OPTIMIZE PUMPING SYSTEMS Diligent analysis, rigorous scrutiny lead to longer system life
AU G UST 2014 PUMP-ZONE.COM
TURBOMACHINERY & PUMP SYMPOSIA Trade Show Preview
SEALS & BEARINGS Tips for Maximizing PERFORMANCE
6 Considerations for REFINERY Pump MAINTENANCE
We’ll Find It Before It Fails Sometimes what doesn’t happen matters most. Expert On Site Testing and Diagnostics – for Optimized Performance Hydro’s highly skilled pump improvement engineers provide complete reliability support for your pump installation base, whether the equipment is recently commissioned or has been in service for many years. Using the latest technology and our broad experience from the field, we identify problems early – ensuring longer life and improved performance. And if you’re faced with an existing problem that is difficult to solve, our field engineers are here to help.
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Hydro’s driving force is engineering. To help our customers maintain critical pump equipment, Hydro’s pump improvement engineers review the pump operating and maintenance history, provide a thorough on site inspection, and perform in-depth pump, driver and system testing. Our field engineers provide global support and are available for both routine and emergency situations.
Root Cause Analysis Engineered Pump Upgrades Condition Monitoring Program Health Audits
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2
From the Editor T
his month we introduce an exciting, fresh, modern look to our logo and design that has been thoughtfully crafted to make the magazine easier for you to read and navigate. While the look has been updated, the content remains the same high-quality technical pumping information that you can’t ind anywhere but in the pages of Pumps & Systems. It makes sense that we introduce this change with a focus on the increasingly vital topic of pump system Michelle Segrest with ITT’s Margaret optimization. Not long ago, the components of a pumping system were designed separately, purchased Gan at the 2014 Offshore Technology Conference. The Pumps & Systems separately and maintained separately. hanks to team returns to Houston for the advancements in technology and increased standards Turbomachinery/Pump Symposia in September. and awareness and the Hydraulic Institute’s development of Pump Systems Matter, today the entire system is examined and modiied to decrease life-cycle costs and save energy. On average, industrial pumps operate at less than 40 percent eiciency, and more than 10 percent of pumps run at less than 10 percent eiciency. h is impacts the bottom line. “he cost to pump ineiciently is beyond your wildest imagination,” says Mike Pemberton, ITT Performance Services Manager and Pumps & Systems Editorial Advisory Board member. “In the past several decades, pump eiciency has only increased 3 percent by design. he biggest advantage in increasing eiciency is happening with automation and controls.” he infrastructure is in place, but the question remains, “How do we optimize?” his year, Pumps & Systems published a three-part series from HI examining the Department of Energy’s pump eiciency regulation changes (Jan.-March 2014, www.pump-zone. com). he series describes how to reduce the burden on U.S. pump manufacturers and support the DOE’s eforts to achieve energy savings and eiciency improvements in the marketplace. According to Pump Systems Matter, the most likely candidates for optimization are large systems, systems with high operating hours, problem systems and production-critical systems. he most common red-l ag symptoms are high energy costs, throttle valves that are generally closed, bypass valves/recirculation lines that are generally open, frequent failures or repair requirements, high operating noise levels (especially at the valve or pump), vibrations in the system and/or pump assembly, systems with multiple parallel pumps with the same number of pumps always operating, constant pump operation in a batch environment or frequent cycle batch operation in a continuous process, and systems that have undergone a change in function. Learn more by visiting www.pumps.org. You can ind a wealth of solutions by reading this month’s cover series, which begins on page 60. As always, pump eiciency will be a major topic at the 43rd Turbomachinery and 30th Pump Symposia in Houston, Sept. 23 – 25. Visit the Pumps & Systems team at Booth 514, and tell us about your pump optimization success stories.
EDITORIAL EDITOR: Michelle Segrest
[email protected] • 205-314-8279 MANAGING EDITOR: Lori K. Ditoro
[email protected] • 205-314-8269 SR. EDITOR, PRODUCTION & CONTENT MARKETING:
Alecia Archibald
[email protected] • 205-314-3878 ASSOCIATE EDITOR: Michael Lambert
[email protected] • 205-314-8274 ASSOCIATE EDITOR: Savanna Lauderdale
[email protected] • 205-278-2839 CONTRIBUTING EDITORS: Laurel Donoho, Joe Evans, Lev Nelik, Ray Hardee CREATIVE SERVICES SENIOR ART DIRECTOR: Greg Ragsdale ART DIRECTORS: Jaime DeArman, Melanie Magee WEB CONTENT EDITOR & WEB ADVERTISING TRAFFIC:
Robert Ring
PRINT ADVERTISING TRAFFIC: Lisa Freeman
[email protected] 205-212-9402 CIRCULATION
AUDIENCE DEVELOPMENT MANAGER:
Lori Masaoay
[email protected] • 205-278-2840 ADVERTISING NATIONAL SALES MANAGER:
Derrell Moody
[email protected] • 205-345-0784 Mary-Kathryn Baker
[email protected] • 205-345-6036 Mark Goins
[email protected] • 205-345-6414 Addison Perkins
[email protected] • 205-561-2603 Vince Marino
[email protected] • 205-561-2601 MARKETING ASSOCIATES:
Ashley Morris
[email protected] • 205-561-2600 Sonya Crocker
[email protected] • 205-314-8276
PUBLISHER: Walter B. Evans, Jr. VP OF SALES: Greg Meineke VP OF EDITORIAL: Michelle Segrest CREATIVE DIRECTOR: Terri Jackson CONTROLLER: Tim Moore
P.O. Box 530067 Birmingham, AL 35253
Editor, Michelle Segrest Pumps & Systems is a member of the following organizations: PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the right to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call 630-739-0900 inside or outside the U.S. POSTMASTER: Send changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. ©2014 Cahaba Media Group, Inc. No part of this publication may be reproduced without 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. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no 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 free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 22, Issue 8.
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EDITORIAL & PRODUCTION
1900 28th Avenue South, Suite 200 Birmingham, AL 35209 205-212-9402 ADVERTISING SALES
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4
This issue
AUGUST Volume 22 • Number 8
COVER
60
SERIES
PUMP SYSTEM OPTIMIZATION 60 STREAMLINED MOTOR MANAGEMENT SYSTEM BOOSTS BIOMASS POWER GENERATION BY Matthias Borutta Phoenix Contact Trusted gateway connections allow for system growth, eiciency and consistent maintenance at Swedish paper mill.
64 INTELLIGENT MONITORING DELIVERS REAL-TIME PUMP PERFORMANCE DATA By Mike Pemberton ITT Pro Services An energy eiciency and reliability study helped one plant save $1 million annually by avoiding downtime.
DEPARTMENTS
COLUMNS
84 EFFICIENCY MATTERS
PUMP ED 101
Smart Air Distribution Systems Upgrade Traditional AODD Pump Technology
89 MAINTENANCE MINDERS 6 Reinery Pump Maintenance Tips
69 CLOSE INSPECTION SOLVES HIGH THRUST BEARING TEMPERATURE PROBLEM By Gary Dyson Hydro Inc. Careful analysis identiied the issue with this multistage oil transfer pump.
73 SYSTEM SELECTION CRUCIAL FOR LONG WASTEWATER PUMP LIFE By Lars Bo Andersen Grundfos Wastewater
94 MOTORS & DRIVES he Diferences Between Submersible & Immersible Motors
98 SEALING SENSE Expansion Joint Selection Optimizes Piping Systems
102 HI PUMP FAQS Understand Speciic Speed & Disc Diaphragm Pump Coupling
20 By Joe Evans, Ph.D. Pump Tech Inc. hree-Phase Voltage Variation & Unbalance
PUMPING PRESCRIPTIONS 26 By Lev Nelik, Ph.D., P.E. Pumping Machinery, LLC Simplify the Equipment Selection Process
PUMP SYSTEM IMPROVEMENT 28 By Ray Hardee Engineered Software, Inc. System Validation & Troubleshooting
GUEST COLUMNS
Driving down investment, energy and maintenance costs translates into big savings throughout an installation’s lifetime.
36 By Heinz P. Bloch, P.E. Pushing Fluid Machinery Leads to Failure
76 REDUCER FITTINGS DECREASE
40 By Amin Almasi
PIPE SIZE TO PREVENT FAILURE
Estimate Pump Installation Costs
By Ross Mahaffey, Aurecon and Stefanus Johannes van Vuuren, University of Pretoria Design of the pump inlet piping can protect overall operation.
64 Augus t 2 014 | Pum ps & S ys t e m s
Cover photo courtesy of Colfax Fluid Handling
PUMP AND FLUID SYSTEMS
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10,000 psi (207 MPa)
© 2014 Weatherford. All rights reserved.
Contact and collaborate with us at
[email protected]
Formation Evaluation
|
Well Construction
|
Completion & Stimulation
|
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6
This issue SSPECIAL PECIAL SECTION
SEALS & BEARINGS
42 CANNED MAGNETIC BEARINGS
50 SELECT SEALS THAT MEET
MINIMIZE CORROSION IN OIL & GAS PROCESSING
THE CHEMICAL CHALLENGES OF HPLC PUMPS
By Richard R. Shultz Waukesha Magnetic Bearings
By Jerry Zawada Trelleborg Sealing Solutions
Safely immerse motor compressors in process gas without risking costly damage.
Abrasive processing and wide temperature range are some of the pumping diiculties for highperformance liquid chromatography.
45 THE RIGHT SEAL & LUBRICANT COMBINATION CAN PREVENT BEARING CONTAMINATION
54 TREATED CARBIDE SURFACES
By James Wong Garlock Sealing Technologies Lip and labyrinth seals provide protection in harsh oil and gas applications.
ENHANCE RUNNING PERFORMANCE By Mark Slivinski Carbide Derivative Technologies Inc. his technology self-lubricates, reduces friction, and performs in wet or dry operating conditions.
AUGUST PRACTICE & OPERATIONS 106 ENERGY EFFICIENT VERTICAL TURBINE PUMPS PROMOTE SUSTAINABLE MINING EFFORTS By Petar Ostojic Neptuno Pumps he computational luid dynamics process advances highly eicient pump designs for diicult applications.
110 SPECIFIC PUMP & VALVE FEATURES SERVE LIQUEFIED NATURAL GAS APPLICATIONS By Gobind Khiani Fluor Canada Ltd. LNG beneits have increased the demand for this cleaner burning fuel and associated production and distribution equipment.
114 DEWATERING PUMPS HANDLE 2 8 10 80 118 124 128
SAND SLURRIES IN POSTHURRICANE RECOVERY
FROM THE EDITOR READERS RESPOND
By Mike Bjorkman BJM Pumps
NEWS TRADE SHOW COVERAGE PRODUCT PIPELINE PUMP USERS MARKETPLACE PUMP MARKET ANALYSIS
Reconstruction and infrastructure upgrades require pumps from durable materials.
EDITORIAL ADVISORY BOARD THOMAS L. ANGLE, P.E., MSC, Vice President Engineering, Hidrostal AG ROBERT K. ASDAL, Executive Director, Hydraulic Institute BRYAN S. BARRINGTON, Machinery Engineer, Lyondell Chemical Co. KERRY BASKINS, VP/GM, Milton Roy Americas WALTER BONNETT, Vice President Global Marketing, Pump Solutions Group R. THOMAS BROWN III, President, Advanced Sealing International (ASI) CHRIS CALDWELL, Director of Advanced Collection Technology, Business Area Wastewater Solutions, Sulzer Pumps, ABS USA JACK CREAMER, Market Segment Manager – Pumping Equipment, Square D by Schneider Electric
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BOB DOMKOWSKI, Business Development Manager – Transport Pumping and Amusement Markets/Engineering Consultant, Xylem, Inc., Water Solutions USA – Flygt DAVID A. DOTY, North American Sales Manager, Moyno Industrial Pumps WALT ERNDT, VP/GM, Crane Pumps & Systems JOE EVANS, Ph.D., Customer & Employee Education, PumpTech, Inc. RALPH P. GABRIEL, Chief Engineer – Global, John Crane BOB LANGTON, Vice President, Industry Sales, Grundfos Pumps LARRY LEWIS, President, Vanton Pump and Equipment Corp. TODD LOUDIN, President/CEO North American Operations, Flowrox Inc. JOHN MALINOWSKI, Sr. Product Manager, AC Motors, Baldor Electric Company, A Member of the ABB 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 MIKE PEMBERTON, Manager, ITT Performance Services SCOTT SORENSEN, Oil & Gas Automation Consultant & Market Developer, Siemens Industry Sector ADAM STOLBERG, Executive Director, Submersible Wastewater Pump Association (SWPA) JERRY TURNER, Founder/Senior Advisor, Pioneer Pump KIRK WILSON, President, Services & Solutions, Flowserve Corporation JAMES WONG, Associate Product Manager – Bearing Isolator, Garlock Sealing Technologies
H ORIZONTAL P UMPING S YSTEMS Borets Equipment is a HPS horizontal multistage pump manufacturer that provides pumping solutions with exceptional customer service.
SERVICE Reliable. Quality. Modular. Horizontal Pumping System (HPS) by Borets Equipment. Cost-competitive and customizable for your specific application, the HPS equipment requires less inventory and delivery time than traditional API 610 multistage, vertical turbine can and reciprocating pump equipment. Engineered for reliability, modularity, and quick replacement of components, the HPS pump has a lower life cycle cost, thanks to minimized downtime and low maintenance Low Pro Design
requirement. The result is a reliable, flexible and innovative pumping system. You provide the application, we’ll provide the Pump Power and Service.
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8
READERS RESPOND
READERS
responD “A Salute to Frank Weis,” From the Editor MARCH 2014
I was sent your article while I was at the American Water Works Association conference in Boston. hank you so much for writing this and sharing some of your thoughts on Frank. I just wanted to share more with someone, so I decided to give you more background. Frank was my irst boss when I joined Smith and Loveless in 1983, fresh out of graduate school. I won’t go into all the engineering details I learned from just watching him but wanted to share the personal side. I worked for, with and shared lunch with Frank many days over my next six years of employment. He treated everyone the same, from the janitor to the president of the company. He was friendly to all, had a great sense of humor, enjoyed pulling pranks on select employees, and I never, ever saw him be upset or have a bad day! We were both alumni of the University of Missouri, and he loved sports, had coached his kids baseball and basketball teams and loved to talk sports of all kinds. He shared his knowledge with any that asked, but he was the most humble guy I have ever known.
