Anda di halaman 1dari 48

MPT

Don’t Be Misled by
FEBRUARY 2018

Vibration Data
How to Choose the
Right Gasket
Modern Pumping Today ®
The Internet of Things
Providing Solutions for the Worldwide Pump Industry Meets the Pump Market

www.modernpumpingtoday.com
The 1st micro PLC
with a can-do attitude

STANDALONE MICRO ANALOG I/O


PLC UNIT EXPANSION MODULES
STARTING AT STARTING AT TEMPERATURE
$199.00
(BX-DM1-10AR-D)
$187.00
(BX-08AD-1)

Low-cost Process Control


The BRX PLC family now includes more analog I/O options for your process control LEVEL
needs. Besides the built-in analog I/O on select units, you now have the option
to expand your system with high-resolution current, voltage, or temperature/
millivolt modules. Monitor and control more temperature, pressure, flow, etc.
with the added expansion modules and BRX PLCs’ easily configured control loops.
• Expansion modules easily snap onto the side of any BRX Micro PLC Unit
creating a sturdy and rugged PLC platform PRESSURE
• FREE Do-more Designer programming software automatically discovers
the I/O with little to no additional setup required
• Use with Do-more Designer’s modular, interchangeable, and run-time
configurable control loop function blocks for versatile process control PSI

FLOW

Research, price, buy at:


www.BRXPLC.com

Order Today, Ships Today!


* See our Web site for details and restrictions. © Copyright 2017 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation
FEBRUARY 2018
22 30
MPT
Modern Pumping Today ®
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266

@ModPumpMag

JEFF FLETCHER Publisher


jeff@modernpumpingtoday.com
38
J. CAMPBELL Editor
jay@modernpumpingtoday.com

TONYA BROWNING Associate Publisher


tonya@modernpumpingtoday.com

DAVID MARLOW Account Executive


davidm@modernpumpingtoday.com

LISA AVERY Art Director

INGRID BERKY Office Manager


A NOTE ON THIS ISSUE:
Thank you for picking up this issue of MPT! This month’s
edition shows off both the versatility and reliability of
equipment available in the industrial pump and rotary
SUBSCRIPTION
inquiries or changes:
equipment markets. Of particular interest is the feature
“How to Choose the Type of Gasket to Use” (pg. 38) 205.380.2048
by Mike Shorts, past president of the Fluid Sealing
Association, wherein you’ll learn best practices for
matching gasket material to your application.
Submersible pumps are known for their reliability, J. Campbell, Editor
but even the sturdiest of equipment wears down. In this Modern Pumping Today
issue’s SWPA Insight (pg. 14), SWPA Executive Director
Adam Stolberg and SWPA’S Vice President Clark
Henry from Environment One Corporation tackle this crucial issue in “Repair or www.highlandspublications.com
312 Lorna Square | Birmingham, Alabama 35216
Replace? Evaluating Your Aging Submersible.”
866.251.1777
One of the highlights from this past fall’s WEFTEC was seeing the new
generation of smart pumps up close on the exhibit floor. In this month’s Pumping TIM GARMON RUSSELL HADDOCK
Trends (pg. 44), Joanne Goh, a researcher at IHS Markit, shares her insights on CEO/President COO/Publisher
how the internet of things will intersect and influence the pump market.
CHRIS GARMON DONNA CAMPBELL
CFO VP, Editorial

EDITORIAL ADVISORY BOARD:


Terry Bell Product Manager, Baldor Electric Company No part of this publication may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopy, recording, or any information
Heinz P. Bloch, P.E. Consulting Engineer, Process Machinery Consulting storage-and-retrieval system without permission in writing from the publisher. The
views expressed by those not on the staff of Modern Pumping Today, or who are
Robert G. Havrin Director of Technology, Centrisys Corporation not specifically employed by Highlands Publications, Inc., are purely their own. All
Industry News material has either been submitted by the subject company or pulled
Michael Mancini Consultant and Trainer, Mancini Consulting Services directly from their corporate website, which is assumed to be cleared for
release. Comments and submissions are welcome, and can be submitted to
John M. Roach Engineering Manager for New Product Development, Trebor International, jay@modernpumpingtoday.com.
Inc.: A Unit of IDEX
Lisa Riles Business Development Manager, Wastewater Pumps, Xylem Inc.: Flygt
Frank Knowles Smith III Executive Vice President, Blacoh Surge Control
Greg Towsley Director of Regulatory and Technical Affairs, Grundfos
Trey Walters, P.E. President, Applied Flow Technology
CONTENTS
INDUSTRY NEWS
6 What's happening in the industry

TRADE SHOW PROFILE


12 Asia Turbomachinery and Pump Symposium

SWPA INSIGHT
14 Repair or Replace? Evaluating Your Aging Submersible

CASE STUDIES
16 Cruise Liner Finds the Right Seal for Booster Pumps
18 Don’t Let Vibration Data Mislead You

WATER & WASTEWATER FOCUS


22 Wastewater Facility Upgrades Prove Their Worth

MAINTENANCE & RELIABILITY


26 Soil Sampling for VOCs: Best Practices Part 2 of 2

PUMP SOLUTIONS
30 Improving Pump and Centrifuge Performance in Crude Oil
Tank Bottom Cleaning and Drilling Solids Control Part 2 of 2

MOTOR SOLUTIONS
34 Extending the Life of Precision Components in
Demanding Applications Part 2 of 2

SEALING SOLUTIONS
38 How to Choose the Type of Gasket to Use

MODERN PUMPING PRODUCTS


42 Featured Product: SUNDYNE'S API 682 and API 685
Upgrades for LMV 801 Line of Direct Drive Pumps

PUMPING TRENDS
44 The Internet of Things and the Pump Market
INDUSTRY NEWS

NETZSCH ANNOUNCES NEW REGIONAL SALES TENCARVA ACQUIRES ASSETS OF SALADIN PUMP
MANAGER FOR THE CENTRAL REGION AND EQUIPMENT
Netzsch Pumps North America, LLC has expanded its Tencarva Machinery Company LLC announces the
sales force by hiring Brian Johnson as the regional sales addition of Saladin Pump and Equipment Co. Inc., in
manager for the central region. He will be responsible Beaumont, Texas, and Lake Charles, Louisiana, to its
for supporting industrial and municipal distributors / operations on February 5, 2018, according to Edwin W.
representative in the states of Michigan, Indiana, Kentucky, Pearce III, Tencarva president.
southern Ohio (municipal only), Illinois, Wisconsin, Pearce explains, "Tencarva Machinery Company has
Missouri, Kansas, Nebraska, Iowa, North Dakota, South purchased the assets of Saladin Pump and Equipment
Dakota, and Minnesota. Co., located in Beaumont, Texas, and also the office in
Johnson has spent thirty years in the pump industry Lake Charles, Louisiana. Saladin Pump is a long-time
having served in varied sales management roles Goulds distributor and, in addition to the ITT companies,
during his previous employment including sales Saladin represents Xylem, John Crane, Warren-
management, district Rupp, Roper, Liquiflo and Prominent, as well as many
manager, strategic other manufacturers."
accounts manager, and John Saladin Jr., formerly Saladin Pump and Equipment
business development Co. Inc. president, and son of founder John Saladin, will
manager. His previous remain with the company for a transition period. All
responsibilities included sixteen full-time employees have become a part of the
the development Tencarva team. Henry
and management of Ritchie, Tencarva vice
distributors, OEMs, president, is overseeing
catalog companies, both the operations
and other specialized and sales activities
niche market channels for Saladin Pump
of distribution. Brian Johnson and Equipment.

