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2 March 2013 www.pump-zone.com PUMPS & SYSTEMS

From the Editor

PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 110, 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. ©2013 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 descrip-tions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media Group, Inc., permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 21, Issue 3.

is a member of the following organizations:

For several years, the industry has been buzzing about pumps used in irrigation and agriculture

applications. It makes sense. Almost 60 percent of the world’s freshwater withdrawals are used for irrigation, according to several sources including a recent study by the USGS Water Science School.

Consider this . . . power plants use 10 times more water than is treated in municipal drinking water plants. In fact, they extract and treat more water than all other industries combined. h e only larger use of water is for irrigation, according to a 2011 study by h e McIlvaine Company.

Ef ective irrigation systems use energy-ei cient equipment and designs that also help minimize the amount of unnecessary water use. Some common causes of wasted energy in irrigation systems, according to the Natural Resources Conservation Service (NRCS), are worn or improperly sized pumps, worn nozzles and improperly sized or designed i ttings. Irrigation equipment problems and maintenance problems tend to go hand in hand. Pumps, motors and engines that are badly designed or poorly maintained reduce the irriga-tor’s degree of control over water applications, making it impossible to maintain correct soil moisture levels. h is leads to crop stress, reduced yields, runof , erosion and other problems.

Agricultural irrigation is an energy intensive operation, and modifying irrigation systems can reduce energy usage and costs. Pressurized irri-gation systems, especially center pivot sprinkler

installations, use a high l ow rate pump and require a large electric motor or engine. h e major causes of increased energy use are associated with pipe-line leaks, engine and pump ei ciency and well maintenance. Poor uniformity of water applica-tion can also af ect energy use by increasing pump-ing time.

As we increase our coverage of pumping systems used in agricultural, irrigation and groundwater applications, our cover series this month features cutting-edge solutions to complex irrigation installations (page 25). h e lead article describes how today’s agricultural irrigation is not just about pumps. Variable speed drives, intelligent control and remote management are all vital to a com-plete energy-ei cient system. Complete pumping systems have replaced large, isolated pumps as the solution moving forward.

Our cover series also includes two articles that describe the diesel versus electric debate for pow-ering the pump (page 30 and page 34).

Pumps & Systems will continue to research and report about pumps in agricultural irrigation. Tell us about your experiences and share your case

studies by contacting me directly, [email protected].

Michelle SegrestEditor

Editorial Advisory Board

Thomas L. Angle, P.E., MSc, Vice President Engineering, Hidrostal AG

Robert K. Asdal, Executive Director, Hydraulic Institute

Bryan S. Barrington, Machinery Engineer, Lyondell Chemical Co.

Kerry Baskins, Vice President of Sales, Viking Pump

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

David A. Doty, North American Sales Manager, Moyno Industrial Pumps

Walt Erndt, Director of Market Development SSB, Environment One Corporation

Joe Evans, Customer & Employee Education, PumpTech, Inc.

Ralph P. Gabriel, Chief Engineer—Global, John Crane

Bob Langton, Vice President, Industry Sales, Grundfos Pumps

Larry Lewis, President, Vanton Pump and Equipment Corp.

Todd Loudin, President/CEO North American Operations, Flowrox Inc.

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

William E. Neis, P.E., President, Northeast Industrial Sales

Lev Nelik, P.E., APICS, President, Pumping Machinery, LLC

Henry Peck, President, Geiger Pumps & Equipment/Smith-Koch, Inc.

Mike Pemberton, Manager, ITT Performance Services

Adam Stolberg, Executive Director, Submersible Wastewater Pump Association (SWPA)

Bruce Stratton, Product Manager, KLOZURE®, Garlock Sealing Technologies

Kirk Wilson, President, Services & Solutions, Flowserve Corporation

PublisherWalter B. Evans, Jr.

VP of SalesGeorge Lake

[email protected] • 205-345-0477

VP of EditorialMichelle Segrest


Creative DirectorTerri Jackson

[email protected]

EDITORIAL

EditorMichelle Segrest


Managing EditorLori K. Ditoro


Associate EditorAmanda Perry


Contributing EditorsLaurel DonohoJoe Evans, Ph.D.

Dr. Lev Nelik, PE, APICS

CREATIVE SERVICES

Creative DirectorTerri Jackson

Senior Art DirectorGreg Ragsdale

Art DirectorJaime DeArman

[email protected]

PRODUCTION

Production Manager/Traffi cLisa Freeman


Web Advertising Traffi cAshley Morris


CIRCULATION

Jeff [email protected] • 630-739-0900

ADVERTISING

Derrell [email protected] • 205-345-0784

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

Mark [email protected] • 205-345-6414

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P.O. Box 530067Birmingham, AL 35253

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Tuscaloosa, AL 35404Phone: 205-345-0477 or 205-561-2600

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Table of Contents March 2013Volume 21 • Number 3

A G

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6 Readers Respond

8 20th Anniversary Top 20 List By Amanda Perry

Top 20 Apps for Pump Users

12 News

15 Calendar of Events

42 Effi ciency MattersBy Arno Gehrer, ANDRITZ GROUPDesign Software Increases Hydraulic Effi ciency

45 Maintenance MindersBy Tom Davis, Maintenance TroubleshootingPump Rebuild Tips

48 Sealing SenseBy The Fluid Sealing AssociationGaskets for Rigorous Applications

51 HI Pump FAQsBy The Hydraulic InstituteSubmersible Pump NPSH3, Trench-Type Wet

Wells & Starting Torque Requirements

65 Product Pipeline

72 Pump Market AnalysisBy Jordan, Knauff & Company

SPECIAL

REPORT

20 Pump Specifi cation, Purchase, Installation & ApplicationBy Amin Almasi, WorleyParsons Services Pty Ltd.Sharing all the information about an application can help with the selection and installation of the ideal pump.

Departments

25 Pump Systems for Today’s Agricultural IrrigationBy Vahan Bagdasarian, GrundfosComplex irrigation applications require customized and cutting-edge solutions.

30 Powering the Pump: Diesel Versus Electric Motors By Tim Albers, Nidec Motor CorporationMake the ideal motor selection for irrigation applications.

34 Powerful Mine DewateringBy Kristen Gurick, Godwin Pumps, a Xylem BrandElectric and diesel centrifugal pump options

The Pump Purchase Process

Columns16 Pump Ed 101

By Joe Evans, Ph.D.

Branch-Line Pumping and Other Options

18 Pumping PrescriptionsBy Lev Nelik, P.E., Pumping Machinery, LLC

Will Impeller Velocity Triangles

Keep You Awake at Night?

2 From the Editor

41 Trade Show Coverage

68 Index of Advertisers

68 Pump Users Marketplace

COVER

SERIES

Agricultural Irrigation & Dewatering

Practice & Operations

54 Prefabricated Treatment System Solves Water Quality ConcernsBy Mark Koester, Koester Associates, Inc.With the simultaneous construction and site preparation, the quick turnaround required for the project was accomplished with cost-effi cient results.

57 New Optimized Aeration System Reduces Energy ConsumptionBy Lars Larsson, Xylem, Inc.A wastewater treatment plant experiences a 65 percent energy savings with the installation of improved equipment.

60 Positive Displacement Pumps in Wastewater TreatmentBy Oakley Roberts, ARO Fluid Products, Ingersoll RandSelect the right pumping technology to keep treatment processes running effi ciently.

62 Power Generation on DemandBy Brad Chrudimsky, Baldor Electric Company, a member of the ABB GroupThe application, geography, regulations and proper size must be considered when choosing a generator set.

READERS RESPOND


“Pump System Design,” February 2013

Thanks for your article “Pump System Design”

published in the February 2013 Pumps &

Systems. It included good items to consider for

simplii ed system modii cations or upgrades.

Homework Background and Answers

For a 12-hour per day operation at 800 gallons

per minute (gpm), there will need to be storage

capacity for at least 576,000 gallons of oil. An approximate 70-foot

diameter by 21-foot deep storage tank was used in the analysis.

To keep the analysis simple, only half the 20-foot storage tank

draw-down was used to arrive at an average lift value. An average lift

of 20/2 + 50 = 60 feet was used. The recommended pump place-

ment close to the storage tank was used.

A 71-foot length of vertical discharge piping and a couple pipe

elbows were also included. Friction losses totaled about 97.7 feet

including tank entrance and process end discharge losses.

The calculated required pump head was 1.3-foot discharge

velocity head + 60 feet of lift + 97.7 feet for friction = 159 feet

(used 160 feet).

Using a 2-pole speed of 3,500 rpm, an approximate specii c

speed value of 2,200 was calculated. Based on the efi ciency-

versus-specii c speed graph at www.mj-scope.com/pump_tools/

pump_efi ciency.htm, a maximum, 81-percent pump efi ciency

might be expected for best-efi ciency-point (BEP) operation.

I did i nd a commercial rei nery/API type pump with an approxi-

mate 78 percent efi ciency at the above design conditions. The

curve indicated an 80 percent best efi ciency zone.

Assuming that the BEP operating head (160 feet) is about 85

percent of the head at zero l ow,

a shutoff head of 188 feet was

estimated.

Equating this shutoff head value

to Vt^2 / 2g, where Vt = [pi(D/12)

(N/60)] is the impeller tip speed, an

impeller diameter of 7.21 inches was

calculated.

The curve for the 78-percent efi -

cient pump indicated an approximate 7.25-inch diameter impeller

for the design conditions. The calculated minimum net positive suc-

tion head available at 6 p.m. full 20-foot draw-down was 37 feet.

This is greater than the curve net positive suction head required

value of 20 feet.

By designing to the average tank draw-down, the estimated

pump performance may vary between 825 gpm at 155 feet in the

morning to 775 gpm at 165 feet at 6 p.m. The design point, 800

gpm at 160 feet, would theoretically be seen around noon.

Good luck rei lling the storage tank each day before 6 a.m.

Lee Ruiz

Oceanside, Calif.

Lev Nelik responds:

h ank you, Lee. Glad to see you got to use the Ei ciency Estimator Program, with close correlation to an actual com-mercial pump. I am reproducing the link you noted from the website (see Figure 1) and compared the numbers to a copy of a performance curve from a randomly selected pump OEM catalogue.

h e 800 gpm and 143-foot head come out with a 6.79-inch impeller and 81.7 percent ei ciency by the program and about the same impeller size and 77 percent ei ciency by a random OEM performance curve. h e dif erence in ei ciency is about 4 percent. h is is a question for Pumps & Systems’ readers. Why the dif erence in ei ciency? (Please feel free to share your answers to Lev’s question. Send these answers to Amanda Perry, [email protected].)

Editor’s Note: For the Estimator Program referenced in the February 2012 column to work, readers may need to download a Microsot Web component from www.microsoft.com/downloads/details.aspx?amp;displaylang=EN&familyid=982B0359-0A86-4FB2-A7EE- F3A499515DD&displaylang=en). Readers should only need to download the program once. P&S

To have a letter considered for Readers Respond, please send it to

Amanda Perry, [email protected].

Lee Ruiz

Figure 1. Screen shot from www.pumpingmachinery.com

Mobile Power

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©2011 Baldor Electric Company

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cle

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m


Top 20 Apps for Pump Users Mobile applications assist pump users in the i eld and on the go.

First of Two Parts

By Amanda Perry

YEARS1 9 9 3 - 2 0 1 3

As we continue to celebrate 20 years as the leading magazine for pump users worldwide, we bring you a favorite Top 20 list compiled from reader surveys and editorial research in each issue. See Part Two of “Top 20 Apps for Pump Users” in

the April issue.

Flatness App for ALiSENSOR LEVEL Alignment Supplies, Inc.

h e Flatness App for ALiSENSOR Level makes geometric measurement cost-ef ective, more accessible and easier to perform. h e app allows users to measure the l atness of surfaces of a wide range of shapes and sizes to be calibrated to user-made i xtures of all sizes. Users can perform precise l atness measurements and customize the number of measurement points for specii c applications. h e measurements are performed quickly, and the user is guided in every step by a live 3D model of the measurement. Upon completing their measuring, users can create an instant PDF report with all the data, including an adjustable-scale schematic drawing of the l atness results. h is app requires separately purchased hardware.

Free / iPad, iPhone, iPod Touch

KoolApp: KoolCode, Refrigerant Slider, CoolGame, Fitters App, Compass Danfoss

Danfoss designed the new KoolCode app for service technicians, refrigeration engineers and in-store technicians to easily look up alarm, error, status and parameter codes for a range of Danfoss refrigeration controllers with a three-digit display. KoolCode joins Refrigerant Slider, CoolGame, Fitters App and Compass in Danfoss’ app library.

Users can look up KoolCode display codes by:• Quick code translation without knowing the controller• Hierarchical controller selection among Danfoss refrigeration controllers• Automatic controller identifi cation using a QR-code scan

Free / Android, iPad, iPhone, iPod Touch

Toolbox Technician Emerson Industrial Automation

Power Transmission Solutions

Power Transmission Solutions designed the award-winning Toolbox Technician app for HVACR technicians. Named an Honorable Mention winner of the 2013 AHR Expo Innovation Award, it combines the Browning Bearing & Belt Drive Pocket Reference Guide with an energy-ei cient calculator.

Toolbox Technician enables users to easily search the reference guide and quickly calculate information on ei ciency savings. h e material can be continually updated as new products are developed, so users will have the most current information. h e upgraded app also provides improved navigation, a belt identii ca-tion wizard and GPS functionality.


PUMPS & SYSTEMS www.pump-zone.com March 2013 9

20READERS CHOICE

Grundfos GO Remote Grundfos Pumps Corporation

Grundfos GO Remote is an app that works as a mobile tool box. GO Remote provides handheld pump control that can save users time on control, reporting and data collection. h is app works with all of Grundfos e-pumps and communicates with radio and infrared technology. Users have full access to all the Grundfos Online tools with this app. Features include product dashboard, status data, alarms and warnings, coni guration/commissioning, create installation report, and read/write proi les. Special hardware from Grundfos is required to communicate with the pumps.


Laser Align LUDECA Inc.

h e Laser Align app is a reference tool for the shat alignment of rotating equipment. Users can access important reference material and learn about key laser shat alignment concepts. Laser Align features several tools with useful reference guides, including Short Flex Tolerance Table, Spacer Shat Tolerance Table, h ermal Growth Calculator and Sot Foot Assistant.

Laser Align also provides interactive links for additional information on Prut echnik laser shat align-ment products and condition monitoring products.



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Amanda Perry is associate editor of Pumps & Systems.

Send information about your favorite mobile

app to her at [email protected].

seepex Pumps, SCT seepex, Inc.

h e seepex Pumps, SCT app provides users with information on seepex’s Smart Conveying Technology (SCT) for progressive cavity pumps. In addition to providing valuable information, the seepex app also has a comparison calculator, which directly shows the potential cost savings that can be made with SCT compared to an equivalent conventional seepex progressive cavity pump over a period of up to 10 years.


Versa-Matic and Sandpiper Mobile Apps Warren Rupp, Inc.

h e Versa-Matic and Sandpiper mobile apps are designed to help pump owners quickly and easily i nd the tools to support pumps installed in the i eld and pumps being built and shipped. Users can locate specii c pump information with quick bar scanning or manual entry. Both apps allow users to review the Chemical Compatibility Guide using the interactive guide, access the latest full line catalogs, and watch service and repair training videos. Although not yet available for Android or Blackberry, users with these devices can use the web version, which allows access to many of the mobile app’s tools.


Pump Energy Savings Calculator Rockwell Automation, Inc.