Augus t 2 014 | Pum ps & S ys t e m s
He went about his work with a quiet determination and knew exactly what he was trying to achieve, even if it didn’t it with the views of management at the moment! He had an amazing inluence on my professional and personal life, and I tell stories related to him almost every week. I left the company in 1989 and moved to Degremont in Virginia, but his inluence had more impact on me than anyone I have worked with since that time. I am now back in Kansas City and was fortunate enough to attend the 50th anniversary of Frank’s work at Smith and Loveless in 2004. As was typical for Frank, he didn’t want it to be a big deal, so the ceremony was held on the shop loor. Several former employees attended, many who had long since retired! I knew then how unique Frank was but have understood this even more in the years that have passed. As great a man as he was from the engineering and invention side, he was an even better man overall. he world was a better place for the time he was here and for all the individuals that got to know him. Andy Mitchell Director, Business Development Metawater USA, Inc.
Frank Weis
Pumps & Systems Editor Michelle Segrest responds: hank you for reading my column about Frank Weis (www.pump-zone.com/blog/ salute-frank-weis) and for responding with these nice comments. he additional insight into the life of this legendary pump innovator is greatly appreciated. Frank Weis was well respected in the pump industry and will be missed by all who knew him.
To have a letter considered for Readers Respond, please send it to Michael Lambert,
[email protected].
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10
NEWS
NEW HIRES, PROMOTIONS & RECOGNITIONS LARRY LEWIS, VANTON PUMP HILLSIDE, N.J. (July 10, 2014) – The Board of Directors of the Vanton Pump and Equipment Corp. voted to name Larry Lewis as the company’s president and chief executive officer. Lewis has served as Vanton’s president since 2010. Vanton Pump and Equipment Corp. supplies chemically inert, thermoplastic pumps and systems that solve fluid containment, dosing and transfer problems. www.vanton.com
SPOTLIGHT PUMPS & SYSTEMS LAUNCHES MIDDLE EAST/NORTH AFRICA MAGAZINE Larry Lewis
DAVID BOEZI, DANFOSS BALTIMORE (June 24, 2014) – Danfoss hired David Boezi as senior director, strategy and global platforms. In this role, Boezi will help Danfoss tailor its high-efficiency compressor portfolio to respond to changing customer needs that are being influenced by new refrigerant and energy-efficiency regulations. Danfoss supplies David Boezi technologies that meet the growing need for food supply, energy efficiency, climate-friendly solutions and modern infrastructure. www.danfoss.com
DICK SHEAR, MULTI W SYSTEMS EL MONTE, Calif. (June 20, 2014) – Multi W Systems Inc. announced the appointment of Dick Shear as general sales manager. Multi W Systems manufactures and distributes pump systems, electrical controls and related engineered machinery. www.multiwsystems.com
BIRMINGHAM, Ala. (July 2, 2014) – Pumps & Systems, the leading magazine for pump users worldwide for more than 20 years, expands its international coverage of powerful technical pumping information to the Middle East/North Africa region. The premier issue of Pumps & Systems MENA will launch in early October 2014. It also will be distributed at the Pumps & Systems booth Nov. 10, 2014, at the Abu Dhabi International Petroleum Exhibition & Conference, the region’s leading conference for oil and gas professionals. Pumps & Systems MENA will publish bimonthly in 2015 following the October 2014 launch and will cover case studies and technical information in the following industries: • Oil & gas (upstream and downstream) • Water & wastewater • Power generation • Food & beverage processing • Building services • Chemical, petrochemical & refinery The regular editorial coverage will also include strategic and insightful market data from respected market research analysts Frost & Sullivan. The magazine will be supported digitally with a website, www.pump-zone.com/mena, and a twice-per-month e-newsletter, Pump Users Digest MENA. Subscribe to the e-newsletter and magazine at www.pump-zone.com/mena.
Dick Shear
PAMELA HENRY, WEF ALEXANDRIA, Va. (June 19, 2014) – The Water Environment Federation (WEF) promoted Pamela Henry to the position of deputy executive director. Having been with WEF for more than 25 years, Henry is a seasoned leader who will oversee a number of key organizational programs including WEFTEC operations and exhibitions, advertising and sponsorships, marketing, Pamela Henry communications and creative services, human resources, and facilities management. WEF is a not-for-profit technical and educational organization of 36,000 individual members and 75 affiliated Member Associations representing water quality professionals around the world. www.wef.org
CHUCK HULL, 3D SYSTEMS ROCK HILL, S.C. (June 17, 2014) – 3D Systems announced that Chuck Hull received the 2014 European Inventor Award in the non-European countries category in recognition of his invention of the threedimensional (3-D) printing technology Stereolithography. Presented Augus t 2 014 | Pum ps & S ys t e m s
annually by the European Patent Office, the award honors inventors who made significant contributions to technological progress and the advancement of society. 3D Systems provides 3-D printing centric design-to-manufacturing solutions including 3-D printers, print materials and cloud-sourced on-demand custom parts for professionals and consumers in materials including plastics, metals, ceramics and edibles. www.3dsystems.com
EDWARD CRANER, HOLT CAT SAN ANTONIO, Texas (June 16, 2014) – HOLT CAT named Edward Craner senior vice president, strategy and marketing. In his new role, Craner will continue to lead and develop corporate strategy, marketing and customer experience initiatives to support sales growth. HOLT CAT sells, rents and services Caterpillar machines, engines, generator sets and trucks. www.holtcat.com
Edward Craner
11
AANNDD ®
HENRI V. AZIBERT, FSA
FLEX-PRO Peristaltic Metering Pump
Three Models Available with Feed Rates Ranging from 0.1 GPH/.03 LPH to 158 GPH/600 LPH. Smooth, Quiet and Eicient Pumping Action. Brushless Variable Speed Motor. Terminal Blocks in Junction Box for Remote Connections. Patented Tube Failure Detection, Patented Safety Switch, Patented Method for Extended Tube Life. One or Two Pump, Engineered Skid System is Available.
WAYNE, Pa. (June 13, 2014) – The Fluid Sealing Association (FSA) announced the appointment of Henri V. Azibert as its new technical director. Pumps & Systems has partnered with the FSA for Henri V. Azibert 10 years and posted exclusive “Sealing Sense” articles in every issue. Azibert will now coordinate these articles, which provide the readers of Pumps & Systems with crucial technical information about mechanical seals, compression packing, gaskets, expansion joints, sealing components and molded packing. Azibert has also joined the prestigious Pumps & Systems Editorial Advisory Board. FSA is an international trade association. Members are involved in the production and marketing of virtually every kind of fluid sealing device in the world. www. fluidsealing.com
JOHN DONAHUE, AWWA BOSTON (June 12, 2014) In a spirited event at the conclusion of the American Water Works Association’s Annual Conference and Exposition in Boston, John Donahue, chief executive John Donahue officer of North Park, Illinois, Water District, accepted the ceremonial AWWA gavel and began his term as president. The gavel passing ceremony was the culmination of a fiveday conference that drew more than 11,000 water professionals and water technology providers to Boston. The American Water Works Association is the largest nonprofit, scientific and educational association dedicated to managing and treating water. www.awwa.org
GREG HEWITT, BALDOR ELECTRIC COMPANY
WAS AS SH DOWN OW
®
SONIC-PRO Ultrasonic Flowmeter
NEW!
Sonic-Pro S4 accurately measures flow using the Transit Time method. It can be used with water containing low levels of chemicals and up to 5% particulates. Optional communication protocols include Industrial Ethernet, Profibus and Modbus.
Ultrasonic Transit Time operation. Optional factory configuration for easy installation. Inline spool piece (inline fitting). 4-20mA and Pulse Outputs. Special low power mode permits operation with battery for limited functions.
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Advanced communication. Data logging
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www.blue-white.com • www.proseries-m.com pu mp-zone.c om | Au gu st 2014
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FORT SMITH, Ark. (June 9, 2014) – Baldor Electric Company promoted Greg Hewitt to mounted bearing engineering manager. In this role, he will be responsible for Greg Hewitt all mounted bearing productrelated engineering and will manage the product development team in Greenville, South Carolina. Baldor Electric Company markets, designs and manufactures industrial electric motors, drives and mechanical power transmission products. www.baldor.com
IP P66 NE EMA A 4X
12
NEWS
manager for OPW Engineered Systems. OPW Engineered Systems provides loading and coupling systems for the safe and efficient loading and unloading of critical hazardous fluids. www.opw-es.com
CHARLES WHISMAN, CH2M HILL DENVER (June 5, 2014) – CH2M HILL announced that Charles Whisman joined the firm as vice president and U.S. oil and gas operations manager for the environment and nuclear market. CH2M HILL provides consulting, design, design-build, operations and program management for government, civil, industrial and energy clients. www.ch2m.com
Charles Whisman
JOHN MOLNAR, ARMSTRONG FLUID TECHNOLOGY
Dave Morrow TORONTO (June 5, 2014) – Armstrong Fluid Technology announced that John Molnar joined DAVE MORROW, OPW the company as technical sales representative, LEBANON, Ohio (June 6, 2014) – OPW announced the promotion of commercial and engineering. In his new role, Dave Morrow to director of product management for its Chemical & he will develop and grow relationships with Industrial business unit. Before this appointment, he was product engineers, contractors and service dealers in the Ontario territory. His main focus will be working John Molnar with standard and YASKAWA AMERICA, INC. acquired Solectria BLACKHAWK SPECIALTY TOOLS acquired configured building Renewables, LLC Trinity Tool Rentals products and design envelope solutions. July 17, 2014 June 10, 2014 Armstrong Fluid Technology designs, engineers and manufactures integrated GE acquired Monsal FRANKLIN ELECTRIC acquired solutions within the building-oriented July 1, 2014 Bombas Leão S.A. fluid-flow equipment industry. www. June 9, 2014 armstrongfluidtechnology.com ACOEM acquired FIXTURLASER
MERGERS & ACQUISITIONS
June 30, 2014
DES-CASE acquired ESCO s sight glass product line June 19, 2014
NATIONAL PUMP COMPANY acquired Bayou City Pump June 3, 2014
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13
AROUND THE INDUSTRY EXONE to Open Combined Production Service Center in Italy NORTH HUNTINGDON, Pa. – (June 19, 2014) The ExOne Company announced the planned opening of a new combined production service center and machine sales center in the Lombardy region of Italy. Said Omar, most recently ExOne’s European sales director, will be ExOne Italy’s managing director. ExOne provides 3-D printing machines and printed products, materials and other services to industrial customers. www.exone.com
WEATHERFORD Opens Integrated Colombia Laboratory BOGOTA, Colombia (June 13, 2014) Javier Betancourt, the president of Agencia Nacional de Hidrocarburos – Colombia, marked the official opening of the new Weatherford lab in
Bogota, Colombia, during a ribboncutting ceremony. This new facility provides traditional core and fluid analysis combined with specialty services such as shale rock properties, geochemistry, wellsite geosciences, frac fluids, drilling fluids and elastomer testing for progressive cavity pumps. Weatherford International provides oilfield products and services across the drilling, evaluation, completion, production and intervention areas. www.weatherford.com
DYNAMIC INDUSTRIES INTERNATIONAL LLC Receives SAGIA License HOUSTON (June 11, 2014) – Dynamic Industries International LLC announced that its Saudi Arabian office received its license to operate from the Saudi Arabian General Investment Authority (SAGIA). Dynamic Industries International LLC provides full-service fabrication, construction
and maintenance services to the offshore worldwide markets. www. dynamicind.com
SIEMENS Invests in Software Grants RICHMOND, Va. (June 5, 2014) Siemens announced more than $1 billion of in-kind software grants for manufacturing programs at community colleges and universities in Virginia. The series of in-kind grants was established as a result of an industry need for skilled workers and is designed to support the state’s largest industrial employer, Newport News Shipbuilding, a division of Huntington Ingalls Industries, and other companies with local ties such as Rolls-Royce. Siemens Industry Sector supplies products, solutions and services for industrial customers. www.siemens.com
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NEWS
AROUND THE INDUSTRY ABB TURBOCHARGING Inaugurates Denmark Facility BADEN, Switzerland (June 4, 2014) ABB Turbocharging announced a ceremony that celebrated the opening of a new service facility in Fredericia,
Denmark. The ceremony also marked the completion of the amalgamation of its activities in Norway, Denmark and Sweden into a single Local Business Unit. ABB Turbocharging Scandinavia comprises service stations in Oslo and
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Bergen in Norway, Göteborg in Sweden, and the new central workshop for Denmark in Fredericia. Additionally, the company has two service engineers and a sales team stationed in Copenhagen. This geographical footprint will soon be furthered by a new service point in Tromsø, Norway. ABB Turbocharging manufactures and services turbochargers. www.abb.com
GRUNDFOS, PUB to Collaborate on Water Technologies SINGAPORE (June 3, 2014) – Pump manufacturer Grundfos and PUB, Singapore’s national water agency, have signed a memorandum of understanding (MOU) to collaborate on the development of water technologies and solutions. The MOU sets out to support PUB in its mission to ensure a robust and sustainable water supply for Singapore and to continuously explore new technologies and solutions to meet current and future water challenges. PUB is a statutory board under the Ministry of the Environment and Water Resources. It is the water agency that manages Singapore’s water supply, water catchment and used water. www.pub.gov.sg Grundfos is a pump manufacturer, offering water solutions with modular, energy efficient and intelligent products and services that can be tailored for industrial, water utility, water supply, urban and agricultural applications. www.grundfos.com
EPA Proposes Guidelines to Cut Carbon Pollution WASHINGTON (June 2, 2014) – At the direction of President Obama and after an unprecedented outreach effort, the U.S. Environmental Protection Agency (EPA) released the Clean Power Plan proposal, which for the first time cuts carbon pollution from existing power plants, the single largest source of carbon pollution in the U.S. The proposal aims to protect public health, move the U.S. toward a cleaner environment and fight climate change while supplying Americans with reliable and affordable power. By 2030, the steps that the EPA is taking will: • Cut carbon emission from the power sector by 30 percent nationwide
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NEWS
AROUND THE INDUSTRY below 2005 levels, which is equal to the emissions from powering more than half the U.S. homes for one year • Cut particle pollution, nitrogen oxides and sulfur dioxide by more than 25 percent • Avoid up to 6,600 premature deaths, up to 150,000 asthma attacks in children, and up to 490,000 missed work or school days—providing up to $93 billion in climate and public health benefits • Shrink electricity bills roughly 8 percent by increasing energy efficiency and reducing demand in the electricity system EPA’s mission is to protect human health and the environment. www.epa.gov
ABAKAN Increases Direct Ownership in MesoCoat
WEF, IWA Sign Water Management MOU
MIAMI (June 2, 2014) – Abakan Inc. announced that it has increased its ownership position in its majority owned subsidiary, MesoCoat Inc., to a 87.5 percent direct and 89.9 percent direct and indirect ownership. The increase is the result of converting an additional $6.2 million in MesoCoat investment into equity and exchanging 21 percent of ownership in Powdermet for 65.3 percent of Powdermet’s shares of MesoCoat. Abakan develops, manufactures and markets advanced nanocomposite materials, fabricated metal products and metal composites for applications in the oil and gas, petrochemical, mining, aerospace and defense, energy, infrastructure, and processing industries. www.abakaninc.com
ALEXANDRIA, Va. (May 27, 2014) The Water Environment Federation (WEF) and the International Water Association (IWA) signed a memorandum of understanding (MOU) intended to accelerate joint work to grow and disseminate water knowledge and to serve and advance the global water profession. WEF is a not-forprofit technical and educational organization representing water quality professionals around the world. www.wef.org IWA is a global network of water professionals that spans the continuum between research and practice, covering all facets of the water cycle. www.iwahq.org
To have a news item considered, please send the information to Savanna Lauderdale,
[email protected].