6 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


INDUSTRY NEWS

BLACKMER EXHIBITING PUMPS AND SALES REPRESENTATIVES JOIN HELWIG


COMPRESSORS AT NPGA 2018 CARBON PRODUCTS
Blackmer®, part of PSG®, a Dover Helwig Carbon Products, Inc.
company, will be featuring its announces the appointment
comprehensive line of pumps and of Pawn Meksyphet as
compressors for the LPG/Autogas sales representative for
market in Booth 1221 at the National the Northern Illinois
Propane Gas Association’s (NPGA) territory. Meksyphet has
2018 Southeastern Convention over eighteen years of
and International Propane Expo. professional sales and account
NPGA 2018, which will be held from management experience
April 6 through 8 at the Georgia in telecommunications and
World Congress Center in Atlanta, nonprofit/political fund-
Georgia, is the largest propane- raising industries. He has Pawn Meksyphet
related tradeshow in the world with held positions at Verizon
over 250 exhibitors and more than 4,000 participants. Wireless, U.S. Billing, and Sprint, and was most recently
At this year’s show, Blackmer will be featuring its sliding involved in the development, marketing and launch of
vane pumps for the LPG market, including its LG, LGL, and over a dozen, independently owned and operated, Sprint
TLGLF models. LPG Series pumps offer the best combined prepaid retail locations in the state of Wisconsin. Pawn
characteristics of sustained high-level performance, served in the Army Reserve and studied at the University of
energy efficiency, trouble-free operation and low Wisconsin–Milwaukee.
maintenance cost. Designed for maximum performance Harold Katz will also join Helwig as sales representative
and reliability in a wide variety of LPG applications, for Southern California. Katz has thirty-five years of sales
these pumps are ideally suited for cylinder filling, motor and sales management experience in the ball bearing,
fueling, bulk transfer in liquid terminals, vaporizers, and on power transmission, linear bearing, and motion control
bobtails and transports. industries. He spent over three decades with Bearing

8 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


INDUSTRY NEWS

Engineers, Inc./ Motion single highest individual


Solutions, Inc. in the roles recognition in all of Genuine
of sales representative, Parts Company.
assistant sales manager, sales Mr. Breen began his
manager, vice-president, career with Berry Bearing
and president. He left to form Company in 1982 and has
his own independent sales held significant key positions
representation organization since Berry Bearing
in 2017 with focus on motor was acquired by Motion
manufacturing, repair, and Industries in 1993. Prior to
overhaul industries. becoming executive vice
Harold Katz
Helwig Carbon Products, president and chief operating
Inc. is one of the last American owned manufacturers officer for U.S. operations
Tim Breen
of carbon brushes, brush holders, and mechanical in 2011, he led Motion
carbons. Helwig Carbon Products is also the only sliding Industries as a senior vice president for the Central United
electrical contact manufacturer that designs, engineers, States. Breen was named President in 2013 before becoming
and manufacturers the complete brush circuit in the company’s president and CEO the following year.
the same facility. “Each year since 1959, we have recognized one Manager
of the Year out of all our associates worldwide,” says Paul
TIM BREEN NAMED 2017 GPC MANAGER Donahue, president and CEO of Genuine Parts Company.
OF THE YEAR “We appreciate the critical role Tim and his Motion Team
Motion Industries, Inc., a leading distributor of maintenance, play in making Motion Industries the successful business
repair, and operation replacement parts is pleased to it is today, and in delivering the excellent results the team
announce that its parent company, Genuine Parts Company delivered in 2017. This award, the highest honor at GPC, is
(GPC), named Motion Industries president and CEO a significant and well-deserved recognition for Tim and the
Tim Breen as its 2017 GPC Manager of the Year. It is the outstanding leadership he provides to the Motion Team.”

10 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


T R A D E S H OW P R O F I L E

Asia Turbomachinery
and Pump Symposium
Exchanging ideas and impacting the industry

T
he Turbomachinery career and industry.
Laboratory at The exhibition will
Texas A&M showcase products and
University is embarking support technologies from
on its second biennial leading rotating machinery
Asia Turbomachinery original equipment
and Pump Symposium manufacturers (OEMs).
(ATPS) in Singapore. Full-size equipment,
ATPS is modeled after cutting-edge technology,
the longstanding Houston and emerging industry
Turbomachinery and Pump trends will be on display.
Symposia (TPS), held
annually since 1972. ATPS is an international assembly for A STRONG FOUNDATION
turbomachinery and pump end-users and manufacturers. It Rooted in the history and successes of the Turbo Lab and
features a renowned technical program that is hand-selected TPS, ATPS promotes professional development, technology
by an advisory committee of engineers, and an international transfer, peer networking, and information exchange among
exhibition. The inaugural 2016 event drew more than 900 industry professionals.
attendees from 38 countries. To further the mission of ATPS, the Turbo Lab has partnered
ATPS 2018 will be held March 13-15 at the Suntec with a number of organizations including major sponsor
Singapore International Convention and Exhibition Centre, Mitsubishi Heavy Industries Compressor Corporation and
with full-day short courses offered in conjunction with badge lanyard sponsor Elliott Group; association partners
the symposia. Paid delegates may choose to engage in Korea Rotating Machinery Engineers Association, Institute
a combination of seven full-day short courses, seventeen of Engineers, Singapore and Institution of Engineers,
tutorials, twenty-five lectures, thirty-nine case studies, eleven Malaysia; and academic partners Nanyang Technological
technical briefs, and twelve discussion groups. New to the University, National University of Singapore and Universiti
symposium are two panel sessions on digitalization and Teknologi Malaysia.

12 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


T R A D E S H OW P R O F I L E

“ATPS is an invaluable networking opportunity for end- including benefits and challenges of working in the oil and
users and suppliers alike—made even more essential at this gas sector. A question-and-answer session will follow, with a
time of flux for the industry,” says Dag Calafell, chairman networking reception closing out the event.
of the 2018 event. “I look forward to a robust, meaningful
symposium sharing leadership insights and successes that Successful Applications of Digitalization in Oil and Gas
strengthen our industry. Together we can create opportunities Digitalization is expected to transform the industrial segment,
despite the challenges we face.” both oil and gas and power. The latest technological
innovations in the industry are not fully understood, due to
TECHNICAL PROGRAM hype versus reality. This session seeks to widen technological
Technical Session perspective for ATPS attendees and remove silos in industry
ATPS hosts the premier professional continuing education for a multidisciplinary approach. The latest trends and
program relied upon by rotating equipment engineers and anticipated changes will be addressed. The discussion will
technicians worldwide, spanning oil and gas, petrochemical, feature first-hand accounts of successful applications, latest
power, aerospace, chemical, and water industries. The available developments in digitalization, as well as pain
program, hand-picked by an influential industry advisory points and potential approaches. The panel will address how
committee, is led by highly-respected practitioners and OEMs are able to help customers with successful application
leaders in their fields. Topics include maintenance, reliability, of digitalization. A question-and-answer session will follow the
troubleshooting, instruction on emerging designs, technology, panel discussion.
and best practices that include case studies with real-world
relevance on problems-solved and lessons-learned. INDUSTRY EXHIBITION
At the centerpiece of ATPS, a remarkable exhibit hall hosts
Industry and Career Panel and Networking Session leading companies from across the globe. Companies
This panel and networking session is intended for delegates and industry experts demonstrate full-size equipment and
enrolled in university, and early-career professionals. The products, and share insights on current practices and future
keynote, by Deloitte Consulting, will cover trends in the trends. Networking opportunities abound for attendees,
oil and gas industry and its role in society and economics. rounding out the valuable transfer of knowledge that has
Panelists will give an overview of their industry experience become the hallmark of ATPS. ◆

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 13


S W PA I N S I G H T

Repair or Replace?
Evaluating
Your Aging
Submersible
By SWPA Executive Director Adam Stolberg
and Clark Henry, Environment One

S
ubmersible pumps are known for their
reliability, but even the sturdiest of
equipment wears down or, eventually,
needs replacement. When to end a pump’s
life cycle rather than extending it is one of the
most important questions a pump owner can
ask. Below, SWPA Executive Director Adam
Stolberg and SWPA’S Vice President Clark
Henry from Environment One Corporation
tackle this crucial issue.

What should pump owners look for when


assessing the need for a replacement?
Pump owners should look at the combination
of the cost and the longevity of the pump
for each instance. The repair cost might be
lower than a new pump, but so too might be
the longevity of the repaired pump. Items
that can drive up repair costs are excessively
corroded castings, damaged electrical
components or items that require more The service technician should be capturing data on every
hours to replace. There are also practices that can drive service call. That data should provide insight into the
up repair costs unnecessarily—especially the mindset: “I system. Reviewing data collected over several sites over
might as well replace this while I’m here.” time can provide further insight into system performance.
That mindset can turn an average repair into an If the replacement pump is able to deliver sufficient
expensive repair and perhaps into a pump replacement. pressure and scouring velocities, it can clean lines that
Repairs should typically only be performed on may have collected deposits with underperforming
components that are damaged. That keeps the labor and pumps. The cleaner lines can improve wastewater
financial impact to a minimum. transmission efficiency and performance.

