize productivity. For
some applications, completely removing of the rotating shaft and the equipment and accurate setting of the split
the equipment shaft was not possible, housing. Being split, the seals can be components by the installer now happens
and so packing was historically the only installed around the shaft as opposed automatically within these modern designs.
sealing device available that could facilitate to being slid onto the shaft during Split mechanical seals are available for
on-site changeouts. equipment assembly. shaft diameters from 1 inch (25 millimeters
In split mechanical seals, all the parts Split mechanical seals were first [mm]) up to 36 inches (915 mm), and with
are split into at least two halves. Like used to seal submarine main propulsion the capability to seal pressures from slight
traditional nonsplit mechanical seals, they shafts back in 1954. It was some time vacuum to 450 pounds per square inch
are applied on rotating equipment, such later, around 1986, when split seals were (psi) (31 Bar), there are many available
as pumps, mixers and agitators. Like other introduced to the process industries as a applications. The materials of construction
mechanical seals, they seal the interface standard, off-the-shelf available rotating are where some limitations may apply
shaft sealing technology. when comparing split mechanical seals to
Since the first-generation split seal cartridge seals.
was introduced, many technological Most noticeable is that the elastomers,
improvements have been made and which are often custom moldings, are
integrated into the latest generation of split typically only offered in fluoroelastomer
seals. These improvements have greatly (FKM), ethylene propylene diene monomer
expanded the window of operation and (EPDM) and tetrafluoroethylene propylene
application of split seals. (FEPM). Face materials are typically limited
The current generation of split to carbon and variants thereof, along with
mechanical seals is comparable in silicon carbides.
performance to cartridge-type mechanical The toughness and density of tungsten
seals. The newest split mechanical seals carbide makes it a great choice for arduous
are self-aligning and installed by simply duties but a poor choice for split seals due
IMAGE 2: Split seal mounting on the undamaged
fastening subassembly halves together to the splitting methods and the rotational
portion of a packing sleeve (Image courtesy of Fluid around the shaft and bolting to the mass separating the split components
Sealing Association) equipment. The need for measurements during rotation.

IMAGE 3: Fully split rotary and stationary assemblies (Image courtesy of A.W. Chesterton) IMAGE 4: Split seal section (Image courtesy of
John Crane)
per minute (mm/min) for the initial 48 to the need for packing adjustments as well
72 operating hours, as a general guide. This as packing gland leakage and associated
initial leakage typically subsides or stops cleanup costs.
completely beyond 200 hours as the split Most split mechanical seals are designed
components go through various cycles of to seal outside of the stuffing box. For the
temperature, pressure and vibration. packing user looking to convert, this means
The single biggest benefit of using split there may even be the opportunity to
seals is that there is no need for equipment switch to split seals without replacing the
disassembly. Split seals eliminate the need packing sleeve.
for removing anything from the pump Split seals can be used on large pumps
except the seal. that pump water-based fluids and can
As split mechanical seals can be be used in applications in a variety of
installed in place—and typically by one industries including power generation,
or two installers—without removing the chemical and water processing, pulp and
pump, motor or coupling, they simplify the paper, desalination and more.
repair process and eliminate the associated
costs with typical solid seal replacement We invite your
or replacement of a worn packing sleeve. suggestions for
article topics as
IMAGE 4: Split seal during installation
The benefit increases with the size of the
well as questions
(Image courtesy of Flowserve) equipment. While there may not be a on sealing issues
sizeable benefit to using split seals on small so we can better respond to the needs of
Leakage is often a concern for pumps, the savings start to add up with the industry. Please direct your suggestions
operators considering split seals. It should increasing shaft sizes. and questions to sealingsensequestions@
be noted that properly installed and For single-stage centrifugal pumps, fluidsealing.com.
applied split seals are known to operate a positive return on investment (ROI)
leak-free for more than 10 years. The typically starts at shaft sizes greater than
splitting of mechanical seals into halves 2.5 inches/65 mm. However, on specialty
generates a multitude of leak paths equipment, difficult to disassemble and
within the seal that are sealed by static double-ended pumps, the ROI starts at
secondary sealing elements. As such, there even smaller shaft sizes. There are some Steven Bullen is the product line director line
is a greater risk of static joint leakage and, important additional cost savings that director for A.W. Chesterton. Bullen has worked
as a result, split mechanical seals are not users can achieve by installing split in the rotating equipment and sealing industry for
over 20 years, holding positions in design and test
recommended for hazardous services. seals on rotating equipment if it is engineering, production engineering, application
Over the years, there have been various currently packed. engineering, sales management and product
opinions regarding the startup leakage management. He has served as the divisional
Installing split seals will eliminate
chairman with the European Sealing Association
phenomena of split seals, wherein the seal sleeve wear and associated maintenance and now also serves as a board member with the
may leak at up to 1 drop/shaft millimeters interventions and costs, and can eliminate Fluid Sealing Association.
HI PUMP FAQS
Friction Loss in Pump Bearings & How

