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     APRIL 2016

    PUMPSANDSYSTEMS.COM

    The Leading Magazine for Pump Users Worldwide

    SYSTEMS

    Strategies for advancing today’soil & gas facilities 4 WAYS TO PREVENT

    Seal Failure

    TAKE THE Valve

    Maintenance Test

    ON PAGE 70

    TRADE SHOW PREVIEW:Houston’s OTC 2016

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    April  2016  | Pumps & Systems

     

    Just a couple of weeks ago, oil

    prices were continuing to make

    headlines—in a good way. As this April

    issue of Pumps & Systems went to the

    printer, the price of U.S. crude was right

    around $38 a barrel. A few days earlier

    it had reached its highest price of

    $38.51 a barrel since Dec. 9, 2015. Brent

    crude futures were around $40 a barrel

    after reaching a high of $41.48 over the

    same time.

    Oil prices are still a far cry from the

    $70-a-barrel range a year ago, making

    the need to increase effi ciencies and

    save money as important as ever in the

    oil and gas industry. e cover series in

    this issue of Pumps & Systems focuses

    on operational advancements in refineries.

    e series begins with an article on page 46 about how a preventive maintenance

    program can reduce costs and increase reliability at refineries, while the benefits of

    monitoring technology at these facilities are explained starting on page 54. An article on

    page 50 showcases an example of a Texas refinery improving its water management with

    reverse osmosis units and by reusing 100 percent of its water on-site.

     An article about the benefits encountered at a Midwest refinery from using graphite-

    metal alloy bearings begins on page 52, and the series concludes with an article on page

    58 about a Southwest pipeline station and tank farm addressing vibration-related issues.

    is issue’s special section dives into the topic of sealing challenges with four

    educational articles. Check out the benefits of using dry gas seals to pump liquids on

    page 32, followed by four ways to prevent seal failure starting on page 36. An article

    on page 40 looks at how the right bearings and seals help in harsh conditions, while

    advancements in seal ring and face materials are discussed starting on page 42.In addition, anyone who has questioned the right time for performing maintenance

    on control valves must check out the article by Singer Valve on page 68. e article

    concludes with a matrix and scorecard that can help keep your equipment operating at

    optimal performance.

     At Pumps & Systems, we strive to be your primary go-to source for information

    pertinent to individuals working in numerous facets of the industries we cover. With

    every issue, we are committed to delivering informative articles that can help end users

    with their jobs on a daily basis.

    We have an open-door policy for suggestions, ideas and comments, so please email me

    at [email protected].

    Sincerely,

     PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicalspostage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves theright to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US andpossessions $5, all other countries $15 US funds (via air mail). Call 630-739-0900 inside or outside the U.S. POSTMASTER: Send changes of address andform 3579 to Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253. ©2016 Cahaba Media Group, Inc. No part of this publication may be reproducedwithout the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements,articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. Theopinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makesno representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS:We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media Group, Inc.,

    permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are freeto publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 24, Issue 4.

    Pumps & Systems is a member of the following organizations:

    EDITORIAL

    SENIOR EDITOR, PUMPS DIVISION: Alecia [email protected] • 205-278-2843

    SENIOR TECHNICAL EDITOR: Mike [email protected]

    MANAGING EDITOR: Amelia [email protected]

    MANAGING EDITOR: Martin [email protected] • 205-278-2826

    MANAGING EDITOR: Savanna [email protected] • 205-278-2839

    CONTRIBUTING EDITORS: Lev Nelik,Ray Hardee, Jim Elsey

    CREATIVE SERVICES

    DIGITAL PROJECT MANAGER: Greg Ragsdale

    ART DIRECTORS: Melanie Magee, Elizabeth Chick

    WEB DEVELOPER: Greg Caudle

    DIGITAL COMMUNITY MANAGER: Amy CashPRINT ADVERTISING TRAFFIC: Lisa [email protected] • 205-212-9402

    CIRCULATION

    AUDIENCE DEVELOPMENT MANAGER: Lori [email protected] • 205-278-2840

    ADVERTISING

    NATIONAL SALES MANAGER: Derrell [email protected] • 205-345-0784

    ACCOUNT EXECUTIVES:

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

    Mark Goins

    [email protected] • 205-345-6414Garrick [email protected] • 205-212-9406

    MARKETING ASSOCIATES:

    Ashley [email protected] • 205-561-2600

    Sonya [email protected] • 205-314-8276

     PUBLISHER: Walter B. Evans Jr.

    VP OF SALES: Greg Meineke

    CREATIVE DIRECTOR: Terri J. GrayCONTROLLER: Brandon Whittemore

    P.O. Box 530067Birmingham, AL 35253

    EDITORIAL & PRODUCTION

    1900 28th Avenue South, Suite 200Birmingham, AL 35209205-212-9402

    ADVERTISING SALES

    2126 McFarland Blvd. East, Suite ATuscaloosa, AL 35404205-345-0784

     Managing Editor  

     Martin J. Reed 

    [email protected]

    FROM THE EDITOR

    Pumps & Systems Managing Editor Martin Reed,Senior Editor Alecia Archibald, Managing EditorAmelia Messamore and Vice President of Sales GregMeineke attend the Hydraulic Institute’s annualconference in Tucson, Arizona, in February.

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    April  2016  | Pumps & Systems

    This issue APRIL

    46  IMPROVE ASSET PERFORMANCE WITH INNOVATIVE SERVICES  By Harald Großmann, Sulzer

    Preventive maintenance programs at refineries can result in reduced costsand better reliability.

    50  TEXAS REFINERY REVAMPS WATER TREATMENT SYSTEM  By Mike Jenkins, Progressive Water Treatment

    e custom solution reduces supply and maintenance costs and provides aconsistent feedwater supply.

    52  FACILITY CHOOSES GRAPHITE-METAL ALLOY BEARINGS  By Eric Ford, Graphite Metallizing Corp.

    e materials are able to withstand dry-run conditions.

    54  SOPHISTICATED MONITORING SAVES LABOR HOURS& DOWNTIME IN REFINERIESBy Brian Phillippi, National Instruments

     An industry with aging infrastructure and increasing demands needs bettermonitoring technology.

    58  SOUTHWEST PIPELINE STATION EMPLOYS MODERN TOOLS TOIMPROVE PUMPING SYSTEM

    By Jay Marchi, ProPump Services

     Various analyses can identify problems and predict future systemvibratory responses.

    COVERS E R I E S

    2  FROM THE EDITOR

    8  NEWS

    88  PRODUCTS

    92  ADVERTISER INDEX

    92  PUMP USERS MARKETPLACE

    96  PUMP MARKET ANALYSIS

    OIL & GAS REFINERIESPUMPING PRESCRIPTIONS

    16  By Lev Nelik, Ph.D., P.E. Pumping Machinery LLC

    Letter from a Reader: Vibration Spectrum Analysis

    PUMP SYSTEM IMPROVEMENT

    20  By Ray HardeeEngineered Software Inc.

    Examine Pump, Process & ControlElements to Solve Fluid PipingSystem Problems

    COMMON PUMPING MISTAKES

    24  By Jim Elsey  Summit Pump Inc.

    Guidelines for Submergence & Air Entrainment

    INDUSTRY INSIGHTS

    30  By Mike Pemberton  Pumps & Systems

    e Future of PredictiveMaintenance

    COLUMNS

    58

    46

    ON THE COVER

    Petro Star’s North Pole Refinery processes petroleum from the Trans Alaska Pipeline and distributes diesel products across the state. (Photo © Judy

    Patrick, courtesy of Petro Star)

    Volume 24 • Number 4

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    April  2016  | Pumps & Systems

    DEPARTMENTS

    62  EFFICIENCY MATTERSCompressors Assist in PropaneTransfer Transition

    By Bill Holmes

    Blackmer

    68  MAINTENANCE MINDERSHow Reliable Is Your Control Valve Maintenance Program?

    By Mark Gimson

    Singer Valve

    72  MOTORS & DRIVESHow Power Factor & InductionMotors Can Impact theBottom Line

    By William Livoti

    WEG Electric Corporation74  SEALING SENSE

    Manage Rubber ExpansionJoints in Piping Systemsto Maximize Reliability &Effi ciency

    By Lloyd B. Aanonsen, P.E.,

    & Joshua Cocciardi

    FSA Members

    78  HI PUMP FAQS Air Pockets in a Piping System,Sealing Device Basics & Rotary

    Pumping System LeakageBy Hydraulic Institute

    S P E C I A L

    S E C T I O N

    SEALING CHALLENGES

    This issue

    THOMAS L. ANGLE, P.E., MSC, VicePresident Engineering, Hidrostal AG

    BRYAN S. BARRINGTON, MachineryEngineer, Lyondell Chemical Co.