Rockwell Automation addresses rising energy costs with h e Pump Energy Savings Calculator app. h is app compares conventional l ow control methods with PowerFlex drives and shows the dif erential power consumption of each. It calculates the potential energy savings of using variable frequency drives to power pumps and fans. Users can calculate energy consumption by entering the minimum pump or fl ow percentages, annual operating hours, cost per kilowatt and other information about their facility or by using the built-in sample data provided by Rockwell Automation.

Free / Android, iPad, iPhone, Blackberry

20W

i klWREADERS CHOICE

Xylect Mobile Xylem Inc.

Xylect Mobile is designed to give users quick and easy access to detailed product information from any location. Since users ot en work on site, the ability to access this information is important. h e app allows users to input specii c requirements and search for the ideal product to meet their needs. It gives users the ability to search by application or product type, input required l ow and pump head specii cations, and identify all available spare parts for a product by inputting the product’s serial number. It also allows users to search products from a dei ned duty point (l ow and head) and from a product denomination.

Free / Android, iPhone, iPad

TDH Pump Calculator Rain for Rent

h e TDH Pump Calculator provides users with a tool to estimate hydraulic conditions required for pump systems. h e app is designed for engineers, i eld operators and technicians. It is based on Hazen-Williams equations, and users can enter the hydraulic parameters of the pumping system. h e app will return the total dynamic head (TDH). It is useful in the i eld or oi ce. Intuitive controls allow users to simulate any combination of pre-loaded valves and i ttings.


20

iled product infoREADERS CHOICE

NEWS


NEW HIRES, PROMOTIONS & RECOGNITIONS

TIM CALLANDER, SJE-Rhombus

DETROIT LAKES, Minn. (Feb. 6, 2013) SJE-Rhombus announces the addition of Tim Callander as regional sales manager for their wholesale controls product line. He will sup-port customers in the central region of North America from Texas to Canada. SJE-Rhombus is a control solutions provider for the water and wastewater industry. www.sjerhombus.com

GREG DUNCAN & CHRIS DISTASO, Pump

Solutions Group

OAKBROOK TERRACE, Ill. (Feb. 1, 2013) Pump Solutions Group (PSG) named Greg Duncan senior director of business develop-ment and Chris Distaso director of engineer-ing. Duncan will be responsible for leading the organization’s growth and proi tability ef orts. Distaso will be responsible for the overall supervision and management of the Research and Development function. PSG is a business unit within Dover Corporation and manufac-tures positive displacement pumps and related technologies. www.psgdover.com

STUART CAMPTON, Precision Polymer

Engineering Ltd

BLACKBURN, England ( Jan. 28, 2013) Precision Polymer Engineering (PPE) appointed Stuart Campton as new distribu-tion manager for its EMEA (Europe, Middle East and Africa) sales territories. h is is a new role to enhance the support that PPE gives to exist-ing dealers and distributors and to identify new partners in new geographies. PPE provides o-rings, technical moldings and sealing solutions to a diverse range of industries. www.prepol.com

MICHAEL JAMMAL, RACO Manufacturing and

Engineering Company Inc.

EMERYVILLE, Calif. ( Jan. 29, 2013) – RACO Manu-facturing and Engineering Company Inc. announced the addition of a new director of engineering and manufactur-ing. Michael Jammal, former program manager at Rockwell Automation, joins the RACO team and will oversee

engineering, engineering-related departments, and new business growth and development. RACO Manufacturing and Engineering Co. provides municipalities, industry and government with remote communications systems and RTUs for data logging, alarm auto dialing, remote monitor-ing, reporting and control. www.racoman.com

ERIC FORD, Graphite Metallizing Corporation

YONKERS, N.Y. ( Jan. 28, 2013) – Graphite Metallizing Corporation named Eric Ford vice president of sales and marketing. Ford joined Graphite Metallizing in 2007 as director of sales. Graphite Metallizing manufactures GRAPHALLOY, a graphite/metal alloy that is a unique self-lubricating bearing material used in machinery and pro-cess equipment. www.graphalloy.com

AROUND THE INDUSTRY

BIO-MICROBICS and HELD & ASSOCIATES Meet with

Nigerian Delegation

SHAWNEE, Kan. ( Jan. 30, 2013) – Bio-Microbics, Inc. and Held & Associates, Inc., hosted an event welcoming the visiting delegation of the U.S. Ambassador to Nigeria. h e purpose of the visit was for the Delegation to participate in AG CONNECT, an international trade show for the agri-culture industry. Bio-Microbics is a manufacturer of decen-tralized wastewater. www.biomicrobics.com

NATIONAL PUMP & COMPRESSOR Opens New Branches

BEAUMONT, Texas ( Jan. 24, 2012) – National Pump & Compressor (NPC) starts 2013 with the opening of three new locations in Williston, N.D.; Fort Collins, Colo.; and Wilmington, Del. In addition, NPC announced the grand opening of the branch in Bakersi eld Calif. NPC produces industrial pumps, industrial compressors, industrial dryers, and related equipment for the industrial, petrochemical, rei nery, construction, marine, oili eld, municipal, environ-mental and mining industries. www.npcrents.com

MCILVAINE COMPANY Revises Growth Forecast

CHICAGO ( Jan. 22, 2013) – McIlvaine Com-pany has revised its forecast for growth in the industrial valve industry over the next i ve years. h e current forecast is for 5 percent

Tim Callander

Stuart Campton

Greg Duncan

Chris Distaso

Continent 2013 ($ Millions)

Africa 2,913

America 15,483

Asia 23,956

Europe 13,340

Total 55,692


growth. h is is being revised to 5.5 percent CAGR for the 2013 to 2017 period. h e basis is the increased anticipated revenues from the sales of smart valves. h is is the latest forecast in Industrial Valves: World Markets published by the McIlvaine Company. McIlvaine Company is a market research company. www.mcilvainecompany.com

FLUKE CORPORATION Recalls Digital Clamp Meters

EVERETT, Wash. ( Jan. 21, 2013) – Fluke Corporation is recalling certain digital clamp meters that were manufac-tured between Sept. 1, 2010, and Oct. 31, 2012. Certain Fluke 373, 374, 375 and 376 Digital Clamp Meters are af ected by the recall. If you own one of these clamp meters, please stop using it immediately, and send it back to Fluke for repair. h e printed circuit assembly in these units may not be properly fastened to the test lead input jack. h is may result in inaccurate voltage readings, including a low or no voltage reading on a circuit energized with a hazardous voltage, presenting a shock, electrocution or thermal burn hazard. Fluke Corporation is a manufacturer of compact, professional electronic test tools. www.l uke.com

HYDRAULIC INSTITUTE Publishes New Standards

PARSIPPANY, N.J. ( Jan. 18, 2013) – The Hydraulic Institute (HI) has published ANSI/HI 9.6.1–2012 Rotodynamic Pumps Guideline for NPSH Margin.

MERGERS & ACQUISITIONS

NSF INTERNATIONAL

acquires INASSA Group LLC Jan. 29, 2013

BILFINGER

acquires Johnson Screens Jan. 22, 2013

DANFOSS

acquires ownership of Danfoss Turbocor Jan. 21, 2013

AES ENGINEERING LTD GROUP

acquires AVT Jan. 16, 2013

SKF GROUP

to acquire Blohm + Voss Industries Gmbh Jan. 9, 2013

SULZER METCO

acquires Protective Coatings LLC Dec. 19, 2012

For details about industry M&A activity subscribe to

Pump Industry Insider and visit www.pump-zone.com.


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NEWS

HI also updated the 1998 edition of the ANSI/HI stan-dard on pump intake design and published ANSI/HI 9.8–2012 Rotodynamic Pumps for Pump Intake Design.

In addition, membership in HI has been opened to pump and supplier companies that manufacture wholly outside North America but who sell into the North American market. h is change signii cantly expands HI membership opportunities globally.

h e Hydraulic Institute’s mission is to be a value-adding resource to member companies, engineering consulting i rms and pump users worldwide. www.pumps.org

XYLEM Expands into the Middle East

ABU DHABI, UAE ( Jan. 16, 2013) – Xylem Inc. will expand its presence in the Middle East region with the open-

ing of a new oi ce in Saudi Arabia in the coming months, as well as up to three additional oi ces in other key regional markets later this year. Xylem is a global water technology provider. www.xyleminc.com

KIRLOSKAR BROTHERS LIMITED

Inaugurates New Delhi Facility

NEW DELHI, India ( Jan. 11, 2013) Kirloskar Brothers Limited (KBL) inaugurated its second Authorised Refurbishment Centre (ARC). h e facility will of er services such as overhauling pumps, impeller bal-ancing, hydro testing, corrocoating, performance enhancement, testing, shot blasting and painting. Kirloskar Brothers Limited is a global l uid management company. www.kirlos-karpumps.com

Clean Water Groups Collaborate to

Shape the Utility of the Future

WASHINGTON ( Jan. 13, 2013)The National Association of Clean Water Agencies, the Water Envi-ronment Research Foundation and the Water Environment Federation have jointly released a document that dei nes the evolving environmental, economic and social roles that clean water utilities are playing in their communities.

h is new “Water Resources Utility of the Future” will transform the way traditional wastewater utilities view themselves and manage their opera-tions. h e document explores how traditional, publicly-owned treat-ment works have mastered their core

Disclo Corp. | Santee, CA | Phone 619.596.3181| www.Disclo.com

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These features give Disclo the ability to produce a superior

product that will signiicantly outlast all other pumps in the market.

Disclo disc pumps reduces operational costs saving hundreds of

thousands of dollars in parts, maintenance and product loss.

For more information contact @disclo.com

Disclo Disc Pumps work on the principles of

boundary layer and viscous drag to produce

pulsation free laminar low.



APRIL WQA AQUATECH USAApril 2 – 5, 2013

Indianapolis Convention Center

Indianapolis, Ind.

630-505-0160 / www.wqa.org

ENDRESS+HAUSER APRIL TRAINING

SCHOOLSApril 8 – 10, Flow School-Introductory

Memphis, Tenn.

April 23 – 24, Pressure & Temperature School

Matthews, N.C.

317-535-7138 / www.us.endress.com

SWPA PUMPING SYSTEMS AND

CONTROLS TRAINING SEMINARApril 17 – 18

Hotel InterContinental O’Hare

Chicago, Ill.

847-681-1868 / www.SWPA.org

CALENDAR

wastewater treatment function and are now redei ning themselves as resource recovery agencies and vital community enterprises.

ITT GOULDS PUMPS’ Heart of

Industry Award, Pulse of Industry

Honor Roll Nominations

SENECA FALLS, N.Y. ( Jan. 10, 2013) – ITT Goulds Pumps is now accepting nominations for the Heart of Industry Award and the Pulse of Industry Honor Roll. h e Heart of Industry Award recognizes industrial operations for excellence in using pump technology to improve plant processing, satisfy customers and enhance our modern way of life. h e deadline is March 1, 2013.

ITT Goulds Pumps is a manu-facturer of pumps for a wide range of industrial markets. www.gould-spumps.com

HYOSUNG GOODSPRINGS

Announces Supplier Agreement

with Siemens

PITTSBURGH (Nov. 20, 2012) Hyosung GoodSprings announced that Siemens selected the company as the supplier for condensate extraction pumps (vertical can) and conden-sate recirculation pumps (API 610) for i ve combined cycle plants being constructed in Texas and Argentina. Hyosung GoodSprings also delivered its i rst circulating water pumps in the U.S. to a geothermal power plant in northern Nevada.

Hyosung GoodSprings manufac-tures pumps. www.hsgoodsprings.com

P&S

To have an item considered for News, please

send the information to Amanda Perry,

[email protected]

Xylem brings you dewatering solutions from Godwin and Flygt. Godwin NC series Dri-Prime® pumps incorporate Flygt N-technology for non-clog performance, sustained high effi ciency and long-term energy savings.

These 3-, 4- and 6-inch pumps offer fl ows to 1,750 gpm and heads to 200 feet. Their ability to handle stringy sewage is second to none. The automatic self-priming system primes and re-primes from dry to 28 feet. Let us show you what our NC series pumps can do. Also available in Heidra® hydraulic submersible pumps.

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godwinpumps.com


PUMP ED 101


By Joe Evans, Ph.D.,

PumpTech, Inc.

P&S Editorial Advisory Board

Branch-Line Pumping and Other OptionsLast of Two Parts

Last month, this column reviewed several examples of open l ow, branch-line pumping applications. We used

the Branch Line Pumping Calculator (available at www.PumpEd101.com) to compare a branch-line system with two dif erent discharge elevations to a multi-line system that used two individual pumps. Based on the input data, the multi-line system was more ei cient, and its breakeven point was barely more than 2 years.

ALTERNATIVE SYSTEMS

In addition to multi-line, multi-pump systems, a system designer has several other alternatives to open-ended, branch-line systems with multiple elevations. One of the most common is the tank-based system. In this type appli-cation, a storage tank is installed at or above the upper most elevation. A lower l ow pump is used to keep the tank i lled, and gravity supplies water, under pressure, to the lower ele-vation discharge points.

One of the more common examples is a municipal water supply system. Elevated tanks or those located on hillsides use gravity to supply pressure to the surrounding areas. Another example is high-rise buildings. Many older build-ings use roof-mounted tanks to supply pressurized water to the upper l oors. One more option is to use a single-service line with two or more pumps operating in series. Figure 1 compares this design to an open-branch system.

SYSTEM COMPARISON

h e upper pipeline shown in Figure 1 is the same open-l ow, branch-line design illustrated in Part 1. h e pump at Point A produces 600 gallons per minute (gpm) at a total dynamic head (TDH) of 200 feet and supplies outl ows of 400 gpm and 200 gpm at branch Points B and C. h e power required to meet the two branch l ows is 43.2 horsepower. h e high horsepower is required because the total head seen by the pump is directly proportional to the elevation at Point C.

h e pumping system in the lower portion of Figure 1 is dif erent. h e pump at Point A still provides 600 gpm, but since it is pumping to Point B only, its discharge head is reduced to 100 feet. A second pump, located at Point B and operating in series, moves the remaining water to Point C. h is design reduces the total power required by 33 percent. h is results in a smaller pump at Point A that requires 21.6 horsepower and an even smaller one at Point B requiring just 7.2 horsepower. Figure 2 is the calculator portion and compares the variables involved in these two alternatives.

As in the coni gurations in Part 1, the required data are entered into the yellow cells, and the column to the let is the open-l ow, branch-line system. h e two columns in the middle represent the series system from Points A to B and B to C. h e initial cost of the branch-line system is $44,000.

When converting to a series system the cost is reduced by $8,000 because of the smaller pump required at Point A.

h e additional pump and controls required at Point B adds an addi-tional $11,000 to the cost of the series system. h erefore, the total additional cost for the series system is $3,000. Based on an annual electrical savings of about $3,300, the payback is less than one year.

For this example, the series system is more ei cient than the single pump system. It also trumps the two pipe-line design shown in Part 1 of this series. h e horsepower required for the series system and the two pipeline design are exactly the same, but the lower piping cost of the series system makes it a more cost-ef ective system.

Figure 1. Comparison of a single service line with two or more pumps operating in series to an

open-branch system


As I stated in Part 1, my branch-line pumping calculator is not a design tool. Instead, it is an evaluation tool that allows you to compare traditional branch-line systems with

several alternatives. Once a choice is made, any number of sot ware systems can assist with the design phase. h e Branch Line Pumping Calculator can be downloaded from

the “Pump Evaluation, Selection & Testing Tools” page at www.PumpEd101.com. P&S

Note: Part 1 (February 2013) of

this series contained an error. When

describing Figure 2, I said that Point

A was at an elevation of 100 feet and

Point B is 100 feet higher. Point A

should have been Point B and Point

B should have been Point C.

