chemical engineering June 2015

SYSTEMSThe Leading Magazine for Pump Users Worldwide

SYSTEMS

JUNE 2015

PUMPSANDSYSTEMS.COM

Trade Show

Preview

ACHEMA & EASA

2 Simple Steps to

Choosing the Right Motor

PLUS: Prevent System Failures In CHEMICAL PUMPING Applications

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Circle 111 on card or visit psfreeinfo.com.

June 2015 | Pumps & Systems

2

From the EditorAs you know, Pumps & Systems is the only trade publication that covers motors and drives in every issue. is

month, we head to San Antonio for the

largest motor-related trade show of the

year, the Electrical Apparatus Service

Association (EASA) Convention &

Exposition.

We recently reported (March 2015)

about how to prepare for the new

Department of Energy Electric Motor

Effi ciency Rule, which takes eff ect in

June 2016. is will certainly be a topic

of conversation at this years EASA event.

Drop by Booth 262 at EASA to visit the Pumps & Systems team.

Original equipment manufacturers and end users should contact their motor suppliers

and prepare a plan to convert their motors to premium effi cient designs if they are not

already being used. e performance of more effi cient motors may be slightly diff erent

because they have less slip and operate at a higher speed. Impeller designs may need

trimming to prevent overloading the motor from increased fl ow. We will continue to

bring you information, and you can also access it quickly at pumpsandsystems.com.

Be sure and see our cover series on motors and drives in this issue, beginning on page

54, which features two simple steps to choosing the right motor.

is month, Pumps & Systems also attends the largest chemical trade show in the

world. ACHEMA is the premier world forum for chemical engineering and processing

and takes place every three years in Frankfurt, Germany. More than 160,000 visitors

from 111 countries attended the show in 2012, and 3,800 exhibitors are expected to

showcase their products and services this year. We hope to see you there!

e challenge for manufacturers and users of many dangerous chemicals is to

construct, handle and transfer them in a way that eliminates any chance for their release

into the atmosphere. Some of the solutions are addressed in this months Effi ciency

Matters (page 84). You can also read about how sealless pumps with magnetic couplings

are helping to solve chemical processing challenges (page 88).

Best regards,

EDITORIAL

EDITOR-IN-CHIEF: Michelle [email protected] 205-314-8279

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

MANAGING EDITOR: Amelia Messamore [email protected] 205-314-8264

MANAGING EDITOR: Michael Lambert [email protected] 205-314-8274

ASSOCIATE EDITOR: Amy [email protected] 205-278-2826

SENIOR EDITOR, PUMPS DIVISION: Alecia [email protected] 205-314-3878

CONTRIBUTING EDITORS: Laurel Donoho, Lev Nelik, Ray Hardee, Jim Elsey

CREATIVE SERVICES

SENIOR ART DIRECTOR: Greg Ragsdale

ART DIRECTORS: Jaime DeArman, Melanie Magee

WEB DEVELOPER: Greg Caudle

PRINT ADVERTISING TRAFFIC: Lisa [email protected] 205-212-9402

CIRCULATION

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

ADVERTISING

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

ACCOUNT EXECUTIVES:

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

Mark [email protected] 205-345-6414

Addison [email protected] 205-561-2603

Garrick [email protected] 205-212-9406

EUROPE-MIDDLE EAST: Maik [email protected] +1 205-567-1547+49 170 58299 59

MARKETING ASSOCIATES:

Ashley Morris [email protected] 205-561-2600

Sonya [email protected] 205-314-8276

PUBLISHER: Walter B. Evans Jr.VP OF SALES: Greg Meineke

VP, EDITOR-IN-CHIEF PUMPS DIVISION: Michelle Segrest

CREATIVE DIRECTOR: Terri J. Gray

CONTROLLER: Brandon Whittmore

P.O. Box 530067Birmingham, AL 35253

EDITORIAL & PRODUCTION

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

ADVERTISING SALES

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

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 offi ces. Subscriptions: Free of charge to qualifi ed industrial pump users. Publisher reserves the right to determine qualifi cations. 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 submis-sion, 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 5.

The Pumps & Systems and Upstream Pumping teams visiting the team from Accudyne at OTC in Houston

Pumps & Systems is a member of the following organizations:

Editor, Michelle Segrest

[email protected]

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4


This issue 54 2 SIMPLE STEPS TO CHOOSING THE

RIGHT MOTOR By Mike Stockman, Franklin Electric

Consider more than the e ciency rating to select the most cost-e ective system for the pumping application.

58 HOW TO PREVENT THE MOST FREQUENT CAUSES OF MOTOR FAILURE Last of Two Parts By Rob Amstutz, GE Power Conversion

Protecting these two components can lead to longer equipment life.

62 STAINLESS STEEL IDEAL FOR EQUIPMENT IN SANITARY ENVIRONMENTSBy David Steen, Baldor Electric Company

is motor material provides an improved total cost of ownership for the food and beverage industry.

64 BEARING PROTECTION FOR VFD-DRIVEN, EXPLOSION-PROOF

MOTORS IMPROVES RELIABILITYBy Rick Munz & Adam Willwerth,

Marathon Electric Motors

In plants that process combustible materials, these motors avoid electrical bearing damage often caused by energy-saving inverters.

68 DOC ENGINE TECHNOLOGY PROVIDES COST-EFFECTIVE TIER 4 COMPLIANCE By Anne Chalmers, Pioneer Pump

Pumping packages that use a diesel oxidation catalyst can minimize cost, maintenance and equipment downtime.

70 ENERGY-EFFICIENT MOTORS CURB ENVIRONMENTAL CRISISBy Zi Ning Chong, Frost & Sullivan

e Chinese government is promoting greater automation and optimization of processes to improve the energy utilization rate.

JUNEVolume 23 Number 6

COVERS E R I E S

PUMPING PRESCRIPTIONS

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

Handling Power Plant Transients

PUMP SYSTEM IMPROVEMENT

18 By Ray Hardee Engineered Software, Inc.

Understand How Valves & Fittings A ect Head Loss

Last of Two Parts

COMMON PUMPING MISTAKES

22 By Jim Elsey Summit Pump Company, Inc.

What You Need to Know About Bearing Oil

Last of Two Parts

GUEST COLUMN

32 By Heinz P. Bloch, P.E.

How Oil Viscosity & Temperature In uence Bearing Function

First of Two Parts

2 FROM THE EDITOR

8 NEWS

91 PRODUCTS

92 PUMP USERS MARKETPLACE

96 PUMP MARKET ANALYSIS

MOTORS & DRIVES

SPECIALS P E C I A LS E C T I O N

CHEMICAL PUMPS & EQUIPMENT

84 SOLID-BODY AODD PUMPS WITHSTAND & CONTAIN DANGEROUS CHEMICALS EFFICIENCY MATTERS

By Peter Schten, Almatec

is equipment avoids the risk of leaks and pipe damage associated with injection mold pumps.

88 STOP SEAL FAILURES IN CHEMICAL APPLICATIONS By James Gross, Dickow Pump Company

Sealless pumps improve reliability and safety when pumping hazardous uids.

54

64

88

COLUMNS

73 TRADE SHOW ELECTRICAL APPARATUS SERVICE ASSOCIATION CONVENTION

90 TRADE SHOW ACHEMA

VR Series vertical multi-stage pumps are now available in 3, 5, 9, 15, 20, 30, 45, 65,

and 95 m3/h options with all 316 stainless steel hydraulics for superior durability,

eciency, and performance. The rugged components ensure long operating life in

the toughest applications: water supply and pressure boosting; heating, ventilation

and air conditioning; light industry; water treatment; irrigation and agriculture.

