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PUMPSANDSYSTEMS.COM
SYSTEMS
CHEMICAL
PROCESSING
How pumps reliably handle
caustics with safety & precision
Special Report
AHRI Standard for VFDs
Trade Show Preview
2015 Chem Show
Evolving Technology
Overcomes Sealing Challenges
UnitedRentals.com/pmp | 800.UR.RENTS
With quality pumps from a quality manufacturer, you can rest assured your fluid-handling
needs are expertly handled at the job site. Whether transporting water for fracking,
transferring solids-laden drilling muds or recirculating tank bottoms, Gorman-Rupp has
the right pump for your oil and gas field needs and its all backed by the best distributor
network and parts inventory in the industry. Contact your local Gorman-Rupp distributor
today for more information on our extensive line of products for the oil and gas industry.
GORMAN-RUPP PUMPS
MXV[SVY4IUS
534
Gorman-Rupp Pumps USA is an ISO 9001:2008 and an ISO 14001:2004 Registered Company
EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
aarchibald@cahabamedia.com 205-278-2843
SENIOR TECHNICAL EDITOR: Mike Pemberton
mpemberton@cahabamedia.com
205-314-8279
MANAGING EDITOR: Amelia Messamore
amessamore@cahabamedia.com
205-314-8264
MANAGING EDITOR: Martin Reed
mreed@cahabamedia.com 205-278-2826
MANAGING EDITOR: Savanna Gray
sgray@cahabamedia.com 205-278-2839
ASSOCIATE EDITOR: Amy Cash
acash@cahabamedia.com 205-314-8274
CONTRIBUTING EDITORS: Lev Nelik,
Ray Hardee, Jim Elsey
CREATIVE SERVICES
SENIOR ART DIRECTOR: Greg Ragsdale
ART DIRECTOR: Melanie Magee
WEB DEVELOPER: Greg Caudle
PRINT ADVERTISING TRAFFIC: Lisa Freeman
lfreeman@cahabamedia.com 205-212-9402
CIRCULATION
AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
lmasaoay@cahabamedia.com 205-278-2840
ADVERTISING
NATIONAL SALES MANAGER: Derrell Moody
dmoody@pump-zone.com 205-345-0784
ACCOUNT EXECUTIVES:
Mary-Kathryn Baker
mkbaker@pump-zone.com 205-345-6036
Mark Goins
mgoins@pump-zone.com 205-345-6414
Addison Perkins
aperkins@pump-zone.com 205-561-2603
Garrick Stone
gstone@pump-zone.com 205-212-9406
MARKETING ASSOCIATES:
Ashley Morris
amorris@cahabamedia.com 205-561-2600
Sonya Crocker
scrocker@cahabamedia.com 205-314-8276
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the
right to determine qualications. 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. 2015 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 23, Issue 11.
This issue
COVER
SERIES
NOVEMBER
Volume 23 Number 11
CHEMICAL PROCESSING
64
COLUMNS
PUMPING PRESCRIPTIONS
14 By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC
LONGEVITY
By Todd Loudin, Flowrox Inc.
This technology helped a facility save $20,000 in one year.
44
SSPECIAL
PECIAL
REPORT
INDUSTRY GUIDELINES
2
8
66
90
91
92
96
Smaller Footprint.
Bigger Performance.
Higher Efficiency
Smaller Footprint
baldor.com
479-646-4711
Cost Effective
This issue
SSPECIAL
PECIAL
SECTION
NOVEMBER
INSTRUMENTATION, CONTROLS
& MONITORING
DEPARTMENTS
68 BUSINESS OF THE
BUSINESS
Global Analysis of the Pump
Market in the Oil & Gas Industry
By Sakthi Pandian
Frost & Sullivan
70 EFFICIENCY MATTERS
74 MAINTENANCE MINDERS
Get the Most from Lubricants
Through Quality Oil Analysis
By Michael Barrett
TestOil
This equipment can provide cost savings and extend motor life in the right application.
82 SEALING SENSE
INFRASTRUCTURE
By Horst Sturm, KSB
84 HI PUMP FAQS
On the Cover: The Flint Hills chemical plant in Port Arthur, Texas. Flint
Hills Resources is a refining, chemicals and biofuels company. (Cover image
courtesy of Colfax Fluid Handling; image by photographer Bill Owens)
NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
FARROKH BATLIWALA, ITT CONTROL
TECHNOLOGIES BUSINESS
WHITE PLAINS, N.Y. (Sept. 29, 2015) ITT
Corporation has appointed Farrokh Batliwala as
president of its Control Technologies business.
In this role, Batliwala will be responsible for
delivering the strategic and operating plans
of ITTs Control Technologies business, which
Farrokh
employs approximately 1,100 people globally.
Batliwala
The business designs and manufactures
products for fuel management, actuation, and noise and energy
absorption for the aerospace and industrial markets, as well as
aerospace environmental control system components. itt.com
Chris Tindell
Jacob Homiller
p u mpsa
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10
NEWS
SPOTLIGHT
XYLEM WELCOMES PUMPS & SYSTEMS FOR TOUR
EMMABODA, Sweden The Pumps & Systems magazine team toured Xylem
Inc.s home city and learned more about the 114-year-old company in the
process. The foundry is one of the worlds most advanced for casting complex
geometric shapes. Xylems Swedish plants focus on solving water challenges
through research and innovation. A full story about the tour can be found on
our website. pumpsandsystems.com/pump-tour-pumps-systemsvisits-xylem-inc
Grundfos Highlights
Manufacturing Center &
Wastewater Pump Production
AURORA, Ill. (Sept. 17, 2015) The
Grundfos S-Line of energy-efficient
wastewater pumps is now locally
assembled at the companys Illinoisbased Water Utility Competency
Center, alongside other Grundfos
brands, such as Yeomans, Morris,
Chicago and Sewer Chewer.