Joe Evans is responsible for customer and

employee education at PumpTech, Inc., a

pump and packaged systems manufacturer

and distributor with branches throughout

the Pacii c Northwest. He can be reached

via his website www.PumpEd101.com.

If there are topics that you would like to

see discussed in future columns, drop him

an email.Figure 2. The Branch Line Pumping Calculator computations of the systems



PUMPING PRESCRIPTIONS By Dr. Lev Nelik, P.E., Pumping Machinery, LLC P&S Editorial Advisory Board

Will Impeller Velocity Triangles Keep You Awake at Night?Last of Two Parts

Apparently, impeller velocity triangles do keep some folks awake at night.

Part 2 contains information that is similar to what was discussed in Part 1, but it includes more detail regarding the vectors for each vane outlet at the same location for the three types of impellers. h is detail will hopefully make the interpretation of the triangle more realistic.

We have shown only three positions on each type to pro-vide the best possible illustration without sacrii cing clarity. h is also helps show, more clearly, the velocity vectors on Figures 1 and 2 from Part 1.

As shown in Figures 1 and 3, the locations for the backward and forward vane inlets are dif-ferent, assuming that the same inlet vane angle is maintained. Note that the impeller curvature (inlet and outlet) is set by a cir-cumference used to i x the rela-tive inlet and outlet velocities. A tangent is drawn to the inlet and outlet from the center of the circumference. Inlet and outlet peripheral velocities are drawn using tangents from the center of the impeller.

In the case of the radial impel-ler (see Figure 2), the vanes are straight to the center of the cir-cumference. Any vane curvature is ignored for simplicity.

Note that for the turbopump (see Figure 4), the l ow vectors for its turbine wheel, which has

the l ow direction reversed compared to the pump impel-ler, are shown as inl ows rather than outl ows like the other examples. In particular, note the match between the vectors at the inlet of the pump and the outlet of the turbine wheel.

We also assumed, for simplicity, that the tangential veloc-ity components at the pump impeller outlet can be consid-ered equal to the turbine inlet and the turbine outlet equal to the pump inlet.

u2

2

W2

u2

W2

v2

2

v

2

v2

Figure 1. Backward-bladed centrifugal impeller (β < 90 degrees)

Editor’s Note: Lev Nelik received many comments on this subject after Part 1 (Pumps & Systems, January 2012). Alberto Delgado, a former process engineer with Brown & Root, provided interesting feedback and detailed fi gures that resulted in several exchanges of ideas between the two. h is infor-mation is presented as a follow up on this advanced and specialized subject of pump hydraulic design and is coauthored by Delgado.


h e following legend applies to Figures 1 through 4, which are used to illustrate the velocity triangles:

U = rotational, peripheral, tip velocity vectorv = absolute resultant velocityW = relative velocity to blade tipα = absolute vector angle

β = blade vane angleω = angular, rotating velocity P&S

Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machinery, LLC, an Atlanta-

based i rm specializing in pump consulting, training, equipment troubleshoot-

ing and pump repairs. Dr. Nelik has 30 years of experience in pumps and pump-

ing equipment. He can be contacted at www.pump-magazine.com.

Alberto Delgado is a retired process engineer who formerly worked at Brown

& Root.

v2

u2

2

W2

v3

u3

3

W3

W 2v 2

u 2

3

W 3

u 3 v 3

2v

2

v

W4

u4

v4

1

W1

v1

u1

v

4

1

v

u2

2

W2

W2

u2

2

v2

v

2

v2

W2

u2

u2

2

2

v

2

W2

v2

v2

Figure 4. A pressure recovery hydraulic turbine, backward bladed (left) and a turbopump, forward bladed (right)

Figure 3. Forward-bladed centrifugal impeller (β < 90 degrees)Figure 2. Radial-bladed centrifugal impeller (β < 90 degrees)

SPECIAL REPORT


More than 90 percent of all pumps in many dif erent industries are centrifugal pumps. Variable-speed, large

centrifugal pumps are well-known for critical and large pumping services. Centrifugal pumps exhibit a suitable operating curve compared to other pumps (for example, axial pumps and positive displacement pumps of er relatively steep curves). h e curve characteristics can be matched with the system requirements. A more backward angle could make a higher reaction (from the pump impeller) and a relatively steeper curve.

As pump stages are put together, the overall l ow range of the combined stages could be less than the smallest l ow range of the individual stages. Because of the compound-ing ef ect, as the l ow is changed, the combined curve of a multistage pump could have a smaller operating range.

When developing a pump system and before specifying and purchasing a pump, many factors should be considered—including the application, installation, lubrication system, pump operation and pump noise generation. h ese consid-erations are discussed in the i rst part of this article. Part 2 will be in the April 2013 issue of Pumps & Systems.

PUMP SPECIFICATION AND PURCHASE

h e pump operation conditions should be divided into a set of normal conditions and a set of abnormal conditions. h e entire anticipated range of operating conditions should be dei ned either by range limits or alternative operating con-ditions. Unusual operating conditions, even insignii cant ones, should be indicated when developing a list. All avail-able details should be shared with the pump manufacturer.

Above: An example of different pump sizes/models in a pump family. These are sealless magnet drive ANSI pumps. Six models

are in this family.

Pump Specii cation, Purchase, Installation & ApplicationSharing all the information about an application can help with the selection and installation of the ideal pump.

First of Two Parts

By Amin Almasi, WorleyParsons Services Pty Ltd.



In many cases, insignii cant system or environmental condi-tions can cause considerable problems. Examples could be corrosive traces in the liquid, even if they are in the parts-per-million level.

h e purchaser should know as much as possible about the system in which the pump will be installed and the l uid that the pump/system will move and then inform the manu-facturer. Particularly, the purchaser should be aware of any unusual conditions and potential upsets that could af ect the pump. An example is the liquid temperature runaway potential in some hot liquid units. h e pump specii cation should note all expected maximum temperature values, and the pump vendor should be asked about the maximum tem-perature that the pump can handle.

Another example is the potential of the sudden dead-heading of a centrifugal pump when switching operations during some batch-type processes. h e pump manufac-turer should also be informed of any fouling potential. h e potential pump conditions should be carefully explored and any fouling potential should be noted. By correctly includ-ing the fouling potentials in the description of the system conditions, the pump vendor may be able to include a solu-tion—such as additional head margins—when selecting/manufacturing the best pump for the application.

h e pump requisition should include a complete list of the scope of supply and service (preferably in a table format). h e pump nozzle orientation is important as well. Ideally, the nozzle orientation details should be agreed upon with the pump manufacturer from the beginning.

Do not assume that the pump vendor is completely knowl-edgeable about the material requirements for the system/process. Stating the minimum material of construction requirement can help the pump vendor during the pump design/selection phase and avoid future problems. h e vendor’s focus is to provide a pump that is compatible with the specii cations and reliable enough to cover the vendor’s guarantee period at the minimum possible cost. With the proper wording of the pump specii cations, the minimum material requirements can be noted. It can also invite com-ments that may reveal the vendor’s experience with pump material selection.

A large number of unscheduled shutdowns are traced back to the vendor design; the vendor material selection; or the component selection—such as seal problems, bear-ing issues, excessive fouling, high degradation, corrosion, erosion and other factors. However, these problems actually rel ect a lack of application knowledge, which could have

been prevented if the purchaser communicated improper specii cations. A good example is the use of austenitic stain-less steels, which are normally considered premium materi-als. However, they cannot be used if chlorides are present in the pumped liquid because of intergranular corrosion and subsequent cracking problems.

h e orientation of the inlet piping and its inl uence on pump performance is important. h ere should be neither pre-rotation nor anti-rotation. h e l ow should be free from random distortion. Based on the design, the liquid veloci-ties and the system/process conditions, a minimum length of straight pipe may be required before the pump inlet.

BID EVALUATION FOR PUMPS

A bid evaluation should be made that factors the energy cost, i rst cost and reliability issues using an established eco-nomic equation. If the data are available, the total cost of ownership can be estimated, which is the best available mea-sure for the bid evaluation of a pump. It is absolutely nec-essary to i x all items and clarify all issues before the pump purchase order placement. Until the vendor is sure he has an order, he will stay in a trading posture.

h e successful bidder becomes the vendor when a con-tract is written and accepted. h is is important because the clock has started at this time, and all future dates will be ref-erenced back to this date. h is also is the date from which the pump delivery is counted.

Figure 1. An example of different pump sizes in a pump family

SPECIAL REPORT


PUMP LUBRICATION SYSTEM

Based on some reports, considerable reductions in the oil l ow of the manufactured lubrication oil system can occur compared to the initially-proposed system that was included at the biding stage. h e purchaser and vendor have many discussions and debates regarding this issue.

In some cases, the lubrication system’s capacity can be reduced by 20 to 30 percent, occasionally by as much as 40 percent for some large and critical pumps. h e proposal technical data (the bid technical details) are not i nal and some modii cations could be expected.

However, an oil l ow reduction of more than 25 per-cent, compared to the purchase order, should not usually occur. Any reduction in excess of 30 percent would require a detailed justii cation. h e vendor should supply the data and the basis for any oil l ow reductions that occur, particu-larly any signii cant reduction in the oil l ow of the hydrody-namic bearings. Sui cient oil supply to the hydrodynamic bearing(s) and the gear units is always a concern.

PUMP INSTALLATION

How and where the pump/pump system will be installed must also be considered. h e prime function of the pump foundation is to hold the pump train in alignment during all operating modes. To perform this function, the foun-dation should be rigid. Establishing and maintaining the alignment between pump train components—particularly for large pump trains delivered in several skids—is dii cult if the foundation is prone to excessive del ections.

h e foundation should be large enough to prevent exces-sive dif erential del ections and dynamic vibrations, which can have considerable ef ects on long-term operation. Another aspect is the foundation’s natural frequency. h e foundation should be tuned in such a way that any founda-tion natural frequency is not in coincidence with any of the pump train excitation frequency. It is desirable to have all the foundation’s natural frequencies well above any pump excitation speed, as far above as practical.

Ideally, the pump can be placed on the foundation, aligned and grouted, and piping can be connected according to the pump installation procedure. Lags ot en occur between dif-ferent steps. Carelessness can delay start-up and could result in an unsuccessful pump installation. More details on instal-lation will be covered in Part 2 in the April 2013 issue.

PUMP OPERATION

In many cases, the main contributors to centrifugal pump problems are related to the seal, the bearing and rotor

dynamics. Long slender rotors can cause problems in cen-trifugal pumps. Some high-speed pump rotors are subjected to critical speeds, which are encountered during startup (particularly in high-pressure pumps).

Sensitivity to unbalance can also cause operational prob-lems. During operation, as time passes, pumps experience degradation, which usually manifests in ever-increasing levels of unbalance. h e more sensitive the rotor, the shorter the runtime.

In many cases, the decision to replace or redesign a pump train component was incorrect. An incorrect diagnosis or wrong interpretation of the reason for a pump failure some-times results in a solution that appears to i x the problem.

However, if it is incorrect, the solution could possibly lead to worse problems in the future because an incorrect symptom-cause relationship is established. Careful problem solving should accurately determine the real cause of a prob-lem and prevent complications.

h e cleanliness of the liquid stream is a key factor, as well, for smooth pump operation and reliability. h e corrosive substances and traces require a special material selection and operation considerations. Fouling because of contami-nation or liquid reaction can cause rapid degradation.

PUMP NOISE

h e overall sound pressure level is generally based on 1 meter from the pump skid’s edge. h is means that the sound pressure level of each component at 1 meter from the skid’s edge could be dif erent, usually lower for the large pump packages, than the indicated noise value for each compo-nent, which is the noise at 1 meter from that component. h e pump package noise is not simply the sum of the noises of dif erent package components.

Figure 2. An example of a belt-driven ANSI pump—the ANSI pump

design can sometimes help overcome issues, such as space

restrictions or low NPSH.



h e gear unit, if used in a pump package, is the major source of noise. For the noise emission of a gear unit, the design of the gear unit has more inl uence than the trans-mitted power. A gear unit may generate the same noise or sometimes a slightly higher noise during part-load opera-tion compared to full-load operation. As another example, a 1-megawatt gear unit and a 1.5-megawatt gear unit using the same design principles may generate practically the same noise level.

h e pump vendor’s sound calculation programs usually do not simulate any sound boundary condition near the pump package. For example, the boundary conditions (such as a wall close to the pump skid) can inl uence the noise measured in the plant. h erefore, an allowance is needed to accommodate for this ef ect. Based on experience, an increase of around 3 to 5 decibels of the expected sound level for a pump package is observed at some unfavorable boundary conditions.

CONCLUSION

When the pump user and the pump vendor work together as a team and if all the engineers involved give sui cient

attention to details, changes and requirements, reliable and high performance pumps can be expected. h e keys to suc-cess are up-to-date knowledge, correct specifying, proper review of pump vendor documents, correct inspection of vendor activities, and modern operation and maintenance policies. h e true proi tability and cost savings in a pump installation can only be achieved by combining perfor-mance, reliability, safety, availability and maintainability. See the April 2013 issue of Pumps & Systems for more infor-mation on installation and alignment. P&S

Amin Almasi is lead rotating equipment engineer at

WorleyParsons Services Pty Ltd., Brisbane, Australia. He pre-

viously worked at Technicas Reunidas (Madrid, Spain) and

Fluor (various ofi ces). He holds a chartered professional

engineer license from Engineers Australia (MIEAust CPEng

– Mechanical) and a chartered engineer certii cate from

IMechE (CEng MIMechE), RPEQ (Registered Professional

Engineer in Queensland). He specializes in rotating machines including cen-

trifugal, screw and reciprocating compressors, gas and steam turbines, pumps,

condition monitoring and reliability. Almasi is an active member of Engineers

Australia, IMechE, ASME, Vibration Institute, SPE, IEEE, and IDGTE. He has

authored more than 60 papers and articles dealing with rotating machines.

Almasi can be reached at [email protected] or +61 (0)7 3319 3902.

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COVER

SERIES


COVER

SERIES

AgriculturalIrrigation & Dewatering

Phot

o co

urt

esy

of G

rundfo

s .



Modern agricultural irrigation is a complex interplay of sustainable energy consumption, water use,

market conditions, and the application of experience and knowledge to ensure the best design for irrigation applications. Understanding past practices, current water and energy issues, and developments in pump technology contributes to building pumping systems that best service the needs of modern agriculture. h e agricultural market is changing rapidly, and farmers cannot rely on the technology and practices of the past.

To keep productivity high and stay competitive in the market, farmers need to focus on proi tability, which includes energy optimization and better use of water resources. Pumping systems play a vital role in providing optimized solutions for energy and water use.

WHAT IS IRRIGATION?

Irrigation is an artii cial application of water to plant roots with the purpose of assisting the growth of agricultural crops. Fertilizer and chemicals can be added to an irrigation system. Irrigation can also play a role in frost protection.

Successful agriculture depends on farmers having sui cient access to water. In the middle of the last century, the common perception was that water was an ini nite resource. Today, we know that water is a resource that must be man-aged. h is is not only a question of more mouths to feed—people consume more calories and eat more meat. h is requires more water to produce food.

Farmers must consider energy con-sumption. Energy for irrigation pumps is one of the highest single cost drivers for farmers. However, many are unaware

of the potential savings from more ef ective and ei cient energy use.