Experience Innovation. Experience Franklin.

franklinwater.com

EXPANDING YOURPUMPINGCAPABILITIES


6


SPECIALS P E C I A LS E C T I O N

JUNEThis issue

THOMAS L. ANGLE, P.E., MSC, Vice President Engineering, Hidrostal AG

ROBERT K. ASDAL, Executive Director, Hydraulic Institute

BRYAN S. BARRINGTON, Machinery Engineer, Lyondell Chemical Co.

KERRY BASKINS, VP/GM, Milton Roy Americas

WALTER BONNETT, Vice President Global Marketing, Pump Solutions Group

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

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

JACK CREAMER, Market Segment Manager Pumping Equipment, Square D by Schneider Electric

BOB DOMKOWSKI, Business Development Manager Transport Pumping and Amusement Markets/Engineering Consultant, Xylem, Inc., Water Solutions USA Flygt

DAVID A. DOTY, North American Sales Manager, Moyno Industrial Pumps

WALT ERNDT, VP/GM, CRANE Pumps & Systems

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

DOUG VOLDEN, Global Engineering Director, John Crane

LARRY LEWIS, President, Vanton Pump and Equipment Corp.

TODD LOUDIN, President/CEO North American Operations, Flowrox Inc.

JOHN MALINOWSKI, Sr. Product Manager, AC Motors, Baldor Electric Company, A Member of the ABB Group

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

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

HENRY PECK, President, Geiger Pump & Equipment Company

MIKE PEMBERTON, Manager, ITT Performance Services

SCOTT SORENSEN, Oil & Gas Automation Consultant & Market Developer, Siemens Industry Sector

ADAM STOLBERG, Executive Director, Submersible Wastewater Pump Association (SWPA)

JERRY TURNER, Founder/Senior Advisor, Pioneer Pump

KIRK WILSON, President, Services & Solutions, Flowserve Corporation

JAMES WONG, Associate Product Manager Bearing Isolator, Garlock Sealing Technologies

EDITORIAL ADVISORY BOARD

INSTRUMENTATION, CONTROLS & MONITORING

DEPARTMENTS

74 MAINTENANCE MINDERSMonitoring Software Enables Scheduled Maintenance at Oil & Gas Facilities

By Cynthia Stone

GE Intelligent Platforms

76 MOTORS & DRIVESMotor Automation Can Help Solve Industry Labor Shortage

By William C. Livioti

WEG

78 SEALING SENSENew FSA/ESA Gasket Handbook O ers Guidance for Equipment Usage & Troubleshooting

By Mike Shorts

FSA Member

82 HI PUMP FAQSCorrosion Prevention, Rotodynamic Pump Speed & How Harmonics A ect VFDs

By Hydraulic Institute

42 PROTECT PUMPS WITH ONE ESSENTIAL TOOL

By Craig McIntyre, Endress+Hauser

Pump sensors can improve system operation and detect dangerous faults.

47 ELIMINATE CABLING COSTS THROUGH PROPRIETARY WIRELESS NETWORKING

By Dave Eifert & Benjamin Fiene, Phoenix Contact

A German municipal water utility optimized pressure booster stations with automated modules.

36 NEW HI DOCUMENT PROVIDES GUIDANCE ON DYNAMIC ANALYSIS OF ROTODYNAMIC PUMPS

By J. Claxton, P.E., Patterson Pump Company, a Gorman-Rupp company

is 10-year project concluded with the recent publication of recommended guidelines for pump professionals.

INDUSTRY UPDATESPECIAL REPORT

8 NEWS


NEW HIRES, PROMOTIONS & RECOGNITIONSTONY SWENDSRUD, PSG

OAKBROOK TERRACE, Ill. (April 23, 2015) PSG, a Dover company, announced that Tony Swendsrud has joined the company as its new chief financial officer. In this role, Swendsrud will be responsible for all facets of PSGs financial functions and will report directly to PSG President Karl Buscher. Swendsrud joins PSG from the Honeywell Corporation, where he held the position of CFO Analytics Americas. Swendsrud holds a bachelors degree in accounting from St. Cloud State University in St. Cloud, Minnesota. He is also a certified public accountant. He will be based in PSGs headquarters office in Oakbrook Terrace, Illinois. psgdover.com

HASAN AVCI, GRUNDFOS

SINGAPORE (April 23, 2015) Pump manufacturer Grundfos has recently appointed Hasan Avci to head its Strategy, Commercial Excellence and Marketing functions in the Asia Pacific region. Avci has been with Grundfos since 2003. Before his posting to Grundfos Asia Pacific headquarters in Singapore, Avci was the director of sales and marketing for Turkey and the Middle East region. In his new role, Avcis main responsibility will be to formulate organizational strategies for performance improvements across the region. He will also implement commercial processes, undertake strategic corporate planning, evaluate new business opportunities and spearhead initiatives to promote business growth. grundfos.com

MICHAEL RICHART, ESE, INC.

MARSHFIELD, Wis. (April 21, 2015) ESE, Inc., has named Michael Richart as the companys director of business operations. Richart brings more than 20 years of experience as a versatile strategic executive. Richart will lead the sales and business operations areas of ESE. Throughout his career, Richart has helped companies succeed by optimizing the intersection of data, people, process and technology. Richart received his Bachelor of Sciences degree in industrial engineering from Purdue University and his MBA from the University of Wisconsin Oshkosh. ese1.com

PAUL COOKE, BOSCH REXROTH

CORPORATION U.S.

CHARLOTTE, N.C. (April 20, 2015) Effective July 1, Paul Cooke has been appointed regional president Americas and president & CEO of Bosch Rexroth Corporation U.S. Cooke will continue as senior vice president sales within the Business Unit Industrial Applications at the headquarters in Lohr, Germany, until the end of June 2015. Cooke has more than 30 years of experience in both industrial technology and general management. He received his

Bachelor with Honors Degree in mechanical engineering from The University of Newcastle in Tyne, England. Berend Bracht, current regional president Americas and president & CEO of Bosch Rexroth Corporation U.S., is resigning from the organization for personal reasons.

JIM LAURIA, MAZZEI INJECTOR

COMPANY, LLC

BAKERSFIELD, Calif. (April 9, 2015) Mazzei Injector Company, LLC, has appointed Jim Lauria as vice president of sales and marketing. Lauria has been a leader in water and wastewater for more than 15 years and has had articles published in prominent water industry publications worldwide. Lauria holds a Bachelor of Chemical Engineering degree from Manhattan College. Lauria will be replacing Paul Overbeck who is retiring. mazzei.net

PHIL CARLIN & MICHAEL SAVIGNAC, OPW

HAMILTON, Ohio, & HODGKINS, Ill. (April 2, 2015) OPW, a Dover company, announced that, as part of its growth strategy and One OPW initiative, it has consolidated its OPW KPS, OPW Fibrelite and OPW Fluid Transfer Group Europe management teams to create a single business unit, named OPW EMEA. Phil Carlin has been appointed managing director of the new business unit and will report directly to OPW President David Crouse. Carlin joined OPW in 2000 and has held multiple positions with the company, including several senior executive positions. He will be based out of OPW EMEA headquarters in Kungsr, Sweden. In addition, Michael Savignac joined OPW as vice president and general manager for the OPW Electronic Systems business unit, succeeding Carlin. Savignac will provide leadership and overall management of the Electronic Systems business unit, which OPW formed in April 2014. Savignac will be based at the OPW facility in Hodgkins, Illinois, and will report to Crouse.

To have a news item considered, please send the information to Amelia

Messamore, [email protected].