Grundfos showcased the submersible
wastewater pumps at the 2015 WEFTEC
To have a news item considered, please send the information to Amelia Messamore, amessamore@cahabamedia.com.
11
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Patented Tube Failure
Detection, Patented
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NEWS
EVENTS
International Association of
Amusement Parks & Attractions
(IAAPA) Attractions Expo
Nov. 16-20, 2015
Orange County Convention Center
Orlando, Fla.
703-836-4800
iaapa.org/expos/iaapa-attractions-expo
ALL-TEST Pro LLC
Electrical Reliability Training
Seminar
Nov. 16-20, 2015
Fairfield Inn & SuitesChicago River North
Chicago, Ill.
860-399-4222 / alltestpro.com
2015 Chem Show
Nov. 17-19, 2015
Javits Center
New York, N.Y.
203-221-9232 / chemshow.com
Lateral & Torsional
Rotodynamics for Centrifugal &
Reciprocating Machinery
Dec. 8-9, 2015
Southwest Research Institute
San Antonio, Texas
210-522-2537
swri.org/9what/events/confer/
rotordynamics-short-course.pdf
POWER-GEN International
Dec. 8-10, 2015
Las Vegas Convention Center
Las Vegas, Nev.
918-831-9160 / power-gen.com
13
In-Line
Close-Coupled
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Handles a wide variety of dif cult uids ef ciently and effectively, without breaking down in service.
The same pump model can handle uctuations in temperature, pressure, solids content and even
product without breakdown. Horizontal pump line includes: in-line, close-coupled, side-by-side, overunder and self-priming con gurations for hard-to-pump applications
SANITARY PUMPS
SUBMERSIBLE PUMPS
API PUMPS
Offer exceptional productivity and cost-savings bene ts. Using the innovative Discpac technology, these pumps offer
a superior alternative to centrifugal, progressive cavity, lobe and gear pumps for viscous, abrasive, high solids and gas
entrained uids as well as handling shear sensitive and delicate chemicals and emulsions. Tests have proven that Disc
pumps can pump oil/water uids without emulsifying them. Built to API Standards for the Oil & Natural Gas industry.
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er 2015
14
PUMPING PRESCRIPTIONS
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
Actual Efficiencies of
New OEM Pumps
While the subject is of great
commercial importance during a
pumps procurement processand
15
1969 Chevelle SS
API Maxum
Creating Value.
Carver Pump Company
2415 Park Avenue
Muscatine, IA 52761
563.263.3410
Fax: 563.262.0510
www.carverpump.com
16
between the 70 and 80 percent valve operating tank level in TK-101 has
increased from 10 to 15 feet of level.
open position. Performing a linear
interpolation between the 70 and 80 How will that effect the system?
Again, the boundary parameters
percent open results in a calculated
valve position of 74 percent for FCV- drive the system operation; in this
101 using the valve sizing equation. example system, the boundary
parameters consist of the supply
The calculated results correlates
tank, the destination tank and the
with the observed valve position.
flow control loop FCV-101 that
Because we have an independent
regulates the flow rate to a set value.
method of calculation using the
Changing any of these boundary
model with the actual observed
values, we can validate the results of values will change the operation
of every item in the system. With
the control valve.
a change of operating parameters,
The total energy values at
the plant operates at 30 psig and a
the inlet and outlet of the head
exchanger and the inlet and outlet
of the flow meter have not been
Q
1,000
=
= 231
Equation 7
Cv =
validated. Because the total energy
dP
19.2
1 FP
.99
calculated by the model at PI-101
SG
.994
and the inlet of FCV-101 have been
Where:
validated, one could assume that the C = flow coefficient (unitless)
v
total energy calculated accurately
Q = flow rate (gpm)
reflects the physical piping system
FP = piping geometry factor (unitless)
even without the validation of
dP = differential pressure across control valve
installed instrumentation.
(pounds per square inch)
Based on the correlation between
SF = specific gravity of process fluid (unitless)
the calculated energy of the
model and the
Table 1. This table describes the manufacturers Cv and valve coefficient values as
observed values
a function of the valve position. This can be used to simulate the operation of the
provided by the
specific control valve under various operating conditions. (Courtesy of the author)
installed plant
instrumentation,
one could assume
that the model
accurately
represents the
operation of the
system under this
condition.
Imagine two
week after the
system has been
validated the
17
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For
Handling
Safe Solutions
Dangerous Chemicals
e
Wh
Award-winning Almatec E-Series Plastic AODD pumps provide safe and reliable
performance when handling the most dangerous acids, solvents, and caustics.