    KERRY BASKINS, VP/GM, Milton RoyAmericas

    R. THOMAS BROWN III, President,Advanced Sealing International(ASI)

    CHRIS CALDWELL, Director ofAdvanced Collection Technology,Business Area Wastewater Solutions,Sulzer Pumps, ABS USA

    JACK CREAMER, Market SegmentManager – Pumping Equipment,

    Square D by Schneider Electric

    BOB DOMKOWSKI, BusinessDevelopment Manager – TransportPumping and Amusement Markets/Engineering Consultant, Xylem, Inc.,Water Solutions USA – Flygt

    WALT ERNDT, VP/GM, CRANE Pumps& Systems

    JOE EVANS, Ph.D., Customer &Employee Education, PumpTech, Inc.

    LARRY LEWIS, President, VantonPump and Equipment Corp.

    WILLIAM LIVOTI, BusinessDevelopment Manager/EnergyEfficiency Specialist, WEG ElectricCorporation

    TODD LOUDIN, President/CEO NorthAmerican Operations, Flowrox Inc.

    MICHAEL MICHAUD, ExecutiveDirector, Hydraulic Institute

    JOHN MALINOWSKI, Sr. ProductManager, AC Motors, Baldor ElectricCompany, A Member of theABB Group

    WILLIAM E. NEIS, P.E., President,Northeast Industrial Sales

    LEV NELIK, Ph.D., P.E., APICS,President, PumpingMachinery, LLC

    HENRY PECK, President, Geiger Pump& Equipment Company

    MARIANNE SZCZECH, Director,Global Marketing and ProductManagement, Pump Solutions Group

    SCOTT SORENSEN, Oil & GasAutomation Consultant & MarketDeveloper, Siemens Industry Sector

    ADAM STOLBERG, Executive Director,Submersible Wastewater PumpAssociation (SWPA)

    JERRY TURNER, Founder/SeniorAdvisor, Pioneer Pump

    DOUG VOLDEN, Global EngineeringDirector, John Crane

    KIRK WILSON, President, Services &Solutions, Flowserve Corporation

    JAMES WONG, Associate ProductManager – Bearing Isolator, GarlockSealing Technologies

    EDITORIAL ADVISORY BOARD

    APRIL

    PRACTICE & OPERATIONS81  SOLID FOUNDATIONS INCREASE

    ROTATING EQUIPMENT RELIABILITYBy Scott Sapita, BaseTek LLC& Thomas Hines, Chemtrade Logistics Inc.

    84  A NEW APPROACH TOPRODUCT DEVELOPMENT

      By Bill Blankemeier & Bill TaylorPeopleFlo Manufacturing

    32  USING DRY GAS SEALS TO PUMP LIQUIDS

    This unconventional solution features bonding consisting of a micro-crystalline layerthat has attributes of natural diamond.

    By Emery Johnson, EagleBurgmann

    36  4 WAYS TO PREVENT SEAL FAILURETake these precautions to maximize your investment.

    By Andrew Kalinen, Flex-A-Seal Inc.

    40  ADVANCED BEARINGS & SEALSOFFSET HARSH CONDITIONSA large petrochemical plant increasedthe service life of its equipment from sixmonths to three years.

    By Tom McDermott, SKF USA Inc.

    42  SOLVING SEALING PROBLEMS BYKEEPING FACES CLOSE & PARALLELAdvances in seal ring and face materialscan improve basic design issuesassociated with mechanical seals.

    By Mark P. Slivinski,Carbide Derivative Technologies Inc.

    84

    32

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    Motors and drives, the key components of yfacility, can be prone to a number of unse

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    8 NEWS

    April  2016  | Pumps & Systems

    BRYCE W. DAVIS

    & JEFF KOEHLER

    WATER PLANET

    LOS ANGELES (Feb. 29, 2016)

    Water Planet announcedthat Bryce W. Davis, Ph.D.,and Jeff Koehler, Ph.D.,

     joined its growing team.Davis, who possesses a

    doctorate in analytical chemistry, joined Water Planet as aresearch and development (R&D) scientist. Previously, he was aprincipal engineer at Polymer Group Incorporated, an applicationengineer for Fiberweb plc. and a materials scientist with FibeRioTechnology Corporation. Koehler is product development specialisttechnical liaison for commercialization of Water Planet’s PolyCeramembranes. Previously, Koehler was principal scientist anddirector of process development at NanoH2O Inc./LG NanoH2O, andprincipal scientist at Nanostream Inc. waterplanet.com  

    JOE ACCETTA, KALENBORN ABRESIST

    URBANA, Ind. (Feb. 26, 2016) – Joe Accetta,president of Kalenborn Abresist Corporation,has announced that he will be retiring in May

    2016. Accetta, a 1973 graduate of NorthwesternUniversity, was originally employed as vicepresident of sales in 1983 and was namedpresident in 1990. He has served in thatcapacity for 26 years. For 10 years prior to1983, Accetta was involved in the sales andAbresist product management for M.H. Detrick, an early jointventure partner in Kalenborn Abresist Corporation.  abresist.com

    CHRISTOPHER BRIDGEWATER

    CORNELL PUMP

    CLACKAMAS, Ore. (Feb. 25, 2016) – CornellPump has announced that ChristopherBridgewater has joined its team as Southwestagricultural regional manager, with

    responsibilities for irrigation, farm dewateringand manure in California, the desert Southwestand the Mountain West. He has more than 20years of experience in the industries, workingin the supply chain process from manufacturing to installation.He has spent the last nine years as a territory manager, increasingsales in his area by more than 600 percent. cornellpump.com

    JOHN TOMLJENOVIC, MIKE MURRAY & KEVIN MOLONEY

    SUMMIT PUMP INC. 

    GREEN BAY, Wis. (March 1, 2016) – John Tomljenovic is SummitPump Inc.’s newest addition as Western regional sales manager.Tomljenovic is responsible for the Western region of the U.S.,

    Western Canada and all of Mexico. He has more than 25 yearsof experience in direct sales and sales management in themechanical seal business. Mike Murray has transitioned fromdirect sales to Midwest regional manager. He has more than 30years of direct professional experience in pump sales, applicationsand troubleshooting. Kevin Moloney is the Eastern regional salesmanager and has responsibility for the Eastern U.S., Canada andportions of the Caribbean. He has more than 30 years of pump andmechanical seal experience. The regional sales managers report to

    Jim Elsey, general manager for Summit Pump.summitpump.com

    NATHAN OLDS, GRUNDFOS 

    DOWNERS GROVE, Ill. (Feb. 11, 2016) – GrundfosPumps Corporation has appointed Nathan Oldsas the vice president of Domestic BuildingServices (DBS) Trade for the U.S. In this role,Olds will manage wholesale distribution for thecompany’s heating and plumbing products. Hewill report to the DBS executive vice president,Terry Teach. us.grundfos.com

    STEVE BASCLAIN, PSG EBSRAY

    OAKBROOK TERRACE, Ill. (Feb. 10, 2016) – PSGhas appointed Steve Basclain to business

    development manager for PSG Ebsray. In thisrole, Basclain will help drive new businessopportunities for the Ebsray brand and supportthe PSG sales teams globally while directing thefunctional areas of applications engineering,customer care, contracts, product managementand aftermarket. He will report directly to John Cosgrove, generalmanager for PSG Ebsray.  psgdover.com/en/ebsray

    ANTHONY MISIAK

    & JEFF DAVIS

    TSURUMI PUMP

    GLENDALE HEIGHTS, Ill. (Feb.

    4, 2016) – Tsurumi Pumphas announced that it hasadded two new regional salesmanagers to its staff. Joiningthe management team areAnthony “Tony” Misiak andJeff Davis. Misiak joined Tsurumi as a regional sales manager inDecember 2015. Misiak will be based in Byron Center, Michigan,and he will be responsible for the Midwest region. Also joiningTsurumi as a regional sales manager is Davis, who startedhis employment in January of this year. He will overseeTsurumi’s Western region and will be based in Lake Sherwood,Missouri. tsurumipump.com

    Jeff KoehlerBryce Davis

    NEW HIRES,PROMOTIONS & RECOGNITIONS

    Nathan Olds

    Steve Basclain

    Jeff

    Davis

    Anthony

    Misiak

    Christopher

    Bridgewater

    Joe Accetta

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    AROUND

    THE INDUSTRY

    Hydraulic

    Institute

    Recognizes

    Four Industry Leaders

    PARSIPPANY, N.J.