Hasan Avci

Michael Richart

Jim Lauria

ACOEM Group acquired VibrAlign, Inc. April 30, 2015 ERIKS Seals and Plastics acquired Seals and Packings, Inc. April 21, 2015 Lewis-Goetz acquired Action Industrial Group April 9, 2015

MERGERS & ACQUISITIONS

Paul Cooke

Michael Savignac

9pumpsandsystems.com | June 2015Circle 118 on card or visit psfreeinfo.com.

10 NEWS


Danfoss Recognized for Impact on Technology, Jobs & Local Partnerships NORDBORG, Denmark (April 24, 2015) During a press conference on April 22, The Economic Development Council of Tallahassee/Leon County announced Danfoss as its featured business for the month of April as part of its Made in Tallahassee: Produced Regionally, Sold Globally initiative. The program is planned as a public awareness campaign that focuses on the important role that the research and development, manufacturing, software development and technology industries play in the success of the local economy. danfoss.com

WERF & WEF Launch Projects to Further Water Sector Innovation ALEXANDRIA, Va. (April 22, 2015) The Water Environment Research Foundation (WERF) and the Water Environment Federation (WEF) are launching three new projects under the Leaders Innovation Forum for Technology (LIFT) program, a joint WERF/WEF initiative designed to promote innovation in the water sector.

The first project, Genifuel Hydrothermal Processing Bench Scale Technology Evaluation (LIFT6T14), will evaluate a new biosolids to energy technology. The project is funded by WERF, the U.S. Environmental Protection Agency (EPA) and approximately 10 utilities participating in the LIFT program. The U.S. Department of Energy is also providing in-kind support.

The next project, Creating the Space to Innovate (LIFT8C14), is co-funded by WERF and WEF to promote the adoption of innovative technologies and practices.

WERF has also awarded The Canton Group with a contract to develop a LIFT Database (LIFT2R14), which is designed to support new water technology innovation, collaboration and implementation for the water sector. The platform will help deliver information on water technologies, facilitate collaboration for speeding innovation into practice, provide data from demonstrations and more. The development of the platform is supported in part with funding from the U.S. EPA. werf.org/lift

Truckee Meadows Water Authority Wins National AwardRENO, Nev. (April 17, 2015) Truckee Meadows Water Authority (TMWA) has received the Presidents Award from the Partnership for Safe Water (PSW). With this award, TMWAs Chalk Bluff Water Treatment Plant ranks among the highest performing water treatment plants in the country for individual filter performance. Only 18 utilities across the country have achieved this award.

The Presidents Award recognizes achieving Phase IVs stringent individual filter performance goals for turbidity. awwa.org

POWER-GEN Europe Launches the Confidence Index to Build Industry ExpertiseLONDON (April 14, 2015) POWER-GEN Europe and its co-located event Renewable Energy World Europe has announced the launch of the POWER-GEN Confidence Indexa pan- European study of the regions power market which will allow power generation industry practitioners from across Europe to have their say on the industry. The results will be launched in September 2015, and they will allow industry decision makers across Europe to make well-informed choices as they navigate the next critical stages of the energy transition.

The report will evaluate the industrys attitude toward new initiatives and give companies insight into how these changes are viewed by the industry.

The survey that feeds into the Index will be carried out on an annual basis and allow the industry to track year-on-year trend analysis and comparison. powergeneurope.com

Xylem Participates in U.S. Presidential Trade Mission to the Peoples Republic of ChinaRYE BROOK, N.Y. (April 13, 2015) Xylem Inc. participated in the U.S. Presidential Trade Mission to the Peoples Republic of China, April 12-17. U.S. Secretary of Commerce Penny Pritzker and Deputy Secretary of Energy Elizabeth Sherwood-Randall led this Smart Cities Smart Growth Business Development Mission, accompanied by representatives from 25 companies.

The trade mission was intended to help U.S. companies launch or increase their business operations in China for sustainable products and services.

Chris McIntire, Xylem senior vice president and president, analytics and treatment, and Shuping Lu, president of Xylem China, represented Xylem on this mission. xyleminc.com

PTDA Welcomes Three New Distributor MembersCHICAGO (April 13, 2015) The Power Transmission Distributors Association (PTDA), an association for the industrial power transmission/motion control (PT/MC) distribution channel, welcomed three new distributor member companies: BK Industrial Solutions, LLC (Beaumont, Texas), SAECOWilson Limited (Auckland, New Zealand) and Warrior Industrial, LLC (McKinney, Texas). ptda.org

SFPUC Completes New Seismic Upgrades to Drinking Water Treatment Plant SAN FRANCISCO (April 10, 2015) The San Francisco Public Utilities Commission (SFPUC) together with San Mateo Board of Supervisors Dave Pine and Peninsula water agencies stood on top of a new 11 million gallon treated water reservoir to celebrate the completion of a $278 million project improving the seismic and operational reliability of the Harry Tracy Water Treatment Plant located in San Bruno. The 43-year-old treatment plant is responsible for treating the drinking water for more than 1 million customers in San Mateo and San Francisco Counties.

The project is part of the SFPUCs $4.8 billion Water System Improvement Program, which consists of 83 projects across seven counties designed to improve seismic and water supply reliability for 2.6 million people in the Bay Area. sfwater.org

ABB Opens New Automation & Power Service Office in Louisiana SULPHUR, La. (April 8, 2015) ABB has opened a new local service office near Lake Charles, Louisiana. The office will provide services and support for ABBs automation and power

AROUND THE INDUSTRY

11

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12


NEWS

portfolio including control systems, instrumentation, analytical products, low-voltage drives, and power systems and products. The new office will offer scheduled in-

center training, as well as customized training courses. ABB has also announed several new investments in the area. abb.com

Xylem Contributions Recognized at HIs 2015 Annual MeetingRYE BROOK, N.Y. (April 2, 2015) Five employees from the Applied Water Systems (AWS) business unit of Xylem were recognized by the Hydraulic Institute (HI) for their longtime service to and involvement in HI. Awards and the team members they

were presented to are as follows: Mark Handzel, Vice President

Product Regulatory Affairs and Director, HVAC Commercial Buildings, Americas Industry Leadership Award for U.S. Department of Energy pump efficiency regulations

Mark Heiser, Test & Validation Manager Industry Leadership Award for development of HI Standard 40.7 and recognition for completion of standard development for DOE pump efficiency regulations

Paul Ruzicka, Chief Mechanical Engineer Industry Leadership Award for development of HI Standard 40.6 and recognition for completion of standard development for DOE pump efficiency regulations

Chris Johnson, Global Engineering Manager, Centrifugal Pumps Recognition for contributions to HI standards development

Jim Roberts, Associate Principal Mechanical Engineer Recognition for 20 years of service to the development of HI standards

xyleminc.com

Powdersville Water District Receives National AwardDENVER (March 30, 2015) Powdersville Water is the first utility in South Carolina to achieve the Directors Award in the Partnership

for Safe Waters Distribution System Optimization Program and one of only 11 nationwide. Powdersville Water received this award for successfully completing a comprehensive self-assessment of distribution system operations. Powdersville Water will be one of a

select group of utilities recognized at the annual conference and exposition of the American Water Works Association in June. awwa.org

AEP Ohio Offers New Energy Efficiency ProgramRALEIGH, N.C. (March 26, 2015) AEP Ohio, a unit of American Electric Power, in partnership with Advanced Energy, has launched the Emotor Rewind Pilot Program to promote energy efficient rewinds in the industrial/manufacturing sector and provide incentives to users and motor service centers. The program covers 300- to 5,000-HP, three-phase induction motors and is expected to achieve annual energy savings of 5,900 to 116,000 kWh, depending on the motor size. AEP Ohio customers located in Ohio will receive $2 per HP, and certified motor service centers will receive $1 per HP. aepohio.com