Viscosity Affects Pump Performance
HYDRAULIC INSTITUTE
How is friction loss in pump

▲
bearings calculated?
The friction will vary with the type of

pump and bearings installed. Considering
vertically suspended pumps, catalog data IMAGE 1: How head, efficiency and power characteristics typically change from operation with water to
published by the manufacturer is based pumping a highly viscous liquid (Image courtesy of Hydraulic Institute)
on the bowl assembly, not the complete
configured pump. In this case, the inlet motors, right-angle gear drives or
case bell and the outlet adapter have to pump bearing pots supplied with thrust CH = Hvis / HW ; CQ = Qvis / QW ;
be considered along with the column head bearings—bearing friction loss will vary Cƞ = ƞvis / ƞW
losses. Additional power losses to consider with the design and bearing type used.
are at the line shaft bearings, thrust For the case of a single-row angular Equation 2
bearing friction losses, mechanical seals, contact ball thrust bearing, losses can be
gear drives and windage. The overall pump estimated by using Equation 1. For more Effects of Liquid Viscosity on Performance.”
efficiency will be less than the published information, refer to ANSI/HI standard As detailed in the standard, the curves
bowl efficiency due to these losses. 14.3 “Rotodynamic Pumps for Design and for head and efficiency for viscous liquids
When considering the additional bearing Application” at pumps.org/standards. (vis) are estimated from the head, flow
losses, friction losses in bearing spiders and and efficiency measured with water (W) by
enclosing-tube spiders, which support the How much does viscosity applying the correction factors CH, CQ and
▲
line-shaft bearing bushings and enclosing affect pump performance? Cƞ, respectively (Equation 2).
tube, respectively, and transmit the radial An updated version of the standard will
forces from the bearing bushings to the Viscosity will affect positive displacement be published in 2021. In preparation for
outer column vary for different pump and rotodynamic pumps differently. In publication, the committee found the new
manufacturers. These losses have to be positive displacement pumps, higher data sources to be within the uncertainty
supplied by the pump manufacturer. viscosity limits leakage (slip), increasing range of data used to develop the empirical
The manufacturer will also have to the displacement volume and volumetric correction factors. HI continues to seek
provide the losses for vertical electric efficiency. However, there will be friction data on viscous performance compared to
losses that will offset volumetric efficiency water test data to refine and expand the
PBL = (C × n × Fn)/100,000 gains. So, at a certain viscosity, the correction factors. Contact hitechnical@
efficiency will decrease. In general, positive pumps.org if you can support this request.
Where: displacement pumps will be affected less For more information, refer to ANSI/
PBL = thrust bearing loss in kW (hp) by viscosity than rotodynamic pumps. HI standard 9.6.7 “Rotodynamic Pumps—
C = numerical coefficient: When a liquid of high viscosity is Guideline for Effects of Liquid Viscosity on
= 0.0013 for metric units pumped by a rotodynamic pump, the Performance” at pumps.org/standards.
= 0.0075 for U.S. performance is changed in comparison
HI Pump FAQs® is produced by the Hydraulic
to performance with water, due to
customary units Institute as a service to pump users,
increased friction losses. The reduction in contractors, distributors, reps and OEMs.
N = pump speed in rpm
performance on viscous liquids may be For more information, visit pumps.org.
Fn = net pump assembly axial
estimated by applying correction factors
thrust in N (lb)
for head, rate of flow and efficiency to the
water performance as outlined in ANSI/HI
Equation 1
9.6.7 “Rotodynamic Pumps—Guideline for