    (Feb. 24, 2016)

    The

    Hydraulic Ins t i tute

    (HI)

    announced

    the recip ients o f several awards

    and honors during its 2016 Annual

    Conference in Tucson , Arizona. Jack

    Claxton , vice president of engineering ,

    Patterson Pump Company , received HI's

    Lifetime Ach ievement Award; Patrick

    Hogg , product manager, Nidec Motor

    Corporation ,

    was

    HI's Young Engineer

    of

    the

    Year

    award recipient ; Wil l iam

    C.

    Livoti , business development manager,

    WEG

    Electric Corporation , received the

    organization 's f irst

    PSM

    Leadership

    Award; and Paul Ruzicka , global

    COE

    residential, commercial wastewater and

    chief engineer at Xylem

    Inc.

    Applied

    Water Systems, received the 2015

    Member

    of

    the

    Year

    award. Claxton

    has

    more than 40 years of service in

    the pump industry and

    has

    been an

    instrumental

    HI

    mem ber for more

    than

    30

    years.

    Hogg has

    been involved

    with

    HI since 2013, is a member of

    10

    commit tees ,

    serves

    as a webinar

    instructor, and ho lds leadership posit ions

    on three committees. Livoti

    has

    more

    than 40 years in the pump indust ry ,

    designing, f ield testing , repairing and

    troubleshoo ting mechan ical seals ,

    compressors , motors and pump ing

    systems. The

    HI

    Board of Directors

    selected Ruzicka for his commitment to

    HI

    in leading and actively participating

    in numerous

    HI

    commit tees in the

    advancem ent of the institute's technical

    work and guiding young engineers

    within the institute's extensive technical

    organization. •

    pumps.org

    US Poll Finds 60 Percent of

    Participants Would Pay More

    for Secure W ater Service

    ALEXANDRIA,

    Va.

    (Feb. 24,

    2016)

    -

    The

    Value of Water Coa lition

    has

    released the

    results

    of

    a new nat ional po l l

    on

    publ ic

    attitudes ab out water, which found th at

    Americans

    are

    deeply concerned with

    the state

    of

    water infrastructure and

    are

    will ing to sup port efforts to invest and

    mode rnize these systems to ensure and

    ma intain reliable water and wastewater

    services. Of the part icipants , 9 5 percent

    support investm ent in water systems,

    and

    60

    percent said they would pay m ore

    for secure water. • theva/ueofwater.org

    Flex-Pro ®Peristalt ic

    Metering Pumps

    provide smooth,

    quiet

    pumping

    act ion and del iver accurate amounts of chemical

    to your

    system. Three Flex-Pro mod els are of fered, featur ing a broad range

    of

    output

    rates, electronics

    options

    and features .

    Advanced Electronics- wi th Exclusive- Built-in, patented

    Tube

    Failure

    easy access

    to controls. Detection.

    Mult iple Signal Input and Innovative, Heavy Duty Rotor : Single piece plastic

    Output (4-20mA, etc.) . rotor means no flexing and increased accuracy

    One Button Prime Mode. with no metal springs or hinges to corrode.

    Flex A Prene

    Heavy Duty Peris ta l t ic Pump Tubing

    Flex-A-Prene ®

    s

    a mult ichannel pump

    tube assembly designed by B lue-White

    exclusively for Proseries-M

    8

    and Flex-Pro•

    Peristaltic Metering Pumps . Flex-A-Prene•

    is engineered for opt imum performance,

    including up to four t imes longer

    service l ife than othe r pump

    tube assemblies.

    pumpsandsystems.com

    I

    April

    2016

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    11

    pumpsandsystems.com | Apri l 2016

    The EcoFlow Seal Flush thermal relief valve automatically and

    reliably controls seal water flow and temperature from your double

    mechanical seals for a drastic reduction in water consumption

    and significant cost savings. A simple installation reduces water

    usage and waste water treatment while boosting cost savings:

    Immediate, significant reduction in seal water consumption

    with no outside power required

    No more monitoring and manually adjusting flow

    Avoids dry runs and protects seal life

    Allows users to leave the water supply on and ensures

    water flows only when needed

    Reduces pump downtime

    Find out how this little valve creates such BIG savings,

    visit ThermOmegaTech.com/EcoFlow today.

    Little thermal

    relief valve.

    Big waterconservation

    savings.

    (877) 379-8258

     THE WORLD LEADER IN SELFACTUATED TEMPERATURE CONTROL SOLUTIONS

        C    i   r   c    l   e    1    1    9   o   n   c   a   r    d   o   r   v    i   s    i   t   p   s    f   r   e   e    i   n    f   o .   c   o   m .

    will help support community-based job creation in U.S. cities and establishnational standards for professionalsseeking to work on GI projects. This

     joint effort will support DC Water’srecently announced legal agreement toconstruct large-scale GI to help controlcombined sewer overflows in the Districtof Columbia, according to the groups.wef.org

    Private Water Players ReshapeGlobal Desalination, PoseidonEnters Top 25BOSTON (Feb. 3, 2016) – The top 25

    desalination system owners, includingboth public and private companies,added a quarter (approximately 25percent) of total capacity additionsin 2015, representing an estimated524,000 cubic meters per day, accordingto a study. Private water players tookan active role in the desalinationmarket in 2015, representing nine ofthe top 10 biggest movers by capacityadditions, according to rankingsreleased by Bluefield Research. Withthe commissioning of its Carlsbad,California, desalination plant, PoseidonResources became the first U.S.company to rank among the top 25private water owners globally,according to Bluefield Research.bluefieldresearch.com

    ISA Announces theContinuation of Beamexas its Premier StrategicPartner for CalibrationRESEARCH TRIANGLE PARK, N.C. (Feb.3, 2016) – The International Societyof Automation (ISA) announced thatBeamex, a calibration company withproducts, services and support in 80

    countries, will continue to serve asits strategic partner for calibration.Over the past several years, throughthe partnership, Beamex and ISAhave collaborated to provide ISAmembers and customers with access toBeamex’s diverse calibration resources,including publications, case studies,webinars, expert advice and more. Thisannouncement signifies that Beamexwill continue to work with ISA to co-develop informational and educationalresources. isa.org

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    12

    April  2016  | Pumps & Systems

    NEWS

    Process Pumps & Steam Turbines

    www.snm.co.jp

    Generating Power for Human Life, SNM 

    TOTAL SOLUTIONS APPROACH

    SNM is the only manufacturer in the world that produces

     API610 process pumps and API611/612 steam turbines in

    the same factory. This total solutions approach uniquelyaddresses the needs of the oil and gas industry.

    ENERGY-SAVING SOLUTIONS

    Mounting data confrms that

    energy savings are realized when

    old pumps in aging plants are

    replaced with high eciency,

    latest model pumps. At SNM our

    pump products and solutions

    address energy-savings concerns

    facing clients across the globe.

    FACTORY SALES OFFICES

    TOKYO, JAPAN

    +81-3-6737-2631

    HOUSTON, TEXAS

    +1-281-990-8594

    GLENDALE, CALIFORNIA

    +1-818-500-8165

    BANGKOK, THAILAND

    +66-2-262-0740

    HIROSHIMA, JAPAN

    +81-823-71-1111   C   i   r   c   l   e   1   1   8   o   n   c   a   r   d   o   r   v   i   s   i   t   p   s   f   r   e   e   i   n   f   o .   c   o   m .

    Recommended Practice forMotor Repair Re-Approved asANSI Standard

    ST. LOUIS (Feb. 1, 2016) – An updatededition of the only American NationalStandard for repair of motors andgenerators—ANSI/EASA AR100-2015:Recommended Practice for the Repairof Rotating Electrical Apparatus—wasrecently published for use by the repairindustry and its customers. The standarddescribes industry best practices forthe repair, rewinding and testing ofelectrical apparatus in order to maintainor enhance the energy efficiency andreliability of both alternating and directcurrent motors and generators. ANSIrequires that standards be re-approved

    at least every five years, promptingthe review and approval of the AR100-2015 edition. The revision introducednew requirements, added or tightenedperformance tolerances in several criticalareas and expanded testing procedures.The standard now includes requirementsrelating to the machining of commutatorsand slip rings, and it establishestemperature limits for the process ofremoving motor windings. Additionalperformance tolerances were addedfor balancing motors rated above 2,500rpm. Finally, testing procedures wereestablished or clarified relating to bearinginsulation, winding surge comparisonand resistance, no-load performance andvibration. ansi.org

    To have a news item considered, please

    send the information to Amelia Messamore,

    [email protected].