ITTs Conoflow Brand Names Enertech Exclusive Global Nuclear Industry RepresentativeWESTMINSTER, S.C. (April 20,

2015) ITTs Conoflow brand has appointed Enertech, a business unit of Curtiss-Wright Nuclear Division, as the exclusive nuclear industry representative for its valve and regulator products globally. ITTs Conoflow manufactures natural gas vehicle (NGV), low-pressure and high-pressure regulators along with filter and specialty regulators. Enertech has served the nuclear power industry for more than 40 years. In this partnership, Enertech will be the point of contact for technical inquiries, quotations and order entry/status, while Conoflow will retain its nuclear quality assurance program, along with certifications and documentation. conoflow.com

EVENTSPump School Training: Centrifugal & Positive Displacement Pumps June 2-3, 2015One Midtown Plaza Atlanta, Ga. 770-310-0866pumpingmachinery.com/pump_school/pump_school.htm

American Water Works Association Annual Conference & Exposition (AWWA-ACE) June 7-10, 2015 Anaheim Convention Center Anaheim, Calif. 800-926-7337 awwa.org

EASAs 2015 Convention & Exhibition June 14-16, 2015 Grand Hyatt San Antonio & Henry B. Gonzalez Convention Center San Antonio, Texas easa.com/convention

ACHEMAJune 1519, 2015Messe FrankfurtFrankfurt am Main, Germanyachema.de/en.html

National Fire Protection Association (NFPA) Conference & ExpoJune 2225, 2015McCormick PlaceChicago, Ill.800-344-3555nfpa.org/training/conference

5th Annual Pumps Hands-on Training: Maintenance, Energy and Reliability Conference (PumpTec-Israel)July 7, 2015Tel Aviv, Israel770-310-0866pumpingmachinery.com/pump_school/pump_school.htm

IDA World CongressAug. 30 Sept. 4, 2015San Diego Convention CenterSan Diego, Calif.wc.idadesal.org/

13


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Letter from a Reader

e following comments relate to

scenarios described in Parts 1 and

2 of Can Deaerators Create Pump

Trips? (Pumps & Systems, March

and April 2015), which discuss

handling power plant transients.

Steady fl ows to and from the

deaerator (DA) and gradual

isentropic thermodynamic changes

from the high to low temperature/

pressure conditions are assumed.

A gradual power plant cool down

period after a shutdown event may

mitigate general or local fl ashing.

From Part 1 at Point A:

DA total tank volume V =

20,000 gallons = 2,674 cubic

feet (ft3).

Tank liquid (water) volume

(Vliq) = 10,000 gallons =

1,337 ft3.

Mass of tank liquid (mliq) =

Vliq

vf= 76,564 lbm.

Mass of tank vapor (mvap) = 0

lbm (all mass is saturated

liquid at vf).

Total mass of tank contents (M)

= mliq + mvap = 76,564 lbm.

Using the above values, the

calculated specifi c volume

(v) should agree with the

temperature-specifi c volume

(T-v) diagram at Point A.

However, calculated v =

V

M= 0.03492 ft3/lbm.

is value is greater than vf

= 0.01746 ft3/lbm from the

diagram. Since the vapor

volume Vvap = mvap x vg =

0 ft3, the analysis might be

conducted by assuming that

the total tank volume revV =

Vliq + Vvap = 1,337 ft3. In other

words, assume the total DA

tank volume is 10,000 gallons

and completely full of liquid

(water) at Point A. en, at

Point A on the diagram, v =

revV

M= 0.01746 ft3/lbm = vf.

Using revV and v for

calculations at Point B, X = 0.003%,

vapor mass mvap = X x M = 2.3

lbm, vapor volume Vvap = mvap

x vg = 24.5 ft3, liquid mass mliq

= (1-X) x M = 76,562 lbm, liquid

volume Vliq = mliq x vf = 1,312.3

ft3. erefore, the total volume and

mass of the tank contents remain

the same. However, the vapor

volume has increased by the same

amount that the liquid volume has

decreased. e less dense vapor

must occupy a larger space than

the reduction in liquid volume.

Because there is no additional tank

space to occupy, some liquid may

be expelled from the 10,000-gallon

DA or excess vapor pressure might

activate a relief valve.

Expelled tank liquid may imply

that the total mass of the DA tank

contents decreases at Point B:

Specifi c volume at Point B is greater

than at Point A. Using vb = 0.018

ft3/lbm at Point B, the calculated

vapor volume is now about 66 ft3

at Point B compared with 24.5 ft3

if v = 0.01746 ft3/lbm. Since the

new liquid volume is now 1,312 ft3,

about 41 ft3 must be expelled from

the tank at Point B: 66 + 1,312 41

ft3 = 1,337 ft3 = the tank volume.

However, I would not expect

a DA tank to be either half full

of liquid without any vapor or

completely full of liquid. A more

likely location for Point A might be

to the right of the saturated liquid

state where a two-phase liquid and

vapor state existsPoint A1.

e originally calculated specifi c

volume, v = 0.03492 ft3/lbm,

represents a liquid and vapor

state at 302 F. If this value is

chosen, a new set of values can be

determined at Point A1 and Point

B1: X = 0.17% at B1, Vvap = +23

ft3, and Vliq = -23 ft3. In this case,

the vapor has enough room for

expansion going from a calculated

1,341 ft3 at A1 to 1,363 ft3 at B1.

However, while the calculated

liquid volume has decreased at B1,

the corresponding liquid mass has

increased. is seems unlikely.

After some trials, it was

determined that reasonable

changes in volume and mass occur

if the specifi c volume is greater

than about 0.29 ft3/lbm for the

given data in this article. If another

specifi c volume such as v = 0.5

ft3/lbm is chosen, another set of

liquid and vapor state values can

be determined at Points A2 and B2:

X = 4.52% at B2, Vvap = -1.33 ft3,

and Vliq = +1.33 ft3. In this case,

the vapor volume has contracted

going from a calculated 2,587 ft3

at A2 to 2,586 ft3 at B2. Now, the

calculated liquid volume and mass

have both increased at B2, while

the calculated vapor volume and

mass have decreased at B2. Vapor

condensation, from state A2 to B2,

Handling Power Plant Transients

14 PUMPING PRESCRIPTIONS


By Lev Nelik, Ph.D., P.E.

Pumping Machinery, LLC,

P&S Editorial Advisory Board

Troubleshooting & repair challenges

is now the result. is seems to

be a realistic outcome after slowly

cooling. Although it should be

noted that, with v = 0.5 ft3/lbm,

there is a substantial diff erence in

liquid and vapor mass and volume

values when compared with the

original calculations from above.

After an emergency trip

situation, there may be ongoing

automatic and/or manual

adjustments as various plant

elements (DAs, pumps, etc.) react

to changing system conditions. If

the liquid+vapor mass (M) within a

fi xed-volume DA tank can decrease

or increase in response to some of

these changes, maybe the specifi c

volume is not necessarily constant

at diff erent thermodynamic states.

Besides the dynamics occurring

inside the DA tank, I would expect

that any major net positive suction

head (NPSH) problem at the pump

suction might be attributed to

entrained air, not water vapor,

being transferred from the DA

liquid to the boiler feed pump.

Before being shut down, the

injected pegging steam might have

removed most of this air.

In Part 2, I would not expect

a signifi cant problem at Pump 2

from an interaction at the junction

of its header and the hotter liquid

in Header 1. If the liquid in Header

2 is gradually cooling and fl owing

past the junction, the temperature

diff erence at a junction may be too

gradual for a fl ashing reaction.

However, for Pump 1, if it is again

started with its header full of 302

F liquid and only 39 psia available

at the junction, there might be an

insuffi cient NPSH condition as

pointed out in the article. Perhaps

Pump 1 would be able to pass

the 50-ft header full of hotter

liquid quick enough to avoid any

signifi cant damage or pump trip.