Modern agriculture requires irrigation solutions that optimize uniformity, reduce energy costs, safeguard the water resource and keep productivity at its best. h e agri-cultural market changes require greater focus on applying knowledge, experience and total irrigation solutions inte-grating all components.

WHAT TO CONSIDER WHEN GETTING WATER TO THE CROP

Irrigation starts with sourcing water for the crop from groundwater or surface water from a channel or storage

Pump Systems for Today’s Agricultural IrrigationComplex irrigation applications require customized and cutting-edge solutions.

By Vahan Bagdasarian, Grundfos

A pump system for today’s irrigation is not only about the pumps. Variable speed drives,

intelligent control and remote management all necessitate the integration of components

in an irrigation system.

COVER

SERIES


pond. Next is water treatment, if necessary, and perhaps the addition of fertilizer or chemicals. Finally, water is delivered to the crop using dif erent techniques—such as l ooding, sprinkler irrigation or drip/micro-spray applications.

Mechanized sprinkler systems, such as pivot irrigation, are ef ective for covering large areas. h ese systems are typically

attached to a pump that can supply the necessary amount of water, pressure and signii cantly more, as a precaution. A valve handles the excess l ow and pressure.

Drip and micro-spray irrigation are used for low-pressure applications in which reducing as much potential evapora-tion and run-of as possible is a requirement. Keeping the

pressure constant is vital to ensure uniform application throughout each zone in the system. h is can be the most energy-ei cient method of irrigation, if managed properly. Achieving this requires that the system be able to compensate for vari-ations in l ow to ensure constant pres-sure as zones cut in and out.

TRADITIONAL APPROACHES AND

PUMPING SOLUTIONS

Groundwater withdrawal has typi-cally involved submersible or vertical turbine pumps that bring water to the surface. For surface water intake, centrifugal pumps in dif erent con-i gurations, split case pumps and end suction pumps have been traditional solutions.

h ese pumps are required to meet changing conditions above and below ground, which have an ef ect on the pressure and l ow required from day to day and from season to season. A pumping system must deliver the right amount of pressure and l ow at the nozzle. h e simple solution is to oversize the pump, so the pump is able to handle a worst case scenario. However, as a result, the pump will almost never operate at its optimal duty point. It will produce too much pressure and consume too much energy, which is not used produc-tively in any way.

Traditionally, water has been dis-tributed from the water source—either groundwater or surface water—at low or constant pressure from pumps operating at single speed. Delivery to the crop has been from




nozzles, where the focus has been on surface coverage, without much atten-tion placed on run-of , canopy evapo-ration and wind drit . Soil moisture monitoring to ensure an even spread over the irrigated area is a relatively new discipline.

In contrast, pressure management has long been an issue. h rough the years, pressure reduction valves have been used to reduce pressure in the system. However, valves are costly to install and require frequent service and replacement, and their operation consumes a lot of energy.

If end users think of an agricul-tural irrigation system as a car and the pump as the motor, would it make sense to drive the car at constant full throttle and control the speed with the brakes? h is is a common approach for irrigation pumps.

MEETING THE CHALLENGES OF

MODERN AGRICULTURE

Complete pumping systems instead of large, isolated pumps are the solu-tion going forward. For example, the costly and time-consuming use of pressure reduction valves to maintain constant pressure can be eliminated by investing in pump controllers for ef ective pressure management. h is saves costs in the long term, reduces the need for service and minimizes energy consumption.

h e same can be said of using valves in sprinkler irrigation. Using a vari-able speed pump and a pressure sensor on the pivot, which would automati-cally adjust the pump performance to match the requirements for the pivot, is a much better approach. h is would ensure higher irrigation uniformity and keep energy costs down. A pump controller of ers the additional advantage of protecting the pump from dry-running or power supply

To keep productivity high and stay competitive in

the market, farmers need to focus on proi tability,

which includes energy optimization and better use

of water resources.

To learn more about the M2L 3000,

visit http://benshaw.cwfc.com,

call 412-968-0100 or e-mail

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COVER

SERIES


irregularities, which will extend the lifetime of the pump. h e rises and falls in water level, below ground and for

surface water, essentially change the specii cations for a pumping system because these variations change the head. A single speed pump dimensioned to lit from the lowest water level will burn energy dollars when the level is high. On the other hand, a variable speed pump adjusts its head and l ow to compensate for water level changes, reducing energy costs.

DESIGNING AN IRRIGATION SYSTEM FOR

TODAY’S APPLICATIONS

Farmers and pump system providers need to think through the specii c irrigation applications in new ways, and in par-ticular they need to think about irrigation system design in the application. h e pumps must be much more integrated with the rest of the irrigation system. h is means the pump must be designed to match the irrigation equipment or the irrigation equipment must be designed to match the pump.

h e current approach of simply installing a pump capable of always delivering more than enough water ends up wast-ing money and energy. Returning to the aforementioned metaphor, which compares the system to a car and the pump to its motor: Purchasing an over-sized motor to place

in a car will end up a costly af air and of ers no guarantee of a comfortable or fuel-ei cient ride.

h ink about this in an irrigation system, in which the pump must do more than simply deliver water to the pipes to be ef ective. For example, adding variable speed drives improves the ei ciency of groundwater withdrawal when pumping directly into an irrigation system. Surface water intake and distribution can be improved by using multi-pump pressure boosting systems. Across the board, moni-toring and control systems further safeguard the reliable l ow of water by protecting the pump from dry-running, motor breakdown or power supply irregularities.

All these elements must be fully integrated into the design to provide the benei ts that a modern irrigation pump system can of er the farmer. Maintaining correct pressure and l ow in the pipes and at the nozzle means more water per kilowatt hour and savings on energy, which is one of the highest cost items in farming.

Earlier, the importance of maintaining a constant pressure in a pivot irrigation system was explained. h is becomes rel-evant if the pivot is equipped with an end gun and maybe even a corner section. As soon as the end gun or corner section comes on, the pressure in the pivot’s main line will drop. h is will impact the irrigation uniformity.

The range of pump applications in agricultural irrigation is many and varied. The

key to success is intelligent pump controls that are designed specifi cally for

each application.

Figure 1. If a pump is specifi ed to run continuously at

the highest level—for example when the corner section

comes on—energy is wasted. The different requirements

for optimal energy use on a pivot application can be met

by using a variable speed pump. This offers substantial

energy savings while maintaining pressure requirements.



h e solution is to replace the pivot’s main pump with a variable speed pump, which will immediately react to a pres-sure drop when an end gun or corner section cuts in. In such a coni guration, it is possible to maintain the same pressure on all the sprinklers and, therefore, deliver high uniformity (see Figure 1).

THE FUTURE: TOTAL SOLUTIONS,

TAILORED TO THE APPLICATION

h e development in irrigation sys-tems described in this article reveals a need for careful consideration of the entire irrigation system and each component’s integration, tailored to the application. h is requires experience and knowl-edge. h e ability to follow water from the source to the crop—from water intake, water treatment and distribu-tion to the irrigation application—and carefully monitor it along the way is critical for an irrigation pump system.

Modern agriculture requires a broader understanding of component integration, and the system must ensure that the farmer is able to respond to issues of energy consumption and water supply, specii cally by isolating areas in which savings can be made, generating increased proi t per acre.

h is is not an exercise that can be carried out in isolation. All relevant local conditions must be added to the equation—such as soil conditions, the crop, topography and weather patterns. Pump control, including monitoring and intelligent manage-ment, is then the way forward.

Energy savings are there to be made and are substantial. h e added ben-ei t for the farmer is, in addition to the lower operating costs, that water is delivered with greater precision to the crop. h is results in a better har-vest, increased proi tability and better water management, ensuring sustain-able agriculture in the future. P&S

Vahan Bagdasarian is innovation manager, Irrigation, for

Grundfos. He can be reached at vbagdasarian@grundfos.

com. With an annual production of more than 16 million

pumps, Grundfos is a provider of pump solutions and special-

izes in circulator pumps for heating and air conditioning and

centrifugal pumps for industrial applications, water supply,

sewage and dosing. www.grundfos.us

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Of the 6.3 million farms in the U.S. in January 1925, only 205,000 received centralized electric services. Private

utility companies that supplied electric power to most of the nation’s consumers argued that it was too expensive to string electric lines to isolated rural areas, and most farmers were probably too poor to af ord it.

To rectify that situation, the Rural Electrii cation Administration (REA) was created by executive order and was charged with administering loan programs for electri-i cation and telephone service in rural areas. Between 1935 and 1939—the i rst 4½ years at er REA’s establishment—the farms using electric services more than doubled.

Even though farmers were gaining access to the power grid, they were still using diesel engines to power their pumps. One reason for this is that they had already invested in diesel. Also, in most cases there simply was not enough juice to power the farmhouse and the pump house.

By the early 1970s, about 98 percent of all U.S. farms had access to af ordable electric service. Many farmers, though, were still using engines to power their pumps and would continue to do so. Most would argue that despite some price spikes, diesel fuel was still cheaper than electricity. At er all, those diesel engines still worked. Why switch to electric?

h e trend toward switching from diesel to electric began gaining steam within the last 15 years. Environmental con-trols and regulations on the operation of diesel engines and the rising cost of diesel fuel have accelerated the conversion. Changing from diesel to electric makes sense from several dif erent standpoints.

COST

Operating and maintenance cost advantages are available when switching from diesel to electric. On the operational front, end users must consider the cost of diesel fuel. It is expensive, and likely to remain so as global demand rises. Figure 1 illustrates that running an engine on electricity is less expensive than running one on diesel. h at was not the case in 1992, but times have changed. h e economics of irri-gation pumping favor electric motors.

Figure 2 details the operating hour scenarios and cost points for diesel and electricity. It shows estimates of the total costs of operation for an irrigation pumping system. h e costs include estimates for energy, repairs, i xed cost depreciation, maintenance and service. Because each pump-ing station will be unique, the costs are an estimate, but they clearly show the economics of today.1

h e cost for electricity can vary depending on when and where it is consumed. Avoiding peak power demand times can lower the costs of electricity even further. In some parts of the U.S., irrigating at of -peak hours is a good economic idea and ot en mandated.

From a maintenance standpoint, electric motors win this battle, too. Maintenance on a diesel motor requires more time and attention than electric motors. Depending on the application, a pump engine may be required to run for extended periods if that pump drives multiple systems during the irrigation season. If so, the diesel engine will con-stantly need to be refueled and the oil levels and i lters will require monitoring.

Electric motors do not have to be refueled. h ey also do not have engine oil and i lters that must be checked and replaced. h ey only require lubrication once every season.

Powering the Pump: Diesel Versus Electric MotorsMake the ideal motor selection for irrigation applications.

By Tim Albers, Nidec Motor Corporation

Figure 1. Total annual costs in thousands to operate a 75-horsepower

irrigation pump 1,500 hours per year using an electric motor or

diesel engine. Source: Curley, Robert G. & Gerald D. Knutson,“Cost Comparison: engines vs.

electric motors for irrigation pumping,” California Agriculture, Vol. 48, Num. 5



ENVIRONMENTAL IMPACT

Perhaps the overriding motivation to change to electric, par-ticularly in the past few years, is the concern with environ-mental issues. An electric motor runs cleaner than a diesel-powered engine. Electric power plants continue to create power in cleaner ways. Also, the addition to the grid of alter-nate energy sources, such as wind and solar, provide electricity with virtually zero carbon emissions.

An electric motor allows for the use of much lower carbon emission power versus a comparable diesel engine. h e harmful environmental ef ects from internal combustion engines outnumber those from electricity.

PUMP CONTROL

In addition, installing pump controls and variable speed controls is easier on an electric motor than it is for a diesel engine. While these types of con-trols can be added to diesel engines, they are costly, and more important, they can reduce the ei ciency of the engine.

h is is not the case when adding controls and variable speed features to electric motors, which when applied correctly, greatly increase the ei -ciency and durability of the motor, improve control in pipelines and canals and reduce energy use. Electric motors can be automated and con-trolled remotely. Variable speed drives and sot starters in electric motors are components that help mitigate power surges. h e technology exists and is growing quickly based on ever decreasing costs to monitor and con-trol an electric-driven irrigation pump system remotely.

THE DECISION

Diesel engines remain in use today and for good reason. In some areas of the world, electricity is unavailable. Also, the diesel engines installed years ago continue to work today. Operators do not want to scrap something that

works to spend more money on new motors, even if those new motors will eventually pay for themselves in reduced operating costs and improved ei ciency and have less impact on the environment.

h e question becomes when to make the switch. h e answer is easy if and when that diesel engine fails. However,

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if end users’ engines are operating well, they should consider having a plan in place to switch to electric motors at some point in the future. Hopefully, they can make that switch when they want to instead of being forced to repair a broken diesel engine to com-plete the irrigation season.

h e bottom line is this—in 2013, for many irriga-tion applications, operators choose electric motors, if electricity is available, to power their pumps. P&S

Figure 2. Operating scenarios and costs for diesel fuel and electricity.

Reference

1. Curley, Robert G. & Gerald D. Knutson,“Cost Comparison: engines vs. electric motors for irrigation pumping,” California Agriculture, Vol. 48,

Num. 5.

Timothy Albers is the director of product management and OEM marketing for the

Industrial Motor Division of Nidec Motor Corporation and is responsible for product

management, marketing and quotation support. During the past 16 years, Albers has

held different positions in marketing for Nidec Motor Corporation and Emerson Motor

Company, including product-line manager for NEMA motors. Before joining Emerson, he

was employed by General Electric Company in the marketing and sales of electric motors

and drives. Albers’ career includes a stint in the U.S. Navy as an operating engineering

ofi cer. He is a senior member of IEEE.

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Mining applications are as diverse as construction or water and wastewater applications. Each jobsite has specii c

requirements and needs. Underground and open pit mines have several layout and design obstacles. Regardless of the mine and its setup, water is a mine’s biggest enemy.

Getting water out—and keeping it out—is the primary focus of any mine plan. h e deeper the mine, the more water that will be encountered and need to be removed. Once dewatering begins, mine planners can get back to what they do best.

MINE DEWATERING

A pump company or dewatering solutions provider can partner with mine planners and engineers in the design

and planning stages. A system analysis should be performed i rst. h en pump selection can begin. Factors to consider in mine planning include portability, easy maintenance and solids-handling.

Another consideration is pH. Pumps can be customized with durable materials of construction specii cally designed for low pH and other corrosive liquids.

Pump systems are completely customizable, and the right one can only be selected at er the operator or mine engineer understands the mine plan. Pump and piping design and pump control can be tailored to the mine plan. In addition to length of l ow, elevation and discharge, consider layout drawings, hydraulic grade lines and pipe wall thickness. Perform friction loss calculations.

Powerful Mine DewateringElectric and diesel centrifugal pump options

By Kristen Gurick, Godwin Pumps, a Xylem Brand

A centrifugal pump with a fuel cube



Also, consider present and future requirements. A mine’s design can change based on weather conditions, landscape vulnerability and market demands. A dewatering pump company can help design the mine plan, so mine operators and engi-neers can focus on mining. A reliable dewatering system allows them to continue working.

h e power source is another component to consider for mine dewatering pump selection. When selecting a centrifugal pump to i t their needs, many mine operators select diesel-driven centrifugal pumps. As with any other application, operators have options. h e initial setup costs should be measured against the lifetime costs of pumping for the project. For a temporary job in a mine or quarry, diesel-driven pumps will typi-cally be the most logical choice. Setup costs are virtually zero. h e pumps run on diesel fuel for the short duration of the project. If available near the mine, natural gas is also an option.