PSG Euro-Center
22069 Van Buren Street
Grand Terrace, CA 92313 USA
P: +1 (909) 512-1224
miguel.blanca@psgdover.com
psgpumps.com/ps1115a
World Headquarters:
Carl-Friedrich-Gau-Str. 5
47475 Kamp-Lintfort,
Germany
P: +49/2842/961-0
info@almatec.de
www.almatec.de
18
2
2
= 139.68 ft
H = Z + 144 P + v = (50 + 20) + 144 x 30 + 0
62
2g
2 x 32.2
Equation 8
19
20
Minimum Flow
Minimum flow is the operating
area where centrifugal pumps will
quickly get into trouble. The power
introduced into a pump by the
driver will manifest as energy or
workeither as a useful flow with
a corresponding head or as heat,
vibration, noise (acoustic energy) or
a combination of all these. Because
no pump is 100 percent efficient,
the energy not used in the work for
the head and flow will show up as
one of these other items.
Technically, four factors affect
minimum flow: fluid temperature
rise, minimum stable flow, internal
recirculation and thrust capacity.
For most cases, we can simplify
these factors and just look at two
main areas. The first area is under
the category of mechanical issues,
and the other is thermal issues. A
minimum continuous flow rate for
a pump should be determined for
mechanical and thermal factors.
The higher of the two becomes the
minimum flow rate for that pump.
Mechanical Issues
When the pump is operated
away from BEP, the radial thrust
will increase dramatically. For a
single volute pump, it is close to a
hyperbolic function. The shaft will
deflect and create issues with the
bearings and seals, dramatically
shortening their useful life. Also,
the flow velocity (angle/profi le)
will not match the impeller vane
speeds (velocity/inlet angle/
angle of incidence), and suction
recirculation will occur, creating
fluid stalls and cavitation.
The shaft deflection ratio (L 3/
D4) comes into play in these
calculations: A low L 3/D4 ratio will
mitigate the deleterious effects.
Calculating MCSF
Minimum continuous stable flow
(MCSF) is defined as the flow rate
below which the pump should
not be operated. The American
Petroleum Institute (API) will
define it as operating without
exceeding specified vibration
limits. The actual calculation of
this MCSF rate is a function of
numerous factors that include
suction energy (in my opinion,
suction energy is otherwise an
outdated concept), suction-specific
speed and specific speed (impeller
geometries). Pay particular
attention to factors that affect the
onset of suction recirculation and
exit turbulence at the vane tips as
these result in vortex cavitation.
Thermal Considerations
While the energy put into a pump
running at minimum flow (for
other than head and flow) may
yield vibration and noise, it is most
likely to manifest as heat. Another
possibility is heating the fluid to
the point of vaporizing the fluid
and cavitating or even exceeding
the design limits of the casing (due
to the vaporization of the fluid to
a gas and causing casing rupture).
The rate at which the temperature
will rise in a pump with a closed
discharge valve can be calculated
using Equation 1.
For my metric (SI) friends,
the temperature TR is degrees
C per second. The power will be
in kilowatts (kW), the specific
heat for water is 4.19 joules per
gram-degree C, and the pump
21
TR =
(0.085) (PSO)
(Q) (C V ) (Sp. Gr.)
Equation 1
Where:
TR = Temperature rise in degrees F per second
PSO = Shutoff power in BHP
C V = Specific heat of water (1.0 BTU per pound-degree F)
Q = Volume of the casing in gallons
MCTF
Minimum continuous thermal flow
(MCTF) is usually not the most
limiting factor in determining a
pumps minimum flow. Typically
the mechanical aspects will be the
limiting factor, but do not ignore
the thermal flow considerations.
Accurate, versatile
chemical pumps
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p u mpsa ndsyst ems.c om | Novemb er 2015
22
T =
ar
Self-priming and low shear
Dry-run capabilities
(PX) (5.1)
(Q) (CP) (Sp. Gr.)
Q
(T) = T pump
QX
Equation 2
Equation 3
24
SPECIAL REPORT
25
Drive Technology
Todays VFDs have three power component sections: an
input rectifier, a fi xed DC-bus section and a transistorized
inverter. Each design can differ slightly in components,
as well as how the power devices are controlledall of
which have an impact on their efficiency. In the early
1990s most VFDs were updated to include newer power
semiconductors, and insulated-gate bipolar junction
transistors (IGBT) were controlled by pulse-width
modulation (PWM) algorithms. This
change greatly enhanced reliability and
Figure 2. Typical VFD circuit diagram
reduced the overall size of VFDs, allowing
electrical variable speed control to replace
mechanical methods of varying flow in
pump systems.
Even though the majority of pumping
systems rarely require running at
full load and speed, the efficiency
calculations and subsequently stated
values for VFDs are typically represented
as a single percentage value. Table 1
shows typical efficiency values in VFD
product literature.
26
SPECIAL REPORT
Input frequency
50 Hz -5 percent to 60 Hz +5 percent
Galvanic isolation
Galvanic isolation between power and control (inputs, outputs and power supplies)
Power factor
Above 99 percent
Efficiency
Switching frequency
Percent Torque
16%
40%
Percent
Speed
50%
25%
56%
VT
100%
CT
VT
75%
100%
CT
VT
CT
CT/VT
VFD Efficiency
While a single value did provide some comparison of VFD
efficiency between manufacturers, it did not provide a
means of comparison at any point other than full load
and speed, where equipment rarely operates in modern
variable volume systems. AHRI Standard 1210 and 1211
addresses this issue by requiring test data be published
at four speed and torque points representing a variable
torque fan or pump motor load, or a constant torque
positive displacement pump or compressor loads. Table 2,
taken from the AHRI Standard, illustrates data that must
be published by manufacturers seeking to be certified.