Of course, the above analysis

is based on simplifi ed ideal

conditions with gradual

thermodynamic changes. Feedback

from readers with experience in

power plants and the eff ects of

transients on pumps would be

insightful.

Lee Ruiz

Oceanside, California

Neliks Response

ank you for your comments.

ese are very diligent and

methodical calculations. I have a

few notes to your comments.

Your assumption of the process

being gradual and isentropic

cannot be assumed, because it

is highly transient. is is one

of the reasons it is not easy to

calculate. Several thermodynamic

sub-processes that are highly

time dependent are taking place:

convection from hotter liquid

to colder, phase transformation

and cooling of the vapor that is

evolving back into liquid phase as

it tries to rise through the colder

liquid layer. Perhaps the only safe

assumption for the process is

that it is adiabatic, assuming no

heat loss through the pipe to the

surroundings occurs as a result of

thick insulation.

My assumption that Point A is

liquid that occupies half of the

tank space with zero vapor above it

is problematic. While the pressure

is signifi cant, a complete absence

of vapor in the space above the

liquid is impossible, as it would

p1 = 69 psi

266 F

302 F

subcooled

saturated

subcooled

?

1 FT3

1 FT3

p2 = 50 psiA

266 F

302 F

Figure 1. Visualization of vaporization and re-condensation (Courtesy of the author)

15


imply full vacuum. Because the

fl uid in the DA is at the saturation

curve or in the subcooled region,

something must be present above

the liquid to maintain pressure.

To explain what keeps the void

above the liquid at pressure in this

case, we would need to understand

more precisely the specifi cs of the

DA design.

Your note is well-placed; if we

instead make a slight adjustment to

starting Point A to be slightly into

a two-phase region, this diffi culty

immediately disappears. e entire

space above the liquid would be

vapor, the combined volume in the

tank could be treated as the entire

tank (20,000 gallons) instead of

half of it (10,000 gallons), and the

total combined specifi c volume

would be total tank volume divided

by total mass (which at Point A is

mostly liquid). at would make

the total combined volume double

that if we used only half the tank.

It does not aff ect Point A but makes

things easier when going to point

B, as we now have a total volume

of the entire 20,000 gallons fi lled

with a mixturesome liquid and

some vapor. From there, vapor

mass fraction x and volume can

be calculated.

My assumption that the entire

system is a constant volume is

valid, because otherwise, it is

impossible to make any other

reasonable assumptions. For

example, we cannot assume

constant pressure at Point B (As an

example, imagine that the tank had

a free heavy lid that would apply

constant pressure and that the

expanding volume of vapor would

move the lid up).

e tank described in these

articles does not have moveable

boundaries. e only openings

are to the condensate piping and

through the running pumps, but

those are essentially closed (by

running water).

As explained in Part 2, vapor

wants to expand according to a new

pressure to which the surface of the

DA is now suddenly at (Point B).

But it is not a steady state process,

and things are very transient. As

vapor tries to form and fl oat up,

it encounters a colder layer above

it and condenses back to liquid

almost instantaneouslyat many

orders of magnitude faster than it

takes for vapor to travel through

the suction header of the running

(colder) pump to reach its entrance.

Instead, what likely is happening is

convective cooling of the hotter leg

by the colder leg via this attempted

vaporization and re-condensation

(see Figure 1, page 15).

Imagine that you have two layers

of fl uid of equal volume, separated

by a very thin membrane. Initially,

69 psi is enough to keep both

liquids subcooled (the lower layer

is subcooled but not as subcooled

as the upper layer). Suddenly,

pressure at the surface drops to

50 psi, at which the top layer is

still subcooled, but the bottom

layer enters the vapor phase. Will

it immediately fl ash out to many

times more vapor volume? If so,

where will it go?

Assume that the membrane is

thin and raptures as vapor forms.

e bubbles trying to form at the

lower layer would have to meet

the colder layer and return to

liquid form. is would go on for

some time and eventually both

fl uids would mix at the average

temperature (266+302)/2. If 50 psi

is in a vapor region, the fl uids will

turn to vapor and fi ll the entire

can. If the can is very tall, there

will be more space for vapor to

form (if it corresponds to vapor

condition). Initially, however, all

was in two liquid layers. After the

drop of pressure (and if the new

condition is vapor phase), however,

the vapor will expand to take up

the complete volume.

Part 2 shows that, for the

conditions used in the example

and at the resultant average

temperature, no two-phase

situationand thus no vapor

exists. is means the system

experiences no cavitation or NPSH

problem. However, in reality, no

vapor would reach the running

pump because the colder column

is not static and mixing with the

hotter liquid. Instead, while vapor

wants to form and transmit its

energy to heat up cooler liquid,

that liquid is actually in motion,

taking a heated chunk and moving

it toward the pump.

By the time the chunk fl ows

through the entire length of pipe,

the resultant rise in temperature

of the fl owing liquid is minuscule.

As a result, it is not even close to

heating the cooler leg substantially.

In other words, it is the DA

temperature that would dictate the

temperature of fl uid reaching the

running pump.

Dr. Nelik (aka Dr. Pump)

is president of Pumping

Machinery, LLC, an Atlanta-

based fi rm specializing in pump

consulting, training, equipment

troubleshooting and pump

repairs. Dr. Nelik has 30 years

of experience in pumps and

pumping equipment. He may

be reached at pump-magazine.

com. For more information, visit

pumpingmachinery.com/pump_

school/pump_school.htm.

16 PUMPING PRESCRIPTIONS


17

pumpsandsystems.com | June 2015Circle 113 on card or visit psfreeinfo.com.

This series discusses valves and fi ttings and evaluates how these devices aff ect the

operation of piping systems. Part 1(Pumps & Systems, May 2015) covered head loss, K value and L/D coeffi cient.

CV Coeffi cient

e CV value is an indication of the capacity of a valve or fi tting and is often used to describe the performance of control valves. e CV coeffi cient is often used to describe the hydraulic characteristics of elements in a pipeline. e defi nition of CV is the number of U.S. gallons per minute (gpm) of 60 F water fl owing through a valve or fi tting results in a 1 pound per square inch (psi) pressure drop across the device. For example, if a device has a

CV value of 200, then when 200 gpm fl ows through the device, a 1 psi pressure drop would occur. Equation 6 describes the CV value.

CV = Q

Pin - PoutSG

Equation 6

WhereCV = Flow coeffi cient (unitless)Q = Flow rate (gpm)P = Pressure (psi)SG = Specifi c gravity of the fl uid

(unitless)

e equation can be rearranged to allow for the solution of the fl ow

rate for a given pressure drop and the pressure drop for a given fl ow rate.

Q = CV dPSGEquation 6 gives the result of using C

V in diff erential pressure instead

of head. If a manufacturer provides information in C

V, users must

convert it to diff erential pressure, then convert the results to head loss. Equation 7 can be used to eliminate the need to convert from pressure to head. It allows for the conversion of a C

V value to a

K value.

K = 890.3 x

d4

(CV)2

Equation 7

WhereK = Resistance coeffi cient

(unitless)CV = Flow coeffi cient (unitless)d = internal diameter (inches)

Calculating the Head Loss

Using K Value

Regardless of the method used to arrive at a K value for a valve or fi tting, Equation 8 is used to calculate the head loss resulting from valves and fi ttings.

hL = 0.00259

KQ2

d4 Equation 8

When multiple valves and fi ttings in a pipeline have the same diameter, the K values for each valve or fi tting can be added. e sum of the K values can be used to calculate the head loss for all the valves and fi ttings.To demonstrate, calculate

the head loss for the valves and fi ttings in a pipeline when 600 gpm of water is fl owing through the following valves and fi ttings: a sharp-edged transition from a tank to pipeline, a full-seated globe valve and a strainer with a CV value of 450. ese full-seated devices are in a 6-inch pipe with a turbulent friction factor of 0.015 inches. e K values are listed in Table 1. e resulting head loss with 600 gpm going through the pipeline is shown in Equation 9.