     

    MERGERS &

    ACQUISITIONS

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    Houston Office: 8885 Monroe Road, Houston Texas 77061 USA

    Toll Free: 1.888.405.0209 Fax: 713.956.2141

    [email protected]

    www.pumpworks610.com • twitter: @PumpWorks610

     We do it fast and we do it right.

    Most pump OEMs make you wait 30 to 50 weeks to deliver

    their API 610 compliant single and multistage pumps.

    By comparison, the PumpWorks 610 Model PWH andModel PWV standard lead times are 16 weeks or less,

    and PWM Multistage pipeline pumps are 28 weeks or less.

    In addition, all of our pumps are manufactured in the USA.

    PumpWorks 610 offers our online ePOD

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    by quickly providing you with pump selection

    and performance curves right off of our website – no log in

    required.

     At PumpWorks 610, you can count on our knowledgeable

    staff to ensure that your finished product meets or exceedsyour exact specifications.

    Why wait longer to get the pump you need when you need

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    PWH API 610 OH2Pumps Deliveredin 16 Weeks

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    delivers.

       C   i   r   c   l   e   1   0   9   o   n   c   a   r   d   o   r   v   i   s   i   t   p   s   f   r   e   e   i   n   f   o .   c   o   m

     .

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    14 NEWS

    April  2016  | Pumps & Systems

    Reliable Plant 2016 April 5 – 7, 2016Kentucky InternationalConvention CenterLouisville, Kentucky 800-597-5460 / conference.reliableplant.com

    PumpTec 2016(Advanced Training) April 6 – 7, 2016 Atlanta, Georgia770-310-0866 / pumpingmachinery.com/pump_school/pump_school.htm

    Offshore Technology ConferenceMay 2 – 5, 2016NRG ParkHouston, Texas972-952-9494 / 2016.otcnet.org 

    2016 EASA ConventionJune 12 – 14, 2016Metro Toronto Convention CentreToronto, Ontario314-993-2220 / easa.com/convention

    National Fire Protection AssociationConference & ExpoJune 13 – 16, 2016Mandalay Bay Convention CenterLas Vegas, Nevada800-344-3555nfpa.org/training/conferences/conference

    American Water Works AssociationAnnual Conference & ExhibitionJune 19 – 22, 2016McCormick PlaceChicago, Illinois

    800-926-7337 / awwa.org 

    World Nuclear ExhibitionJune 28 – 30, 2016Paris Expo - Le Bourget, Hall 2BParis, France33 147 56 65 37 / world-nuclear-exhibition.com

    INDOWATER 2016July 20 – 22, 2016Grand City ConvexSurabaya (East Java), Indonesia+49-40-3999905-0 / indowater.com

    (Image Courtesy of Corp orate Event Images)

    The Offshore Technology

    Conference (OTC) 2016,

    the offshore energy industry’s

    premier annual event, will

    take place May 2-5 at NRG

    Park, formerly Reliant Park,in Houston, Texas. is year’s

    theme is “Endless Innovation.”

    Sponsored by 13 nonprofit

    technical societies involved

    in the energy business, OTC

    2016 is an opportunity to gain

    technical knowledge, learn

    more about best practices and

    see new products and services.

    More than 90,000

    professionals—including

    industry leaders, investors andentrepreneurs—from more

    than 130 countries are

    expected to attend. is year’s

    event is expected to include

    more than 2,100 exhibitors

    from 45 countries and 18

    international pavilions.

    OTC offers learning

    opportunities that include a

    technical program featuring

    global experts and topics

    spanning risk management,

    new and emerging markets, and

    the operation of aging fields

    and hardware.

    e event will offer training

    courses on deepwater riser

    engineering, marine broadbandtechnologies and petroleum

    geology for engineers. Courses

    will be held at the George R.

    Brown Convention Center on

    the days before and the day

    after the conference.

    Other events and activities

    at OTC 2016 include the

    Distinguished Achievement

     Awards Luncheon at the NRG

    Center on May 3.

    e second d5 conference—an OTC event designed to spark

    creativity and innovation in

    the industry—will be at Rice

    University on May 6. Speakers

    will include Helen Greine,

    co-founder of iRobot and CEO

    of CyPhyWorks; Ram Shenoy,

    former chief technolog y offi cer

    at ConocoPhillips; and Gindi

     Vincent, an author, speaker and

    counsel at ExxonMobil.

    For registration or more

    information about OTC 2016,

    call 972-952-9494 or visit

    otcnet.org.

    Offshore TechnologyConference

    PreviewMay 2-5, 2016NRG ParkHouston, Texas

    Exhibition Hours

      Monday, May 29 a.m. to 5:30 p.m.

      Tuesday, May 39 a.m. to 5:30 p.m.

      Wednesday, May 49 a.m. to 5:30 p.m.

      Thursday, May 59 a.m. to 2 p.m.

    EVENTS

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    Letter from a Reader:Vibration Spectrum Analysis

    Regarding the vibration

    spectrum on page 12 of

    the February 2016 issue

    of Pumps & Systems (“Using Pump

    Effi ciency Monitoring to Make

    Faster Decisions,” Figure 1), your

    question of what the spectrum is

    showing needs more information

    to enable an accurate answer:

    • Where is the sensor located?

    • What kind of pump?

    • What is the orientation of the

    sensor? X, Y or Z axis?

    • Is the data averaged, peak hold

    or instantaneous?

    • Is the pump speed constant

    or changing?

    • Is the flow steady or changing?• How many vanes are on

    the impeller?

    • Are the units root mean square,

    peak or other?

    • What is the power required by

    the pump?

    • Is this a Category I or II pump

    per International Standards

    Organization (ISO) 10816-7?

    Making some assumptions

    about the data, an unbalance

    problem appears to be present. It

    is not misalignment or cavitation.

    However, if you look at the

    spectrum, there is a slight peak

     just above one time per revolution

    at maybe 70 hertz (Hz). is could

    be resonance. If so, the running

    speed is less than 20 percent away

    from this natural frequency, and

    the response could be amplified by

    this resonance. While unbalance

    is indicated, it may be a resonance

    problem, and balancing is not, in

    my opinion, a permanent fix.

     Assuming this is a small pump,

     judging by the operating speed, the

    amplitude is probably acceptableper ISO 10816-7. e overall level

    of vibration is probably less than

    0.098 in/s-RMS, which is the Zone

     A/B boundary for new machines.

    But if the small peak at 70 Hz is a

    resonance, then all bets are off. If

    I were the end user, I would not be

    happy with a resonance less than

    20 percent above running speed. As

    the machine wears, the resonance

    will drop in frequency, potentially

    to the point where the running

    speed will sit right on the natural

    frequency. With the low amount of

    damping present in the spectrum,

    this would create amplitudes well

    in excess of the ISO 10816-7 limit.

    —Reader from California

    Nelik’s Response

    Let me start with your ending

    notes first: very observant! e

    small peak just past the 1X is a

    potential problem. With wear and

    lowered stiffness of the system over

    time, the 70 Hz peak may creep

    right onto the 60 Hz resonance.

    Frequent or even continual

    monitoring would be important.e values are still small, and the

    unit is small, judging from data

    shown on the performance curve

    above the spectral plot. Unbalance

    (1X) is small, but the proximity to

    the possible critical frequency may

    lead to issues—though it is hard to

    predict how soon. While immediate

    pump pull and fix is not necessary,

    monitoring is.

    Making some assumptions about the data, an unbalance

    problem appears to be present. It is not misalignment or cavitation.

    However, if you look at the spectrum, there is a slight peak just

    above one time per revolution at maybe 70 hertz (Hz). This could be

    resonance. ... While unbalance is indicated, it may be a resonance

    problem, and balancing is not, in my opinion, a permanent fix.

    16 PUMPING PRESCRIPTIONS

    April  2016  | Pumps & Systems

    By  Lev Nelik, Ph.D., P.E.

    Pumping Machinery, LLC, P&S Editorial Advisory Board

    Troubleshooting & repair challenges

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    Circle 145 on card or visit psfreeinfo.com.

    Sponsored by

    January 28, 2016 How to Read a Pump Curve (available online)

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    May 18, 2016 Vertical Turbine Pumps - Wire-to-Water 

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    educational session will help attendees choose the most appropriate and

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    PUMPING PRESCRIPTIONS

    Regarding

    your other points, the

    location of

    the

    sensor is relevant,

    but

    they

    are

    most often on bearing housings.