Certified VFDs
With the release of AHRI Standard 1210 and 1211,
specifying design engineers, owners and energy managers
can compare VFDs on an equal basis. Efficiency has been
the driving force behind motor regulations that define
minimum levels of acceptable power usage.
VFDs now have a similar tool for those trying to
maximize system efficiency with detailed operating
points that closely define where fans and pumps operate
within variable volume systems. As a result, simple,
certified test data will be published following third-party
verification testing to comply with these new standards.
N ov e mber 2015 | Pum ps & S y st e m s
27
28
SPECIAL SECTION
BY JOSEPH HARMES
FOR PUMPS & SYSTEMS
29
Additional Capabilities
A pilot project is under way to capture rainwater for recycling,
which will be beneficial in times of drought. Using a OneBox
network to manipulate this storage will provide a flood
prevention mechanism.
30
SPECIAL SECTION
Image 3. Completed installation of E/One lowpressure sewer tank with Iota OneBox. Lowprofile features and modern industrial design of
components make for a more attractive amenity.
31
32
SPECIAL SECTION
System Considerations
for VSDs in Industrial
Machinery
The changing landscape of hydraulic drives is leading many
uid power specialists to quickly adapt to VSDs.
BY PAUL STAVROU
BOSCH REXROTH CORPORATION
Growth of VSDs
The combination of advanced electric drive technology
and hydraulics opens a new chapter in electrohydraulic
33
PROTECT PUMPS
PUMP POWER
AMPS
POWER
VALVE CLOSING
PUMPING
FULL LOAD
No Sensitivity
For Low Loads
NO LOAD
VALVE OPENING
NO FLUID
FULL LOAD
34
SPECIAL SECTION
Lift Station
35
36
SPECIAL SECTION
37
800.666.9101 www.thomasprod.com
PS001
38
SPECIAL SECTION
Soft Starters
A soft starter is a solid-state device that protects
alternating current (AC) electric motors from damage
caused by sudden influxes of power by limiting the large
initial in-rush of current associated with motor startup.
They provide a gentle ramp up to full speed and are used
only at startup (and stop if equipped). Ramping up the
initial voltage to the motor produces this gradual start.
Soft starters are also known as reduced voltage soft
starters (RVSS).
Soft starters are used in applications that have the
following requirements:
Speed and torque control during startup (and stop if
equipped with soft stop)
Reducing large startup in-rush currents with a
large motor
39
Provides variable speed control for AC Induction, DC, PMSM and EC motors, 1/50 to 5 HP.
115, 208/230, 400/460 VAC 50/60 Hz 1 and 3 Input.
When a standard off the shelf drive will not meet your needs, KB will work
with you to develop a custom drive solution, Ready to Use Out-of-the-Box.
KB Electronics, Inc.
12095 NW 39th Street, Coral Springs, FL 33065-2516
Designed and
Assembled in USA
40
SPECIAL SECTION
41
42
SPECIAL SECTION
System Vibration
Monitoring Is Essential to
Predictive Maintenance
Modern tools allow plants to predict and prevent costly failures.
BY MIKE PEMBERTON, PUMPS & SYSTEMS
& WILLIAM LIVOTI, WEG
43
Rugged Industrial
Design
Final
OWTRJ["
ORE/32
918-317-2633
www.fwmurphy.com/takecontrol
1511763 09/15
44
CHEMICAL PROCESSING
46
COVER
SERIES
CHEMICAL PROCESSING
ws
Flo
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Image 3. Because of their potential to be hazardous to plant personnel and the environment,
full containment of chemicals and solvents is a top-of-mind concern for plant operators.
Improve
Reliabilityand
Versatility
EnviroGear and G Series Internal Gear Pumps offer you highly reliable and versatile
pumping solutions for a wide range of applications, from thin to viscous fluids. With
field-proven technology thats safer, greener and interchangeable with competitive
technologies, the G Series and EnviroGear line of pumps are the workhorses youve been
looking for!
EnviroGear
Lowest overall cost of ownership
50% reduction in maintenance costs
Single fluid chamber design eliminates leaks
Patented between-the-bearing support
greatly improves reliability
G-Series
Best-in-class delivery
Interchangeable with competitive models
Flexible design for easy installation
Multiple seal options available
Available in cast iron and stainless steel
PSG
22069 Van Buren Street
Grand Terrace, CA 92313-5651
P: +1 (909) 422-1731
psgdover.com
47
Conclusion
Achieving the full containment of hazardous, fl ammable
or explosive chemicals is a daily challenge and concern
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p u mpsa ndsyst ems.c om | Novemb er 2015
48
COVER
SERIES
CHEMICAL PROCESSING
Diaphragm Pumps
Combine Safety & Accuracy
Developments in this technology may oer
signicant savings and improved reliability.
BY STEVE DIGBY
SPX FLOW TECHNOLOGY
49
Chemical Applications
Diaphragm pumps have been proven in a variety of
applications such as the pumping of caustics, ammonia,
methanol, sodium cyanide and all types of acids including
sulphuric, hydrochloric or hydrofluoric, and hydrazine.
One major chemical manufacturer in the Middle East
used the technology for the safe pumping of TEAL. This
particular chemical combusts on contact with moisture,
so pump designs were adapted to incorporate nitrogen
seals to prevent leakage paths from being exposed to air.