Cross Section of Valves &

Fittings

Reference 1 has cross sections of types of valves and fi ttings and the corresponding K values or L/D coeffi cients. ere are too many types of valves and fi ttings to present in this article, but some attributes can be generalized. For example, a full-seat ball valve

A better understanding of complete system operation

Understand How Valves & Fittings Affect Head Loss

Last of Two Parts

hL = 0.00259

KQ2

d4 = 0.00259

11.55 x 6002

6.0654 = 7.95 ft of fl uid

Equation 9

dP = Q2 x SG(CV)2

18 PUMP SYSTEM IMPROVEMENT


By Ray Hardee

Engineered Software, Inc.

with its straight-through design has a much lower

L/D value than a globe valve through which the

fl uid must make four changes of direction and

fl ow around the valve disk within the fl ow path.

e type of valve employed is based on many

factors. Leak tightness is an important factor,

but when two types of valves meet the same

requirements, it is recommended to use the one

with the lower head loss.

Another example of fi ttings with varied loss

coeffi cients are elbows. A short radius 90-degree

elbow has an L/D coeffi cient of 20, but a long radius

90-degree elbow has a L/D coeffi cient of 14. is

may not seem like a signifi cant loss, but it adds up.

So do the associated costs. e pump must supply

the energy that is lost across the valves and fi tting.

Cost of Pipeline Operation

To demonstrate the pumping cost associated with

valves and fi ttings, calculate the operating costs for

diff erent types of valves and fi ttings. Equation 10

can determine the pumping cost.

Item Method Coeffi cient Value K value

Sharp-edged transition

K 0.5 0.5

Globe valve fT L/D 0.015 x 340 5.1

Strainer Cv 450 5.95

Total K for pipeline 11.55

Table 1. Calculation of K value for different methods describing valves and fi ttings (Graphics courtesy of the author)

Valve / Fitting Type K value

Head Loss (ft)

Annual Operating Cost ($)

Elbow short radius 0.33 0.5 $53

Elbow long radius 0.23 0.35 $37

Entrance inward 0.78 1.23 $128

Entrance sharp edge 0.50 0.79 $82

Entrance rounded 0.04 0.06 $7

Ball 0.05 0.08 $8

Gate 0.13 0.20 $21

Plug 0.29 0.45 $47

Butterfl y 0.73 1.14 $118

Globe 5.54 8.58 $893

Table 2. The relationship between K values, head loss and annual operating cost for valves and fi ttings. The example is for 4-inch valves and fi ttings passing 400 gpm.

19


AROzone.com/ACHEMA

Automate Your ProcessesWith the ARO Controller and

EXP Series Electronic Interface Pump

Watch it!

Learn about it!

Experience it!

Visit us at booth #E18 Hall 9 for a demonstration

E i it!

Cir

cle

12

5 o

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ard

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sfre

ein

fo.c

om

.

OC = .746 Q H 247,000 M

OH x $/kWh

Equation 10 WhereOC = Operating cost ($/time)Q = Flow rate (gpm)

H = Head (feet of fl uid) = Density (lb/ft3) = Effi ciency, M motor, P pump,

V variable speed drive (VSD) (percent)

O = Operating hours in evaluation (hours)

$/kWh = Electrical power cost ($/kWh)

In this example, the pump effi ciency is 70 percent, and the motor effi ciency is 90 percent. No VSD is installed, the evaluation period is 8,000 hours, and the cost of power is $0.10/kilowatt-hour (kWh). is example evaluates 4-inch valves and fi ttings with a fl ow rate of 400 gpm. e results are presented in Table 2 (page 19).

Every item placed in a piping system has an operating cost. is should be considered every time a user specifi es a valve time or adds elbows.

Conclusion e often overlooked performance of the multitude of valves and fi ttings adds up. ey have a compounded eff ect on performance in a fl uid operation and need to be taken into consideration for effi ciency planning and optimization.

Next months column will investigate how the control elements operate and the role that these devices play in piping systems and their associated cost.

References1. Flow of uids through valves, ttings, and pipe.

(1957). Chicago: Crane2. Flow of Fluids through Valves, Fittings and

Pipe Technical Paper 410. 2013 Crane Co. Stamford CT 06902.

Ray Hardee is a principal founder of Engineered Software, creators of PIPE-FLO and PUMP-FLO software. At Engineered Software, he helped develop two training courses and teaches these courses in the U.S. and internationally. He is a member of the ASME ES-2 Energy Assessment for Pumping Systems standards committee and the ISO Technical Committee 115/Working Group 07 Pumping System Energy Assessment. Hardee was a contributing member of the HI/Europump Pump Life Cycle Cost and HI/PSM Optimizing Piping System publications. He may be reached at [email protected].

20 PUMP SYSTEM IMPROVEMENT

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Most pump bearings fail

long before their design

life span. e American

Petroleum Institute (API) typically

requires a minimum bearing life

(L10) of 25,000 hours, and ANSI

B73.1 specifi cation for horizontal

ANSI pumps specifi es a minimum

L10 bearing life of 17,000 hours at

maximum load and rated speed.

Prudent end users frequently

request bearings with more

than 40,000 hours L10, but most

bearings do not reach that many

hours of operation before failure.

More than half of pump bearings

fail as a result of contamination,

excess heat or both. Preventing

this introduction of contaminates

is easier and less expensive than

removing them. Some studies

suggest removing contaminates

can be eight to 10 times more

expensive than prevention.

Oil Contamination

is premature failure rate

is typically the result of

contamination of the oil not a

fault of the bearing or pump

manufacturer. Dirt, wear particles

and other foreign debris as well

as improper bearing installation

procedures can contribute to

contamination that leads to

reduced bearing life.

Other forms of contamination

include heat and air in the form

of air entrainment and aeration.

Increased levels of heat and air lead

to increased oxidation rates.

One of the most common sources

of contamination, however, is

water, which is often introduced

because of improper storage and

handling. During pump operation,

water can leak into the bearing

housing from external sources

such as area wash down, spray

from failed mechanical seals (or

packing) or leaks from equipment

near or above the pump. Another

common method of water

introduction is condensation

through machine aspiration

(moisture laden air is drawn in due

to pressure diff erentials).

For example, a pump running

steady state at a given temperature

above ambient for fi ve days is shut

down on Friday at 4 p.m. As the

What You Need to Know About Bearing Oil

Last of Two Parts

By Jim Elsey

Summit Pump, Inc.

Figure 1. Oil level on bottom ball of the bearing (Graphics courtesy of the author)


22

pump cools, the ambient air is drawn into the

bearing housing where it cools and the moisture

condenses, releasing the entrained water into the

housing where it mixes with the oil.

According to sources at the SKF Bearing

Company, 250 parts per million (PPM) water in

the lube oil will reduce bearing life by a factor

of four, and another source states that 0.002

percent water in the oil will reduce the bearing

life by 48 percent. According to other sources, the

reduction of oil contamination levels from the

ISO 21/18 to the ISO 14/11 will increase bearing

life by a factor of 7.