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Advertiser Name RS# Page
ABB Motors&Mechanical..............................❑ 106............. 3 Homa Pump Technology ..............................❑ 104............. 9 SealRyt Corporation ...................................... ❑ 108...........11
ABEL Pumps, L.P. ............................................❑ 138...........70 Hydro, Inc. ........................................................ ❑ 101......IFC,1 TAW, Inc. ...........................................................❑ 146...........71
AE Pumps .........................................................❑ 144...........71 Inpro/Seal ......................................................... ❑ 113...........13 Tigerflow Systems, Inc. ................................ ❑ 117...........19
Arntzen Company .......................................... ❑ 147...........71 Jordan, Knauff & Company ......................... ❑ 127...........38 Titan Flow Control, Inc. ................................. ❑ 122...........46
AutomationDirect.com ................................. ❑ 103.......... BC Load Controls................................................... ❑ 119...........37 Titan Manufacturing, Inc. ............................ ❑ 132...........57
Blue-White Industries Ltd ............................ ❑ 112...........23 Load Controls...................................................❑ 140...........70 TPI ......................................................................❑ 130...........65
Boerger Pumps LLC........................................❑ 123...........46 Magnatex Pumps............................................ ❑ 141...........71 Tuf-Lok International .................................... ❑ 145...........71
Dan Bolen & Associates ................................ ❑ 133...........70 Marsh Bellofram ....................................................................41 United Rentals (P&S) ..................................... ❑ 107............. 7
Duramax Industrial ....................................... ❑ 126...........45 MasterBond Inc. ............................................. ❑ 135...........70 Vaughan Company ........................................ ❑ 105.........IBC
Engines, Inc ..................................................... ❑ 124...........55 MINExpo International ........................................................30 Vesco Plastics Sales .......................................❑ 136...........70
Equipump, Inc. ................................................❑ 134...........70 Motor Protection Electronics ...................... ❑ 128...........38 Wanner Engineering ...................................... ❑ 118...........25
Finish Thompson ............................................❑ 109...........21 Moving Water Industries Corp. (MWI) ...... ❑ 142...........71 Waukesha Bearings Corporation................ ❑ 114...........35
Flexaseal Engineered Seals & Systems .... ❑ 102............. 5 NTN Bearing Corp. .......................................... ❑ 125...........43 WEFTEC ....................................................................................53
FPX ............................................................................................17 Panametrics - BHGE ...................................... ❑ 116...........63 Wilkerson Instrument Co.,Inc. .................... ❑ 137...........71
Franklin Electric .............................................. ❑ 110...........33 Rotech Pumps & Systems, Inc.................... ❑ 143...........71 WorldWide Electric Corp............................... ❑ 115...........29
Graphite Metallizing Corporation............... ❑ 121...........55 RWN Pump & Fabrication.............................❑ 139...........71 Zoeller Pump Co..............................................❑ 120...........27
Heico Fasteners, Inc ...................................... ❑ 131...........57 Schaeffler Group USA Inc. ............................❑ 129...........65 *This ad index is furnished as a courtesy, and no responsibility is assumed
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PRODUCT SHOWCASE
Company Name RS# Page
20th Century Pumps Ltd. .............................❑ 157 ........... 49 Allied Industrial Marketing......................... ❑ 158 ............51 Thomas Pump ................................................ ❑ 169 ........... 48
AW-Lake Company ........................................❑ 162 ........... 50 Megator/Pumps 2000 America ................. ❑ 159 ........... 49 Vertiflo...............................................................❑ 165 ........... 52
Caprari S.p.A. .................................................. ❑ 150 ........... 48 METCAR............................................................ ❑ 160 ............51 Viking Pump, Inc. .......................................... ❑ 166 ............51
Cornell Pump .................................................. ❑ 154 ........... 50 Pioneer Motor Bearings ................................❑ 155 ........... 48 Viking Pump, Inc. ...........................................❑ 167 ............51
Des-Case Corporation ...................................❑ 151 ........... 50 Resimac Americas, Inc. ................................❑ 163 ........... 49 Viking Pump, Inc. .......................................... ❑ 168 ........... 52
ESCO Products, Inc. .......................................❑ 152 ........... 49 Schenck............................................................ ❑ 153 ........... 48 Winters Instruments .....................................❑ 161 ........... 50
Hi-Tech Seals .................................................. ❑ 156 ........... 52 Tesla Disk Pumps........................................... ❑ 164 ........... 52
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PUMP USERS MARKETPLACE
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PUMP MARKET ANALYSIS
Wall Street Pump &

Valve Industry Watch
JORDAN, KNAUFF & COMPANY
The Jordan, Knauff & Company from its pre-pandemic