Hydraulic submersible pumps are another option for mine planning. h ese pumps feature a A diesel-driven centrifugal pump


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power pack i tted to a submerged pump. h e pump ends usually sit at varying levels of submergence, and their power packs sit above ground. h ey are ideal for abrasive i ne sand,

high specii c gravity (such as that found in slurries) and can of er a total dynamic head up to 600 feet. h ese hydraulic submersible pumps can be diesel driven or electric, depend-

ing on system requirements.

ELECTRIC-DRIVEN PUMPS

If a project is more long-running, con-sider electric-driven pumps. Electric submersible pumps have a solid history in mining applications. h ese pumps can handle moderately large l ows (up to 2,500 gallons per minute) or extreme high heads (up to 750 feet).

In addition to these submersible pumps, electric-driven centrifugal pumps are ideal for both prolonged tem-porary pumping and permanent installa-tions. Designed for long-lasting durabil-ity, these pumps were initially used in industrial and municipal applications. However, their benei ts span many more applications. A permanently installed A diesel-driven hydraulic power pack in the foreground (pumps in the background are diesel-

driven booster pumps)

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electric-driven centrifugal pump will provide reliable, con-tinuous pumping and reduced operating and maintenance costs.

While not frequently used in mining applications, elec-tric-driven centrifugal pumps are a viable option for a perma-nent installation or lengthy temporary pumping job. If the

site location is not extremely remote, an electricity source can be found and power lines run to the jobsite. Accessing electricity can outweigh the lifetime costs of a diesel-driven pumping system if the timeframe is long enough. Costs for running electric-driven pumps will eventually be the more economical choice, even factoring in initial setup costs.

For temporary jobs in which refu-eling is dii cult, an electric pump is the ideal solution. Once power lines are established, pump accessibility is almost a nonissue. Lines can be run into underground mines and bolted to the ceiling. Mine planners may not consider this option, but once designed and implemented, electric-driven pumps require less access. h ey do not need refueling, and their motors require less servicing. h ese centrifugal pumps also reduce the carbon footprint of any job.

Case Study: Electric-Driven Pumps

A gold mine had an environmental restriction that would no longer allow diesel-driven pumps, which had been operating at their site, provided by a rental company. h e mine requested a solution for a portable pumping system that could use the voltage that was available at the tailings dam. h e pumps needed to supply 7,500 gal-lons per minute (gpm) to the roaster facility (the location used to heat the ore and extract the gold) and 4,000 gpm to the autoclave system (similar to the roaster facility, but using pres-sure along with heat) at the mine.

A pump provider designed a system that used the electricity available onsite. h e electro center—the house containing the switch gear, variable frequency drive (VFD) and all the pump controls—was on a portable, structural skid and housed within an enclosure. h is unit was placed on the crest of the tailings dam. Using this solution, the company provided three

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electric-driven, 12-inch centrifugal pumps, each capable of heads up to 390 feet and solids-handling capabili-ties up to three inches. h ese pumps provided the necessary l ow rates and allowed the system to be moved up-gradient as the tailings levels rose.

DIESEL-DRIVEN PUMPS

Considering all the benei ts of elec-tric-driven pumps, diesel is still the right i t for many mining applica-tions. If no on-site power can be made available, a permanent diesel- or natural gas-driven pump is a great option. Diesel-powered centrifugal pumps come equipped with a diesel engine for stand-alone operation. h ese pumps will work on any site, no matter how remote. Engines should meet the latest emissions regulations and tier compliance standards.

Standard models of centrifugal pumps are ot en used for high-volume l ow (which can reach 15,000 gpm or more), average total dynamic heads and solids-handling capabilities. Advanced lines of centrifugal pumps are better suited to applications with high or extreme high heads, or those that are used as jetting pumps.

h e total dynamic head of these pumps, single staged, can reach or exceed 600 feet. h is means that, in a mining application, one of these high-head pumps can be sui cient to meet the pumping needs, or great heights can be achieved with just a few pumps staged together.

Safety should always be a consid-eration. When running diesel-driven centrifugal pumps in an underground mine, air should be vented in to bal-ance the diesel exhaust. h is safety condition is eliminated with electric-driven pumps.

Getting water out—and keeping it out—is the

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Case Study: Diesel-Driven Pumps

A coal mine needed to dewater its mine l oor at er a 100-year rain event. All mine operations were stalled. h e mine operators needed to get the process back online as quickly as possible. Given the amount of water, the pumps needed to supply 1,100 gpm with 760 feet of total dynamic head.

A solution was designed that required a six-man crew; 15,000 feet of high density polyethylene (HDPE) pipe; two diesel-driven, eight-inch high-head centrifugal pumps; and onsite fusion machines. All equipment was onsite within 10 days of the l ood event. h e pipe was fused on loca-tion, and the mine was quickly operational again.

CONCLUSION

When water creeps into a mine, it becomes the most important aspect of mine planning. It needs to be dewatered as quickly as possible, but a design also needs to be developed that makes the most sense for the mine. Operators must consider available power sources for the most economi-cal mine plan and reliable mine dewatering system. P&S

Kristen Gurick is a marketing communications specialist for Godwin, a Xylem

brand. She can be reached at [email protected] or 856-467-3636.

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The WQA Aquatech USA conference brings multiple water industry groups together in one event for

education, training, networking and business opportunities. h e conference attracts dif erent water industry groups including process; drinking water; and ultrapure for residential, commercial and industrial users. Attendees can develop relationships and learn about equipment, devices and innovative technology at this annual event through exhibits, hands-on training, roundtable discussions and networking events.

WQA Aquatech USA represents residential, commercial and industrial segments of the water treatment and supply market with emphasis on custom water applications from drinking, process and wastewater. It also showcases tech-nologies—such as RO; membranes; media; and supporting elements, including pumps, tanks, valves, pipes, tubing, and other key products and services.

h e comprehensive water quality forum provides the latest information, tools, resources and strategies for build-ing business. Attendees have the opportunity to connect with manufacturers, suppliers and service providers. It also

provides business and technical educational sessions and opportuni-ties to network with col-leagues and experts.

All vendors at WQA Aquatech USA can be visited in one location, enabling attendees to gain valuable industry data and discover new products and services in one place. h ousands of water industry professionals—such as water treatment dealers, engineers and end users—will attend to learn about trends inl uencing the industry. For more information, visit http://s36.a2zinc.net/clients/wqa/wqa13.

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An international technology group supplies equipment and services for hydropower stations, the pulp and paper industry, solid/liquid separation in the municipal and

industrial sectors, the steel industry and the production of animal feed and biomass pellets. h e company, headquartered in Graz, Austria, operates more than 180 production sites and service and sales companies worldwide.

h e pump division develops and manufactures customized large pumps and standard centrifugal pumps for a wide range of applications and industries, such as: • Water transport and irrigation• Energy sector (cooling water and fl ue gas desulfurization pumps)• Pulp and paper, sugar and bioethanol industries

Many years of experience in hydraulic machinery construction and comprehensive process knowledge form a solid footing for the performance standards met by these pumps. h e company is a single-source supplier—including development, model tests, design, manufacture, project management, and at er-sales service and training.

DESIGN PROCEDURE

h e pump manufacturer has developed a modern design system that consists of com-puter-aided-design-based geometry dei nition, hydraulic optimization by means of numerical l ow simulation and analysis of mechanical behavior.

For an initial impeller or guide vane design, TURBOdesign1 (design sot ware) is extensively used within the company. h e sot ware provides good solutions in a short time period, especially when starting from scratch.

h e hydraulic behavior is then evaluated by solving the full 3D-Navier-Stokes equa-tions in combination with a robust turbulence model. Based on the initial design sot -ware solution, the blade proi le is further optimized by experienced designers and inter-action with the stationary components, such as the casing, must be tuned. Finally, the progress in hydraulic design is verii ed by model test results.

APPLICATION OF THE SOFTWARE TO PUMP DESIGN

Two years ago, the sot ware was introduced to the pump manufacturer for hydraulic development of a new vertical line shat pump (see Figure 1). h is pump type is typi-cally used for irrigation and cooling water supply to thermal power plants.

Because of changing requirements, the pump’s operating range had to be shit ed to higher l ow rates and higher heads. h erefore, the company needed to develop new runner blades and new guide vanes. h e hydraulic designs were verii ed by computa-tional l uid dynamics (CFD), including all l ow-relevant components (see Figure 2).

Design Software Increases Hydraulic Efi ciencyPump manufacturer streamlines the design and production process.

By Arno Gehrer, ANDRITZ GROUP

Figure 1. Pump assembly model of a

vertical line shaft pump with adjust-

able impeller blades


RESULTS

An extensive series of measurements was carried out in the pump company’s in-house hydraulic laboratory on a fully homologous model. h ese experiments provided: • Performance data (fl ow rate, head, power and

effi ciency)

• Cavitation observations• Hydraulic forces (axial thrust, radial force and

momentum) • Stability limits (for example, pressure pulsations)

Compact Design

Compared to the old reference pump, the new design was smaller and had signii cantly higher blade loading and pro-vided greater head and l ow rate (see Figure 3). h e ei -ciency at the design point (OP1) could be improved.

Figure 2. CFD pump modelFigure 3. Model test result—head and effi ciency comparison with

reference design


EFFICIENCY MATTERS


Enhancement of Cavitation Limits

Regarding cavitation, the net positive suction head required (NPSHrequired) curve of the reference design had to be shit ed to higher l ow rates to avoid pressure-side cavitation in the start-up condition, OP2 (see Figures 4 and 5).

Finally, the new design fuli lled the fundamental condi-tion NPSHplant ≥ NPSHrequired for the whole operating range (see Figure 5), and the measurements were completed with a successful acceptance test, witnessed by the manufacturer’s

customers. In conclusion, the sot ware considerably sup-ported the pump manufacturer in accelerating the hydraulic design process. P&S

Arno Gehrer has been a research engineer at ANDRITZ

GROUP since 2001. He obtained his Ph.D. in mechanical

engineering from the University of Graz in Austria. At present,

his main focus is the hydraulic design of turbines and pumps,

both with CFD and model testing. He is leading the group for

hydraulic development & CFD.

Figure 4. CFD result, reference design (old) at OP2—pressure fi eld

and ISO surface of cavitation on the impeller blade surface Figure 5. Model test result—NPSH comparison with reference design

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MAINTENANCE MINDERS

A few years ago, I took a class to learn to be a horologist—a person who repairs antique mechanical

clocks. My instructor said that some of the students may learn to be good clock repair people, but time will tell. h at expression started with clock repair.

If a horologist does a quality job repairing a wall clock, it can be wound and will run for eight days before a rewind is needed. If the horologist repaired the clock poorly, the clock might quit at er only four days and keep bad time. h e device can be rebuilt, but the quality of the time it keeps rel ects on the horologist. Do a bad job, and time tells on you.

In a tighter economy, plants and facilities rebuild their own pumps to cut costs. Some plant managers believe that using plant personnel instead sending it out for repair is less expensive. Time will tell with pumps rebuilds, too.

I have participated in the supervision of many electrical and mechanical repairs. If an electrical mistake is made, it is known quickly. h e lights go out; sparks l y; or even worse, something melts.

However, mechanical repair mistakes are less obvious. Miss a critical step in alignment, ignore the bearing i t or allow the shat to wobble, and the pump continues to run. It pumps, but time will tell how long it will last. h e unit might only last two years when it should have lasted 10 years. At er two years, supervisors may forget who previously serviced the pump, and two years may become the normal expecta-tion. If it stopped working at er a week, management may pay more attention. Rebuilding a pump to last requires skill and a focus on detail. h is article provides steps to follow when rebuilding a pump to lengthen the time interval between repairs.

CHECK FOR PIPING STRAIN

A simple check can be made to avoid piping misalignment and the strain that it puts on critical pump components, such as bearings and mechanical seals. When the pump has been properly shut down with safety locks in place, separate the coupling between the pump and the driver.

Place two dial indicators on the pump coupling half or the pump shat if it is accessible. A good way to hold them

in place is with a magnet base. One indicator is placed on the side of the coupling half to detect horizontal movement. h e other is placed at the top to detect vertical movement.

Depress the indicators and set them at zero. h en release the bolts on the suction and discharge l anges. h ey do not have to be removed, just backed of to be i nger tight. If either indicator moves 0.001 inch or more, piping strain exists and must be corrected before re-installing the pump at er the rebuild.

h is step is ot en skipped. Chances are the new or rebuilt pump put in the same location with the same piping will have a short life because of the twist and stress induced when the piping is secured.

INSPECT BEARING FITS

Installation of anti-friction bearings involves some mea-surement steps. h e bearing is round when it is removed from the box. It has certain prescribed internal clearances that allow for smooth movement. If the shat is oversized or slightly tapered in the bearing seat or if the housing bore is “belled out,” the bearing will not remain round during operation. Roundness in a bearing means long life.

Check the housing bores and shat seats with a microme-ter capable of reading to ten-thousandth of an inch (0.0001

Pump Rebuild TipsAvoid common mistakes to get the longest life from a rebuilt pump.

By Tom Davis, Maintenance Troubleshooting

Trimming the impeller diameter to give a better performance, even if

completed on a lathe, removes unequal amounts of metal from the

cast surfaces resulting in dynamic unbalance.

MAINTENANCE MINDERS


inch) to ensure proper i t. h is step must be completed. If an end user does not know the proper dimensions, they should ask the pump vendor for a “critical dimension checking print,” or look up the proper i t using Machinery Handbook or a similar industrial reference.

Unfortunately, if a machinist fails to make a shat cor-rectly, he/she will ot en leave it slightly oversize and the housing bore a bit undersize. Metal is easier to remove than to add back, so they shoot high on the shat and low on the bore (always leaving metal that can be removed). h ey sometimes leave more than desired. h e pump bearing will install, but it will be pinched on the outside diameter (OD) or expanded too much on the inside diameter (ID) and will fail quickly. Remember, the pump bearing might last a year in this condition, but it should have lasted 10 or more if the dimensions were correct.

ENSURE PUMP SHAFT STRAIGHTNESS

Pump shat s are subjected to unbalanced impellers, worn bearing i ts, impeller rubs and other mechanical strains that can cause them to bow. With the pump shat removed from the pump during the rebuild and all other components removed, end users should take the opportunity to check the shat for straightness.

A pool player takes the cue, lays it on the pool table and rolls it back and forth. If it bumps as it rolls, it is not straight. A similar check on a shat can be completed on a shop bench with a dial indicator and two V-blocks.

Place the shat bearing seats on the V-blocks and position the indicator at the center of the shat . Turn the shat slowly while watching the indicator hand. On a 24-inch pump shat (or smaller), the indicator should not del ect more than 0.002 inch. In the 24-inch to 60-inch range, 0.003 inch is the limit. For 60-inch to 120-inch pump shat s, the del ection can be to 0.006 inch at the midpoint. If a shat is bowed in places, an unnecessary push on the bearings and seal faces occurs with each revo-lution. Seal life is reduced to months instead of years.

CAREFULLY HEAT THE BEARING

FOR SHAFT INSTALLATION

Almost all pump bearings have an interference i t between the ID of the bearing (the bore of the inner race) and the shat seat (the place where the bearing sits on the shat ). h e bearing

bore is smaller than the pump shat and must be pressed on or heated to expand the bore before assembly. An anti-fric-tion bearing is a great example of metallurgy. h e bearing companies use excellent quality control to produce a bear-ing that is hard, but not too hard, to provide a long service life. If the bearing is overheated, it becomes annealed and will not last for its intended life.