Because water in the oil is invisible at low

levels, a lab should test the oil using the Karl

Fisher method or the end user should conduct

a simple sizzle test in which the oil is quickly

subjected to a hot surface temperature of 250 to

300 degrees F. A hot plate is commonly used, but

a metal spoon or aluminum foil with a butane

lighter can also be used. If more than 800 to

1,000 PPM water is present in the oil, a sizzle

sound can be heard when the oil temperature

exceeds 212 to 220 F. If the oil sizzles, too much

water is present in the oil. Because the sizzle

test can have dangerous side eff ects, always

check with plant safety procedures before

conducting the test.

Companies that strive for longer mean time

between failures (MTBF), mean time between

repairs (MTBR) and improved plant reliability

select their oil or grease based on equipment

requirements and properly match them with the

oil properties. ey also store and allocate the oil

using controlled and clean methods.

I have seen end users store oil drums upright,

outside and unprotected with an open bung. I

have also seen mechanics draw oil from drums

into used paper coff ee cups or soft-drink cans.

When confronted, they reply, at is the way we

have always done it, and we are not having any

bearing or oil problems, or I washed out the

container fi rst.

If a pumps bearings are not lasting three to

eight years, the plants equipment lubrication

practices should be questioned. Check with your

oil supplier, or consult articles, books and other

publications that discuss these subjects. e

October 2006 issue of Pumps & Systems magazine

explores this topic, and I highly recommend any


23

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books and technical papers on this

subject by Heinz Bloch (see page

30), Alan Budris or Rojean omas.

Bearing Lubrication Methods

Selection of a bearing design

for a specifi c service will, to a

large degree, determine how it is

lubricated. Depending on the pump

speed, type of service, horsepower

(HP) range and size, diff erent types

of bearings are available.

A properly selected oil-lubricated

ball or roller bearing will work

for most applications less than

200 HP, 400 F (fl uid temperature)

and 3,600 revolutions per minute

(rpm). For some smaller and lower

temperature applications (less than

320 F), grease-lubricated bearings

may also work well. Larger pumps

at higher speeds and system

temperatures will require line,

sleeve or plain journal bearings

for radial support (hydrodynamic

journal bearings) and tilted shoe

(pad) designs for thrust bearings.

Methods and designs that are

acceptable for ANSI specifi cation

pumps may not be acceptable for

API, process, marine and power

generation applications where HP

can often exceed 70,000 brake

horsepower (BHP) with speeds in

excess of 6,000 rpm.

Because most end users at the

high end of the HP and speed

spectrum are aware of oil types,

best practice lubrication techniques

and bearing selection, this article

will examine the middle and

lower range.

Oil splash lubrication may be the

most common method of bearing

lubrication for horizontal pumps

from 5 to 250 BHP. e oil is

contained in a sump in the housing

with the bearings. e machine is

designed so the oil level for proper

operation is at the middle of the

bottom ball in the bearings.

Oil Levels

Oil levels higher than the middle

of the lowest ball bearing will

have negative consequences and

increase oil temperature and air

entrainment. Both of these factors

accelerate the oils oxidation rate

and reduce oil and bearing life.

For splash lubrication, the oil level

should touch the very bottom of

the bottom ball in the bearing.

If the oil drops below the ball or

the outer race, the bearings could

be damaged. If the level is too

24



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low, the bearing could experience

temperature runaway, which is

when the bearing gets hot quickly

and is permanently damaged.

Variations on splash lubrication

design include fl ingers, discs, oil

rings and several other methods/

types of lubrication.

One note of caution is that

rings must be close to perfectly

concentric, and the pump shaft

must be level for the rings to work

correctly. I have rarely seen the

ring remain round, especially after

the fi rst maintenance overhaul. If

not initially leveled, the pump may

not remain level either. Problems

may also arise if the design ratio

of ring to shaft diameters is not

correct. Critical speed can also be

an issue. While the rotor may be

above the fi rst critical speed, the oil

ring speed is typically at 50 percent

of the shaft speed and may be

rotating close to critical frequency.

Other types of lubrication

include grease (with ball bearing

variations of shielded/unshielded

and sealed), oil mist, oil purge and

forced oil feed (oil is pumped to the

bearings for the larger HP pumps

and some marine applications).

Most motor bearings are grease-

lubricated, so it is important to

know if they are open, shielded,

sealed or a combination of these

options. If they are shielded on one

side, the best practice is to place

the shielded side toward the grease

fi tting. I have seen many end users

who order pumps with greased

bearings still add oil to the housing

simply because the installation,

operation and maintenance manual

(IOM) did not specifi cally say not

to. Running the pump with greased

bearings and splash oil lube at the

same time is an incorrect solution.

Oil Changes

e fi rst oil change should be

conducted at a shorter interval

than subsequent changes to

eliminate the contamination that

occurs from startup and run-in

operations. Most ANSI and some

API pump manufacturers will

state that the fi rst change should

come at 200 operating hours and

subsequent changes at 2,000 hours

or 3 months, whichever comes

fi rst. e intervals depend on

operating temperatures and how

contamination ingress is managed.

Some operations will require more

frequent oil changes, and others

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can operate for several years. Oil sample analysis

and experience will aid in decisions regarding oil

change intervals.

Consider how often oil is changed in a car. If a

car was driven at 60 miles per hour for 24 hours a

day and 7 days a week for one year (8,760 hours in a

year), it would drive 525,600 miles.

You would never drive a car that many miles

without changing the oil.

Automatic Oilers

Several automatic oiler types and brands are on the

market. e question to ask is whether the oiler is

vented to atmosphere or to the housing. Old designs

vented to atmosphere, but that is how moisture

gets to the bearing housing and oil. e new best

practices are to vent the oiler to the housing and

keep the housing sealed.

e old method was to also vent the housing,

but that was a source of contamination. e

vents should be eliminated or, at the very least,

used with a desiccant breather or an equalizer

expansion chamber.

Lip Seals Versus Bearing Isolators

For more than a hundred years, lip seals have

served the industry well. While they are simple and

inexpensive, end users should consider replacing

them with the more modern and effi cient bearing

Figure 2. Cross section of bearing isolator

Tuthill

1/2 vert

26


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27


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isolators. Lip seals, regardless of the

manufacturer, will, at best, only last

about 3,000 hours in service. After

approximately four months of operation,

they will fail and potentially allow

water or other contaminants to enter

the bearing housing. e advent of the

bearing isolator is what has allowed

many pump manufacturers to extend

their warranties from one to fi ve years.

e modern bearing isolator will, on

average, last eight to 10 years and, if

properly managed, even longer. During

that time, the isolator will not wear/

score a groove on the shaft and, for the

most part, will prevent the introduction

of contamination to the bearing housing

at both operating and static conditions.

Bearing isolators can be of the labyrinth

or contacting face design, and there are

numerous designs and manufacturers.

e majority of bearing isolators

are orientation specifi c; they normally

have a drain hole (expulsion port) that

should be in the 6 oclock position. If

the port is not at the correct position,

the isolator will not perform properly.

For some types of ANSI pumps, the

outboard isolator will have numerous

evenly spaced expulsion ports because

the housing it fi ts into can be rotated

when setting the impeller clearance.

e fi nal position will not be a fi xed

parameter as it is in other designs, so the

isolator incorporates numerous ports to

satisfactorily operate in any position.

Overfi lling the Bearing Housing

One of the most common problems

I see in the fi eld beyond not reading

the instructions is the overfi lling of

the bearing housings with oil. Bearing

isolators (labyrinth style) will purge any

excess oil from the housing. A common

misconception is that the isolator

The modern bearing isolator will, on average, last eight to 10 years

and, if properly managed, even longer.

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has failed, but it is just doing its

job. e oil will continue to be

expelled until the level is below the

expulsion port.

Setting the automatic oiler

level incorrectly is the next most

common mistake in the industry.