    The type of pump would

    not

    make much

    difference,

    although if it

    is ver t ica l ,

    then

    any unbalance would be a serious i ssue .

    Impeller

    wear

    way below the soleplate

    is

    not

    often detectable by

    the

    analyzers

    I EP O

     

    e a l i n g Equipment Products Co.

    ,

    : 4 1 1 1 1 : : X :

    See how to reduce

    your

    water and energy

    consumption, increase

    equipment reliability and

    improve your product

    y ie ld with SEPC O ® s

    high peiform ance sealing

    solutions. For your

    business and

    your

    own

    peace o f mind, check out

    SEPCO ® 

    April 2016

    I Pumps

    Systems

    Circle

    34

    on card or visit psfreeinfo.com.

    at the top of the structure motor

    area),

    and

    vertical turbine vibrations are

    not easi ly detectable

    by

    the

    vibration

    instruments at the

    top.

    Your point on

    sensor

    location has

    another important

    aspect. If

    the

    signal

    comes

    from

    the axial direction,

    then

    the

    angular misalignment

    may

    be

    an

    i ssue , which is often

    shown

    not as a

    2X but a

    lX

    component. In such cases,

    having

    another

    sensor direction

    is

    important. f it is

    at the

    offset direction

    (para l le l

    of

    vertical,

    for

    example)

    and

    s h o w s 2X (twice

    running

    speed) , then

    misalignment

    is l ike ly (presence

    of

    lX

    and 2X).

    The pump

    speed

    is constant in this

    case, but

    the

    cloud of higher head

    data

    is

    an

    indication of

    the second pump

    joining

    in at some

    time,

    with two of

    them

    now

    generating higher head,

    but at a flow

    only slightly

    higher-a

    typical situation

    with

    two pumps

    running in para l le l .

    Vibration data are

    at

    RMS, as shown

    at the vertical

    axis . The

    pump

    is

    small,

    and vibrations are wel l within

    the

    limits, as you

    noted.

    Interest ingly, the

    resonance

    concern was expressed

    in

    this

    particular case, which is why

    continual

    monitoring is planned .

    Thank you for

    your insightful

    comments and observations . f you

    want

    to be

    involved in

    our committee

    work, let me know, and we wi l l get you

    involved . For more

    information, visit

    pumpingmachinery.com . •

    Dr. Nelik

    (aka

    Dr.

    Pump ) is president

    of Pumping Machinery,

    LLC, an

    Atlanta-based firm specializ ing in

    pump consult ing, t ra in ing, equipment

    troubleshooting and pum p repairs.

    Dr.

    Nelik has 30 years of experience in

    pumps and pumping equipment. He

    may be reached at pump-m agazine.

    com. For more in format ion, v is i t

    pumpingmachinery .com/pump_school /

    pump_school .h tm.

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    Examine Pump, Process & Control Elements toSolve Fluid Piping System Problems

    My past Pumps & Systems 

    columns have dealt with

    using basic engineering

    principles to better understand the

    interaction of pump, process and

    control elements in fluid piping

    systems. e articles demonstrate

    how to hone your troubleshooting

    skills while improving the

    operations of piping systems.

    is month, we will start

    demonstrating how to use this

    knowledge to work through

    problems on real-life systems.

    I am not calling them case

    studies because case studies

    provide a system description,

    as well as information on the

    company, the plant facility, theproblems encountered and maybe

    even the people involved. is

    degree of detail requires multiple

    levels of permission—even before

    the lawyers take a look at it.

    Instead, I will use the line

    from the movies: “Based on an

    actual event.” In this column, all

    the names and places have been

    omitted, but the other pertinent

    facts are presented. ese columns

    are based on actual systemproblems I have encountered in

    my 45-year career in operating,

    designing, testing and supporting

    fluid piping systems. Many of the

    examples come from technical

    support questions from our

    software users and feedback from

    our piping system training classes.

    Increasing System Flow Rate

    In the late ’90s, I was working

    with an electrical utility in British

    Columbia that had a program to

    help its large utility customers

    reduce their plants’ energy

    consumption. e utility would

    evaluate a customer’s pump

    systems to see what could be done

    to reduce energy consumption.

    I got a call from the consultant

    performing the analysis on a water

    makeup system in a nickel mine,

    where water was pumped from

    a river to the mill through a

    5-mile pipeline.

    Over the years, the plant’s river

    water requirements increased.

    e sales engineer for the vertical

    turbine pump manufacturer was

    called in each time. e increased

     A better understanding of complete system operation

    Figure 1. Flow diagram showing the mine water piping system with calculated results(Graphics courtesy of the author)

    Figure 2. Pump curve for one of four identical 10-stage vertical turbinesfor the river water system

    20 PUMP SYSTEM IMPROVEMENT

    April  2016  | Pumps & Systems

    By Ray Hardee

    Engineered Software, Inc.

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    system capacity was accomplished byadding stages to the existing vertical

    turbine pumps, as well as adding

    new pumps. When I was called, four

    10-stage vertical turbine pumps

    were providing approximately 4,100

    gallons per minute (gpm) of river

    water to the mine with a fifth pump

    on standby.

    e Total System

    e utility’s consultant modeled

    the river water system using acommercially available piping

    system simulation program. e

    river water level was 100 feet above

    sea level, and the elevation of the

    mine reservoir liquid level was 435

    feet. e supply header was 12-inch

    steel schedule 40 pipe with a length

    of 21,000 feet from the river to the

    mill. e consultant built the system

    model and asked me if I would look

    at his results (see Figure 1).

    e first thing I asked was if hehad an accurate pump curve for the

    installed vertical turbine pumps. He

    did and provided me with a copy (see

    Figure 2).

    I then asked how the model’s

    calculated results matched the

    physical system. He said the only

    system instrumentation was

    a pressure gauge on the pump

    discharge header reading 430

    pounds per square inch (psi), which

    closely matched the simulation’scalculated results. He also

    mentioned that he double-checked

    the river and tank elevations, pipe

    lengths and pipe diameters based on

    existing design documents, and they

    were correct.

    e fact that he had a

    manufacturer’s supplied pump curve

    and that the actual pump discharge

    pressure closely correlated with the

    calculated pump pressure indicated

    that the model closely resembled

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    the physical system. With an accurate system model,

    proposed system changes could be evaluated.Each of the four pumps were supplying 1,043 gpm,

    which is within the manufacturer’s allowable operating

    range. But with the pump’s best effi ciency point (BEP)

    flow of 2,600 gpm, this represents only 40 percent

    of the pump’s BEP flow—well outside the preferred

    operating range recommended in the American

    National Standards Institute/Hydraulic Institute

    (ANSI/HI) 9.6.3-2012 Rotodynamic (Centrifugal and

    Vertical) Pumps – Guideline for Allowable Operating Region 

    standard. Running a pump this far from its BEP can

    cause premature bearing and seal failure.

    Next, I looked at the flow rate through the supply

    header. With 4,200 gpm through the 12-inch diameter

    pipeline corresponding to a fluid velocity of 12 feet per

    second, the result was a dynamic head loss of 660 feet

    in the pipeline. is head loss added to the 335 feet of

    system static head results in a required pump head of

    1,000 feet.

    Considering the Options

    e flow rate in the river water system needed to be

    increased to 4,500 gpm. As previously stated, a fluid

    piping system is made of the pump, process and control

    elements. Increasing the flow rate to 4,500 gpm in the

    existing system resulted in a head loss in the supply

    header of 767 feet, or a total pump head of 1,102 feet.

    Each element affects the total system operation, and

    when users need to increase the system flow, their first

    thought is to call the pump manufacturer.

    Pump Option

    When the pump manufacturer was called, he stated that

    the existing pumps could not meet the head required for

    the new flow rate because the installed vertical turbine

    pumps were not designed for more than 10 stages.

     Additional pumps were not an option because there

    was no space in the pump house for the added pumps. As a result, the pump sales representative suggested

    replacing the existing pumps with higher-capacity

    pumps. e plant’s utility manager was concerned the

    larger pumps would increase the site’s electrical utility

    demand charges.

    Process Option

    In this system, the process elements consist of the river,

    mine reservoir and the interconnecting piping complete

    with valves and fittings. Because the fluid velocity in

    the 12-inch supply header was so great, installing a new

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    22 PUMP SYSTEM IMPROVEMENT

    April  2016  | Pumps & Systems

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    pipeline parallel to the existing pipe was considered.

    is would allow for a greater flow rate and minimizethe head loss in the supply header.

    System Evaluation

    e cost to operate the existing system with four pumps

    running 8,000 hours per year with a power cost of $0.03

    a kilowatt/hour was approximately $358,000 per year.