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NEWS
EVENTS PumpTec-USA Sept. 10 – 11, 2014 Georgia World Congress Center Atlanta, Ga. 770-310-0866 www.pumpconference.com Turbomachinery/ Pump Symposia Sept. 23 – 25, 2014 George R. Brown Convention Center Houston, Texas 979-845-7417 pumpturbo.tamu.edu WEFTEC Sept. 27 – Oct. 1, 2014 New Orleans Morial Convention Center New Orleans, La. www.weftec.org
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International Association of Amusement Parks and Attractions (IAAPA) Nov. 18 – 21, 2014 Orange County Convention Center Orlando, Fla. 703-836-4800 www.iaapa.org PumpTec-Israel Dec. 3 – 5, 2014 Jointly with Electricity-Israel 2014 Conference Eilat, Israel 770-310-0866 www.pumpingmachinery. com/conference_2014_Israel/ conference_2014_Israel.htm
POWER-GEN International Dec. 9 – 11, 2014 Orange County Convention Center Orlando, Fla. 918-831-9161 www.power-gen.com NGWA Expo & Annual Meeting Dec. 9 – 12, 2014 Las Vegas Convention Center Las Vegas, Nev. www.ngwa.org AHR EXPO Jan. 26 - 28, 2015 McCormick Place Chicago, Ill. www.ahrexpo.com
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20
PUMP ED 101 By Joe Evans, Ph.D. Pump Tech Inc., P&S Editorial Advisory Board
Three-Phase Voltage Variation & Unbalance Last of Two Parts
I
n my July 2014 column, I demonstrated that threephase voltage variation can signiicantly afect several alternating current (AC) motor characteristics. If that variation is large, it can also reduce motor life. Voltage unbalance can be an even bigger problem and is one of the major causes of premature motor failure. A relatively small unbalance of just 2 percent can reduce expected insulation life by half.
Calculating Voltage Unbalance Unlike voltage variation, unbalanced voltage occurs when the three phases are not at the same voltage. An example of perfectly balanced phase voltage is L1/L2 = 460 V, L2/L3 = 460 V and L3/L1 = 460 V. he average voltage is 460 volts. An example of unbalanced phase voltage is L1/L2 = 462 V, L2/L3 = 468 V and L3/L1 = 450 V. Again, the average voltage is 460 V, but the unbalance is 2.2 percent. Voltage unbalance is calculated by the following equation: Percent unbalance = 100 x (maximum voltage deviation from average / average voltage) In the example above, the maximum voltage deviation from the average voltage is 10 V (460 Augus t 2 014 | Pum ps & S ys t e m s
minus 450). Motors from member companies of the National Electrical Manufacturers Association (NEMA) are designed to tolerate no more than 1 percent of voltage unbalance. Why does voltage unbalance shorten motor life? One percent of voltage unbalance can result in 6 to 10 percent of current unbalance. he phase with the lowest voltage exhibits the highest current, which increases the operating temperature of the winding serviced by that phase. It will also increase the over-
all operating temperature of the motor. Figure 1 shows the increase in operating temperature versus voltage unbalance. As shown, an unbalance of just 3 percent can increase operating temperature by almost 20 percent. At 5 percent unbalance, operating temperature will increase by 50 percent.
Temperature Rating & Insulation Class Motor operating temperature is the sum of the ambient temperature surrounding the motor and the
Figure 1. Overheating because of voltage unbalance
21
Voltage unbalance is one of the major causes of premature motor failure. A relatively small unbalance of just 2 percent can reduce expected insulation life by half. temperature rise due to the motor load. he temperature rise is usually measured using the resistance method. Each insulation class has a speciic temperature rating. For example, Class F is rated at 155 C (311 F). he temperature rating is the maximum operating temperature allowed in order to meet an average insulation life of 20,000 hours. Of that rating, 10 C is reserved for the hot spot allowance. he resistance method measures the average temperature rise in the stator windings, but at some places— such as the stator slots—the temperature can be higher than the average measurement. he hot spot allowance is reserved to protect these areas. h is reduces the actual operating temperature (ambient plus measured average) to 145 C. For every 10 degrees over 145 C, insulation life is reduced by half. For every 10 degrees below 145 C, insulation life doubles. Suppose a motor with Class F insulation operates at an ambient temperature of 40 C. he measured temperature rise at full load is 90 C. herefore, the operating temperature is 130 C. he expected insulation life would be about 50,000 hours or about 2.5 times the life at 145 C. But at 3 percent phase voltage unbalance, the operating temperature increases by 19 percent (155 C) and insulation life is reduced by 50 percent. Image 1 shows the windings of a motor that failed because of high voltage unbalance. When a motor loses one phase (single phasing), the other two phases have to carry the entire load. As a result, two sets
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22
PUMP ED 101
of phase windings are destroyed, and the one that lost power is unharmed.
Motor Phase Loss & Failure In the case of unbalance, the winding with the highest current fails and, usually, the other two are still functional. In the motor shown in Image 1, one of the phases has failed, one is normal and the third is beginning to show the efect of higher temperature. Measuring voltage unbalance and i xing the cause are much less costly than having it diagnosed in a motor shop. See “Pump Ed 101” in the July 2008 issue of Pumps & Systems for instructions on diagnosing the cause of unbalanced voltage. Although correcting voltage unbalance is always best, a few rules can allow operation in unbalanced applications. For example, if the leg with the highest current is under the nameplate full load amperage (FLA), it will safely operate. If
Image 1. Windings of a motor that failed because of high voltage unbalance. (Image courtesy of EASA)
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23
Visit Booth 1543 43rd Turbomachinery 30th Pump Symposia Houston, TX
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PUMP ED 101
In addition to reduced insulation life, unbalanced voltage can also increase electrical costs by decreasing motor efficiency.
it is above nameplate FLA but still within the service factor (SF), it may still safely operate. As a rule, if the high current leg is less than 10 percent higher than the average current, it will probably safely operate. A less desirable alternative is to derate the motor’s nameplate horsepower. NEMA suggests derating horsepower to 75 percent of nameplate at an unbalance of 5 percent. At 4 percent unbalance,
it is derated to 82 percent. At 3 percent, it is derated to 88 percent, and at 2 percent, it is derated to 95 percent. In addition to reduced insulation life, unbalanced voltage can also increase electrical costs by decreasing motor eiciency. At 1 percent unbalance, eiciency remains at the nameplate nominal eiciency. However, at 3 percent unbalance, actual motor eiciency can be reduced by 2 percentage points.
Joe Evans is responsible for customer and employee education at PumpTech Inc., a pump and packaged system manufacturer and distributor with branches throughout the Pacific Northwest. He can be reached via his website www. PumpEd101.com. If there are topics that you would like to see discussed in future columns, drop him an email.
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26
PUMPING PRESCRIPTIONS By Lev Nelik, Ph.D., P.E. Pumping Machinery, LLC, P&S Editorial Advisory Board
Simplify the Equipment Selection Process
W
hen the pump selection process starts, the required low of the is often the only known variable for an application. For example, a system must move 2,000 gallons per minute (gpm) from a holding tank to another tank or process. What size pump do should be installed? he size and pressure of the piping and the power of the motor must also be determined. his column helps explain how to make these decisions.
A = pipe area in square inches (in2) In our example, 5 = 2,000 x 0.321 / A A = 2,000 x 0.321 / 5 = 128.4 in2 pipe area, or 12.8 inch diameter
h is diameter can round to a 12inch pipe with a velocity of slightly more than 5 ft/sec. he next step is to igure out the amount of pressure in the system Pump & Piping Size if the pump is 5,000 feet away he longer the piping, the more from the process’discharge. his pressure its internal friction will determination is more complicated generate. A good way to pick a pipe size is to calculate its diameter from because some hydraulic informaan empirical but simple starting tion is needed. Several options can formula. h is will help establish an provide this information: come to approximate range. Pipe velocity is class, consult a piping friction loss usually between 5 and 10 feet per chart or take my word for it that the second (ft/sec). losses for cold water at 2,000 gpm he smaller a pipe’s diameter, the in a 12-inch, 5,000-foot pipe are faster luid lows through it. he about 70 feet. larger the pipe, the more expensive With the low and head deterit is. Also, lowing too slowly may mined, the motor can be sized (see cause particulate matter to settle Table 1). Also, an online Eiciency and clog the line, but lowing too Estimator, which can be found at quickly will wear the pipe. he 5 www.mj-scope.com/pump_tools/ to 10 ft/sec range is usually a good pump_eiciency.htm, ofers useful starting point. Equation 1 can used formulas. for a more accurate calculation. To handle the process speciications, a single-stage pump was seV = Q x 0.321 / A lected. he Eiciency Estimator calEquation 1 culated that a 42-horsepower and 84.5-percent pump eiciency can Where: be expected from a typical pump. V = velocity in ft/sec h is number can be conirmed with Q = low in gpm quotes from pump distributors.
Augus t 2 014 | Pum ps & S ys t e m s
he Eiciency Estimator also suggests an impeller size of 9.77 inches. h is measurement is a good way to roughly verify the appropriate sizes of existing pumps. his process provides useful preliminary information for pump selection.
Motor Size A 1,800-rpm motor speed was selected for this process because it is one of the most common motor speeds in the U.S. he horsepower recommendation can be rounded to select a 50-horsepower motor. If the pump is expected occasionally to operate outside the curve, choosing a 75-horsepower leaves a margin of safety.
Table 1. Sizing motors during pump selection (Graphics courtesy of the author.)
US Units Pump low (gpm)
2,000
Total pump head (ft)
70
Speciic gravity (SG)
1.00
Number of stages Speed (rpm) Header per stage (ft)
1 1,800 70
Impeller diameter (in)
9.77
Speciic speed U.S. (Ns)
3,326
Speciic speed metric (ns)
64.5
Speciic speed universal (Os)
1.22
Eiciency (%)
84.5
Power (hp)
42
27
If a pump has too little NPSHA, it could experience suction problems. Too much NPSHA leads to higher contruction costs. Users must find the right balance.
NPSHA Calculation he suction side must be considered. My last few columns discussed pump suction performance. For example, I discussed how the system afects the operation and the relationship between the low (as a percent of the best eiciency point) and suction recirculation. Many end users question how much net positive suction head available (NPSHA) they need.
If a pump has too little NPSHA, it could experience suction problems. Too much NPSHA leads to higher construction costs. Users must ind the right balance. My next column will describe in detail the beginning of the selection process. For those interested in how to calculate the piping losses estimated (70 feet of head), my Pump School training covers this in-depth.
Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machinery, LLC, an Atlanta-based firm specializing in pump consulting, training, equipment troubleshooting and pump repairs. Dr. Nelik has 30 years of experience in pumps and pumping equipment. He may be reached at pump-magazine.com.
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PUMP SYSTEM IMPROVEMENT By Ray Hardee Engineered Software, Inc.
System Validation & Troubleshooting
I
n the previous article calculating the cost of elements in a piping system (Pumps & Systems, July 2014), the energy consumed and power cost balanced exactly to demonstrate the process. Seldom is life that exact. In the real-world plant, instruments are subject to inaccuracy, pumps may be worn, estimates may be of or the full system may not be accurately represented in the design documents. h is month’s article demonstrates how cross-validating the calculated results can ensure the energy cost balance sheet accurately relects system operation. he key to validating the results is to use multiple means for arriving at the operating cost of each item in the energy cost balance sheet. If the energy cost balance sheet does not add up, troubleshooting skills need to be employed to discover the reason for the difference. h is article will continue to use the example piping system presented in previous articles (see Figure 1).
Prioritizing the System he pump elements provide all the energy that enters the system. hat energy is then consumed by the system’s process and control elements. If the energy cost balance sheet does not balance, operators should begin looking for the source of the problem. he major energy users Augus t 2 014 | Pum ps & S ys t e m s
in the system should be examined, and operators should ind methods to cross-validate the initial estimates.
Pump Performance In the example, the pump’s low rate was determined using the
manufacturer’s pump curve. With a known low rate, the pump eficiency can be determined from the curve. Because the pump eiciency is used in all energy cost calculations, ensuring the accuracy of the value is critical.
Figure 1. Drawing of sample piping system (Article graphics courtesy of the author.)
Figure 2. An example showing the effect internal leakage has on pump performance. Because of internal leakage, the installed pump is not operating as designed.
29
Inaccuracies can occur in real-life operating conditions. For example, if the pump has a worn impeller and excessive internal leakage, it no longer relects the pump curve’s operation. Figure 2 shows a pump curve for the process pump along with an example of the efect that excessive internal leakage can have on the pump curve. Using the calculated head difference of 235 feet (ft), the worn impeller gives a low rate of less than the 4,000 gallons per minute (gpm) used in the previous energy system balance. In addition, the eiciency of a worn impeller would difer from the manufacturer-supplied test curve. h is would result in inaccurate power consumption and operation costs calculations. Operators have other options to determine the low rate through the pump, including portable ultrasonic low meters. hese meters provide a reasonably accurate low measurement in a pipeline without physically changing the piping system. If the observed low rate on the temporary low meter equals the value determined using the pump head and the pump curve, the low rate is validated, and the eiciency is validated by association.
kW = .746 ×
If a power meter is installed on the motor driving the pump, the measured kilowatt (kW) value can be compared to the calculated
power consumed using the pumps low, head and eiciency values as show in Equation 1, at the bottom of page.