Please refer to the manufacturers

instructions for the proper

procedure. Hint: e level in the

oil bulb is not the level of the oil

in the pump housing nor is it the

centerline of the connecting pipe.

Conclusion

Centrifugal pumps are shipped

without oil in the bearing housings;

consequently, the end user must

ensure that oil is in the housing

before startup. e oil must be

of the proper viscosity. e oil

viscosity selection is based on

expected temperatures of the oil

and bearings. e oil supply source

should be clean, and the oil must

remain uncontaminated between

changes. In addition, the oil must

be at the proper level in the bearing

housing. Too much oil is just as

bad, if not worse, than too little oil.

Most bearings fail because of

contamination from water and/or

heat. Labyrinth or magnetic face

type seals (bearing isolators) can

help prevent water introduction

and contamination. Desiccant

breathers or automatic oilers that

vent to the housing in lieu of the

atmosphere can also reduce the

introduction of water.

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original equipment manufacturers for 43 years in most industrial

markets around the world. Elsey is an active member of the American

Society of Mechanical Engineers, the National Association of Corrosion

Engineers and the American Society for Metals. He is the general

manager for Summit Pump, Inc., and the principle of MaDDog Pump

Consultants LLC. Elsey may be reached at [email protected].

Read more online

pumpsandsystems.com/

commonpumpingmistakes.

30



SPX

31

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Some will know from their

experience with automobiles

that thicker oils, such as

Society of Automotive Engineers

(SAE) 30, are more appropriate

for warm summer months. But

thinner oils, perhaps SAE 10, can

help prepare a vehicle for winter

driving. Figure 1 illustrates where

these motor oils fi t in comparison

to the industrial oil designations

used today.

ick oils are more viscous

and may not readily fl ow into the

bearings. Users can heat the oil

or avoid oil rings and other risk-

inducing lube application methods

by using smarter means. ey can

use a jet of oil (oil spray) or convey

the oil mixed with compressed

air in the form of an oil fogalso

called oil mist. Whatever the user

chooses, he or she must guard

against using the thinnest oil

found on the market to avoid the

problem of inadequate oil fi lm

strength and thickness.

Lube Oils for Process Pumps

e MRC Engineers Handbook

states, In general, the oil

viscosity should be about 100

Saybolt Universal Seconds (SUS)

at the operating temperature.1

If for some reason a bearing was

operating at 210 degrees F, Figure

1 would call for a lubricant with

an International Organization

for Standardization (ISO)

viscosity grade (VG) somewhere

between 220 and 320. But that

is unrealistically thick for most

process pump bearings. Oil rings,

if used, would probably slow down

and malfunction in such viscous

oils. Oil overheating may be an

additional concern.

Figure 2 shows a graph from

SKF that is time-tested and widely

applicable.3, 4 It depicts the required

minimum (rated) viscosity v1 as

a function of bearing dimension

and shaft speed.3 A bearing with a

mean diameter of 390 millimeters

(mm) at a shaft speed of 500

revolutions per minute (rpm) would

require v1 = 13.2 centistokes (cSt).

For another example, if a bearing

was mounted on a 70-mm shaft

rotating at 3,600 rpm, we might

assume that the bearings outside

diameter (OD) is twice its inner

diameter (ID), or 140 mm. e

How Oil Viscosity & Temperature Infl uence Bearing Function

First of Two Parts

By Heinz P. Bloch, P.E.

Figure 1. Oil viscosity comparison chart per common industry conversion practice (Courtesy of the author)

By Heinz P. Bloch, P.E.

32 GUEST COLUMN


bearings mean diameter would be 105 mm. To

simplify, consider it 100 mm, and travel up from

100 to a location midway between the 3,000

and 5,000 rpm lines in Figure 2. In this instance,

one could operate with a lubricant which, at the

bearing operating temperature, is somewhere

between 8 and 9 cSt.

Note that a bearings operating temperature

must be known to determine what ISO VG is

needed. e operating temperature derives its

combined thermal input from bearing load and

lube oil frictional drag. Unnecessarily viscous oils

will become hot. Figure 3 (page 32) is helpful in

this regard. Note that Figures 2 and 3 were drawn

years ago and apply to mineral oils. If users choose

premium grade synthetic oils, they will enjoy a

sizeable safety factor in lube applications.

Using lubricants with viscosities in excess of

those needed may generate excess heat and actually

work against operators. However, thicker oils have

their place, and MRC had to cover all the bases with

their 100 SUS rule-of-thumb.

Figure 2. Required minimum (rated) viscosity v1 as a function of bearing

dimension and shaft speed.3 A bearing with a mean diameter of 390 mm at a shaft speed of 500 r/min will require v

1 = 13.2 cSt. (Courtesy of SKF)

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at said, a large bearing (200

decimeters) in a slow speed gearbox

(200 rpm) requires an operating v1

of 40 cSt. Figure 3 shows that ISO

VG 100 (or higher) oils would be

needed here.

Real-World Example

In a recent case history, ISO VG

100 was applied to a large pump

where ISO VG 68 mineral oil or its

equivalent ISO VG 32 would have

suffi ced. An ISO VG 32 synthetic

is the bearing life equivalent

of an ISO VG 68 mineral oil.

e synthetic ISO VG 32 runs

considerably cooler than the

mineral oil equivalent.

With ISO VG 100 mineral oil, the

oil-misted radial bearing ran a few

degrees in temperature lower than

it had with conventional sump and

oil ring lube. e user was pleased

but expressed disappointment at a

triple-row thrust bearing running

as hot as before190 F.

A premium formulation

synthetic ISO VG 32 would have

been suffi cient and would have

given the user everything a solid

reliability professional could have

asked for.

Reliability professionals would

like to see pump bearing housings

with no oil rings, no need for

constant level lubricators and

few, if any, repeat failures. ey

start with the right lubricant.

Why, with all that, is the radial

bearing cool? After all, it is also

surrounded by the thick ISO VG

100. It is cool because it has no

load. e load is in the triple-row

thrust bearing, and that creates

temperature in addition to the

frictional temperature mentioned

earlier in this article.

Part 2 of this series will examine

which temperatures are reasonable,

which are high and which are out of

allowable range for rolling element

bearing housings and pump

bearing housings.

References

1. MRC Engineers Handbook, General

Catalog 60, Copyright TRW, 1982

2. Bloch, H.P.; Improving Machinery

Reliability, Gulf Publishing Company,

Houston, TX, 1983, 1993

3. SKF America, General Catalog,

Kulpsville, PA (2000)

4. Bloch, H.P. Pump Wisdom: Problem

Solving for Operators and Specialists,

John Wiley and Sons, Hoboken, NJ, 2011

Heinz P. Bloch has been a

professional engineer for almost

50 years. He holds a BSME and an

MSME degree (cum laude) from

New Jersey Institute of Technology

and retired as Exxon Chemical

Companys regional machinery

specialist. He may be reached at

[email protected].

Figure 3. For a required viscosity (vertical scale), the permissible bearing operating temperatures (horizontal scale) increase as thicker oils are chosen (diagonal lines). Users enter the vertical scale near 9 cSt and move toward the right, where the line intersects with oils ranging from ISO VG 22 through ISO VG 320. If the user selects ISO VG 32, he or she might start the pump and verify that its oil temperature had leveled off at no greater than 75 C. Alternatively, the user might choose ISO VG 68 and verify that its operating temperature does not exceed 100 C (212 F). The information in this fi gure is per common rule of thumb, using average viscosity improvers. (Courtesy of the author)

Reliability professionals would like to see pump bearing

housings with no oil rings, no need for constant level lubricators and

few, if any, repeat failures. They start with the right lubricant.

34 GUEST COLUMN

chemical engineering June 2015

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Transcript of chemical engineering June 2015