How can a replacement pump kickstart improved To stay on top of a pump’s performance, which inspection
efficiency and performance for an entire system? schedules work best for different applications?
Is replacing a pump the best time to assess The best pumps are those that do not require regular
system performance? maintenance schedules. If the pump contains floats or

14 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


level sensing probes, they typically will require cleaning to
maintain proper performance. The frequency of cleaning
is proportional to the FOG (fats, oils, and grease) content
in the wastewater. The lower the FOG content for the
application (laundromat, conscientious homeowner, etc.)
the less frequently they need to be cleaned (annually, or
semi-annually). If the application has a heavy FOG content
(restaurants, etc.), then very regular maintenance (monthly
perhaps) is required.

What are some key efficiency and


performance points to consider?
Efficiency and performance depends on the type of pump
being used. For centrifugal pumps, understanding the
hydraulic dynamics of the system is critical to selecting
the correct motor/impeller combination. That will ensure
the pumps will perform at the correct point on the pump
curve, which will allow them to perform as well as possible
for as long as possible.
For semi-positive displacement pumps, the pump
selection is a little more straight forward. Because the
discharge volume is relatively constant, the same pump
can be used across the sewer system. Monitoring the
amperage at a location over time can help assist in
identifying line blockages or worn pump components.

If pump users decide to repair an aging pump, where can


they best find quality parts? Will this require a different
approach to maintenance schedules and inspection?
It is always best to use OEM parts for pump repair to
ensure your pump performs as the manufacturer intended.
The use of non-OEM parts can occasionally save a little
amount of cost up front, but will usually lead to more
frequent repairs and significantly more cost in the long
run. Also, the part quality is typically not as high, which
leads to more frequent pump repair as well. This can hurt
the reputation of the product and perhaps the particular
sewer technology.
If a pump is repaired properly (using manufacturer’s
instructions and OEM parts), the repaired pump should be
treated the same as a new pump. Attention should be paid
to maintaining accurate historical service records. Those
records are the key to identifying faulty site conditions that
could be the root cause of repeated failures. ◆

READ MORE

MPT
Modern Pumping Today
Providing Solutions for the Worldwide Pump Industry
®

Visit www.ModernPumpingToday.com

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 15


CASE STUDIES

Cruise Liner Finds


the Right Seal for
Booster Pumps
DiamondFace-coated mechanical seals provide
reliable operational safety and long runtimes under
heavy-duty conditions

E
CAs (Emission-Controlled Areas) were established the lubrication required for the seal faces, and thus on how
a few years ago in the North Sea and Baltic reliably the seals function. In HFO operation, water vapor
shipping areas, the English Channel and the U.S. can be mixed in with the fuel to reduce the amount of soot
and Canadian coastal regions. Ships that operate in these in the exhaust gas.
waters must reduce their sulfur Furthermore, HFO can contain up to
emissions to 0.1 percent m/m. While 30 percent of substances that cannot
heavy fuel oil (HFO) is used as a fuel be defined more precisely according
outside these ECAs, ships switch to to current standards, and thus can
light fuel oil (MDO - Marine Diesel potentially impair the seal. In addition,
Oil) with its lower sulfur content temperature jumps of around 126
within the environmental zones and degrees Fahrenheit (70 degrees
in harbors. Celsius) occur at the booster pumps
These fuel changeovers are and their seals during fuel changes.
particularly frequent on cruise liners, As the vertical screw pumps used
which often go to new destinations have mechanical seals installed
every day. This puts considerable at the top, gas building up in the
strain on machines and components, seal compartment can also cause
including the booster pumps that a lack of lubrication. Furthermore,
transport the fuel from the bunker to the temperature limits for the FKM
the ship’s engines under pressure— (fluoroelastomer) secondary seals
and consequently the mechanical applied as standard are regularly
seals in these pumps, which are exceeded. The operating conditions
designed for stable operating immediately suggest the application
conditions and continuous lubrication of double mechanical seals, but this
of the seal faces. is often impossible due to the limited
installation space and is undesirable
PROBLEM MEDIA AND EagleBurgmann single mechanical seal DF-M7S91. on cost grounds. Conventional
The seal faces of the rotating ring and stationary seat
SPECIAL CONDITIONS are diamond coated.
mechanical seals used to achieve
The seals applied to seal the pump a limited service life of 50 to 500
shafts are exposed to extreme stresses operating hours before unacceptable
due to the lack of lubrication of the seal faces and the leakages occurred. This contrasts sharply with the
constantly changing pressure and temperature conditions. operators’ demand for a MTBF of 8,000 hours.
In addition to the changes between HFO and MDO, the Early wear of the mechanical seals thus caused massive
quality of the heavy fuel oil also has a negative effect on problems for shipyards and cruise ship owners. Time and

16 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


CASE STUDIES

time again, the unavoidable replacement of seals resulted


in a lot of time and money being spent on maintenance.

SOLUTION IN SIGHT: DIAMONDFACE


EagleBurgmann DiamondFace is the key to solving such
sealing problems. The positive experiences gained from
other applications, such as high tolerance to dry running
and significantly longer service life, are impressively
demonstrated yet again in these applications.
The four booster pumps in each of five cruise liners
operated by one of the world’s largest ship owners have
been equipped with type DF-M7S91 single mechanical
seals coated with DiamondFace since 2011. While the
pumps in the first two ships were retrofitted, the DF-M7S91
seals were installed in the other three ships while they
were under construction in Papenburg, Germany.
These twenty seals with the high-tech coating have Vertical screw pumps are used as booster pumps for different grades of fuel.
been working perfectly and without a hitch since
commissioning. The massive leakages that used
to occur have been eliminated and reduced to a
minimum. Running times of up to 10,000 hours are now EagleBurgmann is one of the worldwide leading providers of
achieved by the M7S91, promoted by its extraordinary industrial sealing technology. Mechanical seals, seal supply
tolerance to dry running and the extreme chemical systems, magnetic couplings, carbon floating ring seals, expansion
joints, gaskets and packings as well as comprehensive services
resistance of DiamondFace. This is combined with are used wherever reliability and safety are needed. For more
never before achieved MTBF values, much to the information, visit www.eagleburgmann.us.
operator’s satisfaction. ◆

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 17


CASE STUDIES

Don’t Le t Vibration
Data M islead You
Perform electrical signature analysis
alongside vibration analysis to properly
diagnose motor problems
By Richard Scott, ALL-TEST Pro, LLC.

E
asyTool is a condition monitoring solutions provider THE APPLICATION
with service and support representatives in Italy. A VFD-driven, 15-kilowatt induction motor was used
Located in the town of Fabriano, in the province of to drive an industrial fan on a drying section hood of
Ancona, EasyTool represents ALL-TEST Pro instruments a machine that produces paper. While the machine
and performs regular condition monitoring services for produces paper, this industrial fan extracts the fumes
a local paper manufacturer. Every three months, a field from the machine and sends them through a filter before
engineer travels to the paper manufacturing facility to test releasing the exhaust out to atmosphere.
their equipment, including fans, motors, rollers, and gear
boxes. Data is collected four times throughout the year
for trending and predictive analysis to support the paper
manufacturer’s safety and equipment reliability programs.
In September 2016, Ettore Di Pasquale, field engineer,
used a multi-technology approach to properly diagnose an
issue with an induction motor.

ABOUT SPM INSTRUMENT


SPM Instrument has over forty years’ VFD-driven, 15-kilowatt induction motor

experience with machine condition


monitoring, working with several WHEN VIBRATION ANALYSIS AND ELECTRICAL
SIGNATURE ANALYSIS DISAGREE
industries in more than 50 countries
The initial vibration analysis showed high vibration values
to provide technical service, support, (see figure 1) and a spectrum which could have been
and training in condition monitoring interpreted to be motor unbalance (see figure 2). Even
practices. SPM offers a wide product though the first portion of the spectrum looked similar to
range, from high-tech portable an unbalance pattern, the field engineer knew to continue
instruments to online systems and a investigating investigating.
comprehensive condition monitoring Speed was measured with a strobe and showed that the
software. SPM Instrument’s intelligent revolutions per minute (RPM) had been changing very
solutions are cost-effective, constructive quickly—even though the VFD was set to run the motor at a
and complete. For more information, visit fixed speed of 1,470 RPM. Seeing the speed of the induction
www.spminstrument.us. motor change rapidly is indicative of broken rotor bars.
At this point, the field engineer continued with his multi-
technology approach and performed an Electrical Signature

18 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


CASE STUDIES

and operating current to identify existing and developing


faults in the entire motor system. When in ESA mode, the
ATPOL II™ evaluates the condition of incoming power,
the control circuit, the motor itself, and the driven load.