    Installing a 20-inch pipeline in parallel to the existing

    supply header resulted in a head loss in the supply

    header of only 51 feet. As a result, the new pump head

    requirement was only 406 feet.

    Discussions with the pump supplier determined that

    two of the existing pumps with only five stages per

    pump could deliver 2,350 gpm with 390 feet of head,

    resulting in a total system flow rate of 4,700 gpm. e

    existing pumps have an effi ciency of 83 percent at

    this flow rate, resulting in an annual operating cost

    of $106,000. is created an annual energy savings of

    more than $250,000 across the existing system.

    e cost to replace the five existing pumps with new,

    larger pumps to meet the increased system flow rate

    and head was in the same price range as adding the

    20-inch pipeline. Because the addition of the pumps

    would do nothing to reduce the energy consumption

    of the existing system, the client decided to install the

    pipeline instead of considering pump replacements.

     After the client had instal led the pipeline in parallel,

    I called to see how the system changes had turned

    out. He sent me an as-built model of the system, and

    I noticed that the last 3,000 feet of the new pipeline

    was 24 inches in diameter. I asked if there was a reason

    for the larger pipe diameter in the new pipeline. He

    responded that they had purchased all the 20-inch pipe

    in Western Canada and wanted to get the improvement

    made as quickly as possible, so they purchased 24-inch

    diameter pipe for the remainder. In addition, the utility

    documented the $250,000 savings in energy cost.

     As you can see, there are three elements in a fluidpiping system. As they all work together, they have an

    effect on how the system operates. It is best to consider

    all options when looking at any piping system.

    Ray Hardee is a principal founder of Engineered

    Software, creators of PIPE-FLO and PUMP-FLO software.

    At Engineered Software, he helped develop two training

    courses and teaches these courses internationally. He may

    be reached at [email protected].

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    COMMON PUMPING MISTAKES

    Submergence is a

    commonly overlooked

    pump suction side issue

    that can create mechanical and

    hydraulic performance problems.

    Insuffi cient submergence can leadto increased vibration, a broken

    shaft, shortened mechanical seal

    life, premature bearing failure,

    lower flow rates and diminished

    discharge heads (pressure) for the

    pump. In the worst cases, these

    issues will cause surging and will

    actually stall (air block) the pump.

    Submergence (simple

    submergence) is defined as the

    distance (D) measured vertically

    from the surface of the liquid to thecenterline of the inlet suction pipe.

     A more important term is required

    submergence, also known as

    minimum or critical submergence

    (SC). Required submergence is

    the vertical distance—from the

    fluid surface to the pump inlet—

    required to prevent fluid vortexing

    and fluid rotation (swirling and

    or pre-swirl). Vortexing will

    introduce unwanted air and non-

    condensable gases, which can causepump damage and reduce pump

    performance. A centrifugal pump is

    not a compressor, and performance

    is greatly affected when pumping

    dual and/or multi-phase fluids (gas

    and air entrainment in the fluid).

     A common misconception is that

    inadequate submergence issues are

    found only on vertical and/or very

    large pumps. is issue, however,

    can and will occur on small and/or

    horizontal pumps.

    When a centrifugal pump

    operates at a given flow rate (Q),

    there is a corresponding fluid

    velocity in the suction line (V). You

    can calculate this velocity easily

    by using Equation 1 or by simply

    looking it up in references such as

    Cameron Hydraulic Data (Chapter 3)

    or Crane Technical Paper No. 410,

    Flow of Fluids.

    e velocity of the fluid is an

    important value to know because

    it will determine the correct

    submergence required to prevent

    the formation of vortices.

    Figure 1 shows two separate

    cases; both are for a flow rate of

    300 gallons per minute (gpm),

    but the suction pipe diameter is

    4 inches in one case and 6 inches

    in the other.

    Using Equation 1 and Figure 1,

    we can see that the 4-inch pipe

    yields a velocity of 7.7 ft/s, and

    By Jim Elsey

    Summit Pump Inc.

    Guidelines for Submergence & Air Entrainment

    Figure 1. General guide for minimum submergence based on fluid velocity(Courtesy of the author using data from Hydraulic Institute)

     V =

    Equation 1

    Where:

     V = velocity in feet per second (ft/s)

    D = suction pipe diameter in inches

    (GPM) X (0.4085) ÷ (D) 2

    April  2016  | Pumps & Systems

    24

    Simple solutions for end users

    D = (0.0744 Q) 0.5

    Equation 2

    Where:

    D = recommended suction inlet pipe size in

    inches

    Q = the flowrate in gpm

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    the 6-inch pipe yields a velocity of 3.4 ft/s. Note the

    difference in velocity between 4- and 6-inch piping

    for a flow rate of 300 gpm. Figure 1 indicates thatthe required minimum submergence for the 4-inch

    pipe at a velocity of 7.7 ft/sec will be about 4.5 feet.

    e minimum submergence for the 6-inch pipe at a

    velocity of 3.4 ft/sec will be less than 2 feet. In other

    words, for a given flow rate of 300 gpm and a suction

    pipe diameter of 4 inches, a minimum of 4.5 feet of

    liquid above the inlet pipe will be required at all times

    to prevent the risk of air entrainment due to vortex

    formation. But if the suction line diameter is 6 inches,

    2 feet of submergence will be required to preclude

    vortex formation. at is a difference of more than

    2.5 feet.If you have the 4-inch diameter suction pipe at 300

    gpm but cannot raise the suction side fluid level to

    mitigate air entrainment, you can add a 6-inch suction

    bell to the 4-inch pipe inlet to reduce the velocity

    at the entrance and, in essence, fool the system to

    prevent vortexing. Addition of the 6-inch suction bell

    will reduce inlet velocity to 3.4 ft/sec and reduce the

    minimum required submergence to less than 2 feet. If

    a suction bell cannot be added, then a barrier (anti-

    vortex device such as floating or submerged rafts or

    fixed baffl e plates) that presents a torturous path may

    also be installed.

    Note that, while the barrier may preclude vortices,

    swirl and turbulence in the fluid stream can still

    present unbalance issues with the impeller. e size

    of the barrier can be calculated by knowing the added

    submergence required and then sizing the barrier to

    make the fluid take that same length of travel. Proper

    placement and location of the barrier is important;

    if you are not comfortable or experienced with this

    subject, please consult someone who is. I am reminded

    of an incident at a nuclear power plant 36 years ago

    when I, as the factory field engineer for the pump

    manufacturer, advised the user not to place a 12-foot

    A common misconception is that

    inadequate submergence issues

    are found only on vertical and/

    or very large pumps. This issue,

    however, can and will occur on

    small and/or horizontal pumps.

        C    i   r   c    l   e    1    2    1   o   n   c   a   r    d   o   r   v    i   s    i   t   p   s    f   r   e   e    i   n    f   o .   c   o   m .

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    COMMON PUMPING MISTAKES

    I-beam near the suction of the vertical pump.

    e user determined that I was wrong andsought to block any vortices while measuring

    flow. He securely attached the flow meter to the

    large beam and placed it near the pump suction.

    Less than 3 seconds after the pump was started,

    the beam became an integral part of the suction

    bell and the impeller.

    Besides inadequate submergence issues,

    air and non-condensable gases can enter the

    fluid in other ways. Liquid can fall from above

    the suction tank/sump (e.g. cooling tower), or

    agitation can occur in the upstream process.

    Sometimes air or gases are introduced on

    purpose as part of a process requirement (e.g.

    pulp slurry recycling). An additional issue is

    having a suction tank/sump that is not sized

    properly. A properly sized tank/sump will, by

    design and with respect to volume and geometry,

    allow for suffi cient transient time (hold time) for

    the fluid to facilitate the escape of entrained air

    prior to entering the pump suction.

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    12 TIPS TO REMEMBER

    1  Critical submergence (SC) must be greater than simplesubmergence to prevent vortex formation, but it is still not aguarantee of vortex preclusion.

    2  Pumps that are larger, vertical and/or with impellers of higherspecific speeds are generally more sensitive to submergenceissues, but all centrifugal pumps are susceptible.

    3  Opening impeller clearances by a factor of three to four timesthe normal measurement can allow air and gas to pass throughthe pump with fewer negative effects, but the efficiency, relatedbrake horsepower and cost of operation will be greatly affected.Do not open clearances without consulting the OEM first.

    4  There are various stages, strengths and states of vortex

    generation including incipient, invisible, surface and subsurface.Just because the vortex is not visible to the naked eye does notmean it is not present. The vortex size is a function of the residualangular momentum of the fluid at that point.