Diaphragm pumps can operate under high pressure
and high-flow transfer conditions, and they can handle a
wide range of temperatures. Gear sizes can be combined to
achieve required flow rate and pressure parameters. Pumps
can also be constructed from various materials to handle
different fluid properties, making them an adaptable
solution. Various manufacturers offer configurable
products to meet specific installation needs, as well as
the capability to provide complete pump packages in
a framework with all pipework, valves, controls and
instrumentation. This gives users a fully tested solution
that requires little on-site work and, with the supplier
taking total ownership for the overall package, greater
peace of mind for a smooth-running project.
Conclusion
The latest developments in diaphragm pump technology
combine safety and accuracy with pump configurations
that can increase capacity and reduce maintenance,
offering an even faster return on investment. These
pumps can safely handle a wide variety of harsh,
dangerous chemicals including slurries and hightemperature liquids. The pumps accuracy optimizes the
use of raw materials and increases efficiency in high-flow,
high-pressure applications.
Steve Digby is the commercial manager at the SPX
Brixworth plant in the UK. He is responsible for
all commercial activity from this facility. Digby
also manages the UK external sales team that
works with customers across SPX Bran+Luebbe,
Johnson Pump and Plenty Pump brands.
50
COVER
SERIES
CHEMICAL PROCESSING
Thermoplastic
Pumps Withstand
Acids & Caustics
A large, investor-owned utility in the southern US wanted
to reduce corrosion problems and boiler downtime.
BY KEN COMERFORD
VANTON
lectricity-generating power
plants rely on high-pressure
steam to drive turbines
and create electricity. The
water used to create the steam can
contain minerals, so it is imperative
to extract these to prevent them from
being deposited on the turbine blades
and corroding the steam circuit. To
achieve these goals, power plants
typically treat the condensate with ion
exchange resins.
As part of a cost-reduction and
profitability program, management
at a specific utility headquartered in
the southern U.S. began a planned
program of reducing maintenance
costs through equipment upgrades.
A significant part of the upgrade
program involved reducing corrosion
problems and boiler downtime
associated with pumping acids and
caustics needed to purify the water.
At the companys main power
plant, water bills averaged $6,000 a
month. Boiler water required 100,000 gallons per day,
while another 25,000 gallons per day were needed for
cooling, sealing, and regenerating and rinsing the resins.
A demineralization system removes dissolved solids
Image 1. This power plants demineralization installation uses three acid pumps
made of PVDF handling ambient sulfuric acid at 20 gpm against a 55-foot
total dynamic head. The maintenance department replaced metal pumps that
experienced chronic downtime due to corrosion. (Images courtesy of Vanton)
51
52
COVER
SERIES
CHEMICAL PROCESSING
material specified for the wetted end and the shaft seal was
polyvinylidene fluoride (PVDF). The pump was required to
deliver 20 gpm of acid at ambient temperatures against a
55-foot total dynamic head.
The sulfuric acid and sodium hydroxide required for the
ion exchange purification process is stored in these large
tanks outside the processing building. A
concrete containment vault served to catch
any spillage.
Because of the performance and service
records of the two initial pumps, the
plants maintenance manager decided
to replace all six metal pumps with
thermoplastic pumps manufactured to the
same design specs as the test units.
SERIES
Metering Technology
Eectively Handles
Polyethylene Production
Hydraulically actuated and critical service diaphragms enhance
safety and uptime.
BY KENNY LOQUE
MILTON ROY
53
54
COVER
SERIES
CHEMICAL PROCESSING
Increased Reliability
Failures or unscheduled maintenance activities can have
expensive consequences for plants that run operations
on a 24-hour basis. To guard against failures, many of the
largest chemical processing companies rely on metering
pumps with hydraulically actuated diaphragms (HAD).
The secret to the HAD pumps longevity is a Teflon
diaphragm that acts as a barrier between the piston and
process fluids. The HAD operates with equal pressure
between the hydraulic and process fluids, eliminating
diaphragm stress, since the pressure is essentially equal
on both sides at all times. Without equal pressure on
both sides, the diaphragm would have to withstand all of
the process pressure. With a HAD pump, the diaphragm
is balanced and remains under low stress. None of the
moving parts get stretched or compressed, resulting in
longevity that can run for 96,000 hours (or 10 years of
continuous uptime) with minimal maintenance.
System Flexibility
Because of the toxic nature of fluids, combined with
numerous temperature and pressure variations during
production, flexibility in metering pump design is
essential for process critical operations.
Worker Safety
The harsh nature of the chemicals put through metering
pumps can cause check valves and diaphragms to fail,
causing clogs in the liquid end that lead to potential leaks.
For applications up to 5,000 pounds per square
inch (psi), a critical service diaphragm (CSD) has been
engineered to handle high suction pressure. The CSD
CASE STUDY
THE CHALLENGE
Polypropylene reactor catalyst charge pumps used
by a major polyethylene plant were experiencing
numerous failures, leading to catalytic reactor unit shut
downs and the loss of hundreds of thousands dollars of
production per hour. The facility needed a more reliable
pump that could withstand the harsh chemicals,
pressures and processing conditions, and it needed a
pump that could endure the climate fluctuations within
the region.
THE SOLUTION
One manufacturer engineered a customized reactor
charge pump. The pump featured critical service
liquid ends, a specially designed diaphragm made
from Gylon with thicker walls than standard pumps,
and check valves equipped with hardened balls and
seats. The pumps design enabled it to accommodate
the solids and viscosity encountered in the reactor
fluid and pump the solids continuously to the catalyst
reactor at about 800 psi with accuracy and reliability.