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Q×H×ρ 247,000 × ηP × ηM Equation 1
Where: Q = low rate in gpm H = pump head in ft ρ = luid density lb/ft3 η P = pump eiciency η M = motor eiciency
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PUMP SYSTEM IMPROVEMENT
If the power into the motor as read on its power meter is the same as the calculated power consumption using Equation 1, the pump’s low, head and eiciency values are validated. If a power reading is not available for the motor, the motor’s power consumption can be calculated by measuring the current and voltage supplied to the pump’s motor, then using Equation 2. he motor’s power factor can be read on its nameplate.
Control Valves In last month’s example, the differential pressure across the control valve was calculated by subtracting the sum of the head losses of the process elements from the pump head. h is approach is easy, but any errors made in the previous calculations will compound and can greatly reduce the energy cost balance sheet’s accuracy. Valve manufacturers deine the operation of control valves based on tests that are outlined in published √3 × V × I × Pf P3ϕMotor = industry standards. Manufacturers 1,000 use the ANSI/ISA-75.01.01 Flow Equation 2 Equations for Sizing Control Valves Where: to size control valves for piping P3ϕMotor = motor power in kW systems. he data used in valve V = voltage volts sizing can also be used to calculate I = current amps the diferential pressure across the Pf = motor power factor control valve. Equation 3 shows the basic forIf the calculated value of motor mula for valve sizing. power equals the pump’s power conQ sumption, the pump low, head and Cv = P 1 – P2 eiciency values are validated. FP S
√
Tank Levels and Pressures he tanks and vessels make excellent piping system boundaries. he energy at each tank can be determined by using the elevation of the liquid level in the tank and pressure on the liquid surface. From these values the energy consumed for the static head component can be easily calculated. he results can be cross-validated using installed pressure and level instrumentation. he liquid level can be checked with a sight glass or by manually measuring the liquid level in the tank. he pressure in a closed vessel can be compared using the installed plant instrumentation, installed pressure gauges or a temporary pressure gauge.
Augus t 2 014 | Pum ps & S ys t e m s
Equation 3 Where: Cv = manufacturer-supplied valve coeicient Q = low rate in gpm FP = piping geometry factor (unitless) P1 = absolute pressure measured at valve inlet in lb/in2 P2 = absolute pressure measured at valve outlet in lb/in2 S = luid speciic gravity (unitless)
Rearranging the control valve sizing equation and solving for differential pressure results in Equation 4. dP =
Q2S (CvFP)2 Equation 4
In the example system with a low rate through the level control valve of 2,500 gpm, the control valve position is 65 percent. According to the manufacturer’s data for the control valve, the Cv at this position is 391. he FP of .9996 was calculated by the manufacturer and included in the valve data sheet. he speciic gravity of the process luid was calculated at .993. he low rate through the level control valve was measured at 2,500 gpm. Inserting the values into Equation 4 provides the diferential pressure across the control valve. dP =
Q2S 25002 × .993 = 40.6 psi = (CvFP)2 (391 × .9996)2
Converting the control valve’s diferential pressure of 40.6 pounds per square inch (psi) to feet of luid results in a head loss of 94.3 ft. his result for the control valve calculation validates the number from last month’s calculations.
Process Equipment he diferential pressure across the process equipment was calculated using the pressure drop data supplied by the manufacturer and the
If the calculated value of motor power equals the pump’s power consumption, the pump flow, head and efficiency values are validated.
31
Problems that could affect the head loss calculation include fouling or sedimentation in the pipelines, partially closed valves, or obstructions in the pipe, valves or fittings.
Pipelines In the example, the head loss in the individual pipelines was calculated, then used to determine the head loss in each circuit of the pipeline. h is requires a large number of calculations. he repetitive nature of the calculow rate obtained from the installed validated by installing temporary lations makes this an excellent task low element. In the example, the pressure gauges. to be performed using a computer. heat exchanger pressure drop of Most process equipment has vent Online head loss calculators can be 10 psi was assumed based on the and drain lines installed for mainfound by performing an Internet manufacturer’s supplied data. If the tenance. search. Commercially available heat exchanger tubes were fouled By installing temporary pressure computer programs can also greatly due to internal deposit, the actual gauges on the vent and drain lines— simplify the task. diferential pressure across the heat and correcting the pressure values Problems that could afect the exchanger would be greater than for any diference in elevation of the head loss calculation include fouling the value used in the energy cost gauges—the diferential pressure or sedimentation in the pipelines, calculation. and head loss across the item can be partially closed valves, or obstruche diferential pressure across measured. tions in the pipe, valves or ittings. the process equipment can be Inaccurate determination of the pipe
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PUMP SYSTEM IMPROVEMENT
size or schedule, or inaccurate estimates of the number of ittings or pipe length can also afect the head loss calculation.
Total System If the energy cost balance sheet does not balance, either the measured plant data or the equipment
ump s At P See U posium m Sy 903 Booth
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(pumps, process components or control valves) could be causing the problem. To conirm the accuracy of the measured data, check to see that the instruments are calibrated. he instrumentation department can also make sure the instruments are accurately reading the process parameters. he irst step is to check for cavitation throughout the whole system. Cavitation is caused when the local pressure drops below, then rises above, the vapor pressure of the process luid. Some of the luid is converted from liquid to vapor. he vapor bubbles take up extra space in the low stream, which causes a reduction in the mass low rate. All standards and calculation methods used to determine head loss assume single phase low. If cavitation occurs, the calculated results will not accurately relect what is happening in the system. Cavitation is especially troublesome in pumps and control valves. It can be a major source of maintenance problems and should be corrected prior to performing a system assessment. Next, the interaction of the system’s components should be examined. he best way to accomplish this is to compare the current observed values with previous observed values. For example, the average valve position of the level control valve increased over time from 65 percent open to 71 percent open. he rest of the measured plant data remained the same. Using Equation 4, the head loss across the level control valve decreased from the original 94 ft of loss to 71 ft. he only explanation for this change is that the head loss across the process element increased
Following our recent acquisition of the second largest pump rental company in North America, United Rentals has further expanded its specialty offerings to meet customers’ diverse business needs. Our team is proud to provide the best equipment, tools and solutions in the industry. You’re building the future. We’re here to help.™
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34
PUMP SYSTEM IMPROVEMENT
from the manufacturer’s published value of 23 ft to 46 ft. his is a clear indication of fouling in the process equipment.
Conclusion Gaining a clear picture of how a piping system operates is key to assessing the system.
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Because most operating plants do not have suicient installed plant instrumentation to provide all the data needed for the calculations, many of the values must be calculated using other well-established methods. By performing the calculations and comparing them to available operating data, operators can determine how the system is currently operating. h is information allows operators to correct any problems that adversely afect system operation and perform an accurate assessment of the piping system by completing an energy cost balance sheet. My next few columns will investigate a variety of plant systems. hey will demonstrate what can be gained with a better understanding of system operation and what can be done to reduce operating, maintenance and capital cost within piping systems.
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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 in the U.S. and internationally. He is a member of the ASME ES-2 Energy Assessment for Pumping Systems standards committee and the ISO Technical Committee 115/Working Group 07 “Pumping System Energy Assessment.” Hardee was a contributing member of the HI/Europump Pump Life Cycle Cost and HI/PSM Optimizing Piping System publications. He may be reached at
[email protected].
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36
GUEST COLUMN By Heinz P. Bloch, P.E.
Pushing Fluid Machinery Leads to Frequent Failures Second of Four Parts
D
espite their simplicity, centrifugal pumps often experience repeat failures that even seasoned maintenance and reliability professionals have trouble preventing. h is four-part series explains the reasons behind repeat pump failures and uses a real-world ield example involving boiler feedwater pumps. Deviations from best practices or oversights can range from seemingly insigniicant to stunningly elusive. hese can combine and often cause costly failures.
Operating Diferent Pumps in Parallel he negative experience of a metal producing facility best
demonstrates the consequences of year to meet the plant’s production operating pumps beyond their apneeds. he system has operated in propriate low ranges. h is example this way since being commissioned serves as a reminder of the merits ive years ago. of conducting in-depth reliability reviews before Figure 1. Pump manufacturers usually plot only the net positive suction head required (NPSHR) trend associated with the lowermost curve. At that buying process pumps. point, a head drop or pressure fluctuation of 3 percent exists at BEP flow.1 h is case history extends to the remaining parts of this series. he operating data of the plant’s installed instrumentation is shown in Figure 1. he low rate into the destination tank averages 2,500 gallons per minute (gpm) to maintain the tank level. h is system currently operates for 8,000 hours per
Figure 2. A typical head-versus-flow performance curve
Image 1. This riveted cage bearing failed because of axial (rotor thrust) overload. (Article images and graphics courtesy of the author.) Augus t 2 014 | Pum ps & S ys t e m s
37
h is case history is one of many examples that validate the importance of examining the low-versus-head characteristics (the H/Q curves) of pumps. Such examinations are needed during the procurement phase of new pumps and the troubleshooting of installed but failure-prone process pumps. Seven boiler feedwater (BFW) pumps were installed in the metal producer’s boiler house. Two of the facility’s seven pumps came from Vendor A, two from B and three from C. he respective H/Q curves from vendors A, B and C were not identical. By 2009, these pumps had failed often and randomly. he need for a thoroughly experiencebased failure analysis was recognized. he analysis pointed to hydraulic and mechanical issues. hrough the years, this facility routinely ran several BFW pumps in parallel. Fear of failure may have prompted operating four pumps in parallel when only three were required to provide a speciic low rate. If running three pumps, each pump could have operated closer to its BEP, but operating four pumps led to a greater failure risk. In other words, one or more of these four pumps operated in the questionable or forbidden lowlow and high-internal-recirculation range illustrated in Figure 1.
Low-Flow Range At least two of the pumps had l at H/Q curves, similar to the curve in Figure 2. Running in the low-low range forced one or both pumps into the l at portion of their respective performance curves. When operating in the l at range, even a small change in head (a small change in Δp) results in large diferences in throughput.
Controlling and equalizing load sharing would be diicult. In addition, the internal pump clearances opened as time
progressed. his explanation was in line with the recent escalated failure frequencies. It led to the recommendation of investigating
1970 Dodge Super Bee
Process Maxum
Do you have flows up to 9,900 GPM (2,000 m3/hr), heads up to 720 Ft (220 M), speeds up to 3,500 RPM, and temperatures up to 500°F (260°C)? Then you need Carver Pump Process Maxum Series muscle! With an extended range of hydraulic coverage and rugged construction, the Process Maxum Series is ideal for Industrial Process applications. Manufactured in 35 sizes, standard materials include WCB, WCB/316SS, 316SS and CD4MCu, with others available upon request. A variety of options include various types of mechanical seals and bearing lubrication/cooling arrangements, auxiliary protection devices and certified performance testing. Whatever your requirements, let us build the muscle you need!
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38
GUEST COLUMN
the minimum low allowed for these high-suction-energy, BFW pumps. he concept of high suction energy and what it means in terms of the required net positive suction head available (NPSHA)/net positive suction head required (NPSHR) ratio and/or reduced allowable operating range is thoroughly explained in References 3 and 4. Internal wear and operation at lower-than-designed low afect the hydraulic thrust acting on a pump rotor. his often contributes to thrust bearing failures similar to the one shown in Image 1 and might even explain the excessive wear on the worm wheel of one of the shaft-driven lube oil pumps. In general, rolling element bearings with riveted cages should be avoided in process pumps. Part hree of this
four-part series will explain why this is recommended. References 1. Taylor, Irving, “he Most Persistent Pump-Application Problems for Petroleum and Power Engineers,” ASME Publication 77-Pet-5 (Presented at Energy Technology Conference and Exhibit, Houston, Texas, September 18 – 22, 1977). 2. Bloch, Heinz P., Pump Wisdom: Problem Solving for Operators and Specialists, John Wiley & Sons, Hoboken, N.J., 2011. 3. Bloch, Heinz P. and Alan R. Budris, Pump User’s Handbook, 4th Edition, Fairmont Press, Lilburn, Ga., 2013. 4. ANSI/HI9.6.3-1997, “Allowable Operating Region,” Hydraulic Institute, Parsippany, N.J. 5. SKF USA, Inc., Publication 100 – 955, “Bearings in Centrifugal Pumps,” Version 4, p. 20, Kulpsville, Pa., 2008. 6. Bloch, Heinz P., Practical Lubrication for Industrial Facilities, 2nd Edition, Fairmont Press, p. 179, 2009; “Mechanical Seals in Medium-Pressure Steam Turbines,” presented at the ASLE 40th Annual Meeting in Las Vegas, Nev., May 1985 (later reprinted in Lubrication Engineering, November 1985).
Heinz P. Bloch has been a professional engineer for almost 50 years. He holds a BSME and an MSME degree (cum laude) from New Jersey Institute of Technology and retired as Exxon Chemical Company’s regional machinery specialist. He authored or co-authored 18 comprehensive textbooks dealing with lubrication and fluid machinery topics and published more than 570 technical papers or articles. Bloch has taught reliability improvement and maintenance cost avoidance subjects on six continents. He continues to write for trade journals and advises and teaches machinery reliability improvement subjects. He may be reached at
[email protected].
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Control. Manage. Optimize. Measuring everything from water in hydraulic fracturing or mining operations to gases and liquids from wellheads, the Blancett family of turbine low meter solutions delivers accurate, consistent, reliable and now more informative low measurements. The B3000 low monitor revolutionizes ield measurements with built-in alarm parameters that provide faster warnings when conditions change in the process or pipeline. Visit www.badgermeter.com/blancett or call 800-433-5263 for more information today.
Flow Instrumentation Solutions © 2014 Badger Meter, Inc. Blancett is a registered trademark of Badger Meter, Inc.
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40
GUEST COLUMN By Amin Almasi
Estimate Pump Installation Costs
C
ost estimation errors are common in a variety of projects. Recent studies have shown the cost of machinery can represent 20 to 35 percent of a processing and manufacturing project’s total cost. he estimated costs for new plants and particularly new pump installations are very uncertain and have increased in recent years. he following concepts minimize the cost of pump installations: • Maximizing the extent of manufacturing and installation in the shop environment • Simplifying a pump package’s transportation and installation • Providing modularized components that are easy to change • Reducing on-site personnel supports and encouraging unmanned operation • Eliminating as many standby pumps as possible Very limited literature is available on pump cost estimation. h is column will focus on the cost estimation of the pump installations in diferent projects.