    5  In respect to suction tank or sump design, if the intake pipe ishorizontal, a vertical wall (90 degrees) is better than one with aslope (less than 90 degrees).

    26

    April  2016  | Pumps & Systems

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    6  When referencing charts for calculating minimumsubmergence, keep in mind that the assumption is thatno obstructions or asymmetrical geometries are in thetank/sump.

    7  Do not confuse submergence with net positive suctionhead available (NPSHA). I always recommend that bothvalues be calculated for the worse expected condition.You can have adequate NPSHA and still not have propersubmergence and vice versa.

    8  Critical submergence is a function of factors besides thevertical distance and the acceleration of gravity. Otherfactors are surface tension, viscosity, density and thediameter of the suction pipe opening, especially if there

    is a transition to a smaller-diameter pipe shortly afterthe initial opening. Pay specific attention to the ratio ofthe diameter changes. With surface tension, it is a verysmall factor. In the case of viscosity, it will depend onthe Reynolds number, which is defined as the ratio ofmomentum forces to viscous forces and quantifies therelative importance of these two types of forces for givenflow conditions. Think of it as the amount of turbulence.

    9 In some cases, you can have too much submergencefor a given system design, from the aspect of siphoneffects. This is rare.

    10  Suction (pipe) velocities to the pump should be keptbetween 5 and 8 feet per second. I recommendnot more than 6 feet per second unless there is arequirement for suspended solids (critical carryvelocity) and other slurry rheology concerns.

    11  The suction tank/sump should be sized and designedso that the volume has five to eight minutes of holdtime. For example, if the pump is designed for 200gpm then the tank should be 1,000 to 1,600 gpm in

    effective volume. Proper addition of barriers, bafflesand weirs can reduce the required size.

    12  As a general guideline only, the recommended suctioninlet pipe size (D) can be calculated using Equation 2(see page 24). I always recommend rounding D up tothe next pipe size, not down.

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    COMMON PUMPING MISTAKES

    Dissolved air and gases will come

    out of solution at the eye of the

    impeller because that is typically the

    lowest pressure area. e amount of

    dissolved air and gases coming out of

    solution will be a function of suction

    pressure. e higher the pressure, the

    less likely the gases will be released.

    Note that many manufacturers have

    successfully injected 1 percent air

    into the pump suction to address

    chronic cavitation problems. At air or

    gas amounts higher than 1 percent,

    performance issues will occur. As a

    general guideline, 2 percent free air

    will reduce pump flow by 10 percent,

    and 4 percent air will reduce the

    flow by more than 40 percent. e

    degradation in pump performance

    is dependent on the fluid properties,

    pump design, impeller geometry and

    clearances. Pump performance will

    not get better with more entrained air

    and gas. As a guide, most centrifugal

    pumps will lose the majority of their

    performance between 6 and 12

    percent air entrainment. e average

    pump will likely fail to operate at 14

    percent air entrainment. Some pump

    designs that use vortex impellers,

    recessed impellers, separation

    chambers or air escapes can handle air

    entrainment up to 24 percent.

    References

    Hydraulic Institute and ANSI Specification 9.8

    Hydraulic Intake Design

    Ingersoll-Rand Cameron Pump Division white

    paper: Pump Intake Design

    e Pump Handbook, 4th ed ition, Paul Cooper

    & Charles Heald et al.

    Jim Elsey is a mechanical engineer

    who has focused on rotating

    equipment design and applications

    for the military and several large

    original equipment manufacturers

    for 43 years in most industrial

    markets around the world. Elsey

    is an active member of the

    American Society of Mechanical

    Engineers, the National Association

    of Corrosion Engineers and the

    American Society for Metals. He isthe general manager for Summit

    Pump Inc. and the principal of

    MaDDog Pump Consultants LLC.

    Elsey may be reached at

     [email protected].

    Circle 122 on card or visit psfreeinfo.com.

    28

    April  2016  | Pumps & Systems

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    Circle 102 on card or visit psfreeinfo.com.

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    Process equipment represents

    an enormous investment

    for manufacturers, with

    medium to large plants having

    thousands of assets that support

    the supply chain, production and

    distribution. All equipment must

    be managed effi ciently to ensure

    reliability and productivity. is

    is a priority for industrial plants

    as they seek to move from reactive

    and preventive maintenance

    approaches to predictive.

     According to ARC Advisory

    Group, the growing number of

    plant assets coupled with the

    reduction in skilled labor means

    there are 500 to 2,000 process

    control loops per technical staff

    member. Maintenance personnelare responsible for the associated

    equipment for an individual loop,

    including instruments, valves and

    pumps, making it increasingly

    diffi cult to manage plant assets

    using in-house staff alone.

    With baby boomers retiring

    at the rate of 10,000 per day,

    industrial plants are relying on

    automation solutions to manage

    assets. is dependence is also

    driven by aging infrastructure,competitive market pressures,

    environmental regulations and

    shrinking profit margins.

    Predictive Maintenance

    e growing use of predictive

    analytic software, wireless sensors

    and cloud computing, as well as

    other information technology

    advances, is a key enabler.

    ese technologies broaden the

    scope of real-time performance

    monitoring and machine-

    to-machine communication,

    which, in turn, supports

    the evolution of predictive

    maintenance approaches. In some

    cases, equipment can also be

    self-repairing.

     Accurately predicting remaining

    useful life helps streamline

    the supply chain with the right

    parts arriving for scheduled

    replacement. Unscheduled

    downtime and inventory costs

    are minimized. Suppliers can

    better support equipment using

    remote diagnostics.

    In the future, predictive

    maintenance systems will collect

    real-time and historical data, apply

    analytics, and assess the healthof the equipment and the entire

    production process. e systems

    will prioritize maintenance

    and operator actions based

    on criticality and recommend

    corrective actions. ese expanded

    capabilities will enhance

    maintenance and operating

    decisions while providing

    critical equipment information

    to process control and business

    systems. Plant managementand engineering can make more

    informed decisions related to

    capital budgets and long-term

    modernization plans.

    Intelligent Pump Control

     A common application of

    intelligent pump control is a

    parallel pumping system such as a

    cooling tower. Parallel systems are

    designed to provide incremental

    flow by turning multiple pumps

    on or off to meet changing system

    demand. Cooling tower systems

    are common across manufacturing

    facilities that use heat exchangers.

    ese applications offer an

    opportunity for industrial plants

    to reduce energy consumption and

    improve reliability.

    For example, multi-pump

    application of intelligent

    variable frequency drives (VFDs)

    represents the convergence of

    pump and automation technologies

    for predictive maintenance. e

    pump intelligence embedded in the

    drive’s microprocessor allows the

    pump to identify conditions such

    as dry running, dead-heading and

    cavitation in real time. Conditions

    can be communicated via a digitalbus back to the distributed control

    system (DCS) for display and

    alarming. e operator can quickly

    take corrective action either

    by making adjustments to the

    system at the DCS console or by

    automatically generating a high-

    priority work order requesting

    system maintenance.

    e individual drives are

    interlinked and can be configured

    to automatically change thelead and lag pump(s) at regular

    intervals to even mechanical

    wear over time. If one pump fails,

    the system can automatically

    synchronize and adjust individual

    pump speeds to ensure that flow

    demand is maintained.

    Multi-pump control maintains

    stable process conditions, which

    optimizes the number and speed

    of pumps needed and offers

    smooth startup and shutdowns

    The Future of Predictive Maintenance

    30 INDUSTRY INSIGHTS

    April  2016  | Pumps & Systems

    By  Mike Pemberton 

    Pumps & Systems Senior Technical Editor

    Trends & analysis for pumping professionals

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    because there is no need for aseparate control logic in the

    DCS. e drive’s intelligence

    also operates the pumps in the

    most energy-effi cient manner,

    allows redundancy and provides

    the capability to mix pumps

    of different sizes and powers

    (although the ideal system

    configuration has identical

    pumps). While the multi-pump

    intelligence is embedded in

    the VFD microprocessor, theintelligence could also be in

    the DCS microprocessor or on a

    server in the cloud. While this is

    a special case of using embedded

    intelligence to control a multi-

    pump system, the future will see

    broader use of data to empower

    predictive analytic software forplant-wide asset management.

    Facilities will be able

    to implement mechanical

    systems that self-diagnose

    and automatically adapt to

    equipment failure and process

    upsets. Compared with fixed-

    speed systems, the broader use

    of variable speed pump systems

    requires smaller motors, allows

    removal of the control valves

    at the pump discharge andprevents the need for supporting

    infrastructure such as pneumatic

    lines and control wires. Wide

    application of variable speed

    technology will dematerialize the

    process and reduce maintenance

    and operating costs.