In addition, the pump is unprotected from the weather,
being exposed to conditions ranging from 100 F (38 C)
heat to rain, wind and other harsh conditions. Because
of the reliability of the pumps performance, the plant
operator has installed pumps in other facilities within
the region and across the globe.
55
Conclusion
The production of plastics remains
a huge industry, and it is one that
continues to grow. Because of
the rise in U.S. shale production,
enhancing the ease of delivering
feedstocks, more chemical
processing plants have been
built in the U.S. in the last two
years than in the previous 15
years combined.
The dangers associated with
plastics production are well
understood; the best practices for
safely handling the materials are
codified; and the technology that
automates these best practices
continues to evolve and improve.
Given these factors, the
long-term outlook for domestic
polyethylene production is viable,
and with MET metering pumps
readily available, it truly is a time
when chemical companies can have
their cake and eat it, too.
56
COVER
SERIES
CHEMICAL PROCESSING
The Problem
In this application, the company manufactures
specialty chemical products in batches of up to 5,000
gallons using 37 percent hydrochloric acid (HCL) as
a concentrated base reactant solution. Some of the
reactions are endothermic, and some are exothermic.
When using the acid in a reactor, HCL fumes are often
generated and emitted. The manufacturer had installed
a fume scrubber using water as the scrubbing medium.
The water is sprayed into a column packed with a plastic
fibrous material.
A centrifugal blower takes emissions from the vessel
and blows them through the column. As the HCL vapors
meet the moisture from the water, they are absorbed
and the clean air is released (see Figure 1).
57
58
COVER
SERIES
CHEMICAL PROCESSING
Chemical Environment
Many fluids crystallize when exposed to air or heat from
mechanical seals. Examples are caustics, seawater, brine,
hydrocarbons and sugars. Sealless pumps have no contact
with air. A chemical environment can promote corrosion,
such as acids attacking carbon seal faces, chlorides
attacking stainless steel faces and metal-finishing
36
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N ov e mber 2015 | Pum ps & S y st e m s
59
Rolling Design
Peristaltic Pumps Increase
Equipment Longevity
This technology helped a facility save $20,000 in one year.
BY TODD LOUDIN
FLOWROX INC.
60
COVER
SERIES
CHEMICAL PROCESSING
Sodium Hypochlorite
EPDM
Sodium Bisulfite
Ferric Chloride
NR, EPDM
Lime Slurry
EPDM
Sulfuric Acid
NR, EPDM
Diethylene Glycol
EPDM
Nitric Acid
EPDM, Norprene
Hydrochloric Acid
NR, EPDM
Hydrofluoric Acid
EPDM
Magnesium Hydroxide
NR, EPDM
EPDM
Caustic Soda
EPDM
NR
Animal Fats
NBR
NBR, CSM
Erythorbic Acid
EPDM
Acetone
EPDM
Salt Brine
NR
Sodium Bromide
Norprene
Sodium Permanganate
Norprene
Figure 1. Typical shoe design pump that compresses the hose twice per revolution. This design can lead to heat generation that may shorten hose
lifetime and increase pump operational costs.
61
62
COVER
SERIES
CHEMICAL PROCESSING
63
64
COVER
SERIES
CHEMICAL PROCESSING
65
The pipes to move the cleaning fluid and other liquids are
located overhead to keep the plant floor clear of obstacles.
To pump the fluid to the waste treatment system, the
pumps must overcome more than 70 feet of static head
through 3-inch pipe.
In this challenging environment, the combination of
caustic cleaning fluid, high temperature and high head was
causing the original cast-iron pumps to fail.
The pumps that were originally specked out werent able
to handle what they were exposed to, Jennings said. If
the pump fails, we dont have very much storage space for
recovered fluid. As a result, the maintenance crew would
have to bring in a separate unit to pump it out.
R.F. MacDonald, a large distributor of pumps in
California and Nevada, had completed service work for
COR when it was built. Kevin Peters, sales representative
for R.F. MacDonald, explained that COR had several pumps
in their process that were manufactured overseas, which
meant getting replacement parts could be a challenge.
When Peters asked what CORs pain points were, the
sump pumps quickly floated to the top.
The original pumps were pedestal pumps that sat on
top of a column. The columns extended into the water so
the pumps motors werent subjected to chemicals or heat.
Because the arrangement had a long, extended shaft with a
sleeve bearing, however, the pumps did not last long.
To help COR solve these pumping challenges, Peters
recommended high-temperature, high-head, 316 cast
stainless steel pumps in the COR sumps. These stainless
steel pumps could withstand caustic cleaning solutions,
temperatures up to 200 F and up to 90 feet of head.
These side discharge submersible dewatering pumps were
designed for harsh conditions and are typically used in
sump applications where the liquid level can be controlled
and where the pumps are partially submerged.
The pumps have several features that enable them to
withstand the harsh conditions at the COR facilities.
For example, all metal parts exposed to pumped liquids
are made of 316 stainless steel, and elastomers (gaskets
and O-rings) are made of FKM. In addition, the motor
is protected by double mechanical seals. The lower seal
is made of silicon carbide/silicon carbide, and the upper
66
Exhibition Hours
Tuesday, Nov. 17
Wednesday, Nov. 18
Thursday, Nov. 19
10 a.m. - 5 p.m.
10 a.m. - 5 p.m.