Modern shops use induction heaters or cone heaters to rapidly heat the inner race to allow shat assembly. However, the temperature-sensing mechanism on the heater can ot en be out of calibration or non-existent. In that case, the mechanic must use an infrared thermometer or temperature sensitive crayon that melts at the correct temperature value to make sure that the bearing is not overheated.

h e magic number to avoid is more than 250 F. Most good pump shops never heat them to more than 230 F to avoid the possibility that they will overheat the bearings. Overheating a bearing during assembly removes years from its life, and plant management may never know the true reason for the shortened life cycle.

SQUARE THE BEARING TO THE SHAFT SHOULDER

Improper squareness causes frequent problems. All pump shat s have a shoulder that determines the stopping point for a bearing on the shat . h e face of the inner race of a bearing should meet this shoulder all around the shat —it makes the bearing square to the shat (at a perfect right angle).

Pump manuals caution, “Make sure the bearing is square.” However, many do not indicate how. h e check is an easy one. A feeler gauge of 0.001 inch to 0.002 inch is used to see if any gap exists between the face of the inner race and the shat shoulder at the 12, 3, 6 and 9 o’clock positions.

When using a press to install a bearing, a gap is usually not present, or less chance exists of one. If thermal means are used to expand the inner race (no more than 230 F), the bearing must be held against the shat shoulder so it does not shrink away as it cools. Most mechanics may think that holding the bearing in place for a minute or two will be enough to avoid a gap. h is line of thinking is incorrect. h e bearing should be held in position for 3 to 5 minutes. h is simple step, if not performed, leads to cocked bearings and rapid bearing wear following installation.

If the bearing is not square to the shaft shoulder,

bearing misalignment occurs. Checking square-

ness is vital to ensure that a pump spins freely.


REBALANCE A TRIMMED IMPELLER

With emphasis on energy savings and a desire to operate a pump closer to its best ei ciency point (BEP), the impeller’s diameter is ot en trimmed to ensure that the pump more closely i ts the system’s requirements. h e ai nity laws are used to calculate that, for instance, a 10-inch diameter impeller should be machined down to 9½ inches to better marry the pump curve to the piping. If an end user orders a 9½-inch diameter impeller from the factory, it is dynamically balanced.

However, if a machine shop trims the impeller in a lathe, the impel-ler is unbalanced. It is a casting. h e removal of as little as ¼ inch from the diameter can result in massive unbal-ance when the pump spins at 1,750 rpm or worse at 3,550 rpm.

Asking the machine shop to send the impeller out for dynamic bal-ancing is no trouble and costs little, certainly less than the failed bearings and unplanned downtime that can occur as the pump vibrates because of unbalance. When the pump is assem-bled, that is not the time to think about balance.

Balancing must take place during disassembly. h e components can be placed on a balancing machine and corrected before reassembly. In some cases, the shat and impeller should be assembled together and balanced as a unit to ensure against excessive vibration forces. P&S

Thomas B. Davis (Tom) is a graduate mechanical engineer

who owns Maintenance Troubleshooting, a consulting i rm

specializing in assistance for corrective repair of rotating

equipment. He can be reached at mechanicalengineer@

pobox.com or 302-690-0871.

REBUILD CHECKLIST

• Check for piping strain• Inspect and verify bearing fi ts• Ensure shaft straightness• Use care when heating the

bearing for shaft insertion• Square the bearing to the

shaft shoulder• Rebalance an impeller

after trimming



SEALING SENSE

Grooved metal gaskets with covering faces, ot en called kammproi le gaskets, consist of a metal core with

grooves or serrations in each face. h ey can be supplied with or without a guide ring.

Sot material—such as polytetral uoroethylene (PTFE), l exible graphite or other high temperature facing—is applied to both sides of the concentric serrated sealing core. It is a problem solver for heat exchangers and large vessels since it provides one of the tightest seals combined with superior load bearing characteristics.

PREFERRED IN RIGOROUS APPLICATIONS

Kammproi le gaskets are a preferred design when improved performance at low seating stresses is required. h eir M values, Y stresses and other gasket constants are lower than those of grooved metal gaskets without any facings, other reasons for their preference. Metal to metal contact seals require a higher degree of loading.

While the facing materials are typically sot and easy to seal, the deep grooves keep the facing from extruding under high compressive loads or internal pressures. Kammproi le gaskets have the ability to seal at low compressive stresses, but they also handle higher compressive loads and high internal pressures, making them unique problem solvers.

DIMENSIONAL FLEXIBILITY

Another important use of kammproi le gaskets is when the exact contact dimensions of a l ange are unknown prior to opening the joint.

It may be known that an existing l ange has a raised face (RF), but its exact outside diameter (OD) may not be avail-able until the old gasket is removed. A spiral wound gasket must be sized so that the windings start and end on the l ange.

If the inside diameter (ID) of the windings is smaller than the l ange contact area or the OD of the windings is beyond the OD of the RF, the windings may buckle. h is is not a concern for a kammproi le gasket. It can hang over the RF’s OD without damaging the gasket.

TYPICAL KAMMPROFILE GASKET DESIGNS

h ree typical designs are available—a gasket without a guide ring, with a guide ring and with a loose-i t guide ring. A kammproi le gasket without a guide ring can be applied in recessed l ange applications—such as tongue-and-groove connections or a heat exchanger application—to replace double-jacketed gaskets as an upgrade design (see Figure 1). Note that when a nubbin is present in the sealing area, it is strongly recommended that it be removed when upgrad-ing from a double-jacketed design. h is type kammproi le gasket is acceptable in standard pipe l anges as long as the gasket is sized to center itself on the bolts.

Kammproi le gaskets with a guide ring are manufactured with an integral guide ring for centering (see Figure 2). h ese are recommended for application in RF, ASME B16.5 pipe l anges and also can be sized to EN 12560-6 specii cations.

Kammproi le gaskets with a loose-i t guide ring are applied to nominal pipe size and pressure class l anges and

Gaskets for Rigorous ApplicationsWhat are grooved metal gaskets, and where are they applied?

By FSA members Darine Aghnim & Dave Burgess

Figure 2. Design with guide rings

Figure 3. Design with a loose-fi t guide ring

Figure 1. Design without a guide ring


used when thermal cycling expansions and contractions are present (see Figure 3). h e gasket is designed to comply with either ASME B16.5 l ange or EN 12560-6 specii cations.

OTHER GASKET DESIGNS

h e kammproi le grooves or serrations can be applied as an upgrade to a typical l at metal washer, which can be dif-i cult to seal. Flat washers might be used on a “plug” type threaded application, where the head of the plug will turn down against the washer. Solid metal washers can be tough

to seal, of course. h ese plugs are common on air cooler or i n fan heat exchangers. Typical heat exchanger plugs with this type washer are shown in Image 1.

Kammproi le gaskets can also be designed as a dual seal solution with leak detection device incorporated into l anged assemblies. h ese might be used in critical applica-tions such as phosgene service. h ey have a primary inner sealing area with a relief section and holes on the outer por-tion of the sealing. Past these relief holes is a secondary seal-ing area that maintains the integrity of the bolted joint.

h e kammproi le design with sot facing material can also be applied on the sealing area of ring joint gaskets.

h is is an ideal solution for applications in which cracking or embrittlement has occurred in ring joint l ange grooves (see Figure 4). Kammproi le gaskets can be manufactured in Image 1. Typical heat exchanger plugs with solid metal washers


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SEALING SENSE


dif erent metal materials, shapes (circular and non-circu-lar) and custom-engineered designs to i t dif erent appli-cations. h e recommended l anges sealing surface i nish is 125 to 250 microns per inch.

CONCLUSION

Grooved metal gaskets can ef ectively seal a wide range of applications because of their unique characteristics, design l exibility and facing material options. End users should consult their gasket manufacturer for recommendations for their specii c applications. P&S

NEXT MONTH:

What are the important considerations for the proper

torque of a valve packing gland?

We invite your suggestions for article

topics as well as questions on seal-

ing issues so we can better respond

to the needs of the industry. Please

direct your suggestions and questions

to sealingsensequestions@l uidseal-

ing.com.

Figure 4. Ring joint gasketImage 2. Design with integrated leak detection



HI PUMP FAQs

A. NPSH3 is the net positive suction head required, in meters (feet) that will cause the total head (or i rst-stage head of multistage pumps) to be reduced by 3 percent. Four typical arrangements are available for determining the NPSH3 characteristics of rotodynamic submersible pumps. For all arrangements, the l ow toward the pump must be uniform and free of undue disturbances. A pump tested with suction piping may require a l ow-straightening device before entering the pump. Arrangements for cooling or heating the liquid in the loop may be needed to maintain the required temperature.

In one arrangement (see Figure 11.6.7.2c), the pump is supplied from a closed tank in which the level is held con-stant. h e net positive suction head available (NPSHA) is adjusted by varying the air or gas pressure over the liquid, varying the temperature of the liquid, or both. h is arrange-ment tends to strip the liquid of dissolved air or gas. Testing with a closed loop without the closed tank on the suction side is also acceptable.

In another arrangement (see Figure 11.6.7.2d), the entire pump is mounted in an enclosed tank to allow the NPSH testing to be done without the suction piping connection. h e testing for this arrangement is normally performed at a constant l ow rate while varying the NPSHA by adjusting the air pressure over the liquid in the suction tank.

In each arrangement, water must be used as the test liquid. Taking the following precautions will minimize aeration:• No cascading return fl ow outlets• Reservoir sized for long retention time to allow air to

escape• Inlet line properly located to prevent vortexing• Reservoir baffl es to isolate inlet from the return line• Tight pipe joints to guard against air leakage into the

system

For more information about NPSH tests for rotody-namic submersible pumps, see ANSI/HI 11.6 Rotodynamic Submersible Pumps for Hydraulic Performance, Hydrostatic Pressure, Mechanical, and Electrical Acceptance Tests. P&S

Figure 11.6.7.2d. The entire pump is mounted in an enclosed tank

to allow the NPSH testing to be completed without the suction

piping connection.

Figure 11.6.7.2c. A pump is supplied from a closed tank with a constant

level.

Q. How do I determine the NPSH3 for a rotodynamic submersible pump?

Q. How should I design trench-type wet wells for the intake of rotodynamic pumps, and how are

these different from rectangular intake structures?

A. Trench-type wet wells dif er from rectangular intake structures by the geometry used to form a transition between the dimensions of the inl uent conduit or channel and the wet well itself (see Figure 1). An abrupt transition is used to

create a coni ned trench for the location of the pump inlets.While limited physical modeling work has been con-

ducted on trench-type wet wells, successful applications with individual pump capacities as great as 75,000 gallons per minute (gpm) or 4,730 liters per second (L/s) and

Submersible Pump NPSH3, Trench-Type Wet Wells & Starting Torque RequirementsBy The Hydraulic Institute


HI PUMP FAQs

installation capacities of 225,000 gpm (14,200 L/s) have been constructed for centrifugal pumps. Axial and mixed l ow applications include individual pump capacities of 46,000 gpm (2,900 L/s) and total installation capacities of up to 190,000 gpm (12,000 L/s).

Most applications of the trench-type design have been with the incoming l ow directed along the wet well’s long axis (coaxial). Physical model studies shall be conducted for any

installation with individual pump capacities exceeding 40,000 gpm (2,520 L/s) or stations with capacities greater than 100,000 gpm (6,310 L/s). P&S

Figure 1. Trench-type well

Q. What information is available regarding starting torque

requirements for reciprocating power pumps with liquid bypass?

A. Using reciprocating power pumps requires carefully considering their starting and running torque demands. h ese af ect the selection of driver motors, motor starters, engines, gear reducers, belts or chain drives, couplings, and universal joints. h ese loads’ ef ects on an electrical distribution system require thought, especially for a large pump.

For starting the pump with a liquid bypass, the operator manually opens a bypass valve or a power-actuated dump valve opens automatically. h is

bypasses the liquid during starting and stopping. A check valve in the dis-charge line remains shut if the bypass (dump) valve remains fully or partially open (see Figure 6.47).

h e liquid pressure exerted on the plung-ers (or pistons) is largely caused by liquid mass and friction. When correctly sized, the bypass valve and piping cause low back-pressure. Relatively small torque is required while bypassing the liquid to a tank. With liquid bypass, the total starting torque requirement is mainly related to the mechani-cal inertia of the pump, couplings, gears and

Figure 6.47. Schematics of liquid bypass systemscir

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motor rotor. h ese components are heavy and require substantial starting torque. h e liquid in the pump suc-tion line and in the bypass line must be accelerated from standstill to full liquid velocities.

h e torque needed to accelerate the entire mechanical hydraulic iner-tia system depends on the inertia of all the moving parts—including the liquid, the rate of acceleration and the total system friction. h e rate of accel-eration is important, and the starting torque is directly proportional to it. Peak torque is inversely proportional to the time duration of acceleration.

A few pumps are provided with mechanical suction valve unloader devices. h ey reduce the total start-ing torque required to accelerate the mechanical items—the pump crank-shat , gears, couplings, etc. h ey stop liquid pumping action by mechani-cally holding open the pump’s suction valves, allowing the liquid inducted into each liquid cylinder to be deliv-ered back into the pump suction. Because no liquid pumping occurs, the driving machinery does not need to apply torque to accelerate the liquid. Only the torque to overcome mechanical inertia and friction is needed during the start.

At er the pump and driver have reached full speed, the suction valve unloading devices are retracted, and normal pumping action commences. At this point, the driver must supply additional torque to accelerate the liquid system and meet the total run-ning torque requirement caused by discharge pressure. P&S

Pump FAQs® is produced by the Hydraulic Institute

(HI) as a service to pump users, contractors, dis-

tributors, reps and OEMs. Visit visit www.pumps.

org for more information.



PRACTICE & OPERATIONS


Innovation comes in many forms. At er many years of struggling with water quality and dependability, the

residents of the Pheasant Hill Subdivision formed their own Pheasant Hill Water Corporation. h ey worked with their consultant, Clark Patterson, to perform a needs assessment and applied for a Drinking Water State Revolving Fund (DWSRF) grant. h ey were successful and received a $2-million grant and an additional $600,000 in low-interest i nancing.

DESIGN

Clark Patterson designed the new water treatment system, which included two wells, No. 4 and No. 6; a chlorination system; a pumping system; and a new 30,000 gallon storage tank (see Image 1). Since this system’s source was a well, it has i ltration avoidance, and chlorination is the only treat-ment. Space for a new cartridge i ltration system was designed within the water treatment plant, in case the wells are reclassii ed in the future.

CONSTRUCTION

Once funding was in place, the design, construction and start-up of the new water treatment plant and storage tank was on a fast-track schedule. Clark Patterson evaluated the cost of building the water treatment plant in-place. h e design i rm also examined an inno-vative approach of working with a pump station manufac-turer to design a prefabricated water treatment and pumping system. h e evaluation showed that the prefabricated concept

was more expedient and more cost-ei cient. h e installing contractor awarded the pumping system

contract to Dakota Pump Inc. h e 14-foot wide by 51-foot long by 13-foot high, prefabricated water treatment build-ing is a multi-room water treatment plant that includes:• A stand-by generator room • Space for future fi ltration equipment• A chlorination room• A separate room for pumps and controls

h e stand-by generator with automatic transfer switch comes on when a loss of power occurs (see Image 2). h is allows the plant to continue operation. h e variable-fre-quency-driven booster pumps maintain adequate pressure in the distribution water main, and the chemical feed equip-ment provides proper disinfection. Controls were also a key

Prefabricated Treatment System Solves Water Quality ConcernsWith the simultaneous construction and site preparation, the quick turnaround required for the project was accomplished with cost-efi cient results.