Figure 1. Portable data collector detected high values of vibration at 1X as shown in


the spectrum.

Figure 3: ESA showed very strong variations of motor current confirming speed
variations with current amplitude modulation of 30 percent.

Figure 2. The time waveform in the axial direction showed signs of


frequency modulation.

Max RPM Line Freq 2997,4 (RPM)


3000 RPM Running Speed 1482,9 (RPM)
1000 Hz PPF 63,446 (RPM)
Figure 4: ESA confirms broken rotor bars with values of PPF sidebands of -20 db
20 Ordini THD-I (Max.) 8.865 % related to severe damage (condition 7).

Risoluzione: 0,63 Hz THD-V (Max.) 3.784 %


37,5 CPM Induction Motor (LF: 50 Hz)
Tempo di acquisizione:
Power factor PF is below 0.85
7,2 Secondi
N. di rivoluzionic 360 Current OK
FFT bandwidth was 37.5 RPM and PPF was 63.4 RPM. The spectrum did not show Voltage OK
evidence of PPF sidebands around 1X and harmonics.
Load OK (Ld: 83.1%)
Analysis with the hand-held Vlt-GND ref. NOT neutral OK
ALL-TEST PRO On-Line
Connection OK
II™ energized motor
testing instrument to Rotor RB health is questionable (C:7)
investigate the condition of
Stator (mechanical) OK
the motor’s rotor bars.
Air gap OK
ELECTRICAL
Harmonic distortion Too much (V)
SIGNATURE ANALYSIS
CONFIRMS BROKEN Misalignment/Unbalance OK
ROTOR BARS
Bearing/Unidentified OK
Electrical signature analysis
(ESA) is a diagnostic Bottom line Suspicious operation
technology that uses Figure 5: ATPOL II™ displays results "RB health is questionable (C:7)”. As shown in the
the motors supply voltage table, C7 reports severe damage to the rotor bars.

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 19


CASE STUDIES

The ESA of this induction motor showed significant was performed on the new motor to make sure it was
variations in current (see figure 3—when the motor working as intended.
speeds up, it draws more current; when it slows down, Vibration analysis of the new motor showed that the
it draws less current). The large fluctuations in current vibration had significantly decreased. Where the original,
varied about 30 percent because the motor was varying damaged motor had shown high values of vibration
load due to speed variations. around 11 mm/sec., the vibration analysis of the new motor
showed values around 0.35 (30 times less vibration).
PREVENTING MOTOR FAILURE AND KEEPING More importantly, the new motor was operating at a
EMPLOYEES SAFE constant speed, ensuring the industrial fan could evacuate
The field engineer reviewed his comprehensive analysis fumes from the paper production machine with consistent
with the paper manufacturer’s predictive maintenance air flow. Maintaining speed and air flow for fume suction
and reliability manager, and the suggestion was made to meant creating a healthy and safe work environment for
replace the motor. A new motor was promptly installed the manufacturer’s employees.
during a planned shutdown, and another vibration analysis
LESSONS LEARNED
1. If the broken rotor bars had not been detected, the
motor would have failed. Motor failure would have led
to unsafe working conditions inside the manufacturing
facility. Condition monitoring and predictive
maintenance (PdM) programs are very important
initiatives that every manufacturer should implement.

2. Vibration analysis, while very informative and


important, does not always clearly identify motor faults.
Vibration testing should be performed alongside
Electrical Signature Analysis. It is critical to take a multi-
technology approach when checking the condition of
your motors, as one technology is usually not ‘enough’ to
properly diagnose motor health.

3. There are easy-to-use portable instruments, like the


ALL-TEST PRO On-Line II™ energized motor testing
instrument, that can help you check the health of your
motors. The ATPOL II™ is an invaluable monitoring and
Internals of motor with broken rotor bars (broken rotor bars are not visible in this diagnostic tool that can help you see what is really going
picture).
on with your equipment. Make sure you have the proper
tools to support your condition monitoring program. ◆
Condition db Value Rotor Condition Action
1 >60 Excellent None
2 54-60 Good None
3 48-54 Moderate Trend
Rotor fracture or Increase test
4 42-48 high resistance intervals and Richard Scott is general manager at ALL-TEST Pro, LLC. Since
joint trend 1985, ALL-TEST Pro, LLC has provided industry with the most
Two or more Confirm with advanced predictive maintenance testing and troubleshooting
tools for AC and DC motors, coils, windings, transformers,
5 36-42 bars cracked or motor circuit
generators and more to a wide range of industries worldwide.
broken analysis With a full line of testing instruments, software, accessories
Multiple cracked and training programs, ALL-TEST Pro has the tools you
or broken bars need to perform advanced non-destructive motor testing
6 30-36 Overhaul and analysis for both de-energized motor circuit analysis
and end ring
problems and energized electrical signature and power analysis.
The extensive capabilities of the instruments, coupled with
Multiple broken dependable post-sale training and technical support, ensure
rotor bars and Overhaul or improved productivity, reduced downtime and a rapid return on
7 <30
other severe replace investment. For more information, visit www.alltestpro.com.
rotor problems

20 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


WATER & WASTEWATER FOCUS

Wastewater Facility
Upgrades Prove
Their Worth
Spiraflo Clarifier and Raptor Screen
team up for a dirty job

Clarifier pre-construction at Addison; worn gearbox, cracked walls and a worn arm that would often stick.

W
orking alone in New York Conservation (DEC) requirements, generator and a mechanical
State, approximately 90 Chuck is rightly proud of the clean bar screen.
to 100 miles south of and well maintained Addison Other improvements under LDG’s
Rochester and Lake Ontario, plant Wastewater Treatment Plant. contract included the major task
operator Chuck Wright depends on of replacing the clarifier internals,
the good performance and reliability CLEAN AND RUNNING as well as raw wastewater pumps,
of the equipment he diligently looks SMOOTHLY trickling filter recirculation, and
after near the Village of Addison. The Village of Addison had retained HVAC upgrades. Larson Design
With such a high level of emerging national architecture, Group has also provided engineering
responsibility, the beauty of well- engineering, and survey firm Larson services for the Village’s water
engineered, low maintenance Design Group (LDG) for design and supply and treatment system, local
equipment cannot be construction services, developing streets, and drainage problems within
underestimated—and following a the project scope and funding the Village.
$3.34 million upgrade to bring the applications for rehabilitation of the Amid the substantial improvements,
thirty-four-year-old treatment facility anaerobic digester unit, replacement two pieces of equipment that have
up to code and meet New York of a wastewater pumping station, very steadily kept on doing their job
State Department Environmental installation of a stand-by emergency at the (average) 220,000 gallons per

22 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


WATER & WASTEWATER FOCUS

day (420,000 permitted) plant are a


Spiraflo Clarifier and a Raptor Fine
Screen, which were both supplied
by Lakeside Equipment Corporation
in 2008.
“I do my best to keep everything
clean and running smoothly,” says
Chuck Wright at Addison, “but I have
no problems at all with the clarifier or
the screen. Apart from occasional oil
changes and a few squirts of grease,
these keep working very well”
He adds, “Compared to some
pieces of equipment, Lakeside’s
seals and bearings are of exceptional
quality. Nothing gums up or clogs.
The Raptor Fine Screen does a great
job getting rid of the paper and
heavier particles before they can get
to the clarifier.”