Pump Installation Cost Estimate Historical data could inform pump installation cost estimation models within certain limits. Results have shown a large cost diference between diferent regions. he economies of concentration play an important role in cost. Cost studies have indicated that Augus t 2 014 | Pum ps & S ys t e m s
pump installation cost components usually have economies that are to scale to pump unit capacity and pump train size. he cost estimation of a pump unit or installation in a plant cannot be fully accurate, with the exception of the material cost, particularly the cost of a pump package. h is cost can be estimated from the pump package’s vendor, and the cost of materials could be obtained from suppliers. However, other cost estimations are relatively inaccurate. Labor costs have much larger cost overruns compared to other cost components. he following estimation concept can be employed for a pump unit or installation: (Pump Unit Cost) = A × (Pump Package Cost) + B he factor A is assigned for all auxiliaries and accessories required for each pump package such as the foundation, civil works, piping and additional steel structures for each pump package. his factor is usually between 1.3 and 2.5. he pump package cost includes all skid-mounted facilities such as the driver and lubrication oil system.
he factor B is assigned for all auxiliaries and accessories required for each pump unit, such as unit piping, unit utilities, protection systems, unit pit/drain, unit electrical facilities, safety equipment, unit steel structures and unit civil works. Because the cost underestimating error is generally larger than the overestimating error, proper safety margins for factors A and B are always encouraged. he cost is also a function of the project size or the pump system capacity. A proper set of factors should be developed for a deined range of the pump unit size and capacity for a region. Environmental conditions—soil, terrain, cost of living, population density, economies of scale, noise limits, applicable codes and distances from pump supplies—could afect the installation cost estimation and should be considered when the cost factors are estimated.
Other Costs Studies on recent pump installations have shown that the cost of civil works (site developments, foundations and others) are about 9 to 20 percent of the total cost.
Cost studies have indicated that pump installation cost components usually have economies that are to scale to pump unit capacity and pump train size.
41
hey have also shown that the cost of installation can be approximately 7 to 11 percent of the total cost. he required man-hours for the installation and commissioning of pumps can vary signiicantly. For packaged pumps, the following indications should be noted: • For large pump packages (more than 1 megawatt (MW)), the installation and commissioning man-hours could be between 300 and 900 hours. • For small pump packages (less than 1 MW), the installation and commissioning man-hours could be between 100 and 300 hours.
Case Study he irst case study is presented for a 6 MW pumping unit. he costs of electric motor-driven pump packages are obtained in millions of U.S. dollars (MUSD): • A 3 MW pump package: 0.9 MUSD • A 1.5 MW pump package: 0.6 MUSD • A 0.8 MW pump package: 0.45 MUSD
A proper set of factors should be developed for a defined range of the pump unit size and capacity for a region.
he factor A is estimated at 1.67 for these pump packages. he factor B is estimated at 1.5 MUSD for a 6 MW pump unit. Table 1 compares the cost of these diferent options. As shown, smaller pumps considerably increase costs. A greater number of smaller pumps is more expensive than using a single large pump. he second case study is presented for small pump installations. he following two options are considered: • Option 1: A 320 kW pump, $52,000 • Option 2: A 200 kW pump, $42,000 he factor A is estimated at 1.49 for these small pump packages. he factor B is estimated at $45,000 for Option 1 and $34,000 for Option 2.
Table 1. Costs of different pump arrangement options (Article graphics courtesy of the author.)
Pump Unit
Rough Cost of Packages (MUSD)
Rough Total Cost (MUSD)
Rough Cost Ratio
2×3 MW
1.8
4.5
1
4×1.5 MW
2.4
5.5
1.2
8×0.8 MW
3.6
7.5
1.7
Table 2. Cost analysis for two options of small pumps
Pump Option
Package Cost
Installed Cost Rough Cost Ratio
Option 1: 320 kW
$52,000
$122,000
1
Option 2: 200 kW
$42,000
$97,000
0.80
Table 2 shows the cost analysis for two options of small pumps. Based on Table 2, only about 20 percent total installed cost reduction could be expected for a pump 38 percent smaller in size. Large pumps have economies of scale and low unit cost. In other words, unit costs of pump installations usually decrease as pump size increases.
Amin Almasi is a rotating machine consultant in Australia. He is a chartered professional engineer of Engineers Australia (MIEAust CPEng – Mechanical) and IMechE (CEng MIMechE) and a Registered Professional Engineer in Queensland. He specializes in rotating machines— including centrifugal, screw and reciprocating compressors; gas turbines; steam turbines; engine pumps; subsea and offshore rotating machines; LNG units; condition monitoring; and reliability. Almasi is an active member of Engineers Australia, IMechE, ASME, Vibration Institute, SPE, IEEE and IDGTE. He has written more than 80 papers and articles dealing with rotating equipment, condition monitoring, offshore and subsea equipment, and reliability. Almasi may be reached at
[email protected] or +61 (0)7 3319 3902. pu mp-zone.c om | Au gu st 2014
42 SPECIAL SECTION
SEALS & BEARINGS
Canned Magnetic Bearings Minimize Corrosion in Oil & Gas Processing Safely immerse motor compressors in process gas without risking costly damage. BY RICHARD SHULTZ WAUKESHA MAGNETIC BEARINGS
A
ctive magnetic bearing (AMB) reliability and availability levels have surpassed oil bearings after 10 years of technological advancements. hese advances have made an impact on the industry, drawing attention from major original equipment manufacturers globally. In 2002, an oil and gas processing company required a bearing for a hermetically sealed integral motor compressor. he natural gas from the well contained hydrogen sulide, which lead the company to pursue a corrosion-resistant canned bearing. Finding a reliable bearing for this hermetically sealed integral motor compressor was a challenge—but one worth the cost. he solution included sealed bearings and electrical connectors, which eliminated the need for a costly enclosure surrounding the motor compressor. Installing the motor compressor outdoors, without a building or enclosure, saved the company signiicantly in capital expenditures. he hermetic sealing of the bearings and motor compressor also ensured that emission limits were not exceeded for sites in which operating licenses limited hydrocarbon emissions.
Process Gas Immersion Magnetic bearings are an efective solution for many oil and gas applications because they can be immersed in the process gas. A Augus t 2014 | Pum ps & S yst e m s
canned magnetic bearing with metallic lined stators segregates the electrical connections and windings from the corrosive gas. Canned bearings allow for the placement of the magnet core and windings behind an impervious pressure-rated barrier constructed of corrosion-resistant alloy or other nonmetallic material. Special alloys ensure that the bearings will not corrode, protecting the inside of the machine from serious degradation. With canned AMB designs, the metallic can separates the pressurized volume inside the machine from the cavity and ambient pressures and protects against leakage to the machine’s exterior. he metallic can must withstand the maximum pressure inside the machine, which is equal to the can’s diferential pressure. A proper design of the metallic can and backing system is crucial to survive all the temperature and pressure conditions that the AMBs will encounter during operation. In one 2006 oil and gas installation, the system has operated safely in its environment. After 25,000 hours, the units’ operation provides 99.9 percent availability to its end user. In addition, the canned bearings’ temperature ratings
43
Because they can be immersed in process gas without corroding the electrical connections, canned magnetic bearings offer oil and gas end users a significant advantage. (Article images and graphics courtesy of Waukesha.) EOG location memphis, tnks jkask
Figure 1. A plot of in situ pH against the partial pressure of hydrogen sulfide shows increasing corrosion from Regions 0 (no effect) to 3 and beyond (highest propensity for SSC).
reached 165 C. Other canned bearings have reached 130 C in similar applications.
Managing Corrosion Risks Magnetic bearings must conform to the corrosion safety standards for oil and gas applications, such as National Association of Corrosion Engineers (NACE) MR0175. he bearings’ electrical components are protected from process conditions, including chemical attack by process gas and condensates. he motor compressor can eliminate the use of dry gas seals, avoiding natural and sour gas damage to the environment. Figure 1 has been adapted from NACE MR0175. It details regions of increasing sour gas corrosion to metal alloys used in oil and gas processing equipment. Corrosion is deined by reference to sulide stress cracking (SSC). p u mp-zone.c om | Au gu st 2014
44
SPECIAL SECTION
SEALS & BEARINGS
Figure 1 shows in what levels of sour gas service sealed and canned designs may be applied while still expecting a reasonable service life, based on documented corrosion rates. he dividing line corresponds to a concentration of about 600 parts per million of sulides.
A rotor system inside a pressure vessel also helps cool the motors and bearings and provides electrical connections that penetrate the pressure vessel. Erosion and corrosion can cause costly damage to a machine’s interior. Canned and corrosion-resistant auxil-
A canned magnetic bearing segregates electrical connections and windings from the process gas.
PumpWorks 610
delivers.
iary bearings ofer a beneit to the oil and gas industry, in which environmental regulations continue to increase. hese bearings can be applied in the manufacturing of integral motor compressors, externally driven compressors and turbo expanders.
Richard Shultz is the design engineering manager for magnetic bearing systems at Waukesha Magnetic Bearings. He has 20 years of industrial experience designing magnetic bearing systems and auxiliary bearing systems, specializing in rotordynamics and control system design. He recently instructed at the Magnetic Bearing Short Course at the Texas A&M Turbomachinery Symposium and the Middle East Turbomachinery Symposium in Qatar.
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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 and Model PWV standard lead times are 16 weeks or less, and PWM Multistage pipeline pumps are 28 weeks or less. In addition, all of our pumps are manufactured in the USA. PumpWorks 610 offers our online ePOD Pump Selector to simplify pump configuration by quickly providing you with pump selection and performance curves right off of our website – no log in required. At PumpWorks 610, you can count on our knowledgeable staff to ensure that your finished product meets or exceeds your exact specifications. Why wait longer to get the pump you need when you need it? Visit www.pumpworks610.com or call 1-800-405-0209 for more information.
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
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45
The Right Seal & Lubricant Combination Can Prevent Bearing Contamination Lip and labyrinth seals provide protection in harsh oil and gas applications. BY JAMES WONG GARLOCK SEALING TECHNOLOGIES
Figure 1. Formation of meniscus of oil under the lip (Article graphics courtesy of Garlock Sealing Technologies.)
W
ithin the oil and gas industry, the rotating shafts of equipment—such as pumps, motors, compressors, gearboxes and turbines—perform an essential function in both upstream and downstream applications. his rotating equipment ensures process low and the safety of employees and the surrounding community. Bearings are critical to the reliability of rotating equipment. If they fail, the equipment has to be repaired or replaced. Because they support the shaft, bearings are prone to wear and damage. Lubrication starvation and contamination are the principal factors that cause premature bearing failure, so systems have been developed to prevent these issues. Methods for sealing the gap between a rotating shaft and the stationary bore have evolved with advances in lubrication and lubrication delivery systems. Selecting the right seal for a lubrication system will yield the best bearing protection. Lip seals and labyrinth seals, also known as bearing isolators, are the most common solutions. Lip seals are unidirectional contact type seals. heir geometry is important for maintaining an optimal radial load on the shaft to develop a meniscus of oil on which the lip can ride, which reduces friction and wear on the shaft and lip (see Figure 1). Depending on the direction of the installed seal, it will either prevent egress of lubrication or ingress of contamination (see Figure 2). Bearing isolators are non-contact seals that provide bidirectional sealing capability. heir construction includes two
Figure 2. Direction determines lubricant retention or contaminant exclusion .
p u mp-zone.c om | Au gu st 2014
46
SPECIAL SECTION
SEALS & BEARINGS
components that rotate independently of each other. he stator remains with the bore, and the rotor rotates with the shaft. Between the stator and rotor is the labyrinth—a small, contorted pathway that prevents the egress of lubrication and ingress of contaminants at the same time (see Figure 3).
Grease Purge Grease is an easy lubricant to apply and maintain, and it can be used to prevent contamination. Its consistency makes it easy to seal within bearing chambers. Most equipment designed for grease lubrication is equipped with a purge stream. his allows fresh grease to be pumped into the bearing chamber, replacing degraded or contaminated grease. Grease purging is a common practice, but should only be carried out with an understanding of the grease low’s efect on the seal. Lip seals are suitable for use with grease lubrication, since only one seal installed facing the external environment is typically needed. h is coniguration prevents contamination of the grease by water or dirt and allows it to be purged under the lip if the discharge port becomes plugged or otherwise obstructed. Lip seals are rarely installed with the lip oriented toward the grease. Applications in which no grease should ever escape the seal, such as those in the food industry, are exceptions. In these instances, a metal case lip seal or cover plate that helps retain the seal in the bore is recommended. his helps prevent the seal from blowing out from purge pressure of the grease. Operating temperature is an important consideration when selecting lip seal material. Because grease does not dissipate heat as well as oil, adding another 100 degrees Fahrenheit to the operating temperature is recommended to ensure that the material can withstand the heat. Bearing isolators are also suitable for use with grease lubrication. hey can retain grease within the bearing chamber even during purging. Because of the consistency of grease, the level of lubrication is not a concern. Bearing isolators are customizable. If the equipment does not have a grease discharge port or if the port is obstructed, a special bearing isolator can be designed to purge the grease through the isolator itself (see Figure 4). Oil Bath Oil bath/splash is the simplest type lubrication system. It requires only minimal maintenance. A side glass or dip stick should be provided with these systems to ensure that the proper level of lubrication is maintained. he level typically should be at the center of the lowest rolling element of the bearing. With each rotation of the shaft, the rolling elements distribute the oil within the bearing. h is poses a problem for lip seals. Depending on the size of the bearing and the speed of the shaft, the lip could be starved of oil and unable to develop a meniscus. his means that the lip would contact the shaft, grooving it and reducing the seal’s life. Augus t 2014 | Pum ps & S yst e m s
Bearing isolators are designed for this type lubrication system. In addition to labyrinths that prevent the escape of lubrication, they have drain ports to capture excessive oil splash and drain it back to the sump. With the smaller footprints of today’s pumps, the distance between the bearing and the back of the seal is reduced, creating a more aggressive splash onto the bearing isolator. As a result, manufacturers have redesigned drain ports to capture more lubrication and direct it back to the sump.