(JKC) Valve Stock Index was up level in February 2020.
56% over the last 12 months, and Job gains occurred in IMAGE 1: Stock Indices from July 1, 2020, to June 30, 2021. Local currency
converted to USD using historical spot rates. The JKC Pump and Valve Stock Indices
the broader S&P 500 index was up leisure and hospitality, include a select list of publicly traded companies involved in the pump and valve
37.9%. The JKC pump stock index public and private industries, weighted by market capitalization. Source: Capital IQ and JKC research.
rose 60.2% for the same period.1 education, professional
The Institute for Supply and business services, retail trade (HGLs) projects and one petroleum
Reference
Management’s Purchasing and other services. product project. 1. The S&P Return
Managers Index (PMI) decreased Fossil fuels (petroleum, natural Of the 19 projects, 10 projects figures are
slightly in June to 60.6% from gas and coal) accounted for 79% are new pipelines, seven projects provided by
61.2%. At 92.1%, the Price Index of total U.S. energy consumption are expansions or extensions of Capital IQ.
was the highest since 1979, passing last year. About 21% of U.S. existing systems and two projects
the peak in commodities in 2008. energy consumption in 2020 came are conversions of the commodity Jordan, Knauff
& Company is an
The Production Index rose 2.3 points from nonfossil fuel sources such carried on the pipeline. In 2020, 24 investment bank
to 60.8% as wait times for deliveries as renewables and nuclear, the petroleum liquids pipeline projects based in Chicago
came down and the Supplier Index highest share since the early 1900s. were completed. that provides
Renewable energy consumption merger and
fell to 75.1% from 78.8% in May. On Wall Street, the Dow Jones
acquisition advisory
New orders remained strong at 66%. increased to a record high of 11.6 Industrial Average fell 0.1% while services to the
The Employment Index dropped quads. Increases in consumption the S&P 500 Index and NASDAQ pump, valve
one point to fall below the 50% of renewables used for electricity Composite rose 2.2% and 5.5%, and filtration
industries. Please
level. Labor remains a challenge generation, including wind and solar respectively, in the month visit jordanknauff.
across the supply chain, slowing energy, were partially offset by of June. com for further
down suppliers or preventing declines in biofuel consumption in For the second quarter of information. Jordan,
manufacturers from running at the transportation sector. the year, the Dow, the S&P 500 Knauff & Company
is a member of
full capacity. So far in 2021, two petroleum and the NASDAQ grew 8.2%, 4.6% FINRA.
The Bureau of Labor Statistics liquids pipeline projects have been and 9.5% respectively. Vaccinations
reported total nonfarm payroll completed and 17 more projects and government stimulus These materials were
employment rose by 850,000 in have been announced or are under supported the economy in its prepared for informa-
tional purposes from
June, following increases of 583,000 construction, according to the U.S. recovery from the COVID-19 sources that are be-
Energy Information Administration. lieved to be reliable but
in May and 269,000 in April. pandemic in the first half of the which could change
Employment is up by 15.6 million That total includes 12 crude oil year. An uptick in inflation has without notice. Jordan,
Knauff & Company and
since April 2020 but is down 4.4% projects, six hydrocarbon gas liquids been a concern for investors. Pumps & Systems shall
not in any way be lia-
ble 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 informa-
tion 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
IMAGE 2: U.S. energy consumption and rig counts Source: U.S. IMAGE 3: U.S. PMI and manufacturing shipments Source:
investment offering or
Energy Information Administration and Baker Hughes Inc. Institute for Supply Management Manufacturing Report on deployment of capital.
Business and U.S. Census Bureau

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AU G U S T 2 0 21

The Leading Resource for Pump Users Worldwide

From field to finishing, Hydro's team of pump experts provides comprehensive

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Worldwide Service Centers l 800.223.7867 l hydroinc.com

The Pumps & Systems team had a

Managing Editor Drew Champlin PUBLISHER: Matthew G. Conroy

Pumps & Systems P.O. Box 530067

2 PUMPS & SYSTEMS AUGUST 2021

Increases safety for

Smart. Safe. Productive.

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2 FROM THE EDITOR

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Flexaseal’s HPCS is a true high pressure bellows

EDGE WELDED BELLOWS TECHNOLOGY eliminates the

EXCLUSIVE TRIPLE-PLY, HIGH PRESSURE DESIGN

API 682 4th ED. COMPLIANT, HEAVY DUTY DESIGN can

FLEXdrive TORSIONAL DRIVE SYSTEM eliminates

STEALTHtm PROACTIVE HEALTH TECHNOLOGY enables

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Responsive Customer Service

Designed, Manufactured, and www.flexaseal.com

U A S SY Makes a Big Difference

O D 26 Avoid Premature Bearing

DEPARTMENTS 28 The Impact of Water on

EDITORIAL ADVISORY BOARD

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Visit UnitedRentals.com/PSM to browse the largest fleet in the industry.

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NEW HIRES, PROMOTIONS & RECOGNITIONS

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AROUND THE INDUSTRY

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OF REDUCING WATER USAGE

A New Facility, a New Journey

My June 2021 article talked about taking

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Inpro/Seal® didn’t just invent the Bearing

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Don’t Overlook This Basic Advice,

Last month, we discussed that the system

14 PUMPS & SYSTEMS AUGUST 2021

Percent Thrust and or Reliability

you where the recommended minimum this misunderstanding about centrifugal

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Register at: pumpsandsystems.com/webinars

The Hydraulic Performance of

Pump engineers are familiar with the

IMAGE 3: Swept Key Tips for Using

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The Small Adjustment

ALEX GUNKEL | Schaeffler Group USA Inc.

20 PUMPS & SYSTEMS AUGUST 2021

at 50% BEP, it should be noted that the

the UA pair deﬂected less than both the

Use your smartphone camera to scan the

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