RETROFITTED TO FIT THE NEED


New Lakeside Spiraflo Clarifier at Addison.
The Lakeside Spiraflo Clarifier was
retrofitted into the existing concrete
structure to replace an old center-
feed peripheral take-off clarifier
that performed poorly due to short-
circuiting. With the new peripheral-
feed center take-off Spiraflo Clarifier,
Chuck Wright certainly doesn’t
have to worry about short-circuiting
because its spiraling flow pattern
flows around the baffle skirt and
under the skirt to ensure maximum
use of the entire tank volume
(26-feet diameter—and shallow
8.5-feet depth).
This is in contrast to a typical
center-feed clarifier flow pattern that
is subject to the waterfall effect and
sludge wall creep, which allows the New Lakeside Raptor Screen at Addison.
influent to short-circuit directly to the
effluent weirs, allowing solids carry
over. The center-feed flow pattern
flows counter-current (outward),
compared to the sludge scraper that
is moving solids inward to the sludge
draw-off pit.
This short-circuiting prevents
complete use of the tank volume for
the settling process.

THE SPIRAFLO CLARIFIER: A


CLOSER LOOK
Conversely, wastewater enters the
Spiraflo Clarifier at the periphery

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 23


WATER & WASTEWATER FOCUS

Looking into the new Lakeside Raptor Screen at Addison.

of the tank and is directed along the solids (inward) to the sludge draw-off Nine years later, this equipment
narrow raceway formed by the baffle pit. The spiralling flow pattern makes certainly meets the ‘fit and forget’
skirt and the outer wall. This flow use of total tank volume for more description. There haven’t been any
pattern dissipates the wastewater's effective solids settling. problems at all.”
hydraulic energy as it flows around Twin Tiers Director of LDG’s
the raceway and eventually spirals Operations (Civil Division) Gregory SCREENINGS THROUGH THE
down under the skirt. Wastewater M. Cummings, PE, comments, PROCESS
enters the main settling area from the “Before the recent main upgrade, As well as screening Addison’s
full circumference of the skirt and the previous clarifier was getting wastewater, the Lakeside Raptor also
slowly rises to pass over the centrally overloaded and had started washes, compacts, and transports the
located effluent weirs. The inflow exceeding recommended values, screenings. With a screen diameter
is prevented from flowing directly so we had to act then to keep the of 26 to 71 inches and maximum flow
to the effluent weir by the specially Addison plant in compliance.” capacities higher than 20 million
designed race baffle skirt, which He adds, “We’d had previous gallons per day, liquid flows through
extends down to approximately two experience with Lakeside and always the Raptor’s 3-plane screening
feet above the tank floor. The Spiraflo found them good to work with. We basket, with solids efficiently trapped
hydraulic flow pattern is in the same also knew of the many advantages by the screen bars that form the
direction (inward) as the sludge of the Spiraflo Clarifier, the Raptor circular basket. When liquid rises
collector is rotating and moving the Screen and their proven track record. to a predetermined level, the rake

24 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


WATER & WASTEWATER FOCUS

begins to rotate, cleaning the screen any collected material to ensure is hard to beat. There’s the superior
bars. The rake's teeth pass between free drainage of water, which is then performance, not to mention the
the bars of the screen to remove removed in the compaction process. savings that are made on construction
captured materials. When the rake and installation. The Raptor Screen
reaches the top of the screen, the SUPERIOR PERFORMANCE is also very well designed and
captured material drops into the LDG is currently working with extremely durable, so we are happy
central screw conveyor. For complete the Village to address infiltration with the knowledge that as the
cleaning, the rake reverses direction and inflow (I&I) issues into the village of Addison’s trusted advisor,
and passes through a hinged comb. wastewater collection system. we are providing high quality long-
The central screw conveyor then During periods of wet weather, the lasting solutions for the wellbeing of
transports the material as it is flow through the wastewater system the community.” ◆
washed, compacted, and dewatered can sometimes triple, indicating
on its way to the discharge chute. that water is entering the system
After discharge, dewatered where it shouldn’t be. Work includes
screenings have a solids content uncovering buried manholes,
exceeding 40 percent. televising the entire collection
Lakeside Equipment Corporation
Screenings are initially washed as system and rehabilitating portions is an engineering and manufacturing
they are deposited in the collection of the system where I&I issues are company concentrating on helping
trough. In the upper section of identified to be at their worst. to improve the quality of our water
the transport tube, screenings Gregory M. Cummings adds, “At resources. Lakeside started in the
Spring of 1928 to engineer, develop,
are washed a second time. Larson Design Group we very much
and provide water purification
The macerating action of the screw embrace innovation and welcome systems to municipalities and
breaks down large organic particles, cutting-edge, new approaches companies throughout North
which are then washed back into the within our practice areas, but the America. For more information, visit
flow stream. A spray wash system in tried and tested design and cost- www.lakeside-equipment.com.
the dewatering chamber removes effectiveness of the Lakeside Spiraflo

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 25


MAINTENANCE & RELIABILITY

Soil Sampling for


VOCs: Best Practices
An overview of methods and equipment options
Part 2 of 2
By David Kaminski, QED Environmental Systems, Inc.

See Part 1 on
modernpumpingtoday.com

26 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


MAINTENANCE & RELIABILITY

A
s we touched on in
part 1 of this series, there
are some limitations to low
level analysis. Low level analysis
is considered to be only semi-
quantitative because the aqueous
solution used is a poor solvent for
soil VOCs, which causes results
to be biased low. In addition, high
concentrations of acetone can be
formed by the preservative itself in
some organic-rich soils.
Despite the limitations of low
level analysis, sub-core sampling
using field preservation techniques
is an effective methodology and
is widely accepted by regulators. stable throughout the fourteen-day preserved sub-core samples is more
It is an advantageous method for hold time and beyond. complicated than other methods
laboratories because it requires no There are disadvantages to sub- and can be even more difficult in
further preparation of samples by the core sampling with field preservation. adverse conditions. Lastly, shipping
laboratory doing the analysis, and For example, the seals of the vials restrictions may apply to high level
also doesn’t require any special tools used to collect samples can leak samples as they contain methanol
or procedures for the laboratory to causing a loss of preservative or (although this typically is not an issue
process samples. In addition, VOC VOCs. Another issue is the need if the samples are properly labeled
concentrations in samples collected for more experienced field staff, and have a volume of less than
using field preservation remain as the process used to collect field 500 mL).

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 27


MAINTENANCE & RELIABILITY

and cleanliness, including tests at


extremely high and low temperatures.
In fact, En Core samples can be
stored frozen without any damage.
There are some limitations to the
En Core sampler. If the En Core
is being used under sampling
Method 5035A, the samples must
be preserved at the lab within
forty-eight hours. Additionally, En
Core samples are reported in dry
weight, so an extra jar of soil must
be collected along with En Core
samplers to measure the moisture
content of the soil at the laboratory.
Lastly, the per-sample cost of using
the En Core sampler is higher than
that of the field preserved sub-core
method, though some of this extra
cost is offset by the time savings
created by the En Core sampler.

SUMMARY
To collect quality soil samples that
THE EN CORE® SAMPLER allowing for more sample throughput will deliver accurate data, one of
The only alternative method to sub- per day. Additionally, it requires two different methods of sampling
core sampling with field preservation minimal training to use effectively, should be used: field preservation
within US EPA Method 5035A is doesn’t require field staff to handle of sub-core samples, or sampling
sampling using an En Core sampler. preservative in the field, and has using an En Core sampler. While
The En Core sampler is the only a long shelf life (no preservative widely used in the past, studies
commercially available sampler expiration dates to consider). have shown that the bulk sampling
listed in Method 5035A, and is Because there are no preservatives method is unreliable and highly
both a sampling tool and a sample involved in field work using the En prone to sample bias due to VOC
container. There are three major Core, there are no sample shipping losses. Under either of the two viable
components to the En Core sampler: restrictions, and random error in methods, it is vital to carefully follow
the reusable T-handle, which holds sample results, which often come the best practices for handling a soil
the sampler and is used to push it from mistakes in field preservation, core and sampling from that soil core
into a soil core, the En Core sampler is much less common. Finally, the in order to ensure a quality sample,
itself, which is where the soil sample En Core samples are shipped to the and in turn, quality VOC data. ◆
is collected and stored, and the cap, laboratory in a proprietary VOC-
which seals the sampler shut for proof bag, which further prevents
transport to the lab. Once the sample random error in results. The En Core
is collected, excess dirt is cleaned sampler delivers such consistent
from the sampler upon removing it results in spite of variations in the
from the soil, the cap is snapped into experience of the field staff that use
place on the sampler, and then the it that it is often used to minimize
sampler is removed from the T-handle liability concerns. David Kaminski is senior vice
and placed in a pre-labeled VOC- The En Core sampler is also very president at QED Environmental
proof bag to be shipped to the lab. reliable—millions of En Cores have Systems, Inc. QED Environmental
Systems is the leading manufacturer
The En Core sampler has several been sold without one reported
of innovative environmental
advantages over field preservation analytical incident. This is in part products. For over thirty years their
and bulk sampling methods. First, due to the manufacturing quality expertise has included pumping
because it eliminates transfer of the standards of the En Core, which are systems, landfill products, and air
soil sample into vials and the need higher than those of sample vials. strippers. For more information, visit
www.qedenv.com.
to weigh vials in the field, it is faster Every lot of En Core samplers is
and easier than other methods, tested and analyzed for performance