Oil Mist Oil mist is becoming a popular lubrication system, especially in the oil and gas industry. Oil mist systems are approved by the American Petroleum Institute (API) 610 speciication for centrifugal pumps for the petroleum, petrochemical and natural gas industries. An oil aerosol is dispersed within the bearing chamber to lubricate the bearings. If not vented properly or applied in a closed-loop oil mist system, the pressure will increase within the bearing chamber. h is increased pressure makes capturing the mist within the bearing housing diicult because the higher pressure in the bearing chamber attempts to obtain equilibrium, carrying the oil mist into the environment.
Figure 3. Components of a bearing isolator with the labyrinth pathway highlighted in yellow
47
Figure 4. Custom bearing isolator with purge stream
Lip seals are not recommended because the mist may not be conducive to the formation of an oil meniscus under the lip, resulting in friction and heat that will groove the shaft and damage the seal. Speciically, API 610, 11th Edition, Paragraph 6.10.2.6 states that lip-type seals shall not be used with oil mist systems or any other type lubrication system in API pumps. he same paragraph stipulates that labyrinth- or magnetic-type end shields should be used. Magnetic-type seals work like face-type mechanical seals. Two smooth faces, lapped within two light bands are mated. Force is applied across the faces either by springs or magnets. he face material could be bronze, carbon or ceramic depending on the application temperature, since the seal generates additional heat as the two faces rub against one another. Labyrinth seals, such as bearing isolators, could be used, but without modiication or additional features, they cannot hold back the pressurized oil mist. One way to combat this is the addition of a mechanism to block the pathway to the environment. h is could be an O-ring, felt or a molded polytetraluoroethylene ring in diferent cross-sections. hese rings are strategically placed along the labyrinth and typically have frictional contact with either the isolator or the shaft. Recent advances in bearing isolators include the ability to be used in submerged or looded conditions. hese hybrid bearing isolators combine the beneits of a non-contact, labyrinth-type seal and a contact-type seal to hold a full head of lubrication (see Figure 5). his makes them suitable for use in oil mist applications to prevent the mist from migrating into the atmosphere. Operators should note that these hybrid bearing isolators could be made of steel, which is a sparking material.
Disinfect – Chemical Metering Skids Stop treating the symptoms and fix the problem. Progressive cavity pumps have virtually no pulsation and won‘t vapor lock or require a gas off valve. seepex offers engineered metering systems complete with controls and frameworks for floor or wall mounting. Our progressive cavity pumps are superior in quality, performance, service life and operating costs. Contact us today to find out more.
seepex Inc. 511 Speedway Drive Enon, Ohio 45323
[email protected] www.seepex.com
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48
SPECIAL SECTION
SEALS & BEARINGS
Conclusion Seals and lubrication systems can be combined in many ways. he wrong pairing can lead to premature bearing failure, downtime, lost production, shorter maintenance intervals, and costly equipment repairs and replacement.
t the 130 a sium th #1 y Boo rbo S y mpo b p Sto n / Tu ousto Pump 2014 Show in H
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Figure 5. Hybrid bearing isolator with contact points within the labyrinth to retain oil mist or a full head of lubrication in flooded condition
James Wong is the associate product manager for the bearing isolator product line at Garlock Sealing Technologies. He has extensive experience in industrial sealing technology in dynamic and static applications. He started his career as a product engineer designing and testing seals for dynamic application, including field experience solving challenging applications. Currently, he manages the entire bearing isolator portfolio at Garlock. His name appears on several patent and technical articles pertaining to bearing isolators. Wong also has presented in seminars around the world on the subject of bearing protection. He may be reached at james.wong@ garlock.com.
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Select Seals That Meet the Chemical Challenges of HPLC Pumps Abrasive processing and wide temperature range are some of the pumping difficulties for high-performance liquid chromatography. BY JERRY ZAWADA TRELLEBORG SEALING SOLUTIONS
H
igh performance liquid chromatography (HPLC) is a chemical analysis technique with wide applications, from food and medical safety to manufacturing. HPLC can detect vitamin D levels in blood serum or performance enhancing drugs in urine. he technique has even been used to synthesize blood and determine DNA evidence in forensic investigations. In biotechnical and pharmaceutical manufacturing, HPLC enhances the production process by increasing separation eiciency, improving resolution and shortening analysis time. Instrumentation and system automation have evolved to keep pace with the quality of materials that support HPLC and its applications.
How HPLC Works HPLC passes a liquid sample through a column of a particular absorbent solid material that reacts at divergent rates from an
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In HPLC applications, the use of seals that offer low coefficients of friction and robust dynamic and static sealing is recommended. (Article images courtesy of Trelleborg Sealing Solutions.)
analyzing solvent. he rate of reaction and how the solution separates identify the original components. his technique can determine all the materials in a solution based on known reactions to base chemicals and solid state materials. HPLC instruments include a sampler, pumps and a detector. he sampler brings the mixture samples into the mobile phase stream, which carries it into the column. he pumps deliver the desired low and composition of the mobile phase through the column. Some mechanical pumps mix multiple solvents in ratios changing over time, creating a composition gradient in the mobile phase. he detector—ultraviolet-visible spectroscopy, photodiode arrays (PDAs) or mass spectrometry are commonly
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Long-lasting instruments—with lifespans from five to 20 years—have led to instrument maintenance repair organizations having a more common role in HLPC instrument upkeep.
used—generates a signal proportional to the amount of sample component emerging from the column and allows for quantitative analysis of the sample components. Instrument control software usually ties into the HPLC instrument and provides data analysis. Additionally, a high scan-speed detector capable of collecting enough data points across an analysis’s narrower peaks has often improved the production process.
HPLC Pumping Challenges All piston pumps have multiple replacement parts, such as check values, piston seals and pump piston rods. When working with HPLC instruments, biotechnical and pharmaceutical manufacturers pay close attention to the parts and materials entering their supply chain in terms of their pumping needs. Seals in HPLC pumps must deliver exceptional leak tightness, high resistance to wear and tear, low coeicient of friction and no extrusion into gaps. An HPLC pump seal should withstand aggressive and abrasive processing and ofer excellent temperature capabilities—operating in a range from -253 C to 300 C (-423 F to 572 F). Recommended seals can work at high speeds up to 15 meters per second (49 feet per second). Check valves (inlet and outlet) prevent low from a high-pressure area into the low-pressure area inside the HPLC pump head. As a result, the pump’s piston can deliver a mobile phase low through the column at high pressure. A properly functioning check valve opens and closes quickly and provides a secure seal across a wide pressure range. Check valves in HPLC pumps fail more often than other HPLC parts, such as pistons or piston
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seals, because they are exposed to repeated mechanical stress at high pressure. Failed check valves are also diicult to identify. Unlike external pump leaks, internal pump leaks do not lead to a substantial drop in pressure, and HPLC software programs will not detect them.
Service Kits Increase Longevity Long-lasting instruments—with lifespans from ive to 20 years—have led to instrument maintenance repair organizations (MROs) having a more common role in HLPC instrument upkeep. MROs now make service kits for HPLC part replacements because of instrument longevity. For example, pump manufacturers and MROs can remove metallic spring energizers from an HPLC system because the energizer can afect production results in some cases. Some MROs have developed specialized kits based on consults with operations personnel to determine what parts, supplies and packaging requirements will ensure a customer’s instruments and machines continue to run smoothly. hese organizations partner with material suppliers to eiciently manage inbound and outbound logistics through supply chain services.
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he Future of HPLC HPLC is the largest product segment in the analytical instruments industry. he technology serves several industries for research and development purposes, quality control and process engineering applications. Improvements in system automation, robotics and instrument design are propelling growth in the HPLC market. China and India are driving the market for analytical instruments in Asia, with Latin America ofering good growth prospects. he rise in drug discovery and generic pharmaceutical production, as well as rapid industrialization, has fueled the HPLC market in these regions. Industry research forecasts the HPLC pumps market crossing the $100 million mark in 2014. he global market for HPLC systems and supporting accessories is projected to reach $3.7 billion by 2015.
Jerry Zawada is life sciences segment manager for Trelleborg Sealing Solutions. He has worked with Trelleborg for more than 14 years and was previously vice president for a startup life sciences company. He may be reached at
[email protected].
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3 Ready-to-use
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Treated Carbide Surfaces Enhance Running Performance This technology self-lubricates, reduces friction and performs in wet or dry operating conditions. BY MARK SLIVINSKI CARBIDE DERIVATIVE TECHNOLOGIES INC.
A
n article in the June 2009 issue of Pumps & Systems detailed a new technology to treat the surface of silicon carbides. he treatment is not a coating and not homogenous with depth. Since the publication of this article, independent parties have tested the treatment and returned the results from several applications. h is article summarizes some of those tests.
Background he technology involves treating a inished silicon carbide (SiC) component with a speciic chemistry that etches the silicon from the surface of the SiC and leaves behind the carbon. h is process occurs at the nanoscale. he silicon is removed, and the carbon—which was initially reacted with the silicon and sintered into the SiC substrate—remains in its original, covalently-bonded crystal lattice. During the reaction, the carbon further reorganizes into various nanospecies and creates a treatment zone as shown in Image 1. hese transmission electron microscope images are taken at diferent depths within this treatment zone. Its outer zone is mostly planar graphite and disordered carbon, giving the sur-
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face a controllable, low coeicient of friction in the range of 0.08 to 0.12. Nanocrystalline diamond combined with the carbon and graphite emerges further down into the surface. Eventually, all these constituents merge with the virgin SiC, where SiC and all carbon nanospecies are present.
Image 1. Transmission electron microscope images taken at different depths within the treatment zone (Article images and graphics courtesy of Carbide Derivative Technologies.)
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Compared with current sealing surface solutions, the resulting treated surface runs cooler, longer and withstands significant periods of dry running. It has never delaminated during 25 years of rigorous testing.
As the surface runs in, it operates at the robust zones in which graphite, carbon and nanocrystalline diamond provide a tough,low-friction running surface. Because it is not a coating, and the carbon is covalently bonded to itself and the supporting SiC substrate, this technology cannot delaminate, spall or peel of. Compared with current sealing surface solutions, the resulting treated surface runs cooler, longer and withstands signiicant periods of dry running. It has never delaminated in 25 years of rigorous testing. he 2009 article showed results from l ashing hot water tests. Specimens in that series were run for 24 to 100 hours at 250 F and 140 pounds per square inch (psi). he specially treated specimens exhibited minimal wear scars on the mating rings between 1.7 and 4.4 micrometers (μm), but the untreated SiC specimens wear scars were between 47 and 173 μm. Furthermore, the specially treated surfaces were still smooth, but the untreated surfaces were heavily grooved.
New Tests All the recent tests, detailed in this section, had the hard/hard running combination of a treated SiC surface against another SiCtreated surface. Mechanical Seals A seal pair was run in rigorous water test in conditions that typically damage sealing faces, as shown in Figure 1. he water test lasted for 350 hours. Next, the pump was drained, and the seal was run for another 75 minutes in dry nitrogen before a temperature spike stopped the test. h is
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test proved extensive wet- and dry-running capabilities, even after running under rigorous wet conditions. No leakage occurred throughout the combined test. h is mechanical seal test included stressful water conditions followed by dry nitrogen conditions. Most demonstrations in stressful water conditions, including deionized water, caused the water to l ash or simulate other intermitImage 2. The treated thrust plate (left) and thrust pads (right) with no discernable wear at twice the normal maximum load tent dry and high-temperature running conditions. hese tests, which typically destroy plain SiC sealing faces, have hey also survive extended l ashing or dry-running conditions ranged in duration from 24 to 1,000 hours. Treated sealing for much longer than other solutions. Field examples have shown faces survive such conditions with smooth faces even after the that this technology lengthens the running life in lashing rigors of the test. hydrocarbon service by a factor of 12. Since the surfaces remain Dry nitrogen is diicult to seal with plain, fully contacting seal smooth even after l ashing or dry running, they survive through faces. he 2009 article showed that treated surfaces actually ran process upsets that would normally require shutdowns for pump with lower friction in pin-on-disc tests than in ambient air. Several repair because of seal damage. his is because the treated seal mechanical seal tests in dry nitrogen have been conducted. Some faces stay smooth and enable the pump to recover, be rewetted were fully dry, without the pump being wet before the dry running. and run after a process upset without the seal leaking. Specialized treatment for silicon carbide surfaces has survived tests Emissions are directly proportional to seal wear. he low wear in dry air or nitrogen for durations ranging from 45 minutes to four and resistance to grooving of treated seal faces also provides hours at aggressive pressure velocity conditions of between 6,000 signiicantly lower fugitive emissions for single-seals. All these and 80,000 psi-feet/minute (ft/min). he surfaces typically did not groove. hey remained smooth and continued to provide a good seal- features lengthen plant maintenance cycles. ing surface. hese tests demonstrate that treated seal faces run well in dry air or nitrogen environments. his performance characteristic Bearings he treatment also enhances the performance of bearings. One can provide long-running life for pure dry mixer seals and lightly manufacturer demonstrated improved dry startup capability in a loaded safety seals. hydrodynamic bearing contained in a downhole pump. In operaAnother mechanical seal example tested automotive water tion, the pump runs dry for ive to 10 seconds at startup before pump seals. he industry standard stress test for these products dirty water loods the bearing chamber. A test was performed includes a 15-minute dry-running test. he seal face materials in dirty water with 35 stop/starts—25 forward and 10 reverse. currently used in this industry have diiculty meeting this stanWhile this test typically destroys SiC hydro pads and thrust dard. Figure 2 shows the results of a seal assembly subjected to ive tests, at increasing shaft speeds, for one hour and 15 minutes plates, the treated components were unharmed. he components were able to be reused in another pump and placed into service. of total dry-run time. he seal assembly was allowed to cool to ambient temperature between runs. Some tests of the untreated assemblies were Figure 1. Results of a mechanical seal tested for 350 hours in water stopped before 15 minutes had elapsed. followed by 75 minutes of running in dry nitrogen he results showed erratic temperature behavior from the untreated seal rings and damage to the elastomer bellows. he cumulative wear from the ive tests was a 20-μm wear scar on the mating ring. In contrast, the treated seal faces ran at low temperatures with normal trends. he proi lometry showed no discernible wear, and the seals did not leak under a 25-psi air pressure leak test. hese results demonstrate that treated seal faces enable dramatically longer run times in normally lubricated situations.