10 a.m. - 3 p.m.
(EZMH%/EOEVIOE
Managing Principal
GN$NSVHEROREYJJGSQ
Senior Associate
HOEOEVIOE$NSVHEROREYJJGSQ
GIVE
CLEAN
WATER
THIS IS HOW
In May, Pumps & Systems traveled to
Malawi and Zambia to report on how
pump technology is changing lives
across rural Africa. To continue to
expand access to clean water, Pumps
& Systems has partnered with Design
Outreach to raise $9,200 to install a
LifePump in a village in Malawi.
This money will be used to install the
pump and provide the resources and
training needed for the community to
maintain it. This pump will serve about
300 to 400 people who will gain access
to a clean, reliable source of water
some for the first time in their lives.
67
68
Figure 1. Total pump market in oil and gas industry (Courtesy of Frost & Sullivan)
69
Investment in downstream is
uncertain in regions such as Europe,
while some activity continues in
Asia. Regardless, the growth for the
pump market is expected to have a
moderate demand. Investment in
specific pockets of upstream such
as subsea will lead to a high growth
rate for centrifugal pumps required
for water-handling subsea activities.
The growth rate for PD pumps
in oil and gas is expected to be low
for the current year as a number
of projects face postponement in
investments. However, because
of recovery in oil prices and
continuing upstream activities, the
growth of PD pumps is expected
to recover fairly rapidly. These
pumps are used heavily in wells
where flow is declining and in
places where crude oil may contain
sand content. Reciprocating pumps
are predominantly used for shale
exploration and production in highpressure applications such as frac
pumps. Metering pumps are often
used in exploration and production
activities as well.
In the long term, the oil and gas
industry continues to dominate
the energy requirement globally.
The current market is expected
to continue moderate growth
as investments in extraction
from more inaccessible locations
intensify. These factors are expected
to drive the pump market and
maintain an active demand from
this industry.
Sakthi Pandian is a research
analyst for Frost & Sullivan. She
can be reached by contacting Ariel
Brown, corporate
communications
associate for Frost &
Sullivan, at
ariel.brown@
frost.com.
70
EFFICIENCY MATTERS
71
Equation 3
Where:
a = cross sectional area of the pipe
component or fitting (between
outer diameter and inner
diameter)
E = modulus of elasticity of the
fitting material
L = length of the fitting or
component
72
EFFICIENCY MATTERS
Figure 4.
73
Equation 8
dpipe = Fp/kpipe
Equation 10
Equation 9
74
MAINTENANCE MINDERS
Lubrication Properties
Lube oil analysis helps companies
maintain equipment. In order
to take full benefit from oil
samples test data, it is important
Oil Film
75
76
MAINTENANCE MINDERS
Contaminants: Increased
Alkaline additives also protect the
contaminants from the
components by neutralizing acid
surrounding environment in
and preventing corrosion.
the form of dirt, water and
Hydraulic oils have the added
process contamination are
function of transmitting power.
the leading cause of machine
To function properly, hydraulic
degradation and failure.
oil must be clean and free of
Increased contamination
contaminants. Many contaminants
indicates it is time to take action
will cause oil to foam and entrain
in order to save the oil and avoid
air or water. Entrained air causes
unnecessary machine wear.
the oil to compress under pressure,
Machine wear: An unhealthy
resulting in a loss of power.
machine generates wear
Particulate contaminants can cause
particles at an exponential rate.
the control valves to malfunction
The detection and analysis of
and restrict the oil flow.
these particles assist in making
critical maintenance decisions.
The Role of Oil Analysis
Machine failure due to worn out
Selecting the proper lubricant,
components can be avoided. It
along with maintenance of that
is important to remember that
lubricant, is essential to ensure
healthy and clean oil leads to the
protection for any machine. Proper
minimization of machine wear.
lubrication is defined as the correct
amount of the correct lubricant at
Lubricant condition is monitored
the correct time.
with tests that quantify the oils
Maintaining a lubricant means
ensuring it has the correct viscosity physical properties to ensure
that it is serviceable. Metals and
and the necessary additives for
debris associated with machine
the application. Steps must be
wear are measured to monitor
taken to keep the lubricant clean
equipment health.
and serviceable. Oil analysis is
Some tests target specific
the most effective way to prolong
contaminants that are commonly
the useful life of lubricants, while
found in oils. It is imperative to
maintaining maximum protection
select the proper blend of tests to
of equipment.
monitor the machines lubricant
Oil analysis tests reveal
condition, wear debris and
information that can be broken
contaminants in order to meet the
down into three categories:
goals of successful oil analysis.
Lubricant condition: The
assessment of the lubricant
condition reveals whether the
Elemental Spectroscopy
system fluid is healthy and fit
Elemental spectroscopy is a test
for further service or ready for
that monitors all three categories:
a change.
lubricant condition, wear debris
77
Monitor them.
SKFs EXP4000 and
NetEP dynamic motor
monitoring solutions
reveal adverse impacts
variable-frequency
drives have on motors,
and they can help you
optimize performance
of those VFDs.
78
Figure 1. Cross section view of a typical circulating water pump indicating the
critical components and the impact of the entire installation if the sole plate is
out of level. Also note that the entire rotating assembly pivots off the motor thrust
bearing at the top of the motor. (Graphics courtesy of WEG)
79
Figure 2. A precision motor mounting surface (motor and motor stand) ensures a
flat surface with minimal or no shimming.