28 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


PUMP SOLUTIONS

Improving Pump and


Centrifuge
Performance
in Crude Oil Tank
Bottom Cleaning and
Drilling Solids Control
Part 2 of 2 See Part 1 on
modernpumpingtoday.com
By Jim McMahon

I
n part 1 of this series, we saw that
uses of grinders in petroleum-
related pump situations can vary
widely, from complex crude oil tank-
bottom cleaning to simple portable
grinders used on location. In this
month’s conclusion, we’ll take a
closer look at reclamation of drilling
mud from drill cuttings as well as
the use of grinders for protecting
pumps in petroleum applications.

RECLAIMING OF DRILLING
MUD FROM DRILL CUTTINGS
Drilling fluids (drilling mud) are
integral to the drilling process,
serving to lubricate and cool the
drill bit, as well as convey the
drilled cuttings away from the bore
hole. These fluids are a mixture
of various chemicals in a water-
based, oil-based or synthetic-
based solution. Drill cuttings are
broken bits of solid material that
are produced as the drill bit breaks

30 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


PUMP SOLUTIONS

the rock. Drill cuttings vary in The separated drill cuttings,


size and texture, ranging from fine which were not sifted through the
silt to gravel. screens, but still coated with a large
For both environmental reasons quantity of drilling mud, are slurried
and to reduce the cost of drilling to centrifuges for separation.
operations, drilling fluid losses are Since centrifuges perform better
minimized by stripping them away when particle size is consistent,
from the drill cuttings before the solids control companies grind the
cuttings are disposed of. On drill cuttings to a specific size to achieve
sites, the systems used to reclaim maximum throughput rates.
mud are considered to be of critical “Centrifuges spin at a very
importance to the process throughput high G-force, and particles that
and efficiency of the operation. Mud are too large will wear the throat
reclamation is primarily accomplished of the centrifuge more rapidly,”
using shale shakers with vibrating says Gary Smith, industrial
screens to separate the mud from the distribution sales manager with JWC
shale, with subsequent processing of Environmental (www.jwce.com),
larger cuttings with centrifuges. based in Santa Ana, California, a
The mud passes through the screens leading manufacturer of grinders
and is collected into mud tanks. The for municipal and industrial
drill cuttings remain on top of the shale applications, including for the oil
shaker screens. The vibratory action of and gas industry.
the shakers moves the cuttings down “The solids control people found
the screen and off, where they can be that when they ground up the big
collected and stored in a tank or pit for cuttings into small pieces there
further treatment or disposal. was more surface exposure, and

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 31


PUMP SOLUTIONS

they reclaimed more mud,” adds


Smith. “An important point, because
it increased their mud return by
about 100 percent. This helped
them drill faster, and get on and
off the rig sites in less time. It has
really pushed the efficiency of these
drill operations.”
“For grinding drill cuttings, which
are essentially rock, dual-shafted,
slow-speed, high-torque grinders,
using two stacks of hardened steel
cutters, are the preferred equipment
choice,” continues Smith. “These
grinders will get from three months
to a year grinding solid rock before
the cutters need to be replaced.
That outperforms any other
equipment for this purpose. Plus,
they provide complete protection for
downstream equipment, like pumps
and centrifuges.”

GRINDERS PROTECT PUMPS IN


PETROLEUM APPLICATIONS
Powerful, high-torque grinders
are being employed in a number
of different petroleum-related
applications where pumps need to
be protected. One of these is in the
extraction of oil sands.
Oil sands (tar sands) are a mixture
of sand, water, clay, and bitumen
found in several locations around
the globe, with the largest reserve
located in Alberta, Canada, which
can be upgraded into synthetic
crude oil and other petroleum

32 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


PUMP SOLUTIONS

products. They are scooped up from “When a pump impeller is his pump from potential damage.
open pit mines and transported cruising along at 3,600 rpm the A simple solution that may have
to extraction facilities for finer velocities at the tip are extremely saved them thousands of dollars in
processing. The tar sands are mixed fast, and can easily destroy all pump damage.” ◆
with very hot water, allowing oil the metal on the impeller passing
to separate out at the top of huge too large of a solid. So, in many
separation tanks. applications we specify high-torque
In the separation process, roots, grinders, preferably dual-shaft, to
plant life, and sometimes petrified grind up sludge or debris that could
wood is present that would cause harm the pump.”
pumps to plug in the extraction The uses of grinders in petroleum-
facility, thereby creating problems related pump situations can vary JWC Environmental designs, builds, and
services the world’s most dependable
throughout the production line. widely, from complex crude oil tank-
waste shredders and screening systems
In-line grinders are a necessity here bottom cleaning to simple portable to help municipal facilities and industrial
to grind materials to a size that will grinders used on location. companies solve challenging waste
not plug the pumps. “One of our customers had a reduction and recycling applications.
“Pumps are designed for different large settling pond that was laced Founded in 1973, the company has
built and shipped over 35,000 Monster
applications, so you are going with petroleum, and needed to
shredders and screens to its customers
to be more efficient at pumping use polymers to bind with the around the world, in diverse industries
clean water than you will be at petroleum for extraction,” adds like energy, wastewater, recycling,
pumping a slurry,” says Daniel Namie. “The polymer coagulated oil, chemicals, marine, and facility
Namie, with Superior Pumps of the petroleum, and those big solids management. For more information,
contact Kevin Bates, director of global
Sycamore, Illinois, a distributor could not be run through their pump
marketing, JWC Environmental; at
of pumps for municipal and without clogging it. So, we supplied 949.833.3888 or kevinb@jwce.com; or
industrial applications, including for a portable high-torque, dual- visit www.jwce.com.
petroleum applications. shafted grinder which protected

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 33


MOTOR SOLUTIONS

34 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


MOTOR SOLUTIONS

Extending the
Life of
Precision
Components
in Demanding
Applications
Specialized PVD coatings
increase surface hardness and
durability of precision components
Part 2 of 2 See Part 1 on
modernpumpingtoday.com
By Jeff Elliott

A
s we saw in part 1 of this closer look at how specialized
series, bearings, gears, PVD coatings increase surface
rollers, and other precision hardness and durability for potential
components can experience applications such as bearings, gears,
excessive wear in applications and rollers to significantly increase
with metal-to-metal interaction, lifespan under high load conditions.
repetitive friction at high speeds,
or where little to no lubrication is POTENTIAL APPLICATIONS:
present. To address this problem, BEARINGS
product engineers and component Bearings often suffer from severe
manufacturers often turn to and disproportionately distributed
specialized PVD (physical vapor abrasive wear. A coating such as
deposition) coatings, and in this BALINIT C is particularly suitable
month’s conclusion, we’ll take a for case-hardening as well as ball-