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While treated components have not been tested in the sleeve bearing parts of mag-drive pumps, it is expected that they would protect equipment from damage during dry running. Image 2 shows the results of a hydrodynamic bearing test with treated components. he test was conducted in water with a load that increased incrementally until twice the normal load-bearing capability was reached. As the image shows, the components experienced no discernible wear. Proi lometry measurements also showed no discernible wear. he assembly may have been able to support even higher loads. While treated components have not been tested in the sleeve bearing parts of mag-drive pumps, it is expected that they would protect equipment from damage during dry running. Specially treated SiC components have been demonstrated to run well when mated with certain metallic components. his lexibility makes the technology ideal for protecting mag-drive pumps with either metallic or carbide shafts from damage during dry running.
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Conclusion h is technology allows an improved running surface to be synthesized on a inished SiC component in a net shape, size and roughness process that does not add any new material or require post-treatment polishing. he surface derives from the virgin SiC, where the silicon is etched out of the surface while the carbon already contained in the SiC stays in its original crystal lattice and transforms into carbon nanospecies—including planar graphite and nanocrystalline diamond. he resulting surfaces demonstrate the ability to run for extended periods wet, dry and during l ashing. After operating in demanding conditions, the surfaces are still smooth and able to seal. h is technology allows luid-handling equipment to be rewetted and run after process upsets without stopping the luid loop to repair damaged mechanical seal rings. Because of
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decreased friction, seals employing this Figure 2. Results of multiple 15-minute dry-running tests on the same seal technology run cooler. his reduces l ashing conditions and enables the seal to survive the l ashing. he dramatically reduced wear and grooving directly translates to signiicantly reduced emissions from single seals. Dry nitrogen performance allows long duration and quiet running for pure dry mixer applications. Load bearing capability for hydrodynamic bearings can be substantially increased, and dry running capability for sleeve bearings can be enhanced. All these beneits are possible with hard/hard surface pairings. he technology can have a positive impact on plant maintenance cycles, equipment mean time Mark Slivinski is president of Carbide Derivative Technologies between maintenance and mean time between failures. he Inc. and former vice president of global technology for John technology is currently available in sizes up to 8-inch diameter Crane International. He may be reached at mslivinski@carbidand beyond with capability for 36-inch marine propeller shaft ederivative.com. For more information on CDT treatment for seals including submarines. silicon carbide surfaces, visit www.carbidederivative.com.
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60 PUMP SYSTEM OPTIMIZATION
Streamlined Motor Management System Boosts Biomass Power Generation Trusted gateway connections allow for system growth, efficiency and consistent maintenance at Swedish paper mill. BY MATTHIAS BORUTTA PHOENIX CONTACT
P
aper production requires large amounts of power. he Smurit Kappa plant in Piteå, Sweden, uses its own biomass boilers to meet part of its energy needs. he cleaning system in place for the high-performance steam generator includes a specialized motor management solution to ensure uninterrupted motor operation. At the Smurit Kappa Kraftliner Piteå paper plant in northeast Sweden, 520 employees produce about 700,000 metric tons of Kraftliner paper per year. Kraftliner is a special type of raw paper made of fresh ibers and serves as the base material for manufacturing high-quality corrugated cardboard packaging. he Swedish plant’s annual power consumption is about 520,000 megawatt hours (MWh). Biomass boilers—which burn organic material such as wood— generate 58 percent of that power, creating added value through eiciency and sustainability.. he Piteå production site consists of a pulp mill with two soft-pulp digesters and one hardwood digester and a paper mill with two paper machines. Two boilers produce the energy needed for the mill. One recovery boiler combusts the black liqueur from the process, and a biomass boiler uses mostly the bark from the wood-handling system. he steam from the boiler passes across two steam turbines that generate more than half the electricity required by the mill. h is self-produced electricAugus t 2014 | Pum ps & S yst e m s
ity is a green option because fossil fuel is only required during the startup process.
Lower Costs for Cleaning Routines A special steam cleansing technology boosts the eiciency of the power generation system. A high-performance boiler must be kept clean, ensuring high-eiciency degrees, high availability and minimal ash corrosion. Pressurized steam dissipates the soot, increasing the eiciency compared with conventional methods. he cleansing technology also permits cheap, aggressive fuels for natural, eicient powering. he boilers are cleaned with automatic motorized 8-meter-long cleaning lances that spray pressurized steam onto the boilers’ heat surfaces. A specialized motor management program controls and monitors the motors during this cleansing process. Eiciency & Maintenance Challenges he previous electrical drives in Smurit Kappa’s high-performance boiler were complex and diicult to use. he system required mechanical contactors for reversing the rotational direction of the steam cleansing system’s motors and digital outputs for clockwise and counterclockwise control.
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Smurfit Kappa Kraftliner Piteå in northeast Sweden is one of the Smurfit Kappa group’s 350 production sites. (Article images and graphics courtesy of Phoenix Contact.)
Analog inputs handled the power input, and digital inputs analyzed the return signals. Wire connected all the devices and individual switching cabinets. Documentation and controller programming were time-consuming with the existing system. Adding drives to the setup was a major undertaking that required expert project management. In addition, the switching cabinets left little room for new additions. Consistent maintenance was not efective because of multiple components—such as drives, input/output (I/O) modules, measuring sensors, terminal blocks and contactors. he existing system’s drives were threephase asynchronous motors. A screw conveyor moved the lance in and out of the boiler to blow the soot of surfaces.
The Piteå site produces about 700,000 metric tons of Kraftliner paper per year.
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Each screw conveyor was itted with two mechanical or inductive limit switches. When the screw conveyor reached the end or start position, the rotational direction had to reverse. he limit switches were prone to dirt build-up, which made their signal information for reversing the rotational direction less reliable. Inadequate cleaning could, in a worst-case scenario, damage or destroy the motor. 3.
Fewer Wires, More Space he new motor management system provided several advantages to the steam cleansing system. he program, which included motor management, hybrid motor starters and a ieldbus gateway, detected worn sootblowers before failure. Fewer I/O modules were required, reducing wiring and documentation, and the compact device dimensions opened more installation space. Bus gateways allowed for system expansion during system operation. he gateway forwarded the process data from multiple motor management modules to the control unit, while electronic
motor management units (EMMs) handled monitoring and drive protection with active power monitoring. he solution also included hybrid motor starters, which provided non-wearing motor switching. Relays and the system cabling solution quickly and reliably coupled the ield devices to the controller.
No Need for More Sensors he 22.5-millimeter electronic motor management unit has built-in current transformers to directly read input currents up to 16 amperes. If the applications’ output is higher currents, other EMM modules read them in combination with external current transformers. he range of available components works for all power ratings. Because the EMM can be easily inserted on the existing motor cable, the operator was provided access to all the measurements for easy and cost-efective motor and system monitoring. he ease of installation eliminates the need for additional sensors. he module can retroit existing systems, keeping the system up-to-date with all current status values. Figure 1. Network integration of the motor manager as shown in a Profibus structure
The steam cleansing system uses high-pressure steam to blow the soot off the high-performance boiler’s heating surfaces. The motor management unit’s compact dimensions save considerable space compared with similar components.
The switching cabinets contain a solution that includes motor management, hybrid motor starters and a fieldbus gateway. Augus t 2014 | Pum ps & S yst e m s
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Motor management supplies the data for any application, such as monitoring and protecting pumps, controlling valves or tool machines, or analyzing the systems’ power consumption.
Separate mechanical or non-wearing semiconductor contactors switch three-phase loads. he digital output of the motor management modules implemented on- and of-switching. Motor management supplied the data for any application, such as monitoring and protecting pumps, controlling valves or tool machines, or analyzing the systems’ power consumption. he choice of control system connection—whether independent or ieldbus—does not impact the system’s data collection.
Trusted Connections hrough the program’s ieldbus gateway, which is certiied according to European Norm 50170 as speciied by Decentralized Peripherals, level V1, 31 motor management modules can be connected to each other. he pluggable design means no wiring is needed (see Figure 1). All process data is transferred to the control system. he ieldbus gateway also supports a fail-safe. If any malfunctions occur, the switching behavior can be modiied. he gate-
way also features additional digital inputs and outputs. If communication is based on the Proibus DVP1 system, the device is connected to the network using a general station description. In addition, the system support permits increased lexibility for the entire system: parameter setup, monitoring and diagnosis of the motor management devices. Matthias Borutta studied electrical engineering with a focus on measuring technology at the Göttingen University of Applied Sciences. In 2000, he wrote his final thesis in the field of automation. Since 2001, he has been product manager for electronic load relays and solid state relays in Product Marketing ELR for Phoenix Contact. He may be reached at
[email protected] or +49 5281 946-3112.
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Intelligent Monitoring Delivers Real-Time Pump Performance Data An energy efficiency and reliability study helped one plant save $1 million annually by avoiding downtime. BY MIKE PEMBERTON ITT PRO SERVICES
T
he years leading up to the new millennium saw a rapid evolution of industrial communication networks from analog to digital. By 2000, information technology tools were becoming integrated into luid handling products and systems. his marked the beginning of pump and automation technology convergence. Process instruments, control valves and stand-alone controllers developed from individual hardware units to microprocessor embedded devices that could be digitally linked into a computerbased process management system. Intelligent pumps also joined the march forward in 2000. Today, “smart” centrifugal pumps with variable frequency drive (VFD) controls are becoming an integral component of the industrial process automation architecture. Hard-wired communication systems in ield devices are being replaced by wireless communication as the new standard. What does this communication revolution mean for the traditional pump and automation industry? he migration from hardware to software enables new services that were practically undeliverable in the past. Widespread information low from process assets helps plant operators make better life-cycle-cost decisions and perform true predictive maintenance in real time, without needing to collect data manually. hese changes drive stakeholder innovation and proitability. he old paradigm of business gives way to the life-cycle-costing approach. Organizational structures and stakeholder perceptions are changing. Suppliers are moving from selling commodity products and services to rendering unique, value-added services that are highly customized. While all this may seem vague, new approaches are becoming part of industrial automation and luid handling systems practice and management. he plan-do-check-and-act cycle now should mean making sound inancial decisions that win today and in the future rather than irst cost decisions that win today and fail decidedly in the future. As an example of these changes, consider one pulp mill’s maintenance strategy for dealing with a vat dilution pumping system that
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was causing repeated component and system failures and process downtime. his approach included looking at the system holistically and also considered the use of more intelligent components. Decisions were ultimately made based on life-cycle costs.
Case Study Regular pump breakdowns and undue wear resulting from heavy control valve throttling can cost companies millions each year.
Widespread information flow from process assets helps plant operators make better life-cycle-cost decisions and perform true predictive maintenance in real time. (Article images courtesy of ITT Corporation.)
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In one case study from 2001, a paper mill bleach plant was sufering inancial losses from an oversized pump. After assessing the problem, plant personnel contacted a plant operation specialist. he mill’s energy team determined that nearly two-thirds of the facility’s valves were less than 50 percent open. Many of them were less than 25 percent open. One key pump system had
a capacity of 6,500 gallons per minute (gpm), but the average load was only 2,750 gpm—52 percent of total capacity. he peak low demand was only 5,200 gpm. he 10-inch ball-valve installed in a 14-inch discharge line was undersized. he large pressure drop and associated vibration were causing valve wear, pipe cracks, gasket leaks and frequent downtime. Also, it was diicult to keep the control loop tuned, which required manual operation of the modulating valve. he pump experienced almost 10 failures per year, all of which occurred while the pump was running and during startup and shutdown. A pump is more susceptible to catastrophic damage during startup and shutdown than at any other time. his is primarily because of large pressure changes and water hammer across the pump system components. But the initial shock to the system upon startup involved more than pressure. here was also thermal shock from 220 F (104 C) i ltrate entering the pipes when the pump motor was started. he mill’s reliability engineers conducted a thorough examination of the system. hey determined that automated gate valves, which open slowly as pipes warm to avoid thermal shock and cracking, plus new operating procedures would provide incremental improvements and a reduction in failures. In addition to the gate valve automation, the plant operation specialist recommended installing a low-voltage motor and VFD, operated in pressure control mode, for the three vessels the pump was feeding. Stabilizing the control loops and reducing pressure inside the system turned a frequently failing pump into a properly functioning component of the system. he bleach plant witnessed $18,000 in energy savings in 2002. Energy savings in the same NSKHPS Spherical Roller Bearings process had climbed to $32,000 in 2013 as NSKHPS Spherical Roller Bearings offer higher speed and load capacities energy costs increased. Beyond the eicienfor a wide variety of industrial applications. Their innovative bearing cy improvement, plant representatives also design increases operating life, reduces maintenance costs and optimizes performance, resulting in high satisfaction. Learn more at thinknsk.com reported that the systems-based solution saved them more than $1 million annually in downtime and repair costs.
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A Systems Approach Plants haven’t been clamoring to invest in eiciency for several reasons. One is simply a lack of experience with the methods and techniques used to raise eiciency.
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When components break, operators tend to buy what they think from BEP and impeller diameter. If a mill optimizes 30 percent already works to replace them. of existing pump systems, overall mill process availability will When deciding to modify systems, eiciency improvements dramatically increase while pump seal and bearing failures will may feel unnecessary. No one wants to interrupt day-to-day signiicantly decrease. operation of the plant to overhaul functioning equipment or Reliability improvements can be predicted, and past work systems—especially if they aren’t part of the plant’s specialized orders and CMMS records can be used to estimate annual production equipment. However, critical subsystem issues in many plants have too long been ignored. Engineers and suppliVisit us at the Pump Symposium ers are still oversizing pumps, for a variety Houston, TX | September 23-25 of reasons. Some prepare for increased deBooth #430 mand, imagining future capacity increases that never come. Pump optimization activities allow an increase in the level of condition monitoring through broader use of intelligent motors, pumps with embedded chips, VFDs and wireless vibration monitoring. hese tools ofer real-time information on pump system performance. Pumps are not considered to be an integral component of the process automation architecture. As a result, plant information systems—such as distributed control systems (DCS) and computerized maintenance management systems (CMMS)— typically lack continuously monitored asset data for diagnostic use. Although the DCS monitors most of the key process parameters required for traditional process control, up to 60 percent of the pump systems lack a low measurement on the discharge line. For all practical purposes, almost all of the work orders and asset information is manually entered into the CMMS. Furthermore, other underlying assets, including compressors, blowers, fans and control valves, are rarely connected to the CMMS. he lack of information is a missing link in an e-manufacturing strategy. It can mean that large potential cost savings go unrealized. According to the ARC Advisory Group, up to 40 percent of manufacturing revenues are devoted to maintenance and up to 60 percent of scheduled maintenance checks and motorProud Member of the NATIONAL PUMP COMPANY driven systems are unnecessary. American Petroleum Institute With consideration given to proper 7706 N. 71st Avenue | Glendale, AZ 85303 mounting, alignment and lubrication, 800-966-5240 | 623-979-3560 the three primary determinants of pump www.nationalpumpcompany.com reliability are speed, distance operated circle 147 on card or visit psfreeinfo.com
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maintenance costs. In many cases, process control beneits can be identiied in terms of reduced raw material variability, and life-cycle-cost savings can be estimated based on current costs compared with optimized costs. Making decisions based on long-term operating costs—rather than keeping a large safety margin that allows unnecessarily high flow production— will create an opportunity for the plant of the future. This kind of plant will be available, adaptable and sustainable as required. This thought process needs to be implemented and is increasingly becoming a regulatory requirement. Mike Pemberton is the Energy & Reliability program manager for ITT PRO Services, Plant Performance Services. He is a member of the Hydraulic Institute (HI) and served as co-chairman of the Pump Systems Matter education committee. He is also co-editor of the HI guidebook, Optimizing Pumping Systems: A Guide to Improved Energy Efficiency, Reliability and Profitability.