By Mark Koester, Koester Associates, Inc.

Image 1. The water treatment plant included pressure-maintaining

booster pumping and metering capabilities.


factor for the station. When the tank level lowers to a pre-determined point, the controls call for the well pumps to start. h e components were incorporated into a pre-manufactured and prefabricated water treat-ment plant.

APPEARANCE

h e appearance of the treatment plant was another consideration. Since the project was located in a resi-dential setting, the designers wanted the building to have an appropriate residential look. Dakota Pump Inc worked with the Pheasant Hill Water Corporation and Clark Patterson to incorporate standard 2-inch by 6-inch construction on a prefabricated steel base plate, reinforced to accommodate the structural needs of the water equipment and the building.

h e structural base, walls and ceiling received a high R-value coating of spray foam insulation, and the exte-rior of the building was covered with architectural horizontal siding. With the help of the consultant, the owner was able to choose the style and color for the siding, the type of soi t and fascia, and the color for the laminated asphalt roof shingles. h e result was a treatment building that looks professional and blends with the foliage of the Pheasant Hill subdivision.

INSTALLATION

Prefabricating the water treatment plant building allowed the construc-tion of the treatment plant at the factory to coincide with the general contractor’s site preparation. h is pro-vided a shorter construction window. Once the construction site was fully prepped and the prefabricated water treatment plant was constructed and factory tested, the treatment plant was transported via a specialized tractor-trailer from Mitchell, S.D., to Minisink, N.Y. (see Image 3).

At er the station arrived at the site, it was lit ed into place onto the con-crete foundation. h e inlet and outlet connections were made, and the elec-trical hook-up was completed.

Image 2. A natural gas-fi red generator with automatic transfer

switch provided emergency power service.


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h e station was ready for start-up and commissioning. With this treatment plant, the Pheasant Hill residents have reliable and safe drinking water at consistent pressures and sui cient storage for all conditions. h e prefabricated approach saved the residents money and allowed the project to be completed on schedule. P&S

Mark Koester has been active in the water and wastewater

industry in upstate New York for 30 years. He has a degree in

sanitary engineering and retains leadership positions in the

New York Water Environment Association and New York Rural

Water Association. Koester is also active in the American

Water Works Association and local water works afi liates. He

can be reached at (315)697-3800 or email mark@koesteras-

sociates.com.

Image 3. The oversized treatment system and building was transported via specialized hauler from Mitchell, S.D., to Minisink, N.Y.


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Biological-secondary treatment is the most energy-intensive phase in the wastewater treatment process

with aeration consuming between 25 and 60 percent of the total energy used in a municipal plant.1 According to a report by the Environmental Protection Agency (EPA) in the U.S., these costs are increasing because of rising energy prices and more stringent requirements for el uent quality.2 An increase in environmental awareness and the rising cost of electricity have motivated operators to reduce the energy consumption of biological-secondary treatment in wastewater treatment systems.

TESTS AT SWEDISH WASTEWATER

TREATMENT PLANT

Full scale trials by a global water solution company show that the energy consump-tion of a wastewater treatment plant’s aeration system was successfully reduced by a signii cant 65 percent when more energy ei cient equipment was installed. h e tests were conducted at the Sternö Municipal Wastewater Treatment Plant in southern Sweden.

Built in 1997, the Sternö plant was designed to cater to a population of 26,000 calculated on biological oxygen demand (BOD) 7 load 70 g (pe day)-1. Aeration consumed 44 percent of the plant’s total energy usage.

h e plant consisted of two parallel bio-logical treatment lines that performed the pre-denitrii cation of the wastewater. During the study, one of the treatment lines was used as a test line with the new aeration and control equipment installed.

h e other line with aeration equipment—consisting of tube dif users, lobe blowers and a simple dissolved oxygen (DO) control—was let unchanged and kept as a reference line.

New Optimized Aeration System Reduces Energy ConsumptionA wastewater treatment plant experiences a 65 percent energy savings with the installation of improved equipment.

By Lars Larsson, Xylem, Inc.

New aeration equipment.



h e new aeration equipment installed into the test line was a screw blower; i ne bubble, low-pressure dif users; and measurement equipment.

THE RESULTS

h e results of the full scale trials showed that the new screw blower reduced the energy consumption of the test line by 35 percent.

h e low-pressure dif users reduced the energy consump-tion by another 21 percent. By i ne tuning the controllers, the oxygen concentrations and the air pressure, the energy consumption of the test line was reduced an additional 9 percent. h e i nal energy savings of the test line were 65 ± 2 percent.

Each aeration equipment upgrade increased the energy savings with:• Blower, 35 percent• Diff users, 32 percent• Oxygen control with decreased DO concentrations

and air pressure, 21 percent

EVALUATION PERIODS

h e new installations were performed in stages. h e ef ect of each new installation was evaluated separately, and the results were: • Phase 1 involved the installation of a new screw

blower and a non-tuned DO cascade control system. During Phase 1, the majority of the energy savings was related to the increased effi ciency of the blower.

• Aeration grids were installed during Phase 2. An addi-tional 23 percent of the total energy savings gained during Phase 2 was acquired by the high standard oxygen transfer effi ciency (SOTE) and low system head loss of the new aeration system.

• During Phase 3, a process control system was installed, which increased the energy reduction by an additional 9 percent through a combination of a further decreased system head loss from the most open valve logic and the implementation of DO cascade control and an energy optimized DO profi le. h e DO profi le was energy optimized by changing the DO set points from 1.7/0.7 milligrams per liter

circle 141 on card or go to psfreeinfo.com circle 140 on card or go to psfreeinfo.com


to 0.7/1.0 milligrams per liter, which distributed the load more evenly throughout the length of the basin.

AIRFLOW & AERATION EFFICIENCY

With the new system, aeration ei -ciency was almost three times as high in the test line compared to the reference line. h e required airl ow was reduced by 30 percent, and the system pressure was reduced by 15 percent. h ese savings were gained by a combination of: • A more effi cient blower• A higher SOTE • Lower head loss • Energy-optimized DO control

and DO profi le• More than 40 years of expertise

in wastewater treatment system optimization

PAYBACK PERIOD

h e payback period for implement-ing the aeration system was calcu-lated at four years. If both lines were upgraded, the payback period would decrease to just three years since some of the equipment could be shared between the lines. h ese full-scale tests were performed throughout a 6-month period. h e annual sav-ings for the test plant was more than $28,000 if both of the plant’s treat-ment lines were upgraded. P&S

References

1. WEF, 2009. MOP No. 32: Energy Conservation in Water and Wastewater Facilities.

2. EPA, 2010. Evaluation of Energy Conservation Measures for Wastewater Treatment Facilities. EPA 832-R10-005.

Lars Larsson is the global prod-

uct manager, biological treat-

ment for Xylem, Inc. He can be

reached at +46 8 475 63 60 or

[email protected].

The fi nal energy savings of the test line were 65 ±2 percent.


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Many manufacturers are committed to sustainable practices to improve their environmental, economic

and social performances. Companies that use or produce l uids in manufacturing processes face the challenge of properly disposing of the byproducts. For example, chemical manufacturers, food and beverage processors and metal i nishers generate l uids that have to be treated in accordance with local government regulations before waste l uid is discharged into sewer systems.

h e manufacturing sustainability trend is driven by cus-tomers; shareholders; government regulations; and the increasing costs of process inputs, such as water. As the cost of water increases, the industry is investing heavily in treat-ment processes using recycled water.

Industrial pumps are at the core of wastewater treatment systems, and dif erent pumps are used in the treatment process. Positive displacement pumps are used to transfer liq-uids from tank to tank because they are durable enough to handle a wide range of l uids and solid particles.

Metering pumps play a vital role in the treatment process as well. h is type pump has the technology required to accu-rately dose and meter chemicals at low l ow rates and is one of the smallest positive displace-ment pumps on the market.

Air operated diaphragm pumps (AODP) are the work-horse of the wastewater treat-ment system. h is type of positive displacement pump is durable enough to withstand submersion and continuous l ow rates inherent in waste-water applications. AODPs are

ideal for low- to mid-range l ow rates—up to 350 gallons per minute—and produce enough back pressure, up to 250 psi, to move high viscosity l uids and sediment.

THE PUMP’S ROLE

Positive displacement pumps have three main applications in the wastewater treatment process:• Transferring fl uids from the sump to

the reactor• Dosing chemicals into the reactor and

neutralizer tanks• Drawing slurry off the clarifi er tank to feed the

fi lter press

A typical wastewater treatment process begins as l uid builds in a sump tank. A positive displacement pump is

Positive Displacement Pumps in Wastewater TreatmentSelect the right pumping technology to keep treatment processes running efi ciently.

By Oakley Roberts, ARO Fluid Products, Ingersoll Rand

AODPs are used in multi-step, batch waste treatment systems to remove metal precipitation. One AODP

moves the solution from the collection tank to the treatment tank. Others move the treated waste from

the treatment tank to the drain.


used to move the l uid to a second tank where the rinse water l ow is equalized and pushed into a reactor tank. h e composition and temperature of the l uid running through the system must be considered when specifying this pump because the l uids can be corrosive and abrasive. AODPs can be coni gured to meet the chemical compatibility of the l uids, making them a low-risk solution.

Once the waste l uid is transferred from the sump to the reactor, concentrated chemicals are introduced to neutralize the pH balance. An electromagnetic or mechanically actu-ated simplex diaphragm pump, a highly controllable type of metering pump, doses treatment chemicals at a low l ow rate. h is level of accuracy ensures that the l uids are treated, neutralized and clarii ed to adhere to local regulations.

Finally, the neutralized liquid l ows into the l occulator where a chemical is added that adheres to particulates, caus-ing them to coagulate on the bottom of the clarii er tank. AODPs are used to draw the slurry from the bottom of the tank and prime the i lter press.

AODPs can handle this abrasive and corrosive mixture and produce enough back pressure to force the l uid into the i lter, leaving only solid waste behind. h e clean l uid returns to the treatment process before being discharged to the sewer or reused. h e cake is removed from the i lter press and disposed as solid waste.

SELECTING THE RIGHT AODP

Pumps are critical to manufacturing processes. If one fails, it may force the entire plant to stop production until opera-tors can i nd a way to restore it. Specifying the right pump for the application to increase reliability and prevent unex-pected downtime is critical.

Pumps must be compatible with the l uids they transfer to prevent abrasive and corrosive materials from reacting with the composition material of the pump. Plant manag-ers can ask a pump manufacturer to specify the best com-position material for the application.

Polymer l uid chambers made from nonreactive mate-rials, such as polypropylene or polyvinylidene l uoride (PVDF), are commonly used with elastomeric ball checks and diaphragms to prevent corrosion and increase a pump’s longevity.

Pump manufacturers can consult with plant managers to determine if continuous-duty pumps should be installed to meet the heavy-duty cycle required in wastewater treat-ment. Continuous-duty pumps prevent icing and stalling, and pulsation dampeners can be added to help equalize the pressure l ow and keep the system running reliably.

AODPs of er several unique advantages over other posi-tive displacement pumps: • h ey are powered by compressed air and do not

require electrical hookups at the installation sites, which dramatically reduces installation costs.

• Some AODPs can be submerged in fl uids, making them a convenient option for sumps and pits.

• h ese pumps can be integrated with electric interface control devices, such as solenoids and tank fi ll, to control the pump’s operation.

• AODPs are not damaged by downstream blockages in the system.

• h ey are more compact than other pumps.• h ese pumps have reduced purchase prices because

they do not require electric motors or gear boxes.• AODPs do not have mechanical seals that could leak

or need replacement.• h ey are portable and have plug-and-play capability

for easy installation.

TOTAL COST OF OWNERSHIP

When evaluating if an AODP is right for a facility, plant managers should note the initial purchase price and then include the total cost of ownership. h ese factors will help plant managers determine if an AODP is the most econom-ical pump for the application:• Compare the time required for maintenance on the

AODP and how that aff ects productivity.• Calculate the downtime costs of the plant and

whether it is cost eff ective to keep an extra AODP in stock so it can be replaced quickly.

• Determine whether the AODP pump shares common parts with other units in the plant and manage inven-tory accordingly.

• Select a modular pump design that allows mainte-nance teams to repair one piece of the AODP without disabling the entire unit.

• Consider the installation costs and energy consump-tion required to get the pump up and running.

If specii ed correctly, AODPs can be an ef ective and reli-able solution to a facility’s wastewater treatment process. Plant managers should contact an authorized pump manu-facturer to determine if an AODP is the right choice for their application. P&S

Oakley Roberts is the product management director for ARO

Fluid Products, Ingersoll Rand. He can be reached at oakley_

[email protected] or 419-633-6935. For more information,

visit www.ingersollrandproducts.com.



Generator sets are available in a wide range of power ratings—from small, portable sets to mobile power

systems or large stationary generator sets supplying power in the demanding scenarios worldwide. To determine if a generator set installation is required, the intended application, geographical rules and regulations and proper sizing of the generator set must be considered.

APPLICATION

Generator sets are used in many applications. h e i rst con-sideration is to determine the generator’s intended use. Will it be transported from jobsite to jobsite, provide relief in the event of a catastrophic event, or will it be used to provide power during peak demands? h e intended application must be reviewed to ensure that the correct equipment is specii ed and installed. When deciding if mobile power, emergency power, or a continuous or peak shaving power system is needed, several factors must be addressed.

Diesel mobile and continuous or peak shaving power systems (stationary nonemergency) must comply with the latest Environmental Protection Agency (EPA) engine emission regulations. h ese have become one of the most discussed topics in the power generation industry. h ey must be driven by an EPA-compliant certii ed interim

Tier 4 or a Tier-4-capable engine. By 2015, products in a mobile, continuous or peak shaving application will need to meet the stringent emission regulations of Tier 4 unless the manufacturer uses the Transition Provisions for Equipment Manufacturers Program. h is program gives the manufac-turer l exibility to design products in a timely manner to meet emission regulations.

Emergency power systems have several dif erent require-ments. h e three classii cations for power systems are emergency systems, legally required standby systems and optional standby systems

Articles 700, 701 and 702 from the National Electric Code (NEC) explain each classii cation. Article 700 details emergency systems, which are required to automatically supply illumination, power or both to designated areas essential to human safety if the normal power supply fails. In Article 701, legally required standby systems are intended to automatically supply power (other than those classii ed as emergency systems) to designated areas if power fails and could result in safety hazards and hamper rescue ef orts. Optional standby systems, highlighted in article 702, are installed to supply power to public or private facilities where human safety does not depend on the performance of the system and can supply power automatically or manually.

Power Generation on Demand

The application, geography, regulations and proper size must be considered when choosing a generator set.

By Brad Chrudimsky, Baldor Electric Company, a member of the ABB Group

Mobile generator sets provide temporary relief.


FUEL

When choosing a fuel source, diesel, natural gas and liquid propane have advantages and disadvantages. For example, diesel is portable, easy to store and readily available. Diesel’s disadvantage is its limited shelf life (10 to 12 months). Also, the overall cost of a diesel-driven power system is typically higher because of fuel storage requirements and the need to rei ll the fuel as it is consumed.