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 35


MOTOR SOLUTIONS

and roller-bearing steels because to low loads and vibrations, causing always enough to protect helical-
it can be applied at temperatures potential smearing. Applying PVD gear transmissions against friction
under 392 degrees Fahrenheit (200 coating to the bearings removes any and wear.
degrees Celsius). such possibility. The sliding motion and the force
The PVD coating can be applied between the worm and gear faces
not only to inner and outer races POTENTIAL APPLICATIONS: make it difficult for a lubricant film
and cylinders but also to the balls GEARS to form. For this reason, the gear is
in ball bearings in a highly uniform Gears experience similar wear most often made of bronze in order
coating thickness of 0.5-1 μm. The conditions. The PVD coating to avoid scuffing.
slight increase in roughness is offset significantly reduces scuffing and In service, however, the teeth of
by the good burnishing qualities pitting in gear as well. In fact, the bronze gear wear away quickly
of the coating, which smoothes the BALINIT C has been shown to and the gear must be realigned or
raceway of the inner and outer rings, quadruple the service life of high- replaced. Coating the steel worm
providing additional protection speed gears. with a carbon-based coating can
against scuffing and pitting. The standard FZG C test shows that improve reliability and performance
Bearings in the soft calendar the fatigue strength is increased by by reducing wear on both the worm
rolls of paper machines frequently 10-15 percent over case-hardened and the bronze gear.
experience smearing. Not only does but uncoated gears. In the test, the
PVD coating reduce the possibility failure criterion for gear service life POTENTIAL APPLICATIONS:
of smearing, but by making the was defined as single-tooth wear of 4 PUMPS AND COMPRESSORS
bearings harder with coating, it has percent due to pitting. Screw spindle-, vane-, gear-, lobe-,
been shown that the life of these The main factors in these and centrifugal pumps often function
parts can be increased by a factor improved figures were the lower in abrasive and poorly lubricating
of three or four. As a result, paper local surface pressure (Hertzian media. This may be cooling media
mills are able to hold off on bearing pressure), which resulted from in grinding machines such as screw
replacement until the calendar reduced friction in the rolling pumps and internal gear pumps.
roll needs regrinding, significantly contact, and the superior running-in BALINIT coated screws provide the
reducing costly production downtime. behavior of BALINIT C. ideal combination of hardness and
Similarly, cylindrical roller bearings Coatings can also benefit worm low friction for preventing wear in
in compressors are often exposed gears, where lubrication is not such poorly lubricated conditions.

36 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


MOTOR SOLUTIONS

MPT
Similarly, industrial compressor In most cases, no alteration of the
components, such as reciprocating formula for the coatings is required,
pistons, screws or valve plates as it is already optimized for high
can undergo extensive wear when load, high friction environments.
oil-free operation, dry gases, “I find engineers are most Modern Pumping
Modern Pumping Today
Today ®
®

Providing
Providing Solutions
Solutions for
for the
the Worldwide
Worldwide Pump
Pump Industry
refrigerants, high or low temperature surprised about two factors when Industry

limit the use of lubricants. learning about these specialized PVD


coatings,” says Berger. "First, that the
CUSTOMIZED SOLUTIONS coating can be applied in a thickness
In addition to designing and as low as .5 or 1 micrometers. The
manufacturing PVD coating equipment, other is that these coatings can
Oerlikon Balzers offers coating last the lifetime of the machine or
services at more than 140 coating systems it is in, despite the difficult
centers worldwide, including sixteen operating conditions.” ◆
locations throughout the United States.
According to Dr. Florian Rovere,
director of sales for precision
components in North America,
Oerlikon Balzers is one of the world's
companies like Oerlikon Balzers also
leading suppliers of surface technologies
have the R&D capabilities to tailor that significantly improve the
coating solutions to meet unique performance and durability of precision Visit MPT online for
requirements. In addition to coating components and tools for the metal and the latest industry
thickness and hardness, properties plastics processing industries. For more news, product
information, call 408.375.4408, email reviews, videos,
such as structure, chemical and issue archives, and
balzers.components@oerlikon.com, or
temperature resistance, and adhesion exclusive content you
visit www.oerlikon.com/balzers.
won’t find in print.
can be precisely controlled.
ModernPumpingToday.com

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 37


SEALING SOLUTIONS

How to Choose the


Type of Gasket to Use
Tips for finding the right type of
gasket material for your needs
By Mike Shorts, Triangle Fluid Controls Ltd.

M
any variables affect the a given set of operating conditions, where things can go bad the quickest.
selection of a gasket for a traditionally considered to be Traditionally, temperature, pressure,
pressure vessel or piping temperature, pressure, and the nature and the fluid being sealed were thought
system. Our focus here will be to look of the fluid being sealed. The Fluid of as the primary considerations for
at the considerations you should make Sealing Association (FSA) now choosing a gasket material type. As
when selecting a particular type of recommends looking at the operating gasket materials have become more
gasket material, and not the variations conditions as an entire system, high-tech and as equipment is being
of gasket design offered by gasket including the flanges and fasteners, engineered and built with higher
manufacturers and fabricators. which both play a prominent role in levels of precision, gasket thickness
Gaskets are produced from a wide the proper selection of a gasket type. and allowable gasket stress are two
array of materials including rubber So how do you choose which additional considerations which must
(elastomers), compressed fibre gasket is best for the pressure vessel be high on your evaluation list.
(CNA), PTFE, flexible graphite, and or piping system? Gasket thickness and allowable
metal. Metal can be combined with stress go hand-in-hand and are very
one or more of the above non-metallic GASKET RELATED dependent on the type of material
materials to reinforce the gasket. CONSIDERATIONS being used. For soft materials, thinner
Each material, or combination of Gasket related considerations are by gaskets can withstand higher stresses
materials, offers specific properties far the most dynamic and generally and are less exposed to the media
essential to effective sealing under have the highest profile since this is being sealed.

38 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


SEALING SOLUTIONS

Storage and handleability of your to change. However, understanding On the other hand, tongue-and-
gasket should also be considered as the set of conditions relating to the groove flanges with heavy bolts can
different materials can me more pliable flanges is important when considering apply very high gasket stresses,
or more rigid than others. For large the system and which type of gasket potentially damaging soft gasket
gaskets, rigidity can play in your favour material to choose. materials that are not designed for
to ease installation. How gaskets are extreme loads. Minimum, effective,
stored also play a role in the usable life and maximum stress calculations
of a gasket, adding or subtracting from should be performed to determine the
its performance expectations. gasket suitability for the application.
Gasket manufacturers can provide
FLANGE RELATED information regarding these values
CONSIDERATIONS for a specific material to aid in the
The effects of flange and gasket decision-making process.
interaction on the resulting bolted
joint need to be considered and are FASTENER RELATED
often overlooked when selecting CONSIDERATIONS
a gasket type. Certain aspects of The reliability of a bolted flange
flange construction may become the connection depends largely on the
determining factor(s) in the selection threaded fasteners that are one of
of the gasket to produce the desired the most neglected components in
seal. Flange type, surface finish, the connection. They work like a
compatibility, strength, and deformation Thin, less rigid flanges and/or flanges spring controlling the internal and
are necessary to review before making designed with minimal bolting might external forces to keep the required
any decision. yield improved performance with a non- sealing stress on the gasket. Although
Flange characteristics are typically metallic or non-reinforced gasket due to threaded fasteners are generally
set and can de difficult or impractical its better conformance under low load. considered a mature technology,

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 39


SEALING SOLUTIONS

the fasteners must be capable of


applying adequate load to the gasket
to achieve the desired tightness under
designated operating conditions.
The gasket must be capable of
operation within the design operating
conditions and achieve the seal, given
the available bolt load. The flange
must be rated for the design operating
conditions and of adequate stiffness
to ensure loading on the gasket is
maintained at adequate levels.
The system is complex and with
the variabilities within each category,
the iterations to consider can be
intimidating. The FSA recommends
that you work with your preferred
gasket supplier or manufacturer
whenever you may have doubts.