The latest advances in technology offer real-time information on pump performance, helping plant operators make more informed decisions related to their service.
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Close Inspection Solves High Thrust Bearing Temperature Problem Careful analysis identified the issue with this multistage, oil transfer pump. BY GARY DYSON HYDRO INC.
A
multistage BB5 dif user machine in oil transfer service in the Middle East had been in operation for many years without problems. After a routine maintenance strip down and rebuild, the pump experienced a high thrust bearing temperature of 105 C, which caused it to alarm and shut down. he temperature range had previously been 75 C to 85 C. h is case study describes the method used to solve the high bearing temperature problem and outlines the low physics that contributed to the high thrust bearing temperature. he customer contacted an engineering services company after the original pump manufacturer failed to remedy the problem. he company’s forensic approach to this problem involved two distinct methodologies: • Diligent and in-depth analysis of site data relating to the problem •
Rigorous scrutiny and analysis of the pump geometry and build against the background
he engineering services company identiied several scenarios that could cause this temperature rise, then narrowed down the list to establish a root cause.
Site Data Analysis he behavior of thrust bearing pads during startup is seldom investigated. he temperature rise of the pads can be attributed to two distinct causes—thrust developed during startup and environmental and oil conditions (see Figure 1). he signiicant inding from this data was the temperature rise associated with thrust. he pump could not achieve the temperatures measured prior to maintenance in its current condition. he total thrust bearing temperature includes the oil temperature and environmental conditions. Figure 2. Meridional flow interactions of a pump running at partial capacity
Figure 1. Behavior of thrust bearing pads based on thrust and environmental conditions (Article images and graphics courtesy of Hydro Inc.)
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Based on comparisons with previous site data, both the thrust and oil cooling had altered. Analysis of the temperature data at the motor bearings, which were experiencing oil temperature increases of 10 to 15 C, further supported the conclusion.
Pump Analysis Analysis of the pump build procedures also revealed that a change in thrust quantity was causing a high pad temperature. h is machine can be susceptible to thrust changes due to the axial position of the impeller with respect to the dif user. he engineering services company investigated the build process and discovered that the original bearing housing had not been used in the rebuild. he axial position of the rotors had not been reset correctly, unlike the bearing clearance. h is machine has an adjustment ring behind the thrust collar that is used to account for build tolerances in the components stack. Fitting the new bearing assembly afected the rotor positioning. he adjustment ring had been reitted without ensuring that the rotor centralization had been carried out correctly. he direction of the thrust further complicated the scenario. hrust bearings on this machine are designed to run with the thrust on the inboard pads. When a pump runs back to a lower low, a thrust reversal afects the outer pads. Although this pump was not running at its best eiciency point, its operating low was not reduced enough to cause a thrust reversal. Scrutiny of site data indicated that this pump had always thrust to the outboard pads regardless of any process changes over time. Some pump manufacturers ine-tune the thrust behavior of their machines by adjusting the size of the balance drum and bush based on their initial performance test results. If this process is too time-consuming, manufacturers adjust the axial position of the rotor with respect to the dif user to modify the thrust and bearing temperature. h is rotor setting data is easily overlooked on rebuild, especially since the actual rotor centralization is rarely checked on strip-down. his means it cannot be restored after a component change. Hydraulic Instability and Hydraulic hrust As a pump operates at partial capacity, the low becomes increasingly unstable. Both the impeller and rotor experience an increase in unsteady low interchange. Traditionally, this low regime interaction has been illustrated as in Figure 2 in the meridional plane (see page 69). Although this image is helpful in understanding the low physics, the true picture is far more complex. Figure 3 illustrates the complex nature of the low that develops within the impeller when the pump operates at extreme part load. Point A illustrates the development of a discharge vortex that commences on the hub at the impeller discharge. Point B illustrates the boundary of this interaction with the inlet backlow recirculation within the impeller eye. his inlet backlow recirculation is also illustrated in detail in Figure 4. At partial capacity, the low exits the impeller eye at the hub inlet angle and spirals down the suction channel impinging on splitters of the previous stage. he meridional view clearly depicts these two unstable low interactions with the vortex that exists within the gap between the channel ring and impeller shroud (see Point C in Figure 2, page 69). h is vortex accounts for the developed thrust within this pocket. Any disruption to this vortex leads to a more unpredictable thrust regime.
71 Figure 3. Complex flow interactions of a pump running at partial capacity
Figure 4. Illustration of 3-D inlet backflow recirculation
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he centralization efect of the rotor within this channel inluences both the development and speed of this vortex. he space available for the vortex is either increased or decreased so boundary layer efects begin to dominate.
Figure 5. Rotor with poor centralization
Solution The solution to the high thrust bearing temperature problem lay in a combination of contributing factors, each needing indepth understanding of pump technology and flow physics. The following actions returned the pump to an acceptable temperature: • Oil temperature correction: A thermostatic valve was disabled during pump removal. On commissioning, this valve was left in an inoperable position, which kept the oil from passing through the cooler. he engineering services company identiied the problem and returned the valve to the appropriate setting. •
Rotor centralization: he rotor centralization had been adjusted to of-center by the original equipment manufacturer
to limit the thrust on the outer pads (see Figure 5). he engineering services company restored the rotor to the correct position relative to the dif user, which put the thrust bearing temperature within an acceptable range. • Thrust compensation modification: The engineering services company is now suggesting modifications to the machine to correct the thrust balance based on the actual site operating conditions. This new thrust compensating modification will be designed to ensure the thrust is on the inner thrust pads, giving the bearing an extended operating range. h is case study illustrates the problems that can arise if a meticulous approach is not adopted for even a routine maintenance activity. Severe operational problems can be prevented by repair practices that diligently record every aspect of the pump repair.
Dr. Gary Dyson is managing director with Hydro Global Engineering Services. He has a Ph.D. from Cranfield University and 30 years of experience in the pump industry in senior positions with many manufacturers. His expertise includes pump hydraulic performance, design and reliability improvement. circle 168 on card or visit psfreeinfo.com Augus t 2014 | Pum ps & S yst e m s
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System Selection Crucial for Long Wastewater Pump Life Driving down investment, energy and maintenance costs translates into big savings throughout an installation s lifetime. BY LARS BO ANDERSEN GRUNDFOS WASTEWATER
L
ife-cycle cost calculations for wastewater installations can produce huge savings over time for wastewater companies. he life-cycle costs summarize the total cost of a wastewater installation, and the pump system plays a major role. It is the key element to ensuring the installation’s long-term costefectiveness. Total lifetime costs normally include planning, design, purchasing, investment, installation, commissioning, energy, maintenance and operation, and downtime costs. A system can also incur environmental and disposal costs at the end of its lifetime. he pump system has the highest impact on the lifetime cost of the wastewater installation. However, only three of the costs listed above play a signiicant role in the pump system’s contribution to life-cycle costs: investment, energy and maintenance.
Involve different people to ensure that all aspects of the pump purchase are considered. (Article images and graphics courtesy of Grundfos.)
Investment he initial procurement cost is often seen as the best way to ensure low cost. Meeting investment budgets means keeping in mind that the cost of operation, maintenance and disposal could be ive to 20 times higher than the initial investment. h is is why municipalities and contractors increasingly consider the requirements for performance, reliability and energy consumption when purchasing a pump system.
Energy Decision makers might think that the energy cost of the pump is easy to calculate. But many things must be considered when determining the energy cost of a pump—such as wear, variable load, installation and clogging. If the wrong wastewater pump is chosen, the media content leads to wear, costly breakdown and 3 to 5 percent lower eficiency for every year the pump is not maintained.
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The design of the pump impeller is a key issue because a simple design with large free passage and no inserts or moving parts will wear less than a design without these features, thus ensuring a high efficiency over the pump lifetime.
Most pump brands make it possible to restore eiciency loss. Some have a replaceable wear ring, while others have built-in trimming that allows adjustment of the impeller clearance using outside bolts. Because wear also afects non-replaceable parts of the pump, full restoration of eiciency is impossible. he design of the pump impeller is a key issue, since a simple design with large free passage and no inserts or moving parts will wear less than a design without these features, thus ensuring a high eiciency over the pump lifetime. he pump’s duty point is seldom constant and varies over the course of a day, a year and a pump’s lifetime. Users should look for a pump with a lat eiciency curve. h is ensures high eiciency over a wide duty range and determines whether the pump is using a variable speed drive. If the pump is running with variable speed, a pump with a duty point to the right of the curve should be selected. When adjusting the speed downward, the pump’s duty point moves to a part of the curve with higher eiciency. he energy saved when operating with a variable speed drive depends heavily on the system curve. he savings potential decreases if the static head is small compared to the friction losses. It increases in a system with large friction losses compared to the static head. A variable speed drive can also signiicantly inluence the clogging frequency of the pump, as the water velocity might fall below the self-cleaning velocities in the system. When installing a pump system, measures should be taken to avoid leakages, especially where the connection between the pump and the installation equipment is metal-to-metal (see Figure 2). hese connections become more susceptible to leaks as the system gets older. Seals or gaskets should be placed at all joints. More leakages mean a greater loss of energy. Figure 1. Wear of impeller clearances with different impeller designs
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A small diameter in the rising main leads to increased head requirements and energy consumption, because small pipes amplify the pipe friction losses of the installation. A small rising main also increases the leakage low. To avoid high losses, the water velocity through the pipes should be kept low. he exact maximum velocity depends on the length and roughness of the pipes, but as a rule, the velocity should not exceed 3 meters per second (m/s). Avoiding velocities that are too low is also crucial. Low velocities can cause sedimentation and deposits to build in the pipes, increasing friction losses and energy consumption. Manual pipe cleaning may become necessary to clear the pipes, adding to maintenance costs. For horizontal rising mains, a minimum of 0.7 m/s is recommended, while a vertical rising main should be dimensioned for a velocity of no less than 1 m/s. his is especially important in pump systems with variable operation. Variable speed drives can heavily inluence water velocity, so take care that the pump is not always running at a low speed. he self-cleaning velocity in the pipes otherwise might not be achieved. More than installation clogging, impeller design relates directly to energy cost. he improved nonclogging capability of an impeller is normally achieved by using semi-open impeller designs, but these designs cause eiciency loss. New developments now combine the best of both worlds by having nonclogging, high-eiciency impellers with large free passages, no inserts and no moving parts. Figure 2. Conventional pump with metal-to-metal discharge connection
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Maintenance Maintenance costs are often diicult to estimate. Planned maintenance costs will vary depending on many different factors, such as: • Pump value •
Pump maintenance costs
•
Operational experience
•
Pump failure consequences
•
Pump failure probability
•
System design
its service friendliness. To determine the cost of the repair, take into account the following: • Maintenance to be performed on the pump •
Time required for maintenance activity
•
Number of personnel involved
•
Spare parts cost for maintenance activity
Fast spare part availability also ensures that unplanned maintenance can be conducted quickly and reliably.
With small, inexpensive pumps or pumps that are diicult to maintain due to their placement, planned maintenance activities might be kept to a minimum, while large, expensive pumps might get the full range of planned and predictive maintenance. Stocking recommended spares can make planned maintenance less expensive and more intuitive for operators. his allows worn parts to be changed without special tools or training. Choosing a pump with built-in analogue sensors allows monitoring of the pump’s condition and enhances maintenance planning. Unplanned maintenance costs can be easily predicted based on an operator’s familiarity with the pump brand and
Lars Bo Andersen has worked at Grundfos for the past 18 years in various positions. Starting as a product engineer in 1996, he progressed to project manager to develop pump selection tools supporting life-cycle cost calculations according to best practices from EuroPump and the U.S. Hydraulic Institute. He is currently the global product manager for wastewater based in Bjerringbro, Denmark.
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Reducer Fittings Decrease Pipe Size to Avoid Failure Design of the pump inlet piping can protect overall operation. BY ROSS MAHAFFEY, AURECON AND STEFANUS JOHANNES VAN VUUREN UNIVERSITY OF PRETORIA FIRST OF TWO PARTS
Figure 1. Difference between eccentric and concentric reducers in pump inlet piping (Article graphics courtesy of the authors.)
T
he design of pump inlet piping deines the resulting hydraulic conditions experienced at the pump inlet/impeller. If the design fails to produce a uniform velocity distribution at the pump inlet, noisy operation, random axial load oscillations, premature bearing or seal failure, cavitation damage to the impeller and inlet portions of the casing, and occasional damage on the discharge side due to liquid separation can occur. Any of these issues could lead to pump failure (ANSI/ Figure 2. Calculation of reducer angles HI 9.6.6., 2009). Part of the pump inlet piping design includes the selection of reducer itting type. A reducer itting is typically used in pump station pipe work to reduce the size of the suction pipe to match the size of the pump suction end lange. Reducer ittings used in pump inlet pipe work are divided into two types—concentric and eccentric reducers. he two types of reducer ittings can be described as: • Concentric reducer—he reduction of the pipe size is achieved by decreasing the diameter of the itting at a constant rate over a speciied length, maintaining symmetry around the itting (see Figure 1). Table 1. Minimum straight length required before suction inlet • Eccentric reducer—he reduction of the pipe size is achieved Number of pipe diameters a by decreasing the diameter of the itting at a constant rate over a speciied length, maintaining one side of the itting Reducer Concentric Eccentric horizontally (see Figure 1). 1 pipe size reduction 0 (