Another option and a cleaner burning fuel is liquid pro-pane. Liquid propane is portable and easy to store. It also has a longer shelf life than diesel.

h e third option for fuel is natural gas. It burns cleaner than diesel and is the easiest of the three to obtain. Because of a surplus as a result of the shale gas boom in North America, there is a practically unlimited supply. With the advantages of natural gas comes the hazard of leaky or burst-ing pipes. Because of these hazards, it cannot be used in life safety applications. Also, much more natural gas is needed to produce the same amount of power when compared to other fuels. When making this crucial decision, federal, municipal, state and local codes can help dei ne which fuel source should be used.

AGENCY APPROVALS

Minimum requirements may need to be met when installing a genera-tor set in certain geographical loca-tions. h ird-party safety certii cation standards—such as Underwriters Laboratories UL2200 health and safety of use standards, National Fire Protection Association (NFPA) 110 i re protection standards and/or NFPA 20 installation of stationary i re pumps for i re protection stan-dards—can ensure that the power system is appropriate for the applica-tion. Contacting the local authority having jurisdiction (AHJ) can pro-vide clarity of federal, state, municipal and local rules and regulations. h e AHJ has the i nal say in the generator set installation and commissioning.

If UL2200 or NFPA 110 is specii ed at the time of order, several require-ments need to be met to ensure that the complete system is a safe and reli-able piece of equipment. For instance,

UL2200 requires additional testing and documentation if the generator is wrapped in an enclosure or any modii ca-tions are made to the generator set at er it leaves the original manufacturer’s production site. To carry the UL listing, all system components must meet the UL standards.

Diesel fuel tanks can be installed as a sub-base for generator sets.


WHEN QUALITY AND DELIVERY MATTER

WHEN QUALITY AND DELIVERY MATTERPumpWorks 610 manufactures centrifugal API 610 pumps for oil and gas exploration and production, petroleum refining, gas processing, oil processing, hydrocarbon and crude oil pipeline and offshore production platform applications.

We make the purchase of your API 610 pump an enjoyable process, and we ensure that the finished product meets or exceeds your exact specifications.

OUR PUMPS ARE:

610 pumps in the industry



NFPA 110 sites the importance of the power system to human safety, the amount of time it takes the set to be at full power, and the runtime before the power system must be refueled or recharged. If using the generator set to supply power to a i re pump motor, NFPA 20 standards and NEC Article 695 standards must be met. h e standards make cer-tain that the i re pump motor runs when needed. Correctly calculating the required loads helps properly size the set.

SIZING

Properly sizing the generator set for operating speeds of motors and i re pump motors is crucial. More importantly, sizing the generator set to start a motor versus a i re pump motor is the more dii cult task. Typical motor starting kilo-volt amperes (kVA) allows a 30 percent voltage dip, while NEC 695-7 permits a voltage drop of only 15 percent at the controller line terminals when starting a i re pump motor. To meet this requirement, the generator set must be upsized by as much as three times.

h e generator set can carry a UL2200 listing if the circuit breaker does not exceed the standard’s 125-percent thresh-old. If not sized properly, the third-party certii cations may not apply. h e generator set’s fuel supply shall be sui cient to provide eight hours of i re pump operation at 100 percent of the rated pump capacity and supply required for other demands according to NFPA 20. Contacting federal, state, municipal and local resources can help specify the proper unit. P&S

Brad Chrudimsky is the product marketing specialist for

Baldor Generators and is based at the company’s gen-

erator manufacturing facility in Oshkosh, Wisc. He can be

reached at [email protected]. Baldor Electric

Company is a member of the ABB Group.To carry a UL2200 listing, the generator set components need to safely

operate as a complete system.



SHARK GRINDERSZoeller Engineered Products of ers a line of grinder pumps with models available from 1 to 7 ½ horsepower. Cool run design technology ef ec-tively disperses heat, promoting longer service life. h e units are available with multiple discharge coni gurations and wet end designs. Some models feature reversing cutter design, which prevents cutter jams. Models are available with standard or explosion proof motors.Circle 221 on card or go to psfreeinfo.com

CIRCULATOR PUMPSGrundfos introduces its energy-ei cient circulator pump. MAGNA3 is an energy-optimized, vari-able-speed wet rotor circulator that features a permanent magnet motor design that will cut power consumption up to 85 percent. h e circulator uses a variable-speed electronically commutated motor (ECM) that uses an integrated logic algorithm, enabling the sot ware to automatically determine the lowest pos-sible operating-ei ciency point demand.Circle 220 on card or go to psfreeinfo.com

DATA LOGGEROmega introduces its new series of precision resistance temperature detector (RTD) data loggers. h e OM-CP-RTDTEMP101A accepts 2-, 3- or 4-wire 100 platinum RTD input and features a battery life of 10 years, multiple start/stop function, ultra high speed download, 670,000 reading storage capacity, memory wrap and programmable high and low alarms. h e data logger is ideal for chemical, water and food industries and for lab, HVAC and R&D applications.Circle 200 on card or go to psfreeinfo.com

BALL VALVE SEATMetallized Carbon Corporation introduces its carbon-graphite ball valve seats for use in valves designed to handle hot liquids or hot gases. h e ball valve seats are available in more than 150 grades of Metcar’s carbon/graphite material. h e seats are ideal for use in temperatures from approximately 350 F to 800 F in oxidizing environments. h ey are also ideal for i re safe petroleum industry ball valves. Circle 202 on card or go to psfreeinfo.com

DISINFECTION SYSTEMXylem Inc. has engi-neered enhancements to its most cost-ef ective solution for ultra-violet (UV) wastewater treatment with the WEDECO TAK 55 Smart UV light disinfection system, which is ideal for small- to medium-sized municipalities. h e solution of ers a full menu of options to help custom-ers design their systems to meet el uent qualities—such as combined sewer overl ows, primary or secondary wastewater sources, lagoons, or tertiary wastewater recla-mation and reuse. Circle 203 on card or go to psfreeinfo.com

d f b l f f

PROGRESSING CAVITY PUMPSMoyno, Inc., of ers the L-Frame Progressing Cavity Pump for depend-able performance and maximum operating ei ciency. h ese pumps are ideal for handling clean, thin, shear-sensitive products to viscous, corrosive, abrasive slurries and sludges. All these pumps are available with a variety of drive options, sealing coni gurations, motors and controls.Circle 205 on card or go to psfreeinfo.com

PRODUCT PIPELINE


PRODUCT PIPELINE

TESTING PENDwyer Instruments, Inc., introduces its WPH2 Waterproof pH Testing Pen, which accurately monitors pH and temperature levels in many applications. h e pocket-sized tester is ideal for pH level measurements in the lab, industrial plants or on-the-go in the i eld. It features an easy-to-replace electrode option and a one-touch, three-point auto-calibration. Temperature and pH appear on the large dual display.Circle 207 on card or go to psfreeinfo.com

FUSE HOLDERSWAGO Corporation’s 811 Series Class CC and Midget-Style (10 x 38 mm) Fuse Holders provide machine- and panel-builders with a new approach to branch and supplemental protection. h e holders feature a DIN-rail mount clip for easy installation and removal. Circuit identii cation/marking options are provided by WAGO’s WMB multi-marking strip and exclusive continuous marking strip adapters.Circle 210 on card or go to psfreeinfo.com

CABLE GLANDRST introduces its cable gland section of AlphaX, GammaX and DeltaX prod-ucts, recently approved by the new ATEX standard for explosion-proof products. All armored cables can be mounted with just one gland. h e DeltaX and GammaX series can be dismounted easily and in a controlled manner. h e design of the grounding and sealing inserts ensures that the spare parts cannot be lost during installation.Circle 211 on card or go to psfreeinfo.com


U N M AT C H A B L E E X P E R I E N C E

I N P R I VAT E C O M PA N Y

T R A N S A C T I O N S

MEMBER FINRA, SIPC

Jordan, Knauff & Company is a knowledgeable and experienced provider of a comprehensive line of investment banking services to the pump, valve and filtration industries (“Flow Control”).

Our lines of business include: selling companies, raising debt and equity capital, and assistance on acquisitions.

To learn more about Jordan, Knauff & Company, contact any member of our Flow Control team. Access our Flow Control research at www.jordanknauff.com/flowcontrol.

G. Cook Jordan, Jr.Managing Principal

[email protected]

David A. KakarekaAssociate

[email protected]

ANSI/HI Pump Standards on CDVersion 3.1 Now Available

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current Pump Standards including:

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9.6.1)

— Rotodynamic (Centrifugal & Vertical) Pumps—Guideline for

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Performance, Hydrostatic Pressure, Mechanical, and

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Order the newly-published

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VARIABLE SPEED DRIVESZero-Max variable speed drives meter and dispense seed and fertilizer guided by global positioning systems. h e drives provide accurate and repeatable settings to optimize the seeding and fertilizing process. h e drives can be used as a prime mover connected to a motor, or as a secondary drive connected to a shat in the machine’s driveline.Circle 204 on card or go to psfreeinfo.com

REDUNDANCY MODULESPhoenix Contact’s Quint ORing active redundancy modules use new auto current balancing (ACB) technology for precise load sharing. h e ACB technology, coupled with load current monitoring, remote diagnostics and visual indications, ensures maximum reliability in redundant power systems. h e module, available in two 24-volt DC versions, can also monitor load current.Circle 206 on card or go to psfreeinfo.com

To have a product considered for “Product Pipeline,” please send the information to Amanda Perry, [email protected].

COUPLINGSStaf ord Manufacturing Corp. introduces a full line of rigid shat couplings in a broad range of types, sizes and materials for joining unsupported shat s in applications ranging from delicate instruments to large mixers and pumps. h e couplings are of ered in one-, two- and three-piece designs, with or without keyways. h e couplings are machined from stainless steel, steel and aluminum.Circle 208 on card or go to psfreeinfo.com

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INDEX OF ADVERTISERS

ABZ, Inc. 70 146

Advanced Engineered Pump, Inc. 70 145

AWEA 67 110

Baldor Electric Company 7 100

Bartlett Bearing Company 70 147

BaseTek, LLC 59 139

Benshaw Incorporated 27 112

Blacoh Fluid Control, Inc. 13 114

Blue-White Industries 29 115

Burns Dewatering Service 71 148

Carver Pump Company 39 113

Cascade MVS 52 132

Dakota Pump 47 111

Dan Bolen & Associates, LLC 69 149

Discl o 14 131

Flowrox Inc. 43 116

Frost & Sullivan 68 142

GE Oil & Gas, Surface Pumping Systems 36 101

General Pump 35 117

GIW Industries, Inc. 31 118

Global Pump Company IFC 109

Godwin, a Xylem brand 15 119

GPM, Inc. 44 120

Greyline Instruments Inc. 49 170

Griffco 26 121

Grundfos BC 102

Houston Dynamic Service, Inc. 70 151

Hydraulic Institute 66 144

Jordan, Knauff & Company 66 143

Junty International, LLC 69 152

Load Controls, Inc. 9 122

LobePro 69 150

LUDECA, Inc. 3 103

Magnatex Pumps, Inc. 69 153

Meltric Corporation 71 154

National Pump & Compressor 41 123

NETZSCH Group 32 125

Pioneer Pump 17 124

Proco Products, Inc. 50 133

PumpWorks 610 63 138

Reason Technology Co. Ltd. 53 134

Ruthman Companies 53 135

Scenic Precise Element Inc. 70 155

seepex, Inc. 40 126

SEPCO 38 127

SEPCO 69 156

SERO Pump Systems 71 157

Sims Pump Company 33 108

Sims Pump Company 69 158

Singer Valve 58 141

SJE-Rhombus 56 136

Smith & Loveless IBC 104

Summit Pump, Inc. 71 159

SWPA 64 130

Tarby, Inc. 23 128

Topog-E Gasket 71 160

Trachte, USA 71 161

Tuf-Lok International 71 162

UniqueFlo 68 163

Varisco USA Inc. 68 164

Vaughan 5 105

Vertil o Pump Company 58 140

Vertil o Pump Company 71 166

Vesco 70 165

Vogelsang USA 55 137

Wilden 37 129

Xylem USA 1 106

Zoeller Company 11 107

* Ad index is furnished as a courtesy and no responsibility is

assumed for incorrect information.

Advertiser Name Page RS#


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PUMP MARKET ANALYSIS

Wall Street Pump & Valve Industry WatchBy Jordan, Knauff & Company

The Jordan, Knauf & Company ( JKC) Valve Stock Index was up 10.4 percent over the last 12 months,

below the broader S&P 500 Index, up 13.1 percent. h e JKC Pump Stock Index was up 6.7 percent for the same time period.1

Manufacturing began 2013 on a positive note. In January, the Institute for Supply Management’s Purchasing Managers’ Index (PMI) increased 2.9 percent over December to reach 53.1 percent, the highest level since April 2012. All i ve PMI component indexes—new orders, production, employment, supplier deliveries and inventories—registered growth in January. Most important, the index for new orders moved from contraction at 49.7 percent in December to slight growth at 53.3 percent.

h e Commerce Department reported that shipments of manufactured durable goods increased $2.6 billion (1.1 percent) to $230.1 billion in December. h is followed a 1.8 percent November increase.

Total, nonfarm payroll employment increased by 157,000 jobs in January according to the U.S. Bureau of Labor

Statistics. Employment numbers for November were revised from 161,000 to 247,000 jobs, while the numbers for December were revised from 155,000 to 196,000 additional jobs. Including these revisions, nonfarm payrolls rose 2.2 million in 2012, roughly 180,000 per month. Manufacturing employment was essentially unchanged in January and has changed little since July. Job gains in January occurred in retail trade, construction, health care, and wholesale trade.

Due to ongoing activity in onshore basins, the U.S. Energy Information Administration (EIA) expects U.S. crude oil production to continue its growth during the next two years. Increasing from an average of 6.4 million barrels per day (bpd) in 2012, the EIA predicts that crude oil production will average 7.3 million bpd in 2013 and 7.9 million bpd in 2014. Drilling in tight oil plays in the Williston, Western Gulf and Permian Basins will account for most of the fore-casted growth, with the Western Gulf Basin accounting for more than half the onshore domestic liquid production growth. h e Williston Basin’s Bakken formation (North Dakota and Montana) and the Western Gulf Basin’s Eagle Ford formation (Texas) currently produce about two-thirds of the tight oil in the U.S.

On Wall Street, h e Dow Jones Industrial Average had its largest January increase since 1994. Better-than-expected earnings for the fourth quarter combined with a brighter employment scenario and encouraging numbers from the housing sector boosted the markets. h e Dow Jones Industrial Average increased 5.8 percent, the S&P 500 Index gained 5.1 percent and the NASDAQ Composite rose 4.1 percent in January. P&S

Reference1 h e S&P Return i gures are provided by Capital IQ.

Jordan, Knauff & Co. is an investment bank based in Chicago, Ill., that provides

merger and acquisition advisory services to the pump, valve and i ltration indus-

tries. Please visit www.jordanknauff.com for further information on the i rm.

Jordan Knauff & Co. is a member of FINRA.

Figure 2. U.S. Energy Consumption and Rig Counts

Figure 3. U.S. PMI Index and Manufacturing Shipments

Source: U.S. Energy Information Administration and Baker Hughes Inc.

Source: Institute for Supply Management Manufacturing Report on Business® and U.S. Census Bureau.

Figure 1. Stock Indices from Feb. 1, 2012, to Jan. 31, 2013

Source: Capital IQ and JKC research. Local currency converted to USD using historical spot rates. h e JKC Pump and Valve Stock Indices include a select list of publicly-traded companies involved in the pump and valve industries weighted by market capitalization.

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CALL S&L AFTER MARKET 800.922.9048

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