VALUE VS. COST


The total value of the gasket should
be considered rather than the
purchase price alone. Purchase price
is typically small when compared
with the cost of the equipment,
installation labour, down-time due to
gasket failure, or lack of equipment
availability. The true value of any
given gasket is best measured by its
reliability in the intended application,
not purchase price exclusively. ◆

significant problems continue to exist the fasteners can result in serious Mike Shorts is the president of
with their use. consequences. Such is this spring Triangle Fluid Controls Ltd. and a past
Problems with threaded fasteners effect of the fasteners, the role of the president of FSA. Founded in 1933,
the Fluid Sealing Association® (FSA)
arise from insufficient preload, type of gasket being used can play
is an international trade association.
self-loosening, tensile overload, with or against the fasteners and Member companies are involved in
fatigue, galling, and thread stripping. their effectiveness. the production and marketing of a
While design of a bolted connection wide range of fluid sealing devices
provides for a reliable connection, in GASKET, FLANGE, FASTENER AS primarily targeted to the industrial
market. FSA membership includes a
practice, fastener related failures are A SYSTEM
number of companies in Europe and
not uncommon. In order for a bolted flanged joint Central and South America, but is
Uncertainties about the applied to perform satisfactorily, individual most heavily concentrated in North
forces, the magnitude of the preload components must be suitable for the America. FSA members account
achieved by the tightening process, design operating conditions (chemical for a majority of the manufacturing
capacity for fluid sealing devices in the
inappropriate materials being compatibility, temperature, pressure,
Americas market. For more information,
specified, and most notably human etc.). These same components must email info@fluidsealing.com or visit
error, often results in joint problems be well-suited to maintain a seal www.fluidsealing.com.
in practice. Any problems related to as an assembly. More specifically,

40 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


MODERN PUMPING PRODUCTS

Featured Product
SUNDYNE
API 682 and API 685 Upgrades for
LMV 801 Line of Direct Drive Pumps
Sundyne, a global leader in the design and
manufacture of pumps and compressors announces
a series of upgrades to its line of LMV 801 vertical
direct drive centrifugal pumps. Each API 610 (OH3
or OH5) pump is optimized to address flows to 380
gallons per minute, and heads to 720 feet, which
are demanded by a wide range of applications
across the upstream oil & gas, midstream
gas processing, and downstream refining,
petrochemical and general industrial markets.

New additions to the line of LMV 801 direct drive


pumps include:

• 801CS (API 682 Cartridge Seal)—utilizes a


self-contained process seal that fits seamlessly
onto the pump shaft as a single assembly. The
compact cartridge seal provides operators
and maintenance engineers with a convenient
alternative to standard component seals.

• 801S (API 685 sealless magnetic drive)—


this configuration combines the hydraulics
of Sundyne’s direct-drive pumps with the
magnetic drive technology pioneered by
Sundyne HMD/Kontro more than seventy years
ago. It is built to comply with both API 685
and API 610 standards, and is specifically
engineered to eliminate emissions and improve
personnel safety without compromising on
performance.

• Flexible Mechanical Seal and Sealless


Configurations—the line of direct drive pumps
utilizes standard seal configurations, including
single, double or tandem. Any LMV-801 pump
can be converted in the field to an ultra-
reliable, API 682 cartridge seal, or leak free API
685 sealless magnetic drive configuration.

Each Sundyne direct drive pump is designed to


operate at its best efficiency point and maximize
reliability and tolerance to system variations. The
new enhancements and upgrade options to the line
of LMV 801 pumps are designed to further enhance
performance, while simplifying installation and
maintenance requirements.

For more information, visit www.sundyne.com.

42 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com


MODERN PUMPING PRODUCTS

GEMÜ
Plastic Diaphragm Valve
GEMÜ plastic diaphragm valves are available with a variety of high-quality
plastic body materials and connections. The plastic diaphragm valves support
a large range of industries and applications including chemical, environmental
systems, power generation, water and wastewater treatment, solar, semiconductor,
microelectronics, food and beverage, and processing just to name a few. Many
of the plastic diaphragm valves are supported by an extensive line of pneumatic
operators that can be fully integrated into automated systems allowing industries to
save time and money on their operations, while increasing accuracy and efficiency
in their performance. For more information, visit www.gemu-group.com.

LEYBOLD
EcoDry Plus Dry Compressing Vacuum Pump
The use of vacuum in analytical technology and research and
development is an essential factor that enables modern applications,
for example in the field of measuring instruments. The selection
of suitable equipment and the associated vacuum components is
therefore crucial for success in laboratories. Since 1850, Leybold
has been a partner of customers who have dedicated themselves to
research. With innovative products such as the new EcoDry plus dry
compressing vacuum pump, this company tradition is continuing into
the future. For more information, visit www.leyboldproducts.com.

C. OTTO GEHRCKENS
COG VarioPur®
With COG VarioPur®, the independent seal manufacturer C. Otto
Gehrckens presents a new product range in the premium segment:
the three high-performance materials in the VarioPur series are based
on thermoplastic polyurethanes (TPU/AU) and impress with excellent
properties and are belonging to the best-case-compounds in the TPU
class. Both the abrasion and the extrusion resistance are at least five
times higher than those of the traditional material NBR, which has a
Shore A value of 90. Furthermore, the three TPU materials impress with
excellent gas tightness and a high level of tolerance to a wide range of
gases—from oxygen and nitrogen to all of the synthetic hydrocarbons.
They exhibit no brittleness as a result of exposure to ozone or oxygen.
For more information, visit www.cog.de/en/products.

VISHAY PRECISION GROUP


BLH Nobel Strain Gage Load Cell Product
The BLH Nobel brand of Vishay Precision Group, experts in
standard and custom process weighing and force measurement
solutions, including high-quality and high-accuracy weighing and
control systems, today announced that four of its strain gage load
cell product families are now available with EN ISO 13849 and IEC
61508 functional safety certifications. The EN ISO 13849 functional
safety standard incorporates statistical analysis to help better
predict component, device, and circuitry reliability within the
safety-related parts of industrial machinery control systems. For
more information, visit www.blhnobel.com.

www.modernpumpingtoday.com Modern Pumping Today | February 2018 | 43


PUMPING TRENDS

The Internet of Things


and the Pump Market
Joanne Goh on how the pump industry will evolve

J
oanne Goh is a research analyst act as training devices, as opposed to
in the manufacturing technology paper manuals. The glasses can replace
group at IHS Markit. Her focus areas paper instructions by providing virtual
are motor systems and motor-driven work instructions that also display
equipment across all major verticals. complex work steps.
Prior to joining IHS, Goh worked at As pump manufacturers realized
Advanced Micro Devices (AMD) as an over the past few years, the market
equipment/process engineer, where has generally declined and profits
she was involved in cross-functional were hard to come by. The successful
team projects to drive yield and manufacturers have thus focused on
process productivity improvements. training programs, services, and hiring
Below, she shares her insights on how greater expertise as ways to increase
the internet of things will intersect and their value-add to customers in an effort
influence the pump market. to focus on market share growth.

MPT: What changes are on the horizon MPT: How will this enhance the pump
for the pump industry as suppliers user’s experience? Are fully integrated
embrace the industrial internet? solutions the future for OEMs?
Joanne Goh
Joanne Goh: The global pump market Joanne Goh: Communication is key
has been extremely volatile during MPT: Do you foresee a digital to digitalization in the world of IoT.
the past two years with the decline of transformation in manufacturing lines? Coupled with the downturn in the
global oil and commodity prices. Pump mining and oil and gas industries, pump
manufacturers are looking for ways to Joanne Goh: Pump manufacturers are suppliers are pushing more than ever to
minimize profit losses amid these trying undergoing a digital transformation become integrated solution providers.
economic uncertainties. Topics such as by embracing IIoT, big data, A recent IHS Markit study shows
Industry 4.0 and Industrial Internet of and artificial intelligence. These the numbers of connected nodes in
Things (IIoT) are growing in prominence enabling technologies and related pump (centrifugal pumps and positive
within the industrial automation transformational efforts are providing displacement pumps) and compressor
community, and pump manufacturers are pump manufacturers with a competitive applications will grow substantially
eyeing these as exciting opportunities advantage. with a compound annual growth rate
that could drive profits. Many companies such as KSB, (CAGR) of 46.5 percent from 2016 to
The pump market has seen a growing Sulzer, and WILO have developed 2021. Centrifugal pumps have more
trend to implement new technologies connected machines to enable real- variable flow applications than positive
like this to provide an opportunity time monitoring in the production line displacement pumps, and they will
for pump manufacturers to innovate to improve productivity and reduce therefore utilize more connectivity for
and provide full pump solutions downtime. Intelligence is also being live monitoring purpose. Additionally,
as opposed to merely adding a increasingly embedded into devices, European motor and pump efficiency
component to their overall equipment supporting decentralized analytics, and regulations require full awareness by
portfolios. This means that pump even performing some decision making. the suppliers regarding full system
suppliers are improving their expertise For instance, WILO has implemented efficiency; therefore, the smart and
along the whole supply chain in pump an augmented reality technology in its connected technology will increase in
system applications. manufacturing line with glasses that use quite rapidly going forward. ◆

44 | February 2018 | Modern Pumping Today www.modernpumpingtoday.com