    In these scenarios, facilitiescan continuously monitor assets

    and make system adjustments

    over a wireless or wired network.

    Service technicians, whether

    on or off site, will eventually

    be able to use 3-D printing to

    produce standard or custom

    parts and ship them in a timely

    manner. ese advancements and

    others will al low plants to work

    within budgetary constraints

    and overcome barriers caused bylimited resources.

    Mike Pemberton is the senior

    technical editor for Pumps &

    Systems. He may be reached at

    [email protected].

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    April  2016  | Pumps & Systems

    32

    ouston, Texas, gets hot during the summer,

    with temperatures exceeding 95 F (36 C) in

     August and 90 F (33 C) for an average of 102

    days a year. While air conditioning helps to

    make life tolerable during Houston’s hot, humid days,

    there is no such relief for pipelines that are pumping oil

    and gas products.Keeping pipeline components in optimal condition is

    a constant challenge for oil and gas companies that must

    contend with the effects of rising temperatures on liquid

    pump seals.

    Recently, one company solved a similar problem with

    the seals on its ethane pumping system by incorporating

    a dry gas seal in a liquid-pump application.

    e end user, located in Houston, operates natural gas

    liquid (NGL) fractionation facilities, where it processes

    mixed NGL streams into purity NGL products including

    ethane, propane, normal butane, isobutene and natural

    gasoline. A crucial part of its operation is the ethane

    injection pumps that pump ethane from 410 pounds per

    square inch (psi), or 28 bar, to about 1,100 psi (76 bar).

    While the ethane temperature at suction should be

    approximately 60 F (16 C) on a typical warm, Houston

    summer day, this temperature can increase dramatically.

    e increased temperatures result in seal failure, which

    can cause ethane to vaporize—resulting in product loss.

    Why Liquid Pump Seals Fail

    When operating rotating equipment, some end users

    do not pay enough attention to transient conditions.

    Startup, slow-roll and standby pump conditions must be

    evaluated to ensure proper sealing fluid is being supplied

    to the seals at all times.

    Here is what to look for when evaluating proper liquid

    seal function, highlighting some problems that can occur:

    • Startup: e pump is charged, but at or near suction

    pressure. Liquid ethane at the seal faces is slowlyleaking and vaporizing. When the pump starts,

    how long does it take to build the right pressure in

    the stuffi ng box and get the pressure above vapor

    pressure? Additionally, the heat generation between

    the faces, although not significant, could be enough to

    increase vapor pressure and vaporize the fluid across

    the faces. Damage to sealing faces could be a telling

    sign that this is occurring.

     

     

    SPECIAL SECTION

    SEALING CHALLENGES

    Image 1. Typical design of a dry gas seal (Image and graphiccourtesy of EagleBurgmann)

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    33

    • Slow-roll: e same situation as startup but

    compounded. Without the right speed, the discharge

    pressure is not generated. e pressure in the stuffi ng

    box is not rising quickly enough to ensure the ethanewill reach a high enough pressure to overcome the

    vapor pressure. Also, the heat generation between the

    contacting faces is increasing, and damage is probably

    taking place.

    • Standby: All conditions mentioned above are the

    same, but the seals are sitting idle for many months

    without a flush to the seals. During the standby

    time, evidence has shown that debris has collected

    at or around the seal faces, which, in turn, adds more

    complication to the sealing environment.

    • Ineffi cient operation: Operating the pump too far

    outside of the best effi ciency range and with the wrongoperating parameters results in increased demand for

    drive power and reduced discharge pressure. Both of

    these negatively impact the vapor margin in the seal

    area, which can result in dry running.

    Other transients that play a role in evaluating sealing

    fluid are temperature changes in the product, frequent

    starts and stops, and operator error. ese situations

    can lead to seal failure. At the Houston facility’s ethane

    pumping operations, mean time between failure (MTBF)

    was averaging a little more than three weeks. Something

    needed to be done to prevent seal failure and product loss.

    Meeting the Challenge

    Low vapor margin applications, such as ethane, have

    one thing in common: e liquid would rather be a gas.

    For this reason, many end users incorporate liquid-

    lubricated gas seals. e manufacturer that supplied

    the seals for the facility in Houston, for example, offers

    pump seals that run on a gas film between the faces—either a dual pressurized seal using an inert gas or a dual

    unpressurized seal with the outboard seal operating on

    a gas. A dual unpressurized seal works great in these

    applications, but transients and other unknowns can

    cause problems. Incorporating a clean gas at the seal faces

    helps prevent failure, but certain problems can persist.

    When the manufacturer was evaluating these

    challenges, the Houston facility’s initial solution was to

    use liquid-lubricated seals and take discharge pressure

    directly into the stuffi ng box. But the liquid-lubricated

    seals continually failed, especially on warm summer days

    as the outside temperature rose. e reason had to dowith the inherent nature of ethane.

    For ethane to remain in its liquid state, it must be

    kept at a certain temperature and a certain pressure

    (approximately 300 to 400 psi [21 to 28 bar]) at 60 F

    [16 C]). If the pump is operating properly and the pressure

    and temperature are at their ideal points, then the

    ethane continues to flow as a liquid. But as the outside

    temperature rises on a warm day, the pressure and the

    temperature of the pump also increase. is causes the

    ethane to vaporize at the seal.

    Transient ConditionsLiquid-lubricated seals are designed to handle liquids

    only; they will fail if they are suddenly confronted with

    handling a gas, such as when ethane vaporizes from a

    liquid. In reality, a liquid-lubricated seal can be successful

    EXAMPLE OF TANDEM SEAL WITH INTERMEDIATE LABYRINTH

    1. Seal face, stationary

    2. Seat, rotating

    3. Thrust ring

    4. Spring

    5. Shaft sleeve and seat

    retainer

    6. Intermediate sleeve

    7. Housing (adapted in size to

    the installation space)

    8. “Adjustable” nut for axial

    misalignment

    9. Split ring

    10. Tension ring

    11. Cover

    12. Process side labyrinth

    GBI is gas buffer inlet, GBO

    is gas buffer outlet and D is

    drain. The yellow parts are

    rotating, blue are stationary,

    and gray represents pump shaft

    and housing.

    The details of this seal include:

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    April  2016  | Pumps & Systems

    34 SEALING CHALLENGESSPECIAL SECTION

    in an ethane application, but only

    under conditions that do not change.

    Because the seal environment kept

    changing in the Houston application,the liquid-lubricated seals could not

    work properly.

    Liquid-lubricated seals work best in

    environments where the temperature

    and pressure are at a consistent level.

    For this end-user’s operations, it wasthe transient conditions that caused

    the problems.

    For this application, ethane was

    sealed. For ethane to become a gas,

    it needs a pressure drop or a vapor

    pressure increase above the sealingpressure. Heating the fluid is a quick

    way to achieve this, but using an

    external heater adds complexity and

    maintenance. Using a close-clearance,

    multi-tooth labyrinth on the front

    end of the seal causes the turbulent

    flow during operation to create fluid

    friction that will build heat. e

    rotation of the seal faces also adds

    heat. e closer the gap is between the

    faces, the smaller the leakage and the

    higher the heat generation. But thetransient conditions caused problems.

    Relying on rotation to build heat

    ignores the effects of startup, slow-

    roll and the standby pump.

    Dry Gas Seals

    e solution—a dry gas seal—was

    simple, though a bit unconventional.

    is technology is usually not used

    in liquid-pump applications, but it

    seemed to be a good solution because

    the ethane liquid wants to be a gas.Dry gas seals delivered enhanced

    reliability in operating modes

    where the seal faces are in constant

    contact—turning, ratcheting, coast-

    down and other operating modes that

    create critical conditions for standard

    gas seals. Experience has shown that

    unexpected operating situations,

    such as the transient conditions

    the end user was experiencing, can

    compromise a gas seal.

    Because seal faces are designedprimarily for non-contact operation,

    they are subject to wear when there

    is contact for sustained periods. is

    can cause seal failure resulting in

    downtime and production loss.

    ese seals featured bonding that

    consisted of a micro-crystalline

    layer that has attributes of natural

    diamond. For example, it will

    not flake or chip off, the coating

    is extremely hard and wear-

    resistant, and it offers excellent

    Circle 136 on card or visit psfreeinfo.com.

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    pumpsandsystems.com | Apri l 2016

    35

    heat conductivity and high c