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81
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| Novemb
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82
SEALING SENSE
he practice of insulating
over metallic expansion
joints to minimize heat loss
in a piping system may be common,
but it is not a good idea to follow
this same practice with rubber
expansion joints.
Rubber expansion joints
typically consist of synthetic
(oil-based) elastomers (ethylene
propylene diene monomer [EPDM],
neoprene, chlorobutyl, nitrile or
clorosulphonated polyethlyeneCSM) combined with polyester
or nylon and wire reinforcing
that provide pressure-restraining
capability.
If an end user were to install a
typical rubber expansion joint in a
system needing insulation to cover
the joint in a hot application, that
83
84
HI PUMP FAQS
85
86
87
88
Improved Reliability
One way of aiding seal installation
is an axially restrained drive
ring, which stops the drive ring
from detaching from the retainer
during installation. In addition,
a full-convoluted diaphragm
allows for more axial movement
of the rotary face than the
half-convolution bellows. This
enables the seal rotary to track
Image 1. Seal faces require optimum running conditions to maintain the longest life possible. (Images courtesy of AESSEAL)
89
Reduced Failure
One failure mode of some types of
bellows seals is rupturing bellows
that lead to premature failure.
This rupturing has two main
causes. The first cause is when the
90
PRODUCTS
Notable pump technology products selected by the Pumps & Systems editors:
De-Chlorination Analyzer
Electro-Chemical
Devices DC80 DeChlorination Analyzer
accurately measures
near-zero or zero levels
of chlorine by utilizing
a zero-shift method to
ensure stable and reliable
chlorine measurement. he methodology protects total
chlorine sensors from damage that naturally occurs
when measured water samples contain near-zero or zero
levels of chlorine. he DC-80 De-Chlorination Analyzer
monitors chlorine in drinking water, wastewater,
cooling water and other de-chlorination applications
from 0.05 to 20 ppm.
Circle 201 on card or visit psfreeinfo.com.
Specialty Pumps
Grundfos has
launched an
extended range
of high-eiciency
medium-sized SP submersible groundwater pumps. Many
of the improvements on the new 4-inch SP pump range
are taken from the range of large SP pumps. he range,
which has been expanded from two to three sizes, is built
of corrosion-resistant stainless steel with three material
grades available, covering liquids from drinking water
to seawater. It ofers high eiciency, improved octagonal
discharge and cable guard attachment, high resistance
to abrasives, reliable motors and easy maintenance. A
complete monitoring and control system is available for
constant optimization.
Circle 205 on card or visit psfreeinfo.com.
To have a product considered for our Products page, please send the information to Martin Reed, mreed@cahabamedia.com.
91
FREE PRODUCT INFORMATION
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Comprehensive
Industry Coverage
92
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Tuf-Lok International
*i\ n{n U www.tuflok.com
Full Names and Complete Mailing Address of Publishers, Editor and Managing Editor
Publisher: Walter B. Evans, Jr.
1900 28th Avenue South Ste 200
Birmingham, Alabama 35209
Editor: Alecia Archibald
1900 28th Avenue South Ste 200
Birmingham, Alabama 35209
Managing Editor: Amelia Messamore
1900 28th Avenue South Ste 200
Birmingham, Alabama 35209
Owner: Cahaba Media Group
P.O. Box 530067 Birmingham, AL 35253
Walter B. Evans, Jr.
P.O. Box 530067 Birmingham, AL 35253
Average No. of
Copies Each Issue
During Proceeding
12 Months
37,266
36,828
Paid/Requested Outside County Mail Subscriptions Stated on form 3541 (Include advertisers proof
and exchange copies)
23,310
23,397
Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and Other Paid or Requested
Distribution Outside USPS
23,314
23,399
12,195
11,833
803
1,204
12,998
13,037
Total Distribution
36,312
36,436
954
392
37,266
36,828
64.20%
64.22%
9,110
9,394
32,424
32,793
45,422
45,830
71.38%
71.55%
I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading
information on the form or who omits material or information requested on the form may be subject to criminal sanctions
(including fines and imprisonment) and/or civil sanctions (including civil penalties).
Walter B. Evans, Jr. Publisher
9/23/2015
93
Solve
dry start
problems with
Vesconite Hilube
bushings
Increase MTBR
No swell
Low friction = reduced
electricity costs
Quick supply.
No quantity too small
Tollfree 1-866-635-7596
vesconite@vesconite.com
www.vesconite.com
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94
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Important Properties of
LobePro Rotary Lobe Pumps
Space-saving,
Low maintenance compact design
in place wear part
Self priming to 25 wet
replacement
Pump Capacities up to 2,656 GPM (604 m/hr) with
discharge pressure ratings to 175 psi (12 bar)
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800.433.7642 meltric.com
95
EPOXIES
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univeRsalPoweRCell
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4-20Milliamp,0-10Volt
CallnowFoRyouRFRee30-daytRail
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96
IP6
P66
P6
6
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Standard 61
Standard 61
Vaughans Rotamix System sets the standard for hydraulic mixing, providing the customer with
lower operating and maintenance costs, more efficient breakdown of solids and Vaughans
UNMATCHED RELIABILITY. Its perfect for digesters, sludge storage tanks, equalization basins
and other process or suspension type mixing applications.
- Over 1000 installations worldwide
- Optimizes solids contact with its unique dual rotational zone mixing pattern
- 10 Year Nozzle warranty